DOWNLOAD PDF Cat Bucyrus 7MFBH-56A Feeder Breaker Operation Manual

Operation Manual Bucyrus - Feeder Breaker Model - 7MFBH-56A Doc. No.:

A6474X286

Bucyrus America, Inc. ________________________________________ 4041 Wurno Road Pulaski, VA 24301

Telephone: 540-980-4530 Fax: 540-994-3763

Internet: www.bucyrus.com

__________________________________________________________

This manual is intended to provide GENERAL product information for the Model 7MFBH-56A Feeder Breaker . The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

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

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

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

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

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

© BUCYRUS AMERICA , INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

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

2. Your safety

© BUCYRUS AMERICA, INC.

Your safety .............................................................................. 2.3 Personnel............................................................................. 2.4 Operation ........................................................................ 2.4 Installation and repair...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use ................................................................... 2.5 Unauthorized use............................................................ 2.5 Safety instructions................................................................ 2.7 General rules: ................................................................. 2.7 Storage and transport ..................................................... 2.9 Installation and start-up................................................... 2.9 Operation .......................................................................2.10 Maintenance and repair .................................................2.10 Overview of the safety instructions .....................................2.15 Chapter 3: Storage and transport ..................................2.15 Chapter 4: Installation ....................................................2.15 Chapter 5: Operation .....................................................2.16 Chapter 6: Technical data..............................................2.20

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

4. Installation Installation ............................................................................... 4.3 Points to observe prior to installation................................... 4.3 Who is allowed to carry out installation?......................... 4.3 Which tools are required for installation?........................ 4.3 Notes on installation........................................................ 4.4 Pre-installation check list ................................................ 4.5 Safety features ................................................................ 4.6 Towing the feeder breaker................................................... 4.9

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Table of contents _________________________________________________

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 Operator’s station............................................................ 5.4 Primary valve bank ......................................................... 5.5 Starter enclosure............................................................. 5.9 Control features .............................................................5.11 Conveyor........................................................................5.12 Daily starting procedure .................................................5.13 Shutdown procedure......................................................5.14 Electrical system ............................................................5.15 Starter enclosure.......................................................5.17 Major electrical components .....................................5.19 Hydraulic system............................................................5.21 Major hydraulic components ....................................5.22 Mechanical assemblies..................................................5.25 Crawler assembly (s) ...............................................5.25 Conveyor chain ........................................................5.26 Grease take-up ........................................................5.26 Head shaft ................................................................5.27 Power unit ................................................................5.28 Tail shaft ...................................................................5.28 Breaker assembly .....................................................5.29 Instructions on the maintenance of the feeder ..............5.31 Important notes ........................................................5.31 Before maintenance .................................................5.31 Lubrication and inspection .......................................5.33 Specific lubrication and maintenance procedures ........5.36 Every 8 hours of operation .......................................5.36 Weekly .....................................................................5.38 Every 2 weeks ..........................................................5.42 Monthly .....................................................................5.42 Every 2500 hours ......................................................5.43 Every 6 months ........................................................5.44 Inspection of the feeder ................................................5.47 Inspection of wear parts on the feeder .........................5.48 Inspection of the fire suppression system......................5.49 Recharge of the fire suppression system ......................5.51 Instructions on the adjustment procedures ...................5.53 Conveyor chain adjustment .....................................5.53 Crawler track adjustment .........................................5.55 Instructions on the replacement of wear parts ..............5.57 Head shaft ................................................................5.57 Head shaft sprockets ...............................................5.60 Tail shaft ...................................................................5.63 Conveyor chain ........................................................5.68 Crawler track ............................................................5.71

_________________________________________________________________ Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

5. Operation

________________________________________________ Table of contents Crawler assembly .................................................... 5.74 Power unit ................................................................ 5.81 Conveyor drive motor .............................................. 5.89 Breaker assembly ..................................................... 5.92

6. Technical data Technical data ......................................................................... 6.3 Components of the feeder breaker ...................................... 6.3 Tightening torques................................................................ 6.7 Permissible data ................................................................. 6.15 Lubrication fluids and greases....................................... 6.15

7. For your information

© BUCYRUS AMERICA, INC.

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

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Table of contents _________________________________________________

_________________________________________________________________ Bucyrus – Model 7MFGH-56A Feeder Breaker

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About this manual

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________________________________________________________________

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________________________________________Before starting to work

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

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: Bucyrus – Model 7MFBH-56A Feeder Breaker Serial No.: 54-2112, 54-2163, 54-2178, and 54-2179 and is only permitted to be used for equipment of this type.

© BUCYRUS AMERICA, INC.

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

supervisory personnel who: ■ ■

initiate and/or supervise the activities just indicated.

______________________________________________________________ A6474X286 VLSV/02 1.3

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.

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

© BUCYRUS AMERICA, INC.

service

_________________________________________________________________ 1.4 Bucyrus – Model 7MFGH-56A Feeder Breaker

________________________________________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.

© BUCYRUS AMERICA, INC.

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

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

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

■

Items in lists are marked with bullets.

–

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

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

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

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© BUCYRUS AMERICA, INC.

Before starting to work ________________________________________

_________________________________________________________________ 1.6 Bucyrus – Model 7MFGH-56A Feeder Breaker

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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 Bucyrus America, Inc.

© BUCYRUS AMERICA, INC.

Use only original spare parts from Bucyrus America, Inc. Note that the use of parts from other manufacturers will void the guarantee.

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

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine.

■

of the Mines Inspector and

■

of 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

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

may only be carried out by service engineers from Bucyrus America, Inc. or by specially qualified personnel of the mine.

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© BUCYRUS AMERICA, INC.

and must be able to prove this knowledge.

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

Intended uses include: ■

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

Unauthorized use

© BUCYRUS AMERICA, INC.

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

■

the transport of persons

■

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

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

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© BUCYRUS AMERICA, INC.

Operating conditions __________________________________________

_________________________________________________________________ 2.6 Bucyrus – Model 7MFGH-56A Feeder Breaker

___________________________________________ Safety instructions Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

© BUCYRUS AMERICA, INC.

Inform your colleagues of:

safety equipment

■

your exact location.

■

the work you are performing.

■

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 acoustic and optical start-up warnings of the machine.

symbol plates emergency stop (panic strip)

lock-out

cordon off working area

Observe the symbol plates on the machine.

Press the STOP switch immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

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

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

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Safety instructions ____________________________________________ Never allow parts of your body to come between parts which could move, such as e.g.: ■

conveyor chains

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flights

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pivot points

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boom assemblies

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crawler assemblies

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breaker shaft assemblies

© BUCYRUS AMERICA, INC.

moving parts

_________________________________________________________________ 2.8 Bucyrus – Model 7MFGH-56A Feeder Breaker

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

© BUCYRUS AMERICA, INC.

means of attachment

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

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

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

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

mobile handling equipment

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

Installation and start-up inclined face

environmental acceptability

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

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

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

inspection maintenance instruction and safety tags

operator’s area

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

Verify that all maintenance has been performed.

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

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

Clean any foreign material from the operator’s area.

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

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

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

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

Maintenance and repair

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

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

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

Protect your work area against falling rocks.

replacing components

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

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

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Bucyrus America, Inc. spare parts.

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

For raising the feeder breaker use only: ■

crib blocks with adequate load-holding capacity

■

hoists, jacks or cranes with adequate load-carrying capacity

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© BUCYRUS AMERICA, INC.

Be sure to observe the prescribed maintenance and inspection intervals.

___________________________________________ Safety instructions handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

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

maintenance, repair

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

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

Always replace damaged or lost decals and metal instruction plates.

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

© BUCYRUS AMERICA, INC.

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

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

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

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

the hoses are not pinched or trapped

■

the hoses have no bubbles or blisters

■

the hose or outer sheathes of the hose are not abnormally rigid or hard

■

the outer sheath of the hoses is not damaged

■

the connectors are securely inserted into the sockets

■

the connections are leak-tight

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

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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

Replace hydraulic hoses at the first suspicion of damage. laying hydraulic hoses

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

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting Right

Wrong

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© BUCYRUS AMERICA, INC.

Never try to repair damaged hydraulic hoses.

___________________________________________ Safety instructions ■

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

Fig. 3: Laying hydraulic hoses, bending Right

■

Wrong

always have a little slack.

© BUCYRUS AMERICA, INC.

Fig. 4: Laying hydraulic hoses, crossing Right

■

are not kinked.

■

do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

Wrong

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

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

torn out,

■

kinked,

■

crushed,

■

driven over or

■

twisted by movement of the machine.

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

© BUCYRUS AMERICA, INC.

Right

_________________________________________________________________ 2.14 Bucyrus – Model 7MFGH-56A Feeder Breaker

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

Use only suitable load handling devices.

Chapter 4: Installation CAUTION! Serious damage can be caused to the feeder breaker as a result of incorrect installation.

The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc. IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the prestartup checks should be performed: NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

______________________________________________________________ A6474X286 VLSV/02 2.15

Overview of safety instructions _________________________________ DANGER! Do not operate the machine any of the guards or covers removed.

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

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

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

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

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

Chapter 5: Operation DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

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© BUCYRUS AMERICA, INC.

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

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

________________________________ Overview of safety instructions NOTICE! Once either of the hydraulic control valve handles is released by the operator, the lever will automatically return to the centered (neutral) position.

NOTICE! After oil filling operation is completed, return “POWER FILL” lever to the neutral position or overheating of the machine will occur.

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.

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

WARNING! If the “START” conveyor pushbutton is depressed while the conveyor direction control valve is in either forward or reverse position the conveyor will start running. Ensure that you and other workers are clear of the conveyor before depressing the “START “ conveyor pushbutton to prevent serious injury or death to you or other workers.

WARNING! Stay clear of the conveyor area. If the conveyor lever is in the operating position, the feeder breaker conveyor will automatically restart when the outby belt conveyor restarts. Serious injury or ______________________________________________________________ death to personnel can occur.

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

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

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.

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

WARNING! 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.

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

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

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© BUCYRUS AMERICA, INC.

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 out at the main power center.

________________________________ Overview of safety instructions IMPORTANT! The feeder breaker is equipped with a central lubrication system that allows several lubrication points to be lubricated from one central point.

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.

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

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

© BUCYRUS AMERICA, INC.

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

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

Incorrect tension or adjustment can cause premature wear of sprockets and chain.

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

WARNING! If only one side of the machine is raised during maintenance, 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.

IMPORTANT! The head shaft split sprocket is designed for temporary use only and should be replaced during the first available maintenance shift.

NOTICE! Do not mix and match sprocket halves or premature wear of sprockets and chain could occur.

WARNING! When using an additional 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. ______________________________________________________________ A6474X286

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2.19

Overview of safety instructions _________________________________ 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.

CAUTION! Failure to fill the hydraulic motor thru the case drain port to prime the motor will result in catastrophic damage to the motor.

IMPORTANT! Apply mineral or hydraulic oil to splines of head shaft and motor.

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.

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.

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

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Bucyrus America, Inc. expressly point out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

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

2.20

Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Chapter 6: Technical data

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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.

© BUCYRUS AMERICA, INC.

Before delivery, the hydraulically operated equipment is operated and all axles, gear boxes, hydraulic oil tank, etc. are filled to their maximum fill point.

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. 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).

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

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.

short-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.

long-term storage

If the equipment is to be stored more than six months, the hydraulic components must be completely filled with a corrosion inhibiting/frostproofing fluid such e.g. CV 50.

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.

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

______________________________________________________________ A6474X286 VLSV/02 3.3

Storage and transport _________________________________________ plastic deformation

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

random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

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

natural aging

Even with proper storage, seals and hoses are subject to natural ageing. 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 in this operating manual.

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

Dimensions

■

Weight

■

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.

_________________________________________________________________ 3.4 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

________________________________________ Storage and transport Fig. 6: Lifting points on the feeder breaker Lift point

Lift point Lift point

© BUCYRUS AMERICA, INC.

Lift point

______________________________________________________________ A6474X286 VLSV/02 3.5

Storage and transport _________________________________________ Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid (e.g. CV 50).

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.

electronic components

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

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

_________________________________________________________________ 3.6 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

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.

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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.)

© BUCYRUS AMERICA, INC.

the electrical equipment (control units, signaling devices, etc.) and the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by Bucyrus America, Inc. service engineers or by specially trained personnel.

Which tools are required for installation? tool box

No special tools are required to put the feeder breaker into service.

In addition, various items of auxiliary equipment and machines may be required at the point of installation.

These include i.e.: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

______________________________________________________________ A6474X286 VLSV/02 4.3

Installation___________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the feeder breaker as a result of incorrect installation.

The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc. installation plan

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

© BUCYRUS AMERICA, INC.

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

_________________________________________________________________ 4.4 Bucyrus – Model 7MFGH-56A Feeder Breaker

__________________________________________________ Installation Pre-installation check list

© BUCYRUS AMERICA, INC.

