Cat FB110 Feeder Breaker Operation & Maintenance Manual SN 54-2185 & 54-2193 (1)

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© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

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BI016382 A6474X338 December 2012

Operation and Maintenance Manual FB110 Feeder Breaker Serial Number 54-2185 54-2193

SAFETY.CAT.COM

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This manual is intended to provide GENERAL product information. The illustrations, descriptions, and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

This machine was manufactured under the guidelines, procedures, and requirements of the appropriate government regulatory agencies.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to Caterpillar’ s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations, and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution, or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability. © Caterpillar 2012 ALL RIGHTS RESERVED

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_________________________________________________Table of contents

Table of contents 1. About this manual About this manual................................................................... 1.3 Before starting to work ......................................................... 1.3 Who is this operating manual intended for?......................... 1.3 What is the purpose of this operating manual?.................... 1.4 Characters and symbols ...................................................... 1.5

2. Your safety Your safety............................................................................... 2.3 Personnel ............................................................................. 2.4 Operation......................................................................... 2.4 Installation and repair ...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use.................................................................... 2.5 Unauthorized use ............................................................ 2.5 Safety instructions ................................................................ 2.7 General rules:.................................................................. 2.7 Storage and transport...................................................... 2.9 Installation and start-up ................................................... 2.9 Operation....................................................................... 2.10 Maintenance and repair................................................. 2.10

3. Storage and transport Storage and transport............................................................. 3.3 Storage................................................................................. 3.3 Storage of the machine and spare parts ......................... 3.3 Transport .............................................................................. 3.4 Before transport............................................................... 3.6

4. Installation Installation ............................................................................... 4.3 Points to observe prior to installation ................................... 4.3 Who is allowed to carry out installation? ......................... 4.3 Which tools are required for installation? ........................ 4.3 Notes on installation ........................................................ 4.4 Pre-installation check list................................................. 4.5 Safety features ................................................................ 4.6 Towing the feeder breaker ................................................. 4.10

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Table of contents _________________________________________________ 5. Operation Operation..................................................................................5.3 How to operate the feeder breaker ......................................5.3 Who is allowed to operate the feeder breaker ................5.3 When can conveying be started? ....................................5.3 Controls and indicators.........................................................5.4 Operating procedures......................................................... 5.19 “AUTO”starting procedure ............................................ 5.19 “MANUAL”starting procedure ....................................... 5.20 Shutdown procedure ..................................................... 5.21 Tramming....................................................................... 5.22 Conveyor ....................................................................... 5.23 Electrical system................................................................. 5.27 Hydraulic system ................................................................ 5.39 Mechanical assemblies ...................................................... 5.45 Crawler assembly (s) .................................................... 5.45 Conveyor chain ............................................................. 5.46 Head shaft .................................................................... 5.47 Conveyor power unit ..................................................... 5.48 Tail shaft ....................................................................... 5.48 Breaker and breaker power unit assembly.................... 5.49 Tailpiece assembly ........................................................ 5.52 Instructions on the maintenance of the feeder .................. 5.53 Important notes ............................................................. 5.53 Before maintenance ..................................................... 5.53 Lubrication and inspection ............................................ 5.55 Specific lubrication and maintenance procedures ............. 5.59 Every 8 hours of operation ........................................... 5.59 Weekly .......................................................................... 5.67 Monthly ......................................................................... 5.71 Every 1000 hours .......................................................... 5.74 Every 6 months ............................................................. 5.77 Inspection ........................................................................... 5.79 Inspection of wear parts .................................................... 5.80 Inspection of the fire suppression system .......................... 5.81 Recharge of the fire suppression system ........................... 5.83 Instructions on the adjustment procedures ....................... 5.85 Conveyor chain adjustment .......................................... 5.85 Crawler track adjustment .............................................. 5.87 Under speed sensor calibration..................................... 5.89 Main pump ..................................................................... 5.91 Margin pressure..................................................... 5.91 Pressure compensator .......................................... 5.91 Main relief .............................................................. 5.93 Pressure limiter...................................................... 5.94

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_________________________________________________Table of contents Instructions on the replacement of wear parts ................... 5.95 Head shaft ..................................................................... 5.95 Head shaft sprockets .................................................... 5.99 Tail shaft ..................................................................... 5.102 Conveyor chain ........................................................... 5.108 Crawler track ............................................................... 5.111 Crawler assembly ....................................................... 5.114 Breaker shaft and breaker power unit ......................... 5.123 Conveyor power unit .................................................... 5.148 Breaker bit removal...................................................... 5.156 Tailpiece installation..................................................... 5.157 Roof cylinder ................................................................ 5.161 Foot cylinder ................................................................ 5.163 Tilt cylinder ................................................................... 5.165 Lift cylinder ................................................................... 5.167 Tailpiece tilt cylinder..................................................... 5.169 Tailpiece steering cylinder ........................................... 5.171 Troubleshooting ................................................................ 5.173

6. Technical data Technical data..........................................................................6.3 Components of the feeder breaker .......................................6.3 Tightening torques ................................................................6.7 Permissible data ...................................................................6.9 Lubrication fluids and greases .........................................6.9

7. For your information For your information ...............................................................7.3 Our service............................................................................7.3 Service address ...............................................................7.3 Rebuild facility address ....................................................7.4

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Table of contents _________________________________________________

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1

About this manual

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__________________________________________ Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

This operating manual is intended for: Model FB110 Feeder Breaker Serial No. 54-2185, 54-2193 and is only permitted to be used for equipment of this type.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine. It should, if possible, always be available at the place of operation.

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine. Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who: ■

are in charge of transport

■

perform assembly/disassembly work

■

operate the machine

■

eliminate faults

■

perform daily routine work on the face or in the entry

■

perform maintenance work

■

perform repair work

and supervisory personnel who: ■

initiate and/or

■

supervise the activities just indicated.

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Before starting to work ____________________________________________ What is the purpose of this operating manual? cost-effectiveness

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

service

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “Your safety”with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

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__________________________________________ Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

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Before starting to work ____________________________________________

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2

Your safety

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______________________________________________________ Personnel

Your safety This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by the OEM. Use only original spare parts. Note that the use of parts from other manufacturers will void the guarantee.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations of

further operating manuals

■

the mine,

■

the mine inspector, and

■

the mining supervisory authorities.

Please read also the operating manuals of the components required for operation, e.g. of gearboxes, electric motors, etc., carefully and thoroughly. Clarify any questions before starting work.

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Personnel _______________________________________________________ Personnel Operation training

The machine may only be operated by qualified, trained personnel.

The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit. Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

Installation and repair As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on: ■

safety components (pressure relief valves, extinguishers, etc.)

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

may only be carried out by service engineers or by specially qualified personnel of the mine.

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_______________________________________________ Safety instructions Operating conditions Intended use The feeder breaker has been designed and manufactured purely for transporting mined and crushed material from a continuous miner to the main conveying system for transporting outside.

Intended uses include: ■

The transport of mined and crushed material between continuous miner and main conveying system.

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.

Unauthorized uses include: ■

the transport of persons

■

the transport of objects of any kind such as single props, boards, spare parts, etc.

The OEM accepts no liability for any damage resulting from any such unauthorized use.

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Safety instructions _______________________________________________

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_______________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 db(A).

Inform your colleagues of

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. stop devices, cover plates, etc., are correctly installed.

Observe the optical start-up warnings of the machine.

symbol plates panic strip

lock-out

cordon off working area

Observe the symbol plates on the machine.

Press the panic strip immediately in the event of fault or irregularities in operation. Report any peculiarity to your supervisor so that necessary measures can be taken immediately.

Lock-out and disconnect the power system while performing: ■

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

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Safety instructions _______________________________________________ moving parts

Never allow parts of your body to come between parts which could move, such as: ■

conveyor chains

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flights

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pivot points

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crawler assemblies

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breaker shaft assemblies

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_______________________________________________ Safety instructions Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.

mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

Installation and start-up inclined face

environmental acceptability

On inclined faces secure all component parts by chains, e.g. to the support.

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

inspection maintenance instruction and safety tags

operator’s area

Inspect the machine and have any malfunctioning, broken or missing parts corrected or replaced before use.

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

These are as important as any other equipment on the machine.

Clean any foreign material from the operator’ s area.

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Safety instructions _______________________________________________ Operation Operate the feeder breaker only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective feeder breaker.

Before start-up, ensure that there are no persons around the machine.

Check that all protective devices are installed on the machine and function properly.

Clean the control panel and operator’ s area at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration. securing

Secure your working area over a wide range, in order to avoid endangering other persons.

Lock-out and disconnect power from the machine to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

replacing components

Stop, lock-out and disconnect power from machine to prevent from restarting before replacing any defective components.

Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Caterpillar spare parts. Please refer to the spare parts lists for the order numbers.

For raising the feeder breaker use only: ■

crib blocks with adequate load-holding capacity

■

hoists, jacks or cranes with adequate load-carrying capacity

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_______________________________________________ Safety instructions handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

Never use hydraulic fluid for rinsing or cleaning. Hydraulic fluid represents a very serious danger to health.

maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work on the hydraulic system.

Do not alter the electrical or hydraulic settings from that indicated in this manual or as set at the factory.

Always replace damaged or lost decals and metal instruction plates.

Disconnect power at the main power source on the unit to prevent electrical shock.

Always follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: ■

the hoses are not pinched or trapped

■

the hoses have no bubbles or blisters

■

the hoses or outer sheaths of the hoses are not abnormally rigid or hard

■

the outer sheaths of the hoses are not damaged

■

the connectors are securely inserted into the sockets

■

the connections are leak-tight

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage in the whole system! Flush out the hydraulic lines thoroughly before connecting.

If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

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Safety instructions _______________________________________________ Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn orings.

Replace hydraulic hoses only with hoses of the same or a higher quality.

Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

laying hydraulic hoses

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting

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_______________________________________________ Safety instructions ■

are not bent directly behind the connections. (distance min. 1.5 x nominal diameter).

Fig. 3: Laying hydraulic hoses, bending Right

■

Wrong

always have a little slack.

Fig. 4: Laying hydraulic hoses, crossing Right

■ ■ ■ ■

Wrong

are not kinked. do not have to withstand tensile strains. are protected against thermal radiation. are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

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Safety instructions _______________________________________________

When installing the hydraulic hoses, ensure that they cannot be: ■ ■ ■ ■ ■

torn out, kinked, crushed, driven over or twisted by movement of the machine.

Fig. 5: Laying hydraulic hoses, connections on moving parts Right

Wrong

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3

Storage and transport

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____________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the feeder breaker. Observance of the instructions and tips will increase the service life and availability of the machine. You will also be able to carry out the transport work quicker and more safely.

Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

Components coated with temporary corrosion inhibitor are protected for approximately six months.

Before delivery, the hydraulic functions are tested and the hydraulic pressures are preset to OEM specifications.

Storage of the machine and spare parts no direct exposure to sunlight

dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight.

Protect the equipment and all spare parts stored outdoors against moisture and dirt, e.g. using tarpaulins.

Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.

short-term storage

long-term storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

If the equipment is to be stored more than six months, the following lubrication and corrosion inhibiting procedures must be followed: ■

If the cylinder rods are exposed, the rods must be coated with a corrosion inhibiting fluid or grease.

■

Remove the breather on the hydraulic oil tank and plug. Completely fill the tank with oil.

■

Remove breathers from the gear cases and plug. Completely fill all gear cases.

■

Lubricate all grease points (see the Maintenance section in Chapter 5 of this manual).

■

Coat the conveyor chain and the breaker drive chain with a heavy coat of rust inhibitor fluid or grease.

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Storage and transport _____________________________________________

machine electrics random sample inspection

natural aging

HFA fluids

■

Coat exposed valve bank valve spools with rust inhibitor.

■

Completely drain the water system and refill with a 50/50 antifreeze/ water solution. Pump the antifreeze mix through the system until the antifreeze mix comes out of the water sprays. ENSURE THAT THE SYSTEM IS COMPLETELY PURGED AND THAT NO WATER OR AIR POCKETS EXIST.

■

The equipment must be stored in a well ventilated, dry room. Do not store outdoors.

Electronic components should be stored at temperatures between 0 °F and 176 °F (-18 °C and 80 °C) After a storage period of approximately two years, a random sample inspections must be performed to determine whether the measures taken and the method of storage has prevented damage.

Even with proper storage, seals and hoses are subject to natural aging.

Do not use these parts if they have been stored for more than two years.

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in Chapter 6 of this manual.

IMPORTANT! Take care to ensure that new maintenance supplies are stored separately from existing stock and that removal takes place on the “first in, first out”principle.

Long-term storage of spare components hydraulic components

miscellaneous components

motors

plastic deformation

If a component is to be stored more than six months, the hydraulic component must be completely filled with a corrosion inhibiting fluid. Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow, then seal the ports with plastic or steel plugs.

Store the electrical equipment, electronic components, spare parts of rubber or plastic (such as seals and hoses) and hydraulic fluids only in closed rooms at temperatures of 60 °F (15 °C) to 77 °F (25 °C).

Refer to the motor manufacturer’ s storage procedure guide in the parts manual.

In order to prevent plastic deformation of the seal elements, cylinders must be sotred in an upright position. Some cylinders must be removed so that they can be stored upright.

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____________________________________________ Storage and transport Transport Load units, dimensions, and weights Observe the transport sheets for the machine and spare parts. They contain information on: ■

dimensions,

■

weights,

■

lifting points, etc. (See Fig. 6 for lifting point locations)

Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.

Fig. 6: Lifting points on the feeder breaker

Lifting point

Lifting point

Lifting point (typical 2 places) looking in at the machine: Insert hook into slot and route the chain under the frame and into the conveyor discharge area.

Note: Approximate machine weight is 106,500 lbs, as shown.

16 ton lift eye

16 ton lift eye

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Storage and transport _____________________________________________ Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid.

Transport of equipment at temperatures between -6° F (-21° C) and 40° F (-40° C) is only permissible when certain measures were taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport.

electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

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4

Installation

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______________________________________________________ Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on the safety components (pressure relief valves, fire extinguishing equipment, etc.), the electrical equipment (control units, signaling devices, etc.), and the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by service engineers or by specially trained personnel.

Which tools are required for installation? tool box

General tools are required to put the feeder breaker into service.

Various items of auxiliary equipment and machines may be required at the point of installation, including ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

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Installation ______________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the feeder breaker as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists from Caterpillar. installation plan

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work, a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established

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______________________________________________________ Installation Pre-installation check list NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: ■

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

operate all control valve handles to ensure that they are free and in the neutral position

■

check that the neutral start mechanism is in place and is operational

■

check conveyor and breaker area for any foreign objects and clear any material that may cause a jam

■

check tension of conveyor chain

■

check safety provisions for operational condition on fire suppression system (if equipped)

■

check safety provisions for operational condition on tail shaft cover plate (if equipped)

■

check safety provisions for operational condition on power unit shrouds and guards

■

jog the breaker motor to check for correct rotation of breaker

■

jog the conveyor motor to check for correct rotation of conveyor chain

■

start up the machine and check for correct operation of all stop switches

■

check the operation of the remote start pushbuttons

■

start the machine and allow the hydraulic system to warm up for five (5) to ten (10) minutes

■

check hydraulic system pressures (see spare parts manual for hydraulic schematic)

■

check all control handles to ensure all machine functions are operating properly

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Installation ______________________________________________________ Safety features NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

Safety features include (Reference Fig. 7): guards and covers

The machine is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.

DANGER! Do not operate the machine any of the guards or covers removed.

You or other personnel could be seriously injured from moving or rotating parts.

“PICK BRK/CONV STOP”switch (starter enclosure)

This stop switch is located on the right hand side of the machine, on the starter enclosure cover. Depressing the “PICK BRK/CONV STOP” switch button will shutdown the pick break motor and the conveyor/ pump motor immediately.

“E-STOP”switch (starter enclosure)

This stop switch is located on the right hand side of the machine, on the starter enclosure cover. Depressing the “E-STOP”button will shutdown all machine functions immediately. All power is removed from the machine and the circuit breaker must be reset at the power center before the machine can be restarted.

“EMERGENCY STOP”switch (shuttle car power distribution box)

This stop switch is located on the right hand side of the machine, on the shuttle car power distribution box. Depressing the “EMERGENCY STOP”button will shutdown all machine functions immediately. All power is removed from the machine and the circuit breaker must be reset at the power center before the machine can be restarted.

“EMERGENCY STOP”switch (trailing cable junction box)

This stop switch is located on the right hand side of the machine, on the trailing cable junction box. Depressing the “EMERGENCY STOP”button will shutdown all machine functions immediately. All power is removed from the machine and the circuit breaker must be reset at the power center before the machine can be restarted.

panic strip

The machine is equipped with three panic strips: one is located at the primary operator’ s station and one at the secondary valve bank on the right hand side of the machine and the third is located beside the oil tank on the left side of the machine. Striking with a small amount of force will actuate either of the panic strips. The panic strip is used to break the control circuit in emergency situations. When the panic strip is struck, all machine functions are shutdown immediately.

emergency pull cord

The emergency pull cord is located over the hopper. Pulling the cord from either side of the machine will shutdown the feeder by tripping the master control relay. Power is still on the machine and the machine can be restarted using normal start-up procedures after the latch at the pull cord is flipped and the chord positioned back in the center, neutral, position.

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______________________________________________________ Installation fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators. One is located adjacent to the primary operator’ s station on the right side of the machine and one is located beside the oil tank on the left side of the machine. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

neutral start mechanism

The machine is equipped with a guard that covers the primary valve bank levers, while in neutral position, during start up. The neutral start guard must be in place over the levers for the machine to start.

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Installation ______________________________________________________ Fig. 7: Safety features on the feeder breaker (typical)

Emergency pull cord

Panic strip

Fire suppression actuator

Neutral start mechanism

Panic strip

Panic strip Fire suppression actuator

“EMERGENCY STOP” (trailing cable junction box)

“PICK BREAK/ CONV STOP”

“E-STOP”

“EMERGENCY STOP” (shuttle car distribution box)

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______________________________________________________ Installation Fig. 8: Overview of the feeder breaker (typical) Photo eye sensor

Emergency pull chord

Discharge section

Photo eye sensor

Tailpiece Head shaft

Secondary valve bank

Oil tank power jet fill

Conveyor drive assembly

Breakershaft

Hydraulic oil tank

Air/oil heat exchanger

Roof anchor arm (2)

Starter enclosure

Tailpiece steering cylinder (2) 16 ton lifting eye

Conveyor power unit Breaker power unit

Tailpiece tilt cylinder (2)

Stabilizer foot (2)

Frame lift cylinder (2) Torque hub Crawler assembly (2)

Shuttle car power distribution enclosure

Roof anchor arm cylinder (2)

Primary operator’ s station

Frame tilt cylinder (2) Conveyor chain Receiving section

Conveyor chain grease take-up cylinder and shims (2)

Side staker cylinder (located under machine) Tail shaft

16 ton lift eye (2)

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Installation ______________________________________________________ Towing the feeder breaker WARNING! It is not possible, within the scope of this guide, to anticipate all possible arrangements for towing the feeder breaker. Before attempting to tow the machine, you must take all possible precautions to protect the operators and anyone around the feeder breaker and the towing machine from being injured by either the towing machine or the feeder breaker. The primary towing device being used (cables, bars, etc.) and the towing machine must have load limits strong enough and heavy enough to maintain control through all conditions that may be encountered at any time.

Safety chains or other safety devices must be used in case of failure of the primary towing device. All operators must be alert at all times to prevent either machine from running out of control during towing. Failure to follow the above warning could cause serious injury or death to you or other workers.

To tow the feeder breaker proceed as follows: 1. Couple the towing machine securely to the feeder breaker.

2. Chock front and rear of both crawler drives.

WARNING! Failure to chock the front and rear of both crawlers could allow uncontrolled movement of the feeder breaker. Failure to follow this warning could cause serious injury or death to you or other workers.

3. Rotate the torque hub end cap on both right and left sides of the feeder to the free position as follows (Fig. 9).

4. Remove the two (2) bolts that retains the end cover to the center of the torque hub.

5. Rotate cover and reinstall with the two (2) bolts to disengage torque hub. Torque bolts to 120 in lb.

WARNING! At no time during towing should anyone ride in or on the machine being towed or stand in between the towing machine and the machine being towed. Failure to follow the above warning could cause serious injury or death to you or other workers.

WARNING! Do not exceed 5 mph during towing. Exceeding 5 mph could cause serious injury or death to you or other workers or damage to machine.

6. Remove chocks from crawler and begin towing.

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______________________________________________________ Installation 7. Once the destination is reached, stop both machines and chock both feeder crawlers in both directions to prevent accidental movement.

WARNING! Failure to chock the front and rear of both crawlers could allow uncontrolled movement of the feeder breaker. Failure to follow this warning could cause serious injury or death to you or other workers.

8. Rotate the torque hub end cap on both right and left sides of the feeder breaker to the drive position.

9. Remove the two (2) bolts that retains the end cap to the center of the torque hub.

10. Rotate end cap and reinstall with the two (2) bolts to engage torque hubs to the drive position. Torque bolts to 120 in lb.

Fig. 9: Torque hub disengagement

Retaining bolts (2)

Normal tram position

End cap button pointing outward

Retaining bolts (2)

End cap button pointing inward Freewheel position

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Installation ______________________________________________________

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_______________________________________________________________

5

Operation

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_______________________________________________________Operation

Operation This chapter contains important information on the operation and maintenance of the machine, an overview of the electrical, hydraulic, and mechanical components, how to adjust the machine, and instructions on the replacement of wear parts.

Read this chapter carefully and thoroughly paying particular attention to the safety instructions in Chapter 2, “Your safety”.

How to operate the feeder breaker DANGER! Incorrect operation endangers yourself and others! Incorrect operation of the machine is often the cause of very serious accidents! Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual. Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the feeder breaker?

The feeder breaker is only allowed to be operated by persons with adequate knowledge of the complete machine.

This also includes: ■

what safety devices are installed on the machine,

■

where these safety devices are located, and

■

how these safety devices are to be operated.

When can conveying be started?

Operation must not be started until the safe condition and proper function of the complete machine has been checked and the daily maintenance operations have been carried out.

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Operation _______________________________________________________ Controls and indicators Primary operator’s station The primary controls for the machine are located on the right side of the machine at the primary operator’ s station. The primary operator’ s station (Fig. 10) consists of the following controls and indicators: primary valve bank, system pressure gauge, starter enclosure, panic strip, fire suppression actuator, and shuttle car power distribution box.

Fig. 10: Primary operator’s station (typical - locations may vary)

Shuttle car power distribution box

Starter enclosure

Panic strip

Fire suppression actuator

Primary valve bank

Function gauge

Primary valve bank The primary valve bank (Fig. 11) consists of the following hydraulic controls: NOTICE! Once a hydraulic control valve handles is released by the operator, the lever will automatically return to the centered (neutral) position except for the “POWER FILL/SECONDARY”lever.

“LEFT TRAM”

The first lever from the operator’ s left controls the left tram functions.

To tram in the direction of the receiving end, slowly push the control lever towards the machine and to tram in the direction of the discharge end, slowly pull the control lever towards the operator.

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_______________________________________________________Operation “RIGHT TRAM”

The second lever from the operator’ s left controls the right side tram functions. To tram in the direction of the receiving end, slowly push the control lever towards the machine and to tram in the direction of the discharge end, slowly pull the control lever towards the operator.

WARNING! When tramming the machine from the operator’s station, the operator should stand beside the machine facing the conveyor with the tram control levers at arms length. Care should be taken to ensure that the operator’s feet do not get under the crawler tracks while the machine is moving.

The tram/steering control levers are used for tramming and positioning the machine. To tram the machine forward in a straight direction (towards the receiving end), push both tram control levers forward and to tram the machine in a straight direction in reverse (towards the discharge end), pull back on both tram control levers. To steer left in the direction of the receiving end, push the right tram control lever towards the machine while the left tram control lever is in the neutral position or for tighter turns, pull the left tram control lever towards the operator. To steer right in the direction of the receiving end, push the left tram control lever towards the machine while the right tram control lever is in the neutral position or for tighter turns, pull the right tram control lever towards the operator.

NOTICE! The feeder breaker has skid type steering; it is capable of turning within its own limits.

“LH FRAME LIFT”

The third lever from the operator’ s left controls the movement of the left cylinder at the pivot point of the crawler, which adjusts the ground clearance on the left side of the machine. To increase the ground clearance, slowly push the control lever away from the operator and to decrease the ground clearance, slowly pull the control lever towards the operator.

“RH FRAME LIFT”

The fourth lever from the operator’ s left controls the movement of the right cylinder at the pivot point of the crawler, which adjusts the ground clearance on the right side of the machine. To increase the ground clearance, slowly push the control lever away from the operator and to decrease the ground clearance, slowly pull the control lever towards the operator.

“FRAME TILT”

The fifth lever from the operator’ s left controls the movement of the cylinders mounted to the underside to the hopper and end of the crawlers, which adjust the discharge height of the machine. To raise the height, slowly push the control lever away from the operator and to lower the height, slowly pull the control lever towards the operator.

