Cat FB110 Feeder Breaker Operation & Maintenance Manual (7MFBHM-48DD) – PDF DOWNLOAD

BI016871-01-EN A6474X320 March 2012

Operation and Maintenance Manual FB110 Feeder Breaker FBK02181 FBK02182

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This manual is intended to provide GENERAL product information for the Model 7MFBHM-48DD Feeder Breaker . The illustrations, descriptions, and procedures contained in this publication apply only to THIS machine. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This feeder breaker was manufactured under the guidelines, procedures, and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines and other applicable non-U.S. regulatory agency standards.

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 Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’ 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 Bucyrus America, Inc. 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.

©

BUCYRUS AMERICA , INC. ALL RIGHTS RESERVED

_________________________________________________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 Overview of the safety instructions .................................... 2.15 Chapter 3: Storage and transport.................................. 2.15 Chapter 4: Installation ................................................... 2.15 Chapter 5: Operation..................................................... 2.16 Chapter 6: Technical data ............................................. 2.26

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 ................................................... 4.9

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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 Primary operator’ s station................................................5.4 Secondary operator’ s station......................................... 5.10 Left side of machine ...................................................... 5.13 Right center of machine................................................. 5.13 Starter enclosure ........................................................... 5.14 Control features ............................................................. 5.16 “REGULAR”mode starting procedure................................ 5.17 “TRAM ONLY”mode starting procedure ............................ 5.18 Shutdown procedure .......................................................... 5.19 Conveyor ............................................................................ 5.20 Infrared pump motor controls ............................................. 5.21 Electrical system................................................................. 5.23 Starter enclosure ........................................................... 5.24 Hydraulic system ................................................................ 5.31 Major hydraulic components .................................... 5.32 Mechanical assemblies ...................................................... 5.37 Crawler assembly (s) .................................................... 5.37 Conveyor chain ............................................................. 5.38 Grease take-up ............................................................. 5.38 Head shaft .................................................................... 5.39 Conveyor power unit ..................................................... 5.40 Tail shaft ....................................................................... 5.40 Breaker and breaker power unit assembly.................... 5.41 Tailpiece assembly ........................................................ 5.43 Instructions on the maintenance of the feeder .................. 5.45 Important notes ............................................................. 5.45 Before maintenance ..................................................... 5.45 Lubrication and inspection ............................................ 5.50 Specific lubrication and maintenance procedures ............. 5.52 Every 8 hours of operation ........................................... 5.52 Weekly .......................................................................... 5.55 Every 2 weeks .............................................................. 5.59 Monthly ......................................................................... 5.59 Every 3 months ............................................................. 5.61 Every 2500 hours .......................................................... 5.64 Every 6 months ............................................................. 5.65 Inspection of the feeder ..................................................... 5.67 Inspection of wear parts on the feeder .............................. 5.68 Inspection of the fire suppression system .......................... 5.69 Recharge of the fire suppression system ........................... 5.71 Instructions on the adjustment procedures ....................... 5.73 Conveyor chain adjustment .......................................... 5.73 Crawler track adjustment .............................................. 5.75 Under speed sensor calibration..................................... 5.77 Hydrostatic pump relief valve adjustment...................... 5.79 Hydrostatic pump charge pressure adjustment............. 5.81 Loop flushing valve adjustment ..................................... 5.84

________________________________________________________________ Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_________________________________________________Table of contents Dual relief valve manifold adjustment ........................... 5.86 Secondary valve bank adjustment ................................ 5.89 Flow control valve adjustment ....................................... 5.91 Instructions on the replacement of wear parts .................. 5.93 Head shaft .................................................................... 5.93 Head shaft sprockets .................................................... 5.97 Tail shaft ......................................................................5.100 Conveyor chain ...........................................................5.105 Crawler track ...............................................................5.108 Crawler assembly ........................................................5.111 Breaker shaft and breaker power unit .........................5.119 Conveyor power unit ....................................................5.127 Breaker bit removal ......................................................5.134 Tailpiece installation .....................................................5.135 Roof cylinder ................................................................5.139 Foot cylinder .................................................................5.141 Tilt cylinder ...................................................................5.143 Lift cylinder ...................................................................5.145 Tailpiece tilt cylinder .....................................................5.147 Tailpiece steering cylinder............................................5.149 Troubleshooting.................................................................5.157 Hydraulic.......................................................................5.158 Electrical .......................................................................5.175

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: Bucyrus –Model 7MFBHM-48DD Feeder Breaker Serial No.: 54-2181 AND 54-2182 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.

■

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

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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 Bucyrus America, Inc. Use only original spare parts from Bucyrus America, Inc. 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 from Bucyrus America, Inc. or by specially qualified personnel of the mine.

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_________________________________________ Operating conditions 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.

© BUCYRUS AMERICA, INC.

Unauthorized uses include: ■

the transport of persons

■

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

Bucyrus America, Inc. accepts no liability for any damage resulting from any such unauthorized use.

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© BUCYRUS AMERICA, INC.

Operating conditions __________________________________________

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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).

© BUCYRUS AMERICA, INC.

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 ____________________________________________ 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

© BUCYRUS AMERICA, INC.

moving parts

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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.

© BUCYRUS AMERICA, INC.

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

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 Bucyrus America, Inc. 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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© BUCYRUS AMERICA, INC.

Be sure to observe the prescribed maintenance and inspection intervals.

___________________________________________ 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.

© BUCYRUS AMERICA, INC.

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.

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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© BUCYRUS AMERICA, INC.

Never try to repair damaged hydraulic hoses.

___________________________________________ Safety instructions ■

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

Fig. 3: Laying hydraulic hoses, bending Right

© BUCYRUS AMERICA, INC.

■

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 Wrong

© BUCYRUS AMERICA, INC.

Right

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_________________________________Overview of safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and transport Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

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

© BUCYRUS AMERICA, INC.

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

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

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

Use only suitable load handling devices.

Chapter 4: Installation CAUTION! Serious damage can be caused to the feeder breaker as a result of incorrect installation. The unit should only be installed under the instruction of specialists from Bucyrus America, Inc. 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.

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 prestartup checks should be performed: NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

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Overview of safety instructions _________________________________ 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.

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.

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.

Chapter 5: Operation 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.

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.

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© BUCYRUS AMERICA, INC.

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.

_________________________________Overview of safety instructions 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.

© BUCYRUS AMERICA, INC.

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

WARNING! The “POWER FILL/SECONDARY”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.

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.

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

NOTICE! Once a hydraulic control valve handle is released by the operator, the lever will automatically return to the centered (neutral) position.

CAUTION! The “POWER FILL/SECONDARY”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.

IMPORTANT! There are no control feature reset buttons on the machine and the machine will not automatically restart when a shutdown condition is resolved. If the feeder breaker is shutdown by any one of the control features, the feeder breaker must be manually restarted once the shutdown condition is resolved.

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

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Overview of safety instructions _________________________________ IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.

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.

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.

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.

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.

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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© BUCYRUS AMERICA, INC.

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.

_________________________________Overview of safety instructions 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 cylinders on both sides of the machine.

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.

© BUCYRUS AMERICA, INC.

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

NOTICE! In the event that a sudden jam occurs which could damage the power unit, the breaker is protected by a shear pin.

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.

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.

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.

______________________________________________________________ A6474X320 VLSV/00 2.19

Overview of safety instructions _________________________________ 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.

IMPORTANT! The is equipped with a central lubrication system that allows several lubrication points to be lubricated from a central point. In addition, there are several smaller lubrication manifolds on the machine.

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.

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

NOTICE! It is recommended that oil be at full operating temperature before draining.

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 sever damage to the pump.

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

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

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.

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. ________________________________________________________________

2.20

Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

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

_________________________________Overview of safety instructions 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.

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.

WARNING! Due to grease cylinder being under high pressure, do not visually inspect to see if grease is released. You could be seriously injured from high pressure grease.

© BUCYRUS AMERICA, INC.

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

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

WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.

WARNING! The hose plug and the fitting cap must be properly torqued before proceeding as the system pressure will reach 5,000 psi. Failure to do so may result in serious injury or death.

IMPORTANT! Do not run the pump for a long period of time while setting the reliefs as all of the flow will be going over the relief. Excessive pump operation with the lines plugged will result in overheating and the eventual failure of the pump.

WARNING! Two people are required to adjust the pressure settings. One person must move the conveyor direction valve handle to the forward direction and remain at the conveyor controls and panic bar at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

CAUTION! Do not turn the adjustment screw in any further once it is felt that the screw has bottomed out as this may damage the needle valve and seat. Likewise, do not turn the adjustment screw out all the way as this may present difficulties in reassembly and may introduce contamination into the hydraulic pump.

______________________________________________________________ A6474X320 VLSV/00 2.21

Overview of safety instructions _________________________________ NOTICE! While adjusting the relief pressure, if the system pressure gauge reading is not changing, it must be determined that the conveyor direction valve handle is in the correct position and that the corresponding pump pressure port hose was disconnected and plugged. To resolve this issue, place the conveyor direction valve handle in the opposite direction.

WARNING! The hose fitting must be properly torqued before proceeding as the system pressure will reach 5,000 psi. Failure to do so may result in serious injury or death.

WARNING! The hose plug and the fitting cap must be properly torqued before proceeding as the system pressure will reach 5,000 psi. Failure to do so may result in serious injury or death.

IMPORTANT! Do not run the pump for a long period of time while setting the reliefs as all of the flow will be going over the relief. Excessive pump operation with the lines plugged will result in overheating and the eventual failure of the pump.

WARNING! Two people are required to adjust the pressure settings. One person must move the conveyor direction valve handle to the forward direction and remain at the conveyor controls and panic bar at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

CAUTION! Do not turn the adjustment screw in any further once it is felt that the screw has bottomed out as this may damage the needle valve and seat. Likewise, do not turn the adjustment screw out all the way as this may present difficulties in reassembly and may introduce contamination into the hydraulic pump.

NOTICE! While adjusting the relief pressure, if the system pressure gauge reading is not changing, it must be determined that the conveyor direction valve handle is in the correct position and that the corresponding pump pressure port hose was disconnected and plugged. To resolve this issue, place the conveyor direction valve handle in the opposite direction.

WARNING! The hose fitting must be properly torqued before proceeding as the system pressure will reach 5,000 psi. Failure to do so may result in serious injury or death.

________________________________________________________________ 2.22 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.

_________________________________Overview of safety instructions WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.

WARNING! Two people are required to adjust the pressure setting. Once person must operate the lift cylinder valve handle and remain at the panic bar at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

© BUCYRUS AMERICA, INC.

WARNING! The feeder will move during this step and it must be ensured that all standard safety procedures are adhered to in order to avoid personnel injury and equipment damage. Do not operate the tram function during this adjustment procedure as it is unsafe. Failure to adhere to this warning may result in serious injury or death.

WARNING! Two people are required to adjust the pressure setting. Once person must operate a stabilizer cylinder valve handle and adjust the relief. The second person must remain at the panic bar at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

WARNING! Use caution when retracting foot cylinders. When tension is release off of the belt pulley, the feeder breaker may lurch forward.

Make sure all personnel are clear of the machine when performing this procedure.

WARNING! Two people are required to adjust the pressure setting. Once person must operate the tilt cylinder valve handle and remain at the panic bar at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

______________________________________________________________ A6474X320 VLSV/00 2.23

Overview of safety instructions _________________________________ WARNING! The flow control valve should never be fully closed as it acts as a relief in this circuit. Fully closing the flow control valve could cause hose or component failure, resulting in machine damage or injury to personnel.

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

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.

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.

WARNING! The headshaft must turn freely by hand. If the headshaft does not turn freely by hand, the bearings will fail prematurely.

WARNING! The headshaft must turn freely by hand. If the headshaft does not turn freely by hand, the bearings will fail prematurely.

IMPORTANT! Adhere to all weld specifications shown on Fig. 79. Failure to do so may result in sprocket failure and machine damage.

WARNING! Only install a key for one sprocket. If a key is installed for both sprockets, the chain could bind due to slight length variances in the conveyor chain.

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.

IMPORTANT! Heating or cutting connections with a torch or chisel may be required to ease the removal of T- pins.

________________________________________________________________ 2.24 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

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.

_________________________________Overview of safety instructions WARNING! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) 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.

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.

© BUCYRUS AMERICA, INC.

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.

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 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.

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.

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.

______________________________________________________________ A6474X320 VLSV/00 2.25

Overview of safety instructions _________________________________ Chapter 6: Technical data 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.

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! Bucyrus America, Inc. expressly point 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.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be disposed of per your local EPA standards.

________________________________________________________________ 2.26 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc.! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

_______________________________________________________________

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.

______________________________________________________________ A6474X320 VLSV/00 3.3

Storage and transport _________________________________________ ■

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.

machine electrics

Electronic components should be stored at temperatures between 0 °F and 176 °F (-18 °C and 80 °C)

random sample inspection

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. On request, the inspection can be carried out by Bucyrus.

natural aging

HFA fluids

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 your Bucyrus 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.

________________________________________________________________ 3.4 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________ 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 (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.

Horizontal (lengthwise) center of gravity

Note: Approximate machine weight is 100,000 lbs (45,360 kg), as shown.

Lift point (typical 2 places): Lift hook is to be attached directly under the arrow, hooking into the pocket under the edge of the frame.

______________________________________________________________ A6474X320 VLSV/00 3.5

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.

________________________________________________________________ 3.6 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

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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 Bucyrus America, Inc. service engineers or by specially trained personnel.

Which tools are required for installation? tool box

No special 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.

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

______________________________________________________________ A6474X320 VLSV/00 4.3

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 Bucyrus America, Inc. 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

________________________________________________________________ 4.4 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

__________________________________________________ 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

______________________________________________________________ A6474X320 VLSV/00 4.5

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 BREAK 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 BREAK STOP”switch button will shutdown the pick break motor and the conveyor motor immediately.

“PUMP MOTOR STOP”switch (starter enclosure)

This stop switch is located on the right hand side of the machine, on the starter enclosure cover. Depressing the “PUMP MOTOR STOP”switch button will shutdown all machine functions immediately.

panic strip

The panic strip is located at the primary operator’ s station on the right hand 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.

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 at the secondary operator’ s station. 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.

________________________________________________________________ 4.6 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

__________________________________________________ Installation Fig. 7: Safety features on the feeder breaker

“PICK BREAK STOP”switch

“PUMP MOTOR STOP”switch

Panic strip

Fire suppression actuator location Neutral start mechanism

Fire suppression actuator

______________________________________________________________ A6474X320 VLSV/00 4.7

Installation___________________________________________________ Fig. 8: Overview of the feeder breaker Belt spreader assembly

Discharge section

Secondary operator’ s station

Breaker assembly Roof cylinder (2)

Receiving section Starter enclosure Stabilizer foot (2)

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

Primary operator’ s station Conveyor chain

________________________________________________________________ 4.8 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

__________________________________________________ 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:  Couple the towing machine securely to the feeder breaker.  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.  Rotate the torque hub end cap on both right and left sides of the feeder to the free position as follows (Fig. 9).  Remove the two (2) bolts that retains the end cover to the center of the torque hub.  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.  Remove chocks from crawler and begin towing.

______________________________________________________________ A6474X320 VLSV/00 4.9

Installation___________________________________________________  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.  Rotate the torque hub end cap on both right and left sides of the feeder breaker to the drive position.  Remove the two (2) bolts that retains the end cap to the center of the torque hub.  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

________________________________________________________________ 4.10 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_______________________________________________________________

5

Operation

________________________________________________________________

_______________________________________________________________

________________________________________________________________

___________________________________________________ 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.

______________________________________________________________ A6474X320 VLSV/00 5.3

Operation____________________________________________________ Controls and indicators Primary operator’s station The primary controls for the machine are located on the right hand 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, auxiliary function pressure gauges, conveyor speed pressure gauge, conveyor speed control valve, conveyor direction control valve, starter enclosure, oil level sight gauge, tram/conveyor mode control valve, and fire suppression actuator.

Fig. 10: Primary operator’s station Panic strip

Primary valve bank

Fire suppression actuator

Conveyor speed and direction control valve

Pressure gauge panel

Tram/conveyor mode control valve

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 FRAME LIFT”

The first 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.

________________________________________________________________ 5.4 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

___________________________________________________ Operation “RIGHT FRAME LIFT”

The second 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.

“LEFT TRAM”

The third lever from the operator’ s left controls the offside crawler 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.

“RIGHT TRAM”

The fourth lever from the operator’ s left controls the operator side crawler 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.

“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.

“POWER FILL” and “SECONDARY”

The sixth lever from the operator’ s left has two (2) functions, it controls the “POWER FILL”and “SECONDARY”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 secondary valve bank.

______________________________________________________________ A6474X320 VLSV/00 5.5

Operation____________________________________________________ WARNING! The “POWER FILL/SECONDARY”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. power fill procedure

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.

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.

________________________________________________________________ 5.6 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

___________________________________________________ Operation Fig. 11: Primary valve bank

“LEFT LIFT”

“RIGHT LIFT”

“LEFT TRAM”

“RIGHT TRAM”

“TILT”

“POWER FILL” and “SECONDARY”

two position conveyor direction and speed control valve

The two position conveyor direction and speed control valve (Fig. 12) controls the feeder breaker conveyor chain direction and speed. Push the control lever down to run the conveyor in the direction of the discharge end and pull the control lever up to run the conveyor in the direction of the receiving end. Conveyor chain speed is controlled by the distance that the control handle is pushed.

tram/conveyor mode control valve

The tram/conveyor mode control valve (Fig. 12) allows the operator to change the machine from tram to conveyor mode. Push the control handle down for conveyor mode and pull the handle up for tram mode.

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.

fire suppression

The machine fire suppression (remote) actuators (Fig. 12) 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.

______________________________________________________________ A6474X320 VLSV/00 5.7

Operation____________________________________________________ Fig. 12: Controls and indicators Panic strip Fire suppression actuator

“TRAM/CONVEYOR” mode control valve

“CONVEYOR”speed and direction

________________________________________________________________ 5.8 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

___________________________________________________ Operation Gauge panel The gauge panel (Fig. 13) is used to determine when filters need to be serviced and provide a constant reading of system charge pressure.

“CONVEYOR PRESSURE #4” and “FILTER SVC INDICATOR #1”

The “CONVEYOR PRESSURE #4”gauge is located upstream of the non-bypassing conveyor filter. It displays the pressure going into the filter. The “FILTER SVC INDICATOR #1”gauge is located downstream of the filter and shows the pressure on the discharge side of the nonbypassing filter. The difference between the two pressure readings is used to determine when to change the filter. If the pressure drop is greater than 150 psi, the filter element needs changed.

“AUXILIARY PRESSURE #2” and “FILTER SVC INDICATOR #2”

The “AUXILIARY PRESSURE #2”gauge is located upstream of the non-bypassing auxiliary pressure #2 filter. It displays the pressure going into the filter. The “FILTER SVC INDICATOR #2”gauge is located downstream of the filter and shows the pressure on the discharge side of the non-bypassing filter. The difference between the two pressure readings is used to determine when to change the filter. If the pressure drop is greater than 150 psi, the filter element needs changed.