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

■

check tension of conveyor chain

■

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

■

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

■

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

■

jog the breaker motor to check for correct rotation of breaker

■

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

■

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

■

check the operation of the remote start pushbuttons

■

check operation of the emergency pull cord stop switch located on the receiving end of the machine

■

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 proper hydraulic schematic)

■

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

______________________________________________________________ A6474X286 VLSV/02 4.5

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

emergency stop pull cord switch

The emergency stop pull cord switch is located on the receiving end of the machine. To actuate the switch, pull the cord that is across the conveyor. When the cord is pulled, all machine functions are shutdown immediately.

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.

“STOP” switch (starter enclosure)

This stop switch is located on the left hand side of the machine, on the starter enclosure cover. Depressing the stop switch button will shutdown all machine functions immediately.

“E-STOP” switch (starter enclosure)

This stop switch is located on the left hand side of the machine, on the starter enclosure cover. Depressing the stop switch button will shutdown all machine functions immediately.

panic strip (s)

One panic strip is located at the operator’s station on the left hand side of the machine and the other is located on the right side above the crawler assembly. Striking with a small amount of force will actuate either of the panic strips. The panic strip (s) is used to break the control circuit in emergency situations. When either of the panic strips are struck, all machine functions are shutdown immediately.

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators. One is located adjacent to the operator’s station on the left side of the machine. The other is located adjacent to the crawler 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.

_________________________________________________________________ 4.6 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Safety features include: (Reference Fig.7)

__________________________________________________ Installation neutral start mechanism

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

Fig. 7: Safety features on the feeder breaker

© BUCYRUS AMERICA, INC.

Stop switch (starter)

E-Stop switch (starter)

Fire suppression actuator location

Neutral start mechanism

Panic strip Emergency stop pull cord switch

Fire suppression actuator location

Panic strip

______________________________________________________________ A6474X286 VLSV/02 4.7

Installation___________________________________________________ Fig. 8: Overview of the feeder breaker Head shaft

Discharge section Power unit

Starter enclosure

Hydraulic oil tank Breaker assembly

Torque hub R.H. crawler assembly

Ratio chains (not shown)

Operator’s area

Conveyor chain (not shown) Emergency pull cord stop Receiving section

Tail shaft take-ups Tail shaft

_________________________________________________________________ 4.8 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

L.H. crawler assembly

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

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

© BUCYRUS AMERICA, INC.

To tow the feeder breaker proceed as follows:  Couple the towing machine securely to the feeder breaker.  Chock front and rear of both crawler drives.

WARNING! Failure to chock the front and rear of both crawlers could allow uncontrolled movement of the feeder breaker. Failure to follow this warning could cause serious injury or death to you or other workers.  Rotate the torque hub end cap on both right and left sides of the feeder to the free position as follows (Fig. 9).  Remove the two (2) bolts that retains the end cover to the center of the torque hub.  Rotate cover and reinstall with the two (2) bolts to disengage torque hub. Torque bolts to 120 in lb.

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

WARNING! Do not exceed 5 mph during towing. Exceeding 5 mph could cause serious injury or death to you or other workers or damage to machine.  Remove chocks from crawler and begin towing.

______________________________________________________________ A6474X286 VLSV/02 4.9

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

WARNING! Failure to chock the front and rear of both crawlers could allow uncontrolled movement of the feeder breaker. Failure to follow this warning could cause serious injury or death to you or other workers.  Rotate the torque hub end cap on both right and left sides of the feeder breaker to the drive position.  Remove the two (2) bolts that retains the end cap to the center of the torque hub.  Rotate end cap and reinstall with the two (2) bolts to engage torque hubs to the drive position. Torque bolts to 120 in lb.

Retaining bolts (2)

Normal tram position

© BUCYRUS AMERICA, INC.

Fig. 9: Torque hub disengagement

End cap button pointing outward

Retaining bolts (2)

End cap button pointing inward Freewheel position

_________________________________________________________________ 4.10 Bucyrus – Model 7MFGH-56A Feeder Breaker

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Operation

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___________________________________________________Operation

Operation This chapter contains important information on the operation and maintenance of the machine. It also includes instructions on the replacement of wear parts.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

How to operate the feeder breaker

© BUCYRUS AMERICA, INC.

DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the feeder breaker?

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

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

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.

______________________________________________________________ A6474X286 VLSV/02 5.3

Operation____________________________________________________ Controls and indicators Operator’s station The primary controls for the machine are located on the left hand side.

The operator’s station (Fig. 10) consists of the following controls and indicators: primary valve bank, auxiliary function pressure gauges, conveyor speed pressure gauge, conveyor speed control valve, conveyor direction control valve, starter enclosure, oil level sight gauge, tram/ conveyor mode control valve and fire suppression actuator.

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

Conveyor chain speed flow control

Conveyor direction control valve

Fire suppression actuator

Oil Level sight gauge Starter enclosure

Conveyor speed pressure gauge

Tram/conveyor mode control valve

Auxiliary function pressure gauges

Primary valve bank

_________________________________________________________________ 5.4 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 10: Operator’s station

___________________________________________________Operation Primary valve bank The primary valve bank (Fig. 11) consists of the following hydraulic controls: “POWER FILL”

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

© BUCYRUS AMERICA, INC.

NOTICE! After oil filling operation is completed, return “POWER FILL” lever to the neutral position or overheating of the machine will occur.

“RIGHT FRAME LIFT”

The second lever from the operator’s right 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.

“RIGHT TRAM”

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

“LEFT TRAM”

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

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

The tram/steering control levers are used for tramming and positioning the machine. To tram the machine in a straight direction towards the receiving end, push both tram control levers towards the machine and to tram the machine in a straight direction towards the discharge end, pull both tram control levers towards the operator. 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.

______________________________________________________________ A6474X286 VLSV/02 5.5

Operation____________________________________________________ “LEFT FRAME LIFT”

The fifth lever from the operator’s right 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.

“FRAME TILT”

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

“POWER FILL”

“TILT”

“LEFT LIFT” “RIGHT LIFT” “LEFT TRAM”

“RIGHT TRAM”

auxiliary function pressure gauges

The auxiliary function pressure gauges (Fig. 12) are high pressure gauges (5,000 psi) located to the left of the tram control levers. These gauges give the operator a constant reading of the auxiliary system pressures.

conveyor speed pressure gauge

The conveyor speed pressure gauge (Fig. 12) is a low pressure gauge (600 psi) located to the right of the conveyor direction control lever.

This gauge gives the operator a constant reading of the conveyor speed pressure.

two position conveyor direction

The two position conveyor direction and speed control valve (Fig. 12) controls the feeder breaker conveyor chain direction and speed. Push the control lever down to run the conveyor in the direction of the discharge end and pull the control lever up to run the conveyor in the direction of the receiving end.

_________________________________________________________________ 5.6 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 11: Primary valve bank

___________________________________________________Operation tram/conveyor mode control valve

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

© BUCYRUS AMERICA, INC.

Located on the right side of the discharge end of the machine is two (2) pressure gauges that gives the operator a constant pressure reading for system and charge pressures. See below for a brief description of each gauge. conveyor circuit system pressure gauge

The tram circuit system pressure gauge (Fig. 12) is a high pressure gauge (6,000 psi) located on the right side of the discharge end. This gauge gives the operator a constant reading of the tram circuit system pressure.

conveyor circuit charge pressure gauge

The conveyor circuit charge pressure gauge (Fig. 12) is a low pressure gauge (600 psi) located on the right side of the discharge end. This gauge gives the operator a constant reading of the tram circuit charge pressure.

oil level sight glass

The oil level sight glass (Fig. 12) is located on the side of the oil tank.

The oil level should not be allowed to drop below the bottom of the sight glass.

power fill ball valve

The power fill ball valve (Fig. 12) is located on the left hand side of the discharge section of the machine on top of the oil tank and is used to control the flow of hydraulic fluid from the power fill pump.

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators (Fig. 12). One is located adjacent to the operator’s station on the left side of the machine. The other is located adjacent to the crawler 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.

conveyor chain speed control valve

The conveyor chain speed is controlled by a flow control valve. Turn the knob clockwise to increase speed and counterclockwise to decrease speed.

______________________________________________________________ A6474X286 VLSV/02 5.7

Operation____________________________________________________ Fig. 12: Controls and indicators Power fill ball valve

Starter enclosure

Conveyor speed pressure gauge

Fire suppression actuator

Neutral start mechanism

Primary valve bank

Tram/Conveyor mode control valve

Conveyor direction control valve

Panic strip

Emergency stop pull cord switch

Fire suppression actuator location

Panic strip

System pressure Charge pressure

_________________________________________________________________ 5.8 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Oil level sight glass

___________________________________________________Operation Starter enclosure

© BUCYRUS AMERICA, INC.

The starter enclosure (Fig. 13) is located on the left hand side of the machine and houses the electrics necessary to control the machine and consists of the following machine’s electrical functions: “POWER ON” light

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

“HIGH TEMP” light

The “HIGH TEMP” light will be illuminated when the machine is operating at normal temperatures. If the temperature switch detects a high temperature inside the oil tank, the light will turn off and the motor will shut down.

“HIGH PRESS” light

The “HIGH PRESS” light will be illuminated when the machine is operating at normal pressure. If the pressure switch detects excessive pressure within the hydraulic system, the light will turn off and the motor will shut down.

“LOW OIL” light

The “LOW OIL” light will be illuminated when the oil tank is at normal levels. If a low oil issue is detect at the hydraulic oil tank, the light will turn off and the motor will shut down.

“START” (pushbutton)

The “START” pushbutton (when depressed) is used to start the machine’s electric motor.

WARNING! If the “START” pushbutton is depressed while the conveyor direction control valve is in either forward or reverse position the conveyor will start running. Ensure that you and other workers are clear of the conveyor (s) before depressing the “START “ pushbutton to prevent serious injury or death to you or other workers.

“RESET” (pushbutton)

The “RESET” pushbutton (when depressed) is used to reset the machine’s 15 amp control circuit breaker, which is located on the swing panel.

“STOP” (pushbutton)

This stop switch is located on the left hand side of the machine, on the starter enclosure cover. Depressing the stop switch button will shutdown all machine functions immediately.

“E-STOP” (pushbutton)

This stop switch is located on the left hand side of the machine, on the starter enclosure cover. Depressing the stop switch button will shutdown all machine functions immediately.

______________________________________________________________ A6474X286 VLSV/02 5.9

Operation____________________________________________________ “LIGHT OFF/ON” selector switch

The “LIGHT OFF/ON” selector switch turns the feeder breaker lights on and off.

circuit breaker lever

This lever is used to reset the circuit breaker when it has tripped. If the breaker has tripped, the reset lever must be moved to the “RESET” position first and then to the “ON” position.

Fig. 13: Starter enclosure cover Light Legend

“POWER ON”

“LIGHT OFF/ON” switch

“HIGH PRESS.”, L3 Circuit breaker reset lever

“LOW OIL”, L4

“START”

“RESET”

“STOP”

“E-STOP”

_________________________________________________________________ 5.10 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

“HIGH TEMP.”, L2

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

There is one high temperature switch for the feeder breaker, located onboard the machine at the oil tank. If a high temperature is detected at the oil tank, the motor will be turned off and a light (high temperature) will be illuminated. This light is located on the cover of the electrical enclosure (Fig. 11).

There is one low oil cut off switch for the feeder breaker, it is located onboard the machine at the oil tank. If it detects a low oil issue at the oil tank the motor will be turned off and a light (low oil) will be illuminated. This light is located behind the cover of the electrical enclosure on the swing panel (Fig. 11).

belt sequence sensor and pick breaker sensor

These sensors are used to detect the state of the belt conveyor (running or not running) and to detect the state of the pick breaker (turning or not turning). If the conveyor belt that is used to convey the coal from the feeder breaker stops, the conveyor will stop running. The conveyor will start again when the outby belt conveyor restarts if the conveyor lever is in the operating position.

© BUCYRUS AMERICA, INC.

low oil cut off switch

WARNING! Stay clear of the conveyor area. If the conveyor lever is in the operating position, the feeder breaker conveyor will automatically restart when the outby belt conveyor restarts. Serious injury or death to personnel can occur.

If the pick breaker rotation stops or slows down the pick break sensor will detect this and shut down the motor. motor overload

There is an overload on the crusher/pump motor. If an over current condition is detected, the overload will trip and the motor will be stopped.

______________________________________________________________ A6474X286 VLSV/02 5.11

Operation____________________________________________________ Conveyor Perform daily start-up procedure (see Start-up procedure in this chapter). The conveyor is controlled by a 200 hp crusher motor. The conveyor may be started utilizing the “TRAM/CONVEYOR” mode and conveyor speed/direction control valves located on the left side of the machine.

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

© BUCYRUS AMERICA, INC.

IMPORTANT! If it is necessary to reverse the conveyor, it should be jogged only.

Running the conveyor in the reverse direction for a period of time with material in the hopper, will jam the conveyor and it will be necessary to empty the machine hopper before the conveyor will restart.