“TANK FILL” and “AUX VB”

The sixth lever from the operator’ s left has two (2) functions, it controls the “TANK FILL”and auxiliary valve bank, “AUX VB”oil flow for the machine. To operate the power fill, turn ball valve handle located on the left side of the discharge section to the open position and push the control lever. To de-energize power fill pump, move control lever to the centered position and turn ball valve handle to closed position. Pull the control lever towards the operator to energize the auxiliary valve bank.

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Operation _______________________________________________________ WARNING! The “TANK FILL/AUX VB”lever is the only lever on the valve bank that does not spring return to neutral when released. When not in use, the valve should be manually returned to the neutral position.

Failure to do so could result in unexpected machine movement if the secondary valve bank is energized and a lever on the secondary valve bank is inadvertently moved or machine overheating if the power fill pump is left energized. Unexpected machine movement could result in serious injury to personnel or damage equipment.

To operate the power fill:  Clean suction hose attached to the hydraulic power fill motor, located on top of the oil tank.  Remove the suction hose plug and submerge the suction hose in the new oil supply.  Turn the handle of the ball valve to the open position. The handle should now be inline with the hydraulic hose to which it is attached.  Position the “TANK FILL/AUX VB”lever in the “TANK FILL”position. Oil from the valve bank will now drive the power fill motor and a suction force will be created in the suction line. Oil from the new oil supply will be drawn through the power fill motor to the hydraulic oil tank.  Once the tank is filled to the desired level, pull the power fill lever on the valve bank to the neutral (center) position.  Turn the ball valve handle 90° to close the ball valve.  Remove the suction hose from the new oil supply.  Clean and install hose plug into suction hose. Store the suction hose on top of the oil tank.

CAUTION! After oil filling operation is complete, manually return the “POWER FILL”lever to the centered, neutral, position or overheating of the machine may occur. function pressure gauge

The function pressure gauge (Fig. 11) is located below the primary valve bank. This gauge provides a pressure reading for each active function on the machine.

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_______________________________________________________Operation panic strip

The panic strip (Fig. 11) is used to break the control circuit in emergency situations. Striking the panic strip with a small amount of force will actuate the panic strip: all machine functions are shutdown immediately.

fire suppression

The machine fire suppression (remote) actuator (Fig. 11) is used to activate the fire suppression system on the machine. The fire suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If the fire suppression actuator is actuated, the system must be completely recharged with dry chemicals and expellants.

Fig. 11: Primary valve bank, fire suppression actuator, panic strip, and system pressure gauge

Panic strip

“LEFT TRAM”

“RIGHT TRAM”

Conveyor sections (solenoids controlled via PLC)

“LH FRAME LIFT”

“RH FRAME LIFT”

“FRAME TILT”

“TANK FILL” and “AUX VB”

Fire suppression actuator

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Operation _______________________________________________________ Secondary operator’s station The secondary operator’ s station (Fig. 12) is located at the head shaft on the right side of the machine. The secondary operator’ s station consists of the auxiliary valve bank and a panic strip.

The auxiliary valve bank (Fig. 12) consists of the following controls: “TAIL TILT”

“TAIL STEER”

The first lever from the operators left is the “TAIL TILT”control lever which is used to position the tailpiece vertically (up and down). To tilt the tailpiece up, slowly pull the control lever towards the operator. To tilt the tailpiece down, push the control lever away from the operator.

The second lever from the operator’ s left is the “TAIL STEER”control lever which is used to position the tailpiece horizontally (left and right).

To move the tailpiece away from the operator, push the control lever forward. To move the tailpiece toward the operator, pull the control lever back.

“LEFT FLOOR”

The third lever from the operator’ s left is the “LEFT FLOOR”control lever which controls the left floor (foot) stabilizer cylinder. To lower the foot, slowly push the control lever away from the operator. To raise the foot, slowly pull the control lever towards the operator.

“RIGHT FLOOR”

The fourth lever from the operator’ s left is the “RIGHT FLOOR”control lever which controls the right floor (foot) stabilizer cylinder. To lower the foot, slowly push the control lever away from the operator. To raise the foot, slowly pull the control lever towards the operator.

“LEFT ROOF”

The fifth lever from the operator’ s left is the “LEFT ROOF”control lever which controls the left roof stabilizer cylinder. To raise the arm, slowly push the control lever away from the operator. To lower the arm, slowly pull the control lever towards the operator.

“RIGHT ROOF”

The sixth lever from the operator’ s left is the “RIGHT FLOOR”control lever which controls the left roof stabilizer cylinder. To raise the arm, slowly push the control lever away from the operator. To lower the arm, slowly pull the control lever towards the operator.

“SIDE STAKER”

The seventh lever from the operator’ s left is the “SIDE STAKER”control lever which controls the side staker (stabilizer) cylinder located at the hopper end of the machine. To extend the cylinder, slowly push the control lever away from the operator. To retract the cylinder, slowly pull the control lever towards the operator.

panic strip

The panic strip (Fig. 12) is used to break the control circuit in emergency situations. Striking the panic strip with a small amount of force will actuate the panic strip: all machine functions are shutdown immediately.

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_______________________________________________________Operation Fig. 12: Secondary operator’s station Panic strip

“TAIL TILT”

“TAIL “LEFT STEER” FLOOR”

“RIGHT FLOOR”

“LEFT ROOF”

“RIGHT ROOF”

“SIDE STAKER”

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Operation _______________________________________________________ Shuttle car power distribution box The shuttle car power distribution box (Fig. 13) is located to the left of the primary valve bank. It provides three shuttle car power receptacles and a 120V GFCI tool receptacle.

“EMERGENCY STOP”

There is an “EMERGENCY STOP”button located in the upper right corner of the distribution box. Activating this button will trip the pilot in the trailing cable and all power will be removed from the machine. The power center trip must be reset to restore power to the machine.

“GFCI RECEPTACLE”

There is a 120V GFCI receptacle located on the right side of the distribution box. This receptacle is energized by setting the 15A circuit breaker located beneath the receptacle.

995V circuit breakers

There is a circuit breaker in each of the three separate shuttle car power circuits. To activate the circuit, set the circuit breaker.

For further information about the shuttle car power distribution box, please see the Electrical section of this chapter.

Fig. 13: Shuttle car power distribution box “EMERGENCY STOP”

“CIRCUIT 1 RECEPTACLE”

“CIRCUIT 2 RECEPTACLE”

“CIRCUIT 3 RECEPTACLE”

GFCI circuit breaker

“GFCI RECEPTACLE”

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_______________________________________________________Operation Starter enclosure The starter enclosure (Fig. 14) is located to the left of the primary valve bank and shuttle car power distribution box and houses the primary electrical control components of the machine.

“MAN/OFF/AUTO”

The “OFF/MAN/AUTO”selector switch is used to set the mode of operation. When in “OFF”mode, the breaker and conveyor motors will not start. Manual mode, “MAN”is used to bypass the outby conveyor sequence switch. When in manual mode, the outby conveyor belt does not need to be running. “AUTO”mode is used for normal operations.

“TRAM/OFF/CONV”

The “TRAM/OFF/CONV”selector switch is used to select tram or conveyor mode of operation. When in “OFF”mode, tram and conveyor functions are not active. “TRAM”mode is used when tramming the machine. When in tram mode, conveyor functions are not active. Conveyor mode, “CONV”, is used for normal operations. When in conveyor mode, tramming functions are not active.

“FWD/OFF/REV”

The “FWD/OFF/REV”selector switch is used to select the conveyor direction. When in “OFF”mode, the conveyor will not run. Reverse mode, “REV”, is a momentary function (conveyor runs in reverse as long as switch is held in “REV”position). Forward mode, “FWD”, is used for normal operations.

“LIGHTS OFF/ON”(optional)

The “LIGHTS OFF/ON”selector switch is used to turn the lights on or off. If there is not a light switch, the lights are always on.

“ACKNOWLEDGE ALARMS”or “ALARM RESET”

Used to clear an alarm from the display panel after the condition that generated the alarm is corrected.

“START BREAKER”

The “START BREAKER”pushbutton is used to start the pick breaker motor. When the button is pushed, an alarm sounds for a preset amount of time. After the alarm sound, the breaker motor will start.

The pick breaker motor must be started before the conveyor motor.

“START CONV/PUMP”or “CONVEYOR START”

used to start the conveyor/pump motor. The conveyor/pump motor will not start unless the pick breaker motor is running.

Used to stop the pick breaker and conveyor/pump motors.

“PICK BRK/CONV STOP”or “SYSTEM STOP” “E-STOP”

The “E-STOP”button is used to trip the master control relay, thereby shutting down the machine. Power is still on the machine.

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Operation _______________________________________________________ circuit breaker reset lever

The circuit breaker reset lever is used to reset the main circuit breaker when it has tripped. To reset the breaker, push the handle down, past “OFF”, to “RESET”and then back up to “ON”.

Fig. 14: Starter enclosure

54-2185

54-2193

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_______________________________________________________Operation PLC display

The display panel (Fig. 15) is located in the starter enclosure.

Fig. 15: PLC display panel location PLC display panel

Number pad

On screen navigation keys

Function keys

The display is used to monitor machine performance during operation, to troubleshoot the machine, and to change operating parameters.

“MAIN SCREEN”

The normal operation display screen is the “MAIN SCREEN”(Fig. 16).

This screen displays any active alarm, breaker and conveyor motor amps, breaker speed, conveyor speed, and mode of operation (with or without belt sequence active). It also provides a login/logout access.

This is the only screen available without a password. After logging in, access to four additional screens is displayed.

For alarm information, see the troubleshooting section in this chapter.

Fig. 16: “MAIN SCREEN”

Alarm banner

Operating status

Logout

Login

Screen access

Belt sequence selection status

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Operation _______________________________________________________ After logging in, the functions keys “F1”through “F4”(Fig. 15) are used to access four additional screens: “STATUS”, “PRESETS”, “TIMER 1”, and “TIMER 2”. Currently, function keys “F5”through “F8”are not used.

“STATUS SCREEN”

The “STATUS SCREEN”(Fig. 17) is accessed by pushing function key “F1”. This screen displays the incoming line voltage, breaker speed, conveyor speed, hydraulic oil pressure, vacuum pressure, the current in each phase of the breaker and pump motors. To return to the “MAIN SCREEN”from the “STATUS SCREEN”, press “F1”.

Fig. 17: “STATUS SCREEN”

“PRESETS SCREEN”

The “PRESETS SCREEN”(Fig. 18) is accessed from the “MAIN SCREEN”by pushing function key “F2”. This screen allows access to the preset breaker shaft speed designations for low, medium and high speeds. To return to the “MAIN SCREEN”from the “PRESET SCREEN”, press “F1”. The timer screens can be accessed from the “PRESET SCREEN”by pressing “F3”or “F4”.

Fig. 18: “PRESET SCREEN”

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_______________________________________________________Operation “OPERATION TIMERS SETUP SCREEN”(“TIMERS 1”)

The “TIMERS 1 SCREEN”(Fig. 19) is accessed from the “MAIN SCREEN”by pushing function key “F3”. This screen allows access to the “OPERATION TIMERS SETUP SCREEN”. These are the timers for the breaker idle shutdown, the start-up warning horn, and conveyor run. To return to the “MAIN SCREEN”from the “TIMERS 1 SCREEN”, press “F1”. The “PRESETS”and “TIMER 2”screens can be accessed from the “TIMERS 1 SCREEN”by pressing “F2”or “F4”.

Fig. 19: “OPERATION TIMERS SETUP SCREEN”(“TIMERS 1”)

“JAM TIMERS SETUP SCREEN”(“TIMERS 2”)

The “TIMERS 2 SCREEN”(Fig. 20) is accessed from the “MAIN SCREEN”by pushing function key “F4”. This screen allows access to the “JAM TIMERS SETUP SCREEN”. These are the timers for the breaker overload preset amps, beaker overload delay, conveyor slow backup, and conveyor slow forward. To return to the “MAIN SCREEN” from the “TIMERS 2 SCREEN”, press “F1”. The “PRESETS”and “TIMER 1”screens can be accessed from the “TIMERS 1 SCREEN”by pressing “F2”or “F3”.

Fig. 20: “JAM TIMERS SETUP SCREEN”(“TIMERS 2”)

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Operation _______________________________________________________ Controls and indicators - other locations The following controls and indicators are located as described throughout the machine. foot cylinder locking pin

There is a mechanical locking pin on each foot cylinder (Fig. 21) that must be installed after the feeder is set in the dump position and the foot is planted. The locking pin will hold the cylinder in the extended position in the event that the foot cylinder counterbalance valve fails or is removed. Remove the pin before attempting to retract the cylinder.

Fig. 21: Foot cylinder mechanical locking pin

Locking pin storage tube

power fill ball valve

The power fill ball valve (Fig. 22) is located on the hydraulic oil tank on the left side of the machine and is used to open the hydraulic flow to the power fill pump. To operate the power fill, the ball valve must be opened, handle in line with the hydraulic line. Then the control handle on the primary valve bank (6th handle from the operator’ s left is moved to the “POWER FILL”position (handle pushed forward). To deenergize the power fill pump, move the control lever to the centered position and turn ball valve handle to closed position.

CAUTION! The “POWER FILL/AUX VB”lever is the only lever on the primary valve bank that does not spring return to neutral when released.

When the fill operation is complete, the lever must be manually returned to the neutral position. Failure to return the lever to neutral will result in the machine overheating.

hydraulic oil level sight glass

The hydraulic oil level sight glass (Fig. 22) is located on the hydraulic oil tank on the left side of the machine. The oil level should not be allowed to drop below the bottom of the sight glass.

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_______________________________________________________Operation Fig. 22: Power fill ball valve and oil level sight glass Power fill ball valve

Oil level sight glass

dust suppression system regulator

dust suppression system pressure gauge dust suppression system strainer

The dust suppression system regulator (Fig. 23) is located below the breaker power unit on the right side of the machine and is used to control the flow of water to the six spray nozzles located in the hose crossover tray in the breaker shaft. The water pressure to the nozzles is monitored by the dust suppression system pressure gauge (Fig. 18).

To increase pressure, turn the regulator handle in (cw). To decrease pressure, turn the regulator handle out (ccw).

The dust suppression system pressure gauge (Fig. 23) is used to monitor the water pressure to the spray nozzles. The gauge should read between 5 and 125 psi.

The dust suppression system strainer (Fig. 23) is located below the breaker power unit on the right side of the machine and is used to filter particles from the mine water supply. The strainer should periodically be flushed to avoid becoming clogged. To flush the strainer, turn the ball valve handle, located on the branch of the strainer body, 90° in-line with the outlet. Allow to flush for approximately thirty seconds to one minute and then close the ball valve handle.

Fig. 23: Dust suppression system regulator and pressure gauge Gauge Regulator

Regulator handle

Strainer

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Operation _______________________________________________________ Photo eye pump motor controls An ordinary cap light can be sued to start the pump motor on the machine by simply shining the light on either photo eye sensor for approximately four seconds. A siren will sound for approximately five seconds and then the pump motor will start. The feeder breaker is equipped with two photo eye sensors (Fig. 24) and a photo eye control board enclosure.

Fig. 24: Photo eye Photo eye

Photo eye

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_______________________________________________________Operation “AUTO”mode starting procedure The feeder breaker is normally operated in “AUTO”mode. While in “AUTO”mode, the belt sequence switch is active: the outby belt must be running for the feeder breaker to run.

After reading the previous descriptions and locating each control, the operator is ready to operate the feeder breaker. An experienced operator should monitor a new operator’ s indoctrination to the starting procedure.

WARNING! The machine should not be started if it’s core temperature is below 30° F. If the machine is started at extremely low temperatures pump and pump motor failure could occur.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.

1. Operate all primary and secondary valve bank control levers to ensure that they are free and in neutral position.

2. Position the primary valve bank handle neutral start lock guard over the valve handles so that they cannot be operated. Make sure the magnetic contactors are fully seated and are in direct contact.

IMPORTANT! The machine will not start unless all valve control levers on the primary valve bank are in neutral position and the guard is fully closed, engaging the magnetic switch.

3. Check conveyor for any foreign material or objects.

4. Check that all other personnel are within a safe distance of the machine.

WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the machine.

5. Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET”position and then to the “ON”position.

6. Turn the “OFF/MANUAL/AUTO”selector switch located on the cover of starter enclosure to the “AUTO”position.

7. Engage the “START BREAKER”pushbutton located on the cover of the starter enclosure. An alarm will sound for a preset amount of time and then the pick break motor will start.

8. After the pick break motor starts, engage the “START CONVEYOR” pushbutton located on the cover of the starter enclosure to start the pump motor. ______________________________________________________________ A6474X338

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Operation _______________________________________________________ “MANUAL”mode starting procedure If the machine needs to be operated while the outby belt is off (belt sequence switch by-passed), start the machine in “MANUAL”mode.

After reading the previous descriptions and locating each control, the operator is ready to operate the feeder breaker. An experienced operator should monitor a new operator’ s indoctrination to the starting procedure.

WARNING! The machine should not be started if it’s core temperature is below 30° F. If the machine is started at extremely low temperatures pump and pump motor failure could occur.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.

1. Operate all primary and secondary valve bank control levers to ensure that they are free and in neutral position.

2. Position the primary valve bank handle neutral start lock guard over the valve handles so that they cannot be operated. Make sure the magnetic contactors are fully seated and are in direct contact.

IMPORTANT! The machine will not start unless all valve control levers on the primary valve bank are in neutral position and the guard is fully closed, engaging the magnetic switch.

3. Check conveyor for any foreign material or objects.

4. Check that all other personnel are within a safe distance of the machine.

WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the machine.

5. Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET”position and then to the “ON”position.

6. Turn the “OFF/MANUAL/AUTO”selector switch located on the cover of starter enclosure to the “MANUAL”position.

7. Engage the “START BREAKER”pushbutton located on the cover of the starter enclosure. An alarm will sound for a preset amount of time and then the pick break motor will start.

8. After the pick break motor starts, engage the “START CONVEYOR”pushbutton located on the cover of the starter enclosure to start the pump motor.

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_______________________________________________________Operation Shutdown procedures There are several methods of shutting down the feeder breaker.

1. Allow the machine to run until the hopper is empty. Continue to run the machine until all material that has been carried back into the return line has been cleaned out.

IMPORTANT! If material is very wet or sticky, it is recommended that the return line be flushed with water and the conveyor be allowed to run and clean out the return line before shutting the machine down.

To shutdown the feeder breaker in “REGULAR”mode: 2. Engage the “PICK BKR/CONV STOP”pushbutton located on the starter enclosure. This will stop the pick break motor and the pump motor.

3. Turn the circuit breaker reset switch to the “OFF”position .

The machine can also be shutdown in emergency situations using a panic strip, the “E-STOP”button on the starter enclosure, the pull cord, or the “EMERGENCY STOP”button on the cable connection box.

Activating the panic strip, the “E-STOP”button on the starter enclosure, or the pull cord will open the master control relay, “MCR”. Power will still be on the machine and the machine can be restarted using normal starting procedures. If the “EMERGENCY STOP”button on the cable connection box is activated, the circuit breaker at the power center must be reset before the machine can be restarted.

To shutdown the feeder breaker using a panic strip: There are three (3) panic strips located on the feeder breaker: one at the operator’ s station and one at the secondary valve bank on the right side of the machine and one on the left side of the machine beside of the hydraulic oil tank. Striking any panic strip with a small amount of force will shutdown the machine.

To shutdown the feeder breaker using the “E-STOP”button: There is an emergency stop, “E-STOP”, button located on the cover of the starter enclosured. Push the “E-STOP”button to shutdown the machine.

To shutdown the feeder using the pull cord: There is an emergency pull cord located over the hopper. Pulling this cord will shutdown the machine.

To shutdown the feeder using the “EMERGENCY STOP”button: The “EMERGENCY STOP”button is located on the cable connection box. Striking the button with a small amount of force will shutdown the machine.

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Operation _______________________________________________________ Tramming 1. Turn the “OFF/FWD/REV”selector switch located on the cover of the starter enclosure to the “OFF”position.

2. Turn the “OFF/TRAM/CONVEYOR”selector switch located on the cover of the starter enclosure to the “TRAM”position.

3. Turn the “OFF/MANUAL/AUTO”selector switch located on the cover of starter enclosure to the “MANUAL”position.

4. Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET”position and then to the “ON”position.

5. Engage the “START CONVEYOR”pushbutton located on the cover of the starter enclosure to start the pump motor.

6. Lift up the neutral start valve handle guard all the way back so that the guard will not fall on the operator’ s hands.

The machine can now be trammed.

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_______________________________________________________Operation Conveyor 1. Start the machine in either “AUTO”or “MAN”mode (see Starting procedures in this chapter).

2. Turn the “OFF/TRAM/CONVEYOR”selector switch located on the cover of the starter enclosure to the “CONVEYOR”position.

3. Push the “START CONV/PUMP”button to start the conveyor motor.

4. Turn the “OFF/FWD/REV”selector switch located on the cover of the starter enclosure to the “FWD”position.

It is important to note the following concerning the operation of the conveyor in the forward direction: –

The current of the breaker shaft motor is constantly monitored by the PLC. If the current remains below 100% of the full load current (FLA), the conveyor will continue to run at the set speed.

–

If the current increases above 125% FLA and stays at that level for three seconds, the PLC will assume there is a conveyor jam. The PLC will try to clear the jam by stopping the conveyor, running it in reverse for three seconds at 10% speed, and then running it forward for ten seconds at 25% speed.

–

If the current at this point is still above 125% FLA, the conveyor will repeat the above reverse/forward sequence for a second time.

–

If the current at this point is still above 125% FLA, the conveyor will repeat the above reverse/forward sequence for a third time.

–

If the current at this point is still above 125% FLA, the machine will shutdown and the display will read “BIG JAM”. The conveyor will need to be cleared before operation resumes.

–

If the current drops below 125% FLA at any time during the three reverse/forward sequences, the speed of the conveyor will ramp back up to the set speed.

IMPORTANT! If it is necessary to reverse the conveyor, it should be jogged only. Running the conveyor in the reverse direction for a period of time with material in the hopper, will jam the conveyor and it will be necessary to empty the machine hopper before the conveyor will restart.

Operating the conveyor in reverse 1. Turn the “OFF/FWD/REV”selector switch located on the cover of the starter enclosure to the “REV”position. The conveyor chain will now run in reverse at 25% full speed as long as the switch is in the “REV”position. Note: the conveyor should not be run in reverse for extended periods; only jog the conveyor when in reverse.

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Operation _______________________________________________________ Control system operating parameters The following parameters affect the operation of the machine as indicated: Breaker underspeed If the pick break sensor does not pick up within ten seconds of the breaker motor starting, the control system will shutdown the breaker motor and a “BREAKER UNDERSPEED ALARM”will be displayed.

Breaker motor overload If the breaker motor current exceeds a preset value, the control system will shutdown the machine and the “BREAKER MOTOR OVERLOAD ALARM”will be displayed.

Pump motor overload If the pump motor current exceeds a preset value, the control system will shutdown the machine and the “PUMP MOTOR OVERLOAD ALARM”will be displayed.

High oil temperature If the hydraulic oil temperature exceeds a preset value, the control system will shutdown the machine and the “HIGH OIL TEMPERATURE ALARM”will be displayed.

Low oil level If the hydraulic oil level falls below a preset level for more than three seconds, the control system will shutdown the machine and the “LOW OIL LEVEL ALARM”will be displayed.

Emergency stop If the master control relay is opened by activating a panic strip, the pull cord, or the emergency stop on the starter enclosure, the machine will shutdown and the “EMERGENCY STOP ALARM”will be displayed.

Big jam shutdown If the machine fails to clear a jam after three attempts (see Conveyor operation in this section), the control system will shutdown the machine and the “BIG JAM SHUTDOWN ALARM”will be displayed.

Breaker motor contactor If the auxiliary switch on the breaker motor contactor fails to close within one second of the contactor closing, the control system will shutdown the machine and the “BREAKER MOTOR CONTACTOR ALARM”will display.

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_______________________________________________________Operation Pump motor contactor If the auxiliary switch on the pump motor contactor fails to close within one second of the contactor closing, the control system will shutdown the machine and the “PUMP MOTOR CONTACTOR ALARM”will display.

Pressure line dirty filter If the pressure line hydraulic oil filter pressure, as monitored by the dirt indicator on the end of the filter, closes for more than five seconds, the “PRESSURE LINE DIRTY FILTER ALARM”will be displayed.

Return line dirty filter If the return line hydraulic oil filter pressure, as monitored by the dirt indicator on the end of the filter, closes for more than five seconds, the “RETURN LINE DIRTY FILTER ALARM”will be displayed.

Hydraulic oil water removal filter There is a filter in the case drain lines of the open loop load sense pump and the conveyor motor that removes water from the hydraulic oil. If the filter pressure, as monitored by the dirt indicator on the end of the filter, closes for more than five seconds, the “HYDRAULIC OIL WATER REMOVAL FILTER ALARM”will be displayed.

High oil pressure If the hydraulic oil pressure exceeds 4,800 psi for more than three second, the control system will shutdown the machine and the “HIGH OIL PRESSURE ALARM”will be displayed.

Low pump suction If the vacuum in the main suction line in the hydraulic oil tank is less than a preset value for five seconds, the control system will shutdown the machine and the “LOW PUMP SUCTION ALARM”will be displayed. The vacuum transducer is located in the suction line fitting of the pump suction port.