“AUXILIARY PRESSURE #3” and “FILTER SVC INDICATOR #3”

The “AUXILIARY PRESSURE #3”gauge is located upstream of the non-bypassing auxiliary pressure filter #3. It displays the pressure going into the filter. The “FILTER SVC INDICATOR #3”gauge is located downstream of the filter and shows the pressure on the discharge side of the non-bypassing filter. The difference between the two pressure readings is used to determine when to change the filter. If the pressure drop is greater than 150 psi, the filter element needs changed.

“CHARGE PRESSURE”

The “CHARGE PRESSURE”gauge is a low pressure, 600 psi, gauge that provides the operator a constant reading of the charge pressure.

Fig. 13: Gauge panel “CONVEYOR PRESSURE #4”

“FILTER SVC INDICATOR #1”

“CHARGE PRESSURE”

“AUXILIARY PRESSURE #2”

“AUXILIARY PRESSURE “3

“FILTER SVC INDICATOR #2”

‘ FILTER SVC INDICATOR #3”

______________________________________________________________ A6474X320 VLSV/00 5.9

Operation____________________________________________________ Secondary operator’s station The secondary operator’ s station (Fig. 14) is located at the head shaft on the right side of the machine. The secondary operator’ s station consists of the following controls and indicators: diversion valves, secondary valve bank, power fill ball valve, tank fill hand pump, and fire suppression actuator.

Fig. 14: Secondary operator’s station Secondary valve bank

Fire suppression actuator

Tank fill hand pump

Power fill ball valve

Secondary valve bank NOTICE! Once a hydraulic control valve handle is released by the operator, the lever will automatically return to the centered (neutral) position.

The secondary valve bank (Fig. 15) consists of the following hydraulic controls: “UPPER BELT SPREADER”

The “UPPER BELT SPREADER”lever controls the upper belt spreader cylinder. To raise the upper belt spreader (retract the cylinder), pull the lever back. To lower the upper belt spreader (extend the cylinder), push the lever forward.

“LOWER BELT SPREADER”

The “LOWER BELT SPREADER”lever controls the lower belt spreader cylinder. To raise the lower belt spread (extend the cylinder), push the lever forward. To the lower the lower belt spreader (retract the cylinder), pull the lever back.

________________________________________________________________ 5.10 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

___________________________________________________ Operation “TAILPIECE TILT”

The “TAILPIECE TILT”lever tilts the tailpiece up or down. To tilt the tailpiece up, pull the control lever forward. To tilt the tailpiece down, push the control lever back.

“TAILPIECE STEER”

The “TAILPIECE STEER”lever controls the direction of the tailpiece.

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.

“FLOOR ANCHOR

The “FLOOR ANCHOR”lever controls the foot cylinders. To extend the cylinder (roof or foot), push the control lever forward. To retract the cylinder (roof or foot), pull the control lever back.

“ROOF ANCHOR”

The “ROOF ANCHOR”lever controls the roof cylinders. To extend the cylinder (roof or foot), push the control lever forward. To retract the cylinder (roof or foot), pull the control lever back.

Fig. 15: Secondary valve bank

“UPPER BELT SPREADER”

“LOWER BELT SPREADER”

“TAILPIECE TILT”

“TAILPIECE STEER”

______________________________________________________________ A6474X320 VLSV/00 5.11

Operation____________________________________________________ foot cylinder locking pin

There is a mechanical locking pin on the foot cylinder (Fig. 16) 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. 16: Foot cylinder mechanical locking pin

Locking pin storage tube

power fill ball valve

The power fill ball valve (Fig. 17) 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/SECONDARY”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.

tank fill hand pump

The tank fill hand pump (Fig. 17) is used to manually fill the hydraulic oil tank. To operate the hand pump, release the handle latch and pump the handle up and down. When the filling operation is complete, return the handle to the upright position and latch in place.

Fig. 17: Power fill ball valve and tank fill hand pump

Power fill ball valve Tank fill hand pump

________________________________________________________________ 5.12 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

___________________________________________________ Operation fire suppression actuator

The machine fire suppression (remote) actuators (Fig. 14) 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.

Controls and indicators - left side of machine hydraulic oil level sight glass

The hydraulic oil level sight glass (Fig. 18) 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.

Fig. 18: Oil level sight glass

Oil level sight glass

Controls and indicators - right center of machine dust suppression system regulator

The dust suppression system regulator (Fig. 19) 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. 19). To increase pressure, turn the regulator handle in (cw). To decrease pressure, turn the regulator handle out (ccw).

dust suppression system pressure gauge

The dust suppression system pressure gauge (Fig. 19) is used to monitor the water pressure to the spray nozzles. The gauge should read between 5 and 125 psi.

Fig. 19: Dust suppression system regulator and pressure gauge Regulator handle Gauge

Regulator

______________________________________________________________ A6474X320 VLSV/00 5.13

Operation____________________________________________________ Starter enclosure The starter enclosure (Fig. 20) is located on the right hand side of the machine. The controls and indicators on the front of the starter enclosure are: “POWER ON”light

The “POWER ON”light will be illuminated when it detects incoming power to the starter enclosure.

“HIGH TEMP”light

The “HIGH TEMP”light will be illuminated if the temperature switch detects a high temperature (greater than 150 °F) inside the oil tank. If a high temperature is detected, the motor will shut down and the light will be illuminated.

“LOW OIL”light

The “LOW OIL”light will be illuminated when it detects low oil issue (below the sight glass) at the hydraulic oil tank. There is a low oil switch located on board of the machine at the oil tank. If there is a low oil issue at the tank, the motor will shut down and the light illuminated.

“SEQ SW”light

The sequence switch, “SEQ SW”, light will be illuminated if the outby belt stops.

“PRESSURE SWITCH”light

The “HIGH PRESS”light will be illuminated if the high pressure switch detects excessive pressure (greater than 4,800 psi) within the hydraulic system. If a excessive high pressure is detected, the motor will shut down and the light will be illuminated.

“UNDERSPEED”light

The “UNDERSPEED”light will illuminate if the pick break slows below a preset speed for greater than 3 seconds, or if the pick break stops.

“SAFETY RELAY”light

The “SAFETY RELAY”light turns on and then back off if the panic bar is struck.

“OL1”light

The “OL1”light illuminates if the pick break motor is overloaded.

“OL2”light

The “OL2”light illuminates if the pump motor is overloaded.

“LIGHT SWITCH” “PUMP MOTOR START”

“PUMP MOTOR STOP” “CB2 RESET” “PICK BREAK START”

“PICK BREAK STOP”

The light switch is used to turn “ON”or “OFF”the area lights.

The “PUMP MOTOR START”pushbutton is used to start the pump motor (see Startup procedures in this chapter).

The “PUMP MOTOR STOP”pushbutton is used to stop the pump motor (see Shutdown procedures in this chapter).

The “CB2 RESET”pushbutton is used to reset the machine’ s 5 amp circuit breaker. Push the button to reset.

The “PICK BREAK START”pushbutton starts the pick break motor (see Startup procedures in this chapter).

The “PICK BREAK STOP”pushbutton stops the pick break motor (see Shutdown procedures in this chapter).

________________________________________________________________ 5.14 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

___________________________________________________ Operation “REGULAR/OFF/TRAM ONLY” selector switch

The “REGULAR/OFF/TRAM ONLY”switch is a three (3) position rotary switch that is used to: –

“REGULAR”- run the machine during normal operations.

–

“OFF”- removes power from the motors.

–

“TRAM ONLY”- to tram the machine, the pick break motor will not run.

Fig. 20: Starter enclosure cover

“PRESSURE SWITCH”

“UNDERSPEED”

“SAFETY RELAY”

“REGULAR/OFF/ TRAM ONLY”switch

“POWER ON” “HIGH TEMP.” “LOW OIL” Circuit breaker reset lever “SEQ. SW.”

“OL1”

“OL2”

“LIGHT SWITCH”

“PICK BREAK START”

“PICK BREAK STOP”

“CB-2 RESET”

“PUMP MOTOR START”

“PUMP MOTOR STOP”

______________________________________________________________ A6474X320 VLSV/00 5.15

Operation____________________________________________________ Control features The following is a list of control features that could affect the running of the feeder breaker. high temperature switch

There is a high temperature switch for the feeder breaker located at the oil tank. If a high temperature (greater than 150 °F) is detected, both motors will be turned off and a light (“HIGH TE MP”) will be illuminated on the starter enclosure.

low oil cut off switch

There is a low oil cut off switch for the feeder breaker, located at the oil tank. If it detects a low oil issue (oil level below the sight glass) at the oil tank, the motor will be turned off and a light (“LOW OIL)) will be illuminated on the starter enclosure.

under speed sensor

The under speed sensor detects whether or not the pick break is turning at normal operating speed. If the pick break slows below a preset speed for longer than 3 seconds, or if the pick break stops, both motors will shut down and a light (“UNDERSPEED”) will be illuminated on the starter enclosure.

motor overloads (OL1 and OL2)

There is an overload on each of the motors (pick break & pump motor) if either one of these overloads detects an over current condition, it will trip and both motors will be stopped. These overloads will also detect a phase unbalance (10%) and will trip and stop both motors. A light will illuminate on the starter enclosure is either overload is tripped.

high pressure switch

There is a high pressure switch for the feeder breaker that detects a high pressure situation (greater than 4,800 psi) with the hydraulic system. If the switch detects high pressure, the pump motor will shutdown and the “PRESSURE SWITCH”light on the starter enclosure will be illuminated.

IMPORTANT! There are no control feature reset buttons on the machine and the machine will not automatically restart when a shutdown condition is resolved. If the feeder breaker is shutdown by any one of the control features, the feeder breaker must be manually restarted once the shutdown condition is resolved.

________________________________________________________________ 5.16 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

___________________________________________________ Operation Starting procedure - “REGULAR”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° Fahrenheit. 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.  Operate all primary and secondary valve bank control levers to ensure that they are free and in neutral position.  Position the primary valve bank handle 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.  Check conveyor for any foreign material or objects.  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.  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.  Turn the “REGULAR/OFF/TRAM ONLY”selector switch located on the cover of starter enclosure to the “REGULAR”position.  Engage the “PICK BREAK START”pushbutton located on the cover of the starter enclosure.  The contactor M1 will energize and the pick break motor will start.  Engage the “PUMP MOTOR START”pushbutton located on the cover of the starter enclosure.  The contactor M2 will energize and the pump motor will start.

______________________________________________________________ A6474X320 VLSV/00 5.17

Operation____________________________________________________ Starting procedure - “TRAM ONLY”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° Fahrenheit. 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.  Operate all primary and secondary valve bank control levers to ensure that they are free and in neutral position.  Position the primary valve bank handle lock guard over the valv 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.  Check conveyor for any foreign material or objects.  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.  Turn the main circuit breaker to the “ON”position.  Turn the “REGULAR/OFF/TRAM ONLY”selector switch located in the cover of the starter enclosure to the “TRAM ONLY”position.  Engage the “PUMP MOTOR START”pushbutton located on the cover of the starter enclosure.  The contactor M2 will energize and the pump motor will start.

________________________________________________________________ 5.18 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

___________________________________________________ Operation Shutdown procedure There are several methods of shutting down the feeder breaker.  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:  Engage the “PICK BREAK STOP”pushbutton located on the starter enclosure. This will stop the pick break motor and the pump motor.  Turn the circuit breaker reset switch to the “OFF”position .

To stop the pump motor only while in “REGULAR”mode:  Engage the “PUMP MOTOR STOP”pushbutton located on the starter enclosure. This will stop the pump motor.  Turn the circuit breaker reset switch to the “OFF”position .

To shutdown the feeder breaker in “TRAM ONLY”mode:  Engage the “PUMP MOTOR STOP”pushbutton located on the started enclosure. This will stop the pump motor.  Turn the circuit breaker reset switch to the “OFF”position .

______________________________________________________________ A6474X320 VLSV/00 5.19

Operation____________________________________________________ Conveyor Perform daily start-up procedure (see Start-up procedure for “REGULAR”mode in this chapter). The conveyor is controlled by a 125 hp pump motor. The conveyor may be operated utilizing the “REGULAR”mode switch and conveyor speed/direction control valves located on the right side of the machine.

There is a timer in the conveyor circuit that only allows the conveyor to run for a preset time then times out. If, during this time, a start button is engaged, the timer is reset back to zero and the timer starts timing again.

In the event the conveyor becomes jammed and it is necessary to reverse the chain, this may be done by changing the conveyor two position control valve from forward to reverse.

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.

________________________________________________________________ 5.20 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

___________________________________________________ Operation Infrared pump motor controls An infrared transmitter can be used to start and stop the pump motor on the machine. The feeder breaker is equipped with two (2) infrared receivers located on top of the machine (Fig. 21).

To stop the motor, press the stop button on the transmitter. To start the motor, press the start button on the transmitter.

Fig. 21: Infrared transmitter and receiver Infrared receiver (2)

Infrared transmitter (remote control)

______________________________________________________________ A6474X320 VLSV/00 5.21

Operation____________________________________________________

________________________________________________________________ 5.22 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_____________________________________________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.

© BUCYRUS AMERICA, INC.

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.

Fig. 22: Major electrical component locator Tape switch Starter enclosure

Conveyor motor

Pick break motor

______________________________________________________________ A6474X320 VLSV/00 5.23

Electrical system _____________________________________________ Starter enclosure The starter enclosure (Fig. 23), 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.

© BUCYRUS AMERICA, INC.

Fig. 23: Starter enclosure

Starter enclosure cover

Swing panel - front

Back panel

Swing panel - back

Bottom panel

________________________________________________________________ 5.24 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_____________________________________________Electrical system Starter enclosure cover The cover of the starter enclosure (Fig. 24) consists of indicator lights and switches (see Indicator and controls section in this chapter for a description of the lights and switches). All indicator lights on the cover panel are normally off.

Also, located on the cover is the selector handle for turning the main circuit breaker “ON”and “OFF”. This allows the main power to the machine from the section power supply to be disconnected.

Fig. 24: Starter enclosure cover

© BUCYRUS AMERICA, INC.

“PRESSURE SWITCH”

“UNDERSPEED”

“SAFETY RELAY”

“REGULAR/OFF/ TRAM ONLY”switch

“POWER ON” “HIGH TEMP.” “LOW OIL” Circuit breaker reset lever “SEQ. SW.”

“OL1”

“OL2”

“LIGHT SWITCH”

“PICK BREAK START”

“PICK BREAK STOP”

“CB-2 RESET”

“PUMP MOTOR START”

“PUMP MOTOR STOP”

______________________________________________________________ A6474X320 VLSV/00 5.25

Electrical system _____________________________________________ Swing panel - front side The swing panel (Fig. 25) 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.

Fig. 25: Swing panel (front side) and main circuit breaker

“IS#1”

“IS#2”

“IS#3”

“IS#4”

“TR1”

Indicator lights “CB1”

“CR4” “SR” “CR1”

“CR2”

“CR3”

“CR5”

“CB1”

“CB2”

“CR6”

“RR”

“TR2”

“TR3”

“CB1”is the main circuit breaker for the feeder breaker. The circuit breaker reset switch on the front of the starter enclosure panel is used to control the circuit breaker when the starter enclosure cover is in place.

When looking directly at “CB1”, the circuit breaker is on when the black switch is all the way up. If the circuit breaker has been tripped, the switch will be only partially up. The circuit breaker is off when the switch is down. To reset the circuit breaker, push the switch down past off, then up to on.

________________________________________________________________ 5.26 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Swing panel retaining bolt

© BUCYRUS AMERICA, INC.

_____________________________________________Electrical system “IS#1”and “CR1”

“IS#1”is an intrinsically safe relay that works in conjunction with the high temperature relay “CR1”. If the hydraulic oil temperature exceeds 150°F, the high temperature switch will shut the pump motor down and the “HI TEMP”indicator light will be illuminated.

“IS#2”and “CR2”

“IS#2”is an intrinsically safe relay that works in conjunction with the low oil relay “CR2”. If the oil in the hydraulic tank drops below the bottom of the sight glass on the side of the tank, the low oil switch will shut the pump motor down and the “LOW OIL”light will be illuminated.

“IS#3”and “CR3”

“IS#3”is an intrinsically safe relay that works in conjunction with the sequence switch relay “CR3”. If the outby belt stops, the sequence switch will shutdown the pump motor and the “SEQ SW”light will be illuminated.

“IS#4”and “CR4”

“IS#4”is an intrinsically safe relay that works in conjunction with the pressure switch relay “CR4”. If the hydraulic pressure exceeds 4,800 psi, the pressure switch will shutdown the pump motor and the “PRESSURE SWITCH”light will be illuminated.

“SR”

“SR”is the safety relay. If the panic bar is struck, both the pump motor and the pick break motor will be shutdown and the “SAFETY RELAY” light will be illuminated.

“CR5”

“CR5”is the regular mode relay. When the mode switch on the front of the starter enclosure is in the “REGULAR”position, both the pump motor and the pick break motor can be energized.

“CR6”

“CR6”is the tram only mode relay. When the mode switch on the front of the starter enclosure is in the “TRAM ONLY”position, only the pump motor can be energized. The pick break motor will not run in “TRAM ONLY”mode.

“CB-2”

“CB-2”is the circuit breaker on the control circuit. If the control circuit is overloaded, or if the circuit becomes grounded, “CB2”will trip. To reset the circuit breaker, press the pushbutton on the front of the starter enclosure.

“TR1”

“TR1”is the breaker shaft underspeed timer. If the breaker shaft slows down below the normal speed calibrated during initial machine setup for longer than three (3) seconds, the underspeed sensor will shutdown the pick break motor.

“TR2”

“TR2”is the override timer for the breaker shaft underspeed timer. During startup, the override timer will allow the breaker shaft to run under speed for approximately seven (7) seconds. This override is active during startup only.

“TR3”

“TR3”is the conveyor run time timer. The timer is activated when the pump motor pushbutton, or the start button on the infrared remote, is pushed. The conveyor will run for approximately 2 1/2 minutes. To keep the conveyor running, the operator must push the start button (on the starter enclosure cover or the infrared remote) before the 2 1/2 minutes expires. If the timer is not reset within 2 1/2 minutes, the pump motor will shutdown.

______________________________________________________________ A6474X320 VLSV/00 5.27

Electrical system _____________________________________________ Swing panel - back side The back side of the swing panel (Fig. 26) is accessed by removing the swing panel retaining bolt and swinging the panel out. Located on the panel are relays, a switch, and the infrared receiver board.

Fig. 26: Swing panel - back side “IS#5”

Swing panel retaining bolt location

“CR7”

“IS#5”and “CR7”

“IS RELAY”

infrared receiver board

“IS RELAY”

“IS#5”is an intrinsically safe relay that works in conjunction with the “CR7” neutral position magnetic switch relay. In order to start the machine, the primary valve bank handles must be in neutral and the guard must be in place over the levers, activating the neutral position magnetic switch.

The “IS RELAY”is an intrinsically safe relay for the panic bar (tape switch). When the panic bar is struck, the tape switch will shutdown the machine.