_________________________________________________________________ 5.12 Bucyrus – Model 7MFGH-56A Feeder Breaker

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

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

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

© BUCYRUS AMERICA, INC.

 Operate all valve control levers to ensure that they are free and in neutral position.  Position the primary valve bank handle lock guard over the valve handles so that they cannot be operated. Make sure the magnetic contacts are fully seated and are in direct contact.

IMPORTANT! The machine will not start unless all valve control levers on the primary valve bank are in neutral position and the guard is fully closed, engaging the magnetic switch.  Check conveyor for any foreign material or objects.  Check that all other personnel are within a safe distance of the machine.

WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the machine.  Apply power to the machine. (Line side of the main circuit breaker)  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.  Engage the “START” pushbutton located on the cover of the starter enclosure.  The contactor M1 will energize and the motor will start.

______________________________________________________________ A6474X286 VLSV/02 5.13

Operation____________________________________________________ Shutdown procedure There are several methods of shutting down the feeder breaker.  Allow the machine to run until the hopper is empty. Continue to run the machine until all material that has been carried back into the return line has been cleaned out.

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

To shutdown the feeder breaker proceed as follows:  Engage the pull cord switch located across the receiving end.

This will stop the electric motor.

 Move the conveyor directional control handle to the centered “NEUTRAL” position.  Turn the conveyor speed control knob counter clockwise (CCW) to the lowest speed.

_________________________________________________________________ 5.14 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Depress the “STOP” button located on the cover of the starter enclosure.

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

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

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

© BUCYRUS AMERICA, INC.

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

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

Fig. 14: Major electrical component locator Starter enclosure

Tape switch

Emergency stop pull cord switch

Electric motor 200 hp Tape switch

_____________________________________________________________ A6474X286 VLSV/02 5.15

Electrical system _____________________________________________

© BUCYRUS AMERICA, INC.

Fig. 15: Electrical layout

_________________________________________________________________ 5.16 Bucyrus – Model 7MFGH-56A Feeder Breaker

____________________________________________ Electrical system Starter enclosure The starter enclosure (Fig. 16) located on the left hand side of the discharge end of the machine houses the primary electrical control components.

On the cover of the starter enclosure is the electrical switches . These are labeled and control the start and stop functions for the electric motor. Also, located on the cover is the selector handle for turning the main circuit breaker “ON” and “OFF”. This allows the main power to the machine from the section power supply to be disconnected.

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 out at the main power center.

© BUCYRUS AMERICA, INC.

Fig. 16: Starter enclosure components

Circuit breaker, CB1 Vacuum contactor, M1

Control transformer

Overload, OL1

Terminal blocks

Panel board

IS Relay

Control relays, SR, MCR, BSCR Power supply 120/12VDC

Indicator lights (only the top four lights are used) Timing relay, TR2

Timing relays, TR and TR1 Control circuit breakers, CB2 (15A), CB3 and CB4 (5 amp) Terminal blocks Swing panel

_____________________________________________________________ A6474X286 VLSV/02 5.17

Electrical system _____________________________________________

Panel board The panel board (Fig. 16) is accessed by opening the cover of the starter enclosure and moving the swing panel out. Located on the panel board are the control transformer, the vacuum contactor, and the overload. control transformer, “T1”

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

vacuum contactor, “M1”

“M1” is the vacuum contactor fro the motor.

overload, “OL1”

“OL1” is the overload relay for the motor. If the motor is overloaded, the relay will shut it down.

The swing panel (Fig. 16) is accessed by opening the cover on the starter enclosure. Located on the swing panel are the indicator lights, relays, timers, circuit breaker resets, and the power supply. main circuit breaker, “CB1”

The main circuit breaker, “CB1”, is located to the right of the swing panel. the circuit beaker reset switch on the front of the starter enclosure panel is used to control the circuit breaker when the starter enclosure cover is in place.

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

“IS RELAY”

safety relay, “SR” master control relay, “MCR”

belt slip control relay “BSCR” timer, “TR”

The “IS RELAY” is an intrinsically safe relay for the tape switches.

When either tape switch is struck, the relay will shutdown the machine.

“SR” is the safety relay. If either tape switch is struck, the motor will shutdown.

The master control relay, “MCR”, must be energized for the machine to operate.

The belt slip control relay, “BSCR”, will stop the feeder breaker conveyor if the belt that the feeder breaker is dumping onto stops.

The timer “TR” is a time delay on dropout timer and is normally set at three (3) seconds. If there is a low oil, high temperature, or high pressure condition that lasts for more than three seconds, the machine will shutdown.

_________________________________________________________________ 5.18 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Swing panel

____________________________________________ Electrical system breaker shaft underspeed sensor, “TR1”

“TR1” is the breaker shaft underspeed timer and is normally set for three (3) to five (5) seconds. If the breaker shaft slows down below the normal speed calibrated during initial machine setup for longer than the set time, the underspeed sensor will shutdown the motor.

override timer, “TR2”

“TR2” is the override timer for the breaker shaft underspeed timer and is normally set for two (2) to three (3) seconds longer than “TR1”. During startup, the override timer will allow the breaker shaft to run under speed for approximately seven (7) seconds. This override is active during startup only.

“CB2”

“CB2” is a 15 amp circuit breaker on the control circuit. If the control circuit is overloaded, or if the circuit becomes grounded, “CB2” will trip.

To reset “CB2”, press the push button on the front of the start enclosure.

“CB3” and “CB4”

“CB3” and “CB4” are 5 amp circuit breakers for an optional light. If either breaker trips, it must be reset from the swing panel.

© BUCYRUS AMERICA, INC.

Major electrical components (Reference Fig. 14 and 15) electric motor

The machine has a (200 hp 950 VAC non/X/P) electric motor that drives the pick breaker and hydraulic pump for the feeder breaker.

emergency stop pull cord switch

The emergency stop pull cord switch is located on the receiving end of the machine. To actuate the switch, pull the cord that is across the conveyor. When the cord is pulled, all machine functions are shutdown immediately.

belt sequence sensor and pick breaker sensor

These sensors are used to detect the state of the belt conveyor (running or not running) and to detect the state of the pick breaker (turning or not turning). If the conveyor belt that is used to convey the coal from the feeder breaker stops. If the pick breaker rotation stops or slows down the pick break sensor will detect this and shut down the motor.

high temperature switch

There is a high temperature switch for the feeder breaker located onboard the machine at the oil tank. If it detects a high temperature at the oil tank the motor will be shut down and the “HIGH TEMPERATURE” light will turn off. This light can be seen from the front of the starter enclosure.

low oil cut off switch

There is a low oil cut off switch for the feeder breaker located onboard the machine at the oil tank. If it detects a low oil issue the motor will be shut down and the “LOW OIL” light will turn off. This light can be seen from the front of the starter enclosure.

high pressure switch

There is a high pressure switch for the feeder breaker. If it detects a high pressure situation, the motor will be shutdown and the “LOW OIL” light will turn off. This light can be seen from the front of the starter enclosure.

_____________________________________________________________ A6474X286 VLSV/02 5.19

Electrical system _____________________________________________ One panic strip is located at the operator’s station on the left hand side of the machine and the other is located on the right side above the crawler assembly. Striking with a small amount of force will actuate either of the panic strips. The panic strip (s) is used to break the control circuit in emergency situations. When either of the panic strips are struck, all machine functions are shutdown immediately.

magnetic switch

There is a magnetic switch located at the operator’s station on the primary valve bank. The purpose of the magnetic switch is to ensure that all valve levers on the primary valve bank are in the neutral position before the machine is started. The machine will not start unless the magnetic switch is closed. The switch is closed by placing all the valve levers into the neutral position and then lowering a guard over the levers.

© BUCYRUS AMERICA, INC.

panic strip (s)

_________________________________________________________________ 5.20 Bucyrus – Model 7MFGH-56A Feeder Breaker

____________________________________________ 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.

© BUCYRUS AMERICA, INC.

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

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

Fig. 17: Hydraulic component locator

16

2

14

20

8,9

12

17 5

19

23

4

3

7

6

13

10

21

11

1.

2.

3.

4.

5.

6.

7.

8.

22

24

1

15

primary valve bank 9. pressure gauge (600 psi) 18. conveyor motor tram motor (R.H.) 10. oil/air heat exchanger 19. conveyor pressure gauge tram motor (L.H.) 11. auxiliary pressure filters 20. hydrostatic filter aux. pressure gauges 12. charge filter 21. tilt and lift cylinders (5,000 psi) 13. return filter 22. conveyor control valve loop flushing valve 14. belt sequence valve 23. tram/conveyor speed control tank fill filter 15. oil tank valve tank fill pump 16. hydrostatic pump 24. conveyor chain forward/reverse pressure gauge 17. gear pump control _____________________________________________________________ (10,000 psi) A6474X286

VLSV/02

5.21

Hydraulic system _____________________________________________ Major hydraulic components

hydraulic oil tank

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

hydrostatic pump

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

gear pump

The gear pump located within the power unit supplies hydraulic power to the tram drive motors, tilt and lift cylinder circuits.

primary valve bank

The primary valve bank located on the left hand side of the machine is used to control the machines, 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.

tank fill pump

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

tilt hydraulic cylinders

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

lift hydraulic cylinders

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

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

The machine is equipped with lock pins that should be installed when the unit is not being moved. Pin are located near the lift cylinders on both sides of the machine.

tram motors

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

conveyor motor

The conveyor motor is located on the left hand side of the head shaft and is a radial piston motor that receives hydraulic fluid from the hydraulic pump. The motor is controlled from the two position conveyor direction control valve.

_________________________________________________________________ 5.22 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

(Reference Fig. 17)

____________________________________________ Hydraulic system

© BUCYRUS AMERICA, INC.

loop flush valve

The machine is equipped with a loop flush valve located on the discharge end of the machine on the frame side plate behind the hydrostatic pump. The valve is used to dump approximately 30% of the charge oil to the low pressure side of the circuit.

oil/air heat exchanger

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

two position conveyor direction control valve

The two (2) position conveyor control valve located above the left hand crawler is used to control the conveyor direction of travel.

charge filter

The charge filter located under the gear pump on the right hand side of the machine is used to filter make-up oil from the charge pump to the hydrostatic closed loop system.

pressure filter (s)

The two pressure filter located above the crawler on the left hand side of the machine are used to filter fluid from the piggyback gear pump.

return filter

The return filter located on the left hand side of the of the discharge end of the machine is used to filter fluid from the case drains of the hydraulic pump and conveyor motor.

tank fill filter

The tank fill filter located on top of the oil tank is used to filter fluid that is being pumped with the power fill system from an external source to the hydraulic oil tank.

pressure filter (hydrostatic)

The pressure filter located beside the gear pump is used to filter fluid that is being pumped by the hydrostatic pump.

tram/conveyor mode control valve

The tram/conveyor mode control valve allows the operator to change the machine from tram mode to conveyor mode.

conveyor pressure gauge

The conveyor pressure gauge located on the left side of the machine gives the operator a constant reading of the hydraulic pressure within the conveyor circuit and is used as a reference to control the conveyor chain speed.

auxiliary function pressure gauges

The auxiliary function pressure gauges are high pressure gauges (5,000 psi) located to the left of the tram control levers. These gauges give the operator a constant reading of the auxiliary system pressures.

pressure gauge (10,000 psi)

The conveyor circuit system pressure gauge is a high pressure gauge (10,000 psi) located on the right side of the discharge end. This gauge gives the operator a constant reading of the conveyor circuit system pressure.

pressure gauge (600 psi)

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

conveyor speed control

The conveyor speed control valve is used to control the speed of the conveyor chain.

conveyor direction control

The conveyor direction control valve control which direction the con-

veyor travels: forward or reverse. _____________________________________________________________ A6474X286 VLSV/02 5.23

Hydraulic system _____________________________________________

© BUCYRUS AMERICA, INC.

Fig. 18: Hydraulic schematic

_________________________________________________________________ 5.24 Bucyrus – Model 7MFGH-56A Feeder Breaker

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

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

Crawler assembly (s)

© BUCYRUS AMERICA, INC.

The feeder breaker is trammed by two (2) hydraulically driven crawlers (Fig. 19); one is located on each side of the machine. The complete drive assemblies are housed in crawler frames which enclose, guide and support the tram components. Each tram drive is independently controlled by the operator for moving the machine forward, backward and for making turns.

The crawlers on the machine are hydraulic driven through torque hub gear reducers. Attached to the torque hub is a single sprocket that engages the crawler tracks directly. The crawler track loops around the take-up roller assembly located on the opposite end of the crawler assembly. The idler assembly, along with a grease take-up is used to adjust the tension on the crawler tracks. (See Maintenance section in this chapter for Crawler track adjustment procedure) Fig. 19: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

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

_____________________________________________________________ A6474X286 VLSV/02 5.25

Mechanical assemblies ________________________________________ Conveyor chain The feeder breaker is equipped with a conveyor chain assembly (Fig. 20) 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. 20: Conveyor chain components

Roll pin

© BUCYRUS AMERICA, INC.

