Cat Feeder Breaker FB140 Operation and Maintenance Manual – PDF DOWNLOAD

EM009681 (BI001467) A6474X391 January 2016

Operation and Maintenance Manual FB140 Serial Number: FBS02192 (54-2192) FBS02197 (54-2197) FBS02198 (54-2198)

SAFETY.CAT.COM

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This manual is intended to provide GENERAL product information for the Model FB140 (7MFBHM-48DD) Feeder Breaker . The illustrations, descriptions, and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

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

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

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

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

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

© Caterpillar 2016 ALL RIGHTS RESERVED

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________________________________________________ Table of contents

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

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

3. Storage and transport Storage and transport ............................................................. 3.3 Storage ................................................................................. 3.3 Storage of the machine and spare parts ......................... 3.3 Transport .............................................................................. 3.5 Before transport ............................................................... 3.5

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 Removing and installing the receiving hopper ................... 4.10 Towing the feeder breaker ................................................. 4.14

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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 Function pressure gauge ................................................. 5.8 Power fill and hydraulic oil sight glass ............................. 5.9 Auxiliary valve bank (if equipped) .................................. 5.10 Starter enclosure ........................................................... 5.11 Dust suppression system .............................................. 5.16 Infrared pump motor controls ........................................ 5.17 Radio remote ................................................................. 5.18 “AUTO” mode starting procedure ....................................... 5.22 “MANUAL” mode starting procedure .................................. 5.23 Shutdown procedure .......................................................... 5.24 Tramming the machine ....................................................... 5.25 Conveyor ............................................................................ 5.26 Control system operating parameters ................................ 5.28 Electrical system................................................................. 5.31 Starter enclosure ........................................................... 5.34 Hydraulic system ................................................................ 5.38 Major hydraulic components.......................................... 5.40 Primary hydraulic circuit ................................................ 5.42 Mechanical assemblies ...................................................... 5.45 Crawler assembly (s) .................................................... 5.45 Conveyor chain ............................................................. 5.46 Grease take-up ............................................................. 5.47 Head shaft .................................................................... 5.48 Conveyor power unit ..................................................... 5.49 Tail shaft ....................................................................... 5.50 Breaker and breaker power unit assembly .................... 5.51 Breaker assembly .................................................. 5.52 Breaker power unit assembly ................................ 5.53 Instructions on the maintenance of the feeder .................. 5.55 Important notes ............................................................. 5.55 Before maintenance ..................................................... 5.55 Lubrication and inspection ............................................ 5.57 Specific lubrication and maintenance procedures ............. 5.61 Every 8 hours of operation ........................................... 5.61 Weekly .......................................................................... 5.66 Monthly ......................................................................... 5.71 Every 3 months ............................................................. 5.74 Every 1000 hours .......................................................... 5.75 Every 6 months ............................................................. 5.77 Inspection of the feeder ..................................................... 5.80 Inspection of wear parts ..................................................... 5.81 Inspection of the fire suppression system .......................... 5.82 Recharge of the fire suppression system ........................... 5.84 Procedure to set Amplifier Card ......................................... 5.86 Instructions on the adjustment procedures ....................... 5.88 Conveyor chain adjustment .......................................... 5.90 Crawler track adjustment .............................................. 5.92

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________________________________________________ Table of contents Breaker shaft and power unit height adjustment ........... 5.94 Under speed sensor calibration .................................... 5.96 Main pump adjustments ................................................ 5.98 Main relief pressure………………………………………5.100 Pressure limiter adjustment .......................................... 5.101 Instructions on the replacement of wear parts ................. 5.102 Head shaft ................................................................... 5.102 Head shaft sprockets ................................................... 5.106 Tail shaft ...................................................................... 5.109 Conveyor chain ........................................................... 5.115 Crawler track ............................................................... 5.123 Crawler assembly ........................................................ 5.126 Breaker shaft and breaker power unit ......................... 5.135 Breaker power unit only................................................ 5.141 Breaker shaft only ........................................................ 5.144 Conveyor drive unit ...................................................... 5.153 Breaker bit removal ...................................................... 5.156 Tailpiece installation ..................................................... 5.157 Roof cylinder ................................................................ 5.161 Foot cylinder ................................................................. 5.164 Tilt cylinder ................................................................... 5.166 Lift cylinder ................................................................... 5.168 Tailpiece tilt cylinder ..................................................... 5.171 Tailpiece steering cylinder ............................................ 5.173 Troubleshooting ................................................................. 5.176

6. Technical data Technical data ......................................................................... 6.3 Components of the feeder breaker ...................................... 6.3 Tightening torques................................................................ 6.5 Permissible data ................................................................... 6.7 Lubrication fluids and greases ........................................ 6.7

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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: Cat® FB140 (7MFBHM-56DDH) Feeder Breaker Serial No. 54-2192, 54-2197, and 54-2198 and is only permitted to be used for equipment of this type.

new operation manual

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

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

Who is this operating manual intended for?

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

This includes persons who: ■

are in charge of transport

■

perform assembly/disassembly work

■

operate the machine

■

eliminate faults

■

perform daily routine work on the face or in the entry

■

perform maintenance work

■

perform repair work

and supervisory personnel who: ■

initiate and/or

■

supervise the activities just indicated.

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

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

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

service

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

safety

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

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

Try to memorize the symbols and their meanings.

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

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

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

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

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

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Before starting to work ____________________________________________

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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 Cat®.

Use only original Cat® spare parts. Note that the use of parts from other manufacturers will void the guarantee.

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

Observe the safety and accident prevention regulations of

further operating manuals

■

the mine,

■

the mine inspector, and

■

the mining supervisory authorities.

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

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Personnel _______________________________________________________ Personnel Operation training

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

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

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

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

Intended uses include: ■

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

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

Unauthorized uses include: ■

the transport of persons

■

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

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

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Safety instructions _______________________________________________

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_______________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

Inform your colleagues of

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

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

Observe the optical start-up warnings of the machine.

symbol plates panic strip

lock-out

cordon off working area

Observe the symbol plates on the machine.

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

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

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

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Safety instructions _______________________________________________ moving parts

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

conveyor chains

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flights

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pivot points

■

crawler assemblies

■

breaker shaft assemblies

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

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

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

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

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

mobile handling equipment

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

Installation and start-up inclined face

environmental acceptability

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

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

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

inspection maintenance instruction and safety tags

operator’s area

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

Verify that all maintenance has been performed.

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

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

Clean any foreign material from the operator’s area.

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

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

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

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

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

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

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

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

Protect your work area against falling rocks.

replacing components

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

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

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Cat® spare parts.

Please refer to the spare parts lists for the order numbers.

For raising the feeder breaker use only: ■

crib blocks with adequate load-holding capacity

■

hoists, jacks or cranes with adequate load-carrying capacity

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_______________________________________________ Safety instructions handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

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

maintenance, repair

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

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

Always replace damaged or lost decals and metal instruction plates.

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

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

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

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

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

the hoses are not pinched or trapped

■

the hoses have no bubbles or blisters

■

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

■

the outer sheaths of the hoses are not damaged

■

the connectors are securely inserted into the sockets

■

the connections are leak-tight

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

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

laying hydraulic hoses

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

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting

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_______________________________________________ Safety instructions ■

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

Fig. 3: Laying hydraulic hoses, bending Right

■

Wrong

always have a little slack.

Fig. 4: Laying hydraulic hoses, crossing Right

■ ■ ■ ■

Wrong

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

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

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Safety instructions _______________________________________________

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

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

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

Wrong

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3

Storage and transport

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____________________________________________ Storage and transport

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

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

Storage corrosion protection

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

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

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

dirt and moisture

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

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

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

short-term storage

long-term storage

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

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

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

■

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

■

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

■

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

■

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

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Storage and transport _____________________________________________

machine electrics

■

Coat exposed valve bank valve spools with rust inhibitor.

■

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

■

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

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

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 Caterpillar.

natural aging

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.

HFA fluids

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

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).

motors

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

plastic deformation

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

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____________________________________________ Storage and transport Transport 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.

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.

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.

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Storage and transport _____________________________________________ Fig. 6: Lifting points on the feeder breaker

Lifting Points

Lifting Points

Lifting Points

Note: Approximate machine weight (w/out tailpiece and anchoring accessories) = 82,000 lbs Approximate machine weight, as shown, with tailpiece and anchoring accessories = 86,000 lbs

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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 Cat® service engineers or by specially trained personnel.

Which tools are required for installation? tool box

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

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

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

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

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

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

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

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

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

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

■

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

■

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

■

check tension of conveyor chain

■

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

■

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

■

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

■

jog the breaker motor to check for correct rotation of breaker

■

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

■

check for correct position and/or operation of all stop switches (including pull cord, if equipped)

■

check the operation of the remote conveyor start system

■

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

■

check the breaker shaft for frozen or missing bits

■

check breaker shaft drive chain tension, if equipped

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

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

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

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

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

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

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

“E-STOP” switch (starter enclosure)

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

panic strip

The machine is equipped with three panic strips: one centrally located on each side of the machine and one located at the auxiliary operators station. Striking with a small amount of force will actuate either of the panic strips. The panic strip is used to break the control circuit in emergency situations. When the panic strip is struck, all machine functions are shutdown immediately.

emergency pull cord

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

siren/warning light

The machine is equipped with a siren that will sound upon initial startup and each time the conveyor is restarted after timing out. The warning light will operate the entire time the machine is energized. The siren/ warning light is on a 20 ft. cable and is equipped with a magnetic base so that optimal placement can be determined by mine personnel.

neutral start guard

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

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______________________________________________________ Installation 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 left side of the machine and one is centrally located near the panic strip on the right side of the machine. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

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

convey/tram enable

The machine is equipped with a convey/tram enable solenoid located directly behind the primary valve bank. The CONV/OFF/TRAM mode switch controls the solenoid, making it impossible for the conveyor sections of the valve bank to operate while in TRAM mode and the remaining six valve bank sections inoperable while in CONV mode.

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

Emergency pull cord

Fire suppression actuator Panic strip Neutral start guard

“PICK BK STOP”

Panic strip

“E-STOP”

CONVEY/TRAM ENABLE (behind valve bank)

Fire suppression actuator

Panic strip

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______________________________________________________ Installation Fig. 8: Overview of the feeder breaker (covers removed for clarity)

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Tail shaft Emergency pull chord Photo eye sensors Breaker shaft Breaker shaft cleaner Power unit Fire suppression bottles Head shaft Conveyor drive unit Water/oil heat exchanger

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Dust suppression system Electrical starter enclosure Breaker underspeed sensor (behind oil tank) Hydraulic oil tank Power fill Torque hub (both crawlers) Operator’s station Centralized grease manifold (both sides) Head shaft tachometer (located on right hand end of head shaft)

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Installation ______________________________________________________ Removing and installing the receiving hopper Before moving the machine, it may be necessary to disconnect the hopper from the machine. While removing or installing the hopper, follow all safety procedures and precautions and be aware of the following: To remove the hopper (reference Fig. 9): WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

WARNING! Failure to follow all applicable energy lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

1. Verify that it is safe to start the machine.

2. Start the machine in manual, “MAN”, mode (see Start up procedure in Chapter 5).

3. Raise the machine using the lift and tilt hydraulic cylinders.

4. Block the receiving hopper by placing appropriate blocking under all four corners of the hopper.

5. Lock and tag out the feeder breaker power source.

6. Remove the PT Tech clutch from between the gear reducer and the electric motor to prevent the breaking shaft from moving during transport.

WARNING! If the breaker shaft is allowed to turn during transport, do not place any material on the conveyor. This material could get caught by the rotating breaker shaft. Damage to the material or injury to surrounding personnel could occur.

7. Remove the tail shaft and conveyor chain covers on the receiving hopper.

8. Separate and completely remove the conveyor chain (see Conveyor chain removal procedure in Chapter 5).

9. Tag, remove, and cap all grease hoses for the tail shaft and conveyor chain take-up cylinders.

10. Remove and store all shims.

11. Remove the twelve (12) 1-1/2 inch hex head bolts, nuts, and lock washers that secure the receiving hopper to the main body of the machine.

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______________________________________________________ Installation 12. Anchor the receiving hopper using the two D-rings located on the front of the hopper.

13. Restore electrical power to the machine.

14. Start the machine in manual, “MAN”, mode (see Start up procedure in Chapter 5).

15. Slowly tram the machine about two inches (50 mm) away from the receiving hopper and stop tramming.

16. Ensure that the tail shaft push rods will remain in place inside of the receiving hopper.

Note: The main body of the machine is equipped with tapered dowels that engage the receiving hopper. At this point, the dowels should still be engaged in the hopper.

17. Verify the stability and balance of the main body of the machine and determine if it will need support at the discharge end before proceeding. A suitable means of support would be a utility scoop.

18. After verifying the stability of the machine, continue to tram the machine away from the hopper, completely disengaging the tapered dowels from the receiving hopper.

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Installation ______________________________________________________ Fig. 9: Hopper removal and installation

Bolt (12)

Nut (12)

Alignment dowel (2)

Washer (12)

D-ring anchor (2)

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______________________________________________________ Installation To install the hopper (reference Fig. 9): WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

WARNING! Failure to follow all applicable energy lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

1. Position the receiving hopper so that the feeder breaker can be trammed into position.

2. Block the hopper at all four corners, ensuring that it is stable and level.

3. Start the feeder breaker in manual, “MAN”, mode (see Start up procedure in Chapter 5).

4. Support the discharge end of the feeder breaker with a utility scoop.

5. Slowly tram the feeder breaker and scoop (supporting the discharge end of the feeder breaker) toward the hopper.

6. Ensure that the tapered dowels on the machine align with the holes in the hopper. Using the lift and tilt cylinders, adjust the machine until proper alignment is achieved.

7. Ensure that the push rods line up correctly with the cylinders.

8. Slowly tram forward until the receiving hopper is butted tight to the feeder.

9. Shut down the machine (see Shut down procedure in Chapter 5) and remove power from the machine following all applicable lockout/tagout regulations.

10. Insert the twelve (12) 1-1/2 inch hex head bolts, nuts, and lock washers. Torque bolts to 3,161 ft-lbs (dry).

11. Reconnect all grease hoses for the tailshaft and the conveyor chain take-up cylinders.

12. Install the conveyor chain (see Conveyor chain installation in Chapter 5).

13. Install the tail shaft and conveyor chain covers on the hopper.

14. Install the PT Tech clutch between the reducer and the electric motor.

15. Restore power to the machine.

16. Start the machine in manual, “MAN”, mode (see Start up procedure in Chapter 5).

17. Using the lift and tilt cylinders, raise the machine so that the hopper is lifted off of the blocking.

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Installation ______________________________________________________ Towing the feeder breaker WARNING! It is not possible, within the scope of this guide, to anticipate all possible arrangements for towing the feeder breaker. Before attempting to tow the machine, you must take all possible precautions to protect all personnel from injury. The primary towing device being used (cables, bars, etc.) and the towing machine must have sufficient load limits to maintain control through all conditions that may be encountered at any time during towing. 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 this warning could result in serious injury or death to you or other workers.

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

2. Chock front and rear of both crawler drives.

WARNING! Both the front and rear of the crawler drives must be chocked to prevent uncontrolled movement of the feeder breaker. Failure to follow this warning could result in serious injury or death to you or other workers.

3. Rotate the torque hub end cap on both right and left sides of the feeder to the free position as follows (Fig. 10).

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

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

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

WARNING! Do not exceed 5 mph during towing. Failure to follow this warning could result in serious injury or death to you or other workers or damage to machine.

6. Remove chocks from crawler and begin towing.

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

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

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

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

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

Fig. 10: Torque hub disengagement

Retaining bolts (2)

End cap button pointing outward

Normal tram position

Retaining bolts (2)

End cap button pointing inward

Freewheel position

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Installation ______________________________________________________

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_______________________________________________________________

5

Operation

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_______________________________________________________ Operation

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

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

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

Who is allowed to operate the feeder breaker?

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

This also includes: ■

what safety devices are installed on the machine,

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where these safety devices are located, and

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how these safety devices are to be operated.

When can conveying be started?

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

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Operation _______________________________________________________ Controls and indicators Manual operational controls The machine may be operated manually via hydraulic and electrical controls mounted on the machine (Fig. 11).

Fig. 11: Manual operational controls 3

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Fire suppression actuator Neutral start guard Panic strip Primary valve bank Function pressure gauge Power fill ball valve Oil level sight glass Electrical starter enclosure Dust suppression system Auxiliary valve bank (if equipped)

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_______________________________________________________ Operation fire suppression

There are two (2) fire suppression (remote) actuators (Fig. 12) used to activate the fire suppression system on the feeder breaker; one located centrally on each side of 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.

neutral start guard

The machine is equipped with a guard (Fig. 12) 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.

panic strip

There are three panic strips located on the feeder breaker; one centrally located on each side of the machine and one located at the auxiliary operator’s station (if equipped). 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.

Fig. 12: Fire suppression actuators, neutral start guard, and panic strips 1. Fire suppression actuator location 2. Panic strip 3. Neutral start guard

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Operation _______________________________________________________ Primary valve bank The primary valve bank (Fig. 13) is used to manually operate the machine when radio remote operation is not possible. The valve section handles are stored in a storage tube beside the valve bank. To manually operate the machine, the “MAN/OFF/AUTO” switch must be in the “MAN” position.

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

The first two sections on the operator’s left are conveyor forward and reverse. The two sections can be used independently or together to control conveyor direction and speed. To run the conveyor in the forward direction (towards the discharge end), push either valve handle up. If the conveyor is sluggish, use both valve sections. To run the conveyor in reverse (towards the receiving hopper), push either valve handle down. If the conveyor is sluggish, use both valve sections.

Note: The two conveyor valve sections are tied to a common circuit.

Using both valve sections will increase flow to the conveyor motors, increasing speed.

“LEFT TRAM” “RIGHT TRAM”

The third section from the operator’s left controls the left tram functions.

The fourth section from the operator’s left controls the right side tram functions.

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.

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_______________________________________________________ Operation “LH FRAME LIFT”

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

“RH FRAME LIFT”

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

“FRAME TILT”

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

“TANK FILL” and “AUX VB”

The sixth lever from the operator’s left has two (2) functions, it controls the “TANK FILL” and auxiliary valve bank, “AUX VB” oil flow for the machine. To operate the power fill, turn ball valve handle (Fig. 13) to the open position and push the control lever. To de-energize power fill pump, move control lever to the centered position and turn ball valve handle to closed position. Pull the control lever towards the operator to energize the auxiliary valve bank (if equipped).

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

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

To operate the power fill (Fig. 14): 1. Clean suction hose attached to the hydraulic power fill motor, located on top of the oil tank.

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

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

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

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

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

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

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

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

The function pressure gauge (Fig. 13) is located below the primary valve bank. This gauge provides a pressure reading for each active function on the machine.

