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Operation Manual DBT- Feeder Breaker Model - 7MFBH-56AL Doc. No.:

A6474X246

DBT America ________________________________________________ 4041 Wurno Road Pulaski, VA 24301

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

Internet: www.dbtamerica.com

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This manual is intended to provide GENERAL product information for the Model 7MFBH-56AL Feeder Breaker. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. DBT America 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 DBT America, and these regulatory agencies, or any repair or replacement of parts contrary to DBT America'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 DBT America 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.

© DBT AMERICA 2005 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

© DBT AMERICA 2005

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..............................................2.19

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 .............................................................. 3.5

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

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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 operation be started?..................................... 5.3 Controls and indicators ........................................................ 5.4 Operator’s station............................................................ 5.4 Primary valve bank ......................................................... 5.5 Tram control valve .......................................................... 5.6 Starter enclosure............................................................. 5.9 Conveyor........................................................................5.11 Fire suppression ............................................................5.12 Dust suppression system...............................................5.13 Daily starting procedure .................................................5.14 Shutdown procedure......................................................5.16 Electrical system ............................................................5.17 Starter enclosure.......................................................5.19 Electrical components ...............................................5.20 Hydraulic system............................................................5.21 Hydraulic components ..............................................5.22 Mechanical assemblies..................................................5.27 Breaker assembly ....................................................5.27 Tail shaft ...................................................................5.28 Conveyor chain ........................................................5.28 Grease take-up ........................................................5.29 Head shaft ................................................................5.29 Breaker power unit ...................................................5.30 Crawler assemblies ..................................................5.31 Instructions on the maintenance of the feeder breaker .5.33 Important notes ........................................................5.33 Before maintenance .................................................5.33 Lubrication and inspection .......................................5.35 Specific lubrication and maintenance procedures ........5.38 Every 8 hours of operation .......................................5.38 Weekly .....................................................................5.42 Every 2 weeks ..........................................................5.46 Monthly .....................................................................5.47 Every 3 months ........................................................5.48 Every 6 months ........................................................5.49 Inspection of the feeder breaker ...................................5.52 Inspection of wear parts on the feeder breaker ............5.53 Inspection of the fire suppression system .....................5.54 Recharge of the fire suppression system .....................5.56 Recharge inspection of the fire suppression system ....5.57 Instructions on the adjustment procedures ...................5.59 Conveyor chain adjustment .....................................5.59 Crawler track adjustment .........................................5.61 Breaker drive chain adjustment ...............................5.63 Breaker assembly adjustment ..................................5.64

_________________________________________________________________ DBT – Model 7MFBH-56AL Feeder Breaker

© DBT AMERICA 2005

5. Operation

________________________________________________ Table of contents Instructions on the replacement of wear parts ............. 5.65 Head shaft ............................................................... 5.65 Head shaft sprockets ............................................... 5.68 Tail shaft .................................................................. 5.70 Conveyor chain ........................................................ 5.75 Crawler track ............................................................ 5.78 Crawler assembly .................................................... 5.81 Breaker assembly .................................................... 5.88 Breaker power unit .................................................. 5.95 Conveyor drive motor (s) ........................................5.103

6. Technical data Technical data ......................................................................... 6.3 Components of the feeder breaker ...................................... 6.3 Tightening torques................................................................ 6.7 Permissible data ................................................................. 6.13 Lubrication fluids and greases....................................... 6.13

7. For your information © DBT AMERICA 2005

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

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© DBT AMERICA 2005

Table of contents _________________________________________________

_________________________________________________________________ DBT – Model 7MFBH-56AL Feeder Breaker

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1

About this manual

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________________________________________Before starting to work

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

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: DBT – Model, 7MFBH-56AL Feeder Breaker Serial No.: 54-2132 / 54-2133 and is only permitted to be used for equipment of this type.

© DBT AMERICA 2005

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 prepare the rise heading 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.

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

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

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

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.

© DBT AMERICA 2005

service

_________________________________________________________________ DBT – Model 7MFBH-56AL Feeder 1.4

________________________________________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.

© DBT AMERICA 2005

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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© DBT AMERICA 2005

Before starting to work ________________________________________

_________________________________________________________________ DBT – Model 7MFBH-56AL Feeder 1.6

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2

Your safety

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__________________________________________________ Personnel

Your safety This chapter provides vital information for your safety.

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

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

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

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by DBT America.

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

© DBT AMERICA 2005

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

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of the mine.

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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

and must be able to prove this knowledge.

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 DBT America or by specially qualified personnel of the mine.