Tram control magnet switch If the neutral start switch (see Controls and Indicators section of this chapter) is not in place when the pump motor is started, the control system will not allow the motor to start and the “TRAM CONTROL MAGNET SWITCH ALARM”will be displayed.

Pressure transducer If the hydraulic system pressure transducer reads greater than 1,000 psi, the water solenoid is turned on and the water sprays are activated.

This transducer also activates the high oil pressure alarm and is located in the gauge manifold at the main operator’ s station.

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Operation _______________________________________________________ Breaker idle shutdown timer If the conveyor is running and no cars dump on the conveyor within a two and one half (2-1/2) minute time period, the control system will shutdown the conveyor motor.

If no conveyor function is engaged on a running machine within a fifteen minute time period, the control system will shutdown the breaker motor.

Conveyor speed There is a mag pulse sensor located on the head shaft that counts how many revolutions per minute the head shaft turns. This information is sent to the PLC where it is converted to feet per minute (fpm) and displayed as conveyor speed.

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________________________________________________ Electrical system Electrical system The following pages contain a brief description of the major electrical components and assemblies that are on the feeder breaker.

The machine receives electrical power through a heavy-duty trailing cable. Be sure that the box connector is correctly identified and is securely connected; also check that the cable entrance is in good mechanical condition. Walk along the trailing cable from the power center to the feeder breaker and check the condition of the trailing cable. Give special attention to points most apt to cause damage, such as corners, intersections, and where cable may be run over by moving equipment.

Never use trailing cable with exposed wires or splices which heat up or spark under load.

WARNING! This section is intended only to familiarize the user with the major electrical components of the feeder breaker. All electrical maintenance should be performed only by a qualified electrician with the knowledge of the function of the components involved.

WARNING! Before removing the cover from the starter enclosure and attempting any maintenance or troubleshooting on the machine, the main power must be disconnected and locked and tagged out at the main power center.

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Electrical system _________________________________________________ Fig. 25: Major electrical component locator Head shaft tachometer Belt pulley underspeed sensor Panic strip

Breaker power unit Photo eye board enclosure Trailing cable junction box

Oil temperature probe

Suction transducer High temperature Conveyor power unit Oil level float and switch Panic strip

Starter enclosure

Breaker shaft underspeed sensor and tachometer

Shuttle car power distribution enclosure Emergency pull cord Panic strip Pressure transducer

Photo eye sensor

Photo eye sensor

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________________________________________________ Electrical system belt pulley underspeed sensor

The belt pulley underspeed sensor in mounted on tailpiece on the right hand side of the machine, near the pulley. The sensor will shut down the conveyor electric motor if the conveyor stops running.

breaker shaft underspeed sensor

The breaker shaft underspeed sensor is mounted on the breaker shaft assembly and monitors the speed of the breaker shaft. If the breaker shaft speed falls below a preset value, the electric motors will shut off.

panic strips

emergency pull cord photo eye sensors

high temperature switch

There are three panic strips located on the machine. Activating any one of the panic strips will open the master control relay, “MCR”, thereby shutting down the machine.

Activating the emergency pull cord, located over the hopper, will open the master control relay, “MCR”, thereby shutting down the machine.

The photo eye sensors are used to remotely start the conveyor/pump motor and are mounted on top of the machine on both sides of the hopper. The pump motor will start when a light shines on the sensor for approximately four seconds.

The high temperature switch is mounted on the wall behind the conveyor power unit on the right hand side of the machine and will shut down the machine if the hydraulic oil temperature exceeds a preset value. The temperature probe is located in the oil tank.

low oil switch

The low oil switch is mounted inside the oil tank. The electric motors will shut off if the oil level in the tank falls below a preset value.

breaker power unit

The breaker power unit is a 200 HP, 950 VAC, 3 phase, 60 Hz, 1750 rpm, totally enclosed, fan cooled non-explosion proof electric motor.

conveyor power unit

The conveyor power unit is a 125 HP, 950 VAC, 3 phase, 60 Hz, 1750 rpm, totally enclosed, fan cooled non-explosion proof electric motor.

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Electrical system _________________________________________________ Trailing cable junction box The trailing cable junction box (Fig. 26) is located on the right side of the machine. From the trailing cable junction box, power is sent to a junction box on the shuttle car distribution enclosure. There is an “EMERGENCY STOP”button located on the trailing cable junction box.

When activated, the “EMERGENCY STOP”but will shut the machine down by disconnection the pilot in the incoming trailing cable. If the “EMERGENCY STOP”button is activated, the power must be reset at the main power center.

Fig. 26: Trailing cable junction box

Connection to shuttle car distribution box (not shown)

“EMERGENCY STOP”(optional)

Trailing cable connection

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________________________________________________ Electrical system Shuttle car distribution box The shuttle car distribution box (Fig. 27) is located on the right side of the machine. Power enters the distribution box from the trailing cable junction box and is distributed to the starter enclosure and three shuttle car power circuits.

Fig. 27: Shuttle car distribution box (typical) Ground fault monitor (3)

Circuit breaker “ON/OFF” (3)

“EMERGENCY STOP”button “120 VOLTS CONTROL FUSE

120V GFCI receptacle

“CIRCUIT #1” shuttle car cable receptacle

“CIRCUIT #2” shuttle car cable receptacle

“CIRCUIT #3” shuttle car cable receptacle

120V receptacle circuit breaker

Incoming power cable connection

Outgoing power cable connection to starter enclosure

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Electrical system _________________________________________________ Fig. 27, continued: Shuttle car distribution box Ground fault monitor (3)

Fuse (2) (10A 120V)

Circuit breaker (3)

950 - 120VAC transformer

Bus bar (3)

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________________________________________________ Electrical system ground fault monitor

A ground fault monitor is located in each 995V circuit. The ground fault monitors for ground fault leakage current in the circuit. If a ground fault is connected, the circuit will trip, removing power from that circuit.

There is a ground test function for each ground fault monitor

“EMERGENCY STOP”

When activated, the “EMERGENCY STOP” button will trip the pilot in the trailing cable. If the “EMERGENCY STOP”is activated, all power is removed from the machine and must be reset at the power center.

“120 VOLTS CONTROL FUSE”

The “120 VOLTS CONTROL FUSE”is connected to both the 120V and the 995V circuits. If this fuse is blown, the 995V circuit breakers cannot be set (turned on).

circuit breakers

A thermal-magnetic trip 225A circuit breaker with a trip range of 300 to 650A and 120V UVR (under voltage release) is located in each of the three 995V circuits. Turning the circuit breaker to the “ON”position will energize the shuttle car receptacle. Do not turn the circuit breaker to the “ON”position if the 120V fuse is blown.

CAUTION! Do not set the circuit breaker if the 120V fuse is blown. Internal damage to the circuit may occur.

120V GFCI receptacle and circuit breaker

The 120V GFCI (ground fault circuit interrupter) outlet is located on the right side of the box. The 120V receptacle is energized by setting the single pole, 15A circuit breaker located below the receptacle.

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Electrical system _________________________________________________ Starter enclosure (54-2185) The starter enclosure, located on the right side of the machine, houses the primary electrical control components.

WARNING! Before removing the cover from the starter enclosure and attempting any maintenance or troubleshooting on the machine, the main power must be disconnected and locked and tagged out at the main power center.

There are operational controls located on the front of the starter enclosure (Fig. 28). For control descriptions, see the Controls and Indicators section in this chapter.

Fig. 28: Starter enclosure “MAN/OFF/ AUTO”

“15 AMP CB RESET

“TRAM/OFF/ CONV”

“ACKNOWLEDGE ALARMS”

“FWD/OFF/ REV”

“START BREAKER”

circuit breaker

“LIGHTS ON/OFF”

“START CONV/PUMP”

“PICK BRK/ CONV STOP”

PLC controls and display panel

“E. STOP”

Circuit breaker reset lever

In addition to the switches and the display panel, there is a 15A circuit breaker for control power mounted on the back side of the cover panel.

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________________________________________________ Electrical system Swing panel The swing panel (Fig. 29) is accessed by opening the cover on the enclosure. Located on the swing panel are: indicator lights, relays, timers, and a circuit breaker reset.

Immediately adjacent to the swing panel is the main circuit breaker, CB1, for the feeder breaker.

Note that component locations are typical. Always consult the parts book for your machine to verify locations.

Fuse, 10A

Fuse, 10A

IS relay

Amplifier board #2 TAC monitor

TAC monitor

Current transducer

Amplifier board #1

Digital output module “CRR”

Digital input module “CR2”

“CR1”

Digital input module “CRWS”

Analog output module “MCR”

“SR”

Analog input module Power supply 3

Analog input module Power supply 2

Power supply 1

Resistor

PLC power supply

Fig. 29: Swing panel (typical)

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Electrical system _________________________________________________ PLC power supply

The PLC power supply provides power for the PLC control system.

analog input modules

There are two analog input modules that receive inputs from the current transducers.

analog output module

The analog output module sends a signal to the amplifier boards.

amplifier boards digital input modules

digital output modules

The electronic amplifier boards drive the conveyor speed solenoids.

There are two digital input modules that communicate the positions of the selector switches, sequence switch, and auxiliary contactors to the PLC. The digital out module communicates with the coils and relays based upon input to the two digital input modules.

IS relay

The IS relay is the intrinsically safe relay for the three tape switches (panic strips).

TAC monitors

The TAC monitors pickup the conveyor shaft and pick break speeds and send a signal to the PLC.

current transducer

The current transducer monitors the pick break motor amps.

There are six relays located on the panel:

“SR” “MCR”

“SR”is the safety relay for the tape switches (panic strips).

“MCR”is the master control relay.

“CRWS”

“CRWS”is the water solenoid relay.

“CR1”

“CR1”is the conveyor forward relay.

“CR2”

“CR2”is the tram relay.

“CRR”

“CRR”is the conveyor reverse relay.

resistor fuses

The 33 KΩ, 1/2W resistor works in conjunction with the safety relay, “SR”to close the circuit so the machine can be started.

The two 10A fuses are for the lighting circuit. Once fuse is for the hot side and one is for the neutral side.

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________________________________________________ Electrical system Back panel The back panel (Fig. 30) is accessed by removing the swing panel retaining bolt located in the upper left hand corner of the swing panel and swinging the panel out.

Note that component locations are typical. Always consult the parts book for your machine to verify locations.

Fig. 30: Back panel, typical

“T1”

Vacuum contactor, “F1”

Current transducer (6)

Vacuum contactor, “M1”

Current transformer

Fuse 2)

“OL2”

Voltage transducer

“OL1”

“T1”

“T1”is the control transformer that reduces the voltage to the control circuit from 950V to 120V.

“M1”

“M1”if the vacuum contactor for the pick break motor.

“F1”

“F1”is the vacuum contactor for the conveyor/pump motor.

“OL1”

“OL1”is the overload relay for the pick break motor. If the pick break motor is overloaded, the relay will shutdown the motor.

“OL2”

“OL2”is the overload relay for the conveyor/pump motor. If the conveyor/pump motor is overloaded, the relay will shutdown the motor.

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Electrical system _________________________________________________ current transducers

There are six current transducers on this panel. The first three monitor each phase of the power to the pick break motor and the next three monitor each phase of the conveyor/pump motor. The current draw for each phase is displayed on the display panel on the front of the starter enclosure.

Starting at the top, the transducers are: #1 = Phase A, pick break motor #2 = Phase B, pick break motor #3 = Phase C, pick break motor #4 = Phase A, conveyor/pump motor #5 = Phase B, conveyor/pump motor #6 = Phase C, conveyor/pump motor

voltage transducer fuse

The voltage transducer monitors and the control voltage, which is displayed on the display panel on the front of the starter enclosure.

The 5A fuse is for the power supply for the display panel.

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________________________________________________ Hydraulic system Hydraulic system The following pages contain a brief description of the hydraulic components and assemblies that are on the feeder breaker.

The primary hydraulic system for this machine has been designed to provide hydraulic power for the conveyor drive motor, tram motors, tilt cylinders and lift cylinders.

The secondary hydraulic system for this machine has been designed to provide hydraulic power for the roof cylinders, the stab (foot) cylinders, the tailpiece cylinders, and the side staker cylinder.

WARNING! This section is intended only to familiarize the user with the hydraulic components of the feeder breaker. All hydraulic maintenance should be performed only by a qualified technician with the knowledge of the function of the components involved.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

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Hydraulic system_________________________________________________ Fig. 31: Hydraulic component locator feeder breaker

Tailpiece tilt cylinder (2)

Return/tank fill filter Pressure filter

Secondary valve bank

Conveyor drive reducer and hydraulic motor Piggyback pump

Tailpiece steer cylinder (2)

Pump Suction transducer Oil/water filter Flow divider (tank fill) Ball valve Oil tank Tram motor (2)

Stab (foot) cylinder (2) Sight glass/ thermometer Frame lift cylinder (2)

Heat exchanger Flow control

Primary valve bank System pressure gauge

Roof anchor cylinder (2)

Frame tilt cylinder (2)

Side staker cylinder

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________________________________________________ Hydraulic system Major hydraulic components (Reference Fig. 31) hydraulic oil tank

open loop load sense pump

piggyback gear pump

primary valve bank

The hydraulic oil tank is located on the left hand side of the machine and has a 175 gallon capacity. The hydraulic oil temperature and level is monitored by the PLC via a temperature probe and float switch. The tank is equipped with a sight glass and thermometer.

The open loop load sense pump is a part of the conveyor power unit and is located on the left side of the machine. It supplies hydraulic fluid to all hydraulic functions on the machine.

The piggyback gear pump is bolted to the rear of the open loop load sense pump. This pump supplies hydraulic fluid to the main pump and the conveyor motor for cooling purposes and for the hydraulically driven heat exchanger.

The primary valve bank, located on the right hand side of the machine, is used to control the machine’ s conveyor tilt, lift, tram, and power fill functions and to control flow to the secondary valve bank. All sections of the valve bank are spring return (self centering) except for the power fill section which is detented.

secondary valve bank

The secondary valve bank, located at the head shaft on the right hand side of the machine, is used to control tailpiece steering and tilt, the roof cylinders, the stab (foot) cylinders, and the side staker cylinder.

tank fill pump

The tank fill pump is a flow divider that is hosed to run backwards from normal flow divider operation. The pump is located on top of the hydraulic oil tank on the left side of the machine and is used to replenish oil supply. It is capable of delivering approximately 5 gallons of fluid per 30 seconds.

frame tilt cylinders

The frame tilt hydraulic cylinders are located at the end of the crawler under the hopper on each side of the machine and are used to adjust the discharge height of the machine. The cylinders are controlled by one section of the primary valve bank.

frame lift cylinders

The frame lift hydraulic cylinders are located at the pivot point of the crawler on each side of the machine and are used to adjust the ground clearance of the machine. Each cylinder is individually controlled by separate sections of the valve bank.

WARNING! The tilt and lift hydraulic cylinders have counterbalance cartridges which serve as load holding valves. Do not replace these cylinders with different style cylinders or the machine may fall. The machine could be damaged or you or other personnel could be seriously injured or killed by the falling machine.

The machine is equipped with lock pins that should be installed when the unit is not being moved. Pin are located near the lift cyl-

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Hydraulic system_________________________________________________ tailpiece tilt cylinders

tailpiece steering cylinders

roof anchor cylinders

stabilizer foot cylinders

The tailpiece tilt cylinders are located are located on either side of the tailpiece and are used to adjust the height of the tailpiece. The cylinders are controlled by one section of the secondary valve bank.

The tailpiece steering cylinders are located on either side of the tailpiece and are used to position the tailpiece. The cylinders are controlled by one section of the secondary valve bank.

The roof anchor cylinders are mounted on the frame on either side of the receiving end of the machine. The cylinders are used to raise and lower the roof anchor arms and are controlled independently by two separate sections of the secondary valve bank.

The stabilizer foot cylinders are mounted to the under side of the frame on either side of the mid-section of the machine. The cylinders are used to raise and lower the stabilizer feet and are independently controlled by two separate sections of the secondary valve bank.

side staker cylinder

The side staker cylinder is mounted underneath the receiving section on the left side of the machine. The cylinder is controlled by a section of the secondary valve ban,.

tram motors

The tram motors are located to the inside of each crawler assembly and are used to supply torque to the torque hubs for tramming operations. Each tram motor is individually controlled by separate sections of the primary valve bank.

conveyor motor

The conveyor motor is located on the left hand side of the machine, and is mounted directly to the conveyor reducer. This radial piston motor receives hydraulic fluid from the main valve bank’ s first and second sections.

pressure filter

The pressure filter is located on the right hand side of the machine at the secondary operator’ s station. This filter is used to filter fluid on the pressure side of the hydraulic circuit and is monitored by the PLC system. When the filter reaches 60% capacity, a “PRESSURE LINE DIRTY FILTER”message will display on the PLC display at the primary operator’ s station.

return filter

The return filter is located on the right hand side of the machine at the secondary operator’ s station. This filter is used to filter fluid on the return side of the hydraulic circuit and as the power fill filter. The filter is monitored by the PLC system; a “RETURN LINE DIRTY FILTER”message will display on the PLC display at the primary operator’ s station when the filter reaches 60% capacity..

hydraulic oil water removal filter

The hydraulic oil water filter is located on the left hand side of the machine and is mounted to the hydraulic oil tank. It is used to filter water out of the hydraulic oil. The filter is monitored by the PLC system; a “HYDRAULIC OIL WATER REMOVAL DIRTY FILTER”message will display on the PLC display at the primary operator’ s station when the filter reaches 60% capacity.

The function pressure gauge is located at the primary operator’ s station on the right side of the machine. This single gauge will display the system pressure for the active function. ________________________________________________________________ function pressure gauge

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________________________________________________ Hydraulic system Fig. 32: Hydraulic schematic feeder breaker

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Hydraulic system_________________________________________________

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___________________________________________ Mechanical assemblies Mechanical assemblies The following pages contain a brief description of the major mechanical assemblies that are on the feeder breaker.

WARNING! This section is intended only to familiarize the user with the major mechanical assemblies of the feeder breaker. All mechanical maintenance should be performed only by a qualified technician with the knowledge of the function of the assemblies involved.

Crawler assemblies The feeder breaker is trammed by two (2) hydraulically driven crawlers (Fig. 33); one is located on each side of the machine. The complete drive assemblies are housed in crawler frames which enclose, guide and support the tram components. Each tram drive is independently controlled by the operator for moving the machine forward, backward and for making turns.

The crawlers on the machine are hydraulic driven through torque hub gear reducers. Attached to the torque hub is a single sprocket that engages the crawler tracks directly. The crawler track loops around the take-up roller assembly located on the opposite end of the crawler assembly. The idler assembly, along with a grease take-up is used to adjust the tension on the crawler tracks. (See Maintenance section in this chapter for Crawler track adjustment procedure.)

Fig. 33: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

Torque hub Take-up cylinder & shims Take-up roller assembly

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Mechanical assemblies____________________________________________ Conveyor chain The feeder breaker is equipped with a conveyor chain assembly (Fig. 34) that carries mined material along the conveyor trough from the receiving section and out through the discharge end. The conveyor chain is made up of one basic chain assembly, which repeats sequentially along the entire chain loop. (See Maintenance section in this chapter for Conveyor chain maintenance.)

Fig. 34: Conveyor chain components

Roll pin Chain link section

Flight bar

Grease take-up The feeder breaker is equipped with two (2) conveyor chain grease take-up assemblies (Fig. 35) that provide ease of adjustment for the conveyor chain. The take-up assemblies provide constant tension on the tail shaft around which the conveyor chain rides at the receiving end of the machine. (See Conveyor chain adjustment procedure in the Adjustment Procedure section of this chapter) Fig. 35: Grease take-up main components

Stop valve (2) Shim storage (2)

Take-up cylinder (2)

Grease fitting (2)

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___________________________________________ Mechanical assemblies Head shaft The feeder breaker is equipped with a head shaft (Fig. 36) located on the discharge end of the conveyor. The head shaft is driven from the left hand side via a hydraulic motor and gearbox that is directly mounted to the head shaft.

IMPORTANT! Weld on split sprockets are available for replacement/emergency rebuilds. See the parts manual for your machine or contact your service engineer.

Fig. 36: Head shaft main components

Speed sensor

Sprocket (2)

Bearing (2)

Head shaft assembly

Hydraulic motor

Conveyor drive gearbox

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Mechanical assemblies____________________________________________ Conveyor power unit The conveyor power unit drives the hydraulic pump (s) and pick breaker reducer (Fig. 37). It consists of a 125 HP electric motor coupled to a load sense pump. The power unit has been assembled as a unit and can be removed as a unit or as individual components (see Replacement of wear parts section of this chapter).

Fig. 37: Conveyor power unit main components

Coupling

Connecting tube

Load sense pump

Motor (125 HP)

Tail shaft The feeder breaker is equipped with a tail shaft (Fig. 38) located on the receiving end of the conveyor. The tail shaft is an idler shaft that is driven by the tension of the conveyor chain. There is a slide plate arrangement attached to the tail shaft, which fills the gap between the receiving impact plate and the shaft.

Fig. 38: Tail shaft components Set screw (2)

Slide plate

Adapter (2)

Key (2)

Sprocket or roller (2)

Head shaft

Bearing (2)

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___________________________________________ Mechanical assemblies Breaker and breaker power unit assembly The breaker and breaker power unit (Fig. 39) are assembled with a bolt flange coupling so that they can be installed as individual assemblies.

The power unit can be removed as a separate, complete assembly. To remove the breaker shaft, bolt flange coupling hardware must be removed..

There is an under speed sensor mounted on the right hand end of the breaker shaft that will shutdown the breaker drive motor in the event that breaker shaft slows below a preset speed. There is a tachometer the monitors the breaker shaft rpms.

NOTICE! In the event that a sudden jam occurs which could damage the gear reducer, the breaker is protected by a friction disc clutch (torque limiting) or a magnetic coupler.

Fig. 39: Breaker and breaker power unit assembly

Breaker power unit Under speed sensor and tachometer

Bolt flange coupling

Breaker shaft

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Mechanical assemblies____________________________________________ Breaker assembly The breaker assembly (Fig. 40) on the machine has a 32”(813 mm) pick circle with a 5 point star arrangement. It has a 10”(254 mm) shaft diameter turned down to 8”(203 mm) thru the bearings.

Fig. 40: Breaker assembly main components Tachometer target location (1/213X1/2) hex head

Bit (requires 2 snap rings supplied with bit)

Bearing housing

Seal housing

Bearing retainer

End cap Underspeed sensor mount

Bearing housing

Bearing retainer

Bearing

Side plate

Seal Breaker shaft

Bolt flange

Seal Bearing

End cap

Seal housing

Side plate

Seal ring

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___________________________________________ Mechanical assemblies Breaker power unit The breaker power unit (Fig. 41) drives the pick breaker. It consists of a 200 HP electric motor coupled to a reducer. The power unit has been assembled as a unit and can be removed as a unit or as individual components (see Replacement of wear parts section of this chapter).

Fig. 41: Breaker power unit

Connecting tube

Gear reducer

Electric motor (200 HP)

Magnetic coupling

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Mechanical assemblies____________________________________________ Tailpiece assembly The tailpiece assembly (Fig. 42) attaches to the discharge end of the feeder breaker frame. It consists of a return belt pulley, an impact bed, and tilt and steering cylinders. The belt runs around the belt pulley and over the impact bed.

The tilt and steering cylinders are used to position the tailpiece to correct for misalignment between the belt and the feeder breaker.

The tailpiece assembly, when attached to the feeder breaker, provides a means for quickly advancing and tensioning the belt.

Fig. 42: Tailpiece assembly

Steering cylinder (2) Tilt cylinder (2)

Impact bed

Belt pulley

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____________________________________________________ Maintenance Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine. In particular, observe the safety instructions in chapter 2 “Your safety”.

Important notes Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

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Inadequate maintenance can result in machine damage which leads to considerable costs.

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Use only suitable and approved tools for maintenance work.

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Use only original spare parts when replacing components.

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All electrical work must be supervised and inspected by a certified electrician.

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Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this guide.

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power. The circuit breaker must be in the “OFF”position and the power should be disconnected at the main power source. Follow all Federal and mine safety regulations for lockout/tagout procedures.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF”position and the power should be disconnected at the main power source. Follow all Federal and mine safety regulations for lockout/tagout procedures. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

■

Test the controls to ensure that the unit will not move.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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Maintenance_____________________________________________________ ■

During maintenance or servicing, if either of the tram drives are to be run, the side that is to be run must be jacked clear of the ground and securely blocked. Follow all Federal and mine safety standards for blocking the machine.

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Do not perform maintenance on a hydraulic cylinder while there is a load resting on the hydraulic cylinder. Loads must be securely blocked if maintenance is to be performed with a load on the hydraulic cylinder. Follow all Federal and mine safety standards for blocking the load.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load may fall, causing damage to the machine or serious injury or death to you or other workers. Do not rely on counterbalance valves to hold the load. Always block or place a mechanical lock on the load.

Follow all Federal and mine safety standards for blocking the load.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

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Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

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Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

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Cleanliness can not be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

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____________________________________________________ Maintenance NOTICE! All hydraulic filter elements should be changed after one week of the initial start-up of machine or pre-mature wear of hydraulic components could occur.