Fig. 13: Primary valve bank and function pressure gauge

Valve bank

Function pressure gauge

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_______________________________________________________ Operation Fig. 14: Power fill system and hydraulic oil sight glass

Power fill Sight glass

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Operation _______________________________________________________ Auxiliary valve bank (if equipped) The auxiliary valve bank (if equipped) consists of the following controls: “TAIL TILT”

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

“TAIL STEER”

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

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

“LEFT FLOOR”

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

“RIGHT FLOOR”

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

“LEFT ROOF”

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

“RIGHT ROOF”

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

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_______________________________________________________ Operation Electrical starter enclosure The starter enclosure (Fig. 15) houses the primary electrical control components of the machine. The following switches and controls are located on the front of the enclosure: “MAN/OFF/AUTO”

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

“TRAM/OFF/CONV”

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

“FWD CONV/OFF/REV CONV”

The “FWD CONV/OFF/REV CONV” selector switch is used to select the conveyor direction. If the switch is in “OFF” mode while the “MAN/ OFF/AUTO” switch is in “AUTO” mode, the conveyor will not run. Forward mode, “FWD CONV”, is used for normal operations.

“15A CB RESET”

The “15A CB RESET” pushbutton is used to reset the control circuit breaker.

“PICK BK STOP”

The “PICK BK STOP” pushbutton is used to stop the pick breaker motor.

“E-STOP”

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

“ACKNOWLEDGE ALARMS”

The “ACKNOWLEDGE ALARMS” pushbutton is used to clear an alarm from the display panel after the condition that generated the alarm is corrected. This pushbutton is also used to engage the master control relay when starting the machine for the first time or after the panic switch/e-stop has been pressed.

“CONV START”

The “CONV START” pushbutton will initiate an automatic conveyor run cycle. The conveyor will run for the time duration preset. Note: The conveyor will not run until the breaker motor and hydraulic pump are running.

“START BREAKER”

The “START BREAKER” pushbutton is used to start the breaker motor.

When the button is pushed, an alarm sounds for a preset amount of time. After the alarm sound, the breaker motor will start.

circuit breaker reset lever

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

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Operation _______________________________________________________ Fig. 15: Starter enclosure cover 1

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“MAN/OFF/AUTO” selector switch “TRAM/OFF/CONV” selector switch “FWD CONV/OFF/REV CONV” selector switch PLC display “15A CB RESET” pushbutton “PICK BK STOP” pushbutton “E-STOP” pushbutton “ACKNOWLEDGE ALARMS” pushbutton “CONV START” pushbutton “START BREAKER” pushbutton Main circuit breaker reset lever

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_______________________________________________________ Operation PLC display

The display panel (Fig. 16) is located in the starter enclosure. The display is used to monitor machine performance during operation, to troubleshoot the machine, and to change operating parameters.

Fig. 16: PLC display (touch screen feature) PLC display

Number pad

Function keys

“MAIN SCREEN”

On screen navigation keys

The normal operation display screen is the “MAIN SCREEN” (Fig. 17).

This screen displays any active alarm, breaker motor amps, conveyor speed, breaker and motor hours, and mode of operation (with or without belt sequence active). It also provides a login/logout access. The “MAIN SCREEN” and “STATUS SCREEN” are the only screens available without a password. After log in, access to three additional screens is displayed. For alarm information, see the troubleshooting section in this chapter.

Fig. 17: “MAIN SCREEN”

Operating status Conveyor speed

Alarm banner Motor hours

Login access Logout

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Operation _______________________________________________________ “STATUS SCREEN”

The “STATUS SCREEN” (Fig. 18) is accessed by pushing function key “F1”. This screen displays the conveyor speed, hydraulic oil pressure, vacuum pressure, and the current in each phase of the breaker motor.

To return to the “MAIN SCREEN” from the “STATUS SCREEN”, press “F1”.

Fig. 18: “STATUS SCREEN”

After logging in, the functions keys “F2” through “F4” (Fig. 16) are used to access four additional screens: “PRESETS”, “OPERATION TIMERS”, and “JAM TIMERS” . Currently, function keys “F5” through “F8” are not used.

“PRESETS SCREEN”

The “PRESETS SCREEN” (Fig. 19) is accessed from the “MAIN SCREEN” by pushing function key “F2”. This screen allows access to the preset breaker shaft speed designations for low, medium and high speeds. To return to the “MAIN SCREEN” from the “PRESET SCREEN”, press “F1”. The timer screens can be accessed from the “PRESET SCREEN” by pressing “F3” or “F4”.

Fig. 19: “PRESET SCREEN”

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_______________________________________________________ Operation “OPERATION TIMERS SETUP SCREEN” (“TIMERS 1”)

The “TIMERS 1 SCREEN” (Fig. 20) is accessed from the “MAIN SCREEN” by pushing function key “F3”. This screen allows access to the “OPERATION TIMERS SETUP SCREEN” where the timers for the breaker idle shutdown, the start-up warning horn, and conveyor run timers can be set. To return to the “MAIN SCREEN” from the “TIMERS 1 SCREEN”, press “F1”. The “PRESETS” and “TIMER 2” screens can be accessed from the “TIMERS 1 SCREEN” by pressing “F2” or “F4”.

Fig. 20: “OPERATION TIMERS SETUP SCREEN” (“TIMERS 1”)

“JAM TIMERS SETUP SCREEN” (“TIMERS 2”)

The “TIMERS 2 SCREEN” (Fig. 21) is accessed from the “MAIN SCREEN” by pushing function key “F4”. This screen allows access to the “JAM TIMERS SETUP SCREEN” where the timers for the breaker overload preset amps, beaker overload delay, conveyor slow backup, and conveyor slow forward timers can be set. To return to the “MAIN SCREEN” from the “TIMERS 2 SCREEN”, press “F1”. The “PRESETS” and “TIMER 1” screens can be accessed from the “TIMERS 1 SCREEN” by pressing “F2” or “F3”.

Fig. 21: “JAM TIMERS SETUP SCREEN” (“TIMERS 2”)

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Operation _______________________________________________________ WARNING! The pressure regulator should never be adjusted above 125 psi. dust suppression system regulator

The dust suppression system regulator (Fig. 22) is located below the breaker power unit on the right side of the machine and is used to control the water pressure to the six spray nozzles located in the hose crossover tray over the breaker shaft. The water pressure to the nozzles is monitored by the dust suppression system pressure gauge (Fig. 18). To increase pressure, turn the regulator handle in (cw). To decrease pressure, turn the regulator handle out (ccw).

dust suppression system pressure gauge

The dust suppression system pressure gauge (Fig. 22) is used to monitor the water pressure to the spray nozzles. The gauge should read between 5 and 125 psi.

dust suppression system strainer

The dust suppression system strainer (Fig. 22) is located below the breaker power unit on the right side of the machine and is used to filter particles from the mine water supply. The strainer should periodically be flushed to avoid becoming clogged. To flush the strainer, turn the ball valve handle, located on the branch of the strainer body, 90° in-line with the outlet. Allow to flush for approximately thirty seconds to one minute and then close the ball valve handle.

water solenoid

The water solenoid is located beside the regulator/strainer assembly and is used to control flow of water to the six spray nozzles located in the hosed crossover tray over the breaker shaft. The solenoid is controlled by a pressure transducer located in the hydraulic pressure gauge manifold beside the primary valve bank. When the “MAN/OFF/ AUTO” switch on the starter enclosure is set to “AUTO”, the “TRAM/ OFF/CONV” switch is set to “CONV”, and the hydraulic system pressure reaches 1,000 psi, the solenoid will open and allow water to flow through the water/oil cooler and then to the spray bars. The solenoid activation pressure is adjustable through the PLC.

Fig. 22: Dust suppression system regulator and pressure gauge Water solenoid

Gauge

Regulator

Strainer

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_______________________________________________________ Operation photo eye pump motor controls and remote start/stop stations

The photo eye sensors (Fig. 23) and remote start/stop pushbutton stations are used to control conveyor operation. When the conveyor is started, an adjustable timer with a default value of 2-1/2 minutes is initiated through the PLC. If, during this 2-1/2 minutes, a light is shone on either photo eye sensor for 4 continuous seconds or either remote start button is pushed, the conveyor timer is reset and the conveyor will continue running. If neither action is take, the conveyor will shut down.

When the conveyor shuts down, an adjustable timer with a default value of 15 minutes is activated. If, during this 15 minute period, neither photo eye sensor or remote start button is activated, the pump motor will shut down. If either action is taken, the timers will reset and the conveyor will restart.

In addition, the remote pushbutton station is equipped with a “STOP” button. This button can be used to shut down the pump motor at any time.

Note: A siren will sound upon initial start up and every time the conveyor is restarted after timing out. There will be a start up delay while the siren sounds.

Fig. 23: Photo eye sensors

Photo eye sensors

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Operation _______________________________________________________ radio remote

The machine is equipped with a wireless remote (Fig. 24) that can be used to control tramming and to operate the lift and tilt cylinders. The radio remote is active when the “CONV/OFF/TRAM” selector switch is in the “TRAM” position and the neutral start guard is in place (valve levers in neutral, guard covering handles, magnetic switch engaged).

Fig. 24: Radio remote

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

2 1 3

4

5

6

7

Push to operate bar (deadman switch) Battery good indicator Battery low indicator Left tram Right tram Left lift cylinder Right lift cylinder Tilt cylinder Pump (breaker motor) start/stop Radio remote power on/off Emergency stop Reset

9 8 11

10

12

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_______________________________________________________ Operation The remote is equipped with the following performance and safety features: Power on self diagnostics: When the radio remote is powered on (“POWER” toggle switch is in the “ON” position), a self-test is initiated. when the self-test is complete, the radio remote will beep two times.

Transmit/battery charge indicator: When the battery is good, the green LED will flash with each transmission. When the battery level drops below a preset level, the radio remote will beep every ten seconds and the red LED will flash during data transmission. At this point, there is approximately one hour of battery life remaining. The radio remote will shut itself off before the battery drops low enough to result in erratic operation.

Battery saver: The radio remote will enter sleep mode if there is no input for fifteen minutes. To reset the remote, toggle the “POWER” switch to the “OFF” position and then to “ON”.

The operational controls on the remote are: push to operate bar (deadman switch)

left and right “TRAM”

left and right “LIFT”

“TILT”

“PUMP” “POWER”

“STOP”

“RESET”

The push to operate bar (deadman switch) is a spring-return switch located on top of the radio remote that is used as a safety device that electrically disconnects all functions when released. This bar must be held in while operating any function on the radio remote.

The left and right “TRAM” switches are used to tram the machine.

Each crawler can be trammed independently in either the forward or reverse direction.

The left and right “LIFT” switches are used to operate the lift cylinders.

The left and right cylinders can be raised and lowered independently.

The “TILT” switch is used to operate the left and right tilt cylinders.

These cylinders are not independent and operate on a common hydraulic circuit.

The “PUMP” start/stop switch is used to start the breaker electric motor.

The “POWER” on/off switch is used to power on and off the radio remote.

The “STOP” pushbutton is an emergency stop button used to shutdown the radio remote.

The “RESET” button is used to reset the system and must be pressed after turning the “POWER” switch to the “ON” position. Each time the radio remote is powered “OFF” and then back to “ON” the “RESET” pushbutton must be pressed initially before any command will work.

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Operation _______________________________________________________ remote control batteries

Battery Options The remote control is battery powered. There are two different battery pack options: 

Disposable Alkaline Battery Pack (standard—machine ships with this battery pack) - provides approximately 75 hours of life (based on continuous transmission).



Rechargeable Ni-Cad Battery Pack (optional) - provides approximately 23 hours of life (based on continuous transmission).

Battery Replacement When the “TRANSMIT/LOW BATTERY” LED begins to flash red, there is approximately one hour of continuous operation remaining.

To replace the battery pack: 1. Set the remote control power switch to “OFF”.

2. Unlatch and open the battery door and remove the battery pack from the tray.

3. Insert a fully charged battery pack into the remote control. Ensure that the contacts on the underside of the battery pack align with the corresponding contacts on the battery tray.

4. closs and latch the battery door.

5. Move the remote control power switch to the “ON” position. The “TRANSMIT/LOW BATTERY” LED should flash yellow and two quick beeps will be heard.

6. Operate a non-motion function such as the lights. The “TRANSMIT LOW/BATTERY” LED should flash green, indicating the remote control is fully operational.

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_______________________________________________________ Operation Battery Charging (optional) The Ni-Cad battery pack is rechargeable using the appropriate charging station. Contact your Cat Service Representative for battery and battery charging options.

To recharge: 1. Remove the Ni-Cad battery pack from the radio remote.

2. Connect the charger to a standard 120VAC outlet.

3. Insert the battery pack into the charger. The battery charger red “CHARGING” LED will be lit until the end of the charging process.

When fully charged, the green “FULLY CHARGED” LED will illuminate.

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

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

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

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

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

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

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

3. Check conveyor for any foreign material or objects.

4. Check that all other personnel are clear of the machine.

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

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

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

7. Push the “ACKNOWLEDGE ALARMS” button once to engage the MCR. Press the button a second time to clear any faults.

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

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

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

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

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

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

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

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

3. Check conveyor for any foreign material or objects.

4. Check that all other personnel are clear of the machine.

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

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

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

7. Push the “ACKNOWLEDGE ALARMS” button once to engage the MCR. Press the button a second time to clear any faults.

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

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

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

To shutdown the feeder breaker from the starter enclosure: 2. Engage the “PICK BKR STOP” pushbutton located on the starter enclosure to stop the breaker motor.

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

4. Move the “TRAM/OFF/CONV” switch to the “OFF” position.

5. Move the “MAN/OFF/AUTO” switch to the “OFF” position.

To shutdown the feeder breaker from the radio remote: 2. Move the “PUMP” start/stop toggle switch to the “STOP” position to stop the breaker motor.

3. Move the radio remote “ON/OFF” toggle switch to “OFF”.

4. Move the circuit breaker reset switch, located on the starter enclosure, to the “OFF” position.

5. Move the “TRAM/OFF/CONV” switch located on the starter enclosure to the “OFF” position.

6. Move the “MAN/OFF/AUTO” switch located on the starter enclosure to the “OFF” position.

Emergency stop procedures: The machine can also be shutdown in emergency situations using: 1. Either panic strip, 2. The “EMERGENCY STOP” button on the starter enclosure, 3. The pull cord, 4. The “EMERGENCY STOP” button on either remote start station., or Activating any one of the emergency stop devices will open the master control relay, “MCR”. Power will still be on the machine and the machine can be restarted using normal starting procedures.

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

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

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

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

5. Push the “ACKNOWLEDGE ALARMS” button once to engage the MCR. Press the button a second time to clear any faults.

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

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

The machine can now be trammed.

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

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

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

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

5. Remove the tram valve handles from the primary valve bank.

6. Position the neutral start guard over the primary valve bank.

7. Push the “ACKNOWLEDGE ALARMS” button once to engage the MCR. Press the button a second time to clear any faults.

8. Move the radio remote “POWER” button to the “ON” position.

Listen for 2 beeps.

9. Press the “RESET” button on the radio remote. Listen for 2 beeps.

10. Press and hold the push to operate (deadman) switch on the top of the radio remote.

11. Move the “PUMP START” button on the radio remote to the “START” position.

12. While holding the push to operate switch in, tram the machine using

the left and right “TRAM” switches. ______________________________________________________________ A6474X391 REV 4 5.25

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

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

3. Push the “START BREAKER” button to start the breaker motor.

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

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

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

–

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

–

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

–

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

–

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

–

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

5. Press the “START CONVEYOR” button on the front of the starter enclosure or the “START” button on either one of the remote pushbutton stations. A siren will sound warning that the conveyor is starting. The siren will sound any time the conveyor has timed out and is restarted.

Notes: 1. The PLC controls the speed of the conveyor based upon the amperage monitoring of the breaker motor. There are three preset forward conveyor speeds that are, by default, 20%, 50%, and 100%. These speeds are adjustable and can be reset to suit the operating conditions.

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_______________________________________________________ Operation 2. The conveyor operating time is controlled by a timer that is reset by pushing a start button on the starter enclosure or either remote pushbutton station or shining a light on the photo eye sensor mounted above the hopper. If the timer is not reset within the allotted time, the conveyor will stop.

3. There is a second adjustable timer that will shut down the electric motor if, within a preset amount of time, there is no conveyor activity. If, within this amount of time, the conveyor is idle and a conveyor start button is pushed, the PLC will allow the pump to ramp back up to full flow.

Conveyor reverse IMPORTANT! If it is necessary to reverse the conveyor, it should be jogged only. Running the conveyor in the reverse direction for even a short period of time with material in the hopper may cause the conveyor to jam. It will then be necessary to empty the machine hopper before the conveyor can be restarted.

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

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

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

Breaker idle shutdown timer If the conveyor is running and no cars dump on the conveyor within a 21/2 minute time period (adjustable within the PLC), the control system will shutdown the conveyor motor.

If no conveyor function is engaged on a running machine within a 15 minute time period (adjustable within the PLC), the control system will shutdown the breaker motor.

High oil temperature If the hydraulic oil temperature exceeds a preset value of 165° F, the control system will shutdown the machine and the “HIGH OIL TEMPERATURE ALARM” will be displayed.

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

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

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

The vacuum transducer is located in the suction line fitting of the pump suction port.

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_______________________________________________________ Operation Pressure transducer If the hydraulic system pressure transducer reads greater than 1,000 psi (adjustable within the PLC), the water solenoid is turned on and the water sprays are activated. This transducer also activates the high oil pressure alarm and is located in the gauge manifold at the main operator’s station.

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

Emergency stop If the master control relay is opened by activating an emergency stop device, the machine will shutdown and the “EMERGENCY STOP ALARM” will be displayed.

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

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

Tilt switch There is a tilt switch located on the discharge of the feeder breaker to sense spillage. When activated (held at a 45° angle) for three seconds, the system will display a “TILT SWITCH ACTIVATED” alarm. These feature is disabled in tram mode.

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Operation _______________________________________________________

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

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

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

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

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

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Electrical system _________________________________________________ Fig. 25: Major electrical component locator

7 8 1 5

4

3 2 9

11

7

7 6

6

1. Breaker shaft motor 2. Breaker shaft underspeed sensor 3. Starter enclosure

4.

5.

6.

7.

High temp switch Water solenoid Photo cell (2) Panic strips

8.

9.

10.

11.

10

Conveyor motor Radio control box Photo eye control box Low oil switch

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________________________________________________ Electrical system

breaker motor

breaker shaft underspeed sensor starter enclosure

The breaker motor is a 200 HP, 575 VAC, 3 phase, 60 Hz, 1750 rpm, totally enclosed, fan cooled non-explosion proof electric motor.

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

The starter enclosure is located on the left side of the machine and houses the machines electrical controls.

low oil switch

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

high temperature switch

The high temperature switch is mounted on the wall behind the oil tank on the left side of the machine and will shut down the machine if the hydraulic oil temperature exceeds 165° F. The temperature probe is located in the oil tank.

water solenoid

The water solenoid enclosure is located on the wall behind the conveyor drive reducer. When the conveyor motor forward pressure is greater than 1,000 psi, the pressure transducer signals the PLC to open the electric water valve, activating the dust sprays and the oil cooler (water over oil heat exchanger).

photo eye sensors

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

panic strips

There is one panic strip located near the valve bank on the left side of the machine and one panic strip located near the main grease manifold on the right side of machine. The third panic strip is located above the auxiliary valve bank on the left hand side of machine. Activating either panic strip will open both master control relays, “MCR” and “MCRA”, thereby shutting down the machine.

remote pushbutton station

The remote pushbutton stations (2) are attached with 50 ft. cables and are mounted in the entry to allow the shuttle operator to remotely start and stop the conveyor.