_________________________________________________________________ DBT – Model 7MFBH-56AL Feeder 2.4

© DBT AMERICA 2005

Installation and repair

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

Intended uses include: ■

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

Unauthorized use

© DBT AMERICA 2005

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

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the transport of persons

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

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

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© DBT AMERICA 2005

Operating conditions __________________________________________

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 2.6

___________________________________________ Safety instructions Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

Inform your colleagues of:

© DBT AMERICA 2005

safety equipment

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your exact location.

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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. EMERGENCY 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 EMERGENCY 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

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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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crusher shafts

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boom assemblies

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crawler assemblies

© DBT AMERICA 2005

moving parts

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 2.8

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

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

© DBT AMERICA 2005

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.

______________________________________________________________ A6474X246 VPVR / 01 2.9

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 DBT America 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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 2.10

© DBT AMERICA 2005

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.

© DBT AMERICA 2005

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

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the hoses have no bubbles or blisters

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

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the outer sheath of the hoses is not damaged

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the connectors are securely inserted into the sockets

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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.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

© DBT AMERICA 2005

Fig. 1: Example: 4SP hydraulic hose, designation

1. manufacturer 2. hose type 3. date of manufacture 1st quarter 2000

4. nominal diameter 5. flame-resistant and antistatic

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 2.12

___________________________________________ Safety instructions 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. 2: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 3: Laying hydraulic hoses, twisting Wrong

© DBT AMERICA 2005

Right

■

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

Fig. 4: Laying hydraulic hoses, bending Right

Wrong

______________________________________________________________ A6474X246 VPVR / 01 2.13

Safety instructions ____________________________________________ ■

always have a little slack.

Fig. 5: Laying hydraulic hoses, crossing Right

■ ■ ■ ■

Wrong

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

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

■ ■ ■ ■ ■

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

Fig. 6: Laying hydraulic hoses, connections on moving parts Right

Wrong

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 2.14

© DBT AMERICA 2005

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

________________________________ 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.

© DBT AMERICA 2005

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 DBT America.

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.

______________________________________________________________ A6474X246 VPVR / 01 2.15

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

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.

Chapter 5: Operation

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

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.

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

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.

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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 2.16

© DBT AMERICA 2005

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.

________________________________ Overview of safety instructions 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! 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.

© DBT AMERICA 2005

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.

NOTICE! In the event that a sudden jam occurs which could damage the power unit, the power unit is protected by a torque limiter. See Breaker power unit in chapter 5 for more information on the torque limiter.

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.

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

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

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

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! 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.

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.

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.

WARNING! Breaker drive unit should be supported with an appropriate lifting device before removing any bolts from unit. 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.

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 2.18

© DBT AMERICA 2005

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.

________________________________ Overview of safety instructions Chapter 6: Technical data IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

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

© DBT AMERICA 2005

NOTICE! Use only lubrication fluids and greases approved by DBT America!

These fluids and greases have been tested at DBT America 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! DBT America 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.

______________________________________________________________ A6474X246 VPVR / 01 2.19

© DBT AMERICA 2005

Overview of safety instructions _________________________________

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 2.20

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3

Storage and transport

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________________________________________________________________

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________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the feeder breaker.

Observance of the instructions and tips will increase the service life and availability of the machine. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

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

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

© DBT AMERICA 2005

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.

______________________________________________________________ A6474X246 VPVR / 01 3.3

Storage and transport _________________________________________ plastic deformation

random sample inspection

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.

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 DBT America.

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.

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.

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 3.4

© DBT AMERICA 2005

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 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.

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.

© DBT AMERICA 2005

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.

______________________________________________________________ A6474X246 VPVR / 01 3.5

© DBT AMERICA 2005

Storage and transport _________________________________________

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 3.6

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4

Installation

________________________________________________________________

________________________________________________________________

_________________________________________________________________

__________________________________________________ Installation

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

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

Work on: the safety components (pressure relief valves, fire extinguishing equipment etc.) the electrical equipment (control units, signaling devices, etc.) and

© DBT AMERICA 2005

the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by DBT America 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

______________________________________________________________ A6474X246 VPVR / 01 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 DBT America. 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.

© DBT AMERICA 2005

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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 4.4

__________________________________________________ Installation Pre-installation check list

© DBT AMERICA 2005

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

■

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

■

check safety provisions for operational condition on power unit shrouds and drive chain 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 panic switch which is located on the operator’s station on the left side of the machine. Also, check for correct operation of optional right side panic switch, if equipped

■

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

______________________________________________________________ A6474X246 VPVR / 01 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.

panic strip

The panic strip is located on the left hand side of the machine. Striking with a small amount of force will actuate the panic strip. The panic strip is used to break the control circuit in emergency situations. When the panic strip is struck, all machine functions are shutdown immediately.

emergency 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.