Chain link section

Flight bar

Grease take-up The feeder breaker is equipped with two (2) conveyor chain grease take-up assemblies (Fig. 21) 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 in this chapter) Fig. 21: Grease take-up main components Stop valve (2)

Grease manifold

Grease fitting (2)

_________________________________________________________________ 5.26 Bucyrus – Model 7MFGH-56A Feeder Breaker

_______________________________________ Mechanical assemblies Head shaft The feeder breaker is equipped with a head shaft (Fig. 22 and 23) located on the discharge end of the conveyor. The head shaft is driven from the left hand side via a hydraulic motor that is directly connected to the head shaft.

Fig. 22: Head shaft main components Bearing (2)

Key (2)

Set screw (2)

Head shaft © BUCYRUS AMERICA, INC.

Sprocket (2)

Fig. 23: Conveyor torque arm and hydraulic motor

Torque arm

Coupling

Hydraulic motor

_____________________________________________________________ A6474X286 VLSV/02 5.27

Mechanical assemblies ________________________________________ Power unit The power unit drives the hydraulic pump (s) and pick breaker reducer (Fig. 24). It consists of a 200 HP electric motor, coupled to a reducer, hydrostatic pump and piggyback gear pump. The power unit has been assembled as a unit and can be removed as a unit or as individual components.

Fig. 24: Power unit main components Sprocket

Taperlock bushing Gear box Motor (200 HP)

Taperlock bushing

© BUCYRUS AMERICA, INC.

Coupling Hydrostatic pump

Gear pump

Connecting tube Coupling

Tail shaft The feeder breaker is equipped with a tail shaft (Fig. 25) 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. 25: Tail shaft components

Set screw (2)

Slide plate

Adapter (2)

Key (2)

Sprocket (2)

Head shaft

Bearing (2)

_________________________________________________________________ 5.28 Bucyrus – Model 7MFGH-56A Feeder Breaker

_______________________________________ Mechanical assemblies Breaker assembly The breaker assembly (Fig. 26) on the machine has a 25” (635 mm) pick circle with a 5 point star arrangement. It has a 8” shaft diameter turned down to 6 3/16” (157 mm) thru the bearings. The breaker has a under speed sensor mounted on the left hand side that will shutdown the machine should the breaker be stalled due to a jam.

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

Fig. 26: Breaker assembly main components

Spiral retaining ring Bearing retainer © BUCYRUS AMERICA, INC.

Bit (30) (use 2 snap rings per bit)

Seal

Flange

End cap

Seal wear ring Seal housing

Breaker shaft O-ring Bearing backing ring

Side plate

Bearing housing O-ring Bearing

Bearing Seal

O-ring Side plate

O-ring Seal

Seal Seal wear ring

Seal housing

Spiral retaining ring End cap

Bearing backing ring

Bearing retainer

Bearing housing

Under speed sensor

_____________________________________________________________ Conveyor chain not shown A6474X286 VLSV/02 5.29

© BUCYRUS AMERICA, INC.

Mechanical assemblies ________________________________________

_________________________________________________________________ 5.30 Bucyrus – Model 7MFGH-56A Feeder Breaker

________________________________________________ Maintenance Instructions on the maintenance of the feeder breaker 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

© BUCYRUS AMERICA, INC.

Please observe the following: ■

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

■

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

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus spare parts when replacing components.

■

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

■

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

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power. The circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source.

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.

■

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.

______________________________________________________________ A6474X286 VLSV/02 5.31

Maintenance _________________________________________________ ■

During maintenance or servicing, if either of the tram drives are to be run, the side that is to be run must be jacked clear of the ground and securely blocked.

■

Do not perform maintenance on either boom while there is a load resting on the hydraulic cylinder. Booms must be securely blocked if maintenance is to be performed with either boom in the raised position.

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

■

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

■

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

■

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

_________________________________________________________________ 5.32 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

________________________________________________ Maintenance Lubrication and inspection Maintenance of the feeder breaker includes: ■

Lubrication of the machine in accordance with the lubrication schedule.

■

Inspection of the machine for faults and proper function.

■

Inspection for wear parts.

Lubrication IMPORTANT! The feeder breaker is equipped with a central lubrication system that allows several lubrication points to be lubricated from one central point. See the following section.

© BUCYRUS AMERICA, INC.

Central lubrication system The central lubrication manifold (Fig. 27) is located on the left hand side of the receiving end of the feeder breaker. This allows the following to be easily lubricated from a central point; head shaft, breaker shaft and tail shaft.

Fig. 27: Central lubrication Note: Outboard bearing port used only if applicable on machine.

Tail shaft

Outboard bearing

Breaker

Head shaft

______________________________________________________________ A6474X286 VLSV/02 5.33

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 1: Lubrication and maintenance schedule (feeder breaker) Item

Description

Places

Lubricant

Specification

1

Head shaft bearings

2

Century Replex 2

Spec. 100-3

2

Breaker bearings

2

Century Replex 2

Spec. 100-3

3

Tail shaft and slide tube bearings

4

Century Replex 2

Spec. 100-3

4

Hydraulic oil level (check)

1

Century Hydraulic AW 68

Spec. 100-1

5

Charge filter (check)

1

6

Pressure filter (auxiliary circuit) (check)

2

7

Return filter (check)

1

8

Pressure filter (hydrostatic) (check)

1

9

Bits (breaker)

Century Replex 2

Spec. 100-3

Inspect

Weekly 10

Crawler track take-up bearings

2

11

Conveyor chain tension

12

Fasteners (nuts, bolts and screws)

Inspect

13

Electrical cables, conduits and glands

Inspect

14

Hydraulic hoses and connections

Inspect

15

Hydraulic system pressures

Check

16

Tram reducer (s) (check oil level)

2

80W-90

17

Breaker reducer (Check)

1

Century 220

18

Dust system strainer (Check)

1

19

Charge filter (change)

1

20

Pressure filter (hydrostatic) (change)

1

1

Every 2 weeks 21

Pressure filter (auxiliary circuit) (change)

2

22

Return filter (change)

1

Monthly 23

Conveyor tilt and lift cylinders

8

Century Replex 2

Spec. 100-3

24

Crawler anchor pin (s)

2

Century Replex 2

Spec. 100-3

25

Electric motor

2

Exxon Unirex N-2

Spec. 100-3

26

Breaker reducer

2

Century Replex 2

Spec. 100-3

1

Century 220

Every 2500 hours 27

** Breaker reducer (Change)

_________________________________________________________________ 5.34 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Every 8 hours of operation

________________________________________________ Maintenance Table 1 Continued: Lubrication and maintenance schedule (feeder breaker) Item

Description

Places

Lubricant

Specification

Spec. 100-1

Every 6 months 28

Hydraulic oil tank (change)

1

Century Hydraulic AW 68

29

Tram reducer (change oil)

2

80W-90

30

Power fill filter (change)

1

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

Fig. 28: Lubrication chart (feeder breaker) 5,19 8,20

7,22

© BUCYRUS AMERICA, INC.

25

4,28 18,26,27

30

9

24 16,29 15

6,21 1,2,3 10 23

______________________________________________________________ A6474X286 VLSV/02 5.35

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

Lubricate the feeder breaker head shaft bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 29) located on the left side of the receiving section. Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

tail shaft and slide tube bearings

Lubricate the feeder breaker tail shaft and slide tube bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 29) located on the left side of the receiving section.

Pump grease into the three (3) fittings until new grease can be observed coming out of the tail shaft and bearings.

Lubricate the breaker bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 29) located on the left side of the receiving section. Pump grease into the fittings until new grease can be observed coming out of the bearing return lines.

Fig. 29: Central lubrication panel

Central lubrication panel

hydraulic oil tank

Check the feeder breaker hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 30). The oil level should not be allowed to drop below the bottom of the sight glass. If the hydraulic oil level is low, add oil Spec. 100-1 via the power fill system.

Fig. 30: Hydraulic tank oil level

Oil level sight glass

_________________________________________________________________ 5.36 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

breaker bearings

________________________________________________ Maintenance

© BUCYRUS AMERICA, INC.

charge filter

Check the feeder breaker charge filter’s pop-up style dirt alarm ( Fig. 31) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

pressure filter (auxiliary circuit)

Check the feeder breakers two (2) auxiliary circuit pressure filter’s popup style dirt alarm (Fig. 31) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

return filter

Check the feeder breaker return filter’s pop-up style dirt alarm (Fig. 31) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

pressure filter (hydrostatic)

Check the feeder breaker hydrostatic pressure filter’s pop-up style dirt alarm (Fig. 31) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

breaker bits

Check the breaker bits to see if they will rotate in their holders and for damaged or missing bits (Fig. 31). The bits may be inspected by looking into the receiving end of the machine. If bits need to be replaced, see Bit replacement in this chapter.

Fig. 31: Filter and breaker bit location Pressure filter (hydrostatic)

Charge filter

Breaker bits

Return filter

Pressure filter (s) (auxiliary circuit)

______________________________________________________________ A6474X286 VLSV/02 5.37

Maintenance _________________________________________________ Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 32) 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.

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

conveyor chain tension

With the machine off, check the conveyor chain tension at the head shaft end. (Fig. 33). 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. If adjustment is necessary, see Conveyor chain adjustment procedure in this chapter.

Fig. 33: Conveyor chain tension

Conveyor chain tension check point: proper tension is 2 inches (50 mm) of droop off the bottom of the sprocket.

_________________________________________________________________ 5.38 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 32: Crawler track take-up lubrication

________________________________________________ Maintenance fasteners

© BUCYRUS AMERICA, INC.

electrical cables, conduits and glands

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.

hydraulic hoses and fittings

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

charge filter

Change the charge filter element (Fig. 34). If the element is extremely dirty, a more frequent interval may be required.

hydraulic system pressure (s)

Check the hydraulic system pressure (s) by visually looking at the pressure gauges (Fig. 34). Refer to the hydraulic schematic in your parts manual for correct pressure (s).

Fig. 34: Hydraulic charge filter and system pressure gauges (s) location Conveyor circuit pressure gauges

Charge filter

Tram system circuit pressure gauges

Conveyor speed pressure gauge

______________________________________________________________ A6474X286 VLSV/02 5.39

Maintenance _________________________________________________ tram reducer (s)

Check the oil level in both tram reducer torque hubs (Fig. 35):  Oil level/fill plug should be at the 3 o’clock and 12 o’clock position.  Remove the oil level/fill plugs.  The oil level should be kept at the level of the level/fill plug.  Should it be necessary to add oil, add 80W-90 oil through the fill plug hole until it begins to flow out of the check hole.  Do not overfill the reducer.

Fig. 35: Tram reducer oil level

Check plug location

Drain plug location

breaker reducer

Check oil level in the breaker drive reducer (Fig. 36). Oil level should be maintained inside the sight glass on the side of the reducer when it is in operation. If the reducer does not have a sight glass, a pipe plug will be installed in the side of the reducer slightly below the input shaft center line. This is the level that the fluid should be maintained at. The oil should be changed after the first 500 hours of operation. Use Century 220 lubricant.

Fig. 36: Breaker reducer Inspection cover

Breather

Drain plug

_________________________________________________________________ 5.40 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Fill plug location

________________________________________________ Maintenance dust system strainer

Clean the strainer mounted inside the dust suppression system. Open ball valve (Fig. 37) and allow water to flow from the short attached hose. The flowing water will flush out the filter strainer.

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

Fig. 37: Dust system

© BUCYRUS AMERICA, INC.

Strainer

Ball valve

Short hose

pressure filter (hydrostatic) charge filter

Fig. 38: Filter location

Change the hydrostatic pressure filter’s element (Fig. 38). If the element is extremely dirty, a more frequent interval may be required.

Change the charge filter element (Fig. 38).

Pressure filter (hydrostatic)

Charge filter

______________________________________________________________ A6474X286 VLSV/02 5.41

________________________________________________ Maintenance Every 2 weeks pressure filter (auxiliary circuit)

Change the two (2) pressure filter’s element (Fig. 39). If the element is extremely dirty, a more frequent interval may be required.

return filter

Change the return filter’s element (Fig. 39). If the element is extremely dirty, a more frequent interval may be required.

Fig. 39: Filter location

© BUCYRUS AMERICA, INC.

Pressure filter (s) (auxiliary circuit)

Return filter

Monthly conveyor lift and tilt cylinders

Lubricate grease fittings on the rod and base ends of the conveyor lift and tilt cylinders with Spec. 100-3 (Fig. 40). Pump grease into the fittings until new grease can be observed coming out of the pins.

crawler anchor pins

Lubricate grease fittings on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 40). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 40: Lubrication point location

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

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

Lift cylinder (s) (grease fitting located on rod and base end)

______________________________________________________________ A6474X286 VLSV/02 5.42

________________________________________________ Maintenance Every 2500 hours reducer

Change the oil in the breaker drive reducer (Fig. 41). The reducer oil should be changed after the first 500 hours of operation and ever 2500 hours afterwards. Remove the drain plug and allow the oil to completely drain.