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Electrical system _________________________________________________ Starter enclosure The starter enclosure, located on the left side of the machine, houses the primary electrical control components.

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

There are operational controls located on the front of the starter enclosure (Fig. 26). For control descriptions, see the Controls and Indicators section in this chapter.

Fig. 26: Starter enclosure 1

2

5

1.

2.

3.

4.

5.

6.

3

6

4

7

8

9

10

“MAN/OFF/AUTO” “TRAM/OFF/CONV” “FWD CONV/OFF/REV CONV” PLC display “15A CB RESET” “PICK BRK STOP”

11

7.

8.

9.

10.

11.

“E-STOP” “ACKNOWLEDGE ALARMS” “CONV START” “START BREAKER” Circuit breaker reset lever

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________________________________________________ Electrical system Swing panel - front side The swing panel (Fig. 27) is accessed by opening the cover on the enclosure. Immediately adjacent to the swing panel is the main circuit breaker, CB1, for the feeder breaker.

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

Fig. 27: Swing panel, front side

1

10

1.

2.

3.

4.

5.

6.

7.

8.

11

12

Power Supply Analog input module Analog output module Input module #1 Input module #2 Output module Amplifier card 1 Amplifier card 2

2

13

3

4

5

6

7

14 15 16 17 18 19 20 21

9.

10.

11.

12.

13.

14.

15.

16.

IS Relay AC/DC converter #1 AC/DC converter #2 AC/DC converter #3 AC/DC converter #4 SR MCR CRWS

8

22

17.

18.

19.

20.

21.

22.

23.

9

23

CR1 CR2 CRR SSR R1A Ethernet switch TAC monitor

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Electrical system _________________________________________________ power supply

The power unit houses the system processor for the machine control system.

analog input module

The analog input module receives inputs from the current transducer.

analog output module

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

input module #1

Input module #1 is for the 120V inputs (selector switches, push buttons, etc.).

input module #2

Input module #2 is an analog input module for the current transducer, pressure transducer, vacuum transducer, and TAC monitor.

output module amplifier boards IS relay

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

The electronic amplifier boards drive the conveyor speed solenoids.

The IS relay is the intrinsically safe relay for the panic bars.

AC/DC converter #1

AC/DC converter #1 is the 120VAC/24VDC power supply for the panel view display.

AC/DC converter #2

AC/DC converter #2 is the 120VAC/24VDC power supply for the conveyor and tram forward solenoids, two pressure transducers, and the vacuum transducer.

AC/DC converter #3

AC/DC converter #3 is the 120VAC/24VDC power supply for the reverse tram solenoids.

AC/DC converter #4

AC/DC converter #4 is the 120VAC/24VDC power supply for the forward and reverse tram solenoids (left and right), the lift solenoids (left and right) and tilt solenoids (up and down).

MCR

SR CRWS CR1 and CR2

MCR is the master control relay. This relay receives input from the emergency stop button located on the starter enclosure, and the remote control.

SR is the safety relay for the panic bar.

CRWS is the water solenoid relay.

CR1 and CR2 are conveyor forward relays.

CRR

CRR is the conveyor reverse relay.

SSR

SSR is the strobe/siren relay.

R1A

R1A is the radio remote relay.

Ethernet switch TAC monitor

The Ethernet switch provides access for programming.

The TAC monitor picks up the conveyor shaft and pick break speeds and sends a signal to the PLC.

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________________________________________________ Electrical system Back panel The back panel (Fig. 28) is accessed by removing the swing panel retaining bolt located in the upper left hand corner of the swing panel and swinging the panel out. Note that component locations are typical.

Always consult the parts book for your machine to verify locations.

Fig. 28: Back panel, typical 1

2

4 1. “T1”, control transformer 2. “OL1”, overload 3. “M1”, vacuum contactor

3

5

6

4. Fuse 5. Current transducer 6. Current transformer (3)

“T1”

“T1” is the control transformer that reduces the voltage to the control circuit from 575V to 120V.

“OL1”

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

“M1” fuse current transducer

current transformer

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

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

The current transducer converts the current to a 4 - 20 mA signal that is relayed to the analog input module and is then displayed as full motor current on the PLC display.

300:5 current transformers used to step down the current.

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

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

The secondary hydraulic system for this machine has been designed to provide hydraulic power for the roof cylinders, the foot cylinders, and the tailpiece cylinders

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

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

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________________________________________________ Hydraulic system Fig. 29: Hydraulic component locator

2

17 16

1

3

19 11

9

18 12

8 6

6

15 20

13

5

7

14 4

10

1.

2.

3.

4.

5.

6.

7.

Conveyor motor Piggyback gear pump Open loop load sense pump Pressure filter Valve bank Tram motor (2) System pressure gauge

8.

9.

10.

11.

12.

13.

Hydraulic oil level/temperature gauge Hydraulic oil tank Frame tilt cylinder (2) Hydraulic oil fill hand pump Hydraulic power fill ball valve Return filter

14.

15.

16.

17.

18.

19.

20.

Conveyor/tram engage valve Frame lift cylinder (2) Tailpiece steering cylinders (2) Tailpiece lift cylinders (2) Roof cylinders (2) Stab cylinders (2) Schroeder test mate port

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Hydraulic system _________________________________________________ Major hydraulic components (Reference Fig. 29) conveyor motor

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

piggyback gear pump

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

open loop load sense pump

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

pressure filter

primary valve bank

tram motors

The pressure filter is located on the left hand side of the machine near the operator’s station. This filter is used to filter fluid on the pressure side of the hydraulic circuit.

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

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

system pressure gauge

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

hydraulic oil tank with sight glass and thermometer

The hydraulic oil tank is located on the left hand side of the machine and has a 110 gallon capacity. The hydraulic oil temperature and level is monitored by the PLC via a temperature probe and float switch. The tank is equipped with a sight glass and thermometer.

frame tilt cylinders

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

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.

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________________________________________________ Hydraulic system power fill ball valve

The hydraulic power fill ball valve is located on the left hand of the machine. This valve must be opened before activating the power fill function on the valve bank.

tank fill pump

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

return filter

The return filter is located on the left hand side of the machine near the primary operator’s station. This filter is used to filter fluid on the return side of the hydraulic circuit and as the power fill filter.

conveyor/tram engage valve

The conveyor/tram engage valve is located behind the valve bank on the left side of the machine. The valve is used to disable the conveyor sections of the valve bank when the “TRAM/OFF/CONVEYOR” switch is in the “TRAM” position or to disable the tram, tilt and lift cylinder, and jet fill sections of the valve bank when the “TRAM/OFF/CONVEYOR” switch is in the “CONVEYOR” position. This is accomplished by dumping the hydraulic load sense signal from either the conveyor sections (tram only) or the other sections (conveyor only). Without the load sense signal, a valve bank section is disabled.

frame lift cylinders

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

auxiliary valve bank

The auxiliary valve bank, if equipped, is used to control the tailpiece tilt and steer cylinders and the roof and floor cylinders.

Schroeder test mate port

The Schroeder test mate port is used to connect a Schroeder test mate device to troubleshoot the hydraulic system.

tailpiece lift and steering cylinders

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

roof and stab cylinders

The roof and stab cylinders are used support and stabilize the feeder breaker while conveying of material.

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.

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Hydraulic system _________________________________________________ Primary hydraulic circuit The primary hydraulic circuit is powered by an open loop load sense pump rated at 165cc/75 gpm at 1750 rpm electric motor speed. This pump supplies oil flow to the main valve bank. The main valve bank operates the conveyor motor, tram motors, lift cylinders, tilt cylinders, and power fill function.

There is a suction transducer located between the oil tank and the pump. If the suction pressure drops below a preset value, meaning that the line is pulling in air from either a low oil condition or a leaking suction line, an alarm will be issued by the PLC. If the condition lasts longer than three seconds, the PLC will shutdown the machine to avoid pump damage. From the pump, oil enters a 5 micron by-passing pressure filter and continues to the main valve bank, whose relief is set at 5,000 psi.

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________________________________________________ Hydraulic system Fig. 30: Primary hydraulic schematic

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Hydraulic system _________________________________________________

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

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

Crawler assemblies The feeder breaker is trammed by two (2) hydraulically driven crawlers (Fig. 31); 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 (idler) assembly located on the opposite end of the crawler assembly. The take-up roller 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.)

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Mechanical assemblies ____________________________________________ Fig. 31: Crawler assembly main components

1

6 (access) 4

5 (access)

3 2 4

1

5

6

1.

2.

3.

4.

5.

6.

Cat pad assembly Hydraulic motor Sprocket Torque hub Take-up cylinder and shims Take-up roller assembly

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___________________________________________ Mechanical assemblies Conveyor chain The feeder breaker is equipped with a conveyor chain assembly (Fig. 32) 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. 32: Conveyor chain components

1

3

2

1. Roll pin 2. Flight bar 3. Chain link section

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Mechanical assemblies ____________________________________________ Grease take-up The feeder breaker is equipped with two (2) conveyor chain grease take-up assemblies (Fig. 33) 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. 33: Grease take-up main components

Stop valve (2)

Grease fitting (2)

Shim storage (2)

1.

2.

3.

4.

Stop valve (2) Grease fitting (2) Shim storage (2) Take-up cylinder (2)

Take-up cylinder

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___________________________________________ Mechanical assemblies Head shaft assembly The feeder breaker is equipped with a head shaft (Fig. 34) located on the discharge end of the conveyor. The head shaft is driven from the left hand side via a hydraulic motor directly mounted to the head shaft.

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

Fig. 34: Head shaft main components 10

9 11

7

8

1 6 5 3

4

2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Hydraulic motor Gear box Retaining bolt Retainer Adapter Bearing (2) Head shaft Key (2) Sprocket (2) Sensor unit Gear box support bracket

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Mechanical assemblies ____________________________________________ Conveyor power unit The conveyor power unit drives the hydraulic pump (s) and pick breaker reducer (Fig. 35). It consists of a 125 HP electric motor coupled to a load sense pump. The power unit has been assembled as a unit and can be removed as a unit or as individual components (see Replacement of wear parts section of this chapter).

Fig. 35: Conveyor power unit main components

7 5 6 4

2

3

8

1

1.

2.

3.

4.

5.

6.

7.

8.

9.

9

Hex head bolt, Lockwasher, Flat washer, Hydraulic motor Gearbox Headshaft retainer Headshaft splined adapter Hex head bolt End cap

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___________________________________________ Mechanical assemblies Tail shaft The feeder breaker is equipped with a tail shaft (Fig. 36) 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. 36: Tail shaft components

2

3

4

1

8 9

10

1.

2.

3.

4.

5.

Key (2) Set screw (2) Slide plate Adapter (2) Bearing (2)

7

6

6.

7.

8.

9.

10.

5

Tail shaft Tail shaft roller (2) Bearing grease exit port Slide plate grease entry port Bearing grease entry port

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Mechanical assemblies ____________________________________________ Breaker and breaker power unit assembly The breaker and breaker power unit (Fig. 37) are assembled with a bolt flange coupling so that they can be installed as individual assemblies.

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

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

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

Fig. 37: Breaker and breaker power unit assembly

4 3

2

1.

2.

3.

4.

Under speed sensor Breaker power unit Bolt flange coupling Breaker shaft

1

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___________________________________________ Mechanical assemblies Breaker assembly The breaker assembly (Fig. 38) on the machine has a 32” (813 mm) pick circle with a 5 point star arrangement. It has a 10” (254 mm) shaft diameter turned down to 8” (203 mm) thru the bearings.

Fig. 38: Breaker assembly main components

18 17

13

14

12 21 8

20

10 19

5 15

3 1

16

11 9

6 7 4

2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Bolt flange End cap Seal housing Side plate Bearing housing Seal ring Bearing Bearing retainer Seal Bearing backing ring Breaker shaft

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Bit (requires 2 snap rings, supplied with bit) Bearing backing ring Bearing retainer Seal Bearing Bearing housing Seal hosing Side plate End cap Underspeed sensor mount

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Mechanical assemblies ____________________________________________ Breaker power unit The breaker power unit (Fig. 39) drives the pick breaker. It consists of a 200 HP electric motor coupled to a reducer. The power unit has been assembled as a unit and can be removed as a unit or as individual components (see Replacement of wear parts section of this chapter).

Fig. 39: Breaker power unit 9 8

6 7 5 4

1

1.

2.

3.

4.

5.

6.

7.

8.

9.

3 2

Pump Connecting tube Rotex coupling Electric motor, 200 hp Flexible coupling Torque limiter Companion flange Connecting tube Gear reducer

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

Important notes Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, it is recommend that a general maintenance plan be implemented. For example, develop 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 Cat® 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 Cat® manual.

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

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

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

■

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

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

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Maintenance _____________________________________________________ ■

If either tram drive is to be operated during maintenance or servicing, securely block the crawler clear of the ground. 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 cylinder. If maintenance must be performed while the circuit is under load, securely block the load. 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 as it increase the risk of injury to personnel.

■

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.

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

Table 2: Lubrication and maintenance schedule Item

8 9 10

Description Every 8 hours of operation Head shaft bearing Head shaft bearing seal Breaker bearing Tail shaft and slide tube bearing Tailpiece pulley bearing (if equipped) Hydraulic oil level (check) Breaker bits Weekly Pressure filter (alarm check) Return filter (alarm check) Breaker shaft underspeed sensor

11 12 13 14 15 16

Crawler track take-up bearing Conveyor chain tension Fasteners (nuts, bolts and screws) Electrical cables, conduits and glands Hydraulic hoses and connections Torque hub (check oil level)

17 18 19

1 1 1

20 21

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

22

Crawler chain tension

2

23 24

Breaker reducer (grease) Hydraulic oil tank breather vent Every 3 months Torque limiter Every 1000 hours Breaker reducer oil analysis/change as required * Conveyor reducer oil analysis/change as required * Every 6 months Hydraulic oil tank (change) Torque hub (change oil)

1 2 3 4 5 6 7

25 26 27

28 29

Places 2 2 2 4 2 1 Inspect

Lubricant

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

1 1 Inspect 2 Inspect Inspect Inspect Inspect 2

2 2

2 Inspect

Spec. 100-3

Spec. 100-2 or Spec. 100-13 Spec. 100-6 Spec. 100-6

Spec. 100-3 Spec. 100-14 or Spec. 100-16 Spec. 100-14 or Spec. 100-16 Spec. 100-3

Inspect

1 2

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

* Initial oil change to be done after first 500 hours of operation. ______________________________________________________________ A6474X391

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Maintenance _____________________________________________________ Table 3: Lubricants: Fluids and capacities Location Hydraulic oil tank Breaker reducer Conveyor reducer Torque hub Grease points (except electric motors) Grease points (electric motors)

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

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

Spec. 100-14 or Spec. 100-16

Two pumps per month (hand pump only)

As required

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____________________________________________________ Maintenance Fig. 40: Lubrication chart

5 (tail piece bearing location)

1,2 (bearing and seal location)

5 (tail piece bearing location)

1,2 (bearing and seal location)

12 (chain tension check location) 7 3 (bearing location)

3 (bearing location)

23 (seal location)

10

20

20

12 (take-up cylinder location)

4 (tail shaft and slide tube bearing location)

12 (take-up cylinder location)

4 (tail shaft and slide tube bearing location)

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Maintenance _____________________________________________________ Fig. 40 (continued): Lubrication chart

5 (grease fitting location)

5 (grease fitting location)

17, 27 21, 23 (grease fitting location) 21 (bearing location) 23 (seal location)

19 25

18, 26

28 24

6 16, 29

16, 29

9 22

1, 2 (grease fitting location)

11

3 (grease fitting location) 4 (grease fitting location)

8 22 11

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

Every 8 hours of operation head shaft bearings

breaker bearings

tail shaft and slide tube bearings

Lubricate the feeder breaker head shaft bearings with Spec. 100-3 through the grease fittings located lubrication panel (Fig. 41) located on the right side of the machine at the hopper end. Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

Lubricate the breaker shaft bearings with Spec. 100-3 through the grease fittings located lubrication panel (Fig. 41) located on the right side of the machine at the hopper end. Pump grease into the two (2) fittings until new grease can be observed coming out of the return ports.

Lubricate the feeder breaker tail shaft and slide tube bearings with Spec. 100-3 through the grease fittings located on right side of the machine at the primary operator’s station (Fig. 41). Pump grease into the four (4) fittings until new grease can be observed coming out of the return ports.

Fig. 41: Head shaft, breaker, and tail shaft bearing lubrication

Tail shaft bearings

Breaker bearings

Head shaft bearing

Tail shaft return ports (if equipped)

Breaker return ports

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Maintenance _____________________________________________________ Fig. 41: Head shaft, breaker, and tail shaft bearing lubrication (continued) Head Shaft Bearing Grease Fitting

Head shaft bearing

Tail Shaft Bearing Grease Fitting

Tail shaft bearings

Breaker Bearing Grease Fitting

Breaker bearings

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____________________________________________________ Maintenance hydraulic oil tank

Check the hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 42). The oil level should not be allowed to drop below the bottom of the sight glass. If the hydraulic oil level is low, add hydraulic oil (Spec. 100-1). To add oil via the power fill, reference the following procedure.

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

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

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

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

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

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

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

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

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

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

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

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Maintenance _____________________________________________________ Fig. 42: Hydraulic oil level check Power fill ball valve

Sight glass pressure filter

return filter

The pressure filter is located on the left side of the machine (Fig. 43).

Check the dirt alarm located on the filter and change as required.

The return filter is located on the left side of the machine (Fig. 43).

Check the dirt alarm located on the filter and change as required.

Fig. 43: Pressure and return filter locations

Pressure filter

Return filter

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____________________________________________________ Maintenance breaker bits

Check the breaker bits (Fig. 44) before every shift 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 44: Breaker bits

Breaker bits

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Maintenance _____________________________________________________ Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 45) 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. 45: Crawler track take-up lubrication

Crawler take-up bearings (typical both sides)

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

conveyor chain tension

Check the conveyor chain tension. As the conveyor chain comes around the head shaft sprocket, measure the amount of swag the conveyor chain has from the bottom of the sprocket (Fig. 46). If the swag is greater than 2 inches, adjust the chain tension (see Conveyor chain adjustment procedure in this chapter). With the machine running, visually inspect tail shaft to ensure shaft is turning and conveyor chain is not sliding across tail shaft.

Fig. 46: Conveyor chain tension measurement

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____________________________________________________ Maintenance fasteners

electrical cables, conduits and glands hydraulic hoses and fittings

tram reducers

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

head shaft bearing bolts

■

breaker shaft side plate bolts

■

conveyor drive motor mounting bolts

■

tail shaft retainer hold down bolts

■

all cover and guard retaining bolts

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

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

Check the oil level in both tram reducer torque hubs (Fig. 47):  Position the oil level check and fill plugs at the 3 o’clock and 12 o’clock positions so that they are accessible through the cutouts in the cover .  Remove the oil level check and fill plugs. When correctly filled, oil should just begin to flow from the check oil level check hole.  If it is necessary to add oil, add Spec.100-2 or 100-13 through the fill hole until it begins to flow out of the check hole. Do not overfill the reducer.  Replace the fill and check plugs.