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.

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.

“E” stop switch

“E” stop pushbutton

The “E” 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.

The “E” stop pushbutton is located on the left right side of the machine.

Striking with a small amount of force will actuate the pushbutton. The pushbutton is used to break the control circuit in emergency situations.

When the pushbutton is struck, all machine functions are shutdown immediately.

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 4.6

© DBT AMERICA 2005

Safety features include: (Reference Fig. 7)

__________________________________________________ Installation Fig. 7: Safety features on the feeder breaker “E-STOP” button

Emergency stop pull cord switch

Fire suppression actuator

Starter enclosure

© DBT AMERICA 2005

“E” stop pushbutton

Fire suppression actuator

Panic strip

______________________________________________________________ A6474X246 VPVR / 01 4.7

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

Discharge section Power unit Hydraulic oil tank

Starter enclosure

Operator’s area L.H. crawler assembly

© DBT AMERICA 2005

Breaker assembly R.H. crawler assembly Ratio chains

Conveyor chain

Emergency pull cord stop

Receiving section

Tail shaft

Tail shaft take-ups

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 4.8

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5

Operation

________________________________________________________________

________________________________________________________________

_________________________________________________________________

___________________________________________________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 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.

© DBT AMERICA 2005

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.

______________________________________________________________ A6474X246 VPVR / 01 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. 9) consists of the following controls and indicators: primary valve bank, auxiliary function pressure gauge, conveyor speed pressure gauge, tram control valves, conveyor control valves, panic strip, 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.

Fire suppression actuator

Panic strip

Fire suppression actuator

Starter enclosure Conveyor speed pressure gauge

Tram/conveyor selector lever

Conveyor direction control lever

Conveyor speed control

Tram circuit system pressure gauge

Tram control valve

Primary valve bank

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.4

© DBT AMERICA 2005

Fig. 9: Operator’s station

___________________________________________________Operation Primary valve bank

© DBT AMERICA 2005

The primary valve bank (Fig. 10) consists of the following hydraulic controls: “PTO”

The first lever from the operator’s right controls the “PTO”. To actuate the “PTO”, push the control lever away from the operator.

power fill pump

The “PTO” control lever is also used energize the power fill pump. To operate the power fill, energize the “PTO” control lever and turn ball valve handle located on the left side of the discharge section (Fig. 10) to the open position. To de-energize power fill pump, turn ball valve handle to closed position and move “PTO” control to the centered position.

“LEFT FRAME LIFT”

The second 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.

“RIGHT FRAME LIFT”

The third 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.

“FRAME TILT”

The fourth 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.

Fig. 10: Primary valve bank and power fill Ball valve handle

Power fill pump

“TILT”

“PTO” “FRAME LIFT”

“FRAME LIFT”

______________________________________________________________ A6474X246 VPVR / 01 5.5

Operation____________________________________________________ Tram control valve “LEFT TRAM”

The lower lever (Fig. 11) controls the left hand crawler functions. To tram in the direction of the receiving end, slowly push the control lever towards the receiving end and to tram in the direction of the discharge end, slowly push the control lever towards the discharge end.

“RIGHT TRAM”

The top lever (Fig. 11) controls the right hand crawler functions. To tram in the direction of the receiving end, slowly push the control lever towards the receiving end and to tram in the direction of the discharge end, slowly push the control lever towards the discharge end.

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 receiving end and to tram the machine in a straight direction towards the discharge end, push both tram control levers towards the discharge end. To steer left in the direction of the receiving end, push the right tram control lever towards the receiving end while the left tram control lever is in the neutral position or for tighter turns, push the left tram control lever towards the discharge end. To steer right in the direction of the receiving end, push the left tram control lever towards the receiving end while the right tram control lever is in the neutral position or for tighter turns, push the right tram control lever towards the discharge end.

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

Fig. 11: Tram control valve

“RH TRAM” “LH TRAM”

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.6

© DBT AMERICA 2005

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.

___________________________________________________Operation two position tram/conveyor control valve

The two position tram/conveyor control valve (Fig. 12) controls the flow of hydraulic fluid to either the tram circuit or to the conveyor circuit.