© BUCYRUS AMERICA, INC.

Clean and reinstall drain plug.  Remove inspection cover.  Add Century 220 lubricant as required until fluid is visible in sight glass or begins to flow from the check plug that is slightly below the center line of the input shaft.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Install inspection cover.

Fig. 41: Breaker reducer Inspection cover

Breather

Drain plug

Sight glass plug

______________________________________________________________ A6474X286 VLSV/02 5.43

Maintenance _________________________________________________ Every 6 months hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank (Fig. 42).  Clean all dirt and debris from and around the fill cap and drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and reinstall drain plug.  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.

© BUCYRUS AMERICA, INC.

 Shut down the machine and recheck the oil level. Add oil if necessary.

Fig. 42: Hydraulic tank oil level

Oil level sight glass

Drain plug

power fill filter

Change the power fill filter element (Fig. 38). If the element is extremely dirty, a more frequent interval may be required.

Fig. 38: Power fill filter

Power fill filter _________________________________________________________________ 5.44 Bucyrus – Model 7MFGH-56A Feeder Breaker

________________________________________________ Maintenance tram reducer

Change oil in the tram reducer (Fig. 43).  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.

© BUCYRUS AMERICA, INC.

 Install level and fill plugs.  Do not overfill reducer.

Fig. 43: Tram reducer oil change Fill plug location

Check plug location

Drain plug location

______________________________________________________________ A6474X286 VLSV/02 5.45

Maintenance _________________________________________________ electric motor

Lubricate the feeder breaker’s electric motor with Spec. 100-3 through the two (2) grease fittings located on the central lubrication panel (Fig. 44) located on the right side of the discharge section. 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.

reducer

Lubricate the reducer with Spec. 100-3 through the two (2) grease fittings located on the central lubrication panel (Fig. 44) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

Fig. 44: Electric motor and reducer lubrication Electric motor central lubrication panel © BUCYRUS AMERICA, INC.

Reducer central lubrication panel

_________________________________________________________________ 5.46 Bucyrus – Model 7MFGH-56A Feeder Breaker

________________________________________________ Maintenance Inspection of the feeder breaker CAUTION! During inspection, report any damage, missing parts or other faults to your immediate supervisor.

Prior to each shift the following points should be inspected:  Clean and remove any foreign material from the operator’s station.  Inspect all electrical cables, conduits, hydraulic hoses, fittings and warning devices for signs of wear or damage.  Visually inspect the condition and readability of all tags, labels and reflectors.

© BUCYRUS AMERICA, INC.

 Check the “STOP” button (s) for correct operation.  Check the hydraulic oil level in the feeder breaker by looking at the sight glass. The oil level should be kept at the level of the top sight glass.  Check oil level in the crawler reducers.  Inspect the condition of all electrical and hydraulic components.  Check for proper conveyor chain tensioning.  Check for proper crawler chain tensioning.  Lubricate per the lubrication schedule.  Check power input cable to power source insuring that the voltage and breaker settings are correct.  Check that the cable handling device is intact and oriented correctly.  Check that all covers are installed and secure.  Check the tightness of all connecting elements.

______________________________________________________________ A6474X286 VLSV/02 5.47

Maintenance _________________________________________________ Inspection of wear parts on the feeder breaker

■

the conveyor chain

■

the conveyor chain flights

■

the conveyor drive sprockets

■

the conveyor tail shaft

■

the conveyor wear plates

■

the crawler pads

■

the crawler drive sprockets

■

the crawler idler rollers

_________________________________________________________________ 5.48 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

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.

Inspect:

________________________________________________ Maintenance Inspection of fire suppression system on the feeder breaker To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 45).  Note general appearance for mechanical damage or corrosion.  Check nameplate for readability, corrosion or looseness.  Remove fill cap assembly.  Examine gaskets for elasticity, clean and coat lightly with a good grade of high heat resistant grease.  Inspect threads on fill cap and in fill opening for nicks, burrs, cross threading, rough or feathered edges.

© BUCYRUS AMERICA, INC.

 Check pressure relief vent in fill opening threads for obstruction.  Make certain extinguisher is filled with free flowing Ansul dry chemical to a level of not more than 3” from bottom of fill opening.  Unscrew cartridge and weigh (replace if weight is ½ oz. less than stamped on cartridge).  Inspect thread on cartridge and in receiver/actuator for nicks, burrs, cross threading, rough or feathered edges.  Check pressure vents in receiver/actuator for obstruction.  Examine cartridge receiver gasket for elasticity, clean and coat lightly with a good grade of high heat resistant grease. Return cartridge to receiver/actuator, hand tighten.  Lift extinguisher partially out of bracket and examine bursting disc; should be installed with full disc side facing extinguisher, properly seated and undamaged (scored or ruptured).  Reposition extinguisher, engage bursting disc union (wrench tighten) and close bracket clamp.  Check hoses, fittings and nozzles for mechanical damage.  Check nozzle openings; slot should be closed (capped) with silicone grease.  Check remote actuator (dashboard type).  Remove cartridge and weigh (replace if weight is ¼ oz. less than stamped on cartridge.

______________________________________________________________ A6474X286 VLSV/02 5.49

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

© BUCYRUS AMERICA, INC.

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

_________________________________________________________________ 5.50 Bucyrus – Model 7MFGH-56A Feeder Breaker

________________________________________________ Maintenance Recharge of fire suppression system on the feeder breaker To return your fire suppression system to service after use (Fig. 45).  Pull ring on safety valve to relieve actuator system pressure.  Disconnect actuation system hose at cartridge receiver/actuator assembly.  Open bursting disc union assembly.  Remove extinguisher from bracket.  Replace ruptured bursting disc with new disc. (Full disc side must face extinguisher).

© BUCYRUS AMERICA, INC.

 Fill extinguisher to rated capacity with Ansul dry chemical specified on nameplate.  Clean fill opening threads and gasket seating surface.  Secure fill cap, hand tighten.  Remove cartridge guard assembly.  Remove empty cartridge.  Make certain that receiver/actuator puncture pin is fully retracted.  Screw full charged cartridge into receiver/actuator assembly, hand tighten.  Replace cartridge guard.  Secure extinguisher in bracket.  Assemble bursting disc union, wrench tighten.  Connect actuation system hose at cartridge receiver/actuator assembly, wrench tighten.  Replace cartridge in remote actuator (dashboard type). Pull out button, insert ring pin and remove empty cartridge. Screw fully charged cartridge into actuator, hand tighten. Seal ring pin to actuator button stem with lead and wire seal.  Record date of recharge and notify operating personnel that system is back in service.

______________________________________________________________ A6474X286 VLSV/02 5.51

Maintenance _________________________________________________ Fig. 45: Fire suppression system

Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Breaker coupling Nozzle

Operator’s station

Nozzle Nozzle Breaker motor Nozzle

Oil tank LP canister

LP expellant

_________________________________________________________________ 5.52 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Nozzle

_______________________________________ Adjustment procedures Instructions on the adjustment procedures on the feeder breaker It is essential that adjustments be made periodically to the conveyor chain, breaker drive 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.

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.

© BUCYRUS AMERICA, INC.

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 46):  Close the stop valve on manifold assembly securely.  Attach a grease gun to the grease fitting located on the manifold and apply grease until the required pressure is attained. Sight across the bottom of the head shaft sprocket. The chain should sag 1 1/2” to 2” below the bottom of the head shaft sprocket.  After tensioning chain, remove the allen head bolts from the tail shaft retainers and lift out retainers.  Insert shims over cylinder rod to maintain gap between bearing and end plate of box.  Allow tail shaft pressure to rest completely on shims.

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.  Replace retainers.  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 bleeder valve when releasing pressure. You could be seriously injured from high pressure grease.  Store any unused shims under cover plate.

______________________________________________________________ A6474X286 VLSV/02 5.53

Adjustment procedures ________________________________________ Fig. 46: Conveyor chain adjustment

Stop valve

Grease fitting

© BUCYRUS AMERICA, INC.

Tail shaft retainer

_________________________________________________________________ 5.54 Bucyrus – Model 7MFGH-56A Feeder Breaker

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

To adjust tension on the crawler track with the take-up cylinders proceed as follows (Fig. 47):  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.

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

© BUCYRUS AMERICA, INC.

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

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

You could be seriously injured or even killed by falling loads.  Run crawler in forward direction for 3 minutes at slow speed.  Run crawler in reverse direction for 3 minutes at slow speed.  Shutdown machine.  If necessary, re-adjust chain sag.  Add or remove required amount of shims to maintain correct tension.  Release grease pressure in the cylinder with the needle by turning the knob counter clockwise (CCW), allowing the shims to maintain the correct tension.

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

______________________________________________________________ A6474X286 VLSV/02 5.55

Adjustment procedures ________________________________________ Fig. 47: Crawler track adjustment

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

Idler assembly

Access cover

Take-up cylinder

Needle valve © BUCYRUS AMERICA, INC.

Grease fitting

_________________________________________________________________ 5.56 Bucyrus – Model 7MFGH-56A Feeder Breaker

____________________________________ Replacement of wear parts

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

Head shaft The head shaft (Fig. 48) transmits the torque of the hydraulic motor to the conveyor chain assembly. It is part of a complete assembly. As soon as any component is worn, the component or complete head shaft must be replaced. Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

© BUCYRUS AMERICA, INC.

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

drive shaft

■

sprockets

■

bearings

■

hydraulic motor

Fig. 48: Head shaft main components Sprocket (2)

Head shaft Key (2)

Bearing (2)

______________________________________________________________ A6474X286 VLSV/02 5.57

Replacement of wear parts _____________________________________ How to remove the head shaft To remove the head shaft assembly from the feeder breaker discharge boom proceed as follows (Fig. 49):  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the two (2) sprocket guards located on the end of the discharge boom.  Remove the hydraulic motor. (See Hydraulic motor removal in this chapter).

 Remove the left and right covers from the end of the boom frame.  Remove the four (4) nuts, bolts, and lock washers from each of the head shaft bearings.  Attach an appropriate lifting device to the head shaft and slide out towards the rear of the frame.

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

How to install the head shaft To install the head shaft assembly proceed as follows (Fig. 49):  Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the discharge boom.  Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) nuts, bolts, and lock washers. Torque bolts to 645 ft-lbs.  Install the left and right covers to the end of the boom frame.  Connect the central lubrication hoses on both head shaft bearings.  Install the hydraulic motor. (See Hydraulic motor installation in this chapter).

_________________________________________________________________ 5.58 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Disconnect, tag and cap the central lubrication hoses on both head shaft bearings.

____________________________________ Replacement of wear parts  Align sprockets with conveyor chain and tighten sprocket set screws (two (2) per sprocket).  Install the two (2) sprocket guards on the end of the discharge boom.   Connect conveyor chain. (See Conveyor chain replacement in this chapter).  Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

Fig. 49: Head shaft removal and installation

© BUCYRUS AMERICA, INC.

Conveyor chain (not shown)

Covers

See hydraulic motor removal in this chapter

Head shaft Sprocket guard (s)

______________________________________________________________ A6474X286 VLSV/02 5.59

Replacement of wear parts _____________________________________ Head shaft sprockets The head shaft sprocket transmits the torque of the hydraulic motor to the conveyor chain assembly. It is part of the head shaft assembly. As soon as the sprockets are worn they must be replaced. Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

How to remove the head shaft sprockets To remove the sprockets from the head shaft assembly proceed as follows (Fig. 50):  Remove the drive shaft assembly from the discharge boom (see Drive shaft removal in this chapter).  Remove the two (2) bearings from the head shaft.

 Slide both sprockets from the drive shaft.  Remove old keys.  Inspect all components of the drive shaft for wear and damage.

See parts manual for replacement parts list.

How to install the head shaft sprockets To install the sprockets on the head shaft proceed as follows (Fig. 50):  Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.  Insert one of the keys into the shaft keyway and slide first sprocket onto shaft.  Insert the other key into the shaft keyway and slide second sprocket onto shaft.  Slide both bearings onto shaft.  Install the drive shaft assembly in the discharge boom. (See drive shaft installation in this chapter.

_________________________________________________________________ 5.60 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Remove the two (2) set screws from each sprocket.

____________________________________ Replacement of wear parts How to install the head shaft temporary split sprockets To install the temporary split sprockets on the head shaft proceed as follows (Fig. 50): IMPORTANT! The split sprocket is designed for temporary use only and should be replaced during the first available maintenance shift.  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the two (2) sprocket guards located on the end of the discharge boom.

© BUCYRUS AMERICA, INC.

 Remove damaged sprockets and keys from head shaft. Old sprockets may require cutting to remove.  Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.  Insert new key into shaft keyway.

NOTICE! Do not mix and match sprocket halves or premature wear of sprockets and chain could occur.  Install both sprocket halves onto shaft and and align with conveyor chain.  Temporarily tack weld sprocket halves to head shaft until welding is complete.

IMPORTANT! Blend and smooth welds to avoid chain roller damage.