The infrared receiver board processes the pump motor start and stop signal from the infrared remote.

________________________________________________________________ 5.28 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Infrared receiver board

_____________________________________________Electrical system Back panel The back panel (Fig. 27) 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. Located on the back panel are two vacuum contactors, two overload relays, and the control transformer.

Fig. 27: Back panel

© BUCYRUS AMERICA, INC.

“T1”

“M1”

“OL2”

“M2”

“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.

“M2”

“M2”is the vacuum contactor for the 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 pump motor. If the pump motor is overloaded, the relay will shutdown the pump motor.

______________________________________________________________ A6474X320 VLSV/00 5.29

Electrical system _____________________________________________ Bottom panel The bottom panel (Fig. 28) is located in the bottom of the starter enclosure, directly under the back panel. The bottom panel is accessed by opening the swing panel.

Pick break sensor control board

barrier

pick break sensor control board

Barrier

The purpose of the barrier is to act as a shield between the nonpermissible and permissible environments. The barrier limits the current and voltage to specified levels.

The pick break sensor control board is the control board for the pick break motor.

________________________________________________________________ 5.30 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 28: Bottom panel

____________________________________________ 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 belt spreader cylinders, roof cylinders, the foot cylinders, and the tailpiece cylinders

© BUCYRUS AMERICA, INC.

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.

Fig. 29: Hydraulic component locator feeder breaker

1.

2.

3.

4.

5.

6.

7.

8.

Oil tank Hydrostatic pump Gear pump Primary valve bank Secondary valve bank Tilt and lift cylinders Tram motor Conveyor motor

9.

10.

11.

12.

13.

14.

15.

16.

Belt lift/spreader cylinders Tail pulley cylinder Roof anchor cylinder Counter-balance cartridge Flow divider, power fill Ball valve Dual relief manifold Filter service pressure gauge

17.

18.

19.

20.

21.

Charge pressure gauge Selector valve proportional detented valve Air/oil heat exchanger Filter (pressure (2), charge, aux pressure, return) 22. Tank fill filter 23. Filter, in-line, non-bypass 24. Return manifold

25. Flow control, heat exchanger 26. Tank fill hand pump 27. Check valve 28. Logic check valve 29. Loop flushing valve 30. Foot cylinders (not shown)

______________________________________________________________ A6474X320 VLSV/00 5.31

Hydraulic system _____________________________________________ Major hydraulic components (Reference Fig. 30) hydraulic oil tank

The hydraulic oil tank located on the left hand side of the machine has a 175 gallon capacity and is equipped with a oil level sight glass, high temperature switch and low oil level switch.

hydrostatic pump

The hydrostatic pump located within the power unit is an axial piston, variable displacement and hydraulic displacement control pump that supplies hydraulic power to the conveyor.

The gear pump located within the power unit supplies hydraulic power to the primary and secondary valve banks. The pump stroke and direction of flow is controlled by the proportional detented valve.

primary valve bank

The primary valve bank, located on the right hand side of the machine, is used to control the machine’ s 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, and the foot cylinders.

tank fill pump

The tank fill pump is located on the right hand side of the discharge section of the machine, to the left of the starter box, and is used to replenish oil to the hydraulic tank from an external source. The pump is capable of delivering approximately 5 gallons of fluid per 30 seconds.

tank fill hand pump

The tank fill hand pump is located directly behind the tank fill pump on the right side of the discharge section of the machine, to the left of the starter box, and is used to manually replenish oil to the hydraulic tank from an external source.

tilt hydraulic cylinders

The 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. Both cylinders are controlled by one section of the valve bank.

lift hydraulic cylinders

The 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 cylinders on both sides of the machine.

________________________________________________________________ 5.32 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

gear pump

____________________________________________ Hydraulic system tram motors

© BUCYRUS AMERICA, INC.

conveyor motor

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

The conveyor motor is located on the right hand side of the head shaft and is a radial piston motor that receives hydraulic fluid from the hydrostatic pump.

loop flushing valve

The machine is equipped with a loop flushing valve located on the discharge end of the machine on the frame side plate behind the hydrostatic pump. The valve is used to strip off approximately 3 gpm of the charge oil to flush the case of the conveyor motor.

oil/water heat exchanger

The heat exchanger located on the right side of the machine is used to remove heat from the hydraulic circuit prior to dumping into tank.

proportional conveyor speed/direction control valve

The conveyor control valve located above the right hand crawler at the primary operator’ s station is used to control the conveyor speed and direction of travel.

charge filter

The charge filter is located on the right hand side of the machine on the filter tree located between the starter and the heat exchanger and is used to filter the charge fluid. The filter removes hot oil from the circuit, allowing the charge pump to replenish the circuit with cooler oil.

pressure filter (s)

There are two (2) non-bypassing filters hard plumbed to two (2) bypassing filters located above the crawler on the right hand side of the machine at the primary operator’ s station and are used to filter fluid on the pressure side of the primary valve bank circuit.

return filter

The return filter located on the right hand side of the of the discharge end of the machine on the bottom of the filter tree, between the starter and the heat exchanger, is used to filter return flow from the primary valve bank and the diversion valve.

tank fill filter

The tank fill filter located beside the starter enclosure is used to filter fluid that is being pumped with the power fill system or the hand pump from an external source to the hydraulic oil tank.

pressure filter (hydrostatic)

The pressure filter is located on the right hand side of the discharge end of the machine on the top of the filter tree, between the starter and the heat exchanger, and is used to filter oil in the hydrostatic (conveyor) loop while the conveyor is running forward. The filter bypasses when the conveyor is running in reverse.

conveyor pressure gauge (6,000 psi)

The conveyor pressure gauge is a 6,00 psi gauge located on the right side of the machine gives the operator a constant reading of the hydraulic pressure within the conveyor circuit.

auxiliary function pressure gauges

The auxiliary function pressure gauges are high pressure gauges (6,000 psi) located below the tram control levers. These gauges give the operator a constant reading of the secondary system pressures.

______________________________________________________________ A6474X320 VLSV/00 5.33

Hydraulic system _____________________________________________ charge pressure gauge (600 psi)

filter service indicator gauges (6,000 psi)

The charge pressure gauge is a low pressure gauge (600 psi) located on the right side of the machine. This gauge gives the operator a constant reading of the charge pressure.

The filter service indicator gauges are a set of 6,000 psi gauges located at the primary operator’ s station on the right side of the machine. The gauges are used to determine the amount of contamination in the nonbypass filters (conveyor and two auxiliary) by allowing the pressure drop across the filters to be measured. The filter service indicator gauges are located downstream of the filter while the corresponding pressure gauges are located upstream of the filter. If the differential pressure reading (filter service indicator gauge - pressure gauge) exceeds 150 psi, the filter needs changed.

Table 1: Corresponding pressure gauges Pressure gauge

Corresponding filter service indicator gauge

“AUXILIARY PRESSURE #2” “FILTER SVC INDICATOR #2” “AUXILIARY PRESSURE #3” “FILTER SVC INDICATOR #3” upper belt spreader cylinder

There is one upper belt spreader cylinder located on each side of the tailpiece. The cylinders are used to raise and lower the upper belt spreader.

lower belt spreader cylinder

There is one lower belt spreader cylinder located on each side of the tailpiece. The cylinders are used to raise and lower the lower belt spreader.

________________________________________________________________ 5.34 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

“CONVEYOR PRESSURE #4” “FILTER SVC INDICATOR #1”

____________________________________________ Hydraulic system

© BUCYRUS AMERICA, INC.

Fig. 31: Hydraulic schematic

______________________________________________________________ A6474X320 VLSV/00 5.35

© BUCYRUS AMERICA, INC.

Hydraulic system _____________________________________________

________________________________________________________________ 5.36 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_______________________________________ 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 assembly (s)

© BUCYRUS AMERICA, INC.

The feeder breaker is trammed by two (2) hydraulically driven crawlers (Fig. 32); 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. 32: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

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

______________________________________________________________ A6474X320 VLSV/00 5.37

Mechanical assemblies ________________________________________ Conveyor chain The feeder breaker is equipped with a conveyor chain assembly (Fig. 33) 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. 33: Conveyor chain components

Roll pin

© BUCYRUS AMERICA, INC.

Chain link section

Flight bar

Grease take-up The feeder breaker is equipped with two (2) conveyor chain grease take-up assemblies (Fig. 34) 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. 34: Grease take-up main components

Stop valve (2)

Grease manifold

Grease fitting (2)

________________________________________________________________ 5.38 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_______________________________________ Mechanical assemblies Head shaft The feeder breaker is equipped with a head shaft (Fig. 35) located on the discharge end of the conveyor. The head shaft is driven from the right 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 Bucyrus America, Inc. parts manual for your machine or contact your Bucyrus America, Inc. service engineer.

© BUCYRUS AMERICA, INC.

Fig. 35: Head shaft main components

Bearing (2)

Sprocket (2)

Key (2) Head shaft Set screw (2 per sprocket, located 180° from the set screw)

Gearbox

Hydraulic motor

______________________________________________________________ A6474X320 VLSV/00 5.39

Mechanical assemblies ________________________________________ Conveyor power unit The conveyor power unit drives the hydraulic pump (s) and pick breaker reducer (Fig. 36). It consists of a 125 HP electric motor coupled a hydrostatic pump and piggyback gear 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. 36: Conveyor power unit main components

Connecting tube

Motor (125 HP)

Hydrostatic pump

Gear pump

Tail shaft The feeder breaker is equipped with a tail shaft (Fig. 37) 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. 37: Tail shaft components Set screw (2)

Slide plate

Adapter (2)

Key (2)

Sprocket (2)

Head shaft

Bearing (2)

________________________________________________________________ 5.40 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Coupling

_______________________________________ Mechanical assemblies Breaker and breaker power unit assembly The breaker and breaker power unit (Fig. 38) are assembled so that they can be installed and removed as a unit or as separate assemblies.

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.

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).

Fig. 38: Breaker and breaker power unit assembly

© BUCYRUS AMERICA, INC.

Breaker shaft

Under speed sensor Breaker power unit

______________________________________________________________ A6474X320 VLSV/00 5.41

Mechanical assemblies ________________________________________ Breaker assembly The breaker assembly (Fig. 39) 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.

Breaker power unit The breaker power unit (Fig. 40) drives the pick breaker. It consists of a 150 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. 40: Breaker power unit Flexible coupling Taperlock bushing

Electric motor Taperlock bushing

Reducer

Companion flange

Torque limiter

Connecting tube

________________________________________________________________ Conveyor chain not shown 5.42 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 39: Breaker assembly main components

_______________________________________ Mechanical assemblies Tailpiece assembly The tailpiece assembly (Fig. 41) 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.

© BUCYRUS AMERICA, INC.

Fig. 41: Tailpiece assembly

Impact bed

Steering cylinder Tilt cylinder

Belt pulley

______________________________________________________________ A6474X320 VLSV/00 5.43

Mechanical assemblies ________________________________________ Belt spreader assembly The belt spreader assembly (Fig. 41) attaches to the mobile tailpiece of the feeder breaker. It consists of an upper and lower belt spreader, two lift cylinders for the upper belt spreader, and two lift cylinders for the lower belt spreader.

The belt spreader assembly is used to position the belt height during belt structure removal and installation.

Fig. 41: Belt spreader assembly

© BUCYRUS AMERICA, INC.

Upper belt spreader

Upper belt spreader cylinder

Lower belt spreader cylinder

Lower belt spreader

Upper belt spreader

Lower belt spreader

________________________________________________________________ 5.44 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ 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.

■

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

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus America, Inc. spare parts when replacing components.

■

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

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this Bucyrus America, Inc. 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. ______________________________________________________________ A6474X320

VLSV/00

5.45

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.

■

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.

■

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

■

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

■

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.

________________________________________________________________ 5.46 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ 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 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Description Every 8 hours of operation Head shaft bearings Head shaft bearing seals Breaker bearings Tail shaft and slide tube bearings Hydraulic oil level (check) Charge filter (check) Pressure filter (auxiliary circuit) (check) Return filter (check) Pressure filter (hydrostatic) (check) Bits (breaker) Weekly Crawler track take-up bearings Conveyor chain tension Fasteners (nuts, bolts and screws) Electrical cables, conduits and glands Hydraulic hoses and connections Tram reducer (s) (check oil level)

Breaker reducer (check) Conveyor reducer (check) Dust system strainer (check) Charge filter (change) Tailpiece bearing Every 2 weeks Pressure filter (auxiliary circuit) (change) Return filter (change) Pressure filter (hydrostatic) (change) Monthly Power fill filter (check/change as required) Conveyor tilt cylinders (rod and base) Conveyor lift cylinders (rod and base) Crawler anchor pin (s) Foot cylinder Every 3 months Breaker electric motor Conveyor electric motor Breaker reducer (grease) Torque limiter (check clutch wear) First 500 hours then every 2500 hours **Breaker reducer (change) **Conveyor reducer (change)

Places

Lubricant

Specification

2 2 2 4 1 1 2 1 1 Inspect

Spec. 100-3

2 1 Inspect Inspect Inspect 2

Spec. 100-3

1 1 1 1 2

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

Spec. 100-2 or Spec. 100-13 Century 220 Century 220

Spec. 100-3

2 1 1 1 4 4 2 4

Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3

2 2 2 1 1 1

Spec. 100-3 Spec. 100-3 Spec. 100-3

Century 220 Century 220

** Change reducer oil after first 500 hours of operation and every 2500 hours afterwards.

______________________________________________________________ A6474X320 VLSV/00 5.47

Maintenance _________________________________________________ Table 2 Continued: Lubrication and maintenance schedule Item 36 37

38 39 40 41 42 43 44

Description Every 6 months Hydraulic oil tank (change) Tram reducer (change oil)

Places

Lubricant

Specification

1 2

As required Non-bypass filter, aux pressure (change) Non-bypass filter, conveyor (change) Grease manifolds - location reference Belt pulley manifold Conveyor motor manifold Breaker motor manifold Main manifold Headshaft bearing seal manifold

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

2 1

Table 3: Lubricants: Fluids and capacities Location Hydraulic oil tank Breaker reducer Tram reducer

Grease points

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

Approximate capacity

Notes

175 gal (663 L) 10 gal (38 L) 2.5 gal per side (10 L per side) As required

________________________________________________________________ 5.48 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

27

     

32

43,44

5,36 6,8,9,20, 23,24,39

   

    

   

    

  

   

  

42

U .S .A .

3

31     

28      

10     

________________________________________________ Maintenance

Fig. 42: Lubrication chart

12

4

26

11

30 7,22,38

33

16,37

17,34

41

19

29

25

21

1,2

40

______________________________________________________________ A6474X320 VLSV/00 5.49

Maintenance _________________________________________________ Lubrication and inspection Maintenance includes: ■

lubrication of the machine in accordance with the lubrication schedule.

■

inspection of the machine for faults and proper function.

■

inspection of wear parts.

Lubrication IMPORTANT! The is equipped with a central lubrication system that allows several lubrication points to be lubricated from a central point. In addition, there are several smaller lubrication manifolds on the machine. central lubrication manifold

head shaft bearing seal lubrication manifold

The central lubrication manifold (Fig. 43) is located on the right hand side of the receiving end of the feeder breaker. This allows the following to be easily lubricated from a central point; head shaft bearings, breaker shaft, tail shaft, and tail shaft bearings.

Mounted directly beneath the central lubrication manifold is the head shaft bearing seal lubrication manifold (Fig. 43). The Taconite seals on the head shaft bearings are lubricated from this manifold.

tailpiece belt pulley lubrication manifold

The tailpiece belt pulley manifold (Fig. 43) is located beside the belt pulley on the right hand side of the machine. Both tailpiece belt pulley bearings are lubricated from this manifold.

conveyor motor lubrication manifold

The conveyor motor lubrication manifold (Fig. 43) is located below the heat exchanger on the right hand side of the machine. The manifold is used to lubricate the bearings on the electric conveyor motor.

breaker motor lubrication manifold

The breaker motor lubrication manifold (Fig. 43) is located to the left of the primary operator’ s station on the right hand side of the machine and is used to lubricate the electric breaker motor’ s bearings.

________________________________________________________________ 5.50 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance Fig. 43: Lubrication manifold locations Breaker motor lubrication manifold Head shaft bearing seal lubrication manifold

Central lubrication manifold

           

  

     

  

    

 

P R M

I N

O U D L Y A D E T H E

   

  

    

    

U .S . A .

Conveyor motor lubrication manifold Tailpiece pulley bearing lubrication manifold

______________________________________________________________ A6474X320 VLSV/00 5.51

Maintenance _________________________________________________ Specific lubrication and maintenance procedures Every 8 hours of operation head shaft bearings

Lubricate the feeder breaker head shaft bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 44) located on the right side of the receiving section. Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

head shaft bearing seals

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

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 the central lubrication panel (Fig. 44) located on the right side of the receiving section.

Pump grease into the four (4) fittings until new grease can be observed coming out of the tail shaft and bearings.

breaker bearings

Lubricate the breaker bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 44) located on the lright side of the receiving section. Pump grease into the fittings until new grease can be observed coming out of the bearing return lines.

Fig. 44: Lubrication panels

Head shaft bearing (right side)

Head shaft bearing (left side)

Head shaft bearing seal (right side)

Breaker shaft (right side)

Head shaft bearing seal (right side)

Breaker shaft (left side)

Tail shaft bearing (right side)

Tail shaft (right side)

Tail shaft bearing (left side)

Breaker shaft grease return (2)

Tail shaft (left side)

________________________________________________________________ 5.52 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance hydraulic oil tank

Check the feeder breaker hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 45). The oil level should not be allowed to drop below the bottom of the sight glass. If the hydraulic oil level is low, add oil Spec. 100-1.

Fig. 45: Hydraulic tank oil level

Oil level sight glass

charge filter

Check the feeder breaker charge filter’ s pop-up style dirt alarm ( Fig. 46) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

pressure filter (auxiliary circuit)

Check the two (2) auxiliary circuit pressure filter’ s pop-up style dirt alarm (Fig. 46) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

return filter

Check the return filter’ s pop-up style dirt alarm (Fig. 46) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

pressure filter (hydrostatic)

Check the hydrostatic pressure filter’ s pop-up style dirt alarm (Fig. 46) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

Fig. 46: Filter locations

Hydrostatic pressure filter

Charge pressure filter

Return pressure filter

Auxiliary pressure filter

Auxiliary pressure filter

______________________________________________________________ A6474X320 VLSV/00 5.53

Maintenance _________________________________________________ breaker bits

Check the breaker bits (Fig. 47) 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. 47: Breaker bits Breaker bits

________________________________________________________________ 5.54 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 48) 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. 48: Crawler track take-up lubrication

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

conveyor chain tension

fasteners

electrical cables, conduits and glands hydraulic hoses and fittings

Check the conveyor chain tension. With the machine running, visually inspect tail shaft to ensure shaft is turning and conveyor chain is not sliding across tail shaft. If adjustment is necessary, see Conveyor chain adjustment procedure in this chapter.

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.