Fig. 47: Tram reducer oil level Fill plug

Check plug

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Maintenance _____________________________________________________ breaker reducer

Check oil level in the breaker drive reducer (Fig. 48). To access the dipstick, remove the cover from on top of the reducer. If oil is needed, add oil (Spec. 100-6) through the dipstick hole or the fill port until the correct level is reached on the dipstick. .

Fig. 48: Breaker reducer oil level

Fill port, breather, and dip stick

Drain plug (located on bottom of gearcase)

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____________________________________________________ Maintenance dust system strainer

Clean the strainer mounted inside the dust suppression system located under the breaker power unit on the right side of the machine. Turn the ball valve handle (Fig. 49) to open the water line. Allow to flush for approximately thirty seconds to one minute. Close ball valve.

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

Fig. 49: Dust system strainer Pressure gauge

Ball valve

Regulator handle

Regulator

Strainer

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Maintenance _____________________________________________________ tailpiece bearing (belt pulley)

Grease the tailpiece bearing (2 places) through the grease manifold (Fig. 50) 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. 50: Tailpiece bearing (belt pulley)

Grease manifold

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____________________________________________________ Maintenance Monthly crawler anchor pins

Lubricate grease fittings on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 51). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 51: Crawler anchor pin lubrication

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

Lubricate the breaker power unit electric motor with Spec. 100-14 or Spec. 100.16 high temperature grease through the two (2) grease fittings located on the lubrication manifold (Fig. 52) 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.

breaker reducer

Lubricate the breaker reducer with Spec. 100-3 through the two (2) grease fittings located on the below the breaker electric motor (Fig. 52) located on the right side of the machine. Pump only one or two pumps of grease into each fitting using a hand grease gun.

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

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Maintenance _____________________________________________________ Fig. 52: Breaker reducer lubrication

Electric motor grease fitting (2)

conveyor motor/gearbox

Breaker reducer grease fitting (2)

Check the gearbox oil level through the oil level sight glass. If low add oil thought the breather/fill port.

Fig. 53: Conveyor motor/gearbox

Breather/fill port

Sight glass Drain plug

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____________________________________________________ Maintenance hydraulic oil tank breather vent

Check the breather vent element on the hydraulic oil tank (Fig. 54) and change as required.

Fig. 54: Hydraulic oil tank breather vent Breather vent

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Maintenance _____________________________________________________ Every three months breaker reducer cooling fan

Remove the connecting tube cover (Fig. 55) and inspect the breaker reducer fan. Clean all accumulated debris from the fan, guard, and deflector.

Fig. 55: Breaker reducer cooling fan

Cooling fan

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____________________________________________________ Maintenance Every 1000 hours breaker reducer oil analysis

Every 1000 hours of operation, analyze a breaker reducer oil sample.

Follow mine analysis oil change guidelines to determine whether oil needs changed. If no mine standards are established, the following guidelines may be used: ■

Water content is greater than 500 ppm (0.05%)

■

Iron content exceeds 150 ppm

■

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

■

Copper content exceeds 75 ppm

■

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

■

Viscosity changes more than ±15%

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

Change the oil in the breaker drive reducer (Fig. 56) as indicated by the oil analysis or every six months/2500 hours of operation.

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

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Maintenance _____________________________________________________ Fig. 56: Breaker reducer Oil fill, breather, and dip stick location

Drain plug (located under cooling fan)

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____________________________________________________ Maintenance Every 6 months hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank (Fig. 57).  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. 57: Hydraulic tank oil level

Power fill ball valve

Breather vent

Sight glass

Drain plug (under tank)

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Maintenance _____________________________________________________ tram reducer

Change oil in the tram reducer (Fig. 58).  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. 58: Tram reducer oil change Fill plug

Check plug

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____________________________________________________ Maintenance breaker power unit torque limiter

Inspect the breaker power unit torque limiter clutch for wear. The measurement shown in Fig. 59 should be 3.55 inches for a new torque limiter. When the measurement reaches 3.46 inches, rebuild using kit part number 622432 or replace the entire torque limiter (see the Cat® parts book for your machine for torque limiter part number).

Fig. 59: Torque limiter wear check

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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: 1. Clean and remove any foreign material from the operator’s station.

2. Inspect all electrical cables, conduits, hydraulic hoses, fittings and warning devices for signs of wear or damage.

3. Visually inspect the condition and readability of all tags, labels and reflectors.

4. Check the “STOP” button (s) for correct operation.

5. 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.

6. Check oil level in the crawler reducers.

7. Inspect the condition of all electrical and hydraulic components.

8. Check for proper conveyor chain tensioning.

9. Check for proper crawler chain tensioning.

10. Lubricate per the lubrication schedule.

11. Check power input cable to power source insuring that the voltage and breaker settings are correct.

12. Check that the cable handling device is intact and oriented correctly.

13. Check that all covers are installed and secure.

14. Check the tightness of all connecting elements.

15. Check that the neutral start mechanism is installed on the primary valve bank.

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____________________________________________________ Maintenance Inspection of wear parts In order to be able to determine in good time when a repair shift has to be scheduled, and to avoid damage to other components, it is essential to inspect all the following wear parts as to their degree of wear: 1. conveyor chain 2. conveyor chain flights 3. conveyor drive sprockets 4. conveyor tail shaft 5. conveyor wear plates 6. crawler pads 7. crawler drive sprockets 8. crawler idler rollers

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Maintenance _____________________________________________________ Inspection of fire suppression system To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 60).

1.

Note general appearance for mechanical damage or corrosion.

2.

Check nameplate for readability, corrosion or looseness.

3.

Remove fill cap assembly.

4.

Examine gaskets for elasticity, clean and coat lightly with a good grade of high heat resistant grease.

5.

Inspect threads on fill cap and in fill opening for nicks, burrs, cross threading, rough or feathered edges.

6.

Check pressure relief vent in fill opening threads for obstruction.

7.

Make certain extinguisher is filled with free flowing Ansul dry chemical to a level of not more than 3” from bottom of fill opening.

8.

Unscrew cartridge and weigh (replace if weight is ½ oz. less than stamped on cartridge).

9.

Inspect thread on cartridge and in receiver/actuator for nicks, burrs, cross threading, rough or feathered edges.

10. Check pressure vents in receiver/actuator for obstruction.

11. 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.

12. 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).

13. Reposition extinguisher, engage bursting disc union (wrench tighten) and close bracket clamp.

14. Check hoses, fittings and nozzles for mechanical damage.

15. Check nozzle openings; slot should be closed (capped) with silicone grease.

16. Check remote actuator (dashboard type).

17. Remove cartridge and weigh (replace if weight is ¼ oz. less than stamped on cartridge.

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____________________________________________________ Maintenance 18. Inspect threads on cartridge and in actuator for nicks, burrs, cross threading, rough or feathered edges.

19. Check pressure safety vent in actuator body for obstruction.

20. Examine actuator cartridge gasket for elasticity, clean and lightly coat with a good grade of high heat resistant grease.

21. Pull ring pin and operate actuator button several times to check for free movement.

22. Seal ring pin to puncture lever with lead and wire seal. Return cartridge to remote actuator, hand tighten.

23. Record date of maintenance and notify operating personnel that system is back in service.

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Maintenance _____________________________________________________ Recharge of fire suppression system To return your fire suppression system to service after use (Fig. 60).

1.

Pull ring on safety valve to relieve actuator system pressure.

2.

Disconnect actuation system hose at cartridge receiver/actuator assembly.

3.

Open bursting disc union assembly.

4.

Remove extinguisher from bracket.

5.

Replace ruptured bursting disc with new disc. (Full disc side must face extinguisher).

6.

Fill extinguisher to rated capacity with Ansul dry chemical specified on nameplate.

7.

Clean fill opening threads and gasket seating surface.

8.

Secure fill cap, hand tighten.

9.

Remove cartridge guard assembly.

10. Remove empty cartridge.

11. Make certain that receiver/actuator puncture pin is fully retracted.

12. Screw full charged cartridge into receiver/actuator assembly, hand tighten.

13. Replace cartridge guard.

14. Secure extinguisher in bracket.

15. Assemble bursting disc union, wrench tighten.

16. Connect actuation system hose at cartridge receiver/actuator assembly, wrench tighten.

17. 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.

18. Record date of recharge and notify operating personnel that system is back in service.

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____________________________________________________ Maintenance Fig. 60: Fire suppression system Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Nozzle

Breaker coupling

Operator’s station

Nozzle Nozzle Breaker motor Nozzle

Nozzle

Oil tank LP canister

LP expellant

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Adjustment procedures ___________________________________________ Procedure to set Amplifier Card (EV1M2-12/24) 1. Start the pick breaker 2. Go to the valve bank and lift the valve bank handle retainer bar out of the way, so you can visibly see the movement of the conveyor handles (when the conveyor is running).

3. Place the machine in Conveyor, Forward and then Manual mode.

The conveyor will start.

4. On the display, go to the “Present Screen” (see fig. A1) Fig. A1: Preset Screen

5. Select “Low Speed” and change the percentage to “20%”. (Note: this percentage can be anything you want, as long as it is large enough to get the conveyor to start moving). The conveyor will be running full speed because Imin and Imax are at the same reference point (the valve handles will be visibly all the way forward). Next the Imin must be set.

6. Go to the amplifier cards on the back of the door, there will be two.

Find the Imin set screw (shown on Fig. A2 as item #9) Fig. A2: Imin & Imax set screw Imin Imax

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___________________________________________ Adjustment procedures

7. Turn Imin set screw counter clockwise. Visually verify (that the handles are moving) for which solenoid you are controlling, and get the handle to where it is 20% displaced from its rest position. This will have to be done to both amp cards.

8. Once you have both valve handles in the same position, you can go to the display and select “High Speed” on the “Preset Screen” (verify high percentage is set to 100%), your conveyor should be running at full speed (the valve handles should be fully displaced). If the handles are not fully displaced, you will need to adjust the Imax. Go to the amplifier cards, turn the Imax set screw (shown on Fig. A2 as item #10) clockwise, until you see the valve handles fully displaced (all the way forward).

9. Go back to the “Preset Screen” and select “Low Speed” and verify the valve handles went to your set low speed (handles displaced 20%) and reselect “High Speed” to verify high speed was set (handles fully displaced).

10. Go to the “Preset Screen” and select “Medium Speed” and enter your medium speed percentage. You do not need to adjust the amplifier card for the medium set point.

11. Once you have set the Imin and Imax set points you can change the percentages on the “Preset Screen” to what you want between your two set point percentages.

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

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

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

Conveyor chain tension With the machine off, check the conveyor chain tension at the head shaft end (Fig. 61). When the conveyor chain is properly tensioned, there will be approximately 2 inches (50 mm) of droop on the bottom side of the head shaft sprockets. With the machine running, visually inspect tail shaft to ensure shaft is turning and conveyor chain is engaging the tail shaft sprockets properly.

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___________________________________________ Adjustment procedures Fig. 61: Conveyor chain tension

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Adjustment procedures ___________________________________________ 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. 62): 1. Close the needle valve on manifold assembly securely.

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

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

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

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

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

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

5. Replace retainers.

6. Release pressure on the take-up cylinders by opening the top valve to vent grease. After grease has vented, close valve.

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

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

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___________________________________________ Adjustment procedures Fig. 62: Conveyor chain adjustment

Needle valve (2)

Grease fitting (2)

Shim storage (2)

Grease take-up cylinder (2)

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

To adjust crawler track tension with the take-up cylinders (Fig. 63): 1. Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

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

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

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

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

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

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

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

7. Shutdown machine.

8. If necessary, re-adjust chain sag.

9. Add or remove shims to maintain correct tension.

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

11. Install shim retainer plate.

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

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

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___________________________________________ Adjustment procedures Fig. 63: Crawler track adjustment

When properly tensioned, chain sag should be 2” at center of crawler.

Access cover

Cylinder retainer bar/shim retainer plate mount

Retainer plate

Grease fitting

Needle valve

Take-up cylinder

Shims (located behind retainer plate)

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Adjustment procedures ___________________________________________ Breaker shaft and power unit height adjustment To adjust the height of the breaker shaft and power unit (Ref. Fig. 64): 1. Remove covers to gain access to both ends of the break shaft, above the breaker shaft, and the power unit.

2. Attach a lifting device to the power unit and breaker shaft so that both components remain level during the adjustment procedure.

3. Take up all slack in the lifting device.

4. Remove all breaker shaft side plate hardware. a.

1-1/4 inch lock washers (24)

b.

1-1/4 inch hex nuts (24)

c.

1-1/4X5 inch hex head bolts (4)

d.

1-1/4X4 inch hex head bolts (20)

5. Remove the pivot lug mounting plate hardware. a. 1 inch lock washers (4) b. 1X2 inch hex head bolts (4) WARNING! Failure to adjust both the position of both the torque arm bracket and the breaker shaft side plates to the same height will result in misalignment of the power unit and the breaker shaft. The breaker shaft will bind, resulting in machine damage.

6. Using the lifting device, adjust the height of the breaker shaft and power unit. The assembly may be adjusted up or down in two inch increments.

7. Reinstall the breaker shaft side plate hardware. a.

1-1/4 inch lock washers (24)

b.

1-1/4 inch hex nuts (24)

c.

1-1/4X5 inch hex head bolts (4)

d.

1-1/4X4 inch hex head bolts (20)

7. Reinstall the pivot lug mounting plate hardware. a. 1 inch lock washers (4) b. 1X2 inch hex head bolts (4) 8. Remove the lifting device.

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___________________________________________ Adjustment procedures Fig. 64: Breaker shaft and power unit height adjustment

Pivot lug mounting plate and hardware

Breaker shaft side plate and hardware

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Adjustment procedures ___________________________________________ Underspeed sensor calibration To calibrate the underspeed sensor (Fig. 65): 1. Start the feeder breaker (see Startup procedure in this chapter).

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

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

3. Confirm red LED lights up when intended target passes in front of sensor 4. Press calibration switch to set the unit to desired targets. The green LED will confirm calibration state.

Fig. 65: Under speed senor calibration

Test switch

Calibrate switch

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___________________________________________ Adjustment procedures Fig. 65: Under speed senor calibration (continued)

Test/set switch, SW1 Speed 1 control switch

Test/set switch, SW1

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

Main pump adjustments Margin pressure The adjustment of the load sense margin pressure is located on the control block at the top rear of the pump. It is the adjusting screw located at the front of the block.

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

2. With no functions active, the margin pressure should read 30 bar (435 psi). If adjustment is necessary: a. Locate the margin pressure cartridge (Fig. 66). b. Loosen the hex nut that holds the adjustment stem in place. c.

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

d. Once the desired pressure, 30 bar (435 psi), is obtained, tighten the hex nut while holding the adjustment stem in place. e. After the hex nut is tight, recheck the pressure to ensure the adjustment stem did not move. If necessary, readjust.

Pressure compensator The adjustment of the pressure compensator setting is located on the control block at the top rear of the pump. It is the adjusting screw located at the rear of the block. The pressure compensator must be adjusted while the pump is “loaded”. This is best accomplished with the conveyor function engaged.

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

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

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___________________________________________ Adjustment procedures 3. Zero out the margin pressure adjustment by turning the adjustment stem (Fig. 66) clockwise (in) all the way. This system will now be a pressure compensated system and will maintain system pressure at all times. The pressure should now read 350 bar (5,000 psi). If adjustment is necessary: a. Loosen the hex nut that holds the adjustment stem in place. b. Turn the stem clockwise (in) to increase pressure or counterclockwise (out) to decrease pressure. c.

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

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

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

Fig. 66: Pump

Pressure compensator adjustment

Margin pressure adjustment

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Adjustment procedures ___________________________________________ Main relief pressure To adjust the main relief (Fig. 67): 1. Maximize the main relief setting. a. Loosen the jam nut that holds the adjustment stem in place. b. Turn the adjustment stem fully clockwise.

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

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

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

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

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

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

Fig. 67: Main relief Main relief adjustment (on end of block)

Pressure limiter “A” adjustment

System pressure

Pressure limiter “B” adjustment

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___________________________________________ Adjustment procedures Pressure limiter adjustment To adjust the pressure limiter (Fig. 67).

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

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

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

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

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

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

7. Replace the cap over the adjustment stem.

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

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Replacement of wear parts _________________________________________

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

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

Head shaft The head shaft (Fig. 68) transmits the torque of the hydraulic motor to the conveyor chain assembly and is part of a complete assembly. As soon as any component is worn, the component or complete head shaft must be replaced. Due to high abrasion forces, the chain sprockets are subject to a very high level of wear.

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

head shaft

■

sprockets (2)

■

bearings (2)

Fig. 68: Head shaft main components Sprocket (2) Head shaft Key (2)

Bearing (2)

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________________________________________ Replacement of wear parts How to remove the headshaft To remove the headshaft assembly from the feeder breaker proceed as follows (Fig. 69): WARNING! You could be seriously injured or even killed by falling loads.

Whenever instructed to lift or block, observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

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

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

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

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

5. Remove the last cover’s support post.

6. Block and secure tailpiece.

7. Unpin and fold down tailpiece tilt cylinders (if equipped). It is not necessary to remove hydraulic hoses.

8. Remove the tailpiece hoppers (2) (if equipped) and head shaft filler plates (2) using appropriate lifting equipment.

9. Remove the hydraulic motor. The motor can remain on the gearbox if desired. a. Disconnect, tag, and cap all hydraulic hoses. b. Remove the five (5) 1/2” bolts, lock washers, and flat washers from the end of the motor.

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

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

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

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Replacement of wear parts _________________________________________ 13. Attach an appropriate lifting device to the headshaft and slide out towards the rear of the frame.

How to install the headshaft To install the headshaft assembly proceed as follows (Fig. 69): 1. Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the feeder breaker. The gear reducer may be installed on shaft if desired.

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

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

Torque bolts to 645 ft-lbs.

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

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

4. Install the left and right sprocket guards and head shaft filler plates.

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

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

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

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

9. Install cover support post and cover.

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

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

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________________________________________ Replacement of wear parts 12. Using an appropriate lifting device install the tailpiece hoppers (2) and head shaft filler plates (2) (if equipped) using appropriate lifting equipment (see installing the tailpiece in this chapter).

13. If equipped, attach the tailpiece lift cylinders (2) into the tailpiece hopper weldments using pins and cotter pins (see installing the tailpiece in this chapter).

Fig. 69: Head shaft removal and installation

10

9 11

7

8

1 6 5 3

4

2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Hydraulic motor Gear box Retaining bolt Retainer Adapter Bearing (2) Head shaft Key (2) Sprocket (2) Sensor unit Gear box support bracket

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Replacement of wear parts _________________________________________ Head shaft sprockets The head shaft sprockets transmit the torque of the hydraulic motor to the conveyor chain assembly and are part of the headshaft assembly.