Weld notes: 1. Preheat sprocket weld joint to 600°F - 800°F. 2. Maintain preheat temperature during welding process.

3.

Max interpass temperature not to exceed 1500°F.

4.

Use low hydrogen rod (E7018) or wire (class E71T. SPEC AWS A5.20).

5.

Post weld heat sprocket joint 600°F - 800°F.

6.

If possible / practical, bury sprocket with dirt or wrap with a weld blanket for a minimum of eight (8) hours.

______________________________________________________________ A6474X286 VLSV/02 5.61

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

Fig. 50: Head shaft sprocket removal and installation Head shaft

Bearing (2)

3/8 X 45° weld chamfer

Sprocket guard

Hydraulic motor

Conveyor chain

Sprocket (2) & key (2)

Split sprocket

_________________________________________________________________ 5.62 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

3/8 X 45° weld chamfer

____________________________________ Replacement of wear parts Tail shaft The tail shaft (Fig. 51) allows for even adjustments 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.

© BUCYRUS AMERICA, INC.

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

shaft

■

sprocket (2)

■

slide plate

■

key (2)

■

set screw (2)

■

roller bearing (2)

■

piston rod adapter (2)

Fig. 51: Tail shaft main components Set screw (2)

Slide plate

Adapter (2)

Key (2)

Sprocket (2)

Head shaft

Bearing (2)

______________________________________________________________ A6474X286 VLSV/02 5.63

Replacement of wear parts _____________________________________ How to remove the tail shaft To remove the tail shaft assembly from the receiving boom proceed as follows (Fig. 52):  Release tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).  Remove the five (5) bolts and lock washers from each of the tail shaft retainers and lift out the retainers.  Disconnect, tag and cap the central lubrication hoses to the tail shaft.  Remove the tail shaft shims.  Separate conveyor chain and fold back to clear tail shaft. (See Conveyor chain replacement in this chapter).

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

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 52):  With an appropriate lifting device, insert tail shaft into receiving boom.  Fold the conveyor chain over tail shaft.  Connect conveyor chain (see Conveyor chain replacement in this chapter.  Connect central lubrication hoses and lubricate tail shaft and slide plate bearings with Spec. 100-3 grease.  Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).  Install the tail shaft retainers with the five (5) bolts and lock washers in each side.  With machine running, visually inspect tail shaft to ensure that the shaft is turning and conveyor chain is not sliding across tail shaft.

_________________________________________________________________ 5.64 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Fig. 52: Tail shaft removal and installation

Cover Tail shaft retainer plates (2)

Shims

© BUCYRUS AMERICA, INC.

Take-up cylinder

Tail shaft

______________________________________________________________ A6474X286 VLSV/02 5.65

Replacement of wear parts _____________________________________ How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 53):  Remove the tail shaft assembly from the receiving boom. (See How to remove the tail shaft in this chapter).  Slide both roller bearings and piston rod adapters from the tail shaft.  Remove the set screws from both tail shaft sprockets and slide sprockets from the shaft.  Remove the tail shaft from the slide plate.  Visually inspect all components for damage or wear and replace as necessary.

To assemble the tail shaft assembly proceed as follows (Fig. 53):  Thoroughly clean all parts that will be installed.  Grease tail shaft with Spec. 100-3 grease.  Slide tail shaft into the slide plate.  Insert keys into keyways on tail shaft.  Slide both sprockets onto tail shaft, one on each end.  Install set screws into both rollers, ensuring that rollers and tail shaft slide plate are centered on tail shaft.  Tighten set screws. Torque to 100 ft-lb.  Install both roller bearings and adapter plates on tail shaft, one on each end.  Install grease fittings, if required.  Install assembled tail shaft into machine. (See How to install the tail shaft in this chapter).

_________________________________________________________________ 5.66 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

How to assemble the tail shaft

____________________________________ Replacement of wear parts Fig. 53: Tail shaft disassembly and assembly Set screw (2)

Slide plate

Adapter (2)

Key (2)

Head shaft

Bearing (2)

© BUCYRUS AMERICA, INC.

Sprocket (2)

______________________________________________________________ A6474X286 VLSV/02 5.67

Replacement of wear parts _____________________________________ Conveyor chain The conveyor chain (Fig. 54) 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

6 link chain section Spiral pin Flight bar

_________________________________________________________________ 5.68 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 54: Conveyor chain main components

____________________________________ Replacement of wear parts How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 55):  Lay conveyor chain sections on a clean flat surface.  Insert connector pins through flight end and align holes in spiral pin with holes in flight bar.  Insert spiral pin.  Drive spiral pin in with a hammer and punch. Ensure that spiral pin is recessed on both sides of flight bar.  Repeat the previous assembly instructions until the complete chain has been assembled.

© BUCYRUS AMERICA, INC.

Fig 55: Conveyor chain assembly

Extended pin connecting link Spiral pin (4)

Block link assembly

Flight bar

Side bar

6 link chain section

______________________________________________________________ A6474X286 VLSV/02 5.69

Replacement of wear parts _____________________________________ How to remove the conveyor chain assembly To remove the conveyor chain assembly proceed as follows:  Release tension on the conveyor. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain by removing spiral pins and connecting links in one section of the chain.  Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the conveyor chain and slowly pull the conveyor chain completely out of the machine.

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

If not retracted, see Conveyor chain adjustment in this chapter.  Run a cable or pull rope with an adequate load limit through the bottom conveyor pan and connect to the conveyor chain.  Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to the other end of the cable or pull rope and slowly pull the conveyor chain completely through the bottom conveyor pan.

IMPORTANT! If old conveyor chain is still on machine, installation can be facilitated by connecting the new conveyor chain to the old conveyor chain via the chain connectors and pulling it through the bottom conveyor pan.  Fold conveyor chain back over the tail shaft and drive shaft and slowly pull the chain along the conveyor ensuring that the chain is under the chain hold downs.  Ensure that the chain is properly meshed with the drive sprockets and aligned with the tail shaft roller.  Connect conveyor chain (see How to assemble the conveyor chain sections in this chapter for proper connection).  Adjust tension on the conveyor chain (see Conveyor chain adjustment procedure in this chapter.  With machine running, visually inspect tail shaft to ensure that that the shaft is turning and conveyor chain is not sliding across tail shaft.

_________________________________________________________________ 5.70 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

WARNING! When using an additional 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.

____________________________________ Replacement of wear parts Crawler track The crawler track (Fig. 56) assembly (left and right) carries the machine via torque received from the tram drive reducer. The crawler track is made up of one basic crawler pad assembly, which repeats sequentially along the entire pad loop. As soon as any component of the crawler track is worn the component or complete crawler track assembly must be replaced.

Each crawler track consists of the following main components: ■

crawler pad

■

connector pin

■

t-pin

Fig. 56: Crawler track main components

© BUCYRUS AMERICA, INC.

Crawler pad

Connector pin and T-pin

______________________________________________________________ A6474X286 VLSV/02 5.71

Replacement of wear parts _____________________________________ How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 56):  Lay crawler track pads on a clean flat surface.  Align pads with chain connecting holes centered.  Insert connector into center of crawler pad connecting holes.  Drive T-pin through connecting pin and bend end to secure.  Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly

 Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Crawler track tension must be released (see Crawler track adjustment in this chapter).  Separate the crawler pads.

To separate the crawler pads proceed as follows (Fig. 56) IMPORTANT! Heating or cutting connections with a torch or chisel may be required to ease the removal of T- pins.  Drive or cut T-pin from crawler pad connection using hammer and punch.  Separate crawler track assembly.  Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the crawler track assembly and slowly pull the crawler track completely out from under the machine.

_________________________________________________________________ 5.72 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

To remove the crawler track pad assembly proceed as follows (Fig. 56):

____________________________________ Replacement of wear parts WARNING! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the crawler track, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the crawler track.  Inspect the crawler drive sprocket and idler rollers for wear or damage. Replace if necessary.

How to install the crawler track pad assembly To install the crawler track pad assembly proceed as follows (Fig. 56):

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X286 VLSV/02 5.73

Replacement of wear parts _____________________________________ Crawler assembly The crawler assembly (Fig. 57) 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.

■

hydraulic drive motor

■

tram drive torque hub

■

cat pad assembly

■

take-up roller assembly

■

grease take-up assembly

■

drive sprocket

© BUCYRUS AMERICA, INC.

The crawler assembly consists of the following main components:

Fig. 57: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

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

_________________________________________________________________ 5.74 Bucyrus – Model 7MFGH-56A Feeder Breaker

____________________________________ Replacement of wear parts How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 58):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.  Crawler track tension must be released (see Crawler track adjustment in this chapter.  Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear take-up.

© BUCYRUS AMERICA, INC.

 Securely block under the crawler frame.  Disconnect, tag and cap hydraulic hoses going to the tilt cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers  Remove the eight (8) bolts from the tilt cylinder mounting bracket.  swing the tilt cylinder and mounting bracket free of the crawler frame.  Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to the take-up assembly and slowly pull the assembly out of the crawler frame.

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

______________________________________________________________ A6474X286 VLSV/02 5.75

Replacement of wear parts _____________________________________ How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 58):  Remove old take-up assembly (see previous section, How to remove crawler take-up assembly).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Inspect all components for wear or damage prior to assembly.  Clean all dirt and debris from inside crawler frame.  Attach appropriate lifting device to take-up assembly and slide assembly completely into the end of crawler frame.

 Swing the tilt cylinder and mounting bracket into crawler frame and secure with the eight (8) bolts, washers and nuts.  Connect hydraulic hoses to tilt cylinder.  Purge hydraulic system of air.  Adjust crawler track pad tension, see How to adjust crawler track pad tension in this chapter.

_________________________________________________________________ 5.76 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Fig. 58: Crawler take-up removal and installation

Tilt cylinder

© BUCYRUS AMERICA, INC.

Tilt cylinder mounting bracket

Crawler frame

______________________________________________________________ A6474X286 VLSV/02 5.77

Replacement of wear parts _____________________________________ How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 59):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Crawler track tension must be released (see Crawler track adjustment in this chapter).  Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear sprocket.

 Remove slotted nut, roll pin and washer from lift cylinder anchor pin.  Slide anchor pin out of crawler frame and swing tilt cylinder free of the crawler frame.  Remove the six (6) bolts and lock washers that secure the removable side plate to crawler frame and remove side plate.  Remove the twelve (12) bolts and lock washers that secure the torque hub to the crawler frame.  Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.  Remove the four (4) bolts and lock washers that secure the hydraulic motor and adapter plate to the torque hub.  Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.  Slide adapter plate and motor off of torque hub.  Remove adapter plate gasket.  Remove the four (4) nuts and lock washers that secure the hydraulic motor to the adapter plate. And remove adapter plate.  Remove the twenty (20) bolts and lock washers that secure the sprocket to the torque hub and separate hub and sprocket.  Inspect all components for wear or damage.

_________________________________________________________________ 5.78 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 59):  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.  Inspect all components for wear or damage prior to installation.

© BUCYRUS AMERICA, INC.

 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

 Place hydraulic motor gasket onto motor adapter plate.  Install adapter plate and gasket onto hydraulic motor and secure with the four (4) nuts and lock washers. Apply Loctite 242 (blue) to nuts.  Place adapter plate gasket onto torque hub.  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

 Weld four (4) keepers across motor flanges to prevent motor movement.  Clean all dirt and debris from mounting area of crawler frame.  Attach an appropriate lifting device to the torque hub and slide complete assembly into crawler frame.  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.

______________________________________________________________ A6474X286 VLSV/02 5.79

Replacement of wear parts _____________________________________ ■

step 1 – 50 ft-lb

■

step 2 – 140 ft-lb

■

step 3 – 280 ft-lb

■

step 4 – 420 ft-lb

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

■

step 1 – 300 ft-lb

■

step 2 – 600 ft-lb

■

step 3 – 905 ft-lb

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

Fig. 59: Crawler drive disassembly and assembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

10.

11.

12.

13.

14.

15.

16.

17.

18.

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

19.

20.

21.

22.

23.

24.

25.

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

_________________________________________________________________ 5.80 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Install the removable side plate and secure with the six (6) bolts and lock washers. Torque incrementally as follows.

____________________________________ Replacement of wear parts Power unit The power unit (Fig. 60) has been assembled as a unit and can be removed as a unit or as individual components. As soon as any component of the power unit is worn or damaged, the component must be replaced.

The power unit consists of the following main components: ■

gear pump

■

hydrostatic pump

■

pump coupling

■

motor (200 hp)

© BUCYRUS AMERICA, INC.

■ reducer/motor coupling ■

reducer

■

sprocket

■

connecting tube

Fig. 60: Power unit main components Sprocket Reducer Coupling Motor (150 HP)

Connecting tube Coupling Hydrostatic pump Gear pump

Mounting base

______________________________________________________________ A6474X286 VLSV/02 5.81

Replacement of wear parts _____________________________________ How to remove the power unit To remove the power unit as a complete assembly proceed as follows (Fig. 61):  Remove power unit covers from the machine.  Disconnect and tag all electrical wiring to the drive motor.