Table 2: Lubrication and maintenance schedule Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Description Every 8 hours of operation Head shaft bearings Head shaft bearing seals Head shaft tachometer Breaker bearings Tail shaft and slide tube bearings Tailpiece pulley bearing Hydraulic oil level (check) Water filter (alarm check) Pressure filter (alarm check) Return filter (alarm check) Breaker bits Weekly Breaker shaft tachometer and underspeed sensors Crawler track take-up bearings Conveyor chain tension Fasteners (nuts, bolts and screws) Electrical cables, conduits and glands Hydraulic hoses and connections Tram reducer (check oil level)

Places 2 2 Inspect 2 4 2 1 1 1 1 Inspect

2 Inspect Inspect Inspect Inspect 2 1 1 1

22 23 24

Conveyor electric motor

2

25 26

Breaker reducer (grease) Hydraulic oil tank breather vent Every 3 months Breaker reducer cooling fan Breaker power unit magnetic coupling Every 1000 hours Breaker reducer oil analysis/change as required * Conveyor reducer oil analysis/change as required * Every 6 months Hydraulic oil tank (change) Tram reducer (change oil)

29 30 31 32

Specification Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-1

Inspect

Conveyor reducer (check oil level) Breaker reducer (check oil level) Dust system strainer (check) Monthly Crawler anchor pin (s) Breaker electric motor

27 28

Lubricant

2 2

2 Inspect

Spec. 100-3

Spec. 100-2 or Spec. 100-13 Spec. 100-6 Spec. 100-6 Spec. 100-3 Spec. 100-14 or Spec. 100-16 Spec. 100-14 or Spec. 100-16 Spec. 100-3

Inspect Inspect

1 2

Spec. 100-1 Spec. 100-2 or Spec. 100-13

* Initial oil change to be done after first 500 hours of operation. ______________________________________________________________ A6474X338

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Maintenance_____________________________________________________ Table 3: Lubricants: Fluids and capacities Location Hydraulic oil tank Breaker reducer Conveyor reducer Tram reducer Grease points (except electric motors) Grease points (electric motors)

Specification Spec. 100-1 Spec. 100-6 Spec. 100-6 Spec. 100-2 or Spec. 100-13 Spec. 100-3

Approximate capacity 175 gal (663 L) 15 gal (57 L) 6.7 gal (25 L) 2.5 gal per side (10 L per side)

Spec. 100-14 or Spec. 100-16

Two pumps per month (hand pump only)

As required

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____________________________________________________ Maintenance Fig. 43: Lubrication chart 10 1,2 (grease fitting location) 9

1,2 (bearing and seal location)

3 1,2 (bearing and seal location)

4 (bearing location)

25 (seal location)

22

14 (chain tension check location)

11

4 (bearing location) 12 22

14 (take-up cylinder location)

5 (slide tube bearing location)

5 (tail shaft bearing location)

14 (take-up cylinder location)

5 (slide tube bearing location)

5 (tail shaft bearing location)

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Maintenance_____________________________________________________ Fig. 43 (continued): Lubrication chart

6 (grease fitting location)

6 (bearing location)

6 (bearing location) 23, 25 (grease fitting location)

19, 29

23 (bearing location)

21 25 (seal location)

27, 28

20, 29

8 24 (bearing location)

24 (grease fitting location)

31 26 7

18, 32

13

4 (grease fitting location)

18, 32

13

5 (grease fitting location)

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____________________________________________________ Maintenance Specific lubrication and maintenance procedures WARNING! The feeder breaker is equipped with lubrication manifolds to allow the remote greasing of bearings. It is important to check the bearing to ensure it is receiving adequate lubrications. Running the machine with inadequately lubricated bearings may result in premature bearing failure and/or machine damage.

Every 8 hours of operation head shaft bearings

head shaft bearing seals

head shaft tachometer sensor

Lubricate the feeder breaker head shaft bearings with Spec. 100-3 through the grease fittings located lubrication panel (Fig. 44) located on the right side of the machine at the secondary operator’ s station.

Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

Lubricate the feeder breaker head shaft bearing Taconite seals with Spec. 100-3 through the grease fittings located on the lubrication panel (Fig. 44) located on the right side of the machine at the secondary operator’ s station. Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

Inspect and clean the head shaft tachometer sensor, located on the right had side of the head shaft.

Fig. 44: Head shaft bearings and seals lubrication and tachometer sensor

Bearing and seal location (typical both sides)

Tachometer

Lubrication panel

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Maintenance_____________________________________________________ breaker bearings

Lubricate the breaker bearings with Spec. 100-3 through the grease fittings located on the frame on the right side of the machine, to the right of the breaker reducer (Fig. 45) located on the right side of the receiving section. Pump grease into the fittings until new grease can be observed coming out of the bearing return lines. It is recommended that a weekly inspection of the bearings and grease hoses be carried out to ensure bearings are actually receiving grease.

Fig. 45: Breaker bearing lubrication

Grease fittings (2)

Return lines (2)

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____________________________________________________ Maintenance tail shaft and slide tube bearings

Lubricate the feeder breaker tail shaft and slide tube bearings with Spec. 100-3 through the grease fittings located on right side of the machine at the primary operator’ s station (Fig. 44). Pump grease into the four (4) fittings until new grease can be observed coming out of the tail shaft and bearings. To see the bearings, the tail shaft cover (Fig. 46) must be removed.

Fig. 46: Tailshaft and slide tube bearings

Grease fittings location (4)

Tail shaft bearing location

Tail shaft bearing location Slide tube bearing location

Slide tube bearing location

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Maintenance_____________________________________________________ tailpiece pulley bearings

Grease the tailpiece bearings (Fig. 47) through the two grease fittings on the manifold located on the right side of the tailpiece (Fig. 47) with Spec. 100-3. Pump new grease into the fittings until old grease can be observed coming out of the bearing.

Fig. 47: Tailpiece bearing lubrication

Grease fitting manifold

hydraulic oil tank

Tailpiece bearing (typical both sides)

Check the hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 48). The oil level should not be allowed to drop below the bottom of the sight glass. If the hydraulic oil level is low, add hydraulic oil (Spec. 100-1). To add oil via the power fill, reference the following procedure.

WARNING! The “TANK FILL/AUX VB”lever is the only lever on the valve bank that does not spring return to neutral when released. When not in use, the valve should be manually returned to the neutral position.

Failure to do so could result in unexpected machine movement if the secondary valve bank is energized and a lever on the secondary valve bank is inadvertently moved or machine overheating if the power fill pump is left energized. Unexpected machine movement could result in serious injury to personnel or damage equipment.

To operate the power fill: 1. Clean suction hose attached to the hydraulic power fill motor, located on top of the oil tank.

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____________________________________________________ Maintenance 2. Remove the suction hose plug and submerge the suction hose in the new oil supply.

3. Turn the handle of the ball valve to the open position. The handle should now be inline with the hydraulic hose to which it is attached.

4. Position the “TANK FILL/AUX VB”lever in the “TANK FILL”position. Oil from the valve bank will now drive the power fill motor and a suction force will be created in the suction line. Oil from the new oil supply will be drawn through the power fill motor to the hydraulic oil tank.

5. Once the tank is filled to the desired level, pull the power fill lever on the valve bank to the neutral (center) position.

6. Turn the ball valve handle 90° to close the ball valve.

7. Remove the suction hose from the new oil supply.

8. Clean and install hose plug into suction hose. Store the suction hose on top of the oil tank.

CAUTION! After oil filling operation is complete, manually return the “POWER FILL”lever to the centered, neutral, position or overheating of the machine may occur.

Fig. 48: Hydraulic oil level check Power fill ball valve

Sight glass

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Maintenance_____________________________________________________ hydraulic oil water filter

The hydraulic oil water filter is located on the left side of the machine and is mounted to the hydraulic oil tank (Fig. 50). The filter is monitored by the PLC and when the filter reaches 60% capacity, an alarm will be displayed on the PLC view panel, located on the right side of the machine on the starter enclosure (Fig. 49). The alarm will display on the ‘ MAIN SCREEN”and will read “HYDRAULIC OIL WATER REMOVAL FILTER DIRTY”. When the alarm is displayed, the filter should be changed.

Fig. 50: Water filter location

Water filter

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____________________________________________________ Maintenance pressure filter

The pressure filter is located on the right side of the machine at the secondary operator’ s station (Fig. 49). The filter is monitored by the PLC and when it reaches a preset limit, an alarm will be displayed on the PLC view panel, located on the right side of the machine on the starter enclosure (Fig. 49). The alarm will display on the ‘ MAIN SCREEN”and will read “PRESSURE LINE DIRTY FILTER”. When the alarm is displayed, the filter should be changed.

return filter

The return filter is located on the right side of the machine at the secondary operator’ s station (Fig. 49). The filter is monitored by the PLC and when it reaches a preset limit, an alarm will be displayed on the PLC view panel, located on the right side of the machine on the starter enclosure (Fig. 49). The alarm will display on the ‘ MAIN SCREEN”and will read “RETURN LINE DIRTY FILTER”. When the alarm is displayed, the filter should be changed.

Fig. 49: Pressure and return filter locations and PLC display

PLC display

Return filter

Pressure filter

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Maintenance_____________________________________________________ breaker bits

Check the breaker bits (Fig. 50) to see if they will rotate in their holders and for damaged or missing bits. The bits may be inspected by looking into the receiving end of the machine. If bits need to be replaced, see Bit replacement in the Replacement of wear parts section of this chapter.

WARNING! Do not enter the hopper unless power center is locked and tagged out and machine main circuit breaker is in the “OFF”position. If these procedures are not followed, serious injury or death can result.

Fig. 50: Breaker bits

Breaker bits

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____________________________________________________ Maintenance Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 51) with Spec. 100-3. The fittings (one per side) may be reached through the slot in the end of the crawler frame on the outside of each crawler.

Pump grease into the fitting until new grease can be observed coming out of the bearings.

Fig. 51: Crawler track take-up lubrication

Crawler take-up grease fitting location (typical both sides)

conveyor chain tension

Check the conveyor chain tension. As the conveyor chain comes around the head shaft sprocket, measure the amount of swag the conveyor chain has from the bottom of the sprocket (Fig. 52). If the swag is greater than 2 inches, adjust the chain tension (see Conveyor chain adjustment procedure in this chapter). With the machine running, visually inspect tail shaft to ensure shaft is turning and conveyor chain is not sliding across tail shaft.

Fig. 52: Conveyor chain tension measurement

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Maintenance_____________________________________________________ fasteners

electrical cables, conduits and glands hydraulic hoses and fittings

tram reducers

Due to the machine being subjected continual shock loading and vibration, close attention to all mounting bolts and screws is required. Loose fasteners will cause premature wear and failure to bearings, couplings, etc. Inspect and tighten as required the following fasteners: ■

head shaft bearing bolts

■

breaker shaft side plate bolts

■

conveyor drive motor mounting bolts

■

tail shaft retainer hold down bolts

■

all cover and guard retaining bolts

Visually inspect all electrical cables and glands for signs of wear or damage.

Visually inspect all hydraulic hoses and fittings for signs of wear, damage or leakage. This inspection should be performed with machine running.

Check the oil level in both tram reducer torque hubs (Fig. 53):  Position the oil level check and fill plugs at the 3 o’ clock and 12 o’ clock positions so that they are accessible through the cutouts in the cover .  Remove the oil level check and fill plugs. When correctly filled, oil should just begin to flow from the check oil level check hole.  If it is necessary to add oil, add Spec.100-2 or 100-13 through the fill hole until it begins to flow out of the check hole. Do not overfill the reducer.  Replace the fill and check plugs.

Fig. 53: Tram reducer oil level Fill plug

Check plug

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____________________________________________________ Maintenance conveyor reducer

Check oil level in the conveyor drive reducer (Fig. 51). Oil level should be maintained inside the sight glass located in the middle of the reducer when it is in operation. If needed, add oil (Spec. 100-6) until the correct level is reached.

Fig. 51: Conveyor reducer oil check Vent/fill port

Sight glass

breaker reducer

Check oil level in the breaker drive reducer (Fig. 52). To access the dipstick, remove the cover from on top of the reducer. If oil is needed, add oil (Spec. 100-6) through the dipstick hole or the fill port until the correct level is reached on the dipstick. .

Fig. 52: Breaker reducer oil level

Fill port

Dipstick location (located on top of reducer)

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Maintenance_____________________________________________________ dust system strainer

Clean the strainer mounted inside the dust suppression system located under the breaker power unit on the right side of the machine. Turn the ball valve handle (Fig. 53) to open the water line. Allow to flush for approximately thirty seconds to one minute. Close ball valve.

IMPORTANT! A short hose is attached to ball valve in dust suppression system to allow water to be directed away from other machine components.

Fig. 53: Dust system strainer Dust system pressure gauge

Short hose

Ball valve

Strainer

Regulator

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____________________________________________________ Maintenance Monthly crawler anchor pins

Lubricate grease fittings on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 54). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 54: Crawler anchor pin lubrication

Crawler anchor pin (s) (grease fitting located inside crawler frame)

breaker electric motor

Lubricate the breaker power unit electric motor with Spec. 100-3 through the two (2) grease fittings located on the lubrication manifold (Fig. 55) located on the right side of the machine. Pump only one or two pumps of grease into each fitting.

NOTICE! Incorrect grease or over greasing may cause serious damage to the electric motor.

Fig. 55: Breaker electric motor Breaker electric motor bearing location

Breaker electric motor bearing grease fitting location

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Maintenance_____________________________________________________ conveyor electric motor

Lubricate the conveyor power unit electric motor with Spec. 100-3 through the two (2) grease fittings located on the lubrication manifold (Fig. 56) located on the left side of the machine. Pump only one or two pumps of grease into each fitting.

NOTICE! Incorrect grease or over greasing may cause serious damage to the electric motor.

Fig. 56: Conveyor electric motor Conveyor electric motor bearing location

Conveyor electric motor bearing lubrication fitting location

breaker reducer

Lubricate the breaker reducer with Spec. 100-3 through the two (2) grease fittings located on the below the breaker electric motor (Fig. 57) located on the right side of the machine. Pump only one or two pumps of grease into each fitting using a hand grease gun.

IMPORTANT! Rapid greasing with a power grease gun can force grease inward past the seals, causing seal leaks.

Fig. 57: Breaker reducer lubrication

Grease fitting (2)

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____________________________________________________ Maintenance hydraulic oil tank breather vent

Check the breather vent element on the hydraulic oil tank (Fig. 58) and change as required.

Fig. 58: Hydraulic oil tank breather vent Breather vent

Every three months breaker reducer cooling fan

Remove the connecting tube cover (Fig. 59) and inspect the breaker reducer fan. Clean all accumulated debris from the fan, guard, and deflector.

breaker power unit magnetic coupling

Remove the connecting tube cover (Fig. 59) and inspect the breaker power unit magnetic coupling. If debris is found, clean the coupling.

Fig. 59: Connecting tube cover

Connecting tube cover

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Maintenance_____________________________________________________ Every 1000 hours breaker and conveyor reducer oil analysis

Every 1000 hours of operation, analyze a breaker and conveyor reducer oil sample. Follow mine analysis oil change guidelines to determine whether oil needs changed. If no mine standards are established, the following guidelines may be used: ■

Water content is greater than 500 ppm (0.05%)

■

Iron content exceeds 150 ppm

■

Silicon (dust/dirt) is more than 25 ppm greater than silicon concentration in sample from new oil container

■

Copper content exceeds 75 ppm

■

TAN (Total Acid Number) is 50% greater than that in sample from new oil container

■

Viscosity changes more than ±15%

At a minimum, oil should be changed in both reducers every six months/2500 hours of operation. breaker reducer oil change

Change the oil in the breaker drive reducer (Fig. 60) as indicated by the oil analysis or every six months/2500 hours of operation.

NOTICE! It is recommended that oil be at full operating temperature before draining.  Remove the drain plug and allow the oil to completely drain.  Clean and reinstall drain plug.  Remove the cover.  Remove the fill port plug and add lubricant, Spec. 100-6, until fluid reaches the correct level on the dipstick. When filling the reducer, allow enough time for all cavities inside the reducer to fill but take care to not overfill the reducer.  Install fill port plug.  Install inspection cover.

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____________________________________________________ Maintenance Fig. 60: Breaker reducer

Fill port

Cover

Dipstick location (located on top of reducer)

Drain plug

conveyor reducer oil change

Change the oil in the conveyor drive reducer (Fig. 61) as indicated by the oil analysis or every six months/2500 hours of operation.

NOTICE! It is recommended that oil be at full operating temperature before draining.  Remove the drain plug and allow the oil to completely drain.  Clean and reinstall drain plug.  Remove the fill port plug and add lubricant, Spec. 100-6, until fluid reaches the correct level on the sight glass. When filling the reducer, allow enough time for all cavities inside the reducer to fill but take care to not overfill the reducer.  Install fill port plug.

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Maintenance_____________________________________________________ Fig. 61: Conveyor reducer Sight glass

Fill port and vent

Drain plug

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____________________________________________________ Maintenance Every 6 months hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank (Fig. 62).  Clean all dirt and debris from around the fill cap and drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and reinstall drain plug.  Remove the fill cap and pour 20 gallons (76 L) of oil (Spec. 100-1) through the fill cap strainer to avoid cavitating the pumps with the power fill unit.

CAUTION! The oil tank must contain a minimum of 20 gallons ( 76 liters) of oil to operate the power fill function. This is to ensure that the hydraulic pumps are not run dry, causing severe damage to the pump.  Add oil Spec 100-1 as required via the power fill system until fluid is visible in sight glass.  Install fill cap.  Start the machine and allow the hydraulic pump to run in order to purge air from the system.  Shut down the machine and recheck the oil level. Add oil if necessary.

Fig. 62: Hydraulic tank oil level Power fill ball valve Breather vent

Oil level sight glass

Drain plug (under tank)

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Maintenance_____________________________________________________ tram reducer

Change oil in the tram reducer (Fig. 63).  Clean all dirt and debris from and around the level and fill plugs.  Rotate reducer until drain plug is at the 6 o’ clock position and remove drain plug and allow the oil to completely drain.  Clean and reinstall drain plug.  Rotate reducer until plugs are at the 12 o’ clock and 3 o’ clock positions.  Add oil (80W-90) through the fill hole until fluid begins to flow from the check plug.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Install level and fill plugs.  Do not overfill reducer.

Fig. 63: Tram reducer oil change Fill plug

Check plug

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____________________________________________________ Maintenance Inspection CAUTION! During inspection, report any damage, missing parts or other faults to your immediate supervisor.

Prior to each shift the following points should be inspected:  Clean and remove any foreign material from the operator’ s station.  Inspect all electrical cables, conduits, hydraulic hoses, fittings and warning devices for signs of wear or damage.  Visually inspect the condition and readability of all tags, labels and reflectors.  Check the “STOP”button (s) for correct operation.  Check the hydraulic oil level in the feeder breaker by looking at the sight glass. The oil level should be kept at the level of the top sight glass.  Check oil level in the crawler reducers.  Inspect the condition of all electrical and hydraulic components.  Check for proper conveyor chain tensioning.  Check for proper crawler chain tensioning.  Lubricate per the lubrication schedule.  Check power input cable to power source insuring that the voltage and breaker settings are correct.  Check that the cable handling device is intact and oriented correctly.  Check that all covers are installed and secure.  Check the tightness of all connecting elements.  Check that the neutral start mechanism is installed on the primary valve bank.

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Maintenance_____________________________________________________ Inspection of wear parts In order to be able to determine in good time when a repair shift has to be scheduled, and to avoid damage to other components, it is essential to inspect all the following wear parts as to their degree of wear: ■

the conveyor chain

■

the conveyor chain flights

■

the conveyor drive sprockets

■

the conveyor tail shaft

■

the conveyor wear plates

■

the crawler pads

■

the crawler drive sprockets

■

the crawler idler rollers

________________________________________________________________ 5.80 FB110 Feeder Breaker

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____________________________________________________ Maintenance Inspection of fire suppression system To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 64).  Note general appearance for mechanical damage or corrosion.  Check nameplate for readability, corrosion or looseness.  Remove fill cap assembly.  Examine gaskets for elasticity, clean and coat lightly with a good grade of high heat resistant grease.  Inspect threads on fill cap and in fill opening for nicks, burrs, cross threading, rough or feathered edges.  Check pressure relief vent in fill opening threads for obstruction.  Make certain extinguisher is filled with free flowing Ansul dry chemical to a level of not more than 3”from bottom of fill opening.  Unscrew cartridge and weigh (replace if weight is ½ oz. less than stamped on cartridge).  Inspect thread on cartridge and in receiver/actuator for nicks, burrs, cross threading, rough or feathered edges.  Check pressure vents in receiver/actuator for obstruction.  Examine cartridge receiver gasket for elasticity, clean and coat lightly with a good grade of high heat resistant grease. Return cartridge to receiver/actuator, hand tighten.  Lift extinguisher partially out of bracket and examine bursting disc; should be installed with full disc side facing extinguisher, properly seated and undamaged (scored or ruptured).  Reposition extinguisher, engage bursting disc union (wrench tighten) and close bracket clamp.  Check hoses, fittings and nozzles for mechanical damage.  Check nozzle openings; slot should be closed (capped) with silicone grease.  Check remote actuator (dashboard type).  Remove cartridge and weigh (replace if weight is ¼ oz. less than stamped on cartridge.

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Maintenance_____________________________________________________  Inspect threads on cartridge and in actuator for nicks, burrs, cross threading, rough or feathered edges.  Check pressure safety vent in actuator body for obstruction.  Examine actuator cartridge gasket for elasticity, clean and lightly coat with a good grade of high heat resistant grease.  Pull ring pin and operate actuator button several times to check for free movement.  Seal ring pin to puncture lever with lead and wire seal. Return cartridge to remote actuator, hand tighten.  Record date of maintenance and notify operating personnel that system is back in service.

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____________________________________________________ Maintenance Recharge of fire suppression system To return your fire suppression system to service after use (Fig. 64).  Pull ring on safety valve to relieve actuator system pressure.  Disconnect actuation system hose at cartridge receiver/actuator assembly.  Open bursting disc union assembly.  Remove extinguisher from bracket.  Replace ruptured bursting disc with new disc. (Full disc side must face extinguisher).  Fill extinguisher to rated capacity with Ansul dry chemical specified on nameplate.  Clean fill opening threads and gasket seating surface.  Secure fill cap, hand tighten.  Remove cartridge guard assembly.  Remove empty cartridge.  Make certain that receiver/actuator puncture pin is fully retracted.  Screw full charged cartridge into receiver/actuator assembly, hand tighten.  Replace cartridge guard.  Secure extinguisher in bracket.  Assemble bursting disc union, wrench tighten.  Connect actuation system hose at cartridge receiver/actuator assembly, wrench tighten.  Replace cartridge in remote actuator (dashboard type). Pull out button, insert ring pin and remove empty cartridge. Screw fully charged cartridge into actuator, hand tighten. Seal ring pin to actuator button stem with lead and wire seal.  Record date of recharge and notify operating personnel that system is back in service.

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Maintenance_____________________________________________________ Fig. 64: Fire suppression system Conveyor motor

Nozzle

Nozzle

Hopper end

Remote actuator

LP canister LP expellant

Breaker coupling

Operator’ s station

Nozzle Breaker motor

Starter box

Nozzle

Remote actuator

Pump

Nozzle

Conveyor coupling

Nozzle Nozzle

Nozzle

Oil tank LP canister

LP expellant

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___________________________________________ Adjustment procedures Instructions on the adjustment procedures The purpose of this section is to provide procedures for the major adjustments required on the feeder breaker.

It is essential that adjustments be made periodically to the conveyor chain and crawler tracks, as otherwise damage can be caused to other parts of the machine or to the assembly itself. Inspect the adjustments at regular intervals.

In addition to the mechanical adjustments, there are hydraulic settings and electrical timers that may require adjustment.

Conveyor chain adjustment The conveyor chain is a complete assembly and should be checked for correct tension at regular intervals.

NOTICE! The following adjustment procedure for conveyor chain take-up must be performed on both right and left hand sides of the conveyor.

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 65): 1. Close the needle valve on manifold assembly securely.

2. Attach a grease gun to the grease fitting located on the manifold and apply grease until the required chain tension is obtained.

Sight across the bottom of the head shaft sprocket. The chain should sag approximately two inches below the bottom of the head shaft sprocket.

3. After tensioning the conveyor chain, locate the tailshaft take-up grease cylinders to the inside of the crawler tilt cylinders and remove the hardware that secures the shim pack onto the grease cylinder rod.

4. Insert shims over cylinder rod to fill the gap between the cylinder and the take-up push rod. Note the thickness and number of shims so that the other side is shimmed to the same length.

NOTICE! Make certain that the same amounts of shims are used on both sides of the conveyor to prevent chain from stretching unevenly.

Incorrect tension or adjustment can cause premature wear of sprockets and chain. Measure the exposed rod length on the grease take-up cylinders and make sure they are within 1/4”of each other.