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

How to remove the head shaft sprockets Note: If replacing one piece sprockets with split sprockets, torch the old sprockets off of the shaft and then follow Split sprocket installation procedure.

To remove the sprockets from the head shaft assembly (Fig. 70): 1. Remove the headshaft assembly from the feeder (see Headshaft removal in this chapter).

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

3. Remove the two (2) set screws from each sprocket (it may be necessary to apply heat to loosen Loctite).

4. Slide both sprockets from the drive shaft.

5. Remove old keys.

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

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

How to install the head shaft sprockets To install the sprockets on the head shaft (Fig. 70): 1. Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.

2. Insert one of the keys into the shaft keyway and slide first sprocket onto shaft (see Fig. 69 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 69 for weld specifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.

3. Insert the other key into the shaft keyway and slide second sprocket onto shaft (see Fig. 69 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 68 for weld spcifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.

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

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

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________________________________________ Replacement of wear parts How to install the head shaft split sprockets To install the split sprockets on the head shaft proceed as follows (Fig. 70): IMPORTANT! Adhere to all weld specifications shown on Fig. 70. Failure to do so may result in sprocket failure and machine damage.

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

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

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

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

5. Thoroughly clean and degrease the drive shaft.

6. Insert key into shaft keyway.

7. Install both sprocket halves onto shaft and tack weld in place (see Fig. 69 for location). Ensure sprocket alignment and proper spacing with conveyor chain.

8. Preheat sprocket weld joint to 600°F .

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

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

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

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Replacement of wear parts _________________________________________ Fig. 70: Head shaft sprocket removal and installation 1

3/8 X 45° weld chamfer

3

2

3/8 X 45° weld chamfer

Split sprocket (typical) 5

1.

2.

3.

4.

5.

4

General notes: 1.

2.

3.

Bearing (2) Head shaft Sprocket guard Sprocket (2) and key (2) 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 (optional) Taconite seal (optional)

(optional for one piece sprockets)

(optional for one piece sprockets)

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________________________________________ Replacement of wear parts Tail shaft The tails haft (Fig. 71) 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.

Fig. 71: Tail shaft main components 2

4

3

1

7 6 5 1.

2.

3.

4.

5.

6.

7.

Key (2) Set screw (2) Slide plate Adapter (2) Bearing (2) Tail shaft Sprocket or roller (2)

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Replacement of wear parts _________________________________________ How to remove the tail shaft WARNING! You could be seriously injured or even killed by falling loads.

Whenever instructed to lift or block, observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

To remove the tail shaft assembly (Fig. 72): 1. Remove the RTV silicone from twelve (12) bolt heads and remove the bolts from each end of the tailshaft retainers and lift out the retainers.

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

3. Release tension on the conveyor chain by removing the tail shaft shims. Open the valves on the grease cylinder take-up manifold located on the left hand side of the machine, directly above the tilt cylinder. Pry the tailshaft toward the discharge end of the machine to fully collapse the grease take-up cylinders.

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

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

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

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

How to install the tail shaft To install the tail shaft assembly (Fig. 72): 1. Apply a coat of grease to the bearing guide bars.

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

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

4. Fold the conveyor chain over tailshaft.

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________________________________________ Replacement of wear parts

 5. Connect conveyor chain (see Conveyor chain replacement in this chapter.

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

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

8. Coat the twelve (12) 3/4-10X1-1/2” countersunk bolts with Never Seez and install the tailshaft retainers. Fill the bolt heads with blue RTV silicone.

9. Open the grease valves on the conveyor chain take-up manifold to allow shims to carry the conveyor chain load.

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

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Replacement of wear parts _________________________________________ Fig. 72: Tail shaft removal and installation 3

2

5 4

1

6

10 9

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Countersunk bolt, 3/4-10X1-1/2” (12) Tail shaft retainer, right hand Tail shaft cover Push rod Grease take-up cylinder Shims Grease manifold Tail shaft retainer, left hand High speed swivel Tail shaft

8

7

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________________________________________ Replacement of wear parts How to disassemble the tail shaft To disassemble the tail shaft assembly (Fig. 73): 1. Remove the tailshaft assembly from the feeder breaker. (see Tailshaft removal procedure in this chapter).

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

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

4. Remove the tailshaft from the slide plate.

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

How to assemble the tail shaft To assemble the tail shaft assembly (Fig. 73): 1. Thoroughly clean all parts that will be installed.

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

3. Slide tailshaft into the slide plate.

4. Insert key into keyway on tailshaft.

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

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

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

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

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

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

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Replacement of wear parts _________________________________________ Fig. 73: Tail shaft disassembly and assembly Set screw (2)

Key (2) Tail shaft

Roller (2)

Bearing (2) Slide plate

Piston rod adapter (2)

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________________________________________ Replacement of wear parts Conveyor chain The conveyor chain (Fig. 74) is made up of one basic chain assembly which repeats sequentially along the entire chain loop. As soon as any component of the conveyor chain is worn the component or complete conveyor chain assembly must be replaced.

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

6 link chain section

■

flight bar

■

spiral pin

Fig. 74: Conveyor chain main components

Spiral pin

6 link chain section

Flight bar

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Replacement of wear parts _________________________________________ Measure Chain for Elongation One of the most important areas in the evaluation of chain wear is the elongation of the chain. This is obtainable in the field and does not require chain disassembly or return to manufacturer for analysis.

To measure a chain for elongation: The selected strand must be under some load to pull out internal clearances and must be supported, if necessary, to insure the chain lies in a straight line.

The ideal selected strand should include 20 pitches, to ensure a result representative of the entirety of the chain. If less are measured, the absolute minimum of four pitches is considered acceptable (more pitches measured, provides a higher resolution of elongation). Always use an even number of pitches for straight sidebar chain.

Use any reasonably accurate measuring device (steel ruler, calipers, tape measure, etc.).

Determine the distance from a spot on the first pitch to the same spot on the last pitch. The edge of the pin head is usually a good spot to measure (see Fig. 75).

Fig. 75: Chain elongation measurement

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________________________________________ Replacement of wear parts Replacement chain should be order at approximately 2.6% elongation and replaced at approximately 3% elongation. It is highly recommended that the head shaft sprockets be changed at the same time as a new chain is installed to obtain maximum chain life.

Table 4 lists chain order and replacement values.

Table 4: Chain elongation values Chain Pitch

Baseline Length (20 pitches) 70 inches

Order Length (approximately 2.6%) (20 pitches) 71 13/16 inches

Replacement Length (approximately 3%) (20 pitches) 72 1/8 inches

3.500 3.750

75 inches

76 15/16 inches

77 1/4 inches

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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. 76): 1. Lay conveyor chain sections on a clean flat surface.

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

3. Insert spiral pin.

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

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

Fig: 76: Conveyor chain assembly 6 link chain section

Extended pin connecting link

Spiral pin (4)

Flight bar Block link assembly Side bar

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Replacement of wear parts _________________________________________ TAC monitor for conveyor speed sensor To replace the conveyor speed sensor TAC monitor: Note: The machine shipped from the factory with TAC monitor model 22-8100. This model is obsolete and has been replaced with model 220 -8100. All instructions are for the installation of 220-8100.

1. Disconnect power from the machine following all applicable lockout/tagout regulations.

2. Open the control panel enclosure and locate the existing TAC monitor, mounted on the front side of the swing panel (Fig. 77).

Fig. 77: TAC monitor location (typical)

TAC monitor

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________________________________________ Replacement of wear parts 3. Disconnect the existing monitor and remove.

4. Mount the new monitor on the swing panel. Connect the wires as shown in Table 5. Note: the connections on the model 22-8100 TAC monitor do not match the connections on the new monitor.

Table 5 is for the 220-8100 model only.

Table 5: Terminal connections (220-8100 model) Terminal

Connection Front

1

No connection

2

No connection

3

4-20mA Output - Positive (+)

4

4-20mA Output - Common (1)

5

No connection

6

No connection

7

Sensor Input (+)

8

Sensor Input Common (-) Back

9

No connection

10

No connection

11

No connection

12

No connection

13

No connection

14

No connection

15

AC Input (N)

16

AC Input (H)

5. Restore power to the machine.

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Replacement of wear parts _________________________________________ Setup and display indicators When power is applied to the TAC monitor, the display will should show the following: 000 RPM - displays the actual value from the remote speed sensor. If “Line Open” is displayed, check the 4-20mA line. The maximum line resistance is 0-500 ohm.

10-XXXX RPM - displays the current speed range of the TAC monitor (10 to XXXX RPM). The display should read 10-100 RPM. If the correct range is not selected, chose the correct range as follows: 1. Press and hold the “SET” button for approximately 4 seconds. The display should now show models from 100 RPM top range to 6000 RPM top range.

2. Using the arrow key, highlight the 100 RPM top range model from the list.

3. With the 100 RPM top range model selected, press and hold the “SET” button for approximately 4 seconds. The display will now change back to normal operation with eh new RPM range shown on the bottom of the screen.

Note: If a selection is not made with approximately 10 seconds, the display will return to normal operation and will keep the existing model speed range.

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________________________________________ Replacement of wear parts Crawler track The crawler track (Fig. 78) assembly (left and right) carries the machine via torque received from the tram drive reducer. The crawler track is made up of two crawler pad links, one block link and one pin link, which alternatingly repeat 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: 1. Crawler pad block link 2. Crawler pad pin link 3. T-head cotter pin Fig. 78: Crawler track main components

2 1

3

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Replacement of wear parts _________________________________________ How to assemble the crawler track pads (Fig. 78) To assemble the crawler track pads proceed as follows: 1. Lay crawler track pads on a flat surface.

2. Align pads with chain connecting holes centered.

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

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

5. Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly (Fig. 78) To remove the crawler track pad assembly proceed as follows: 1. Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

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

3. Separate the crawler pads (Fig. 78).

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

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

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

4. Inspect the crawler drive sprocket and idler rollers for wear or damage. Replace if necessary.

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________________________________________ Replacement of wear parts How to install the crawler track pad assembly To install the crawler track pad assembly proceed as follows (Fig. 78): 1. Remove old crawler track pad assembly (see previous section, How to remove crawler track pad assembly).

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

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

3. Slide crawler track pad assembly under crawler assembly.

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

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

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

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Replacement of wear parts _________________________________________ Crawler assembly The crawler assembly (Fig. 79) 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.

Fig. 79: Crawler assembly main components

1

2

5

4

3

1.

2.

3.

4.

5.

Crawler track Hydraulic motor (not shown) Torque hub Grease take-up (located behind cover) 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. 80): 1. Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

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

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

4. Securely block under the crawler frame.

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

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

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

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

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

9. Inspect all components for wear or damage.

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Replacement of wear parts _________________________________________ How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 80): 1. Remove old take-up assembly (see previous section, How to remove crawler take-up assembly).

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

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

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

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

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

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

7. Connect hydraulic hoses to tilt cylinder.

8. Purge hydraulic system of air.

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

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________________________________________ Replacement of wear parts Fig. 80: Crawler take-up removal and installation

1

3

2

1. Tilt cylinder 2. Tilt cylinder mounting bracket 3. Crawler take-up

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Replacement of wear parts _________________________________________ How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 81): 1. Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

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

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

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

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

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

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

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

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

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

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

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

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

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________________________________________ Replacement of wear parts 13. If not replacing the hydraulic motor, it is not necessary to separate the adapter plate from the hydraulic motor. If replacing the hydraulic motor, remove the four (4) nuts and lock washers that secure the hydraulic motor to the adapter plate. And remove adapter plate.  14. Thoroughly clean and degrease the adapter plate mating face.

15. Remove the twenty (20) bolts and lock washers that secure the sprocket to the torque hub and separate hub and sprocket.

16. Inspect all components for wear or damage.

______________________________________________________________ A6474X391 REV 4 5.131

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Replacement of wear parts _________________________________________ How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 81): 1. Remove old crawler drive assembly (see previous section, How to remove crawler drive assembly).

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

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

3. Place sprocket onto torque hub and secure with the twenty (20) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

■ ■ ■

Step 1: 70 ft-lb Step 2: 140 ft-lb Step 3: 210 ft-lb

4. Thoroughly clean and degrease the adapter plate and mating faces of the torque hub and hydraulic tram motor.

5. Apply Loctite 518 gasket eliminator or equivalent to the adaptor plate. Be sure to apply the sealant completely around all bolt holes to prevent leakage.

6. Place hydraulic motor gasket onto motor adapter plate.

7. Apply Loctite 518 to the second side of the motor gasket.

8. Install adapter plate and gasket onto hydraulic motor and secure with the four (4) nuts and lock washers. Apply Loctite 242 (blue) to nuts.

9. Apply Loctite 518 to the adapter plate gasket.

10. Place adapter plate gasket onto the adapter plate.

11. Apply Loctite 518 gasket eliminator or equivalent to the second side of the adaptor plate gasket. Be sure to apply the sealant completely around all bolt holes to prevent leakage.

12. Install motor and adapter plate assembly onto torque hub, being careful not to damage motor shaft or gasket. Secure with the (4) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows: ■ ■ ■

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

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________________________________________ Replacement of wear parts 13. If using a motor adapter plate that does not have the keepers already installed, weld four (4) keepers against the motor flanges to prevent motor movement.

14. Clean all dirt and debris from mounting area of crawler frame.

15. Attach an appropriate lifting device to the torque hub and slide complete assembly into crawler frame.

16. Secure torque hub assembly to frame with the twelve (12) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

■ ■ ■ ■

Step 1: 50 ft-lb Step 2: 140 ft-lb Step 3: 280 ft-lb Step 4: 420 ft-lb

17. Connect hydraulic hoses to drive motor.

18. Install and connect crawler and track pad assembly (see How to install the crawler track pad assembly in this chapter).

19. Install the removable side plate and secure with the six (6) bolts and lock washers. Torque incrementally as follows.

■ ■ ■

Step 1: 300 ft-lb Step 2: 600 ft-lb Step 3: 905 ft-lb

20. Apply grease to anchor pin and slide anchor pin through crawler frame and tilt cylinder. Secure pin with slotted nut, washer and roll pin.

21. Purge hydraulic system of air.

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

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Replacement of wear parts _________________________________________ Fig. 81: Crawler drive disassembly and assembly

25 1

16, 17

21

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18

8

10, 13, 14 9

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3, 4

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6, 7

22 5 19

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crawler frame torque hub washer (high collar lock) (12) cap screw (socket head) (12) sprocket washer (high collar lock) (20) cap screw (socket head) (20) gasket (adaptor plate) plate (adaptor)

10.

11.

12.

13.

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washer (lock) (8) cap screw (hex head) (4) gasket washer (flat) (4) nut (hex) (4) keeper washer (lock) (6) bolt (hex head) (6) crawler pad

19.

20.

21.

22.

23.

24.

25.

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

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________________________________________ Replacement of wear parts Breaker shaft and breaker power unit The breaker power unit (Fig. 82) and the breaker shaft assembly (Fig. 83) can be removed or installed as a single assembly or as two separate assemblies.

Fig. 82: Breaker power unit main components

7

8

9

10

6 4 5 2

3

1

1.

2.

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4.

5.

Pump assembly Connecting tube Pump coupling Electric motor, 200 hp Flexible coupling

6.

7.

8.

9.

10.

Torque limiter clutch Taperloc bushing Companion flange Connecting tube Gear reducer

It is important to check the torque limiter clutch (item 3) for wear.

See the Maintenance section of this chapter for the wear check procedure.

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Replacement of wear parts _________________________________________ Fig. 83: Breaker shaft assembly

1

2

1. Breaker shaft assembly 2. Breaker power unit assembly

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.136

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________________________________________ Replacement of wear parts How to remove the breaker shaft and breaker power unit Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: 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.

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.

To remove the breaker shaft and breaker power unit as a single assembly (Fig. 84).

1. Turn the machine main circuit breaker (CB1) to the “OFF” position.

2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

3. Remove all power unit and breaker shaft covers.

4. Remove the junction box access panel of the electric motor. Tag and disconnect the cable leads from the motor leads.

5. Remove and cap all grease lines from the breaker shaft, gear reducer, and electric motor.

6. Remove the power unit support structure.

7. Remove the under speed sensor by loosening the nuts on the ubolt and sliding the sensor out.

8. Attach an appropriate lifting device to the breaker shaft and power unit assembly in such a manner to keep breaker shaft and power unit level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting hardward is removed.

9. Remove the hardware from the breaker side plates and the power unit reaction pin.

10. Lift the breaker shaft and power unit out of the machine as an assembly.

______________________________________________________________ A6474X391 REV 4 5.137

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Replacement of wear parts _________________________________________ How to install the breaker shaft and breaker power unit Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: 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.

To install the breaker shaft and breaker power unit as a single assembly (Fig. 84).

1. Attach an appropriate lifting device in such a manner as to keep the breaker shaft and power unit level during the lift and slowly lift the unit onto the machine.

2. Install the power unit reaction pin and the hardware into the breaker side plates.

3. Install the under speed sensor on the left hand side of the breaker shaft. The distance from the sensor end to end cap target is approximately 1/8 to 1/4 inch.

4. Remove caps and install all grease lines to the breaker shaft, gear box, and electric motor.

5. Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.

6. Install the power unit cover support structure.

7. Install all power unit covers.

8. Turn the machine circuit breaker on.

9. Unlock and remove tags from electric power at the power center.

10. Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.

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________________________________________ Replacement of wear parts Fig. 84: Breaker shaft and power unit removal and installation

18 17 15 9

1

10 8

11

12 3

16 19 4 6

2

5

7

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2.

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6.

7.

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9.

10.

Breaker assembly Stub shaft Breaker power unit assembly Socket head shoulder bolt, 1X3 (12) Lock washer, 3/4 (12) Hex nut, 3/4 (12) Hex head bolt, M24x65-10.9 Pivot lug Power unit reaction pin Pivot lug mounting plate

11.

12.

13.

14.

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16.

17.

18.

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Lock washer, 1” (4) Hex head bolt, 1X2 (4) Underspeed sensor mount (shown on next page) U-bolt, 2X3-3/4X3/8-16 (shown on next page) Hex head bolt, 1-1/4X5 (4) Hex head bolt, 1-1/4X4 (20) Lock washer, 1-1/4 (24) Hex nut, 1-1/4 (24) Reducer end cover (reference only)

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Replacement of wear parts _________________________________________ Fig. 84, continued: Breaker shaft and power unit removal and installation

14

13

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.140

BI001467

________________________________________ Replacement of wear parts How to remove the breaker power unit assembly Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: 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.

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.

To remove the breaker power unit proceed as follows (Fig. 84).

1. Turn the machine main circuit breaker (CB1) to the “OFF” position.

2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

3. Remove all power unit covers.

4. Remove the junction box access panel of the electric motor. Tag and disconnect the cable leads from the motor leads.

5. Remove and cap all grease lines from the gear reducer and electric motor.

6. Remove the under speed sensor.

7. Attach an appropriate lifting device to the power unit assembly in such a manner as to keep the power unit level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting power unit reaction pin and bolts from breakershaft bolt flange and stub shaft are removed.

8. Remove the twelve (12) one inch socket head sholder bolts, twelve (12) 3/4 inch lock washers, and twelve (12) 3/4 inch hex nuts that connect the breaker shaft bolt flange to the stub shaft.