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.  Disconnect, cap, and tag all hydraulic hoses to the hydraulic pumps and grease lines to the electric motor and gearbox.

 Separate and remove breaker drive chain.  Attach an appropriate lifting device to the complete unit and slowly lift the unit from the machine.

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

How to install the power unit Note: Before installing the power unit, ensure all dirt and debris is cleaned from the area so that the unit will sit flat in the machine.

To install the power unit as a complete assembly proceed as follows (Fig. 61):  Attach an appropriate lifting device to the complete unit and slowly lift the unit onto the machine and align mounting base holes with holes in the frame.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Secure mounting base to frame with the nine (9) base bolts, lockwashers, flatwashers, and nuts previously removed.  Connect all hydraulic hoses to the hydraulic pumps.  Connect all electrical wiring to the drive motor.  Connect all grease lines to the drive motor and gearbox.

_________________________________________________________________ 5.82 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Remove the nine (9) mounting base bolts.

____________________________________ Replacement of wear parts  Connect the drive chain. (See Breaker drive chain installation and adjustment in this chapter).  Apply an adequate amount of hydraulic oil on the drive chain, if necessary.  Check oil level in gearbox. Oil should be visible in the lower sight glass only.  Install breaker drive covers.

Fig. 61: Power unit removal and installation

© BUCYRUS AMERICA, INC.

Power unit

Mounting bolts

This bolt not used in this model only.

______________________________________________________________ A6474X286 VLSV/02 5.83

Replacement of wear parts _____________________________________ How to disassemble the breaker power unit To disassemble the power unit proceed as follows (Fig. 63):  Remove complete unit from machine. (See How to remove the drive unit in this chapter)  Remove the four (4) bolts and lockwashers from gear pump (item 26) and remove pump.  Open access cover on connecting tube (item 8) and loosen the two (2) bolts on the pump end and set screw on the motor end of the coupling.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Remove the eight (8) bolts and lockwashers from connecting tube (item 8) and remove connecting tube from motor (item 5).  Remove coupling (item 7) and key from motor shaft.  Remove the four (4) bolts and nuts from motor base and the eight (8) bolts, lockwashers, and nuts from the reducer base. With the aid of a lifting device, slowly lift motor and reducer from mounting base (item 11).  Remove sprocket (item 6) and key from reducer shaft.  Separate motor and reducer coupling halfs by removing the twelve (12) bolts from around the center of coupling (item 3).  With the aid of a lifting device, slowly separate motor (item 5) and reducer (item 1).  Remove the bolt, lockwasher, and end cap (item 21) the end of the reducer shaft.  Remove the three (3) bolts that secures the taper lock (item 2) to the reducer shaft.  Insert two (2) of the bolts removed from the taper lock into the jack screw threaded holes located in the end of the taper lock (Fig. 64).

Tighten both bolts equally until the taper lock is free from reducer shaft.  Remove the bolt, lockwasher and end cap (item 21) the end of the motor shaft.

_________________________________________________________________ 5.84 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Remove the four (4) bolts and lockwashers from hydrostatic pump (item 25). With the aid of a lifting device, slowly pull pump from coupling (item 7) and connecting tube (item 8).

____________________________________ Replacement of wear parts  Remove the three (3) bolts that secures the taper lock (item 4) to the motor shaft.  Insert two (2) of the bolts removed from the taper lock into the jack screw threaded holes located in the end of the taper lock (Fig. 62).

Tighten both bolts equally until the taper lock is free from motor shaft  Visually inspect all components for wear or damage and replace if necessary.

Fig. 62: Taper lock removal and installation

Jack screw holes (2) for bushing removal

© BUCYRUS AMERICA, INC.

Bolt holes (3) for bushing installation

______________________________________________________________ A6474X286 VLSV/02 5.85

Replacement of wear parts _____________________________________ How to assemble the power unit To assemble the power unit proceed as follows (Fig. 63):  With the aid of a lifting device, slowly lift reducer onto mounting base (item 1) and align mounting holes. Secure reducer with the eight (8) bolts, lockwashers and nuts to mounting base. Torque bolts to 460 ft-lb.

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.  Slide reducer coupling element half (item 3) onto reducer shaft.

 Install end cap (item 21) onto reducer shaft and secure with bolt and lockwasher. Torque bolt to 80 ft-lb.  Slide motor coupling element half (item 3) onto motor shaft.  Slide taper lock (item 4) and shaft key onto motor shaft. Locate motor coupling element so that motor shaft has .5 inch (12.7 mm).

Secure taper lock with the three (3) bolts supplied with taper lock.

Torque bolts to 85 ft-lb.  Install end cap (item 21) onto motor shaft and secure with bolt and lockwasher. Torque bolt to 80 ft-lb.  With the aid of a lifting device, slowly lift motor onto mounting base (item 1) and align mounting holes and coupling halfs. Secure reducer with the eight (8) bolts, lockwashers and nuts to mounting base. Torque bolts to 280 ft-lb.  Connect coupling (item 3) with the twelve (12) bolts supplied with coupling.  Insert key into slot of motor shaft and slide motor coupling half (item 7) onto motor shaft until shaft and coupling face are flush.  Tighten set screw in motor half of coupling.  Insert coupling element into motor half of coupling.  Align the 8 holes of connecting tube (item 8) with motor (item 5)and secure with the eight (8) bolts and lockwashers.  Slide pump half of coupling (item 7) onto hydrostatic pump shaft (item 25) until a .67” (17 mm) shaft end gap is acquired. Tighten the two (2) coupling half bolts.

_________________________________________________________________ 5.86 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Slide taper lock (item 2) and shaft key onto reducer shaft. Locate reducer coupling element so that taper lock is flush with the end of the reducer shaft. Secure taper lock with the three (3) bolts supplied with taper lock. Torque bolts to 85 ft-lb.

____________________________________ Replacement of wear parts  With the aid of a lifting device, slowly lift hydrostatic pump (item 25) and carefully align pump half and motor half of coupling. Secure pump to connecting tube with four (4) bolts and lockwashers.

Coupling spacing should be .18” (4.5 mm) after pump mounting bolts are tightened.  Align mounting holes and shaft of gear pump (item 26) with hydrostatic pump (item 25) and secure with four (4) bolts and lockwashers.  Install completed power unit onto machine. (See How to install the power unit in this chapter)  Fill hydrostatic pump thru case drain port with system oil before running pump.

© BUCYRUS AMERICA, INC.

 Check gearbox oil level. Oil shoud be visible in the lower sight glass only.

CAUTION! Failure to fill the hydraulic motor thru the case drain port to prime the motor will result in catastrophic damage to the motor.

Fig. 63: Power unit disassembly and assembly

______________________________________________________________ A6474X286 VLSV/02 5.87

Replacement of wear parts _____________________________________

© BUCYRUS AMERICA, INC.

Fig. 63: Power unit disassembly and assembly (continued)

1.

2.

3.

4.

5.

6.

7.

8.

9.

reducer taper lock bushing coupling taper lock bushing motor sprocket coupling connecting tube washer (lock)

10.

11.

12.

13.

14.

15.

16.

17.

18.

bolt mounting base bolt washer (lock) nut (lock) bolt washer (lock) nut (lock) end cap

19.

20.

21.

22.

23.

24.

25.

26.

27.

washer (lock bolt end cap retainer bar retainer bar retainer bar hydrostatic pump gear pump washer (lock)

28.

29.

30.

35.

36.

37.

38.

39.

40.

bolt washer (flat) bolt key key element hub key key

_________________________________________________________________ 5.88 Bucyrus – Model 7MFGH-56A Feeder Breaker

____________________________________ Replacement of wear parts Conveyor drive motor The conveyor drive motor transmits torque to the head shaft assembly.

It is also part of the head shaft assembly. As soon as any component of the assembly is warn or damaged, the component must be replaced.

How to remove the conveyor drive motor To remove the conveyor drive motor proceed as follows (Fig. 64): WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

© BUCYRUS AMERICA, INC.

 Disconnect, cap and tag all hydraulic hoses to the conveyor motor.  Remove the two (2) pins and cotter keys from the torque arm and remove torque arm connecting link.  Remove conveyor motor cover bolts and remove cover.  Remove torque mounting bolt located inside conveyor motor.  Attach an appropriate lifting device to two (2) of the conveyor motor torque arm mounting bolts and slowly slide the the motor from the coupling and headshaft.

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.  Disconnect lifting device and remove the torque arm mounting bolts.  Remove torque arm from conveyor motor.  Slide coupling from headshaft.  Inspect all components for wear or damage.

______________________________________________________________ A6474X286 VLSV/02 5.89

Replacement of wear parts _____________________________________ How to install the conveyor drive motor To install the conveyor drive motor proceed as follows (Fig. 64): 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.  Apply a coat of mineral oil to the splines of the headshaft, coupling and conveyor motor. Do not use never seez.

IMPORTANT! Apply mineral oil or hydraulic oil to splines of head shaft and motor.

 Install torque arm on conveyor motor with mounting bolts. Torque bolts to 400 ft-lb.  Remove conveyor motor cover bolts and remove cover.  Attach an appropriate lifting device to two (2) of the conveyor motor torque arm mounting bolts and slowly lift and slide the the motor onto the coupling and headshaft.

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.  Bolt conveyor motor to headshaft with torque mounting bolt located inside conveyor motor. Torque bolt to 280 ft-lb.  Install conveyor motor cover with cover bolts. Torque bolts to 59 ftlb.  Install torque arm connecting link with the two (2) pins and cotter keys.  Connect all hydraulic hoses to the conveyor motor.  Purge hydraulic system of air.

_________________________________________________________________ 5.90 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Slide coupling onto headshaft.

____________________________________ Replacement of wear parts Fig. 64: Conveyor drive motor removal and installation Pin and cotter key (2 places) Connecting link

Head shaft

Torque arm

cover bolts (torque to 59 ft-lb)

© BUCYRUS AMERICA, INC.

Coupling

Mounting bolt (torque to 280 ft-lb)

Mounting bolts (torque to 400 ft-lb)

______________________________________________________________ A6474X286 VLSV/02 5.91

Replacement of wear parts _____________________________________ Breaker assembly The breaker assembly (Fig. 65) is assembled as a complete unit and should be removed as a unit for repairs except for the replacement of the shear hub assembly, bits, and magnetic cutoff assembly. As soon as any component of the breaker assembly is worn or damaged, the component or complete assembly must be replaced.

■

breaker shaft

■

shear hub assembly

■

bearing housing (2)

■

bearing (2)

■

bits (25)

■

bearing retainer (2)

■

under speed sensor

■

breaker side plate (2)

■

retaining cap (2)

■

dust cover

© BUCYRUS AMERICA, INC.

The breaker assembly consists of the following main components:

Fig. 65: Breaker assembly main components Under speed sensor mount

Breaker side plate (2)

Bearing (2)

Bearing housing (2)

Breaker

Shear hub

Retainer cap (2)

Pick (25)

_________________________________________________________________ 5.92 Bucyrus – Model 7MFGH-56A Feeder Breaker

____________________________________ Replacement of wear parts How to remove the breaker assembly To remove the breaker assembly from the machine proceed as follows (Fig. 66):  Remove covers and guards as required to gain access to the breaker assembly.  Release tension on the breaker drive chain and remove chain (see Breaker drive chain removal in this chapter).  Disconnect, tag, and cap the bearing central lubrication hoses.

© BUCYRUS AMERICA, INC.

 Attach an appropriate lifting device around the breaker shaft assembly and apply just enough lift to remove the twenty (20) bolts, nuts, and washers (10 per side) that secure the breaker assembly to the frame.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  With the aid of the lifting device, slowly lift the complete assembly out of the frame.

How to install the breaker assembly To install the breaker assembly into the machine proceed as follows (Fig. 66):  With the aid of the lifting device, slowly lift the breaker assembly into the frame and align mounting holes.  Secure the breaker with the twenty (20) bolts, nuts, and washers (10 per side) and securely tighten. Torque bolts to 900 ft-lb.  Install breaker drive chain and adjust tension. (See Breaker drive chain adjustment in this chapter).  Connect the bearing central lubrication hoses.  Install covers and guards.

______________________________________________________________ A6474X286 VLSV/02 5.93

Replacement of wear parts _____________________________________

© BUCYRUS AMERICA, INC.

Fig. 66: Breaker assembly removal and installation

_________________________________________________________________ 5.94 Bucyrus – Model 7MFGH-56A Feeder Breaker

____________________________________ 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. 67):  Remove the two (2) external retaining rings from the shank end of the bit with a pair of external retaining ring pliers.  Remove the bit from its holder. If the bit will not pull easily from its holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.

IMPORTANT! If the bit will not pull easily from its holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.

How to install the breaker bit

© BUCYRUS AMERICA, INC.

 To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 67):  Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.  Install the external retaining rings (two per bit) on the shank end of the bit with a pair of external retaining ring pliers. Ensure that the retaining ring is completely seated inside grooved area of the bit.