5. Replace retainers.

6. Release pressure on the take-up cylinders by opening the top valve

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Adjustment procedures ___________________________________________ WARNING! Due to grease cylinders being under high pressure, do not stand in direct line of grease fitting or needle valve when releasing pressure. You could be seriously injured from high pressure grease.

7. Store any unused shims inside the shim storage boxes.

Fig. 65: Conveyor chain adjustment

Grease take-up cylinder

Shims

Shim storage

Grease take-up cylinder

Needle valve (2)

Grease fitting (2)

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___________________________________________ Adjustment procedures Crawler track The crawler track is a complete assembly and should be checked for wear and correct tension at regular intervals.

To adjust crawler track tension with the take-up cylinders (Fig. 66): 1. Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

2. Chain sag should be approximately two inches at the center of the crawler.

3. Remove the access cover located on the side of the crawler and locate the needle valve inside crawler frame. Turn valve knob counter clockwise (CCW) to open valve and pump grease into the fitting until the correct adjustment is achieved. Chain sag should be 1 3/4”at the center of the crawler.

4. Turn needle valve knob clockwise (CW) to close.

WARNING! If only one side of the machine is raised, be careful and only move the control lever for that particular side. Moving the wrong control lever could cause the machine to move and fall off its supports.

You could be seriously injured or even killed by falling loads.

5. Run crawler in forward direction for 30 seconds at slow speed.

6. Run crawler in reverse direction for 30 seconds at slow speed.

7. Shutdown machine.

8. If necessary, re-adjust chain sag.

9. Add or remove shims to maintain correct tension.

10. Release grease pressure in the cylinder by loosening the grease fitting and then turning the needle valve knob counter clockwise (CCW), allowing the shims to maintain the correct tension.

11. Install shim retainer plate.

WARNING! The grease cylinder is under high pressure. Do not visually inspect to see if grease is released. You could be seriously injured from high pressure grease.

12. Store and secure any unused shims on back of crawler cover plate.

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Adjustment procedures ___________________________________________ Fig. 66: Crawler track adjustment

Access cover

When properly tensioned, chain sag should be 1 3/4”at center of crawler.

Cylinder retainer bar/ shim retainer plate mount

Retainer plate

Grease fitting

Needle valve

Take-up cylinder

Shims (located behind retainer plate)

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___________________________________________ Adjustment procedures Underspeed sensor calibration To calibrate the underspeed sensor (Fig. 67): 1. Start the feeder breaker (see Startup procedure in this chapter).

2. Start the conveyor belt and run at the slowest normal operating speed expected.

IMPORTANT! Calibration should be performed with the conveyor belt running the slowest normal operating speed expected to avoid nuisance shutdowns.

3. Turn Speed 1 control switch left (ccw) until it stops (approximately 7 o’ clock).

4. Hold test/set switch (SW1) in the set position to engage relay (RY1).

5. Turn Speed 1 control switch right (cw) slowly until critical speed LED (LED 3) stays on continuously.

IMPORTANT! For all speed adjustments, the critical speed LED (LED 3) must stay on continuously.

6. Continue turning Speed 1 control right (cw) until margin LED (LED 4) begins to blink. a. The control relay will drop out with the above at a 15% slow down. b. For a 20% margin, adjust the Speed 1 control so that the margin light (LED 4) is continuously on. c.

For a 10% margin, turn the Speed 1 control left (ccw) until the margin light (LED 4) turns off.

7. After the relay status LED is illuminated, return the test/set switch to the run position.

8. A momentary test position is provided to simulate the loss of sensor signal, which releases the relay.

9. Clean any accumulated dirt and grease from around the sensor to avoid sensor interference.

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Adjustment procedures ___________________________________________ Fig. 67: Under speed senor calibration

Test/set switch, SW1 Speed 1 control switch

Margin LED

Test/set switch, SW1

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___________________________________________ Adjustment procedures There are two pumps on the machine: an open loop, load sense pump and a piggyback fixed displacement gear pump. The open loop, load sense pump powers all hydraulic functions while the piggyback fixed displacement gear pump supplies cooling flow to the cases of the main pump and the conveyor drive motor and drives the heat exchanger fan motor. There are no adjustments on the gear pump.

Main pump adjustments Margin pressure To adjust the margin pressure on the main pump: 1. Tee a multi-gauge into the system pressure line.

2. With no functions active, the margin pressure should read 30 bar (435 psi). If adjustment is necessary: a. Locate the margin pressure cartridge (Fig. 68). b. Loosen the hex nut that holds the adjustment stem in place. c.

Turn the stem clockwise (in) to increase pressure or counterclockwise (out) to decrease pressure.

d. Once the desired pressure, 40 bar (435 psi), is obtained, tighten the hex nut while holding the adjustment stem in place. e. After the hex nut is tight, recheck the pressure to ensure the adjustment stem did not move. If necessary, readjust.

Pressure compensator To adjust the pressure compensator setting: 1. Tee a multi-gauge into the system pressure line.

2. Adjust the main relief valve to 370 bar (5,365 psi) (see Main relief adjustment procedure in this section).

3. Zero out the margin pressure adjustment by turning the adjustment stem (Fig. 68) clockwise (in) all the way. This system will now be a pressure compensated system and will maintain system pressure at all times. The pressure should now read 350 bar (5,000 psi). If adjustment is necessary: a. Loosen the hex nut that holds the adjustment stem in place. b. Turn the stem clockwise (in) to increase pressure or counterclockwise (out) to decrease pressure. c.

While holding the adjustment stem in place, tighten the hex nut.

4. Adjust the main relief valve to 370 bar (5,365 psi).

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Adjustment procedures ___________________________________________ 5. Once the pressure compensator is set, reset the margin pressure adjustment to 30 bar (435 psi) (see Margin pressure adjustment procedure in this section).

Fig. 68: Pump

Pressure compensator adjustment

Margin pressure adjustment

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___________________________________________ Adjustment procedures Main relief pressure To adjust the main relief (Fig. 69): 1. Maximize the main relief setting. a. Loosen the jam nut that holds the adjustment stem in place. b. Turn the adjustment stem fully clockwise.

2. Adjust the pressure compensator to 5,500 psi (see Pressure compensator adjustment procedure in this section).

3. Read the pressure on the system pressure gauge. If needed, adjust the main relief until the pressure reads 370 bar (5,365 psi).

Turn the adjustment stem clockwise to increase pressure or counterclockwise to decrease pressure. The relief will be audible when dumping over.

4. Tighten the jam nut to secure the relief adjustment stem.

5. Adjust the pressure compensator to 350 bar (5,000 psi) (see Pressure compensator adjustment procedure in this section).

6. Once the pressure compensator is set, reset the margin pressure to 30 bar (435 psi) (see Margin pressure adjustment procedure in this section).

Fig. 69: Main relief Main relief adjustment

Pressure limiter “A”adjustment

System pressure gauge

Pressure limiter “B”adjustment

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Adjustment procedures ___________________________________________ Pressure limiter adjustment To adjust the pressure limiter (Fig. 69).

1. Locate the pressure limiters on the bottom of the valve bank under the handle 2. Refer to the hydraulic schematic to determine which pressure limiter, A or B, needs adjusted. To determine the pressure limiter setting, bottom out the cylinder (fully extend or retract). The system pressure gauge will read the function pressure.

IMPORTANT! To determine the pressure limiter settings on the tram sections, the feeder breaker will have to be safely stalled out by deadheading into the rib in both directions or by plugging and capping both A and B ports.

3. If an adjustment is need, remove the cap over the adjustment stem.

4. Loosen the hex nut that holds the adjustment stem in place.

5. Turn the adjustment stem clockwise (in) to increase pressure or counterclockwise (out) to decrease pressure setting.

6. Once the desired pressure is obtained, tighten the hex nut while holding the adjustment stem in place.

7. Replace the cap over the adjustment stem.

8. Retest the function to ensure the pressure adjustment was not changed while tightening the hex nut. If necessary, repeat adjustment.

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________________________________________ Replacement of wear parts

Instructions on the replacement of wear parts It is essential that wear parts are replaced before they reach the lowest wear limit, as otherwise damage can be caused to other parts of the machine. Inspect the wear parts at regular intervals.

IMPORTANT! For head shaft bearing installation and clearance setting procedures, see vendor literature in the parts manual.

Headshaft The headshaft (Fig. 77) transmits the torque of the hydraulic motor to the conveyor chain assembly and is part of a complete assembly. As soon as any component is worn, the component or complete headshaft must be replaced. Due to high abrasion forces, the chain sprockets are subject to a very high level of wear.

The head shaft assembly consists of the following main components: ■

drive shaft

■

sprockets (2)

■

bearings (2)

■

hydraulic motor

Fig. 77: Head shaft main components Sprocket (2)

Head shaft

Key (2)

Sprocket (4)

Bearing (2)

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Replacement of wear parts_________________________________________ How to remove the headshaft To remove the headshaft assembly from the feeder breaker proceed as follows (Fig. 78): 1. Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).

2. Remove the two (2) sprocket guards located over the head shaft sprockets by removing the five (5) 3/4”bolts that secure each guard to the mounting plate.

3. Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).

4. Remove the last cover on the right hand side of the machine.

5. Block and secure tailpiece.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

6. Unpin and fold down tailpiece tilt cylinders (see Tailpiece removal procedure). It is not necessary to remove hydraulic hoses.

7. Remove the tailpiece hoppers (2) and head shaft filler plates (2) using appropriate lifting equipment (see Tailpiece removal procedure).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

8. Remove the hydraulic motor. The motor can remain on the gearbox if desired.

CAUTION! The hydraulic motor is heavy. Use proper lifting techniques. a. Disconnect, tag, and cap all hydraulic hoses. b. Remove the five (5) 1/2”bolts, lock washers, and flat washers from the end of the motor.

9

Remove the conveyor gear reducer (see Conveyor gear reducer removal/installation procedure in this chapter). The conveyor gear reducer may remain on the shaft if desired.

10. Disconnect, tag and cap the central lubrication hoses on both head shaft bearings and head shaft bearing seals.

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________________________________________ Replacement of wear parts 11. Remove the four (4) 1”bolts, flat washers, lock washers, and nuts from each of the headshaft bearings. Note that there may be bearing shims under the bearing. If shims are present, make note of their thickness, quantity and location.

12. Attach an appropriate lifting device to the headshaft and slide out towards the rear of the frame.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

How to install the headshaft To install the headshaft assembly proceed as follows (Fig. 78): 1. Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the feeder breaker. The gear reducer may be installed on shaft if desired.

2. Reinstall bearing shims, if applicable, back into the same location as they were removed from. Make sure to install the shims of the same thickness and quantity.

3. Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) 1”bolts, nuts, and lock washers.

Torque bolts to 645 ft-lbs.

NOTICE! After tightening the four (4) 1”bolts and nuts and before installing the gear reducer, ensure that the headshaft can turn freeely by hand. If it cannot, loosen the nuts and bolts and add or remove shims between the frame and the piloow block base as required.

WARNING! The headshaft must turn freely by hand or the bearings will fail prematurely.

4. Install the left and right sprocket guards, head shaft filler plates, tailpiece hoppers, amd tailpiece tilt cylinders (see Tailpiece installation procedure).

5. Connect the central lubrication hoses on both head shaft bearings.

6. Install the hydraulic motor onto the input shaft of the gear reducer. a. Install the five (5) 1/2”mouting bolts, lock washers, and flat washers and torque to 100 ft-lbs. b. Reconnect hydraulic hoses.

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Replacement of wear parts_________________________________________ 7. Install the conveyor gear reducer (see Conveyor gear reducer removal/installation procedure in this chapter). The gear reducer may have been installed.

8. Clean and lubricate splined end of headshaft and splined adapater with ISO 68 hydraulic fluid or coat with Never Seez.

9. Install cover support post.

10. Connect conveyor chain. (See Conveyor chain replacement in this chapter).

11. Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

Fig. 78: Headshaft removal and installation

Nut (8)

Headshaft bearing

Pin

Flat washer (8)

Headshaft assembly

Hex bolt (4) (5/8”X1-3/4”)

Lock washer (8)

Hex bolt (8) (1”X 5”)

Female clevis

Swivel bearing Splined adapter

Male clevis Hex bolt (5) (1/2”X 2 1/4”)

Hydraulic motor

Retaining bolt

Shaft retainer

Reducer end cover

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________________________________________ Replacement of wear parts Headshaft sprockets The headshaft sprockets transmit the torque of the hydraulic motor to the conveyor chain assembly and are part of the headshaft assembly.

As soon as the sprockets are worn, they must be replaced. Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

How to remove the headshaft sprockets To remove the sprockets from the headshaft assembly (Fig. 79): 1. Remove the headshaft assembly from the feeder (see Headshaft removal in this chapter).

2. Remove the two (2) bearings from the headshaft.

3. Remove the two (2) set screws from each sprocket. It may be necessary to apply heat because the screw are retained with Loctite.

4. Slide both sprockets from the drive shaft.

5. Remove old keys.

6. Inspect all components of the drive shaft for wear and damage.

See the parts manual for your machine for a replacement parts list.

How to install the headshaft sprockets To install the sprockets on the headshaft (Fig. 79): 1. Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.

2. Insert one of the keys into the shaft keyway and slide first sprocket onto shaft (see Fig. 80 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 79 for weld specifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.

3. Insert the other key into the shaft keyway and slide second sprocket onto shaft (see Fig. 79 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 80 for weld spcifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.

4. Install bearings on shaft (ss Bearing installation procedure in this chapter). Note that the bearing housing must be installed on shaft so that the Taconite seal is facing the middle of the shaft. Only one of the bearings must have the internal spacer remvoed to allow the shaft to float and not be in a bind.

5. Install the drive shaft assembly in the feeder breaker. (See Drive shaft installation in this chapter.)

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Replacement of wear parts_________________________________________ How to install the head shaft split sprockets To install the split sprockets on the head shaft proceed as follows (Fig. 79): IMPORTANT! Adhere to all weld specifications shown on Fig. 79. Failure to do so may result in sprocket failure and machine damage.

1. Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).

2. Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).

3. Remove the two (2) sprocket guards located on the end of the feeder breaker.

4. Remove damaged sprockets and keys from head shaft. Old sprockets may require cutting to remove.

5. Thoroughly clean and degrease the drive shaft.

6. Insert key into shaft keyway.

7. Install both sprocket halves onto shaft and tack weld in place (see Fig. 79 for location). Ensure sprocket alignment and proper spacing with conveyor chain.

8. Preheat sprocket weld joint to 600°F .

9. Weld sprocket halves together and do not exceed 800°F maximum interpass temperature. Ensure that the weld is smooth in the tooth area to prevent damage to the conveyor chanin bushings during chain operation.

10. If possible, cover sprocket with insulating blanket and allow weld to coolt to a maximum of 100°F before uncovering. If this is not possible, then post weld heat to 800°F. 11. Connect conveyor chain. (See Conveyor chain replacement in this chapter).

12. Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

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________________________________________ Replacement of wear parts Fig. 79: Head shaft sprocket removal and installation Bearing (2)

Head shaft

3/8 X 45° weld chamfer

Sprocket guard

3/8 X 45° weld chamfer

Split sprocket (typical)

Conveyor chain

Sprocket (2) & key (2)

General notes: 1.

2.

3.

4.

Do not mix and match halves with other sprockets.

Install sprocket and keys on head shaft.

OK to temporarily tack weld sprocket halves to head shaft until welding is complete.

Blend and smooth welds to avoid chain roller damage.

Weld notes: 1.

2.

3.

4.

5.

6.

7.

All welds chamfers are 1/2 X 45° except as noted above.

Preheat sprocket weld joint 600°F - 800°F. Maintain preheat temperature during entire welding process.

Max interpass temperature not to exceed 800°F. Use low hydrogen rod (E7018) or weld wire (Class E71T Spec AWS A5.20).

Post weld heat sprocket joint 600°F - 800°F. If possible/practical, bury sprocket in dirt or wrap with a welding blanket for a minimum of 8 hours or until sprocket temp reaches 100°F.

Taconite seal Taconite seal

(optional for one piece sprockets)

(optional for one piece sprockets)

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Replacement of wear parts_________________________________________ Tailshaft The tailshaft (Fig. 80) allows for even adjustments and friction free transition to the conveyor chain assembly. As soon as any component of the tailshaft is worn the component or complete tail shaft assembly must be replaced. Due to the high abrasion forces the tailshaft is subject to a very high level of wear.

The tailshaft assembly consists of the following main components: ■

tail haft

■

roller (2)

■

slide plate weldment

■

key (2)

■

roller set screw (2)

■

take-up bearing (2)

■

piston rod adapter (2)

Fig. 80: Tail shaft main components

Set screw (2)

Tail shaft

Key (2)

Piston rod adapter (2)

Bearing (2) Slide plate

Roller (2)

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________________________________________ Replacement of wear parts How to remove the tailshaft To remove the tailshaft assembly (Fig. 81): 1. Remove the RTV silicone from five (5) bolt heads and remove the bolts from each end of the tailshaft retainers and lift out the retainers.

2. Make sure the grease take-up release valves are closed and pump up the grease cylinders until the grease shims are loose.

3. Release tension on the conveyor chain by removing the tail shaft shims. Open the valves on the grease cylinder take-up manifold located under the main valve bank. Pry the tailshaft toward the discharge end of the machine to fully collapse the grease take-up cylinders.

4. Disconnect, tag and cap the central lubrication hoses to the tail shaft.

5. Separate conveyor chain and fold back to clear tail shaft. (See Conveyor chain replacement in this chapter).

6. It may be necessary to remove the take-up cylinders from the feeder frame and disengage the take-up pushrod from the take-up bearing.

7. Attach an appropriate lifting device to the tail shaft assembly and and slowly lift from machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

How to install the tail shaft To install the tailshaft assembly (Fig. 81): 1. Apply a coat of grease to the bearing guide bars.

2. With an appropriate lifting device, insert tail shaft into the receiving end of the feeder breaker. Center the tail shaft in the feeder breaker frame, ensuring that the slots of the take-up bearing are aligned witht the guide bars and that the bearings are fully seated on the guide bars. It may be necessary to loosen the set screws of the bearing retainer collars and reposition the bearings so that the bearing slots are aligned with the frame guide bars. Apply Loctite 242 and torque set screws to 100 ft-lbs if loosened.

3. Install the take-up pushrod into the take-up bearing.

4. Fold the conveyor chain over tailshaft.

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Replacement of wear parts_________________________________________ 5. Connect conveyor chain (see Conveyor chain replacement in this chapter.

6. Connect central lubrication hoses and lubricate the tailshaft slide plate and take-up bearings with Spec. 100-3 grease until grease is seen coming out of the bearings and from the tailshaft slide plate tube.

7. Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).

8. Install the tailshaft retainers with the five (5) bolts in each side and fill the bolt heads with RTV silicone.

9. With machine running, visually inspect tailshaft to ensure that the chain is smoothly engaging the rollers.

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________________________________________ Replacement of wear parts Fig. 81: Tailshaft removal and installation Cover Tailshaft retainer plates (2)

Tailshaft

Tailshaft take-up push rod (2)

Take-up bearing Cylinder mount (2)

Tail shaft slide plate 90° grease hose elbow

Swivel grease fitting

Grease cylinder (2) Piston rod adaptor Take-up shim retainer(2)

Gusset (2)

Shims

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Replacement of wear parts_________________________________________ How to disassemble the tailshaft To disassemble the tailshaft assembly (Fig. 82): 1. Remove the tailshaft assembly from the feeder breaker. (see Tailshaft removal procedure in this chapter).

2. Loosen the set screws (2 per bearing assembly) and slide both take-up bearings and piston rod adapters from the tailshaft.

3. Loosen the set screw from the tailshaft roller and slide sprockets from the shaft. Note that heat may be required to loosen set screw as Loctite was used during installation.

4. Remove the tailshaft from the slide plate.

5. Visually inspect all components for damage or wear and replace as necessary.

How to assemble the tailshaft To assemble the tailshaft assembly (Fig. 82): 1. Thoroughly clean all parts that will be installed.

2. Grease tailshaft with Spec. 100-3 grease.

3. Slide tailshaft into the slide plate.

4. Insert key into keyway on tailshaft.

5. If equipped with sprockets, apply Loctite 242 (blue) on set screw and install set screw into the sprocket with the key, ensuring that the sprockets and tail shaft slide plate are centered on tail shaft.

6. Tighten set screw and torque to 100 ft-lb.

7. Install both take-up bearings onto the tail shaft, flush with the ends of the shaft.

8. Apply Loctite 242 (blue) to the set screw and install. Tighten and torque to 100 ft-lb.

9. Install swivel grease fittings in the ends of the shaft and the 90° grease hose elbows into the take-up bearings.

10. Install tailshaft into machine. (see Tailshaft installation procedure in this chapter).

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________________________________________ Replacement of wear parts Fig. 82: Tail shaft disassembly and assembly Set screw (2)

Tail shaft

Key (2)

Piston rod adapter (2)

Bearing (2) Slide plate

Roller (2)

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Replacement of wear parts_________________________________________ Conveyor chain The conveyor chain (Fig. 83) is made up of one basic chain assembly which repeats sequentially along the entire chain loop. As soon as any component of the conveyor chain is worn the component or complete conveyor chain assembly must be replaced.

Each conveyor chain section consists of the following main components: ■

6 link chain section

■

flight bar

■

spiral pin

Fig. 83: Conveyor chain main components

6 link chain section

Spiral pin

Flight bar

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________________________________________ Replacement of wear parts How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 84): 1. Lay conveyor chain sections on a clean flat surface.

2. Insert connector pins through flight end and align holes in spiral pin with holes in flight bar.

3. Insert spiral pin.

4. Drive spiral pin in with a hammer and punch. Ensure that spiral pin is recessed on both sides of flight bar.

5. Repeat the previous assembly instructions until the complete chain has been assembled.

Fig: 84: Conveyor chain assembly

Extended pin connecting link Spiral pin (4)

Block link assembly

Flight bar

Side bar

6 link chain section

How to remove the conveyor chain assembly To remove the conveyor chain assembly proceed as follows: 1. Release tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

2. At the chain disassembly/assembly point, raise the chain a minimum of 3”high and block it under the flight.

Note: There are notches in the frame on both sides of the conveyor deck. The notches are to provide access to the conveyor chain during disassembly and assembly. This is the chain disassembly/assembly point.

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Replacement of wear parts_________________________________________ 3. Separate conveyor chain by removing spiral pins and connecting links in one section of the chain.

4. Connect a pulling device (e.g. winch or lifting tackle with adequate load limit), or the new conveyor chain, to either end of the old conveyor chain and slowly pull the old conveyor chain completely out of the machine.

WARNING! When using a pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the conveyor chain, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable. Use only approved lifting equipment for connecting pulling devices to the conveyor chain.

How to install the conveyor chain assembly To install the conveyor chain assembly proceed as follows: 1. Check to ensure that the conveyor tail shaft is completely retracted.

If not retracted, see Conveyor chain adjustment in this chapter.

2. If the old conveyor chain was not used to install the new conveyor chain, then run a cable or pull rope with an adequate load limit through the bottom conveyor pan and connect to the conveyor chain.

3. Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to the other end of the cable or pull rope and slowly pull the new conveyor chain completely through the bottom conveyor pan.

IMPORTANT! If old conveyor chain is still on machine, installation can be facilitated by connecting the new conveyor chain to the old conveyor chain via the chain connectors and pulling it through the bottom conveyor pan.

4. Fold conveyor chain back over the tail shaft and drive shaft and slowly pull the chain along the conveyor ensuring that the chain is under the chain hold downs.

5. Ensure that the chain is properly meshed with the sprockets on the head and rollers on the tailshaft.

6. Connect conveyor chain (see How to assemble the conveyor chain sections in this chapter for proper connection).

7. Adjust tension on the conveyor chain (see Conveyor chain adjustment procedure in this chapter.

8. With machine running, visually inspect tail shaft to ensure that the conveyor chain is properly engaged with the tailshaft rollers.

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________________________________________ Replacement of wear parts Crawler track The crawler track (Fig. 85) assembly (left and right) carries the machine via torque received from the tram drive reducer. The crawler track is made up of one basic crawler pad assembly, which repeats sequentially along the entire pad loop. As soon as any component of the crawler track is worn the component or complete crawler track assembly must be replaced.

Each crawler track consists of the following main components: ■

crawler pad

■

connector pin

■

roll pin

Fig. 85: Crawler track main components

Connector pin

Roll pin Crawler pad

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Replacement of wear parts_________________________________________ How to assemble the crawler track pads (Fig. 85) To assemble the crawler track pads proceed as follows: 1. Lay crawler track pads on a clean flat surface.

2. Align pads with chain connecting holes centered.

3. Insert connector into center of crawler pad connecting holes.

4. Drive rool pin through connecting pin and bend end to secure.

5. Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly (Fig. 85) To remove the crawler track pad assembly proceed as follows: 1. Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

2. Crawler track tension must be released (see Crawler track adjustment in this chapter).

3. Separate the crawler pads (Fig. 85).

IMPORTANT! Heating or cutting connections with a torch or chisel may be required to ease the removal of T- pins. a. Drive or cut roll pin from crawler pad connection using hammer and punch. b. Separate crawler track assembly. c.

Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the crawler track assembly and slowly pull the crawler track completely out from under the machine.