Push the control lever down to energize the tram circuit and pull the control lever up to energize the conveyor circuit.

two position conveyor direction control valve

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

conveyor speed control valve

The conveyor speed control valve (Fig. 12) allows the operator to adjust the speed of the conveyor. To increase conveyor speed, turn the adjustment knob clockwise (CW). To decrease conveyor speed, turn the adjustment knob counter-clockwise (CCW).

The auxiliary function pressure gauge (Fig. 12) is a high pressure gauge (6,000 psi) located to the left of the tram control levers. This gauge is equipped with a needle valve that will allow the operator to stop the flow of hydraulic fluid for maintenance purposes.

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 is equipped with a needle valve that will allow the operator to stop the flow of hydraulic fluid for maintenance purposes.

© DBT AMERICA 2005

auxiliary function pressure gauge

Located on the right side of the discharge end of the machine is four (4) pressure gauges (Fig. 12) that gives the operator a constant pressure reading for system and charge pressures. Each gauge is equipped with a needle valve that will allow the operator to stop the flow of hydraulic fluid to each individual gauge for maintenance purposes. See below for a brief description of each gauge. tram 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.

tram circuit charge pressure gauge

The tram 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.

conveyor circuit system pressure gauge

The conveyor 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 conveyor 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 conveyor circuit charge pressure.

______________________________________________________________ A6474X246 VPVR / 01 5.7

Operation____________________________________________________ panic strip

The panic strip (Fig. 12) is located on the left hand side of the machine.

Striking with a small amount of force will actuate the panic strip. The panic strip is used to break the control circuit in emergency situations.

When the panic strip is struck, all machine functions are shutdown immediately .

fire suppression actuator (s)

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.

Conveyor circuit system pressure gauge

Conveyor circuit charge pressure gauge

Tram circuit system pressure gauge Fire suppression actuator

Panic strip Tram circuit system pressure gauge

Conveyor speed pressure gauge

Tram/conveyor selector lever

Conveyor direction control lever

Conveyor speed control Fire suppression actuator

Tram circuit system pressure gauge

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.8

© DBT AMERICA 2005

Fig. 12: Controls and indicators

___________________________________________________Operation Starter enclosure

© DBT AMERICA 2005

The starter enclosure (Fig. 13) is located on the left hand side of the machine, it consists of the following machine’s electrical functions: “POWER”

This red light will be illuminated anytime electrical power is connected to the machine.

“HIGH TEMP”

This red light will be illuminated anytime the hydraulic fluid has overheated (approximately 140°).

“LOW OIL”

This red light will be illuminated whenever the hydraulic fluid level is low.

“SEQ SW”

This red light will be illuminated whenever belt sequence switch opens (belt stops).

“OVER LOAD”

This red light will be illuminated whenever the overload has tripped.

“SAFETY RELAY”

This red light will be illuminated whenever the “E-STOP” (pull cord at hopper) is pulled or the panic strip is engaged.

“UNDER SPEED”

This red light will be illuminated whenever the pick breaker slow down for any reason.

“ON/OFF” light switch “MAN/OFF/AUTO” selector switch

The light switch is a two (2) position (“ON/OFF”) rotary switch that is used to turn the area lights “ON’ or “OFF”.

The “MAN/OFF/AUTO” switch is a three (3) position rotary switch that is used to turn the area lights “ON’ or “OFF”.

–

“MAN” - is used to bypass the belt sequence switch.

–

“AUTO” - is used with the belt sequence switch to stop the conveyor when the outby belt stops.

“START”

The “START” pushbutton is used to start the machine.

“STOP”

This red pushbutton switch (when depressed) stops the electric motor on the machine.

“E-STOP”

This red push-button is connected to the emergency stop panic strip on the machine, and when energized, all machine functions shutdown immediately.

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.

______________________________________________________________ A6474X246 VPVR / 01 5.9

Operation____________________________________________________ Fig. 13: Starter enclosure controls and indicators

“MAN/OFF/AUTO” Selector switch

“START”

“STOP”

“E-STOP”

“LOW OIL” “HIGH TEMP”

“POWER”

“OVERLOAD”

“SAFETY RELAY”

“UNDER SPEED”

“ON/OFF” Light switch

Circuit breaker reset lever

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.10

© DBT AMERICA 2005

“SEQ SW”

___________________________________________________Operation Conveyor Perform daily start-up procedure (see Start-up procedure in this chapter). The conveyor may be started utilizing the conveyor direction and speed control valves located on the left side of the hopper (Fig. 14).