Fig. 67: Breaker bit removal and installation

Retaining rings Bit holder

Breaker bit

______________________________________________________________ A6474X286 VLSV/02 5.95

© BUCYRUS AMERICA, INC.

Replacement of wear parts _____________________________________

_________________________________________________________________ 5.96 Bucyrus – Model 7MFGH-56A Feeder Breaker

_______________________________________________________________

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Model 7MFBH-56A Feeder Breaker. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

The technical data listed in this chapter is for stock machines only.

Customer specials may not be listed.

Components of the feeder breaker Technical data sheet

© BUCYRUS AMERICA, INC.

general

performance

Overall length: Overall width: Tramming height (min.): Ground clearance (min.): Ground clearance (max.): Receiving height (min.): Discharge height (max.)

Operating height (max.): Level hopper capacity: Capacity (w/ optional 12” sideboards): Receiving impact plate: Breaker impact plate: Coal line material: Return line material: Mainframe side plates: Weight:

approx. 34’ 61/2” approx. 11’ approx. 44” approx. 7” approx. 24” approx. 13” approx. 53” approx. 78” approx. 440 ft³ approx. 530 ft³ HRS + CCO wear plate T1 + CCO wear plate HRS + CCO wear plate HRS + CCO wear plate HRS + CCO wear plate approx: 75,000 lbs

Material input size (max.): Maximum material strength: Nominal output size:

approx. 2’ x 3’ x 4’ approx: 30,000 psi approx: 8” (one dimension) approx. 1,500 TPH @ 135 fpm coal @ 65 lb/ft³

Discharge rate (max.): Material to be broken: breaker drive

Drive motor: Reducer: Coupling: Drive type:

200hp/950v/AC/3ph/ TEFC right angle Link-Belt LC250 Omega Chain and sprocket driven

______________________________________________________________ A6474X286 VLSV/02 6.3

conveyor chain

Conveyor width: Number of strands:

Conveyor speed: Flight attachment

approx. 56” 2 @ 200,000 lb strand ultimate approx. 3 1/2” approx. 15/16” 2 1/2” X 5” solid alloy steel approx. 135 fpm max. pin

Shaft diameter: Bearing bore: Overload protection:

5” 4 15/16” hydraulic relief

Shaft diameter: Bearing bore: Take-up:

3 15/16” 3 15/16” grease cylinders w/locking shims

Drive motor: Mounting:

piston motor direct mounted on head shaft splined shaft hydraulic relief

Chain pitch: Chain pin diameter: Flights:

head shaft

tail shaft

conveyor drive

Overload protection: crawlers

Tram speed: Drive: Take-up: Overall length: Center to center distance: Pad width: Ground pressure:

breaker

Shaft diameter: Bearing bore:: Pick circle diameter: Running pick force: Pick force maximum:: Overload protection: Under speed protection: Breaker speed: Height setting: Breaker bits and holders:

approx. 47 fpm Fairfield W12 torque hub grease cylinder w/locking shims approx. 96.5” approx. 79” approx. 15” approx. 25.3 psi approx. 8” approx. 6 3/16” approx. 27” approx. 9,400 lbs approx. 60,000 lbs shear pin magnetic sensor 67 rpm manually adjustable 2” increments heavy duty, rock type bits with carbide insert with hard surface weld holder is improved design alloy steel

_________________________________________________________________ 6.4 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Technical data ________________________________________________

_______________________________________________ Technical data hydraulic

Conveyor/tram pump: Tram motors: Lift cylinders: Tilt cylinders: Filters: Reservoir: Hydraulic fluid Heat exchanger: Hydraulic fittings:

Electrical

Breaker motor:

© BUCYRUS AMERICA, INC.

Starter:

Enclosure:

Contactor: Circuit overload protection: Panic switch (2): Belt sequence switch: Breaker underspeed: Remote start:

axial piston variable displacement Char Lynn 4000 series 19in³/rev Double acting 17” stroke Double acting 17” stroke (5) 12 micron pressure line 175 gal. capacity w/oil level switch ISO 68 Mineral Oil oil to air type JIC (standard) 200 hp/950v/AC/3ph/ 60Hz/1750rpm/TEFC 200 hp/single/950v/ AC/3ph/60Hz/ mine duty IP65 rating, adequate for low pressure water wash down vacuum type circuit breakers tape switch magnetic sensor magnetic sensor tilt switch optional

______________________________________________________________ A6474X286 VLSV/02 6.5

features

■

Head shaft is removable horizontally as a unit.

■

Tailshaft is removable vertically as a unit.

■

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

■

Torque hubs can be free-wheeled for towing by reversing cap in center of hub.

■

Independently controlled frame lift cylinders.

■

Heavy duty guards at discharge end of machine.

■

Sectionalized covers over power units.

■

Extra heavy duty chain hold-downs at breaker transition.

■

Manual centralized lubrication system.

■

12” high hinged sideboards.

■

8 point Ansul dry chemical fire suppression system.

■

Emergency stop pull cord switch over hopper.

■

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

■

Operator’s valve handle retainer with electric safety interlock to prevent accidental activation of hydraulic cylinder functions.

_________________________________________________________________ 6.6 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Technical data ________________________________________________

___________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Set screws

© BUCYRUS AMERICA, INC.

Table 4: Hex bolts, 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 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

Table 5: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

______________________________________________________________ A6474X286 VLSV/02 6.7

Tightening torques ____________________________________________

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 7: FSR hex bolts (SAE 5 and 325 steel) Nominal diameter

Recommended torque setting

¼” 5/16” 3/8”

9 ft-lbs 18 ft-lbs 31 ft-lbs

7/16” ½” 9/16” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½” 1 ¾” 2” 2 ¼” 2 ½” 2 ¾” 3”

50 ft-lbs 75 ft-lbs 110 ft-lbs 150 ft-lbs 250 ft-lbs 378 ft-lbs 583 ft-lbs 782 ft-lbs 1,097 ft-lbs 1,461 ft-lbs 1,748 ft-lbs 3,114 ft-lbs 4,504 ft-lbs 6,497 ft-lbs 7,144 ft-lbs 12,092 ft-lbs 15,744 ft-lbs

_________________________________________________________________ 6.8 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Table 6: Set screws (Socket standard steel)

___________________________________________ Tightening torques

© BUCYRUS AMERICA, INC.

Table 8: FSR hex bolts (SAE 5 and 325 steel) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting 26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs 30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

______________________________________________________________ A6474X286 VLSV/02 6.9

Tightening torques ____________________________________________ Table 8: 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

Property class 5.6 8.8 10.9 12.9

Torque Ma

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 8: 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

_________________________________________________________________ 6.10 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Table 8: Untreated screw, black finish (Coarse thread, continued)

___________________________________________ Tightening torques Table 9: Untreated screw, black finish (Fine thread) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25

Nm

27

52

95

Ft-lbs

19

38

70

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

Table 9: Untreated screw, black finish (Fine thread, continued)

© BUCYRUS AMERICA, INC.

Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5

Nm

150

225

325

Ft-lbs

110

165

239

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

Table 9: Untreated screw, black finish (Fine thread, continued) Property class

Torque Ma

8.8

Nm

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399

Ft-lbs 10.9 12.9

610

780

449

575

Nm

640

860

1100

Ft-lbs

472

634

811

Nm

770

1050

1300

Ft-lbs

567

774

958

______________________________________________________________ A6474X286 VLSV/02 6.11

Tightening torques ____________________________________________ Table 10: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M33 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nm

36

Ft-lbs

26

42

Nm

83

132

Ft-lbs

61

97

58

Nominal diameter M18

M20

M22

121

171

230

54

89

126

169

200

275

390

530

147

202

287

390

88

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 10: Electrically zinc plated (Coarse thread, continued) Property class 5.6

8.8

10.9

12.9

Torque Ma

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

_________________________________________________________________ 6.12 Bucyrus – Model 7MFGH-56A Feeder Breaker

© BUCYRUS AMERICA, INC.

Table 10: Electrically zinc plated (Coarse thread, continued)

___________________________________________ Tightening torques Table 11: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

Torque Ma Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

Recommended torque setting M8 X 1 25 18 35 25 42 30

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 11: Electrically zinc plated (Fine thread, continued)

© BUCYRUS AMERICA, INC.

Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 11: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

______________________________________________________________ A6474X286 VLSV/02 6.13

© BUCYRUS AMERICA, INC.

Tightening torques ____________________________________________

_________________________________________________________________ 6.14 Bucyrus – Model 7MFGH-56A Feeder Breaker

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© BUCYRUS AMERICA, INC.

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

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Bucyrus America, Inc. expressly point out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

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

______________________________________________________________ A6474X286 VLSV/02 6.15

Permissible media ____________________________________________ Approved suppliers:

Supplier

Brand name

1

Amoco Oil Company

Amoco AW oil No.68

2

Gulf Oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil Company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hyldraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers

Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

_________________________________________________________________ 6.16 Bucyrus – Model 7MFGH-56A Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 12: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 13: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf Oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460

6

Unocal 76

7

Shell Oil Company

8

Century Lubricating Oils, Inc.

9

Texaco Lubricants Company

Hulbest EP-7 Powergear 460 Meropa 680

10

Exxon

Spartan EP 460

11

Pennzoil

Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

608 Almosal Vari-Purpose Gear Lubricant Gear Oil 460

14

Hydrotex

933 Industrial Gear Lubricant

15

Phillips

16

Miners Oil

All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680

______________________________________________________________ A6474X286 VLSV/02 6.17

Permissible media ____________________________________________

1

Supplier Amoco Oil Company

2 3 4

Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc.

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Brand name Amolith Grease 2 EP Rykon Premium Grease 2 EP Gulfcrown Grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith Grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Table 15: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century Oils Limited Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid Grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

_________________________________________________________________ 6.18 Bucyrus – Model 7MFGH-56A Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 14: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ Permissible media Table 16: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company

5 6

Cincinnati – Vulcon Company Cities Service Oil company

7 8

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

9

© BUCYRUS AMERICA, INC.

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

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

22 23

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

24 25

Wynn Oil company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks Fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion fire resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR

Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant hydraulic Fluid HY-Guard

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Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf Oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil Company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

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©© BUCYRUS AMERICA, INC.

Table 17: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

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© BUCYRUS AMERICA, INC.

Table 18: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) Supplier Brand name 1

Amoco Oil Company

American Industrial Oil No. 68

2

Gulf Oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy – Medium

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754

6

Unocal 76

7

Shell Oil Company

Unax RX68 or Turbine Oil 68 Turbo 68

8

Century Lubricating Oils, Inc.

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

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1

Amoco Oil Company

American Industrial Oil No. 150

2

Gulf Oil

Harmony 150

3

Mobil Oil Corporation

DTE Oil EX. Heavy

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961

6

Unocal 76

7

Shell Oil Company

Unax RX 700 or Turbine Oil 700 Turbo 150

8

Century Lubricating Oils, Inc.

Centraulic R&O 150

9

Atlantic Richfield Company

10

Texaco Lubricants Company

Duro 600 or S-700 Regal Oil R&O 150

11

Exxon

Teresstic 150

12

Pennzoil

Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15

Conoco Inc.

Dectol R&O 76

16

Hydrotex

System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Table 20: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier Brand name 1 Amoco Oil Company Cylinder oil No. 1000 2 Mobil Oil Corporation Extra Hecla Super Cylinder Oil 3 Chevron U.S.A. Chevron Cylinder Oil W ISO 1000 4 Sun Oil Company Sun Steam Cylinder Oil 5 Unocal 76 Worm gear Lube 250 or Stevalc 6 Century Lubricating Oils, Inc. Garwal 680 7 Atlantic Richfield Company Modoc 195 8 Texaco Lubricants Company 650 T Cylinder Oil 1000 9 Exxon Cylesstic TK-1000 10 Pennzoil Cylinder Oil #1000 11 Conoco Inc. Inca Oil 1000

_________________________________________________________________ 6.22 Bucyrus – Model 7MFGH-56A Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 19: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

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© BUCYRUS AMERICA, INC.

Table 21: Light gear oil, SAE 40 motor oil (Spec. 100-10)

1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil Company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 22: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 23: Multi-purpose tractor hydraulic fluid (Spec. 100-12)

1 2 3 4

Supplier Exxon / Mobil Century / Fuchs Shell Chevron

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid

5 6 7

BP Lubricants Quaker State Conoco

Tractran UTH Quaker State FCI HD Powertran Fluid

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©© BUCYRUS AMERICA, INC.

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_________________________________________________________________ 6.24 Bucyrus – Model 7MFGH-56A Feeder Breaker

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For your information

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

© BUCYRUS AMERICA, INC.

Service address Beckley, WV 200 George Street, Suite 4 Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

______________________________________________________________ A6474X286 VLSV/02 7.3

Our service __________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

© BUCYRUS AMERICA, INC.

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

_________________________________________________________________ 7.4 Bucyrus – Model 7MFGH-56A Feeder Breaker