9. Remove cotter pins from the power unit reaction pin and remove the pin.

10. Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.

11. Lift the power unit out of the machine.

______________________________________________________________ A6474X391 REV 4 5.141

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Replacement of wear parts _________________________________________ How to install the breaker power unit assembly To install the breaker power unit proceed as follows (Fig. 84).

Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

1. Attach an appropriate lifting device to the power unit in such a manner that the power unit is level during the lift and slowly lift the unit onto the machine.

2. Install the power unit reaction pin and secure with cotter pins.

3. Bolt the breaker shaft bolt flange to the stub shaft.

4. Remove the lifting device.

5. Install the under speed sensor on the breaker shaft. Distance

from sensor end to end cap target is approximately 1/8” to 1/4”. Note (Reference Fig. 85): The end cap is gear shaped with eight “teeth”. The teeth are targets for the underspeed sensor.

Fig. 85: Sensor target

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________________________________________ Replacement of wear parts 6. Remove caps and install all grease lines to the gear box and electric motor.

7. Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.

8. Install all power unit covers.

9. Unlock and remove tags from electric power at the power center.

10. Turn the machine circuit breaker on.

11. Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.

______________________________________________________________ A6474X391 REV 4 5.143

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Replacement of wear parts _________________________________________ How to remove the breaker shaft assembly only Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: 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.

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.

To remove the breaker shaft assembly (Fig. 86).

1. Turn the machine main circuit breaker (CB1) to the “OFF” position.

2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

3. Remove all breaker shaft and gear reducer covers.

4. Remove and cap all grease lines from the breaker shaft.

5. Remove the underspeed sensor from the breaker shaft by loosening the nuts on the u-bolt just enough to allow the senosr to slide out.

6. Properly support the breaker shaft gear reducer so that it does not fall during breaker shaft removal. Ensure that the power unit reaction pin is in place and not removed during this procedured.

7. Attach an appropriate lifting device to the breaker shaft in such a manner that the breaker shaft is level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting hardware is removed.

8. Remove the hardware from the breaker side plates and from between the two halves of the bolt flange and the stub shaft flange.

9. Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.

10. Lift the breaker shaft out of the machine.

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.144

BI001467

________________________________________ Replacement of wear parts How to install the breaker shaft assembly Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: 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.

To install the breaker shaft assembly (Fig. 86).

1. Attach an appropriate lifting device to the breaker shaft in such a manner that the breaker shaft is level during the lift and slowly lift the unit onto the machine.

2. Install the one inch hex bolts, hex nuts, and lock washers into the breaker side plates. Torque to 545 ft-lbs.

3. Install the one inch socket head shoulder bolts, 3/4 inch lock washers, and 3/4 inch hex nuts to attach breaker shaft bolt flange to stub shaft in gear reducer. Torque to 240 ft-lbs.

4. Remove support from under gear reducer.

5. Remove lifting device from breaker shaft.

6. Remove caps and install all grease lines to the breaker shaft.

7. Install all breaker shaft and power unit covers.

8. Turn the machine circuit breaker on.

9. Unlock and remove tags from electric power at the power center.

______________________________________________________________ A6474X391 REV 4 5.145

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Replacement of wear parts _________________________________________ How to disassemble the breaker power unit To disassemble the breaker power unit proceed as follows (Fig. 86): 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! Follow all applicable rules and regulations regarding lockout/ tagout procedures.

IMPORTANT! Caterpillar does not recommend field disassembly or repair of the breaker shaft. If the breaker shaft requires repair, please consult your service representative.

1. Remove complete unit from machine. (See Breaker shaft and breaker power unit removal/installation procedure in this section.)

2. Remove the reducer end cover, bolts, and lock washers.

3. Remove the stub shaft retaining bolt and lock washer.

4. Remove the stub shaft and key from the gear reducer. Note: A jacking screw may be needed to push the stub shaft out of the reducer.

5. Open the access door on the small connecting tube.

6. Loosen the two socket head cap screws that retain the pump coupling half.

7. Attach a lifting device to the pump assembly and take up any slack so that the weight of the pump assembly is resting on the lift device.

8. Remove the four 5/8X2 hex head bolts, 5/8 lock washers, and 5/8 flat washers that retain the pump assembly and remove the pump assembly and the pump coupling half.

9. Attach a lifting device to the small connecting tube.

10. Remove the eight 5/8X2-1/4 hex bolts, 5/8lock washers, and 5/8 flat washers that retain the small connecting tube.

11. Loosen the socket set screw on the motor coupling half and remove from the motor shaft.

12. Attach a lifting eye and lifting device to the electric motor. Take up any slack in the lifting device.

13. Open the access door on the large connecting tube.

14. Remove the eight M12X1.75X35 socket head cap screws and lock washers that attach the flexible coupling to the torque limiter.

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.146

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________________________________________ Replacement of wear parts 15. Remove the eight 3/4X2-1/4 hex bolts, lock washers, and flat washers that retain the electric motor to the connecting tube.

16. Remove the electric motor and flexible coupling sub-assembly.

17. Loosen the three 1/2-13X1-1/2 socket head cap screws on the motor taper loc bushing and remove the flexible coupling and the taper loc bushing using a dead blow hammer.

18. Remove the 1/2X-1/2 hex head cap screw, 1/2 lock washer, and end cap from the electric motor shaft and remove the electric motor key, if necessary.

19. Block under the torque limiter and remove the twelve 7/16-20 socket head cap screws and twelve 7/16 lock washers that retain the torque limiter to the companion flange.

20. Remove the eight M12X1.75X35 socket head cap screws and M12 lock washers that secure the torque limiter to the flex coupling and remove the torque limiter.

21. Loosen the three 1/2-13X1-1/2 socket head cap screws on the reducer taper loc bushing and remove the companion flange and the taper lock bushing sub-assembly from the reducer input shaft using a dead blow hammer.

22. Remove the reducer fan by loosening the set screw in the fan hub.

23. Remove the reducer input shaft seal grease line from the input shaft and the grease manifold.

24. Remove the M16 hex head cap screw, M16 lock washer, and end cap from the gear reducer input shaft.

25. Remove the key from the gear reducer input shaft.

26. Attach a lifting device to the large connecting tube.

27. Remove the four 1X5 hex head bolts and 1 inch lock washers that retain the large connecting tube to the reducer.

______________________________________________________________ A6474X391 REV 4 5.147

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Replacement of wear parts _________________________________________ Fig. 86: Breaker power unit assembly

3

2

1

1. End cover 2. Stub shaft retaining bolt, M24X65 3. Stub shaft

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________________________________________ Replacement of wear parts Fig. 86, continued: Breaker power unit assembly 33

21,22 9,10,11 19 8

20

25

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15

35 34 27

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1

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30,31,32

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3

Pump Hex head bolt, 5/8X2 (4) Lock washer, 5/8 (4) Connecting tube, small Hex head bolt, 5/8X2-1/4 (8) Lock washer, 5/8 (8) Coupling Motor End cap Lock washer Hex head bolt, 1/2X1-1/2 Hex head bolt, 3/4X2-1/4 (8) Lock spring washer, 3/4 (8) Cover, connecting tube Connecting tube, large Flat washer, 1/2 (2) Lock washer, 1/2 (2) Hex head bolt, 1/2X1 (2)

19.

20.

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24.

25.

26.

27.

28.

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30.

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33.

34.

35.

Socket head bolt, 1/2-13X1-1/2 (3) Bushing Socket head bolt, M12X1.75X35 (8) Lock washer, M12 (8) Flexible coupling Torque limiter Socket head bolt, 1/2-13X1-1/2 (3) Bushing Companion flange Lock washer, 7/16 (12) Socket head cap screw, 7/16-20X1-1/4 (12) Hex head bolt, M16X2X40 Lock washer, M16 End cap Gear reducer Lock washer, 1” (4) Hex head cap screw, 1X5 (4)

______________________________________________________________ A6474X391 REV 4 5.149

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Replacement of wear parts _________________________________________ Fig. 86, continued: Breaker power unit assembly

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.150

BI001467

________________________________________ Replacement of wear parts How to assemble the breaker power unit To assemble the breaker power unit proceed as follows (Fig. 86): WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

1. Attach a lifting device to the large connecting tube and position on the gear reducer.

2. Attach the large connecting tube to the gear reducer with four 1X5 hex head cap screws and four one inch lock washers. Torque to 900 ft-lb.

3. Attach input shaft seal grease hard line to the input shaft seal housing and the grease manifold.

4. Install the key in the keyway of the gear reducer input shaft.

5. Install the end cap, M16 lock washer, and M16X2X40 hex head bolt to retain the key.

6. Install the reducer fan and secure by tightening the set screw.

7. Install the taper loc bushing and companion flange onto the input shaft of the gear reducer (see Fig. 85 for correct position). Apply Loctite 242 to the three 1/2-13X1-1/2 socket head cap screws and install to secure the bushing. Torque to 90 ft-lb.

8. Install the torque limiter on the companion flange. Apply Loctite 242 to the 7/16-20 socket head cap screws and tighten to secure the torque limiter.

9. Install the key in the keyway of the electric motor shaft.

10. Install end cap, 1/2 lock washer, and 1/2X1-1/2 hex head bolt into the electric motor shaft to retain the motor shaft key.

11. Install the taper loc bushing and flex coupling on to the electric motor shaft. Do not tighten cap screws.

12. Attach an appropriate lifting device to the electric motor and slowly position the electric motor shaft (with flex coupling and taper loc bushing installed) inside the large connecting tube. Secure with eight 3/4 lock spring washer and eight 3/4X2-1/4 hex head bolts.

Torque to 379 ft-lb.

13. Align the flex coupling with the torque limiter. Apply Loctite 242 to the eight M12X1.75X35 socket head bolts and install the bolts and eight M12 lock washers. Torque to 90 ft-lb.

14. Adjust the electric motor side of the flex coupling assembly and taper loc bushing until proper clearance between the flex coupling jaws is achieved.

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Replacement of wear parts _________________________________________ 15. Remove the three 1/2-13X1-1/2 socket head cap screws, apply Loctite 242, and reinstall. Torque to 90 ft-lbs.

16. Replace the large connecting tube access cover and secure.

17. Verify that the electric motor shaft key is installed and is retained, if applicable, with end cap and bolt. Install the pump coupling onto the electric motor shaft (see Fig. 85 for correct coupling position).

Apply Loctite 242 to the set screw and tighten to secure the coupling.

18. Install the small connecting tube onto the electric motor and secure with eight 5/8 lock washer and eight 5/8X2-1/4 hex head cap screws. Torque to 210 ft-lb.

19. Remove the bolt from and open the door of the small connecting tube.

20. Attach a lifting device to the pump and orient as shown in Fig. 85.

21. Guide the pump shaft inside the small connecting tube and align the splined shaft with the pump coupling. Secure with four 5/8 lock washers and four 5/8X2 hex head cap screws. Torque to 210 ft-lb.

22. Verify the jaw spacing of the pump coupling (see Fig. 85). Adjust as required by loosening the set screw on the electric motor shaft side and reposition. Once correct position is achieved, tighten set screw.

23. Apply Loctite 242 to the threads of the pump coupling socket head cap screws on the pump side hub. Install cap screws and tighten.

24. Install the key into the keyway of the stub shaft.

25. Apply Never Seeze to the outside diameter of the stub shaft and the key and install into the hollow bore of the gear reducer.

26. Install the stub shaft M24X65 retaining bolt and M24 lock washer and torque bolt to 1,000 ft-lb.

27. Install reducer output shaft end cap and retaining hardware.

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________________________________________ Replacement of wear parts Conveyor drive unit The conveyor drive unit (Fig. 87) has been assembled as a unit and can be removed and installed as a unit.

Fig. 87: Conveyor drive unit 7 5 6 4

2

3

8

1

1.

2.

3.

4.

5.

6.

7.

8.

9.

9

Hex head bolt, Lockwasher, Flat washer, Hydraulic motor Gearbox Headshaft retainer Headshaft splined adapter Hex head bolt End cap

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Replacement of wear parts _________________________________________ How to remove the conveyor drive unit (Fig. 87) Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: 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.

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.

1. Remove the last cover on the left hand side of the machine.

2. Remove the last cover’s support post.

3. Remove the hydraulic motor: a. Disconnect, tag, and cap all hydraulic hoses to the motor. b. Attach an appropriate lifting device to the motor and take up all slack so that the weight of the motor is resting on the lifting device. c.

Remove the five (5) 1/2 inch bolts, lock washers, and flat washers from the end of the motor.

4. Remove the conveyor gear reducer: a. Insert a lifting lug into the threaded hole on top of the gear reducer and attach an appropriate lifting device to the lug.

Take up all slack so that the weight of the gear reducer is resting on the lifting device. b. Remove the four (4) bolts from the end cap on the output stage of the reducer. c.

Insert two (2) of the bolts in the threaded pusher holes to remove the cover.

d. Remove the retaining bolt. e. Remove the retainer end cap. f.

Remove the cotter pin and retainer pin from the clevis on the front of the reducer.

g. Using the lifting device, slide the gear reducer off of the head shaft. h. Remove the splined adapter from the head shaft.

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.154

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________________________________________ Replacement of wear parts How to install the conveyor drive unit (Fig. 87) 1. Install the hydraulic motor onto the input shaft of the gear reducer: a. Attach an appropriate lifting device to the motor and position the motor on the gear reducer. b. Install the five (5) 1/2 inch mouting bolts, lock washers, and flat washers and torque to 400 ft-lbs. c.

Reconnect hydraulic hoses.

2. Install the conveyor gear reducer: a. Attach an appropriate lifting device to the lifting lug located on top of the reducer and position the reducer on the head shaft. b. Insert the retainer end cap and secure with the M20X2.5X100 Grade 10.9 retaining bolt. Torque the bolt to 450 ft-lbs. c.

Insert the reaction pin and secure with 1/4 inch cotter pin.

d. Place the end cap on the output stage of the reducer and secure with four (4) bolts.

3. Install the last cover’s support post.

4. Install the last cover on the left hand side of the machine.

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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. 88): 1. Remove the external retaining rings from the shank end of the bit with a pair of external retaining ring pliers.

2. Remove the bit from its holder. If the bit will not pull easily from its holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.

IMPORTANT! If the bit will not pull easily from its holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.

How to install the breaker bit To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 88): 1. Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.

2. Install the external retaining rings (two per bit) on the shank end of the bit with a pair of external retaining ring pliers. Ensure that the retaining ring is completely seated inside grooved area of the bit.

Fig. 88: Breaker bit removal and installation

Retaining rings

Bit holder

Breaker bit

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________________________________________ Replacement of wear parts Installing the tailpiece To install the tailpiece on the feeder breaker (Reference Fig. 89: Tailpiece installation): WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

1.

Install spacer blocks into the underside of the tailpiece weldment. a.

Make sure that bolts will pass through the bearing spacers and the tailpiece weldment.

b. Tack weld bearing spacer blocks to tailpiece weldment.

2.

Install belt pulley assembly using hex bolts, flat washers, hex nuts, and lock washers.

3.

Bolt impact bed assembly to tailpiece weldment using flat washers, lock washers, hex nuts, and bolts.

4.

Install slider assembly using flat washers, lock washers, hex nuts, and bolts.

5. Install knuckle piece to tailpiece weldment using tailpiece swivel pin, flat washer, hex nut, keeper pin, and cotter pin.

6. Tighten the hex nut onto the tailpiece swivel pin then weld the pin keeper across the flat of the tailpiece swivel pin on three sides.

7. Position the assembled knuckle joint and the tailpiece frames to the main frame. (Reference figure 86 for placement). Install pins.

8. Install the tailpiece hopper weldments on the main frame using flat washers, lock washers, hex nuts and bolts and flat washers, lock washers, hex nuts, and bolts.

9. Install tailpiece tilt cylinders into the tailpiece hopper weldments and the tailpiece weldment using the swivel clevis weldments, pins, and cotter pins.

10. Install the steering cylinders between the tailpiece frame and the knuckle joint weldment using pins and cotter pins.

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Replacement of wear parts _________________________________________ 11. Refer to the hydraulic schematic (Fig. 90) for hydraulic installation of the cylinders. Route all hoses, avoiding pinch points, so that hose damage does not occur.

Fig. 89: Tailpiece installation

Tailpiece hopper (2)

Tailpiece skirt

Rubber skirt

Impact bed assembly Valve bank

Tilt cylinder

Steering cylinder

Belt pulley assembly

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________________________________________ Replacement of wear parts Fig. 89: Tailpiece installation (continued)

Knuckle clevis

Slider saddle assembly

Swivel pin

Tailpiece mount clevis

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Replacement of wear parts _________________________________________ Fig. 90: Tailpiece and Roof Support hydraulic schematic

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________________________________________ Replacement of wear parts Roof cylinder and roof anchor arm removal and Installation (typical both sides) To remove the roof cylinder (reference Fig. 91):  1. Extend the roof anchor arm pullout far enough to rest on adjacent cover.

2. Retract the roof cylinder until the anchor arm pullout rests on cover.

3. Shutdown the feeder breaker (see Shutdown procedure in this manual).

4. Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

5. For the left hand roof anchor remove the eight (8) hex bolts located towards the hopper end of the hinged cover above main valve bank. Flip up cover to access roof anchor cylinder and arm. a. If no room to flip cover, pull pins on opposite side of cover and completely remove cover.

6. There are no covers to remove to access the right hand roof anchor, skip step 5.

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.

7. Attach an appropriate lifting device to the roof cylinder and take in any slack in chain.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

8. 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.

9. Pull the upper cotter pin and upper roof cylinder pin. Pull the lower cotter pin and lower cylinder pin.

10. Lift the roof cylinder free from the machine.

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Replacement of wear parts _________________________________________ 11. If necessary, remove the roof anchor arm: a. Attach an appropriate lifting device to the roof anchor arm and take up any slack in chain. b. Remove the cotter pin from the anchor arm clevis and pull pin. c. Lift anchor arm free from machine.

To install the roof cylinder (reference Fig. 91): 1. If necessary, install the roof anchor arm: a. Extend anchor arm pullout far enough to rest on cover when lifted into position. b.

Attach an appropriate lifting device to the roof anchor arm, lift into place and rest anchor arm pullout on adjacent cover.

c.

Lower anchor arm into clevis, insert the anchor arm pin and secure with cotter pin.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  2. Lower the roof cylinder into place with an appropriate lifting device.

3. Place the lower cylinder eye into clevis and install the lower cylinder pin and cotter pin.

4. Place the upper cylinder eye into clevis and install the upper cylinder pin and cotter pin. Remove lifting device.

5. Install the hydraulic hoses to the roof cylinder.

6. Install the cover over the main valve bank on the left hand side of machine. Note: For right hand roof anchor arm it is not necessary to install any covers.

7. Re-energize machine and start the feeder breaker (see “AUTO” or “MANUAL” starting procedures in this manual).

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.