WARNING! When using an additional pulling device for pulling the crawler track, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable. Use only approved lifting equipment for connecting pulling devices to the crawler track.

4. Inspect the crawler drive sprocket and idler rollers for wear or

damage. Replace if necessary. ________________________________________________________________ 5.112 FB110 Feeder Breaker

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________________________________________ Replacement of wear parts How to install the crawler track pad assembly To install the crawler track pad assembly proceed as follows (Fig. 85): 1. Remove old crawler track pad assembly (see previous section, How to remove crawler track pad assembly).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

2. Check to ensure that crawler track tension cylinder is completely retracted (see Crawler track adjustment in this chapter).

3. Slide crawler track pad assembly under crawler assembly.

4. Fold pad assembly over both ends of crawler assembly. Ensure that pad assembly meshes with drive sprocket and idler roller.

5. Connect crawler track pad assembly (see How to assemble crawler track pad assembly in this chapter for proper connection).

6. Adjust tension on the crawler track pad assembly (see Crawler track pad adjustment procedure in this chapter for proper adjustment).

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Replacement of wear parts_________________________________________ Crawler assembly The crawler assembly (Fig. 86) consists of a take-up assembly and drive assembly that transmits torque to the crawler track via a hydraulic drive motor coupled to the tram drive torque hub. As soon as any component of the drive assembly is worn or damaged, the component must be replaced.

The crawler assembly consists of the following main components: ■

hydraulic drive motor

■

tram drive torque hub

■

cat pad assembly

■

take-up roller assembly

■

grease take-up assembly

■

drive sprocket

Fig. 86: Crawler assembly main components Crawler pad assembly

Hydraulic motor (not shown)

Take-up roller assembly Take-up access

Torque hub access

Sprocket

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________________________________________ Replacement of wear parts How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 87): 1. Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.

2. Crawler track tension must be released (see Crawler track adjustment in this chapter.

3. Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear take-up.

4. Securely block under the crawler frame.

5. Disconnect, tag and cap hydraulic hoses going to the tilt cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers 6. Remove the eight (8) bolts from the tilt cylinder mounting bracket.

7. Swing the tilt cylinder and mounting bracket free of the crawler frame.

8. Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to the take-up assembly and slowly pull the assembly out of the crawler frame.

WARNING! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the take-up, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable. Use only approved lifting equipment for connecting pulling devices to the take-up.

9. Inspect all components for wear or damage.

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Replacement of wear parts_________________________________________ How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 87): 1. Remove old take-up assembly (see previous section, How to remove crawler take-up assembly).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

2. Inspect all components for wear or damage prior to assembly.

3. Clean all dirt and debris from inside crawler frame.

4. Attach appropriate lifting device to take-up assembly and slide assembly completely into the end of crawler frame.

5. Install and connect crawler and track pad assembly, see How to install the crawler track pad assembly in this chapter.

6. Swing the tilt cylinder and mounting bracket into crawler frame and secure with the eight (8) bolts, washers and nuts.

7. Connect hydraulic hoses to tilt cylinder.

8. Purge hydraulic system of air.

9. Adjust crawler track pad tension (see How to adjust crawler track pad tension in this chapter).

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________________________________________ Replacement of wear parts Fig. 87: Crawler take-up removal and installation Tilt cylinder

Crawler take-up

Tilt cylinder mounting bracket

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Replacement of wear parts_________________________________________

How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 88): 1. Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

2. Crawler track tension must be released (see Crawler track adjustment in this chapter).

3. Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear sprocket.

4. Disconnect, cap and tag all hydraulic hoses to hydraulic motor.

5. Remove slotted nut, roll pin and washer from lift cylinder anchor pin.

6. Remove anchor pin from crawler frame and crawler guide weldment.

7. Remove the six (6) bolts and lock washers that secure the removable side plate to crawler frame and remove side plate.

8. Remove the twelve (12) bolts and lock washers that secure the torque hub to the crawler frame.

9. Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.

10. Remove the four (4) bolts and lock washers that secure the hydraulic motor and adapter plate to the torque hub.

11. Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.

CAUTION! Do not bump hydraulic motor or hydraulic motor fittings when removing the motor from the machine.

12. Remove the adapter plate and motor from the torque hub as an assembly.

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________________________________________ Replacement of wear parts 13. If not replacing the hydraulic motor, it is not necessary to separate the adapter plate from the hydraulic motor. If replacing the hydraulic motor, remove the four (4) nuts and lock washers that secure the hydraulic motor to the adapter plate. And remove adapter plate.

14. Thoroughly clean and degrease the adapter plate mating face.

15. Remove the twenty (20) bolts and lock washers that secure the sprocket to the torque hub and separate hub and sprocket.

16. Inspect all components for wear or damage.

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Replacement of wear parts_________________________________________ How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 88): 1. Remove old crawler drive assembly (see previous section, How to remove crawler drive assembly).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

2. Inspect all components for wear or damage prior to installation.

3. Place sprocket onto torque hub and secure with the twenty (20) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

■ ■ ■

Step 1: 70 ft-lb Step 2: 140 ft-lb Step 3: 210 ft-lb

4. Thoroughly clean and degrease the adapter plate and mating faces of the torque hub and hydraulic tram motor.

5. Apply Loctite 518 gasket eliminator or equivalent to the adaptor plate. Be sure to apply the sealant completely around all bolt holes to prevent leakage.

6. Place hydraulic motor gasket onto motor adapter plate.

7. Apply Loctite 518 to the second side of the motor gasket.

8. Install adapter plate and gasket onto hydraulic motor and secure with the four (4) nuts and lock washers. Apply Loctite 242 (blue) to nuts.

9. Apply Loctite 518 to the adapter plate gasket.

10. Place adapter plate gasket onto the adapter plate.

11. Apply Loctite 518 gasket eliminator or equivalent to the second side of the adaptor plate gasket. Be sure to apply the sealant completely around all bolt holes to prevent leakage.

12. Install motor and adapter plate assembly onto torque hub, being careful not to damage motor shaft or gasket. Secure with the (4) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows: ■ ■ ■

Step 1: 25 ft-lb Step 2: 50 ft-lb Step 3: 70 ft-lb

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________________________________________ Replacement of wear parts 13. If using a motor adapter plate that does not have the keepers already installed, weld four (4) keepers against the motor flanges to prevent motor movement.

14. Clean all dirt and debris from mounting area of crawler frame.

15. Attach an appropriate lifting device to the torque hub and slide complete assembly into crawler frame.

16. Secure torque hub assembly to frame with the twelve (12) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

■ ■ ■ ■

Step 1: 50 ft-lb Step 2: 140 ft-lb Step 3: 280 ft-lb Step 4: 420 ft-lb

17. Connect hydraulic hoses to drive motor.

18. Install and connect crawler and track pad assembly (see How to install the crawler track pad assembly in this chapter).

19. Install the removable side plate and secure with the six (6) bolts and lock washers. Torque incrementally as follows.

■ ■ ■

Step 1: 300 ft-lb Step 2: 600 ft-lb Step 3: 905 ft-lb

20. Apply grease to anchor pin and slide anchor pin through crawler frame and tilt cylinder. Secure pin with slotted nut, washer and roll pin.

21. Purge hydraulic system of air.

22. Adjust crawler track pad tension (see How to adjust crawler track pad tension in this chapter).

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Replacement of wear parts_________________________________________ Fig. 88: Crawler drive disassembly and assembly 21 16, 17

25

1

21

24

18

8

10, 13, 14 9

12

15

10, 11

3, 4

23

6, 7

22 5 19

20

2

1.

2.

3.

4.

5.

6.

7.

8.

9.

crawler frame torque hub washer (high collar lock) (12) cap screw (socket head) (12) sprocket washer (high collar lock) (20) cap screw (socket head) (20) gasket (adaptor plate) plate (adaptor)

10.

11.

12.

13.

14.

15.

16.

17.

18.

washer (lock) (8) cap screw (hex head) (4) gasket washer (flat) (4) nut (hex) (4) keeper washer (lock) (6) bolt (hex head) (6) crawler pad

19.

20.

21.

22.

23.

24.

25.

bushing bushing pin (crawler anchor) washer (flat) nut (castle) pin (cotter) side plate (removable)

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________________________________________ Replacement of wear parts Breaker shaft and breaker power unit The breaker power unit (Fig. 89) and the breaker shaft assembly (Fig. 90) can be removed or installed as a single assembly (Fig. 91) or as two separate assemblies.

The power unit (Fig. 89) consists of the following main components: ■

motor (200 hp)

■

connecting tube

■

magnetic coupling

■

gear reducer

WARNING! Magnets can cause pacemakers defibrillators, or other electronic medical devices to malfunction or reset to factory settings. People with any of these medical devices must maintain a safe distance (10 ft) when coupling is disassembled.

WARNING! Ferrous metals are powerfully drawn to the magnets in the magnet rotor and are very difficult to separate. Keep conductor components, tools, fasteners, and metal work surfaces such as steel benches away from the magnets. In the event of accidental magnetic attachment, use plastic wedges to separate parts from the magnets.

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Replacement of wear parts_________________________________________ Fig. 89: Breaker power unit main components Gear reducer

Connecting tube

Magnetic coupling Motor (200 HP)

Fig. 90: Breaker shaft assembly

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________________________________________ Replacement of wear parts Fig. 91: Breaker shaft and power unit assembly Power unit assembly

Breaker shaft assembly

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Replacement of wear parts_________________________________________ How to remove the breaker shaft and breaker power unit To remove the breaker shaft and breaker power unit as a single assembly (Fig. 92).

1. Turn the machine main circuit breaker (CB1) to the “OFF”position.

2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF”position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

3. Remove all power unit and breaker shaft covers.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

4. Remove the junction box access panel of the electric motor. Tag and disconnect the cable leads from the motor leads.

5. Remove and cap all grease lines from the breaker shaft, gear reducer, and electric motor.

6. Remove the power unit support structure.

7. Remove the under speed sensor and tachometer by loosening the nuts on the u-bolt and sliding the sensor out.

8. Attach an appropriate lifting device to the breaker shaft and power unit assembly in such a manner to keep breaker shaft and power unit level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting hardward is removed.

9. Remove the hardware from the breaker side plates and the power unit reaction pin.

10. Lift the breaker shaft and power unit out of the machine as an assembly.

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________________________________________ Replacement of wear parts Fig. 92: Breaker shaft and power unit removal and installation 1

5 8

6 3

19 7 9

4 3 6

10

2

12

31

11

21

26

25

27

20

14 30 18

16 15

13

22, 23, 24

17

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Replacement of wear parts_________________________________________ Fig. 92, continued: Breaker shaft and power unit removal and

8, 7, 9, 10

31

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Breaker shaft assembly Filler plate (2) Washer, lock 1-1/4 (24) Bolt, hex head 1-144X4 (20) Bolt, hex head 1-1/4X5 (4) Nut, hex 1-1/4 (24) Stub shaft Screw, socket head shoulder 1X3 (12) Washer, lock 3/4 (12) Nut, hex 3/4 (12)

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Power unit assembly Bolt, hex head M30X80 Pivot lug weldment Mounting plate, pivot lug Reaction pin Washer, lock 1”(4) Bolt, hex head 1X2 (4) Pin, cotter 3/8X4 (2) Key Cylinder mount weldment

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

Grease cylinder (3) Washer, flat 3/8 (6) Washer, lock 3/8 (6) Bolt, hex head 3/8X1-1/4 (6) Breaker retainer (2) Breaker retainer (2) Grease fitting (5) Underspeed sensor mount U-bolt Power unit guide assembly Low speed output shaft cover plate

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________________________________________ Replacement of wear parts How to install the breaker shaft and breaker power unit To install the breaker shaft and breaker power unit as a single assembly (Fig. 92).

1. Attach an appropriate lifting device in such a manner as to keep the breaker shaft and power unit level during the lift and slowly lift the unit onto the machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

2. Install the power unit reaction pin and the hardware into the breaker side plates.

3. Install the tachometer and under speed sensor on the left hand side of the breaker shaft. The distance from the sensor end to end cap target is approximately 1/8 to 1/4 inch. Note: Ensure that a 1/213X1/2 hex head cap screw is installed in the breaker end cap or the tachometer will not read correctly.

4. Remove caps and install all grease lines to the breaker shaft, gear box, and electric motor.

5. Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.

6. If necessary, adjust the height of the breaker shaft using the grease cylinders. There is one grease cylinder mounted under each breaker side plate and one mounted under the reaction pin (see Breaker shaft height adjustment procedure in this chapter).

7. Install the power unit cover support structure.

8. Install all power unit covers.

9. Turn the machine circuit breaker on.

10. Unlock and remove tags from electric power at the power center.

11. Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.

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Replacement of wear parts_________________________________________ How to remove the breaker power unit assembly To remove the breaker power unit proceed as follows (Fig. 92).

1. Turn the machine main circuit breaker (CB1) to the “OFF”position.

2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF”position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

3. Remove all power unit covers.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

4. Remove the junction box access panel of the electric motor. Tag and disconnect the cable leads from the motor leads.

5. Remove and cap all grease lines from the gear reducer and electric motor.

6. Remove the under speed sensor and tachometer.

7. Attach an appropriate lifting device to the power unit assembly in such a manner as to keep the power unit level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting power unit reaction pin and bolts from breakershaft bolt fland and stub shaft are removed.

8. Remove the bolts that connect the breaker shaft bolt flange to the stub shaft.

9. Remove cotter pins from the power unit reaction pin.

10. Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.

11. Lift the power unit out of the machine.

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________________________________________ Replacement of wear parts How to install the breaker power unit assembly To install the breaker power unit proceed as follows (Fig. 92).

1. Attach an appropriate lifting device to the power unit in such a manner that the power unit is level during the lift and slowly lift the unit onto the machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

2. Install the power unit reaction pin and secure with cotter pins.

3. Bolt the breaker shaft bolt flange to the stub shaft.

4. Remove the lifting device.

5. Install the tachometer and under speed sensor on the breaker shaft. Distance from sensor end to end cap target is approximately 1/8”to 1/4”. Note: Ensure that a 1/2-13X1/2 hex head cap screw is installed in the breaker end cap or the tachometer will not read correctly.

6. Remove caps and install all grease lines to the gear box and electric motor.

7. Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.

8. Install all power unit covers.

9. Unlock and remove tags from electric power at the power center.

10. Turn the machine circuit breaker on.

11. Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.

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Replacement of wear parts_________________________________________ How to remove the breaker shaft assembly only To remove the breaker shaft assembly (Fig. 92).

1. Turn the machine main circuit breaker (CB1) to the “OFF”position.

2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF”position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

3. Remove all breaker shaft and gear reducer covers.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

4. Remove and cap all grease lines from the breaker shaft.

5. Remove the underspeed sensor and tachometer from the breaker shaft by loosening the nuts on the u-bolt just enough to allow the senosr to slide out.

6. Properly support the breaker shaft gear reducer so that it does not fall during breaker shaft removal. Ensure that the power unit reaction pin is in place and not removed during this procedured.

7. Attach an appropriate lifting device to the breaker shaft. in such a manner that the breaker shaft is level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting hardware is removed.

8. Remove the hardware from the breaker side plates and from between the two halves of the bolt flange and the stub shaft flange.

9. Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.

10. Lift the breaker shaft out of the machine.

________________________________________________________________ 5.132 FB110 Feeder Breaker

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________________________________________ Replacement of wear parts How to install the breaker shaft assembly To install the breaker shaft assembly (Fig. 92).

1. Attach an appropriate lifting device to the breaker shaft in such a manner that the breaker shaft is level during the lift and slowly lift the unit onto the machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

2. Install the hardware into the breaker side plates.

3. Install hardware to attach breaker shaft bolt flange to stub shaft in gear reducer.

4. Remove support from under gear reducer.

5. Remove lifting device from breaker shaft.

6. Remove caps and install all grease lines to the breaker shaft.

7. Install all breaker covers.

8. If necessary, adjust the height of the breaker shaft using the grease cylinders. There is one grease cylinder mounted under each breaker side plate and one mounted under the reaction pin (see Breaker shaft height adjustment procedure in this chapter).

9. Turn the machine circuit breaker on.

10. Unlock and remove tags from electric power at the power center.

11. Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.

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Replacement of wear parts_________________________________________ How to remove the breaker power unit only To remove the breaker power unit (Fig. 92).

1. Turn the machine main circuit breaker (CB1) to the “OFF”position.

2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF”position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

3. Remove the breaker power unit covers.

4. Block underneath the gear reducer and the electric motor to prevent units from falling during removal.

5. Remove motor junction box cover and tag and disconnect power leads.

6. Remove grease lines from gear reducer and electric motor.

7. Attach an appropriate lifting device to the power unit. Take up slack in lifting device so weigth of power unit is supported by the lfiting device.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

8. Remove pivot pin and hardware connecting the bolt flange of the breaker shaft to the stub shaft.

9. Lift the breaker breaker power unit out of the machine.

________________________________________________________________ 5.134 FB110 Feeder Breaker

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________________________________________ Replacement of wear parts How to install the breaker power unit To install the breaker power unit (Fig. 92).

1. Ensure that the machine is locked and tagged out at the power center. Follow standard Federal and mine lockout/tagout procedures.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF”position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

2. Attach an appropriate lifting device to the power unit and position the power unit in the machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

3. Install the pivot pin.

4. Install the hardware that secures the bolt flange of the breaker shaft to the stub shaft.

5. Connect grease lines to the gear reducer and electric motor.

6. Remove motor junction box cover and tag and disconnect power leads.

7. Remove the breaker power unit covers.

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Replacement of wear parts_________________________________________ How to disassemble the breaker power unit To disassemble the breaker power unit (Fig. 93): WARNING! Magnets can cause pacemakers defibrillators, or other electronic medical devices to malfunction or reset to factory settings. People with any of these medical devices must maintain a safe distance (10 ft) when coupling is disassembled.

WARNING! Ferrous metals are powerfully drawn to the magnets in the magnet rotor and are very difficult to separate. Keep conductor components, tools, fasteners, and metal work surfaces such as steel benches away from the magnets. In the event of accidental magnetic attachment, use plastic wedges to separate parts from the magnets.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

IMPORTANT! Field disassembly or repair of the breaker shaft is not recommended. If the breaker shaft requires repair, please consult your service representative.

1. Remove the power unit from the machine (see power unit removal procedure in this section). While it is not required to remove the breaker shaft with the power unit, this procedure details the procedure for removing both.

2. Attach an appropriate lifting device to the breaker shaft (if attached) and remove the bolts, lock washers, and nuts from the coupling flange and stub shaft.

3. Remove the low speed output shaft cover bolts and the cover.

4. Remove the M30 hex head cap screw from the stub shaft.

5. Insert a hex head cap screw into the threaded hole in the gear reducer retainer plate. As the bolt is threaded into the hole, it will push the stub shaft out of the hollow bore of the reducer.

6. Install a lifting eye into the top of the electric motor.

7. Attach an appropriate lifting device to the electric motor.

8. Remove the connecting tube access cover.

9. Remove the bolts that attach the magnetic coupling to the shrink disc on the motor shaft.

10. Loosen the bolts that secure the shrink disc to the electric motor

shaft. ________________________________________________________________ 5.136 FB110 Feeder Breaker

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________________________________________ Replacement of wear parts 11. Using a gear puller, a brass hammer, or a hammer and wooden block, carefully remove the shrink disc from the electric motor shaft.

12. Securely block the magnetic coupling so that it will not move when it is disconnected from the gear reducer shaft.

13. Remove the bolts that secure the shrink disc to the gear reducer shaft.

14. Attach a lifting device to the magentic coupling assembly and remove from the connecting tube. Note: Hubs must be removed from the magnetic coupling assembly before the power unit is reassembled.

15. Attach a lifting device to the connecting tube and take up the slack so that the weight of the connecting tube is resting on the lifting device.

16. Remove the bolts that secure the connecting tube to the gear reducer and lift the connecting tube out of the frame.

17. Using a gear puller, a brass hammer, or a hammer and wooden block, carefully remove the shrink disc from the gear reducer.

18. Remove fan from gear reducer by loosening the set screw and removing the key.

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Replacement of wear parts_________________________________________ Fig. 93: Breaker power unit assembly and disassembly 1

6

5

7

4

13 12 11

2 9

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

8

10

3

Gear reducer Magnetic coupling assembly Electric motor Connecting Tube Flat washer, 1-1/4”(4) Lock washer, 1-1/4”(4) Bolt, hex head, 1-1/4X5-1/2 (4) Lock washer, 3/4”(8) Bolt, hex head, 3/4X2-1/4 (8) Connecting tube cover Flat washer, 1/2”(2) Lock washer, 1/2”) (2) Bolt, hex head, 1/2X1 (2)

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________________________________________ Replacement of wear parts Fig. 93, continued: Breaker power unit assembly and disassembly

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Replacement of wear parts_________________________________________ Fig. 94: Magnetic coupling assembly

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Replacement of wear parts_________________________________________ How to assemble the breaker power unit To assemble the breaker power unit (Fig. 93 and Fig. 94): WARNING! Magnets can cause pacemakers defibrillators, or other electronic medical devices to malfunction or reset to factory settings. People with any of these medical devices must maintain a safe distance (10 ft) when coupling is disassembled.

WARNING! Ferrous metals are powerfully drawn to the magnets in the magnet rotor and are very difficult to separate. Keep conductor components, tools, fasteners, and metal work surfaces such as steel benches away from the magnets. In the event of accidental magnetic attachment, use plastic wedges to separate parts from the magnets.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

1. Remove the key from the gearbox input shaft and modify it by cutting it to the length of the fan hub. Note the location of the fan to aid in reinstallation and remove the fan.

2. Attach a lifting device to the connecting tube and secure the connecting tube to the gear reducer with four 1-1/4X5-1/2 hex head bolts, lock washers, and flat washers. Torque to 1,900 ft-lb.

3. Ensure that the coupling hubs and the mounting shafts are deburred, degreased, clean, and dry.

4. Mark engagement lengths on the motor and gearbox shafts: Motor shaft engagement length: 3.33 inches Gearbox shaft engagement length: 1.74 inches 5. Install the fan on the gearbox and insert the modified key from Step 1. Secure the fan by tightening the set screw.

6. Remove the gearbox hub from the magnetic coupling by inserting jacking screws (save for later installation) to jack hub from conductor plate.

7. Loosely install hub connections bolts into the gearbox side hub.

8. Place gearbox side shrink disc on gearbox side hub. NOTE: Do not tighten shrink disc cap screws at this time.

9. Install the gearbox side hub and shrink disc onto the gearbox shaft until it aligns with the engagement mark made on the shaft in Step 5.

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Replacement of wear parts_________________________________________ 10. Tighten the gearbox shrink disc clamp bolts as follows until the hub cannot be hand rotated independent of the shaft. a. After confirming correct position of the hub and shrink disc, hand tighten three equally spaced locking screws, making sure that the outer collars of the shrink disc are parallel. Hand tighten the remaining locking screws.

11. Place a dial indicator on the hub and measure for radial and face runout. Total Indicated Runout (TIR) must be less than 0.003 inch (0.08 mm). (Fig. 95) Fig. 95: Run out measurement Hub connection bolt Shrink disc

Face runout

Pilot diameter (radial) runout

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________________________________________ Replacement of wear parts 12. If runout is greater than 0.003 inch, locate the high point of TIR at 12:00 and apply a blow with a soft face mallet on the edge of the hub to correct runout. Once TIR is less than 0.003 inch, proceed to Step 12. If TIR cannot be achieved, installation cannot continue.

13. When correct TIR is achieved, final torque (22 ft-lb) the shrink disc bolts as follows: a. Using a torque wrench set to 23 ft-lb, tighten locking screws in a clockwise sequence using 1/4 turns for several passes until 1/4 turns can no longer be achieved. b. Continue to apply overtorque for 1 to 2 more passes. Note: Overtorque is required to compensate for system related relaxation of locking screws since tightening a given screw will always relax adjacent screws. c.

Reset the torque wrench to 22 ft-lb and check all locking crews.

No screws should turn at this point. If screws turn, repeat Step b for 1 to 2 more passes.

14. Remove the electric motor shaft key from the electric motor shaft (it is not used in this application).

15. Clean, degrease, and dry the electric motor shaft.

16. Remove the electric motor shaft drive hub from the magnetic coupling by removing the connecting cap screws (save for later installation) and inserting hub jacking screws to jack hub from conductor plate of the magnetic coupling.

17. Loosely install hub connection bolts into the electric motor hub and place electric motor side shrink disc on hub.

18. Install motor side hub and shrink disc on to the electric motor shaft until it aligns with the engagement mark made on the shaft in Step 5. Note: Do not tighten shrink disc cap screws at this time.

19. Tighten the electric motor shrink disc clamp bolts as follows until the hub cannot be hand rotated independent of the shaft: a. After confirming correct position of the hub and shrink disc, hand tighten three equally spaced locking screws, making sure that the outer collars of the shrink disc are parallel. Hand tighten the remaining locking screws.

20. Place a dial indicator on the hub and measure for radial and face runout. Total Indicated Runout (TIR) must be less than 0.003 inch (0.08 mm). (Fig. 95)

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Replacement of wear parts_________________________________________ 21. If runout is greater than 0.003 inch, locate the high point of TIR at 12:00 and apply a blow with a soft face mallet on the edge of the hub to correct runout. Once TIR is less than 0.003 inch, proceed to Step 12. If TIR cannot be achieved, installation cannot continue.