The running speed of the conveyor is controlled by a pressure reducing valve located below the conveyor direction control valve. To increase conveyor speed, turn the adjustment knob clockwise (CW). To decrease conveyor speed, turn the adjustment knob counter-clockwise (CCW).

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.

© DBT AMERICA 2005

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.

Fig. 14: Conveyor control levers

Conveyor speed pressure gauge Tram/conveyor selector lever

Conveyor speed control

Conveyor direction control lever

______________________________________________________________ A6474X246 VPVR / 01 5.11

Operation____________________________________________________ Fire suppression The machine is equipped with a fixed nozzle dry chemical fire suppression system (Fig. 15). The system consists of three (3) major components: storage canister, actuation device and a delivery system. The system is actuated manually by two (2) pneumatic actuators; one is located at the operator’s station and the other is located at the hopper end on the right hand side. The basic agent storage system is a tank filled with Ansul FORAY (monoammonium phosphate base) dry chemical, which is effective on Class A,B and C fires. The dry chemical extinguishing agent is delivered from the canister through hydraulic hoses and pre-set nozzles into the fire prone areas of the machine. The dry chemical is pressurized through the use of a gas expellant cartridge.

To actuate the fire suppression system from either of the two (2) actuators, pull the safety pin and strike inward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine.

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

Fig. 15: Fire suppression system Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Nozzle

Breaker coupling

Operator’s station

Nozzle Nozzle Breaker motor Nozzle

Nozzle

Oil tank LP canister

LP expellant

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.12

© DBT AMERICA 2005

Actuation line valves are used at the branches to each actuation device to improve system reliability and, if necessary, to increase the overall effective lineal length of the actuation line. These check valves eliminate the possibility of the pressure of the actuator from flowing to the other actuator and possibly causing it to be damaged or expelled from the machine and not allowing proper actuation of the dry chemical agent.

___________________________________________________Operation Dust suppression system The machine is equipped with a six (6) point dust suppression system (Fig. 16). Whenever the conveyor is running, a pendulum valve located above the conveyor flights is opened to allow water to flow through the system. Water is directed first to the heat exchanger, where it is used to cool the hydraulic system fluid. After it passes through the heat exchanger, it continues to the spray manifolds, where it is discharged through water sprays to reduce float dust in the breaker area of the machine. When the conveyor is not running and the pendulum valve is closed, a second ball valve in the system can be opened, allowing water to bypass the pendulum valve. See maintenance section in this chapter for more information on the dust suppression system.

Fig. 16: Dust suppression system

Regulator #2

Regulator #1

© DBT AMERICA 2005

Ball Valve #2

Strainer Ball Valve #1 Water sprays

Pendulum valve

Heat exchanger

______________________________________________________________ A6474X246 VPVR / 01 5.13

Operation____________________________________________________ Daily starting procedure (Reference Fig. 17) 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.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine. ) Operate all valve control levers to ensure that they are free and in neutral position. ) Check conveyor for any foreign material or objects.

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 left door of the starter enclosure by first moving the circuit breaker lever to the “RESET” position and then to the “ON” position.

Regular mode (conveying) ) Depress and release the “START” button located on the cover of the starter enclosure to start machine. ) Push the two position tram/conveyor control lever down for conveyor mode. ) Push the two position conveyor direction control lever to the desired directon of travel. Push the control lever down to run the conveyor in the direction of the discharge end (forward) and pull the control lever up to run the conveyor in the direction of the receiving end (reverse). ) Adjust the conveyor speed control valve to the desired speed. To increase conveyor speed, turn the adjustment knob clockwise (CW). To decrease conveyor speed, turn the adjustment knob counter-clockwise (CCW).

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.14

© DBT AMERICA 2005

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

___________________________________________________Operation Tram only mode ) Depress and release the “START” button located on the cover of the starter enclosure to start machine. ) Push the two position tram/conveyor control lever up to the centered “NEUTRAL” to stop the conveyor. After conveyor has stopped, Move the control handle to the “TRAM” mode.

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.

Fig. 17: Start control (s) locator Circuit breaker reset lever

© DBT AMERICA 2005

“START”

Conveyor direction control lever

Tram control levers

Tram/conveyor selector lever

Conveyor speed control

______________________________________________________________ A6474X246 VPVR / 01 5.15

Operation____________________________________________________ Shutdown procedure (Reference Fig. 18) ) 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. ) Stop the machine by depressing the “STOP” push-button located on the starter enclosure. ) Turn the “MAN / OFF / AUTO” switch to the “OFF” position. ) Turn the “ON / OFF” switch to the “OFF” position.