______________________________________________________________ A6474X320 VLSV/00 5.55

Maintenance _________________________________________________ charge filter

Change the charge filter element (Fig. 49). If the element is extremely dirty, a more frequent interval may be required.

Fig. 49: Hydraulic charge filter

Charge filter

Charge pressure filter

tram reducer (s)

Check the oil level in both tram reducer torque hubs (Fig. 50):  Oil level/fill plug should be at the 3 o’ clock and 12 o’ clock position.  Remove the oil level/fill plugs.  The oil level should be kept at the level of the level/fill plug.  Should it be necessary to add oil, add 80W-90 oil through the fill plug hole until it begins to flow out of the check hole.  Do not overfill the reducer.

Fig. 50: Tram reducer oil level

Fill plug location

Drain plug location

Check plug location

________________________________________________________________ 5.56 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance breaker reducer

Check oil level in the breaker drive reducer (Fig. 51). Oil level should be maintained inside the sight glass on the side of the reducer when it is in operation. If the reducer does not have a sight glass, a pipe plug will be installed in the side of the reducer slightly below the input shaft center line. This is the level that the fluid should be maintained at. The oil should be changed after the first 500 hours of operation. Use Century 220 lubricant.

Fig. 51: Breaker reducer

Sight glass

conveyor reducer

Check oil level in the conveyor drive reducer (Fig. 52). Oil level should be maintained inside the sight glass on the side of the reducer when it is in operation. The oil should be changed after the first 500 hours of operation. Use Century 220 lubricant.

Fig. 52: Conveyor reducer

Sight glass

______________________________________________________________ A6474X320 VLSV/00 5.57

Maintenance _________________________________________________ dust system strainer

Clean the strainer mounted inside the dust suppression system. Open ball valve (Fig. 53) and allow water to flow from the short attached hose. The flowing water will flush out the filter strainer.

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

Regulator

Dust system pressure gauge

tailpiece bearing (belt pulley)

Strainer

Ball valve

Short hose

Grease the tailpiece bearing (2 places) through the grease manifold (Fig. 54) located on the right hand side of the machine with Spec. 1003. Pump new grease into the fitting until old grease can be observed coming out of the bearing.

Fig. 54: Tailpiece bearing (belt pulley) Grease manifold

________________________________________________________________ 5.58 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance Every 2 weeks pressure filter (auxiliary circuit)

Change the two (2) pressure filter’ s element (Fig. 55). If the element is extremely dirty, a more frequent interval may be required.

return filter

Change the return filter’ s element (Fig. 55). If the element is extremely dirty, a more frequent interval may be required.

pressure filter (hydrostatic)

Change the hydrostatic pressure filter’ s element (Fig. 55). If the element is extremely dirty, a more frequent interval may be required.

Fig. 55: Filter location Charge pressure filter

Hydrostatic pressure filter

Auxiliary pressure filter

Return pressure filter

Auxiliary pressure filter

Monthly power fill filter

Check the power fill filter element (Fig. 56) and change as necessary depending on the frequency of tank fill system. If the element is extremely dirty, a more frequent interval may be required.

Fig. 56: Power fill filter

Power fill filter

______________________________________________________________ A6474X320 VLSV/00 5.59

Maintenance _________________________________________________ conveyor tilt cylinders

Lubricate grease fittings on the rod and base ends of the conveyor tilt cylinders with Spec. 100-3 (Fig. 57). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 57: Conveyor tilt cylinders

Tilt cylinder (2) (grease fitting located on rod and base end)

conveyor lift cylinders

Lubricate grease fittings on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 58). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 58: Conveyor lift cylinders Lift cylinder (2) (grease fitting located on rod and base end)

crawler anchor pins

Lubricate grease fittings on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 59). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 59: Crawler anchor pins

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

________________________________________________________________ 5.60 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance foot cylinder

Grease the foot cylinder (2) through the fittings located on the rod and cylinder eye (4 places) (Fig. 60) with Spec. 100-3. Pump new grease into the fitting until old grease can be observed coming out of the bushing.

Fig. 60: Foot cylinder grease points

Foot cylinder (2) (grease fitting located on rod and base end)

Every 3 months 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. 61) 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. 61: Breaker electric motor

Electric motor central lubrication panel

______________________________________________________________ A6474X320 VLSV/00 5.61

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. 62) 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. 62: Conveyor electric motor

Electric motor central lubrication panel

breaker reducer

Lubricate the reducer with Spec. 100-3 through the three (3) grease fittings located on the reducer (Fig. 63) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

Fig. 63: Breaker reducer lubrication

Grease fitting

Grease fitting (2)

________________________________________________________________ 5.62 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance torque limiter

Check torque limiter clutch disk wear as shown. Clutch disk must be changed when 3.46”is measured as shown in Fig. 64.

Fig. 64: Torque limiter clutch wear 3.55”New thickness 3.46”Worn thickness

______________________________________________________________ A6474X320 VLSV/00 5.63

Maintenance _________________________________________________ Every 2500 hours breaker drive reducer

Change the oil in the breaker drive reducer (Fig. 65). The reducer oil should be changed after the first 500 hours of operation and ever 2500 hours afterwards.

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 inspection cover.  Add lubricant, Spec. 100-6, as required until fluid is visible in sight glass or begins to flow from the sight glass (if removed) that is slightly below the center line of the input shaft.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Install inspection cover.  Do not overfill reducer.

Fig. 65: Breaker reducer Inspection cover (fill access)

Drain plug

Fill plug (alternate)

Sight glass

________________________________________________________________ 5.64 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance conveyor drive reducer

Change the oil in the conveyor drive reducer (Fig. 66). The reducer oil should be changed after the first 500 hours of operation and ever 2500 hours afterwards.

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.  Add lubricant, Spec. 100-6, as required until fluid is visible in sight glass or begins to flow from the sight glass (if removed) that is slightly below the center line of the input shaft.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Install inspection cover.

Fig. 66: Conveyor reducer Fill plug

Sight glass

Drain plug

______________________________________________________________ A6474X320 VLSV/00 5.65

Maintenance _________________________________________________ Every 6 months hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank (Fig. 67).  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. 67: Hydraulic tank oil level

Drain plug (not shown)

Oil level sight glass

________________________________________________________________ 5.66 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance tram reducer

Change oil in the tram reducer (Fig. 68).  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. 68: Tram reducer oil change

Fill plug location when at 12 o’ clock

Check plug location when at 3 or 9 o’ clock

To drain, position a plug at 6 o’ clock

______________________________________________________________ A6474X320 VLSV/00 5.67

Maintenance _________________________________________________ Inspection of the feeder breaker 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.

________________________________________________________________ 5.68 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance Inspection of wear parts on the feeder breaker 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

______________________________________________________________ A6474X320 VLSV/00 5.69

Maintenance _________________________________________________ Inspection of fire suppression system on the feeder breaker To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 69).  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.

________________________________________________________________ 5.70 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ 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.

______________________________________________________________ A6474X320 VLSV/00 5.71

Maintenance _________________________________________________ Recharge of fire suppression system on the feeder breaker To return your fire suppression system to service after use (Fig. 69).  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.

________________________________________________________________ 5.72 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

________________________________________________ Maintenance Fig. 69: Fire suppression system

Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Breaker coupling Nozzle

Operator’ s station

Nozzle Nozzle Breaker motor Nozzle

Nozzle

Oil tank LP canister

LP expellant

______________________________________________________________ A6474X320 VLSV/00 5.73

Maintenance _________________________________________________

________________________________________________________________ 5.74 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_______________________________________ 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. 70):  Close the needle valve on manifold assembly securely.  Attach a grease gun to the grease fitting located on the manifold and apply grease until the required pressure is attained. Sight across the bottom of the head shaft sprocket. The chain should sag 1 1/2”to 2”below the bottom of the head shaft sprocket.  After tensioning chain, remove the allen head bolts from the tail shaft retainers and lift out retainers.  Insert shims over cylinder rod to maintain gap between bearing and end plate of box. Measure the exposed rod length on the grease take-up cylinders and make sure they are within 1/4”of each other.

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.  Allow tail shaft pressure to rest completely on shims.  Replace retainers.  Release pressure on the take-up cylinders by opening the top valve to vent grease. After grease has vented, close valve.

______________________________________________________________ A6474X320 VLSV/00 5.75

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.  Store any unused shims under cover plate.

Fig. 70: Conveyor chain adjustment

Shims

Needle valve (2)

Grease fitting (2)

________________________________________________________________ 5.76 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Shim storage

_______________________________________ 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 tension on the crawler track with the take-up cylinders proceed as follows (Fig. 71):  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.  Chain sag should be 1 3/4”at the center of the crawler.  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.  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.  Run crawler in forward direction for 3 minutes at slow speed.  Run crawler in reverse direction for 3 minutes at slow speed.  Shutdown machine.  If necessary, re-adjust chain sag.  Add or remove required amount of shims to maintain correct tension.  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.  Install shim retainer plate.

WARNING! Due to grease cylinder being under high pressure, do not visually inspect to see if grease is released. You could be seriously injured from high pressure grease.  Store and secure any unused shims on back of crawler cover plate.

______________________________________________________________ A6474X320 VLSV/00 5.77

Adjustment procedures ________________________________________ Fig. 71: Crawler track adjustment

Access cover

© BUCYRUS AMERICA, INC.

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)

________________________________________________________________ 5.78 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_______________________________________ Adjustment procedures Underspeed sensor calibration To calibrate the underspeed sensor (Fig. 72), proceed as follows:  Start the feeder breaker (see Startup procedure in this chapter).  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.  Turn Speed 1 control switch left (ccw) until it stops (approximately 7 o’ clock).  Hold test/set switch (SW1) in the set position to engage relay (RY1).  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.  Continue turning Speed 1 control right (cw) until margin LED (LED 4) begins to blink.  The control relay will drop out with the above at a 15% slow down.  For a 20% margin, adjust the Speed 1 control so that the margin light (LED 4) is continuously on.  For a 10% margin, turn the Speed 1 control left (ccw) until the margin light (LED 4) turns off.  After the relay status LED is illuminated, return the test/set switch to the run position.  A momentary test position is provided to simulate the loss of sensor signal, which releases the relay.

______________________________________________________________ A6474X320 VLSV/00 5.79

Adjustment procedures ________________________________________ Fig. 72: Under speed senor calibration

© BUCYRUS AMERICA, INC.

Bottom panel - starter enclosure

________________________________________________________________ 5.80 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_______________________________________ Adjustment procedures Hydrostatic pump relief valve adjustment The hydrostatic pump used to drive the conveyor chain on the feeder breaker has two main pressure relief valves and one charge relief valve (Fig. 73). The main relief valves are preset at 5,000 psi and the charge relief valve at 350 psi.

To adjust the main relief: WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.  1. Locate the forward direction pressure port on the hydrostatic pump (Fig. 73) and remove the forward pressure hose from the pump. Plug the hose end and cap the pump fitting.

WARNING! The hose plug and the fitting cap must be properly torqued before proceeding as the system pressure will reach 5,000 psi. Failure to do so may result in serious injury or death.  2. Turn the machine on (refer to Start up section in this chapter).

IMPORTANT! Do not run the pump for a long period of time while setting the reliefs as all of the flow will be going over the relief. Excessive pump operation with the lines plugged will result in overheating and the eventual failure of the pump.  3. Two people are required to adjust pressure settings. One person must move the conveyor direction valve handle to the forward direction, monitor the pressure gauges, relay pressure gauge readings to the mechanic making the adjustments, and be ready to shutdown the machine via the panic bar, if necessary. The second person will perform the actual pressure adjustment at the hydrostatic pump (Fig. 73).

WARNING! Two people are required to adjust the pressure settings. One person must move the conveyor direction valve handle to the forward direction and remain at the conveyor controls and panic bar at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

The conveyor forward pressure must be adjusted if the system pressure gauge does not read 5,000 psi when the conveyor direction valve is placed in the forward direction.

If the system pressure gauge does read 5,000 psi during the conveyor forward relief pressure test, then proceed to Step 8.  4. Locate the corresponding relief pressure adjustment valve for the forward pressure port (Fig. 73).

______________________________________________________________ A6474X320 VLSV/00 5.81

Adjustment procedures ________________________________________  5. Loosen the hex jam nut by turning counterclockwise.  6. Insert an internal hex key into the pressure adjustment screw and turn the internal hex key clockwise to increase the conveyor relief pressure setting and counterclockwise to decrease the conveyor relief pressure setting.

NOTICE! While adjusting the relief pressure, if the system pressure gauge reading is not changing, it must be determined that the conveyor direction valve handle is in the correct position and that the corresponding pump pressure port hose was disconnected and plugged. To resolve this issue, place the conveyor direction valve handle in the opposite direction.  7. Monitor the system pressure gauge until the desired 5,000 psi pressure relief setting is obtained for the conveyor pressure.  8. Lock the pressure adjustment screw in place by turning the hex jam nut clockwise while still holding the pressure adjustment screw with the internal hex key so as not to alter the desired pressure setting. Once the hex jam nut is snugged down, observe the system pressure gauge to ensure the relief pressure setting was not accidentally changed during the tightening of the hex jam nut. If the relief pressure setting has changed, loosen the hex jam nut and readjust the pressure to 5,000 psi with the adjustment screw.  9. Return the conveyor direction valve handle to the neutral position and turn the machine off.  10. Cautiously remove the hose plug and fitting cap from the conveyor pressure hose and the pump pressure port. Adhere to all safety procedures when performing this step. Install the pressure hose to the pressure port on the pump.

WARNING! The hose fitting must be properly torqued before proceeding as the system pressure will reach 5,000 psi. Failure to do so may result in serious injury or death.  11. Return to Step 1 and repeat the adjustment procedure for the conveyor reverse pressure relief setting.  12. Restart the machine and check for leaks at the pressure ports of the hydrostatic pump by positioning the conveyor direction control valve in both forward and reverse direction.

________________________________________________________________ 5.82 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

CAUTION! Do not turn the adjustment screw in any further once it is felt that the screw has bottomed out as this may damage the needle valve and seat. Likewise, do not turn the adjustment screw out all the way as this may present difficulties in reassembly and may introduce contamination into the hydraulic pump.

_______________________________________ Adjustment procedures Hydrostatic pump charge pressure adjustment WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.  1. Start the machine (see Start-up procedure in this chapter).  2. The charge pressure gauge (Fig. 75) should read 350 psi while the machine is at idle, the conveyor direction valve handle is in neutral, and the oil temperature is between 90°F and 110°F. Locate the charge pressure adjustment screw (Fig. 73).

Note: The charge pressure will drop slightly (as low as 290 psi) while the conveyor is running. This is normal and does not require further adjustment after initial setting.

Note: The charge pressure will vary depending on oil temperature (the hotter the oil, the lower the pressure and the cooler the oil, the higher the pressure). This is normal and does not require further adjustment after initial setting.  3. Insert an internal hex key into the pressure adjustment screw and turn the internal hex key clockwise to increase the charge pressure setting and counterclockwise to decrease the charge pressure setting.

CAUTION! Do not turn the adjustment screw in any further once it is felt that the screw has bottomed out as this may damage the needle valve and seat. Likewise, do not turn the adjustment screw out all the way as this may present difficulties in reassembly and may introduce contamination into the hydraulic pump.  4. Monitor the charge pressure gauge until the desired 350 psi pressure setting is obtained for the charge pressure.  5. Lock the pressure adjustment screw in place by turning the hex jam nut clockwise while still holding the pressure adjustment screw with the internal hex key so as not to alter the desired pressure setting. Once the hex jam nut is snugged down, observe the charge pressure gauge to ensure the relief pressure setting was not accidentally changed during the tightening of the hex jam nut. If the charge pressure setting has changed, loosen the hex jam nut and readjust the pressure adjustment screw.  6. Turn off the machine.

______________________________________________________________ A6474X320 VLSV/00 5.83

Adjustment procedures ________________________________________ Fig. 73: Pump relief valves Charge pressure relief adjustment System pressure relief adjustment, forward: located directly across from forward system pressure port

System pressure port, forward

System pressure port, reverse

________________________________________________________________ 5.84 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

System pressure relief adjustment, reverse: located directly across from reverse system pressure port

_______________________________________ Adjustment procedures Fig. 74: Valve banks

Lift, right

Tram, left

Tram, right

Lift, left

Tilt

Sends flow to secondary valve bank - used for setting secondary valve bank pressure relief

Auxiliary system pressure gauge

Charge pressure gauge

Auxiliary system pressure gauge

______________________________________________________________ A6474X320 VLSV/00 5.85

Adjustment procedures ________________________________________ Loop flushing valve adjustment WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.

The loop flushing valve (Fig. 75) is mounted on the frame behind the breaker power unit. The valve is preset from the factory at 290 psi, which is measured by the charge pressure gauge while the conveyor is running.

If an adjustment is required:

 Two people are required to adjust the pressure setting. One person must move the conveyor direction valve handle to the forward direction, relay pressure gauge readings to the mechanic making the adjustment, and be ready to shutdown the machine via the panic bar, if necessary.

WARNING! Two people are required to adjust the pressure setting. One person must move the conveyor direction valve handle to the forward direction and remain at the panic bar at all times during the adjustment procedure. Failure to do so may result in serious injury or death.  Operate the conveyor directional control lever to run the conveyor.  Loosen the jam nut on the adjustment hex by turning out (ccw).  Turn the adjustment hex in (cw) to increase the setting or turn out (ccw) to decrease the setting.  When the correct setting is obtained, tighten the jam nut on the adjustment stem by turning in (cw) while holding the adjustment hex in place.

________________________________________________________________ 5.86 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

 Start the machine (see Start up procedure in this chapter).

_______________________________________ Adjustment procedures Fig. 75: Loop flushing valve Jam nut and adjustment hex Loop flushing valve

Charge pressure gauge

______________________________________________________________ A6474X320 VLSV/00 5.87

Adjustment procedures ________________________________________ Dual relief manifold relief valve adjustments WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.

The dual relief manifold (Fig. 76) is mounted on the frame behind the breaker power unit. The purpose of the two relief valves is to limit the maximum pressure to each of the inlet sections on the primary valve bank. The design pressure setting is 2,250 psi. The setting for each relief is read from the corresponding auxiliary pressure gauge while deadheading a function. The top relief cartridge (2) limits the pressure into the first inlet section (both left sections and left tram) while the bottom relief cartridge (1) limits pressure to the mid-inlet section (right tram, tilt, and power fill).

 Two people are required to adjust the pressure setting. One person must operate the lift cylinder valve handle on the primary valve bank, relay pressure gauge readings to the mechanic making the adjustment, and be ready to shutdown the machine via the panic bar, if necessary. The second person will perform the actual pressure adjustment at the dual relief manifold.

WARNING! Two people are required to adjust the pressure setting. One person must operate the lift cylinder valve handle and remain at the panic bar at all times during the adjustment procedure. Failure to do so may result in serious injury or death.  Measure the setting of cartridge 2 by fully extending or retracting (deadheading) one of the lift cylinders, then reading the pressure on “AUXILIARY PRESSURE #2”gauge while the cylinder is deadheaded. The reading should be 2,250 psi.