22. Attach a lifting device to the electric motor and align motor with connecting tube. Install eight mounting bolts and hand tighten only. NOTE: Do not remove lifting device; let the weight of the motor rest on the lifting device, not the hand tight connecting bolts.

23. Install the center assembly of the magnetic coupling by attaching a lifting device to the assembly and aligning the match marks on the magnet rotor and gearbox hub. Torque hub/rotor cap screws (gearbox side only) to 85 ft-lb.

24. Align match marks on the conductor housing of the magnetic coupling and the electric motor hub. Attach the conductor housing to the motor hub with cap screws and torque to 60 ft-lb.

25. If housing lines up with motor hub, go to Step 26. If it does not, rotate the coupling until it is lined up.

26. Insert jacking screws into jacking holes in conductor housing. Adjust jacking screws until air gap is near equal on both sides of the magnet rotor.

27. After the electric motor hub is tightened to magnetic coupling and BEFORE the electric motor shrink disc is tightened to the electric motor side hub, the eight (8) bolts installed in Step 22 must be incrementally and evenly torqued to 400 ft-lb in a crossing pattern.

28. Final torque (44 ft-lb) the electric motor side shrink disc bolts as follows: a. Using a torque wrench set to 46 ft-lb, tighten locking screws in a clockwise sequence using 1/4 turns for several passes until 1/4 turns can no longer be achieved. b. Continue to apply over-torque for 1 to 2 more passes. Note: Over-torque is required to compensate for system related relaxation of locking screws since tightening a given screw will always relax adjacent screws. c.

Reset the torque wrench to 44 ft-lb and check all locking crews. No screws should turn at this point. If screws turn, repeat Step b for 1 to 2 more passes.

29. Remove all jacking screws from the conductor housing assembly.

30. Inspect hubs for proper engagement with shaft.

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________________________________________ Replacement of wear parts 31. Inspect coupling assembly to ensure air gap is spaced equally on both sides of the magnet rotor. a. If the magnet rotor is touching the copper conductor housing, reinsert the jacking screws into the jacking holes in the conductor housing. b. Loosen the shrink disc cap screws on the motor side, and c.

Repeat Steps 24 through 26.

32. Replace the connecting tube access cover.

33. Apply never Seeze to the key and stub shaft and install the sub assembly into the hollow bore of the gear reducer.

34. Install an M30 hex head cap screw into the end of the stub shaft and torque to 900 ft-lb.

35. Install the low speed output shaft cover and bolts. Torque to 15 ftlb incrementally and evenly in a crossing pattern.

36. Attach an appropriate lifting device to the breaker shaft (if removed with the power unit) and secure the coupling flange to the stub shaft with twelve (12) 1X3 shoulder bolts, and twelve (12) 3/4 lock washers and nuts. Torque to 376 ft-lb.

37. Install the assembled power unit into the machine (see Power unit installation procedure in this chapter).

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Replacement of wear parts_________________________________________ Fig. 93: Breaker shaft and power unit installation

Breaker shaft Breaker power unit

Breaker shaft and power unit height adjustment procedure To adjust the height of the breaker shaft and power unit: 1. Remove covers to gain access to both ends of the breaker shaft and power unit.

2. Remove all breaker shaft side plate and reaction pivot mount hardware.

3. Loosen only, do not remove, the retainers located on the reaction pivot mount.

4. Locate the grease cylinder manifold on the feeder frame rear pivot mount.

To lower: 5. To lower the breaker shaft and power unit, make sure grease needle valve openings are pointed away from people and slowly crack open one at a time.

6. Incrementally and evenly lower the breaker shaft and power unit to the desired height and close the needle valves.

7. Install all hardware, tighten the retainer hardware on the reaction pivot mount, and install all covers.

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________________________________________ Replacement of wear parts To raise: 5. To raise the breaker shaft and power unit make sure grease needle valves are closed and pointed away from people and slowly pump grease into grease cylinder.

6. Incrementally and evenly raise the breaker shaft and power unit to the desired height.

7. Install all hardware, crack each needle valve to remove store pressure from grease cylinders, tighten the retainer reaction pivot mount bolts, and install all covers.

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Replacement of wear parts_________________________________________ Conveyor power unit The conveyor power unit (Fig. 94) has been assembled as a unit and can be removed and installed as a unit.

The power unit consists of the following main components: ■

electric motor (125 hp)

■ coupling ■

connecting tube

■

Open loop load sense pump

Fig. 94: Conveyor power unit Electric motor

Connecting tube Lock washer

Motor mount (Bolt, washer, and lock nut) Coupling

Flat washer

Flat washer Hex head bolt

Hex head bolt

Lock washer

Open loop load sense pump

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________________________________________ Replacement of wear parts How to remove the conveyor power unit (Fig. 94) 1. Turn the main circuit breaker on the feeder breaker to the “OFF” position.

2. Lock and tag out the power to the feeder breaker at the main power center. Follow all Federal, State, and mine rules.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF”position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

3. Remove the covers.

4. Attach an appropriate lifting device to the power unit. Take up the slack in the lifting device so that the power unit is supported and wont’tilt and fall when unbolted from the frame.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or devices and keep a safe distance from suspended loads.

5. Disconnect, tag, and cap all hydraulic hoses.

6. Disconnect grease lines to conveyor electric motor.

7. Remove access cover on junction box of conveyor and motor and remove the cable leads from the motor leads.

8. Reinstall junction box cover.

9. Remove the four bolts that secure the motor to the frame.

10. Lift power unit assembly from machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or devices and keep a safe distance from suspended loads.

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Replacement of wear parts_________________________________________ How to install the conveyor power unit (Fig. 94) 1. Attach an appropriate lifting device to the power unit and lift the power unit into the machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or devices and keep a safe distance from suspended loads.

2. Align the electric motor foot bolt holes with the mounting plate bolt hoes.

3. Install the four 3/4”diameter hex bolts, washers, and nuts. Torque to 380 ft-lbs.

4. Connect hydraulic hoses.

5. Ensure that the hydrostatic pump is primed. To prime the hydrostatic pump, remove the case drain fitting (see Fig. 92) and pour hydraulic fluid (Spec. 100-1) until the pump housing is full.

6. Connect grease lines to the electric motor.

7. Remove junction box cover.

8. Attach motor leads to cable leads and seal junction box cover. Follow all Federal, State, and mine regulations.

9. Install machine covers.

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________________________________________ Replacement of wear parts How to disassemble the conveyor power unit (Fig. 94) WARNING! Before removing each pump and the connecting tube be sure to properly support the component. Failure to properly support the component may result in damage to the component or injury to personnel.

WARNING! Remove all fittings from the pumps and plug the ports before removal. Failure to remove fittings and plug ports could result in damage to the pumps.

1. Remove two M10 bolts and spring washers and remove priority gear pump. Save the o-ring and splined pump insert from the rear of the open loop pump (Fig. 95).

IMPORTANT! Remove and save the o-ring and splined pump insert from the rear of the open loop pump.

Fig. 95: Open loop pump assembly

O-ring

Splined insert Open loop pump Bolt (2)

Spring washer (2)

Priority gear pump

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Replacement of wear parts_________________________________________ 2. Remove the bolt and lock washer from hinged access cover on the connecting cover and open the access cover.

3. Loosen the two socket head cap screw bolts that retain the Rotex coupling half to the open loop pump splined shaft.

4. Remove the four bolts, lock washers, and flat washers on the open loop pump.

CAUTION! The pump is heavy. To avoid injury, use proper lifting techniques.

5. Slide the open loop pump shaft, coupling hub, and element clear of the connecting tube.

6. Remove the eight bolts, lock washers, and flat washers and then remove the connecting tube.

7. Loosen the set screw from the coupling hub on the electric motor shaft and slide the hub off of the shaft.

8. Remove the key from the electric motor shaft.

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________________________________________ Replacement of wear parts How to assemble the conveyor power unit (Fig. 94) 1. Install the key in the electric motor shaft.

2. Apply Never Seez to the electric motor shaft and install the coupling hub onto the electric motor shaft. Roughly position the hub even with the end of the shaft. Do not tighten the set screw as final positioning of the hub will be determined at the end of assembly.

3. Install the element onto the coupling hub on the electric motor.

4. Apply Never Seez onto the open loop pump splined shaft. Install the remaining coupling hub onto the hydrostatic pump splined shaft (refer to Fig. 96 for dimensions).

5. Clean all mating surfaces on the connecting tube and the electric motor.

6. Apply Loctite 242 (blue) to the eight bolts and install bolts, flat washers, and lock washers into the connecting tube. Torque incrementally and evenly to 170 ft-lbs as follows: ■ ■ ■

Step 1: 50 ft-lbs Step 2: 100 ft-lbs Step 3: 170 ft-lbs

IMPORTANT! It is extremely important that the connecting tube pulls up evenly on the electric motor. If the connecting tube is cocked, misalignment between the pump and the electric motor will occur and the coupling will fail.

7. Install the open loop pump. Align the pilot hub on the pump with the pilot bore of the connecting tube while simultaneously engaging the jaws of the Rotex coupling halves.

8. Install four bolts, flat washers, and lock washers and torque incrementally and evenly to 280 ft-lbs as follows: ■ ■ ■

Step 1: 90 ft-lbs Step 2: 200 ft-lbs Step 3: 280 ft-lbs

Refer to Figure 96 to verify distance between the coupling jaws and the coupling element of 0.18”. This distance must be maintained to avoid element failure. Adjust the gap as required by repositioning the hub on the electric motor shaft as required.

9. Check coupling half alignment by using a straight edge across the two coupling halves (see Fig. 96). Rotate the electric motor and measure the spacing in at least two places to ensure the electric motor and pump shafts are aligned. If there is misalignment, the connecting tube may be cocked or the mating surfaces may not be clean. This misalignment must be corrected before proceeding with assembly.

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Replacement of wear parts_________________________________________ IMPORTANT! The coupling halves must be aligned before proceeding with assembly. If the coupling haves are not aligned, component failure may occur.

10. Apply Loctite 242 (blue) to the set screw on the coupling hub of the electric motor shaft and torque to 275 in-lbs.

11. Remove the end plate from the open loop pump in order to install the back gear pump by removing the four bolts.

12. Verify that the o-ring and splined pump insert are pre-installed by the pump manufacturer. If not, the o-ring and splined pump insert that were removed during disassembly can be reused or replaced with a new o-ring and splined insert (see the parts manual that shipped with your machine).

13. Apply clean hydraulic fluid to the shaft of the piggy back gear pump and to the o-ring of the hydrostatic pump.

14. Install the gear pump being careful to properly align the splines and not cut the o-ring.

15. Install the four bolts, lock washers, and flat washers in the gear pump. Torque incrementally and evenly to 80 ft-lbs as follows: ■ ■ ■

Step 1: 20 ft-lbs Step 2: 50 ft-lbs Step 3: 80 ft-lbs

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________________________________________ Replacement of wear parts Fig. 96: Conveyor power unit disassembly/assembly Electric motor to coupling mating surface

Place straight edge along this edge to determine alignment

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Replacement of wear parts_________________________________________ Breaker bits How to remove the breaker bit To remove the breaker bit from the breaker shaft bit holder proceed as follows (Fig. 97): 1. Remove the external retaining rings from the shank end of the bit with a pair of external retaining ring pliers.

2. Remove the bit from its holder. If the bit will not pull easily from its holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.

IMPORTANT! If the bit will not pull easily from its holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.

How to install the breaker bit To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 97): 1. Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.

2. Install the external retaining rings (two per bit) on the shank end of the bit with a pair of external retaining ring pliers. Ensure that the retaining ring is completely seated inside grooved area of the bit.

Fig. 97: Breaker bit removal and installation

Retaining rings Bit holder

Breaker bit

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________________________________________ Replacement of wear parts Tailpiece installation To install the tailpiece on the feeder breaker (Reference Fig. 98: Tailpiece installation): WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

1. Install spacer blocks (Item 14) into the underside of the tailpiece weldment (Item 6). a. Make sure that bolts (Item 37) will pass through the bearing spacers and the tailpiece weldment. b. Tack weld bearing spacer blocks (Item 14) to tailpiece weldment (Item 6).

2. Install belt pulley assembly (Item 15) using hex bolts, flat washers, hex nuts, and lock washers (Items 37, 36, 35, and 22).

3. Bolt impact bed assembly (Item 13) to tailpiece weldment (Item 6) using flat washers, lock washers, hex nuts, and bolts (Items 31, 32, 33, and 34).

4. Install slider assembly (Item 18) using flat washers, lock washers, hex nuts, and bolts (Items 27, 28, 29, and 30).

5. Install knuckle piece (Item 4) to tailpiece weldment (Item 6) using tailpiece swivel pin, flat washer, hex nut, keeper pin, and cotter pin (Items 7, 38, 39, 40, 43).

6. Tighten the hex nut (Item 39) onto the tailpiece swivel pin (Item 7) then weld the pin keeper (Item 40) across the flat of the tailpiece swivel pin (Item 7) on three sides.

7. Position the assembled knuckle joint and the tailpiece frames to the main frame. (Reference Figure 10 for placement). Install pins (Item 5).

8. Install the tailpiece hopper weldments (Items 8 and 9) on the main frame using flat washers, lock washers, hex nuts and bolts (Items 23, 24, 25, and 26) and flat washers, lock washers, hex nuts, and bolts (Items 27, 28, 29, and 30).

9. Install tailpiece tilt cylinders (Item 12) into the tailpiece hopper weldments (Items 8 and 9) and the tailpiece weldment (Item 6) using the swivel clevis weldments, pins, and cotter pins (Items 11, 16, and 41).

10. Install the steering cylinders (Item 10) between the tailpiece frame (Item 6) and the knuckle joint weldment using pins and cotter pins (Items 16 and 41).

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Replacement of wear parts_________________________________________ 11. Refer to the hydraulic schematic (Fig. 99) for hydraulic installation of the cylinders. Route all hoses, avoiding pinch points, so that hose damage does not occur.

Fig. 98: Tailpiece installation

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

knuckle piece pin tailpiece weldment tailpiece swivel pin tailpiece hopper weldment tailpiece hopper weldment steering cylinder swivel clevis weldment tailpiece tilt cylinder impact bed assembly

14.

15.

16.

18.

22.

23.

24.

25.

26.

27.

spacer block belt pulley assembly pin slider assembly lock washer flat washer lock washer hex nut bolt flat washer

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

lock washer hex nut bolt flat washer lock washer hex nut bolt hex nut flat washer bolt

38.

39.

40.

41.

43.

flat washer hex nut keeper pin cotter pin cotter pin

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________________________________________ Replacement of wear parts Fig. 98: Tailpiece installation (continued)

Detail A

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Replacement of wear parts_________________________________________ Fig. 99: Hydraulic schematic

________________________________________________________________ 5.160 FB110 Feeder Breaker

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________________________________________ Replacement of wear parts Roof cylinder and roof cylinder mount weldment removal and installation To remove the roof cylinder (reference Fig. 97): 1. With the anchor arm slightly raised, appropriately block under the anchor arm.

2. Slowly retract the roof cylinder until the arm is resting on the blocking.

3. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

4. Turn the circuit breaker to the “OFF”position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF”position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

5. Attach an appropriate lifting device to the roof cylinder and take up any slack.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

6. Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.

7. Remove the cotter pin from one end of each roof cylinder pin and remove the pins.

8. Slowly lift the cylinder off of the feeder breaker.

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Replacement of wear parts_________________________________________ To install the roof cylinder (reference Fig. 97): 1. Attach an appropriate lifting device to the roof cylinder and position the roof cylinder into the mount and to the roof anchor arm WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

2. Install the cylinder pins into each end of the cylinder and secure with cotter pins.

3. Reconnect the hydraulic hoses to the cylinder.

4. Restore power to the feeder breaker.

5. Raise the anchor arm and remove the support Fig. 97: Roof cylinder removal and installation

Anchor arm

Cylinder pin (typical both ends)

Cotter pin (typical both ends)

Roof cylinder

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________________________________________ Replacement of wear parts Foot cylinder removal and installation To remove a foot cylinder (reference Fig. 98): 1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF”position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF”position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

3. Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.

4. Remove the cotter pin from the outrigger arm pin, remove the castle nut, and washer and pull the outrigger arm pin.

5. Remove the two cotter pins from the cylinder eye pin and pull the cylinder eye pin.

To install a foot cylinder (reference Fig. 98): 1. Mount the cylinder eye to the outrigger mount plate. a. Position the cylinder eye in the outrigger mount plate clevis. b. Insert the cylinder eye pin through the cylinder eye and outrigger mount plate clevis. c.

Install the two cotter pins through the cylinder eye pin.

2. Position the foot clevis on the rod eye and align the rod eye in the outrigger arm weldment.

3. Install the outrigger arm pin through the outrigger arm weldment, foot, and rod eye. Install the washer and castle nut on the end of the pin.

4. Reconnect the hydraulic hoses to the cylinder.

5. Reconnect power to the machine.

6. Purge the hydraulic system of air.

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Replacement of wear parts_________________________________________ Fig. 99: Foot cylinder removal and installation

Washer Outrigger foot Outrigger arm pin

Castle nut

Cotter pin

Foot cylinder

See detail A

Cotter pin (2)

Outrigger arm

Cylinder pin

Outrigger mount plate

Detail A

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________________________________________ Replacement of wear parts Tilt cylinder removal and installation To remove a tilt cylinder (reference Fig. 99): 1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF”position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF”position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

3. Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.

4. Attach an appropriate lifting device to the tilt cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

5. Pull a cotter pin out of the pin through the cylinder eye and remove the pin.

6. Unbolt the eight 1 inch hex head bolts from the crawler frame and cylinder cradle.

7. Remove the trunnion blocks from the cylinder mounting trunnions.

To install a tilt cylinder (reference Fig. 99): 1. Attach an appropriate lifting device to the tilt cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

2. Align the cylinder in the mounting clevises on the machine.

3. Install the pin through the rod eye and secure with a cotter pin.

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Replacement of wear parts_________________________________________ 4. Lower the cylinder with trunnion blocks into the cylinder cradle already installed on the crawler frame.

5. Align trunnion block tapped holes with thru holes of the crawler frame and install the eight 1 inch bolts and lockwashers. Torque to 905 ft-lb (dry).

6. Reconnect the hydraulic hoses to the cylinder.

7. Reconnect power to the machine.

8. Purge the hydraulic system of air.

Fig. 99: Tilt cylinder removal and installation

Pin

Cotter pin (2 per pin)

Tilt cylinder

Trunnion block

Trunnion block

Mounting bolts (8)

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________________________________________ Replacement of wear parts Lift cylinder removal and installation To remove a lift cylinder (reference Fig. 100): 1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF”position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF”position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

3

Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.

4. Attach an appropriate lifting device to the lift cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

5. Pull a cotter pin out of the pin through the cylinder eye and remove the pin.

6. Pull a cotter pin out of the pin through the rod eye and remove the pin.

To install a lift cylinder (reference Fig. 100): 1. Attach an appropriate lifting device to the lift cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

2. Align the cylinder in the mounting clevises on the machine.

3. Install the pin through the cylinder eye and secure with a cotter pin.

4. Install the pin through the rod eye and secure with a cotter pin.

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Replacement of wear parts_________________________________________ 5. Reconnect the hydraulic hoses to the cylinder.

6. Reconnect power to the machine.

7. Purge the hydraulic system of air.

Fig. 100: Lift cylinder removal and installation Cotter pin (2 per pin) (typical both ends)

Pin (typical both ends)

Lift cylinder

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________________________________________ Replacement of wear parts Tailpiece tilt cylinder removal and installation To remove a tailpiece tilt cylinder (reference Fig. 101): 1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF”position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF”position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

3

Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.

4. Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

5. Pull cotter pin out of the pin through the cylinder eye.

6. Pull cotter pin out of the pin through the rod eye.

To install a tailpiece tilt cylinder (reference Fig. 101): 1. Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

2. Align the cylinder in the mounting clevises on the machine.

3. Install the pin through the cylinder eye and secure with a cotter pin.

4. Install the pin through the rod eye and secure with a cotter pin.

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Replacement of wear parts_________________________________________ 5. Reconnect the hydraulic hoses to the cylinder.

6. Reconnect power to the machine.

7. Purge the hydraulic system of air.

Fig. 101: Tailpiece tilt cylinder removal and installation

Cotter pin (4) (2 per eye) Pin (2) Tailpiece tilt cylinder

________________________________________________________________ 5.170 FB110 Feeder Breaker

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________________________________________ Replacement of wear parts Tailpiece steering cylinder removal and installation To remove a tailpiece steering cylinder (reference Fig. 102): 1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF”position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF”position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

3. Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.

4. Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

5. Pull cotter pin out of the pin through the cylinder eye.

6. Pull cotter pin out of the pin through the rod eye.

To install a tailpiece steering cylinder (reference Fig. 102): 7. Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

8. Align the cylinder in the mounting clevises on the machine.

9. Install the pin through the cylinder eye and secure with a cotter pin.

10. Install the pin through the rod eye and secure with a cotter pin.

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Replacement of wear parts_________________________________________ 11. Reconnect the hydraulic hoses to the cylinder.

12. Reconnect power to the machine.

13. Purge the hydraulic system of air.

Fig. 102: Tailpiece steering cylinder removal and installation

Pin (2) Tailpiece steering cylinder

Cotter pin (4) (2 per eye)

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_________________________________________________ Troubleshooting Troubleshooting procedures Typical hydraulic problems The most common causes for improper hydraulic functions are: ■

contaminated or poor quality hydraulic oil

■

low or insufficient oil in the system

■

using the wrong type or viscosity grade of hydraulic oil

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments (such as reliefs)

■

mechanical or structural damage leading to component failure

■

components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, or other critical components

The greatest aid to troubleshooting a hydraulic system is the confidence that comes with knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles.

Contaminants in hydraulic systems The primary cause of hydraulic component failure is SYSTEM CONTAMINATION. Cleanliness must be a high priority when servicing the hydraulic system. Even very small particles can damage system components by scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are given below: 1. Ensure that bulk oils are at acceptable cleanliness levels.

–

implement ISO Cleanliness Code standards for bulk hydraulic oils

–

evaluate bulk oil shipments for cleanliness by conducting particle counts and maintain records

–

minimize drum usage by utilizing tote tanks and five gallon pails

–

utilize plastic versus steel storage tanks, if possible

–

install desiccant breathers on all bulk tanks

–

use sealed plastic containers for adding oil to small sumps

–

locate bulk tanks near equipment and pump directly to reservoirs

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Troubleshooting _________________________________________________ –

utilize filter carts to maintain oil cleanliness standards

–

properly train personnel on the importance of clean oil and best practices for storage and handling

–

monitor the program closely and look for continuous improvement

2. Eliminate contamination source through “clean”maintenance practices. This is best achieved by understanding the primary sources of contamination during maintenance and troubleshooting which are given below: –

always clean the area around the component that is to be removed and inspected

–

store components in a plastic bag after inspection and prior to replacement on machine

–

cap off all open hoses/fittings

–

never touch a filter with bare hands when installing it back onto the machine

–

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame

Contact your service representative for more information on implementing an effective program to ensure that your oil and maintenance practices are not contributing to your equipment failure.

________________________________________________________________ 5.174 FB110 Feeder Breaker

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_________________________________________________ Troubleshooting Open loop pump troubleshooting The pump used on this machine is a axial piston pump with load sense and pressure compensation control. Maximum displacement is 165 cc/ rev (10 cubic inches) and maximum service pressure is 400 bar (6,090 psi). There is a secondary gear pump mounted to the rear of the main pump that supplies cooling flow to the cases of the main pump and the conveyor drive motor. In an open loop configuration, there is no charge pump. The supply to the pump is a direct suction line to the hydraulic oil reservoir.

A pressure transducer is located at the pump inlet to monitor for a blocked suction line, however, it does not guard against aeration caused by a leaking suction line or low oil level in the reservoir. If either of these occur, the pump will make an erratic grinding noise and will run at elevated temperatures. The pump will fail quickly at these conditions and should be shutdown immediately. Investigate oil level and suction hose integrity and identify and correct the issue before operating the pump.

At startup, the pump will be on full stroke to prime itself. Once the pump is at full speed, its control will de-stroke the displacement to a minimum and reduce system pressure to approximately 30 bar (435 psi). This mode is referred to as “standby”or “margin”and is typical of load sense controlled pumps. In standby, the system pressure gauge will read 30 bar (435 psi) and the load sense pressure gauge will read 0 bar. The actual output of the pump is at low pressure and only at a flow rate required to make up for internal system leakage. In this mode, the pump is waiting for a signal to provide higher pressure and flow to meet a specific task. That signal is in the load sense line which connects the pump control to the main valve bank. When valves are shifted to run a function of the machine. For example, the conveyor control valves will connect the load pressure of the conveyor motor circuit to the load sense line. The pump will quickly respond by increasing its displacement to create the pressure to meet that conveyor load.

At this point, the load sense gauge will read the load of the conveyor function and the system pressure gauge will reflect that load pressure plus the margin pressure. If the conveyor requires 250 bar (3,625 psi) to operate, the system pressure will be 280 bar (250 bar +30 bar) (4,061 psi).