) Turn the conveyor speed control knob counter clockwise (CCW) to the lowest speed.

Fig. 18: Shutdown control (s) locator ‘MAN/OFF/AUTO”

“STOP”

“ON/OFF” Conveyor speed control Tram/conveyor selector lever

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.16

© DBT AMERICA 2005

) Move the tram/conveyor directional control handle to the centered “NEUTRAL” position.

____________________________________________ Electrical system Electrical system The following pages contain a brief description of the 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.

© DBT AMERICA 2005

WARNING! This section is intended only to familiarize the user with the 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. 19: Electrical component locator Electric motor

Emergency stop pull cord switch

Tape switch junction box

Starter enclosure

Oil float switch

Temperature switch

Connection box for slip / seq

_____________________________________________________________ A6474X246 VPVR / 01 5.17

Electrical system _____________________________________________

© DBT AMERICA 2005

Fig. 20: Electrical layout

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.18

____________________________________________ Electrical system Starter enclosure The starter enclosure (Fig. 21) 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 box are the electrical switches and indicator lights for the machine. These are labeled and control the start and stop functions for the electric motor. Located on the right side of 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.

© DBT AMERICA 2005

Fig. 21: Starter enclosure locator

Starter enclosure

Fig. 22: Starter enclosure components

I.S. relay for tape switch

I.S. relays for high temp, low oil & seq

Control circuit breakers

Control relays

Light fixture Control transformer Terminal blocks

Timing relays

Vacuum contactor & current transducer

Circuit breaker Overload block & heater strips

_____________________________________________________________ A6474X246 VPVR / 01 5.19

Electrical system _____________________________________________ Electrical components (Reference Fig. 19)

panic strip

The machine has one (200 hp) electric drive motor that drives the breaker and hydraulic pumps.

The machine has one panic strip located on the left hand side of the machine. Striking with a small amount of force will actuate the panic strip. The panic strip is used to break the control circuit in emergency situations. When the panic strip is struck, all machine functions are shutdown immediately .

emergency 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.

temperature switch

The machine is equipped with a temperature switch located on the back of the starter enclosure. It is used to monitor the temperature of the fluid inside the primary oil tank.

oil float switch

The machine is equipped with a oil float switch located inside the primary oil tank. It is used to monitor the level of the fluid inside the primary oil tank.

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.20

© DBT AMERICA 2005

electric motor

____________________________________________ 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.

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.

© DBT AMERICA 2005

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. 23: Hydraulic component locator

1. oil tank 2. tandem hydrostatic pump 3. tandem gear pump 4. valve bank 5. tilt and lift cylinders 6. tram motors 7. conveyor motors 8. power fill pump 9. pressure gauge manifold 10. manifold block

11. pressure gauge (6,000 psi) 12. pressure gauge (600 psi) 13. stop valve 14. loop flush valve 15. heat exchanger 16. charge filters 17. pressure filter 18. return filter 19. quick disconnect coupling 20. cross port relief valve

21.6-way double selector valve 22. power fill pump filter 23. tram valve 24. conveyor direction valve 25. tram/conveyor valve 26. pressure reducing valve 27. pressure filter 28. counter balance valve 29. ball valve

_____________________________________________________________ A6474X246 VPVR / 01 5.21

Hydraulic system _____________________________________________ Hydraulic components

hydraulic oil tank

The hydraulic oil tank located on the left hand side of the machine has a 80 gallon capacity and is equipped with a oil level sight glass, temperature switch and low oil level warning light.

tandem hydrostatic pump

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

tandem gear pump

The tandem gear pump located within the power unit supplies hydraulic power to the 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 and PTO functions. All sections of the valve bank are spring return (self centering) except for the PTO section which is detented.

power fill pump

The power fill pump is located on the left hand side of the discharge section of the machine 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.

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 tram valve bank.

conveyor motors

The conveyor motors located on each side of the head shaft are radial piston motors that receives hydraulic fluid from the hydraulic pump.

Both motors are controlled from the two position conveyor direction control valve.