WARNING! The feeder will move during this step and it must be ensured that all standard safety procedures are adhered to in order to avoid personnel injury and equipment damage. Do not operate the tram function during this adjustment procedure as it is unsafe. Failure to adhere to this warning may result in serious injury or death.  Loosen the jam nut on the relief by turning out (ccw).  Turn the hex key adjustment in (cw) to increase the setting or out (ccw) to decrease the setting.  Once the desired setting is obtained, tighten the jam nut by turning in (cw) while hold the hex key in place.

________________________________________________________________ 5.88 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

To adjust relief cartridge 2:

_______________________________________ Adjustment procedures To adjust relief cartridge 1:  Two people are required to adjust the pressure setting. One person must operate the tilt cylinder valve handle on the primary valve bank, relay pressure gauge readings to the mechanic making the adjustment, and be ready to shutdown the machine via the panic bar, if necessary. The second person will perform the actual pressure adjustment procedure at the dual relief manifold.

WARNING! Two people are required to adjust the pressure setting. One person must operate the tilt cylinder valve handle and remain at the panic bar at all times during the adjustment procedure. Failure to do so may result in serious injury or death.  Measure the setting of cartridge 1 by fully extending or retracting (deadheading) the tilt cylinders, then reading the pressure on “AUXILIARY PRESSURE #3”gauge while the cylinders are deadheaded. The reading should be 2,250 psi.

WARNING! The feeder will move during this step and it must be ensured that all standard safety procedures are adhered to in order to avoid personnel injury and equipment damage. Do not operate the tram function during this adjustment procedure as it is unsafe. Failure to adhere to this warning may result in serious injury or death.  Loosen the jam nut on the relief by turning out (ccw).  Turn the hex key adjustment in (cw) to increase the setting or out (ccw) to decrease the setting.  Once the desired setting is obtained, tighten the jam nut by turning in (cw) while hold the hex key in place.

______________________________________________________________ A6474X320 VLSV/00 5.89

Adjustment procedures ________________________________________ Fig. 76: Dual relief manifold Relief cartridge 2

Dual relief manifold

© BUCYRUS AMERICA, INC.

Relief cartridge 1

“AUXILIARY PRESSURE #2”

“AUXILIARY PRESSURE #3”

________________________________________________________________ 5.90 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_______________________________________ Adjustment procedures Secondary valve bank relief adjustment The secondary valve bank (Fig. 77) is fitted with a relief in the inlet section. The designed setting is 2,250 psi.  Two people are required to adjust the pressure setting. One person must operate the foot cylinder valve handle on the secondary valve bank and adjust the relief valve cartridge. The second person will relay pressure gauge readings to the mechanic making the adjustment and will be ready to shutdown the machine via the panic bar, if necessary.

WARNING! Two people are required to adjust the pressure setting. One person must operate a stabilizer cylinder valve handle and adjust the relief. The second person must remain at the panic bar at all times during the adjustment procedure. Failure to do so may result in serious injury or death.  Measure the setting of cartridge by fully retracting (deadheading) the foot cylinders, then reading the pressure on “AUXILIARY PRESSURE #3”gauge while the cylinder is deadheaded. The reading should be 2,250 psi.

WARNING! Use caution when retracting foot cylinders. When tension is release off of the belt pulley, the feeder breaker may lurch forward.

Make sure all personnel are clear of the machine when performing this procedure.  Loosen the jam nut on the relief cartridge by turning out (ccw).  Turn the adjustment screw in (cw) to increase the setting and out (ccw) to decrease the setting.  Once the correct setting is obtained, tighten the jam nut by turning in (cw) while holding the adjustment screw in place.

______________________________________________________________ A6474X320 VLSV/00 5.91

Adjustment procedures ________________________________________ Fig. 77: Secondary valve bank adjustment

Adjustment screw

Roof/foot cylinder valve handle, right

Diversion valve, left hand (push in for foot cylinder, out for roof cylinder)

Diversion valve, right hand (push in for foot cylinder, out for roof cylinder)

“AUXILIARY PRESSURE #3”

________________________________________________________________ 5.92 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Roof/foot cylinder valve handle, left

_______________________________________ Adjustment procedures Flow control valve adjustment This flow control valve (Fig. 78) is used to control the heat exchanger fan speed by limiting the flow allowed to the heat exchanger motor.

The fan is designed to operate at 3,450 rpm, which requires an approximate flow rate of 3.3 gpm to the motor. The pump section driving the motor produces approximately 4.7 gpm.

The flow control is an adjustable orifice that allows flow to bypass the motor. It also acts as a relief in this circuit, therefore it should never be fully closed as it could cause hose or component failure.

WARNING! The flow control valve should never be fully closed as it acts as a relief in this circuit. Fully closing the flow control valve could cause hose or component failure, resulting in machine damage or injury to personnel.

Turning the adjustment in (cw) closes the flow control and thus limits the amount of bypass flow, increasing fan speed. Turning the adjustment out (ccw) opens the flow control, allowing more flow to bypass, decreasing fan speed.

There are three ways to set the flow control valve: 1. Using a tachometer:  Using the tachometer to adjust fan speed is a two person job: one person will point the tachometer and the other person will adjust the flow control.  Put a piece of reflective tape on the end of a fan blade.  Start the machine (see Startup procedure in this chapter).  Point a tachometer at the fan to measure the fan speed.  Adjust the flow control out (ccw) to decrease fan speed and in (cw) to increase fan speed.

2. Using a flow meter:  Hard plumb a flow meter between the tee going to the flow control valve and the heat exchanger motor (or use a jumper hose).  Adjust the flow control out (ccw) to increase flow or in (cw) to decrease flow until a flow rate of 3.3 gpm is obtained.

3. Using a pressure gauge:  Add a pressure gauge to the inlet motor.  Adjust flow control to maintain 500 psi at the motor. The motor operates at approximately 500 psi to maintain the designed fan speed.

______________________________________________________________ A6474X320 VLSV/00 5.93

Adjustment procedures ________________________________________

Heat exchanger motor

Flow control valve

Flow control valve adjustment

________________________________________________________________ 5.94 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 78: Flow control valve adjustment

____________________________________ Replacement of wear parts

Instructions on the replacement of wear parts on the feeder breaker 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 (Link-Belt) in the parts manual.

Head shaft

© BUCYRUS AMERICA, INC.

The head shaft (Fig. 79) transmits the torque of the hydraulic motor to the conveyor chain assembly. It is part of a complete assembly. As soon as any component is worn, the component or complete head shaft must be replaced. Due to the 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

■

bearings

■

hydraulic motor

Fig. 79: Head shaft main components

Sprocket (2)

Head shaft Key (2)

Sprocket (4)

Bearing (2)

______________________________________________________________ A6474X320 VLSV/00 5.95

Replacement of wear parts _____________________________________ How to remove the head shaft To remove the head shaft assembly from the feeder breaker proceed as follows (Fig. 80):  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Remove the two (2) sprocket guards located over the head shaft sprockets.  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the last cover on the right hand side of the machine.  Remove the last cover’ s support post.

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.  Unpin and fold down tailpiece tilt cylinders. It is not necessary to remove hydraulic hoses.  Remove the tailpiece hoppers (2) and head shaft filler plates (2) using appropriate lifting equipment.

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.  Remove the hydraulic motor.

CAUTION! The hydraulic motor is heavy. Use proper lifting techniques.  Disconnect, tag, and cap all hydraulic hoses.  Remove the five bolts from the end of the motor.  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 the frame is equipped with a notch to allow for the passage of the reducer housing.  Disconnect, tag and cap the central lubrication hoses on both head shaft bearings and head shaft bearing seals.

________________________________________________________________ 5.96 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

 Block and secure tailpiece.

____________________________________ Replacement of wear parts  Remove the four (4) nuts, bolts, and lock washers from each of the head shaft bearings. Note that there may be bearing shims under the bearing. If shims are present, make note of their thichness, quantity and location.  Attach an appropriate lifting device to the head shaft 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 head shaft

© BUCYRUS AMERICA, INC.

To install the head shaft assembly proceed as follows (Fig. 80):  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 and installed into feeder if the feeder frame is equipped with an access notch.  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.  Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) nuts, bolts, and lock washers. Torque bolts to 645 ft-lbs.

WARNING! The headshaft must turn freely by hand. If the headshaft does not turn freely by hand, the bearings will fail prematurely.  Install the left and right sprocket guards, head shaft filler plates, tailpiece hoppers, amd tailpiece tilt cylinders.  Connect the central lubrication hoses on both head shaft bearings.  Install the hydraulic motor onto the input shaft of the gear reducer.  Install the five 1/2”X 2 1/4”hex head mouting bolts, lock washers, and flat washers and torque to 104 ft-lbs.  Reconnect hydraulic hoses.  Install the conveyor gear reducer (see Conveyor gear reducer removal/installation procedure in this chapter). The gear reducer may have been installed with the headshaft if the feeder breaker frame is equipped with an access notch. Fill with Century 220 lubricant to oil is visible in the sight glass.  Clean and lubricate splined end of head shaft with ISO 68 hydraulic fluid.

______________________________________________________________ A6474X320 VLSV/00 5.97

Replacement of wear parts _____________________________________  Install cover support post and cover.  Connect conveyor chain. (See Conveyor chain replacement in this chapter).  Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

Fig. 80: Head shaft removal and installation

Conveyor chain (not shown) Nut 1”

Male clevis Swivel bearing

Female clevis

Cotter pin Head shaft Pin Hydraulic motor

Hex bolt (5) 1/2”X 2 1/4”NC Hex bolt (8) 1”X 5”NC

Splined adapter Flat washer

Shaft retainer

Retaining bolt M20 X 2.5 X 100 10.9

Reducer end cover

Access notch

________________________________________________________________ 5.98 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Lock washer

____________________________________ Replacement of wear parts Head shaft sprockets The head shaft sprocket transmits the torque of the hydraulic motor to the conveyor chain assembly. It is part of the head shaft 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 head shaft sprockets To remove the sprockets from the head shaft assembly proceed as follows (Fig. 81):  Remove the head shaft assembly from the feeder (see Head shaft removal in this chapter).  Remove the two (2) bearings from the head shaft.

© BUCYRUS AMERICA, INC.

 Remove the two (2) set screws from each sprocket. It may be necessary to apply heat because the screw are reained witth Loctite.  Slide both sprockets from the drive shaft.  Remove old keys.  Inspect all components of the drive shaft for wear and damage.

See parts manual for replacement parts list.

How to install the head shaft sprockets To install the sprockets on the head shaft proceed as follows (Fig. 81):  Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.  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. 81 for weld spcifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.  Insert the other key into the shaft keyway and slide second sprocket onto shaft (see Fig. 81 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.  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. One of the bearings must have the internal spacer remvoed to allow the shaft to float and not be in a bind.  Install the drive shaft assembly in the feeder breaker. (See Drive shaft installation in this chapter.) ______________________________________________________________ A6474X320

VLSV/00

5.99

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. 81): IMPORTANT! Adhere to all weld specifications shown on Fig. 81. Failure to do so may result in sprocket failure and machine damage.  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the two (2) sprocket guards located on the end of the feeder breaker.

 Thoroughly clean and degrease the drive shaft.  Insert key into shaft keyway.  Install both sprocket halves onto shaft and tack weld in place (see Fig. 81 for location). Ensure sprocket alignment and proper spacing with conveyor chain.  Preheat sprocket weld joint to 600°F .  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.  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.  Connect conveyor chain. (See Conveyor chain replacement in this chapter).  Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

________________________________________________________________ 5.100 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Fig. 81: 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)

© BUCYRUS AMERICA, INC.

Sprocket (2) & key (2)

Hydraulic motor

General notes: 1.

2.

3.

Conveyor chain

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)

______________________________________________________________ A6474X320 VLSV/00 5.101

Replacement of wear parts _____________________________________ Tail shaft The tail shaft (Fig. 82) allows for even adjustments and friction free transition to the conveyor chain assembly. As soon as any component of the tail shaft is worn the component or complete tail shaft assembly must be replaced. Due to the high abrasion forces the tail shaft is subject to a very high level of wear.

■

shaft

■

sprocket (2)

■

slide plate weldment

■

key

■

sprocket set screw

■

take-up bearing (2)

■

piston rod adapter (2)

■

take-up bearing set screw (4)

© BUCYRUS AMERICA, INC.

The tail shaft assembly consists of the following main components:

Fig. 82: Tail shaft main components

Sprocket set screw

Slide plate

No key

Piston rod adapter (2)

Key

Set screw

Set screw

Set screw

Set screw

Sprocket (2)

Tail shaft

No set screw

Bearing (2)

________________________________________________________________ 5.102 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

____________________________________ Replacement of wear parts How to remove the tail shaft To remove the tail shaft assembly from the receiving end of the feeder breaker proceed as follows (Fig. 83):  Remove the RTV silicone from five (5) bolt heads and remove the bolts from each end of the tail shaft retainers and lift out the retainers.  Release tension on the conveyor chain by removing the tail shaft shims. (See Conveyor chain adjustment in this chapter).  Disconnect, tag and cap the central lubrication hoses to the tail shaft.  Separate conveyor chain and fold back to clear tail shaft. (See Conveyor chain replacement in this chapter).

© BUCYRUS AMERICA, INC.

 It may be necessary to unpin the take-up cylinders from the feeder frame and remvoe the cylinder rod from the take-up bearing.  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 tail shaft assembly into the receiving end of the feeder breaker proceed as follows (Fig. 83):  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.  Install the take-up cylinder rod into the take-up bearing and insert take-up cylinder pin throught the mounting clevis on the frame. It may be necessary to loosen the set screws of the bearing retainer coolars and reposition the bearings so that the bearing slots are aligned with the frame guide bars.  Fold the conveyor chain over tail shaft.  Connect conveyor chain (see Conveyor chain replacement in this chapter.  Connect central lubrication hoses and lubricate the tail shaft slide plate and take-up bearings with Spec. 100-3 grease.

______________________________________________________________ A6474X320 VLSV/00 5.103

Replacement of wear parts _____________________________________  Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).  Install the tail shaft retainers with the five (5) bolts in each side and fill the bolt heads with RTV silicone.  With machine running, visually inspect tail shaft to ensure that the chain is smoothly engaging the sprockets.

Fig. 83: Tail shaft removal and installation

Cover

Shims Take-up cylinder Tail shaft slide plate

Take-up cylinder pin Tail shaft Piston rod adaptor 90° grease hose elbow

Take-up bearing

Swivel grease fitting

________________________________________________________________ 5.104 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Tail shaft retainer plates (2)

____________________________________ Replacement of wear parts How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 84):  Remove the tail shaft assembly from the feeder breaker. (See How to remove the tail shaft in this chapter).  Loosen the set screws (2 per bearing assembly) and slide both take-up bearings and piston rod adapters from the tail shaft.  Loosen the set screw from the tail shaft sprocket and slide sprockets from the shaft. Note that heat may be required to loosen set screw as Loctite was used during installation.  Remove the tail shaft from the slide plate.  Visually inspect all components for damage or wear and replace as necessary.

© BUCYRUS AMERICA, INC.

How to assemble the tail shaft To assemble the tail shaft assembly proceed as follows (Fig. 84):  Thoroughly clean all parts that will be installed.  Grease tail shaft with Spec. 100-3 grease.  Slide tail shaft into the slide plate.  Insert key into keyway on tail shaft.

WARNING! Only install a key for one sprocket. If a key is installed for both sprockets, the chain could bind due to slight length variances in the conveyor chain.  Slide both sprockets onto tail shaft, one on each end.  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.  Tighten set screw and torque to 100 ft-lb.  Install both take-up bearings onto the tail shaft, flush with the ends of the shaft.  Apply Loctite 242 (blue) to the set screw and install. Tighten and torque to 100 ft-lb.  Install swivel grease fittings in the ends of the shaft and the 90° grease hose elbows into the take-up bearings.  Install tail shaft into machine. (See How to install the tail shaft in this chapter). ______________________________________________________________ A6474X320 VLSV/00 5.105

Replacement of wear parts _____________________________________ Fig. 84: Tail shaft disassembly and assembly

Sprocket set screw

Slide plate

No key

Piston rod adapter (2)

Key

Set screw

Set screw

Set screw

Set screw

Tail shaft

No set screw

Bearing (2)

© BUCYRUS AMERICA, INC.

Sprocket (2)

________________________________________________________________ 5.106 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

____________________________________ Replacement of wear parts Conveyor chain The conveyor chain (Fig. 85) 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

© BUCYRUS AMERICA, INC.

Fig. 85: 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. 86):  Lay conveyor chain sections on a clean flat surface.  Insert connector pins through flight end and align holes in spiral pin with holes in flight bar.  Insert spiral pin.  Drive spiral pin in with a hammer and punch. Ensure that spiral pin is recessed on both sides of flight bar.  Repeat the previous assembly instructions until the complete chain has been assembled.

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:  Release tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).  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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© BUCYRUS AMERICA, INC.

Fig: 86: Conveyor chain assembly

____________________________________ Replacement of wear parts  Separate conveyor chain by removing spiral pins and connecting links in one section of the chain.  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:

© BUCYRUS AMERICA, INC.

 Check to ensure that the conveyor tail shaft is completely retracted.

If not retracted, see Conveyor chain adjustment in this chapter.  If the old conveyor chain was nut 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.  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.  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.  Ensure that the chain is properly meshed with the sprockets on the head and tail shafts.  Connect conveyor chain (see How to assemble the conveyor chain sections in this chapter for proper connection).  Adjust tension on the conveyor chain (see Conveyor chain adjustment procedure in this chapter.  With machine running, visually inspect tail shaft to ensure that the conveyor chain is properly engaged with the tail shaft sprockets.

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Replacement of wear parts _____________________________________ Crawler track The crawler track (Fig. 87) 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

■

t-pin

Fig. 87: Crawler track main components

© BUCYRUS AMERICA, INC.

Crawler pad

Connector pin and T-pin

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____________________________________ Replacement of wear parts How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 87):  Lay crawler track pads on a clean flat surface.  Align pads with chain connecting holes centered.  Insert connector into center of crawler pad connecting holes.  Drive T-pin through connecting pin and bend end to secure.  Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly

© BUCYRUS AMERICA, INC.

To remove the crawler track pad assembly proceed as follows (Fig. 87):  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.  Crawler track tension must be released (see Crawler track adjustment in this chapter).  Separate the crawler pads.

To separate the crawler pads proceed as follows (Fig. 87) IMPORTANT! Heating or cutting connections with a torch or chisel may be required to ease the removal of T- pins.  Drive or cut T-pin from crawler pad connection using hammer and punch.  Separate crawler track assembly.  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.

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Replacement of wear parts _____________________________________ WARNING! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) 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.  Inspect the crawler drive sprocket and idler rollers for wear or damage. Replace if necessary.