The adjustment of the load sense margin pressure is located on the control block at the top rear of the pump. It is the adjusting screw located at the front of the block.

The pump control includes a second stage for pressure compensation.

This feature limits the maximum output pressure of the pump. When the pressure compensation setting is reached, the pump will quickly destroke to a minimum output. This condition is referred to as “dead head”or “stall”. The pump will continue to hold this pressure until the function is stopped. In the conveyor function, stall may arise from an obstruction in the breaker and this condition is monitored by a pressure transducer. The pump itself can operate in this mode indefinitely due to the operation of the pressure compensator.

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Troubleshooting _________________________________________________ The pump itself can operate in this mode indefinitely due to the operation of the pressure compensator. There is no excess hydraulic heat generated because relief valves are not opening to control the pressure limitation. If there is significant heating during a stall or high pressure operation, check the setting of the system relief located in the inlet of the main valve bank. This relief valve is preset to 370 bar (5,365 psi). To verify its setting, the pump compensator must be raised to 380 bar (5,510 psi). Once the relief is correctly adjusted, reduce the pump compensator to 350 bar (5,075 psi). If the relief is set lower than the pressure compensator, the relief valve will open, causing system heating.

The adjustment of the pressure compensator setting is located on the control block at the top rear of the pump. It is the adjusting screw located at the rear of the block. The pressure compensator must be adjusted while the pump is “loaded”. This is best accomplished with the conveyor function engaged.

The main pump is an efficient device: displacement efficiency when new is approximately 98%. The pump will produce nominal 74.75 gpm at 1,750 rpm. This means internal leakage is only 1.5 - 2.0 gpm. As a pump ages and wears, the efficiency will decrease, resulting in increased flow from the case drain port. Because the flow from the main pump case is a combination of internal leakage and the cooling flow, the case drain flow from a new pump will average 6 gpm. If case drain leakage exceeds 10 gpm, the main pump should be changed out. An acceptable method of measuring case drain leakage is to use a five gallon bucket and a stop watch. If the five gallon bucket is filled in 30 seconds, the pump needs changed.

When removing a used pump, use the plugs from the replacement pump and duct tape to seal off all ports on the used pump.

If a pump is replaced, it is critical that the pump case be filled before start up. It is often difficult to do this well underground, so start with filling and plugging the pump before taking underground. Pumps stored on site should be filled with oil. The pump has two case drain ports the highest on should be used for filling.

Upon installation, top up oil in pump case at the highest case drain port.

Jog the pump motor at least five time before starting up. If the pump is properly filled and priming, it will run and sound smoothly on startup.

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_________________________________________________ Troubleshooting Table 4: Troubleshooting excessive noise

Pump Noisy Cause

Motor Noisy Remedy

Cause

Cavitation

A

Coupling misaligned

Air in fluid

B

Motor or coupling worn or damaged

Coupling misaligned

C

Pump worn or damaged

E

Relief/Counterbalance Valve Noisy Remedy C

Cause

Remedy

Setting too low or too close to another valve setting

D

Worn poppet and seat

E

Remedies A. Any or all of the following:       

replace dirty filters wash strainers in solvent compatible with system fluid clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed check fluid temperature

B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling D.  install and/or adjust pressure gauge E.  overhaul or replace defective parts

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Troubleshooting _________________________________________________ Table 5: Troubleshooting excessive heat Pump Heated Cause Fluid heated

Motor Heated

Remedy See Fluid Heated

Cause Fluid heated

Relief Valve Heated

Remedy See Fluid Heated

Cause Fluid heated

Fluid Heated

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cavitation

A

Excessive load

C

Valve setting incorrect

D

Fluid dirty or low supply

F

Air in fluid

B

Worn or damaged motor

E

Worn or damaged valve

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve, motor, cylinder, or other component

E

Remedies A. Any or all of the following:     

replace dirty filters clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed

F.  change filters  check system fluid viscosity; change if necessary  fill reservoir to proper level G.  clean cooler and/or strainer  repair or replace cooler

B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling  locate and correct mechanical binding  check for workload in excess of circuit design D.  adjust setting on valve E.  overhaul or replace defective parts

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_________________________________________________ Troubleshooting Table 6: Troubleshooting incorrect flow No Flow Cause

Low Flow Remedy

Excessive Flow

Cause

Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

E of F

Remedies A. Any or all of the following:    

replace dirty filters clean clogged inlet line clean reservoir breather vent fill reservoir to proper level

B. Any or all of the following:

F. Any or all of the following  check position of manually operated controls G.  reverse rotation H.  replace with correct unit

 tighten leaky inlet connections  bleed air from system C. All of the following:  check for damaged pump or pump drive  replace and align coupling D.  adjust setting on valve E.  overhaul or replace part

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Troubleshooting _________________________________________________ Table 7: Troubleshooting incorrect pressure No Pressure Cause

Remedy

No flow

See Table 5

Low Pressure Cause Pressure relief path exists Damaged pump, motor, or cylinder

Remedy See Table 5 E

Erratic Pressure Cause

Remedy

Air in fluid

B

Worn relief valve

E

Contamination in fluid

A

Worn pump, motor, or cylinder

E

Remedies A.  replace dirty filters and system fluid B.  tighten leaky connections  fill reservoir to proper level and bleed air from system C.  gas valve for leakage  charge to correct pressure  overhaul if defective D.  adjust valve E.  overhaul or replace part

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_________________________________________________ Troubleshooting Hydraulic system (general) Table 9: Hydraulic system (general) troubleshooting Trouble or symptom

Probable cause

Test, check and/or remedy

Components not properly cleaned during servicing.



Disassemble components and reclean parts.



Air breather left off.



Add breather.



Hose lines not properly covered when servicing machine.



Keep hose ends protected from contamination while disconnected.

Clean hose lines before reconnecting.



Filter elements not replaced at proper intervals or when indicated.



Replace elements at proper intervals.

Tank return lines not below fluid level.



Check oil level.



Oil contaminated with incompatible foreign matter.



Drain out oil and replace with clean oil and change filter.



Suction leak to pump aerating oil.



Replace or tighten fittings and lines.

moisture in oil 

Soluble oil solution splashing into poorly sealed tank gasket or fill holes left open.



Drain out and refill with clean oil.

Check fill pipes to see if they are properly closed.

dirty oil 

foaming oil 



Moisture in cans of replacement oil. 

Replace with new cans of oil.



Extreme temperature differential in certain geographical locations.



Store oil in an area that protects against exposure to frequent extreme temperature changes.

Fluid viscosity too high.



Check fluid specifications.

overheating of system  

Excessive slippage or internal leak-  age past pump or cylinders.

Fluid viscosity too low. Test components for specified flow or bypass conditions.



Oil level too low.



Check/add oil.



Improper air circulation around reservoir.



Check to see if the area around the reservoir is clear.



System relief valve set too high or too low.



Reset the relief valve to specifications.

Sticking selector or other control valve.



Isolate circuits/components and identify fault.

prolonged operation of a function at  pressures above normal idle condition

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Troubleshooting _________________________________________________ Table 9 (continued): Hydraulic system (general) troubleshooting Trouble or symptom

Probable cause

Test, check and/or remedy

Sealing compound (pipe dope, Teflon tape).



Clean or replace seals. Drain and replace oil as necessary.



Tank or component ports left open to atmosphere.



Cap or plug properly. Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.



Lines left unprotected or dirty repaired components.



Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.



Repair parts not properly protected while stored.



Check and clean parts thoroughly before installation. Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.

foreign matter sources  in the circuit

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_________________________________________________ Troubleshooting Hydraulic cylinders Table 10: Hydraulic cylinder troubleshooting Trouble or symptom

Probable cause Piston seal leak.

Test, check and/or remedy 

Repair seals or replace cylinder.



Replace cartridge or cylinder as required.



Correct leaks.

Pressure too low.



Check pressure of circuit controls and cylinder to insure designed system pressure is attained.



Piston seal leak.



Repair seals or replace cylinder.



Piston rod broken internally.





Contamination in hydraulic system resulting in scored cylinder bore.

Repair as required or replace cylinder.



Replace cylinder. Check oil cleanliness and change as required.

Excessive friction due to misalignment and/or side loading.



Inspect cylinder installation for proper operation and/or for foreign objects that inhibit the normal operation of the cylinder.

Air in circuit.



Cycle cylinder to full stop positions to purge air.

excessive or rapid piston  seal wear

Excessive system pressure due to over adjustment.



Check and correct pressure adjustment to rated limits.



Excessive friction due to misalignment and/or side loading.



Inspect cylinder installation for proper operation and/or for foreign objects that inhibit the normal operation of the cylinder.

Excessive pressure.



Check and correct pressure adjustment to rated limits.



Seal is pinched or extruded.



Replace seal and/or cylinder as required.



Seal deterioration (soft or gummy). 

Check for contamination of fluids (incompatibility). Flush system and refill with correct fluid. Replace seal and/or cylinder as required.

Dirt has scored the piston or the rod.



Replace cylinder.

piston freezes to the tube 

Scoring in the piston.



Replace cylinder.

packing and gasket leaks  develop

Excessive heat/wear.



Replace seal and/or cylinder as required.

cylinder drifts  

Control cartridge by-passing.



Other circuit leaks.

cylinder fails to move  the load when actuated

erratic or chatter in operation 



cylinder body seal leak 

piston is leaking 

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Troubleshooting _________________________________________________ Hydraulic pump Table 11: Hydraulic pump troubleshooting Trouble or symptom

Probable cause

Test, check and/or remedy

Vacuum leaks in suction line.



Check for leaks in fittings or damaged suction lines.



Vacuum leaks in the pump shaft seal.



Check pump shaft seal for signs of brittleness or damage due to excessive heat. Replace seal as required.



Poor alignment with drive mechanism.



Check pump shaft and motor shaft insert, as well as pilot engagement, for interference.



Incorrect fluid in system.



Check fluid specifications - change fluid if necessary.



System relief settings.



Pressure adjustment too low or cartridge fouled with foreign material. Readjust to correct setting and/ or clean foreign material from cartridge.



Pump cavitation.



Check fluid level for proper level.

Check for aeration of fluid reservoir.

Check for vacuum leaks in suction lines. Repair all faults as required and/or replace pump as required.



Worn or damaged gears/ housing.



Replace pump.



Worn or faulty bearing.



Replace pump.



Reversed rotation.



Check pump motor wiring.



Plugged or restricted suction line or  suction strainer.

Clean by removing the foreign material blocking oil flow.



Plugged reservoir filter breather.



Clean or replace filter breather as required.

Torn or worn seals.



Replace seal.



Gland bearing worn.



Excessive gland bearing wear will likely require pump replacement.



Seal deterioration (soft or gummy).



Check oil for fluid compatibility.

Drain oil tank and replace oil as required or if questionable. Replace seals.



Seal deterioration (hardened or loss  of elasticity).

Replace seal.



Seal deterioration (flat spots on I.D.).

Check pump shaft for possible bearing wear. Replace seal.

pump makes excessive noise 

seal leak 



 Loose or worn pump parts.  Replace worn pump parts. ________________________________________________________________ 5.184 FB110 Feeder Breaker

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_________________________________________________ Troubleshooting Table 11 (continued): Hydraulic pump troubleshooting Trouble or symptom

Probable cause

Test, check and/or remedy

Low oil level in reservoir.



Fill to proper level.



Oil intake hose suction strainer plugged.



Clean or replace strainer.



Air leak in suction line preventing priming.



Tighten or replace suction lines.

Pump shaft turning too slowly.





Check pump motor and controls to insure proper pump speed is attained.



Oil viscosity too high.



Replace with recommended oil.



Wrong shaft rotation.



Check pump motor wiring.



Pump shaft or parts broken.



Replace shaft or broken parts.



Pump damaged due to contamination.



Change pump, drain and replace oil in the reservoir and replace filter elements.

Shaft seal worn.



Replace seals.



Hose connections leaking.



Tighten flange bolts or adapters and hose connections as required. Replace hose, adapters, and/or seals as required.



Pump housing bolts loose or improperly torqued.



Tighten bolts to correct torque and/or replace pump if correct performance cannot be attained.

excessive pump wear 

Contaminated hydraulic oil being circulated through the system.



Drain oil from the reservoir and replace it with clean hydraulic oil. Replace filter elements and implement frequent element changes until the desired cleanliness of the system is attained.



Oil viscosity too low.



Replace with recommended oil and change filter elements.



Excessive pump loads.



Check relief valve adjustment.

Reset to correct setting.

pump fails to deliver oil 

oil leakage around pump 

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Troubleshooting _________________________________________________ Table 11 (continued): Hydraulic pump troubleshooting Trouble or symptom

Probable cause

pump parts inside  the housing are broken 

Test, check and/or remedy

Seizure due to lack of oil.



Excessive system pressure above maximum pump rating.

Check oil level and refill to design level for proper operation. Replace pump and filter elements.



Replace pump and filter elements.

Minimize the relief pressure adjustment before starting the new pump.

Replace relief valve if correct adjustment cannot be obtained.



Replace pump and filter elements.



Replace pump and filter elements, suction strainer, and suction hoses to insure that no foreign material can damage new pump.



Excessive torque to housing bolts.



Solid matter being drawn in from reservoir and wedged in pump.

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_________________________________________________ Troubleshooting Valves Table 12: Valve troubleshooting Trouble or symptom

Probable cause

Test, check and/or remedy

Valve spring broken.



Replace the spring, valve cartridge, or valve assembly as required.

Open valve in the system.



Locate and repair the open valve condition.

valve piston sticks 

Dirt in the system.



Remove the valve and clean it thoroughly; flush the system as necessary. Replace valve as required and replace filter elements.

certain passages are blocked or  pressure fluctuates

Dirt in the system.



Remove the valve and clean it thoroughly; flush the system as necessary. Replace valve as required and replace filter elements.

Air in the system.



Check for leaks and other points that may allow air into the system.

Repair as required.



Pressure or volume too high.



Check for correct pressure and/or volume adjustments and reset as required.

valve leaks internally 

Valve piston and body worn.



Replace the valve.



Check and replace filter elements as required.



Check for proper pressure and/or volume adjustments and reset as required.



Remove the valve and clean it thoroughly; flush the system as necessary.

Dirt in the system.



Drain and replace the oil in the reservoir. Check and replace all filter elements.

Pinched, blown or missing section seal.



Replace section seal.



Stud fasteners not correctly torqued.



Replace section seals and retorque.



Mounting plate not level.



Loosen mounting bolts and shim as required.



Contamination/butts on seal.



Clean seal groove and replace section seal.

operating pressure  cannot be changed 

the pressure fluctuates and there is  extreme noise in the valve

excessive leakage or  sticking pistons occurs



oil leaks  between sections

Valve excessively hot.

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Troubleshooting _________________________________________________ Table 12 (continued): Valve troubleshooting Trouble or symptom

Probable cause

Test, check and/or remedy

Over-pressurized tank core.



Correct high back pressure condition.

Worn or damaged spool seals.



Replace seals and seal retainers.

Broken centering spring.



Replace centering spring.

Misalignment of operating linkage.



Check linkage for mechanical binding.

Foreign particles in system.



Clean valve and system.

Cylinder leaking or worn.



Check cylinder, repair as needed.



Port relief valve not holding.



Remove and clean or replace.



Spool or housing scored or worn excessively.



Replace section.

oil leaks at either  end of spool  spring centered spools  do not return to neutral   load will not hold 

load drops when spool  moved from neutral

Dirt or foreign particles lodged be tween check valve poppet and seat.

Disassemble, clean, and reassemble.



Scored or sticking check valve pop-  pet.

Replace poppet.

Worn pump.



Check flow and pressure.

Defective cylinder or motor.



Repair or replace.



Low reservoir oil level.



Add oil to specifications.



Clogged suction strainer.



Clean or replace.



Suction line restricted.



Check lines.



Relief valve not properly set.



Check pressure setting.



Relief valve poppet or seat scored and sticking open.



Replace relief valve.



Valve spool not shifted full stroke.



Check spool linkage travel.

no motion, slow, or erratic  system operation 

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_________________________________________________ Troubleshooting Bearings Table 13: Bearing troubleshooting Trouble, symptom or cause

Probable cause

Test, check and/or remedy

Wrong type of grease or oil.



Consult the lubrication chart for the proper lubricant.



Low oil level; loss of lubricant through seal; excessive grease.



Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.



Insufficient clearance in bearing.



Replacement bearing should be identical to original equipment to ensure proper internal clearance.



Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.



Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.



Shaft out of line.



Correct alignment and be sure shafts are coupled in a straight line.

Insufficient clearance in bearing.



Replacement bearing should be identical to original equipment to ensure proper internal clearance.



Foreign matter acting as abrasive.



Clean bearing housing and replace worn seals.



Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.



Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.



Shaft and other parts of bearing assembly distorted.



Replace bearing, shaft and other parts as needed.

Enlarged housing bore causing spinning of outer ring in housing.



Re-bore housing and press steel bushing in bore, then machine bore to correct size.



Foreign matter acting as abrasive.



Clean bearing housing and replace worn seals.



Unbalanced loading.



Check balance of rotating parts and rebalance as needed.

Chip in bearing housing; insufficient clearance in bearing; Ball or roller dented from extreme loading.



Replace with OEM bearing; do not hammer on any part of bearing; clean housing and use fresh lube.

overheating bearing 

noisy bearing 

vibrating bearing 

unsatisfactory performance 

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Troubleshooting _________________________________________________

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_______________________________________________________________

6

Technical data

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__________________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Model 7MFBHM-48DD Feeder Breaker, serial number 54-2185. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc.

Read this chapter through carefully and pay particular attention in particular to the safety instructions.

The technical data listed in this chapter is for serial number 542185 only. Other machines with the same model number may vary.

Technical data sheet general

Overall length: ...................................................... without tailpiece .............................................approx. 33’9-1/2” with tailpiece ..................................................approx. 38’ Overall width.........................................................approx. 11’5” Tramming height: Minimum ........................................................approx. 65-1/2” Maximum .......................................................approx. 87-1/2” Ground clearance (max. w/ tail piece)..................approx. 9-3/8” Receiving height (min.):........................................approx. 28” Discharge height of belt .......................................approx. 32-5/8” Operating height (max.): ......................................approx. 80-3/8” Heaped hopper capacity: .....................................approx. 1,090 ft³ Weight: less tail piece and roof and floor anchors: .....approx: 90,000 lbs assembled......................................................approx. 106,500 lbs

performance

Material input size (max.): .......................approx. 2’x 2’x 3’ Maximum material strength:....................approx. 30,000 psi Nominal output size:................................approx. 8”(one dimension) Discharge rate (max.): 3”pick to flight clearance ..................approx. 1,485 TPH @ 102 fpm 5”pick to flight clearance ..................approx. 1,664 TPH @ 102 fpm 7”pick to flight clearance ..................approx. 1,843 TPH @ 102 fpm Material to be broken:..............................Coal @ 88 lb/ft³

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Technical data ___________________________________________________

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_______________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Set screws Table 14: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

Table 15: Hex and socket head cap screws, coarse thread (Grade Nominal diameter ¼” 5/16” 3/8” 7/16” ½” 9/16” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting (lubed) 8 ft-lbs 16 ft-lbs 28 ft-lbs 45 ft-lbs 70 ft-lbs 99 ft-lbs 135 ft-lbs 240 ft-lbs 390 ft-lbs 545 ft-lbs 830 ft-lbs 1,160 ft-lbs 1,525 ft-lbs 2,030 ft-lbs

Recommended torque setting (dry) 13 ft-lbs 26 ft-lbs 47 ft-lbs 75 ft-lbs 115 ft-lbs 165 ft-lbs 225 ft-lbs 400 ft-lbs 645 ft-lbs 905 ft-lbs 1,380 ft-lbs 1,935 ft-lbs 2,540 ft-lbs 3,380 ft-lbs

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Tightening torques _______________________________________________ Table 16: Untreated screw, black finish (Coarse thread) Property class

Torque

5.6 8.8 10.9 12.9

Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15 10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Table 16: Untreated screw, black finish (Coarse thread, continued) Property class

Torque

5.6

Nm

39

62

Ft-lbs

28

Nm

89

8.8 10.9 12.9

Ma

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

85

130

184

250

315

45

70

95

135

184

232

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 16: Untreated screw, black finish (Coarse thread, continued) Property class

Torque

5.6

Nm

470

Ft-lbs 8.8 10.9 12.9

Ma

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

635

865

1111

1440

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

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_______________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Only use approved lubrication fluids and greases! These fluids and greases have been tested and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent. Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins. In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! It is expressly pointed out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be disposed of per your local EPA standards.

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Permissible media________________________________________________ Approved suppliers: Table 17: Anti-wear hydraulic oil (Spec 100-1) Supplier

Brand name

1

Amoco Oil Company

Amoco AW oil No.68

2

Gulf oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hydraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers

Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

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_______________________________________________ Permissible media Table 18: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460

6

Unocal 76

7

Shell Oil company

8

Century Lubricating Oils, Inc.

9

Texaco Lubricants Company

Hulbest EP-7 Powergear 460 Meropa 680

10

Exxon

Spartan EP 460

11

Pennzoil

Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

608 Almosal Vari-Purpose Gear Lubricant Gear oil 460

14

Hydrotex

933 Industrial Gear Lubricant

15

Phillips

16

Miners Oil

All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680

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Permissible media________________________________________________ Table 19: Extreme pressure motor bearing grease (Spec. 100-3) Supplier

Brand name

1

Amoco Oil Company

2 3 4

Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil company Century Lubricating Oils, Inc.

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Amolith grease 2 EP Rykon Premium Grease 2 EP Gulfcrown grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Table 20: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century oils Limited Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

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_______________________________________________ Permissible media Table 21: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company

5 6

Cincinnati –Vulcon Company Cities Service Oil company

7 8

10 11

Century Oils limited Fiske Bros. Refining Company Getty Oil company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

12 13 14 15 16 17

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and chemical Co. Pennzoil Quaker Chemical Company

18

Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

9

19 20 21 22 23

Standard Oil Company of Ohio (Boron Sohio) Sun Oil company Tower Oil Company

24 25

Wynn Oil company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion fire resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant hydraulic Fluid HY-Guard

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Permissible media________________________________________________ Table 22: Extreme pressure gear oil, SAE 90 (Spec. 100-6) Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

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_______________________________________________ Permissible media Table 23: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) Supplier Brand name 1

Amoco Oil Company

American Industrial Oil No. 68

2

Gulf oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy –Medium

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754

6

Unocal 76

7

Shell Oil Company

Unax RX68 or Turbine Oil 68 Turbo 68

8

Century Lubricating Oils, Inc.

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

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Permissible media________________________________________________ Table 24: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name 1

Amoco Oil Company

American Industrial oil No. 150

2

Gulf Oil

Harmony 150

3

Mobil Oil Corporation

DTE Oil EX. Heavy

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961

6

Unocal 76

7

Shell Oil company

Unax RX 700 or Turbine Oil 700 Turbo 150

8

Century Lubricating Oils, Inc.

Centraulic R&O 150

9

Atlantic Richfield Company

10

Texaco Lubricants Company

Duro 600 or S-700 Regal Oil R&O 150

11

Exxon

Teresstic 150

12

Pennzoil

Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15

Conoco Inc.

Dectol R&O 76

16

Hydrotex

System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Table 25: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier Brand name 1 Amoco Oil Company Cylinder oil No. 1000 2 Mobil Oil Corporation Extra Hecla Super Cylinder Oil 3 Chevron U.S.A. Chevron Cylinder Oil W ISO 1000 4 Sun Oil Company Sun Steam Cylinder Oil 5 Unocal 76 Worm gear Lube 250 or Stevalc 6 Century Lubricating Oils, Inc. Garwal 680 7 Atlantic Richfield Company Modoc 195 8 Texaco Lubricants Company 650 T Cylinder Oil 1000 9 Exxon Cylesstic TK-1000 10 Pennzoil Cylinder Oil #1000 11 Conoco Inc. Inca Oil 1000

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_______________________________________________ Permissible media Table 26: Light gear oil, SAE 40 motor oil (Spec. 100-10)

1 2 3 4

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 27: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 28: Multi-purpose tractor hydraulic fluid (Spec. 100-12)

1 2 3 4

Supplier Exxon / Mobil Century / Fuchs Shell Chevron

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid

5 6 7

BP Lubricants Quaker State Conoco

Tractran UTH Quaker State FCI HD Powertran Fluid

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_______________________________________________ Permissible media Table 29: Synthetic EP gear lubricants (Spec. 100-13)

1

Supplier Fuchs

Brand name Powergear H680

Table 30: High temperature lithium complex motor bearing grease (Spec. 100-14) 1 2 3

Supplier Mobil Conoco Phillips Shell

Brand name Mobilith SHC 100 Triton 100 Albida EMS 2

Table 31: High demulsibility EP gear oil (Spec. 100-15) 1

Supplier Conoco

Brand name GLW Gear Oil 220

Table 32: Lithium complex semi-synthetic electric motor bearing grease (Spec. 100-16) 1

Supplier Fuchs

Brand name Renolit S2TX

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7

For your information

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_____________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service address Beckley, WV 351 Ragland Road Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

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Our service______________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

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