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.22

© DBT AMERICA 2005

(Reference Fig. 23)

____________________________________________ Hydraulic system

© DBT AMERICA 2005

pressure gauge manifold

The pressure gauge manifold located on the right side of the discharge end of the machine consists of two (2) low pressure (charge) and two (2) high pressure (system) gauges. These pressure gauges gives the operator a constant reading of the charge and system pressures. Each pressure gauge is fitted with a needle valve to allow the operator to shut off line pressure in the case that a pressure gauge may malfunction.

loop flush valves

The machine is equipped with two (2) loop flush valves located within each conveyor circuit. These valves are used to dump approximately 30% of the charge oil to the low pressure side of each circuit.

heat exchanger

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

tram valve

The two (2) section tram valve located is on the left hand side of the machine is used to control the machines tram functions. Both sections of the valve bank are spring return (self centering).

two position tram/conveyor control valve

The two (2) position tram/conveyor control valve is used to control the flow of hydraulic fluid to either the tram or conveyor circuit.

two position conveyor direction control valve

The two (2) position conveyor control valve is used to control the conveyor direction of travel.

6-way double selector valve (s)

The 6-way double selector valves located on each side of the discharge section are used to allow operation of either the conveyor or tram motors independently.

charge filter (s)

Two (2) charge filter (s) are located within the machines hydraulic circuit that are used to filter the charge fluid. These filters remove hot oil from the circuit, allowing the charge pump to replenish the circuit with cooler oil.

pressure filter (s)

Three (3) pressure filter (s) are located within the machines hydraulic circuit that are used to filter fluid on the pressure side of the circuit.

return filter power fill filter ball valve

The return filter is used to filter fluid from the case drains of the hydraulic pump and motors.

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

The ball valve is located on the left hand side of the discharge section of the machine and is used to control the flow of hydraulic fluid from the power fill pump.

_____________________________________________________________ A6474X246 VPVR / 01 5.23

Hydraulic system _____________________________________________

© DBT AMERICA 2005

Fig. 24: Hydraulic circuit

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.24

____________________________________________ Hydraulic system

Conveyor

Right Tram Left Tram

© DBT AMERICA 2005

Fig. 25: Hydraulic schematic

_____________________________________________________________ A6474X246 VPVR / 01 5.25

© DBT AMERICA 2005

Hydraulic system _____________________________________________

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.26

_______________________________________ 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.

Breaker assembly

© DBT AMERICA 2005

The breaker assembly (Fig. 26) on the machine has a 19” pick circle with a 4 point star arrangement. It has an 8” shaft diameter turned down to 6 3/16” 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 power unit is protected by a torque limiter. See Breaker power unit in this chapter for more information on the torque limiter.

Fig. 26: Breaker assembly main components Shims Seal

Back-up ring

Seal housing

O-ring

Snap ring Sealing ring Seal

Pick and roll pin

Bearing backing ring

Bearing

Bearing housing

Sprocket

End cap

Retainer cap Breaker shaft

Side plate

_____________________________________________________________ A6474X246 VPVR / 01 5.27

Mechanical assemblies ________________________________________ Tail shaft The machine is equipped with a tail shaft (Fig. 27) 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. 27: Tail shaft components Tail shaft Grease fitting (2)

Key (2) Set screw (2)

Slide plate

Roller bearing (2) Piston rod adapter (2)

Conveyor chain The conveyor chain assembly (Fig. 28) carries mined material along the conveyor trough from the receiving section, through the breaker and out to 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. 28: Conveyor chain components

Roll pin Chain link section

Flight bar

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.28

© DBT AMERICA 2005

Roller (2)

_______________________________________ Mechanical assemblies Grease take-up The machine is equipped with a conveyor chain grease take-up assembly (Fig. 29) that provides ease of adjustment for the conveyor chain.

The take-up assembly provides 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. 29: Grease take-up main components

Stop valve (2) Grease manifold

Check valve (2)

Auto relief indicator (2) © DBT AMERICA 2005

Grease fitting (2)

Head shaft The feeder breaker is equipped with a head shaft (Fig. 30) located on the discharge end of the conveyor. The head shaft is driven from both sides via hydraulic motors that are directly connected to the head shaft.

Fig. 30: Head shaft main components Head shaft

Sprocket (2) & key (2)

Bearing (2)

Hydraulic motor (2)

_____________________________________________________________ A6474X246 VPVR / 01 5.29

Mechanical assemblies ________________________________________ Breaker power unit The breaker power unit drives the breaker assembly and hydraulic pump (s) (Fig. 31). It consists of a 200 HP electric motor, coupled to a Link-Belt (Model LC250) right angle gear reducer, via a torque limiter.

The power unit has been assembled as a unit and can be removed as a unit or as individual components. For additional information on power unit components, refer to the manufacturers information supplied with the parts manuals.