How to install the crawler track pad assembly To install the crawler track pad assembly proceed as follows (Fig. 87):

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.  Check to ensure that crawler track tension cylinder is completely retracted (see Crawler track adjustment in this chapter).  Slide crawler track pad assembly under crawler assembly.  Fold pad assembly over both ends of crawler assembly. Ensure that pad assembly meshes with drive sprocket and idler roller.  Connect crawler track pad assembly (see How to assemble crawler track pad assembly in this chapter for proper connection).  Adjust tension on the crawler track pad assembly (see Crawler track pad adjustment procedure in this chapter for proper adjustment).

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© BUCYRUS AMERICA, INC.

 Remove old crawler track pad assembly (see previous section, How to remove crawler track pad assembly).

____________________________________ Replacement of wear parts Crawler assembly The crawler assembly (Fig. 88) 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.

© BUCYRUS AMERICA, INC.

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. 88: 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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Replacement of wear parts _____________________________________ How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 89):  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.  Crawler track tension must be released (see Crawler track adjustment in this chapter.  Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear take-up.

 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  Remove the eight (8) bolts from the tilt cylinder mounting bracket.  Swing the tilt cylinder and mounting bracket free of the crawler frame.  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.  Inspect all components for wear or damage.

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© BUCYRUS AMERICA, INC.

 Securely block under the crawler frame.

____________________________________ Replacement of wear parts How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 89):  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.  Inspect all components for wear or damage prior to assembly.  Clean all dirt and debris from inside crawler frame.  Attach appropriate lifting device to take-up assembly and slide assembly completely into the end of crawler frame.

© BUCYRUS AMERICA, INC.

 Install and connect crawler and track pad assembly, see How to install the crawler track pad assembly in this chapter.  Swing the tilt cylinder and mounting bracket into crawler frame and secure with the eight (8) bolts, washers and nuts.  Connect hydraulic hoses to tilt cylinder.  Purge hydraulic system of air.  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. 89: Crawler take-up removal and installation

Tilt cylinder mounting bracket Crawler take-up

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© BUCYRUS AMERICA, INC.

Tilt cylinder

____________________________________ Replacement of wear parts How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 90):  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.  Crawler track tension must be released (see Crawler track adjustment in this chapter).  Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear sprocket.

© BUCYRUS AMERICA, INC.

 Disconnect, cap and tag all hydraulic hoses to hydraulic motor.  Remove slotted nut, roll pin and washer from lift cylinder anchor pin.  Remove anchor pin from crawler frame and crawler guide weldment.  Remove the six (6) bolts and lock washers that secure the removable side plate to crawler frame and remove side plate.  Remove the twelve (12) bolts and lock washers that secure the torque hub to the crawler frame.  Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.  Remove the four (4) bolts and lock washers that secure the hydraulic motor and adapter plate to the torque hub.  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.  Remove the adapter plate and motor from the torque hub as an assembly.  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.

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Replacement of wear parts _____________________________________  Thoroughly clean and degrease the adapter plate mating face.  Remove the twenty (20) bolts and lock washers that secure the sprocket to the torque hub and separate hub and sprocket.  Inspect all components for wear or damage.

How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 90):  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.

 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

 Thoroughly clean and degrease the adapter plate and mating faces of the torque hub and hydraulic tram motor.  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.  Place hydraulic motor gasket onto motor adapter plate.  Apply Loctite 518 to the second side of the motor gasket.  Install adapter plate and gasket onto hydraulic motor and secure with the four (4) nuts and lock washers. Apply Loctite 242 (blue) to nuts.  Apply Loctite 518 to the adapter plate gasket.  Place adapter plate gasket onto the adapter plate.  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.  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. ________________________________________________________________

5.118

Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

 Inspect all components for wear or damage prior to installation.

____________________________________ Replacement of wear parts ■ ■ ■

Step 1: 25 ft-lb Step 2: 50 ft-lb Step 3: 70 ft-lb

 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.  Clean all dirt and debris from mounting area of crawler frame.  Attach an appropriate lifting device to the torque hub and slide complete assembly into crawler frame.

© BUCYRUS AMERICA, INC.

 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

 Connect hydraulic hoses to drive motor.  Install and connect crawler and track pad assembly (see How to install the crawler track pad assembly in this chapter).  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

 Apply grease to anchor pin and slide anchor pin through crawler frame and tilt cylinder. Secure pin with slotted nut, washer and roll pin.  Purge hydraulic system of air.  Adjust crawler track pad tension (see How to adjust crawler track pad tension in this chapter).

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Replacement of wear parts _____________________________________

1.

2.

3.

4.

5.

6.

7.

8.

9.

crawler frame torque hub Washer (allen lock) bolt sprocket washer (lock) bolt gasket (adaptor plate) plate (adaptor)

10.

11.

12.

13.

14.

15.

16.

17.

18.

washer (lock) bolt gasket washer (flat) nut keeper washer (lock) bolt crawler pad

19.

20.

21.

22.

23.

24.

25.

bushing bushing pin (crawler anchor) washer (flat) nut (castle) pin (cotter) removable sideplate

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© BUCYRUS AMERICA, INC.

Fig. 90: Crawler drive disassembly and assembly

____________________________________ Replacement of wear parts Breaker shaft and breaker power unit The breaker power unit and the breaker shaft assembly can be removed and installed as a single assembly or as two separate assemblies.

Fig. 91 and 92 show the breaker power unit and breaker shaft installed in the machine.

Fig. 91: Breaker power unit and breaker shaft removal/installation

© BUCYRUS AMERICA, INC.

Breaker shaft

Breaker power unit

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Replacement of wear parts _____________________________________

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Breaker assembly Hex head bolt, 1-1/4X4-1/2 (24) Lock washer, 1-1/4 (24) Hex nut, 1-1/4 (24) Stub shaft Socket head shoulder screw, 1X3 (12) Lock washer, 3/4 (12) Hex nut, 3/4 (12) Key Power unit assembly Pivot lug weldment Pivot lug mount plate

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

Power unit reaction pin Lock washer, 1”(4) Hex head bolt, 1X2-1/4 (4) Cotter pin, 3/8X4 (2) Breaker shaft guard weldment U-bolt, 2X3-3/4X3/8-16 Lock washer, 7/8 (7) Flat washer, 7/8 (4) Hex nut, 7/8 (4) Hex head bolt, 4/8X2-3/4 (4) End cap Hex head bolt, 7/8X2-1/2 (3)

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© BUCYRUS AMERICA, INC.

Fig. 92: Breaker shaft and breaker power unit assembly removal/installation

____________________________________ Replacement of wear parts How to remove the breaker shaft and breaker power unit assembly To remove the breaker shaft and power unit as a single assembly proceed as follows (Fig. 92).  Turn the machine main circuit breaker (CB1) to the “OFF”position.  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.

© BUCYRUS AMERICA, INC.

 Remove the roof anchor cylinder and roof cylinder mount weldment as an assembly (see roof anchor cylinder removal/installation procedure in this section).  Remove the central grease manifold from the cover support weldment. It is not necessary to remove the grease hoses from the manifold.  Remove the area light from the cover support weldment. It is not necesssary to remove the area light electrical cable.  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.  Remove the primay operator’ s station mounting hardware from the cover support structure and remove the junction box access panel of the electric motr. Disconnect the cable leads from the motor leads. Tag for assembly purposes.  Remove and cap all grease lines from the breaker shaft, gear reducer, and electric motor.  Remove the under speed sensor and shaft guard.  Attach an appropriate lifting device to the breaker shaft and power unit assembly. Take all slack out of the lifting device in order to support the assembly when mounting hardward is removed.  Remove the hardware from the breaker side plates and the power unit reaction pin.  Lift the breaker shaft and power unit out of the machine as an assembly.

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Replacement of wear parts _____________________________________ How to install the breaker shaft and power unit assembly To install the breaker shaft and breaker power unit as a single assembly proceed as follows (Fig. 93).  Attach an appropriate lifting device to the complete unit 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.  Install the power unit reaction pin and the hardware into the breaker side plates.  Remove the lifting device.

 Remove caps and install all grease lines to the breaker shaft, gear box, and electric motor.  Install the primary operator’ s station.  Install all power unit and breaker covers.  Install the area light on to the cover support weldment.  Install the central grease manifold.  Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.  Install the roof anchor cylinder and roof cylinder mount weldment (see roof anchor cylinder removal/installation procedure in this section).

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.  Unlock and remove tags from electric power at the power center.  Turn the machine circuit breaker on.  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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© BUCYRUS AMERICA, INC.

 Install the shaft guard and under speed sensor on the gear box.

Note: distance from the sensor end to end cap target is approximately 1/8”to 1/4”.

____________________________________ Replacement of wear parts How to remove the breaker power unit assembly To remove the breaker power unit proceed as follows (Fig. 93).  Turn the machine main circuit breaker (CB1) to the “OFF”position.  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.

© BUCYRUS AMERICA, INC.

 Remove the roof anchor cylinder and roof cylinder mount weldment as an assembly (see Roof anchor cylinder removal/installation procedure in this section).  Remove the central grease manifold from the cover support weldment. Grease hoses do not need to be removed from the manifold.  Remove the area light from the cover support weldment. It is not necesssary to remove the area light electrical cable.  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.  Remove the primay operator’ s station mounting hardware from the cover support structure and remove the junction box access panel of the electric motr. Disconnect the cable leads from the motor leads. Tag for assembly purposes.  Remove and cap all grease lines from the gear reducer and electric motor.  Remove the under speed sensor and shaft guard.  Attach an appropriate lifting device to the power unit assembly.

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.  Remove the bolts that connect the breaker shaft bolt flange to the stub shaft.  Remove the power unit reaction pin.  Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.  Lift the power unit out of the machine. ______________________________________________________________ A6474X320 VLSV/00 5.125

Replacement of wear parts _____________________________________ How to install the breaker power unit assembly To install the breaker power unit proceed as follows (Fig. 93).  Attach an appropriate lifting device to the power unit 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.  Install the power unit reaction pin.  Bolt the breaker shaft bolt flange to the stub shaft.  Remove the lifting device.

 Remove caps and install all grease lines to the gear box and electric motor.  Install the primary operator’ s station.  Install all power unit covers.  Install the area light on to the cover support weldment.  Install the central grease manifold.  Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.  Install the roof anchor cylinder and roof cylinder mount weldment (see roof anchor cylinder removal/installation procedure in this section).

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.  Unlock and remove tags from electric power at the power center.  Turn the machine circuit breaker on.  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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© BUCYRUS AMERICA, INC.

 Install the shaft guard and under speed sensor on the gear box.

Distance from sensor end to end cap target is approximately 1/8”to 1/4”.

____________________________________ Replacement of wear parts How to remove the breaker shaft assembly To remove the breaker shaft assembly proceed as follows (Fig. 93).  Turn the machine main circuit breaker (CB1) to the “OFF”position.  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.

© BUCYRUS AMERICA, INC.

 Remove all 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.  Remove and cap all grease lines from the breaker shaft.  Properly support the breaker shaft reducer so that it does not fall during breaker shaft removal. Ensure that he power unit reaction pin is in place and not removed during this procedured.  Attach an appropriate lifting device to the breaker shaft. Take all slack out of the lifting device in order to support the assembly when mounting hardward is removed.  Remove the hardware from the breaker side plates.  Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.  Lift the breaker shaft out of the machine.

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Replacement of wear parts _____________________________________ How to install the breaker shaft assembly To install the breaker shaft assembly proceed as follows (Fig. 93).  Attach an appropriate lifting device to the breaker shaft 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.  Install the hardware into the breaker side plates.  Install hardware to attach breaker shaft bolt flange to stub shaft in gear reducer.  Remove support from under gear reducer.

 Remove caps and install all grease lines to the breaker shaft.  Install all breaker covers.  Turn the machine circuit breaker on.  Unlock and remove tags from electric power at the power center.  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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© BUCYRUS AMERICA, INC.

 Remove lifting device from breaker shaft.

____________________________________ Replacement of wear parts How to disassemble the breaker power unit To disassemble the breaker power unit proceed as follows (Fig. 93):  Remove complete unit from machine. (See breaker shaft and breaker power unit removal/installation procedure in this section.)  Cut the bolt safety wire from the end of the three cap retainer bolts.  Remove the end cap bolts, lockwashers, and end caps.  Attach an appropriate lifting device to the breaker shaft and remove from the hollow output shaft of the gear reducer.

© BUCYRUS AMERICA, INC.

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! Bucyrus America, Inc. does not recommend field disassembly or repair of the breaker shaft. If the breaker shaft requires repair, please consult your Bucyrus America, Inc. service representative.  Install a lifting eye into the top of the electric motor.  Attach an appropriate lifting device to the electric motor.  Remove the connecting tube access cover.  Remove the three socket head cap screws from the taperlock bushing on the electric motor shaft.  Install two bolts back into the taperlock bushing mounting/ unmounting screw holes and separate the taperlock bushing from the flex coupling.  Remove the electric motor from the connecting tube by removing eight bolts and lock washers.  Remove the gear reducer from the connecting tube by removing the twelve bolts and lock washers.  Remove the flex coupling from the torque limiter by removing eight M12 bolts and lock washers.  Remove the torque limiter from the companion flange by removing the twelve 7/16”bolts and lock washers.  Remove the three bolts from the taperlock bushing on the gear reducer input shaft.  Install two bolt back into the mounting/unmounting holes and separate the taperlock bushing from the companion flange.

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Replacement of wear parts _____________________________________ How to assemble the breaker power unit To assemble the breaker power unit proceed as follows (Fig. 93):  Install 1/2”key in keyway of high speed shaft of the gear reducer.  Install 2 3/8”taper lock bushing and companion flange onto high speed shaft of the gear reducer. See Fig. 92 for correct orientation and location on shaft. Torque bolts to 104 ft-lbs.  Install torque limiter onto companion flange using twelve 7/16”UNF bolts and lockwashers. Torque to 67 ft-lbs.  Install 7/8”key into motor shaft.  Install flexible coupling and taperlock bushing onto motor shaft.

Install three taperlock bushing bolts (refer to Fig. 92 for proper location on electric motor shaft). Torque to 104 ft-lbs.

 Install electric motor, flexible coupling, and taperlock bushing subassembly onto connecting tube using eight bolts. Torque to 379 ftlbs.  Bolt the flexible coupling onto the torque liimiter using eight M12 bolts and lockwashers. Torque to 379 ft-lbs.  Refer to Fig. 93 for correct clearance between flex coupling jaws and coupling element.  If clearance is incorrect, loosen the taper lock bushing bolts and reposition the taperlock bushing accordingly. Retorque the bolts to 90 ft-lbs.  Install the connecting tube access cover.  Apply Never Seez to breaker shaft end and install key into keyway.  Install breaker shaft into hollow gear reducer low speed shaft.  Install end cap, lockwashers, bolts, and safety wire.  Install shaft guard onto gear reducer.

________________________________________________________________ 5.130 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

 Install connecting tube onto gear reducer using twelve bolts and lockwashers. Torque to 379 ft-lbs.

____________________________________ Replacement of wear parts Fig. 93: Breaker shaft and power unit disassembly and assembly Breaker shaft

End cap retainer bolts and safety wire (located behind weldment)

© BUCYRUS AMERICA, INC.

End cap (located behind weldment)

Shaft guard weldment

______________________________________________________________ A6474X320 VLSV/00 5.131

Replacement of wear parts _____________________________________ Fig. 93: Breaker shaft and breaker power unit disassembly and assembly (continued) Connecting tube access cover Taper lock busing

Flexible coupling

Taper lock bushing

Electric motor

Torque limiter

Companion flange

Gear reducer

Socket head bolt (8) M12 X 1.75 X 35

Socket head bolt (3) 1/2”-13 X 1 1/2”

Hex bolt (12) 3/4”X 2”

Socket head bolt (12) 7/16-20 X 1 1/4”NF

Socket head bolt (3) 1/2”-13 X 1 1/2”

________________________________________________________________ 5.132 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Hex bolt (8) 3/4”X 2”

____________________________________ 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)

■ connecting tube ■

coupling

■

hydrostatic pump

■

piggyback gear pump

Fig. 94: Conveyor power unit main components

© BUCYRUS AMERICA, INC.

Electric motor

Connecting tube

Coupling

Case drain

Motor mounts Hex bolt (8) 5/8 X 1 3/4 NC

Gear pump Hydrostatic pump

Hex bolt (4) 1/2 X 1 1/2 Grade 2

Hex bolt (4) 3/4 X 2 NC

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Replacement of wear parts _____________________________________ How to remove the conveyor power unit (Fig. 94)  Turn the main circuit breaker on the feeder breaker to the “OFF” position.  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.  Remove the covers.

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.  Disconnect, tag, and cap all hydraulic hoses.  Disconnect grease lines to conveyor electric motor.  Remove access cover on junction box of conveyor and motor and remove the cable leads from the motor leads.  Reinstall junction box cover.  Remove the four bolts that secure the motor to the frame.  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.

________________________________________________________________ 5.134 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

 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.

____________________________________ Replacement of wear parts How to install the conveyor power unit (Fig. 94)  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.  Align the electric motor foot bolt holes with the mounting plate bolt hoes.  Install the four 3/4”diameter hex bolts, washers, and nuts. Torque to 380 ft-lbs.

© BUCYRUS AMERICA, INC.

 Connect hydraulic hoses.  Ensure that the hydrostatic pump is primed. To prime the hydrostatic pump, remove the case drain fitting (see Fig. 94) and pour hydraulic fluid (Spec. 100-1) until the pump housing is full.  Connect grease lines to the electric motor.  Remove junction box cover.  Attach motor leads to cable leads and seal junction box cover. Follow all Federal, State, and mine regulations.  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.  Remove four bolts, lock washers, and flat washers and remove gear pump. Save the o-ring and splined pump insert from the rear of the hydrostatic pump.

 Remove the 1/2”bolt and lock washer from hinged access cover on the connecting cover and open the access cover.  Loosen the two socket head cap screw bolts that retain the Rotex coupling half to the hydrostatic pump splined shaft.  Remove the four bolts, lock washers, and flat washers on the hydrostatic pump.

CAUTION! The hydrostatic pump is heavy. To avoid injury, use proper lifting techniques.  Slide the hydrostatic pump shaft, coupling hub, and element clear of the connecting tube.  Remove the eight bolts, lock washers, and flat washers and then remove the connecting tube.  Loosen the set screw from the coupling hub on the electric motor shaft and slide the hub off of the shaft.  Remove the key from the electric motor shaft.

________________________________________________________________ 5.136 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

IMPORTANT! Remove and save the o-ring and splined pump insert from the rear of the hydrostatic pump.

____________________________________ Replacement of wear parts How to assemble the conveyor power unit (Fig. 94)  Install the key in the electric motor shaft.  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.  Install the element onto the coupling hub on the electric motor.  Apply Never Seez onto the hydrostatic pump splined shaft. Install the remaining coupling hub onto the hydrostatic pump splined shaft (refer to Fig. 93 for dimensions).

© BUCYRUS AMERICA, INC.

 Clean all mating surfaces on the connecting tube and the electric motor.  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.  Install the hydrostatic 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.  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 93 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.  Check coupling half alignment by using a straight edge across the two coupling halves (see Fig. 95). 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.  Apply Loctite 242 (blue) to the set screw on the coupling hub of the electric motor shaft and torque to 275 in-lbs.  Remove the end plate from the hydrostatic pump in order to install the piggy back gear pump by removing the four bolts.  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 your Bucyrus America, Inc. parts manual that shipped with your machine).