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________________________________________ Replacement of wear parts Fig. 91: Roof cylinder removal and installation (typical both sides) Roof anchor arm pullout (2)

Roof anchor arm (2)

Cotter pin (2) Anchor arm pin (2)

Cylinder pin (4) Roof cylinder (2) Cotter pin (4)

Left hand side (with cover)

Hinged cover Anchor arm pullout resting on adjacent cover

Right hand side (no cover)

Anchor arm pullout resting on cover. Right and left side shown individually.

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Replacement of wear parts _________________________________________ Foot cylinder removal and installation To remove a foot cylinder (reference Fig. 92): Note: If room permits, lower the foot for this procedure.

1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

3. Block the cylinder and foot as necessary.

4. 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.

5. Remove the cotter pin from the outrigger arm pin, remove the castle nut, and washer and pull the outrigger arm pin.

6. Remove the two cotter pins from the cylinder eye pin and pull the cylinder eye pin.

To install a foot cylinder (reference Fig. 92): 1. Mount the cylinder eye to the outrigger mount plate. a. Position the cylinder eye in the outrigger mount plate clevis. b. Insert the cylinder eye pin through the cylinder eye and outrigger mount plate clevis. c.

Install the two cotter pins through the cylinder eye pin.

2. Position the foot clevis on the rod eye and align the rod eye in the outrigger arm weldment.

3. Install the outrigger arm pin through the outrigger arm weldment, foot, and rod eye. Install the washer and castle nut on the end of the pin. Secure with new cotter pins.

4. Reconnect the hydraulic hoses to the cylinder.

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________________________________________ Replacement of wear parts 5. Reconnect power to the machine.

6. Purge the hydraulic system of air.

Fig. 92: Foot cylinder removal and installation

See detail A

Castle nut

Outrigger foot Washer Foot cylinder

Outrigger mount plate

Cylinder pin

Outrigger arm pin

Outrigger arms Detail A

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Replacement of wear parts _________________________________________ Tilt cylinder removal and installation To remove a tilt cylinder (reference Fig. 93): 1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

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

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

4. Attach an appropriate lifting device to the tilt cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

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

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

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________________________________________ Replacement of wear parts To install a tilt cylinder (reference Fig. 93): 1. Attach an appropriate lifting device to the tilt cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

2. Align the cylinder in the mounting clevises on the machine.

3. Install the pin through the cylinder eye and secure with a cotter pin.

4. Install the pin through the rod eye and secure with a cotter pin.

5. Reconnect the hydraulic hoses to the cylinder.

6. Reconnect power to the machine.

7. Purge the hydraulic system of air.

Fig. 93: Tilt cylinder removal and installation

1

2

3

4

1.

2.

3.

4.

Pin (2) Cotter pin (2 per pin) Tilt cylinder Mounting clevis

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Replacement of wear parts _________________________________________ Lift cylinder removal and installation To remove a lift cylinder (reference Fig. 94): Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: 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.

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.

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.

1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

3

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

4. Attach an appropriate lifting device to the lift cylinder.

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

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

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________________________________________ Replacement of wear parts To install a lift cylinder (reference Fig. 94): Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: 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.

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.

1. Attach an appropriate lifting device to the lift cylinder.

2. Align the cylinder in the mounting clevises on the machine.

3. Install the pin through the cylinder eye and secure with a cotter pin.

4. Install the pin through the rod eye and secure with a cotter pin.

5. Reconnect the hydraulic hoses to the cylinder.

6. Reconnect power to the machine.

7. Purge the hydraulic system of air.

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Replacement of wear parts _________________________________________ Fig. 94: Lift cylinder removal and installation Cotter pin (2 per pin) (typical both ends)

Pin (typical both ends)

Lift cylinder

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________________________________________ Replacement of wear parts Tailpiece tilt cylinder removal and installation To remove a tailpiece tilt cylinder (reference Fig. 95): 1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

3. Install spacer blocks into the underside of the tailpiece.

4. 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.

5. 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.

6. Pull cotter pin out of the pin through the cylinder eye. Remove pin.

7. Pull cotter pin out of the pin through the rod eye. Remove pin.

To install a tailpiece tilt cylinder (reference Fig. 95): 1. Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

2. Align the cylinder in the mounting clevises on the machine.

3. Install the pin through the cylinder eye and secure with a cotter pin.

4. Install the pin through the rod eye and secure with a cotter pin.

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Replacement of wear parts _________________________________________ 5. Reconnect the hydraulic hoses to the cylinder.

6. Reconnect power to the machine.

7. Purge the hydraulic system of air.

Fig. 95: Tailpiece tilt cylinder removal and installation

Cotter pin (4) (2 per eye)

Tailpiece tilt cylinder

Pin (2)

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________________________________________ Replacement of wear parts Tailpiece steering cylinder removal and installation To remove a tailpiece steering cylinder (reference Fig. 96): 1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

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

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

4. Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

5. Pull cotter pin out of the pin through the cylinder eye.

6. Pull cotter pin out of the pin through the rod eye.

To install a tailpiece steering cylinder (reference Fig. 96): 1. Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

2. Align the cylinder in the mounting clevises on the machine.

3. Install the pin through the cylinder eye and secure with a cotter pin.

4. Install the pin through the rod eye and secure with a cotter pin.

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Replacement of wear parts _________________________________________ 5. Reconnect the hydraulic hoses to the cylinder.

6. Reconnect power to the machine.

7. Purge the hydraulic system of air.

Fig. 96: Tailpiece steering cylinder removal and installation

Pin (2)

Cotter pin (4) (2 per eye)

Tailpiece steering cylinder

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________________________________________ Replacement of wear parts

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Troubleshooting _________________________________________________ Troubleshooting procedures Typical hydraulic problems The most common causes for improper hydraulic functions are: ■

contaminated or poor quality hydraulic oil

■

low or insufficient oil in the system

■

using the wrong type or viscosity grade of hydraulic oil

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments (such as reliefs)

■

mechanical or structural damage leading to component failure

■

components by-passing (internal leaking or inability to hold pressure) which leads to erosion of bushings, valve spools, or other critical components

The greatest aid to troubleshooting a hydraulic system is the confidence that comes with knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles.

Contaminants in hydraulic systems The primary cause of hydraulic component failure is SYSTEM CONTAMINATION. Cleanliness must be a high priority when servicing the hydraulic system. Even very small particles can damage system components by scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are given below: 1. Ensure that bulk oils are at acceptable cleanliness levels.

–

implement ISO Cleanliness Code standards for bulk hydraulic oils

–

evaluate bulk oil shipments for cleanliness by conducting particle counts and maintain records

–

minimize drum usage by utilizing tote tanks and five gallon pails

–

utilize plastic versus steel storage tanks, if possible

–

install desiccant breathers on all bulk tanks

–

use sealed plastic containers for adding oil to small sumps

–

locate bulk tanks near equipment and pump directly to reservoirs

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_________________________________________________ Troubleshooting –

utilize filter carts to maintain oil cleanliness standards

–

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

–

monitor the program closely and look for continuous improvement

2. Eliminate contamination source through “clean” maintenance practices. This is best achieved by understanding the primary sources of contamination during maintenance and troubleshooting which are given below: –

always clean the area around the component that is to be removed and inspected

–

store components in a plastic bag after inspection and prior to replacement on machine

–

cap off all open hoses/fittings

–

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

–

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame

Contact your Service Representative for more information on implementing an effective program to ensure that your oil and maintenance practices are not contributing to your equipment failure.

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Troubleshooting _________________________________________________ Machine specific hydraulic troubleshooting Before troubleshooting this machine, it is important to understand the fundamentals of the hydraulic system. This feeder breaker has an open loop hydraulic circuit and uses an axial piston pump with load sense and pressure compensation control. Maximum displacement is 165 cc/rev (10 cubic inches) and maximum service pressure is 400 bar (6,090 psi). There is a secondary gear pump mounted to the rear of the main pump that supplies cooling flow to the cases of the main pump and the conveyor drive motor.

Open loop system In an open loop system, oil is supplied directly from and is returned directly to the hydraulic oil tank. Unlike a closed loop system, there is no charge pump.

Load sense, pressure compensated pump At startup, the pump will be on full stroke to prime itself. Once the pump is at full speed, its control will de-stroke the displacement to a minimum and reduce system pressure to approximately 30 bar (435 psi). This mode is referred to as “standby” or “margin” and is typical of load sense controlled pumps. In standby, the system pressure gauge will read 30 bar (435 psi) and the load sense pressure gauge will read 0 bar. The actual output of the pump is at low pressure and only at a flow rate required to make up for internal system leakage. In this mode, the pump is waiting for a signal to provide higher pressure and flow to meet a specific task. That signal is in the load sense line which connects the pump control to the main valve bank. When valves are shifted to run a function of the machine. For example, the conveyor control valves will connect the load pressure of the conveyor motor circuit to the load sense line. The pump will quickly respond by increasing its displacement to create the pressure to meet that conveyor load.

At this point, the load sense gauge will read the load of the conveyor function and the system pressure gauge will reflect that load pressure plus the margin pressure. If the conveyor requires 250 bar (3,625 psi) to operate, the system pressure will be 280 bar (250 bar +30 bar) (4,061 psi).

The pump control includes a second stage for pressure compensation.

This feature limits the maximum output pressure of the pump. When the pressure compensation setting is reached, the pump will quickly destroke to a minimum output. This condition is referred to as “dead head” or “stall” . The pump will continue to hold this pressure until the function is stopped. In the conveyor function, stall may arise from an obstruction in the breaker and this condition is monitored by a pressure transducer. The pump itself can operate in this mode indefinitely due to the operation of the pressure compensator. There is no excess hydraulic heat generated because relief valves are not opening to control the pressure limitation.

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_________________________________________________ Troubleshooting The advantages of the open loop, load sense, pressure compensated system are: 1. System runs cooler.

2. Less energy is used during idle time.

3. Individual functions can be set at different compensator pressures, resulting in increased efficiency.

4. Increased efficiency equals longer component and oil life.

To achieve these benefits, however, the system must be properly adjusted and maintained.

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Troubleshooting _________________________________________________ Open loop pump troubleshooting A pressure transducer is located at the pump inlet to monitor for a blocked suction line. However, it does not guard against aeration caused by a leaking suction line or low oil level in the reservoir. If either of these occur, the pump will make an erratic grinding noise and will run at elevated temperatures. The pump will fail quickly at these conditions and should be shutdown immediately. Investigate oil level and suction hose integrity and identify and correct the issue before operating the pump.

If there is significant heating during a stall or high pressure operation, check the setting of the system relief located in the inlet of the main valve bank. This relief valve is preset to 370 bar (5,365 psi). To verify its setting, the pump compensator must be raised to 380 bar (5,510 psi). Once the relief is correctly adjusted, reduce the pump compensator to 350 bar (5,075 psi). If the relief is set lower than the pressure compensator, the relief valve will open, causing system heating. See the adjustment section of this manual for pressure compensator adjustment procedures.

The main pump is an efficient device: displacement efficiency when new is approximately 98%. The pump will produce nominal 74.75 gpm at 1,750 rpm. This means internal leakage is only 1.5 - 2.0 gpm. As a pump ages and wears, the efficiency will decrease, resulting in increased flow from the case drain port. Because the flow from the main pump case is a combination of internal leakage and the cooling flow, the case drain flow from a new pump will average 6 gpm. If case drain leakage exceeds 10 gpm, the main pump should be changed out.

An acceptable method of measuring case drain leakage is to use a five gallon bucket and a stop watch. If the five gallon bucket is filled in 30 seconds, the pump needs changed.

When removing a used pump, use the plugs from the replacement pump and duct tape to seal off all ports on the used pump.

If a pump is replaced, it is critical that the pump case be filled before start up. It is often difficult to do this well underground, so start with filling and plugging the pump before taking underground.

Pumps stored on site should be filled with oil. The pump has two case drain ports - the highest one should be used for filling.

Upon installation, top up oil in pump case at the highest case drain port.

Jog the pump motor at least five time before starting up. If the pump is properly filled and priming, it will run and sound smoothly on startup.

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_________________________________________________ Troubleshooting Function specific hydraulic troubleshooting Following is a partial list of function specific hydraulic troubleshooting.

In all situations, if the problem arises when trying to activate a hydraulic function from the remote control, manually activate the valve bank to ensure there is not a remote control issue.

Always consult the hydraulic schematic for your machine to verify pressure settings.

1. Conveyor runs slow a. Check flow to the motor with an inline flow meter i.

If flow is low, troubleshoot the pump.

ii.

If flow is good, troubleshoot the motor.

2. System is running hot a. Troubleshoot the pump for excessive leakage. b. Troubleshoot the motor for excessive leakage. c.

Verify the relief setting on the inlet valve bank; adjust as necessary.

3. Conveyor won’t run in either direction a. Verify that solenoids are shifting. b. Troubleshoot the load sense circuit (load sense signal to the pump). c.

Troubleshoot the motor.

d. If the system pressure is high (approximately 4,800 psi), check for mechanical problems.

4. Conveyor runs in the wrong direction a. Hydraulic lines are reversed.

5. Conveyor only runs in one direction a. Check solenoids. b. Troubleshoot the load sense circuit (load sense signal to the pump).

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Troubleshooting _________________________________________________ 6. No tram a. Verify pressure on gauge when tram is enabled. If pressure reading is approximately 2,250 psi, the system may be maxed out and not able to tram. b. Verify if both tracks do not tram.

c.

i.

If neither track trams, it is most likely an enabler valve issue.

ii.

If only one track does not tram, it is most likely a valve section or the tram motor.

Troubleshoot the pump. i.

If the conveyor works, the pump is OK.

ii.

If the conveyor does not work, continue with pump troubleshooting.

d. Verify that the tram enabler valve is working correctly (check for 24V signal). e. Check for a load sense signal at the pump when tramming is activated. i.

If there is a signal, troubleshoot the tram motors a. If tram motors are OK, check for mechanical damage.

7. Cylinder does not operate a. Check fuses (see electrical schematic). b. Troubleshoot the load sense circuit (load sense signal to the pump). c.

Troubleshoot the pump. i.

If the conveyor works, the pump is OK.

ii.

If the conveyor does not work, continue with pump troubleshooting.

d. Check the pressure gauge to ensure that the system isn’t maxed out. e. Check for oil by-pass in the cylinder. f.

Check the counterbalance valve.

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_________________________________________________ Troubleshooting Table 5: Troubleshooting excessive noise

Pump Noisy Cause

Motor Noisy Remedy

Cause

Cavitation

A

Coupling misaligned

Air in fluid

B

Motor or coupling worn or damaged

Coupling misaligned

C

Pump worn or damaged

E

Relief/Counterbalance Valve Noisy Remedy C

Cause

Remedy

Setting too low or too close to another valve setting

D

Worn poppet and seat

E

Remedies A. Any or all of the following:       

replace dirty filters wash strainers in solvent compatible with system fluid clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed check fluid temperature

B. Any or all of the following:    

tighten leaky inlet connections fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir bleed air from system replace pump shaft seal; also replace shaft if worn at seal journal

C. All of the following:  

align unit check condition of seals, bearings, and coupling

D. Install and/or adjust pressure gauge E. Overhaul or replace defective parts

______________________________________________________________ A6474X391 REV 4 5.183

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Troubleshooting _________________________________________________ Table 6: Troubleshooting excessive heat Pump Heated Cause Fluid heated

Motor Heated

Remedy See Fluid Heated

Cause Fluid heated

Relief Valve Heated

Remedy See Fluid Heated

Cause Fluid heated

Fluid Heated

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cavitation

A

Excessive load

C

Valve setting incorrect

D

Fluid dirty or low supply

F

Air in fluid

B

Worn or damaged motor

E

Worn or damaged valve

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve, motor, cylinder, or other component

E

Remedies A. Any or all of the following:     

replace dirty filters clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed

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

F. Any or all of the following:   change filters  check system fluid viscosity; change if necessary  fill reservoir to proper level G. Any or all of the following:  

clean cooler and/or strainer repair or replace cooler

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

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.184

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_________________________________________________ Troubleshooting Table 7: Troubleshooting incorrect flow No Flow Cause

Low Flow Remedy

Cause

Excessive Flow Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

E of F

Remedies A. Any or all of the following:    



replace dirty filters clean clogged inlet line clean reservoir breather vent fill reservoir to proper level

B. Any or all of the following:  

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 F. Check position of manually operated controls G. Reverse rotation H. Replace with correct unit

______________________________________________________________ A6474X391 REV 4 5.185

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Troubleshooting _________________________________________________ Table 8: Troubleshooting incorrect pressure No Pressure Cause

Remedy

No flow

See Table 5

Low Pressure Cause Pressure relief path exists Damaged pump, motor, or cylinder

Remedy See Table 5 E

Erratic Pressure Cause

Remedy

Air in fluid

B

Worn relief valve

E

Contamination in fluid

A

Worn pump, motor, or cylinder

E

Remedies A. Replace dirty filters and system fluid B. Any or all of the following:  

tighten leaky connections fill reservoir to proper level and bleed air from system

C. Any or all of the following:   

gas valve for leakage charge to correct pressure overhaul if defective

D. Adjust valve E. Overhaul or replace part

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.186

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

Probable cause

dirty oil 

Test, check and/or remedy

Components not properly cleaned during servicing.



Disassemble and clean.



Air breather left off.



Install breather.



Hose lines not properly covered when servicing machine.



Cap hose ends while disconnected and clean before reconnecting.



Filter elements not replaced at proper intervals or when indicated.



Replace filter elements at proper intervals.

Tank return lines not below fluid level.



Check oil level and add oil if needed.

Oil contaminated with incompatible foreign matter.



Change the oil and replace oil filter.

foaming oil 







Suction leak to pump aerating oil.



Check fittings and lines; tighten or replace as needed.

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.



Moisture in replacement oil.



Replace oil.



Extreme temperature differences.



Store oil in an area that protects against exposure to frequent extreme temperature changes.

Fluid viscosity too high.



Check fluid specifications.

overheating of system 



Excessive slippage or internal leak-  age past pump or cylinders.



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 setting incorrect.



Reset the relief valve to specifications.

prolonged operation of a function at  pressures above normal idle condition

Sticking selector or other control valve.



Isolate circuits/components and identify fault.

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

______________________________________________________________ A6474X391 REV 4 5.187

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

Probable cause

foreign matter sources  in the circuit



Test, check and/or remedy

Sealing compound (pipe dope, Teflon tape).



Clean or replace seals. Drain and replace oil as necessary.

Tank or component ports left open to atmosphere.



Cap or plug properly. Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.

  





Lines left unprotected or dirty repaired components.



Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.



Repair parts not properly protected while stored.



Check and clean parts thoroughly before installation. Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.188

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_________________________________________________ Troubleshooting Hydraulic cylinders Table 10: Hydraulic cylinder troubleshooting Trouble or symptom

Probable cause

cylinder drifts 

Test, check and/or remedy

Piston seal leak.



Replace cylinder.



Control cartridge by-passing.



Replace cartridge or cylinder as required.



Other circuit leaks.



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.

erratic or chatter in operation 

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 cylinder.



Seal deterioration (soft or gummy). 

cylinder fails to move  the load when actuated



cylinder body seal leak 

piston is leaking 

Check for contamination of fluids (incompatibility). Flush system and refill with correct fluid. Replace cylinder.

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 cylinder.