 Install the gear pump being careful to properly align the splines and not cut the o-ring.  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

________________________________________________________________ 5.138 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

 Apply clean hydraulic fluid to the shaft of the piggy back gear pump and to the o-ring of the hydrostatic pump.

____________________________________ Replacement of wear parts Fig. 95: Conveyor power unit disassembly/assembly

© BUCYRUS AMERICA, INC.

Electric motor to coupling mating surface

Place straight edge along this edge to determine alignment

______________________________________________________________ A6474X320 VLSV/00 5.139

Replacement of wear parts _____________________________________ How to remove the breaker bit To remove the breaker bit from the breaker shaft bit holder proceed as follows (Fig. 96):  Remove the external retaining rings from the shank end of the bit with a pair of external retaining ring pliers.  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

 Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.  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. 96: Breaker bit removal and installation

Retaining rings Bit holder

Breaker bit

________________________________________________________________ 5.140 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 96):

____________________________________ Replacement of wear parts Installing the tailpiece To install the tailpiece on the feeder breaker (Reference Fig. 97: 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.  Install spacer blocks (Item 14) into the underside of the tailpiece weldment (Item 6).  Make sure that bolts (Item 37) will pass through the bearing spacers and the tailpiece weldment.  Tack weld bearing spacer blocks (Item 14) to tailpiece weldment (Item 6).

© BUCYRUS AMERICA, INC.

 Install belt pulley assembly (Item 15) using hex bolts, flat washers, hex nuts, and lock washers (Items 37, 36, 35, and 22).  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).  Install slider assembly (Item 18) using flat washers, lock washers, hex nuts, and bolts (Items 27, 28, 29, and 30).  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).  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.  Position the assembled knuckle joint and the tailpiece frames to the main frame. (Reference Figure 10 for placement). Install pins (Item 5).  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).  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).  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).

______________________________________________________________ A6474X320 VLSV/00 5.141

Replacement of wear parts _____________________________________  Refer to the hydraulic schematic (Fig. 98) for hydraulic installation of the cylinders. Route all hoses, avoiding pinch points, so that hose damage does not occur.

© BUCYRUS AMERICA, INC.

Fig. 97: 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

________________________________________________________________ 5.142 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 97: Tailpiece installation (continued)

Detail A

______________________________________________________________ A6474X320 VLSV/00 5.143

Replacement of wear parts _____________________________________

© BUCYRUS AMERICA, INC.

Fig. 98: Hydraulic schematic

________________________________________________________________ 5.144 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

____________________________________ Replacement of wear parts Roof cylinder and roof cylinder mount weldment removal and installation To remove the roof cylinder (reference Fig. 99):  Fully retract the roof cylinder.  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  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.

© BUCYRUS AMERICA, INC.

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.  Attach an appropriate lifting device to the roof cylinder and roof cylinder mounting weldment.

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.  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.  Remove the sixteen bolts, two rows of four on each side of the mounting weldment, that attach the mounting weldment to the frame. NOTE: It is not necessary to remove the mount weldment if the roof cylinder only is being replaced. If the roof cylinder is being replaced, skip this step.  Lift the cylinder and weldment off of the feeder breaker. NOTE: If the roof cylinder only is being replaced, skip this step.  Remove the eight bolts, four on each side of the cylinder, that attach the roof cylinder to the mounting weldment.

______________________________________________________________ A6474X320 VLSV/00 5.145

Replacement of wear parts _____________________________________ To install the roof cylinder (reference Fig. 99):  Attach an appropriate lifting device to the roof cylinder and position the roof cylinder in the mounting weldment.

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.  Install the eight bolts, four on each side of the cylinder, to secure the roof cylinder to the mounting weldment.

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.  Position the cylinder and mounting weldment on the feeder breaker. NOTE: If the roof cylinder only is being replaced, omit this step.  Install the sixteen bolts, two rows of four on each side of the mounting weldment, that attach the mounting weldment to the frame.

Note: If the roof cylinder only is being replaced, omit this step.  Reconnect the hydraulic hoses to the cylinder.  Restore power to the feeder breaker.

Fig. 99: Roof cylinder removal and installation

Roof cylinder

Cylinder mounting bolts (8)

Roof cylinder mounting weldment

Mounting weldment bolts (16)

________________________________________________________________ 5.146 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

 Attach an appropriate lifting device to the roof cylinder and roof cylinder mounting weldment. NOTE: If the roof cylinder only is being replaced, the mounting weldment will still be bolted to the machine frame. Attach an appropriate lifting device to the roof cylinder only.

____________________________________ Replacement of wear parts Foot cylinder removal and installation To remove a foot cylinder (reference Fig. 100):  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  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.

© BUCYRUS AMERICA, INC.

 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.  Remove the cotter pin from the outrigger arm pin, remove the castle nut, and washer and pull the outrigger arm pin.  Remove the two cotter pins from the cylinder eye pin and pull the cylinder eye pin.

To install a foot cylinder (reference Fig. 100):  Mount the cylinder eye to the outrigger mount plate.  Position the cylinder eye in the outrigger mount plate clevis.  Insert the cylinder eye pin through the cylinder eye and outrigger mount plate clevis.  Install the two cotter pins through the cylinder eye pin.  Position the foot clevis on the rod eye and align the rod eye in the outrigger arm weldment.  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.  Reconnect the hydraulic hoses to the cylinder.  Reconnect power to the machine.  Purge the hydraulic system of air.

______________________________________________________________ A6474X320 VLSV/00 5.147

Replacement of wear parts _____________________________________ Fig. 101: Foot cylinder removal and installation

Washer Outrigger foot Outrigger arm pin

Castle nut

Cotter pin

Foot cylinder

Cotter pin (2)

Outrigger arm

Cylinder pin

Outrigger mount plate

Detail A

________________________________________________________________ 5.148 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

See detail A

____________________________________ Replacement of wear parts Tilt cylinder removal and installation To remove a tilt cylinder (reference Fig. 101):  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  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.

© BUCYRUS AMERICA, INC.

 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.  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.  Pull a cotter pin out of the pin through the cylinder eye and remove the pin.  Pull a cotter pin out of the pin through the rod eye and remove the pin.

To install a tilt cylinder (reference Fig. 101):  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.  Align the cylinder in the mounting clevises on the machine.  Install the pin through the cylinder eye and secure with a cotter pin.  Install the pin through the rod eye and secure with a cotter pin.

______________________________________________________________ A6474X320 VLSV/00 5.149

Replacement of wear parts _____________________________________  Reconnect the hydraulic hoses to the cylinder.  Reconnect power to the machine.  Purge the hydraulic system of air.

© BUCYRUS AMERICA, INC.

Fig. 101: Tilt cylinder removal and installation

Pin (2 places)

Cotter pin (4) (2 per pin)

Tilt cylinder (2)

________________________________________________________________ 5.150 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

____________________________________ Replacement of wear parts Lift cylinder removal and installation To remove a lift cylinder (reference Fig. 102):  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  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.

© BUCYRUS AMERICA, INC.

 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.  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.  Pull a cotter pin out of the pin through the cylinder eye and remove the pin.  Pull a cotter pin out of the pin through the rod eye and remove the pin.

To install a lift cylinder (reference Fig. 102):  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.  Align the cylinder in the mounting clevises on the machine.  Install the pin through the cylinder eye and secure with a cotter pin.  Install the pin through the rod eye and secure with a cotter pin.

______________________________________________________________ A6474X320 VLSV/00 5.151

Replacement of wear parts _____________________________________  Reconnect the hydraulic hoses to the cylinder.  Reconnect power to the machine.  Purge the hydraulic system of air.

Cotter pin (4) (2 per pin)

Pin (2 places)

Lift cylinder (2)

________________________________________________________________ 5.152 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 102: Lift cylinder removal and installation

____________________________________ Replacement of wear parts

Tailpiece tilt cylinder removal and installation To remove a tailpiece tilt cylinder (reference Fig. 103):  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  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.

© BUCYRUS AMERICA, INC.

 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.  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.  Pull cotter pin out of the pin through the cylinder eye.  Pull cotter pin out of the pin through the rod eye.

To install a tailpiece tilt cylinder (reference Fig. 103):  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.  Align the cylinder in the mounting clevises on the machine.  Install the pin through the cylinder eye and secure with a cotter pin.  Install the pin through the rod eye and secure with a cotter pin.

______________________________________________________________ A6474X320 VLSV/00 5.153

Replacement of wear parts _____________________________________  Reconnect the hydraulic hoses to the cylinder.  Reconnect power to the machine.  Purge the hydraulic system of air.

Cotter pin (4) (2 per eye) Pin (2) Tailpiece tilt cylinder

________________________________________________________________ 5.154 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 103: Tailpiece tilt cylinder removal and installation

____________________________________ Replacement of wear parts

Tailpiece steering cylinder removal and installation To remove a tailpiece steering cylinder (reference Fig. 104):  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  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.

© BUCYRUS AMERICA, INC.

 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.  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.  Pull cotter pin out of the pin through the cylinder eye.  Pull cotter pin out of the pin through the rod eye.

To install a tailpiece steering cylinder (reference Fig. 104):  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.  Align the cylinder in the mounting clevises on the machine.  Install the pin through the cylinder eye and secure with a cotter pin.  Install the pin through the rod eye and secure with a cotter pin.

______________________________________________________________ A6474X320 VLSV/00 5.155

Replacement of wear parts _____________________________________  Reconnect the hydraulic hoses to the cylinder.  Reconnect power to the machine.  Purge the hydraulic system of air.

Pin (2) Tailpiece steering cylinder

Cotter pin (4) (2 per eye)

________________________________________________________________ 5.156 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 104: Tailpiece steering cylinder removal and installation

____________________________________ Replacement of wear parts Belt spreader cylinder removal and installation To remove a belt spreader cylinder (Fig. 103):  If removing the upper belt spreader cylinder, position the upper belt spreader at its lowest position and securely block. If removing the lower belt spreader cylinder, position the lower belt spreader at ground level.  Shut down the feeder breaker (See Shutdown procedure in this chapter).

© BUCYRUS AMERICA, INC.

 Turn the circuit breaker to the “OFF”position. Disconnect and lock and tag out the main power source. Follow all Federal and mine practices for locking and tagging out a power source.

WARNING! Before performing maintenance on a machine, the circuit breaker should be in the “OFF”position and the power supply should be locked and tagged out at the main power source. Failure to do so may result in electrical shock or accidental machine movement.  Disconnect, tag, and cap all 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 the hose is disconnected while circuit pressurized, the load will fall and accidental machine movement could occur. Machine damage or serious injury or death may result.  Attach an appropriate lifting device to the cylinder, taking up the slack so that the weight of the cylinder rests on the lifting device.

WARNING! Observe the safe working load limit of all lifting devices. Serious injury or death can occur from falling loads.  Disconnect the rod end of the cylinder from the belt spreading lifting arm by removing the two (2) cotter pins from the retaining pin and knocking out the pin.  Disconnect the tube end of the cylinder from the frame by removing the two (2) cotter pins from the retaining pin and knocking out the pin.

______________________________________________________________ A6474X320 VLSV/00 5.157

Replacement of wear parts _____________________________________ Fig. 204: Belt spreader cylinder removal

Belt spreader upper cylinder

Belt spreader upper cylinder (rod end pin)

Belt spreader upper lift arm

© BUCYRUS AMERICA, INC.

Belt spreader upper cylinder (cylinder tube pin - behind bracket)

Belt spreader lower cylinder (cylinder tube pin)

Belt spreader lower cylinder

Belt spreader lower cylinder (rod end pin)

Belt spreader lower lift arm

________________________________________________________________ 5.158 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

____________________________________ Replacement of wear parts To install a belt spreader cylinder (Fig. 103):  Position the tube end of the cylinder in the mounting clevis located on the frame.  Install a retaining pin through the clevis and cylinder eye and secure by installing a cotter pin in each end of the retaining pin.  Position the rod end of the cylinder in the mounting clevis located on the belt spreader lifting arm.  Install a retaining pin through the clevis and rod eye and secure by installing a cotter pin in each end of the retaining pin.  Reconnect the hydraulic hoses to the cylinder.

© BUCYRUS AMERICA, INC.

 Reconnect power to the machine.

______________________________________________________________ A6474X320 VLSV/00 5.159

Replacement of wear parts _____________________________________ Upper belt spreader removal and installation To remove the upper belt spreader (Fig. 204):  Position the upper belt spreader at its lowest position. Attach a lifting device to the upper belt spreader, taking up slack so that the weight of the upper belt spreader rests on the lifting device.  Shut down the feeder breaker (See Shutdown procedure in this chapter).  Turn the circuit breaker to the “OFF”position. Disconnect and lock and tag out the main power source. Follow all Federal and mine practices for locking and tagging out a power source.

 Attach a lifting device to the lifting arm, taking up slack so that the weight of the lifting arm rests on the lifting device.  Unbolt the cross tube from the lifting arm by removing the four (4) bolts that connect the two pieces. Repeat for the other end. The cross tube is now free from the lifting arms and can be set on the floor, out of the way.  While supporting the cylinder, unpin the cylinder from the lifting arm by removing the two cotter pins from the retaining pin and knocking the pin out.  Remove the end bracket by removing the six (6) bolts that secure it to the frame and the one (1) bolt that secures it to the lifting arm.

Repeat for the other end.  The lifting arms are now free to slide off of the belt spreader assembly.

________________________________________________________________ 5.160 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

WARNING! Before performing maintenance on a machine, the circuit breaker should be in the “OFF”position and the power supply should be locked and tagged out at the main power source. Failure to do so may result in electrical shock or accidental machine movement.

____________________________________ Replacement of wear parts Fig. 204: Upper belt spreader removal

Upper cross tube

© BUCYRUS AMERICA, INC.

Lower cross tube

Bolts (4 each side)

Upper lifting arm

Cylinder retaining pin Lower lifting arm

Bolts (4 each side)

Bolt (6)

End bracket

Bolt (1)

______________________________________________________________ A6474X320 VLSV/00 5.161

Replacement of wear parts _____________________________________ To install the upper belt spreader (Fig. 204):  Position the lifting arm on the belt spreader assembly.  Position the end bracket on the belt spreader assembly and secure with seven (7) bolts.  Position the cylinder rod eye in the mounting clevis on the lifting arm and install the retaining pin. Secure the retaining pin by installing a cotter pin into each end of the pin.  Bolt the cross tube to the lifting arm with four bolts on each end.

© BUCYRUS AMERICA, INC.

 Restore power to the machine.

________________________________________________________________ 5.162 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

____________________________________ Replacement of wear parts Lower belt spreader removal and installation To remove the lower belt spreader (Fig. 204):  Lower the lower belt spreader to the floor.  Remove the upper belt spreader (See Upper belt spreader removal in this chapter).  Detach the cross tube from the lower belt spreader lifting arms by removing the four (4) bolts on each end.  While supporting the cylinder, unpin the cylinder from the lifting arm by removing the two cotter pins from the retaining pin and then knocking out the retaining pin.  Slide the lifting arm off the belt spreader assembly.

© BUCYRUS AMERICA, INC.

To install the lower belt spreader (Fig. 204):  Position the lifting arm on the belt spreader assembly.  Install the upper belt spreader (See Upper belt spreader installation in this chapter).  Position the cylinder rod eye in the mounting clevis on the lifting arm and install the retaining pin. Secure the retaining pin by installing a cotter pin into each end of the pin.  Restore power to the machine.

______________________________________________________________ A6474X320 VLSV/00 5.163

© BUCYRUS AMERICA, INC.

Replacement of wear parts _____________________________________

________________________________________________________________ 5.164 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_____________________________________________ Troubleshooting Troubleshooting procedures The following section lists problems that may be encountered when servicing the feeder breaker and can aid in locating and correcting these problems.

For machine wiring diagrams, electrical schematics, and hydraulic schematics, please consult the Bucyrus America, Inc. parts manual that shipped with your machine.

© BUCYRUS AMERICA, INC.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures may require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all electrical work performed.

For maintenance procedures and tests that DO NOT require the controller to be energized, precautions include: ■

Before removing the controller cover, remove the power from the system by disconnecting the trailing cable. Follow all local, state, Federal, and mine lockout/tag out procedures.

For maintenance procedures that DO require the controller be energized while the cover is off: ■

At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be in the “OFF”position.

During any maintenance, observe the following: ■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to prevent bolts, nuts, washers, or other small metal fasteners from being dropped or lost inside the controller. These fasteners could cause electrical shorts inside the controller.

______________________________________________________________ A6474X320 VLSV/00 5.165

Troubleshooting ______________________________________________ Hydraulic troubleshooting WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall. Machine damage or injury to personnel may result.

WARNING! Never check for hydraulic leaks with your hands. Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Do not attempt to locate hydraulic leaks by feeling around hoses and fittings with bare hands. Check for leaks with a piece of cardboard.

Typical hydraulic problems

■

contaminated oil or poor oil quality

■

low or insufficient oil in the system

■

using the wrong type of oil or wrong viscosity grade

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments, such as relief valves

■

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, and other critical components

The greatest aid to troubleshooting a hydraulic system is the confidence of knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles. Every component has an intended purpose and the operating characteristics of each component should be clearly understood before attempting to troubleshoot the machine. Before troubleshooting this machine, familiarize yourself with the hydraulic schematic in the Bucyrus America, Inc. parts book that shipped with your machine.

It is important to know the capabilities of the system. Each component in the system has a maximum rated speed, flow, torque, or pressure. If the system is loaded beyond the specifications, the possibility of failure is greatly increased. The correct operating pressures of the system must be know and must always be checked and set with a pressure gauge. When in doubt, always assume that the correct pressure is the lowest pressure that will allow adequate performance of the system functions while remaining below the maximum rating of the machine’ s components.

________________________________________________________________ 5.166 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

The most common cause of improper hydraulic function are:

_____________________________________________ Troubleshooting 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 be scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this operation manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are listed below for your information.

1. Ensure that bulk oils are at acceptable cleanliness levels.

© BUCYRUS AMERICA, INC.

Areas where Bucyrus America, Inc. customers have made improvements in the past include: –

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

–

use 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

–

use filter carts to maintain oil cleanliness standards

–

properly train personnel on the importance of clean oil and best practices for storage and handling

–

monitor your 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.

–

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 the machine

–

cap off all hoses/fittings

______________________________________________________________ A6474X320 VLSV/00 5.167

Troubleshooting ______________________________________________ –

never touch a filter with bare hands when installing it in the machine

–

pay close attention to the filler/breather cap and replace it when damaged or at the recommended interval

Following are general tables, listed in a cause/remedy format, to assist in troubleshooting the feeder breaker. Before performing troubleshooting, safely shutdown and disconnect the machine as follows:  Lower or mechanically secure (block) all suspended loads.  Relieve any pressure in the system.  Isolate the electrical power supply.

© BUCYRUS AMERICA, INC.

Refer to the Shutdown procedure listed in this chapter for a detailed shutdown procedure.

________________________________________________________________ 5.168 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_____________________________________________ 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

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X320 VLSV/00 5.169

Troubleshooting ______________________________________________ Table 5: Troubleshooting excessive heat

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

________________________________________________________________ 5.170 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Pump Heated

_____________________________________________ Troubleshooting Table 6: Troubleshooting incorrect flow No Flow

© BUCYRUS AMERICA, INC.

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

F. Any or all of the following  check position of manually operated controls G.  reverse rotation H.  replace with correct unit

B. Any or all of the following:  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

______________________________________________________________ A6474X320 VLSV/00 5.171

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

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

________________________________________________________________ 5.172 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

A.  replace dirty filters and system fluid

_____________________________________________ Troubleshooting Table 8: Troubleshooting faulty operation No Movement Cause

© BUCYRUS AMERICA, INC.

No flow or pressure

Slow Movement

Remedy

Cause

See Table 5 Low flow

Erratic Movement

Excessive Speed or Movement

Remedy

Cause

Remedy

See Table 5

Erratic pressure

See Table 6

Excessive flow

See Table 5

Air in fluid

See Table 3

Overriding work load

G

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

D

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

Worn or damaged cylinder or motor

D

No lubrication of machine ways or linkage

No lubrication of machine ways or linkage

F

F

Sticking valve

C

Sticking valve

C

Worn or damaged cylinder or motor

D

Worn or damaged cylinder or motor

D

Pilot filter clogged

See Table 5

Cause

Remedy

Remedies A.  check fluid temperature  check system fluid viscosity; change if necessary B.  locate bind and repair C.  clean and adjust or replace part  check condition of system fluid and filters D.  overhaul or replace part E.  repair command console or interconnecting wires F.  lubricated G.  adjust, repair, or replace counterbalance valve

______________________________________________________________ A6474X320 VLSV/00 5.173

Troubleshooting ______________________________________________ Hydraulic system (general) Table 9: Hydraulic system (general) troubleshooting Probable cause

dirty oil 

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.

foaming oil 



Moisture in cans of replacement 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 

Replace with new cans of oil.



Excessive slippage or internal leak-  age past pump or cylinders.



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

Fluid viscosity too low. Test components for specified flow or bypass conditions.

________________________________________________________________ 5.174 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Trouble or symptom

_____________________________________________ Troubleshooting Table 9 (continued): Hydraulic system (general) troubleshooting Trouble or symptom

Probable cause 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.

© BUCYRUS AMERICA, INC.

foreign matter sources  in the circuit

Test, check and/or remedy

______________________________________________________________ A6474X320 VLSV/00 5.175

Troubleshooting ______________________________________________ Hydraulic cylinders Table 10: Hydraulic cylinder troubleshooting Probable cause

cylinder drifts 

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.



Repair as required or replace cylinder.



Contamination in hydraulic system resulting in scored cylinder bore.



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). 

Piston seal leak.



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 

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.

________________________________________________________________ 5.176 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Trouble or symptom

_____________________________________________ Troubleshooting Hydraulic pump Table 11: Hydraulic pump troubleshooting Trouble or symptom

Probable cause

© BUCYRUS AMERICA, INC.

pump makes excessive noise 

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.



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).



Seal deterioration (flat spots on I.D.).

seal leak 



Clean by removing the foreign material blocking oil flow.

Replace seal.

Check pump shaft for possible bearing wear. Replace seal.

 Loose or worn pump parts.  Replace worn pump parts. ______________________________________________________________ A6474X320 VLSV/00 5.177

Troubleshooting ______________________________________________ Table 11 (continued): Hydraulic pump troubleshooting Probable cause

pump fails to deliver oil 

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.

oil leakage around pump 

________________________________________________________________ 5.178 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Trouble or symptom

_____________________________________________ 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.



Check oil level and refill to design level for proper operation. Replace pump and filter elements.

Excessive system pressure above maximum pump rating.



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.

© BUCYRUS AMERICA, INC.



______________________________________________________________ A6474X320 VLSV/00 5.179

Troubleshooting ______________________________________________ Valves Table 12: Valve troubleshooting Probable cause

operating pressure  cannot be changed

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.



the pressure fluctuates and there is  extreme noise in the valve

excessive leakage or  sticking pistons occurs



oil leaks  between sections

Valve excessively hot.

________________________________________________________________ 5.180 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Trouble or symptom

_____________________________________________ Troubleshooting Table 12 (continued): Valve troubleshooting Trouble or symptom

Probable cause

oil leaks at either  end of spool

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.

 spring centered spools  do not return to neutral   load will not hold 

© BUCYRUS AMERICA, INC.

Test, check and/or remedy

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.

no motion, slow, or erratic  system operation 

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.

______________________________________________________________ A6474X320 VLSV/00 5.181

Troubleshooting ______________________________________________ Bearings Table 13: Bearing troubleshooting Probable cause

overheating bearing 

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.

noisy bearing 

vibrating bearing 

unsatisfactory performance 

________________________________________________________________ 5.182 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Trouble, symptom or cause

_____________________________________________ Troubleshooting Electrical system troubleshooting This feeder breaker has two (2) modes of operation, regular mode (normal running) and tram mode (tram only). In regular mode, the pick breaker motor must start first, then the pump motor. In tram mode, only the pump motor is started.

There are nine (9) indicating lights located in the cover of the start enclosure used to help troubleshoot the feeder breaker: L1 - Control (120VAC) Power On - normally on.

L2 - High Temperature - Hydraulic oil high temperature - normally off.

L3 - Low Oil - Hydraulic oil low in the hydraulic oil tank - normally off.

L4 - Sequence Switch - Outby belt is not running - normally off

© BUCYRUS AMERICA, INC.

L5 - Underspeed - Breaker is running below a preset speed - normally off.

L6 - Safety Relay - normally off L7 - OL1 Overload - Pick breaker motor overloaded - normally off L8 - OL2 Overload - Pump motor overloaded - normally off.

L9 - Pressure Switch (hydraulic) - normally off.

If the pick breaker motor will not start, check the following.

1. Is the stop pushbutton, located in the cover, closed?

2. Is the “REG-OFF-TRAM ONLY”selector switch in the regular, “REG”, position?

3. Is the pressure switch light L( on? If so, the pressure switch has tripped.

4. Is overload light L7 on? If so, the pick breaker motor overload has tripped.

5. Is the high temperature light L2 on? If so, the oil temperature switch has tripped.

6. Is the low oil light L3 on? If so the hydraulic tank low oil switch has tripped.

7. If all the above are healthy, check the tape switch and ensure that the safety relay, “SR”, is energized.

______________________________________________________________ A6474X320 VLSV/00 5.183

Troubleshooting ______________________________________________ If the pick breaker motor starts but the pump motor will not start, check the following: 1. Is overload light L8 on? If so, the pump motor overload has tripped.

2. Is the high temperature light L2 on? IF so, the hydraulic oil temperature switch has tripped.

3. Is the sequence switch light L4 on? If so, the outby belt is not running.

© BUCYRUS AMERICA, INC.

4. Is the low oil light L3 on? If so, the hydraulic tank low oil switch has tripped.

________________________________________________________________ 5.184 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_______________________________________________________________

6

Technical data

________________________________________________________________

__________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Model 7MFBHM-48DD Feeder Breaker. 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 stock machines only.

Customer specials may not be listed.

Components of the feeder breaker Technical data sheet general

performance

Overall length: without tailpiece ................................approx. 33’(9,992 mm) with tailpiece .....................................approx. 36’6”(11,134 mm) Overall width:...........................................approx. 10”7”(3232 mm) Tramming height (min.): ..........................approx. 48”(1,199 mm) Ground clearance (min.): ........................approx. 7”(190 mm) Ground clearance (max.): .......................approx. 24”(622 mm) Receiving height (min.):...........................approx. 13”(330 mm) Discharge height (max.) ..........................approx. 48”(1,199 mm) Operating height (max.): .........................approx. 74”(1,864 mm) Level hopper capacity: ............................approx. 370 ft³ (10.5 m3) Capacity (w/ optional 12”sideboards):....approx. 420 ft³ (12 m3) Receiving impact plate: ...........................HRS + CCO wear plate Breaker impact plate: ..............................T1 + CCO wear plate Coal line material:....................................HRS + CCO wear plate Return line material: ................................HRS + CCO wear plate Mainframe side plates: ............................HRS + CCO wear plate Weight (machine only):............................approx: 80,000 lbs (36,288 kg) Material input size (max.): .......................approx. 1’x 2’x 3’ (305 mm x 610 mm x 915 mm) Maximum material strength:....................approx. 30,000 psi (207 N/mm2) Nominal output size:................................approx. 8”(203 mm) (one dimension) approx. 1”(25.4 mm) (pick to flight clearance) Discharge rate (max.):.............................approx. 1,225 TPH @ 135 fpm (1.1E6 kg/hr @ 39.6 m/min) Material to be broken:..............................Coal @ 65 lb/ft³ (1,041 kg/m3)

______________________________________________________________ A6474X320 VLSV/00 6.3

Technical data________________________________________________ conveyor chain

head shaft

tail shaft

conveyor drive

Conveyor width:................................ approx. 48”(1,232 mm) Number of strands:........................... 2 @ 280,000 psi/strand (1,931 N/m2) Ultimate Strength Chain pitch: ...................................... approx. 3 .75”(95.25 mm) Chain pin diameter: .......................... approx. 1.13”(28.7 mm) Flights: .............................................. 2 3/4”X 5”(70 mm x 127 mm) solid alloy steel Flight attachment.............................. Cross pin, not bolted w/ optional stainless steel roll pins Conveyor speed (max): .................... approx. 130 fpm (39.6 m/min) Shaft diameter: ................................. 5”(127 mm) Bearings ........................................... 2 pillow block assemblies Bearing bore: .................................... 4 15/16”(125.4 mm) Overload protection: ......................... Hydraulic relief Shaft diameter: ................................. 3 15/16”(100 mm) Bearing bore: .................................... 3 15/16”(100 mm) Take-up: ........................................... Grease cylinders w/locking shims Drive motor:...................................... 125 hp/1050v/AC/3ph/50Hz/MSHA Reducer: ........................................... Hydro-mechanical w/ 29:1 reduction Overload protection: ......................... Hydraulic relief Motor speed control:......................... Hydraulic displacement Motor/shaft coupling: ........................ Splined

breaker drive

Drive motor:...................................... 125hp/1050v/AC/3ph/50Hz/MSHA Reducer: ........................................... LC250, 25:1 reduction, Link Belt Reducer housing: ............................. Fabricated steel Motor/reducer coupling..................... Jaw type, coupled to torque limiter Reducer/shaft coupling..................... Flange type Overload protection .......................... PT Tech torque limiter

breaker

Shaft diameter: ................................. approx. 10”(254 mm) Bearing bore::................................... approx. 8”(203 mm) Pick circle diameter: ......................... approx. 32”(812 mm) Running pick force:........................... approx. 12,680 lbs (56,406 N) Pick force maximum:: ....................... approx. 116,000 lbs (516,014 N) Overload protection: ......................... PT Tech torque limiter Under speed protection: ................... Motor amp monitoring Breaker speed: ................................. 56 rpm Height setting: .................................. Manually adjustable, 2”increments Breaker bits and holders: ................. Heavy duty, rock type bits with carbide insert, holder is improved design alloy steel Bit pattern: ........................................ Star design

________________________________________________________________ 6.4 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

_______________________________________________ Technical data crawlers

Tram speed ...................................... 47 fpm (14.32 m/min) Drive ................................................. W12C Fairfield torque hub (opt W16C) Take-up: ........................................... Grease cylinder Overall length: .................................. approx. 98”(2,489 mm) Center to center distance: ................ approx. 79”(2,007 mm) Pad width:......................................... approx. 15”(381 mm) Ground pressure: ............................. approx. 33.8 psi (0.233 N/mm2 @ 80,000 lbs (36,288 kg) GVW Maximum tractive force .................... 70,478 lbs (313,514 N) @ 3,500 psi (241 bar)

hydraulic

Conveyor/tram pump:..............................2 stage/ 5.1 in3/section (83.66 cc/section), gear pump, 3,500 psi (241 bar) max pressure Tram motors: ...........................................Char Lynn 4000 series 24 in³/rev (393.36 cc/rev) Lift cylinders: ...........................................Double acting: 17”(432 mm) stroke, 6”(152 mm) bore Tilt cylinders: ...........................................Double acting: 17”(432 mm) stroke, 6”(152 mm) bore Filters (2): ................................................12 micron, pressure line Reservoir: ................................................175 gal (662 L) capacity Heat exchanger: ......................................Oil to air type (standard) Oil to water (optional) Hydraulic fittings: .....................................JIC (standard)

Electrical

Power unit motor: ....................................125hp/1050v/AC/3ph/ 50Hz/1750rpm/MSHA Starter:.....................................................125hp/1050v/AC/3ph/50Hz/ MSHA Contactor:................................................Vacuum type Belt sequence switch:..............................Electronic sensor Remote start:...........................................

Trailing Cable ..........................................Max 750’(228 m) 4/0 Shielded

by Customer

______________________________________________________________ A6474X320 VLSV/00 6.5

Technical data________________________________________________ features

■

Head shaft is removable horizontally as a unit.

■

Breaker and tailshaft are removable vertically as a unit.

■

8 point Ansul dry chemical fire suppression system.

■

Baffle plates and ratio chains included to ratio material into breaker opening.

■

Manual centralized lubrication system. Optional automatic lubrication system.

■

Locking shims included for tailshaft and crawler take-up cylinders.

■

Tunnel housing between electric motor and reducer designed to allow removal of the torque limiter without removing electric motor..

■

Fairfield Torque Hubs have a freewheel to allow towing.

________________________________________________________________ 6.6 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

___________________________________________ 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

© BUCYRUS AMERICA, INC.

Table 14: Grade 8 bolt torque specifications (Imperial) (calculated at 75% proof load) Bolt size

Recommended torque setting (ft-lbs) (dry)

Recommended torque setting (ft-lbs) (wet)

1/4 5/16

13 26

8 16

3/8

47

28

7/16

75

45

1/2

115

70

9/16

165

99

5/8

225

135

3/4

400

240

7/8

645

390

1

905

545

1-1/8

1,380

830

1-1/4

1,935

1,160

1-3/8

2,540

1,525

1-1/2

3,380

2,030

______________________________________________________________ A6474X320 VLSV/00 6.7

Tightening torques ____________________________________________

Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00

(54) (92)

(41) (69)

(78) (133)

(59) (99)

(91) (156)

(68) (116)

M7 X 1.00

(156)

(116)

(222)

(167)

(260)

(195)

M8 X 1.25

(2250

(169)

(333)

(242)

(377)

(284)

M10 X 1.50

37

28

53

40

62

47

M12 X 1.75

65

49

93

69

108

81

M14 X 2.00

104

78

148

111

173

130

M16 X 2.00

161

121

230

172

269

202

M18 X 2.50

222

167

318

238

372

279

M20 X 2.50

314

235

449

337

525

394

M22 X 2.50

428

321

613

460

716

537

M24 X 3.00

543

407

776

582

908

681

M27 X 3.00

796

597

1139

854

1331

998

M30 X 3.50

1079

809

1543

1158

1804

1353

M33 X 3.50

1468

1101

2101

1576

2455

1842

M36 X 4.00

1886

1415

2699

2024

3154

2366

________________________________________________________________ 6.8 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Table 15: Metric bolt torque specifications (calculated at 75% proof load)

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© BUCYRUS AMERICA, INC.

NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc.! These fluids and greases have been tested at Bucyrus America, Inc. 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! Bucyrus America, Inc. expressly point 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.

______________________________________________________________ A6474X320 VLSV/00 6.9

Permissible media ____________________________________________ Approved suppliers:

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 (Fuchs)

Hyldraulic 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

________________________________________________________________ 6.10 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 16: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 17: Extreme pressure gear oils (Spec. 100-2)

1 2 3

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation

4

Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8

Shell Oil Company Century (Fuchs).

9 10 11

Texaco Lubricants Company Exxon Pennzoil

12

Lubricating Engineers

13 14 15

Conoco Inc. Hydrotex Phillips

16

Miners Oil

Brand name Amoco Permagear EP 460 EP Lubricant HD 460 Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460 Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680 Hulbest EP-7 Powergear 460 Meropa 680 Spartan EP 460 Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube 608 Almosal Vari-Purpose Gear Lubricant Gear oil 460 933 Industrial Gear Lubricant All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

______________________________________________________________ A6474X320 VLSV/00 6.11

Permissible media ____________________________________________

1

Supplier 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 (Fuchs)

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Brand name 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 19: 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

________________________________________________________________ 6.12 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 18: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ Permissible media Table 20: 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

Century Oils Limited Fiske Bros. Refining Company Getty Oil Company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

9

© BUCYRUS AMERICA, INC.

10 11 12 13 14 15 16 17 18 19 20 21

Century (Fuchs) Imperial Oil and Grease Mobil Oil Corporation National Oil and Chemical Co. Pennzoil Quaker Chemical Company Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

22 23 24 25

Standard Oil Company of Ohio (Boron Sohio) Sun Oil company Tower Oil Company 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

______________________________________________________________ A6474X320 VLSV/00 6.13

Permissible media ____________________________________________

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 (Fuchs)

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

________________________________________________________________ 6.14 Bucyrus –Model 7MFBHM-48DD Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 21: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

© BUCYRUS AMERICA, INC.

___________________________________________ Permissible media Table 22: 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. Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 5 Sun Oil Company Sunvis 754 6 Unocal 76 Unax RX68 or Turbine Oil 68 7 Shell Oil Company Turbo 68 8 Century (Fuchs) 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. Detol R&O 68 or Turbine Oil 68 14 Hydrotex 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

______________________________________________________________ A6474X320 VLSV/00 6.15

Table 23: 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. Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 5 Sun Oil Company Sunvis 961 6 Unocal 76 Unax RX 700 or Turbine Oil 700 7 Shell Oil Company Turbo 150 8 Century (Fuchs) Centraulic R&O 150 9 Atlantic Richfield Company Duro 600 or S-700 10 Texaco Lubricants Company 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 24: 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 (Fuchs) 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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©© BUCYRUS AMERICA, INC.

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Table 25: 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 (Fuchs) 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 26: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century (Fuchs)

Brand name Synthetic EP Gear Lubricants

Table 27: Multi-purpose tractor hydraulic fluid (Spec. 100-12) 1 2 3 4 5 6 7

Supplier Exxon / Mobil Century (Fuchs) Shell Chevron BP Lubricants Quaker State Conoco

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid Tractran UTH Quaker State FCI HD Powertran Fluid

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1

Supplier Century (Fuchs)

Brand name Powergear H680

Table 29: 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 30: High demulsibility EP gear oil gear oil (Spec. 100-15) Supplier Conoco

Brand name GLW Gear Oil 220

© BUCYRUS AMERICA, INC.

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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

________________________________________________________________ 7.4 Bucyrus –Model 7MFBHM-48DD Feeder Breaker