______________________________________________________________ A6474X391 REV 4 5.189

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

Probable cause

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 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, aeration of fluid reservoir, and leaks in suction lines.

Repair all faults as required and/or replace pump as required.



Worn or damaged gears/ housing.



Replace pump.



Worn or faulty bearing.



Replace pump.



Reversed rotation.



Check pump motor wiring.



Plugged or restricted suction line or suction strainer.



Clean by removing the foreign material blocking oil flow.



Plugged reservoir breather.



Clean or replace breather as required.

Torn or worn seals.



Replace seal.



Gland bearing worn.



Replace pump.



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 



Replace seal.

Check pump shaft for possible bearing wear. Replace seal.

 Replace worn pump parts.  Loose or worn pump parts. ________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.190

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_________________________________________________ Troubleshooting Table 11 (continued): Hydraulic pump troubleshooting Trouble or symptom

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 correct oil.



Wrong shaft rotation.



Check pump motor wiring.



Pump shaft or parts broken.



Replace pump.



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 and replace oil in reservoir. Replace filter elements and implement frequent element changes until the desired cleanliness of the system is attained.



Oil viscosity too low.



Drain and replace oil in reservoir and change filter elements.



Excessive pump loads.



Check relief valve adjustment and reset as needed.



oil leakage around pump 

______________________________________________________________ A6474X391 REV 4 5.191

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Troubleshooting _________________________________________________ Table 11 (continued): Hydraulic pump troubleshooting Trouble or symptom

Probable cause

pump parts inside  the housing are broken

Test, check and/or remedy

Seizure due to lack of oil.



Replace pump and filter elements.

Check oil level and add as needed.



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.



Excessive torque to housing bolts.



Replace pump and filter elements.



Solid matter being drawn in from reservoir and wedged in pump.



Replace pump and filter elements, suction strainer, and suction hoses to insure that no foreign material can damage new pump.

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.192

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_________________________________________________ Troubleshooting Valves Table 12: Valve troubleshooting Trouble or symptom

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.



the pressure fluctuates and there is  extreme noise in the valve

excessive leakage or  sticking pistons occurs

Valve excessively hot.

    





Remove the valve and clean it thoroughly; flush the system as necessary.

Dirt in the system.



Drain and replace the oil in the reservoir. Replace all filter elements as required.

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.



oil leaks  between sections

______________________________________________________________ A6474X391 REV 4 5.193

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

Probable cause

oil leaks at either  end of spool

Test, check and/or remedy

Over-pressurized tank core.



Correct high back pressure condition.

Worn or damaged spool seals.



Replace seals and seal retainers.

Broken centering spring.



Replace centering spring.



Misalignment of operating linkage.



Check linkage for mechanical binding.



Foreign particles in system.



Clean valve and system.

Cylinder leaking or worn.



Check cylinder, repair as needed.



Port relief valve not holding.



Remove and clean or replace.



Spool or housing scored or worn excessively.



Replace section.

 spring centered spools  do not return to neutral

load will not hold 

load drops when spool  moved from neutral

Dirt or foreign particles lodged be tween check valve poppet and seat.

Disassemble, clean, and reassemble.



Scored or sticking check valve pop-  pet.

Replace poppet.

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.

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.194

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_________________________________________________ Troubleshooting Bearings Table 13: Bearing troubleshooting Trouble, symptom or cause

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 

______________________________________________________________ A6474X391 REV 4 5.195

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Troubleshooting _________________________________________________ Machine specific electrical troubleshooting Following is a partial list of electrical issues and related troubleshooting. This list is not all inclusive. Always consult the schematic for your machine when troubleshooting.

1. Machine won’t start, panel view display is on a. Start procedure was not followed. b. E-stop is active. c.

Pull cord is active.

d. Tape switch is bad. e. Safety relay (SR) or main control relay (MCR) is bad. f.

Bad switching repeater.

2. Machine won’t start, panel view display is not on a. Main circuit breaker or 15 amp circuit breaker is not set. b. No incoming power. c.

5 amp fuse is blown.

d. AC/DC converter is bad.

3. Machine starts but main circuit breaker immediately trips a. Instantaneous trip setting on circuit breaker is incorrect. b. The motor is shorted (pulling too many amps). c.

Cable between enclosure and motor is bad.

d. Bad incoming power from the power center.

4. Machine starts but C441 overload relay trips a. Overload relay settings are incorrect. b. Check output to current transducers. c.

Check power to overload relay.

5. Water solenoid does not work a. Verify that the water solenoid relay contacts close. b. Verify 120VAC signal. c.

Check water solenoid relay coil for power.

d. Verify PLC output. e. Check solenoid connections. f.

Bad switching repeater

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 5.196

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_________________________________________________ Troubleshooting 6. Photo eye quits working a. Shine a light on the photo eye and check the photo eye control box for a green LED (may take a couple of seconds to illuminate). i.

No green light indicates a bad photo eye or loose wiring in the box.

ii.

If the green light illuminates, check the photo switch relay for correct operation (it closes). a. If relay is bad, replace the photo eye control box. b. If relay closes, check wiring to input of PLC and verify that the input light is illuminated.

7. Conveyor won’t run in “AUTO” mode a. Check the belt sequence switch settings and adjustments. b. Check the tilt switch (if equipped). c.

Verify that the conveyor handles move when the conveyor function is remotely activated. i.

Check the operation of the enabler valve solenoid (manually activate the solenoid push rod, see Fig. 97).

Fig. 97: Tram enabler valve solenoid Manual solenoid activation

______________________________________________________________ A6474X391 REV 4 5.197

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6

Technical data

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__________________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Model 7MFBHM-48DD Feeder Breaker, serial number 54-2197 & 54-2198.

Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

The technical data listed in this chapter is for serial number 542197 & 54-2198 only. Other machines with the same model number may vary.

Technical data sheet general

Overall length: with tailpiece.................................................. approx. 38’ 8-7/8” Overall width: ....................................................... approx. 130-7/16” Tramming height (without sideboards): Minimum........................................................ approx. 57-5/8” Maximum....................................................... approx. 75-7/16” Ground clearance (max. w/ tail piece) ................. approx. 17-1/2” Receiving width ................................................... approx. 129” Receiving height (min.): ....................................... approx. 11” Discharge height of belt (typical dump position).. approx. 24-11/16” Operating height (max. - typical dump position): with tailpiece.................................................. approx. 72” without tailpiece............................................. approx. 61-7/16” Heaped hopper capacity:..................................... approx. 1,090 ft³

performance

Weight: less tailpiece and anchoring accessories ..... approx: 82,000 lbs with tailpiece and anchoring accessories ..... approx. 86,000 lbs Material input size (max.): ...................... approx. 2’ x 3’ x 4’ Maximum material strength: ................... approx. 30,000 psi Nominal output size: ............................... approx. 8” (one dimension) Discharge rate (max.): 1” pick to flight clearance ................. approx. 930 TPH @ 102 fpm 3” pick to flight clearance ................. approx. 1,073 TPH @ 102 fpm 5” pick to flight clearance ................. approx. 1,215 TPH @ 102 fpm Material to be broken: ............................. Coal & Rock @ 60 lb/ft³

______________________________________________________________ A6474X391 REV 4 6.3

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Technical data ___________________________________________________

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 6.4

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_______________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Set screws Table 14: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

Table 15: Hex and sockethead cap screws, coarse thread (Grade 8) Nominal diameter ¼” 5/16” 3/8” 7/16” ½” 9/16” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting (lubed) 8 ft-lbs 16 ft-lbs 28 ft-lbs 45 ft-lbs 70 ft-lbs 99 ft-lbs 135 ft-lbs 240 ft-lbs 390 ft-lbs 545 ft-lbs 830 ft-lbs 1,160 ft-lbs 1,525 ft-lbs 2,030 ft-lbs

Recommended torque setting (dry) 13 ft-lbs 26 ft-lbs 47 ft-lbs 75 ft-lbs 115 ft-lbs 165 ft-lbs 225 ft-lbs 400 ft-lbs 645 ft-lbs 905 ft-lbs 1,380 ft-lbs 1,935 ft-lbs 2,540 ft-lbs 3,380 ft-lbs

______________________________________________________________ A6474X391 REV 4 6.5

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Tightening torques _______________________________________________ Table 16: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15 10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Table 16: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 16: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 6.6

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_______________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Use only lubrication fluids and greases approved by Caterpillar.

These fluids and greases have been tested at Caterpillar 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! Caterpillar expressly points 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.

______________________________________________________________ A6474X391 REV 4 6.7

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Permissible media ________________________________________________ Table 17: Anti-wear hydraulic oil (Spec. 100-1) specification Limit

Type

ISO VG

61/75

68

ASTM Grade

380/345

315

Pour Point (ASTM D-97)

Max. 20° F (-7° C)

-20° F

Flash Point (ASTM D-92)

Min. 415° F (212° C)

400° F

Viscosity SUS @ 100° F 283-347

352

SUS @ 210° F 50-58

56

CST @ 40° C

61.2 - 74.8

CST @ 100° C

8.5 Typ.

Viscosity Index (ASTM D-2270)

Min. 90

96

Oxidation Test (ASTM D-943)

2.0 mg KOH max after 1000 hrs

Rust Prevention Test (ASTM D-665, A & B

Pass

Pass

Foam Test (ASTM D-892-46T)

Pass

Pass

Four Ball Wear Test (ASTM D-2266) (40 KG, 1800 RPM, 130° F, one hour)

Not more than 0.50 mm scar diameter

0.50 mm

400 mg max

294 mg

Copper

200 mg max

131 mg

Iron

100 mg max

3 mg

50 mg max

25 mg

Sludge & Metal Corrosion (ASTM D-943) (conducted at conclusion of 1000 hour oxidation test) Insoluble sludge in oil and water layers plut that adhering to the catalyst coils or the test tub.

Metals in combined oil, water, and sludge (ASTM D-810-59)

Pump Wear Test (ASTM D-2882) (Total Ring and Vane Weight Loss) Hydrolytic Stability Test (ASTM D-2619)

0.1

Copper Specimen Weight Loss

0.05 mg/CM2 max

Acidity of Water Layer

6.0 mg KOH max

0.5

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 6.8

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_______________________________________________ Permissible media Table 18: Anti-wear hydraulic oil (Spec 100-1) approved suppliers Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation Chevron U.S.A.

1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18

Sun Oil Company Unocal 76 Shell Oil company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers Conoco Inc. Hydrotex Phillips Miners Oil

Brand name Amoco AW oil No.68 Harmony 68 AW Mobil DTE-16 Chevron hydraulic Oil Aw ISO 68 Sunvis 868 Unax AW 68 Shell Hydraulic Oil #33 Hydraulic AW 68 Duro AW S-315 Oil Texaco Rando Oil HD 68 Nuto 68 Pennzbell AW 68 Hydraulic Oil Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil Super Hydraulic oil 68 Systems 5K 68 Maginus A Oils 81350 Hydraulic Oil 68AW

______________________________________________________________ A6474X391 REV 4 6.9

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Permissible media ________________________________________________ Table 19: Extreme pressure gear oils (Spec. 100-2) specification Limit

Type

ISO VG

460

460

SAE Grade, Extreme Pressure Type

140

140

Pour Point (ASTM D-97)

Max. 20° F (-7° C)

20° F

Flash Point (ASTM D-92)

Min. 450° F (232° C)

440° F

SUS @ 100° F 283-347

1844/4345

22372609

SUS @ 210° F 50-58

120/200

149

CST @ 40° C

414/506

CST @ 100° C

30.3

Viscosity

Viscosity Index (ASTM D-2270)

Min. 85

96

Oxidation Test, Oil blown for 312 hours at 250° F 6% max (95° C). Ten liters of dry air per hour. Percent increase SSU viscosity at 210° F

2.2% increase

Four Ball Wear Test (ASTM D-2266) (20 KG, 1800 RPM, 130° F, one hour)

Max 0.8 mm scar diameter

0.27 mm

Four Ball EP Test (ASTM D-2783)

Load wear index not less than 45

47

Timken Test (ASTM D-2782)

Min. 60 lbs

65 lbs

Coefficient of Friction

Max. 0.1

Unknown

Water in Oil

1.5 mL max.

0.8 mL

Free Water

81 mL min.

83.0 mL

After Centrifuge

2 mL max.

0.7 mL

Total Water

84.85 mL min.

83.7 ml

Demulsibility Test (ASTM D-2711)

Demulsibility Test (USS 244 Requirement) Water in Oil

2.0 mL max.

Free Water

80 mL max.

After Centrifuge

2.0 mL max.

Total Water

30 mL min.

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 6.10

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_______________________________________________ Permissible media Table 20: Extreme pressure gear oils (Spec. 100-2) approved suppliers 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 Lubricating Oils, Inc.

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

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Permissible media ________________________________________________ Table 21: Extreme pressure motor bearing grease and hand grease (Spec. 100-3)specification Limit NLG1 Grade Number 2

Type 2

Worker Penetration (ASTM D-217)

265-295

280

Dropping Point (ASTM D-566) Bomb Oxidation (ASTM D-942)

Min. 350° F (177° C) Not more than 10 PSI DROP

373° F 2.5

Rust Inhibitors

Required

Yes

Wheel Bearing Test (ASTM D-1263) (6 Hours @ 235° F )

Not more than 5% loss

Water Washout (ASTM D-1264)

Loss not more than 5% @ 100° F Loss not more than 15% @ 175° F

Grease Mobility

Not less than 0.1 gram flow per Second @ 0° F

Timken OK Load (ASTM D-2509)

Not less than 50 lbs.

(50 lbs.)

Four Ball EP Test (ASTM D-2569)

Load wear index not less than 30.0 Weld point not less than 200 kg. Min.

31 200

4.25 4.00

Four Ball Wear Test (ASTM D-2266) Not more than 0.60 mm. SCAR diameter 0.44 (20KG., 1800 RPM, 130° F, One Hour) Table 22: Extreme pressure motor bearing and hand grease (Spec. 100-3) approved suppliers 1

Supplier Amoco Oil Company

2 3 4 5 6 7 8

Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century - Fuchs

9 10 11 12 13

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14

Hydrotex

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 Replex 2, 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

15 16

Phillips Atlantic Richfield Company

Philube EP Grease Litholine H EP-2 Grease

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 6.12

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_______________________________________________ Permissible media Table 23: Extreme pressure gear oil, SAE 90 (Spec. 100-6) specification Limit

Type

SAE Grade

90

90

ISO Viscosity Grade

320

320

Viscosity Index (ASTM D-2270)

95 min.

96

Flash Point (ASTM D-92)

420 min. (215° C)

440

Pour Point (ASTM D-97)

0° F (-18° C)

+10

Timken Load Test (ASTM D-2782)

60 lbs. weld

60 lbs.

Four Ball Wear Test (ASTM D-2266)

220 kg point min.

220 weld point

20kg, 1800 rpm, 130° F, 1 hour

0.5mm scar diameter

0.30 wear scar

SUS @ 100° F 283-347

720-1750 sec

1000 sec

SUS @ 210° F 50-58

100-120 sec

119

CST @ 40° C

288/352

CST @ 100° C

24

Viscosity

FZG Test

12

Table 24: Extreme pressure gear oil, SAE 90 (Spec. 100-6) approved suppliers 1 2 3 4

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8 9 10 11 12

Sun Oil Company Unocal 76 Shell Oil company Century Lubricating Oils, Inc. Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13 14 15

Conoco Inc. Hydrotex Phillips

16 17 18 19 20

Atlantic Richfield Cities Service Pennzoil Miner Oil Texaco, Lubricants Company

Brand name Amoco Premagear EP 320 EP Lubricant HD 320 Mobil gear 632 Chevron gear compound EP ISO 320 Sunep 320 Extra Duty NL Gear Lube 6EP Omala 75 Hulbest EP-6 Meropa 320 Spartan EP 320 Super Maxol EP 220 Gear Lube 605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320 932 Industrial Gear Lube Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000 Citgo EP Compound 110 Pen Gear #320 Gear Oil EP220 Texaco Multigear EP 80W-90

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Permissible media ________________________________________________ Table 25: Synthetic EP gear lubricants (Spec. 100-13) specification Limit ISO Viscosity Grade (ASTM D-2422)

680

AGMA Grade (AGMA 9005)

8 EP

API Gravity (ASTM D-1298)

25.0

Type

Viscosity SUS @ 100° F 283-347

236 calculated

SUS @ 210° F 50-58

3564 calculated

CST @ 40° C (ASTM D-445)

671 cst

CST @ 100° C (ASTM D-445)

48 cst

Viscosity Index (ASTM D-2270)

125

Flash Point (ASTM D-92)

450° F (232° C)

Pour Point (ASTM D-97)

15° F (-9° C)

Timken OK Load (ASTM D-2782)

80 lbs

Four Ball EP, Weld Point (ASTM D-2783)

315 kgf

Four Ball LWI (ASTM D-2783)

51 kgf

Falex (ASTM D-4172)

3000 lbs typ,

FZG Pass Stages (ASTM D-5182)

13

Copper Corrosion (ASTM D-130)

1 lb

Rust Protection, Dist. Water (ASTM D-665)

Pass

Rust Protection, Sea Water (ASTM D-665)

Pass

Emulsibility (ASTM D-1401M) Water-Millimeters

1 hour

Water-Millimeters

15 24 hours

Water-Millimeters

30 48 hours

Foam Suppression (ASTM D-892) 5 minutes

75 mls/max

10 mls/max Oxidation Stability (ASTM D-2893)

7% inc.

Table 26: Synthetic EP gear lubricants (Spec. 100-13) approved suppliers

1

Supplier Fuchs

Brand name Powergear H680

________________________________________________________________ FB140 (7MFBHM-48DD) Feeder Breaker 6.14

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_______________________________________________ Permissible media Table 27: Synthetic lithium complex grease for electric motor bearings (Spec. 100-14) specifications Limit

Type

NLG1 Grade

2

Thickener

Lithium soap complex

Base Oil Type

Synthetic polyalphaolefin base oils (POA)

Worked Penetration (60 strokes) (ASTM D-217)

265 - 295

280

Dropping Point (ASTM D-2265)

470° F (243° C) min

509° F (260° C)

Water Washout Resistance Weight 10% or less Loss @ 175° F (79° C) (ASTM D-1264)

6%

Grease Mobility (US Steel Test LT-37)

18 grams/min @ 0° F (-18° C) min

20 grams/min

Four Ball Wear (ASTM D-2266)

0.70 mm Max scar diameter

0.50 mm

Four Ball EP Weld Load (ASTM D2596)

530 lb (240 kg) min

550 lb (250 kg)

Timken OK Load (ASTM D-2509)

55 lb (25 kg) min

65 lb (30 kg)

Rust Corrosion Protection (ASTM D1743)

Pass

Pass

Base Oil Viscosity @ 104° F (40° C)

95 - 120

100

Table 28: Synthetic lithium complex grease for electric motor bearings (Spec. 100-14) approved suppliers 1

Supplier Mobil Oil Corp.

Brand name Mobility SHC 100

2 3

Conoco-Phillips Shell

Triton 100 Albida EMS 2

______________________________________________________________ A6474X391 REV 4 6.15