Fig. 31: Breaker power unit main components

Bearing Coupling Sprocket

Tandem pump

Mounting bracket Connecting tube Motor (200 HP)

Connecting tube

Gear reducer Mounting base

Flexible coupling

Torque limiter

Bushing (Taperlock)

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.30

© DBT AMERICA 2005

Gear pump

_______________________________________ Mechanical assemblies Crawler assemblies The feeder breaker is trammed by two (2) hydraulically driven crawlers (Fig. 32); one is located on each side of the machine. The complete drive assemblies are housed in crawler frames which enclose, guide and support the tram components. Each tram drive is independently controlled by the operator for moving the machine forward, backward and for making turns.

The crawlers on the machine are hydraulic driven through torque hub gear reducers. Attached to the torque hub is a single sprocket that engages the crawler tracks directly. The crawler track loops around the take-up roller assembly located on the opposite end of the crawler assembly. The idler assembly, along with a grease take-up is used to adjust the tension on the crawler tracks. (See Maintenance section in this chapter for Crawler track adjustment procedure) Fig. 32: Crawler assembly main components

© DBT AMERICA 2005

Cat pad assembly Hydraulic motor (not shown)

Take-up roller assembly

Take-up cylinder & shims Sprocket Torque hub

_____________________________________________________________ A6474X246 VPVR / 01 5.31

© DBT AMERICA 2005

Mechanical assemblies ________________________________________

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.32

________________________________________________ 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

© DBT AMERICA 2005

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 DBT 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 DBT America 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.

______________________________________________________________ A6474X246 VPVR / 01 5.33

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.

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.34

© DBT AMERICA 2005

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.

© DBT AMERICA 2005

Central lubrication system The central lubrication system (Fig. 33) located on the left hand side of the receiving end of the machine allows the following to be easily lubricated from a central point; head shaft, breaker shaft and tail shaft.

Fig. 33: Central lubrication Outboard bearing

Tail shaft

Breaker

Note: Outboard bearing port used only if applicable on machine.

Head shaft

Central lubrication manifold

______________________________________________________________ A6474X246 VPVR / 01 5.35

Maintenance _________________________________________________ Table 1: Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

Every 8 hours of operation 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

Outboard breaker bearing (if applicable)

1

Century Replex 2

Spec. 100-3

5

Reducer input and output shaft

2

Century Replex 2

Spec. 100-3

6

Hydraulic oil level (check)

1

Century Hydraulic AW 68

Spec. 100-1

7

Charge filter (s) (check)

2

8

Pressure filter (auxiliary circuit) (check)

1

9

Return filter (check)

1

10

Pressure filter (hydrostatic) (check)

2

11

Bits (breaker) (inspect)

1

12

“E-STOP” and panic strip (check)

2

Century Replex 2

Spec. 100-3

13

Crawler track take-up bearings

2

14

Conveyor chain tension

1

15

Fasteners (nuts, bolts and screws)

Inspect

16

Electrical cables, conduits and glands

Inspect

17

Hydraulic hoses and connections

Inspect

18

Hydraulic system pressures

Check

19

Breaker reducer (check oil level)

1

AGMA #5 mild Extreme pressure

Spec. 100-2

20

Tram reducer (s) (check oil level)

2

Century Hulbest EP-7 Powergear 460

Spec. 100-2

21

Strainer (dust system) (clean)

1

22

Breaker drive chain

1

Chain lube

Every 2 weeks 23

Charge filter (s) (change)

2

24

Pressure filter (auxiliary circuit) (change)

1

25

Return filter (change)

1

26

Pressure filter (hydrostatic) (change)

2

27

Power fill filter (change)

1

Monthly 28

Conveyor tilt and lift cylinders

4

Century Replex 2

Spec. 100-3

29

Crawler anchor pin (s)

2

Century Replex 2

Spec. 100-3

2

Exxon Unirex N-2

Spec. 100-2

Century Hydraulic AW 68 Century Hulbest EP-7 Powergear 460 AGMA #5 mild Extreme pressure

Spec. 100-1

Every 3 months 30

Electric motor (breaker) Every 6 months

31

Hydraulic oil tank (change)

1

32

Tram reducer (change oil)

2

33

Breaker reducer (change oil)

1

Spec. 100-2 Spec. 100-2

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.36

© DBT AMERICA 2005

Weekly

________________________________________________ Maintenance

© DBT AMERICA 2005

Fig. 34: Lubrication chart

______________________________________________________________ A6474X246 VPVR / 01 5.37

Maintenance _________________________________________________ Specific lubrication and maintenance procedures

head shaft bearings

Lubricate the head shaft bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 35) 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.

breaker shaft bearings

Lubricate the breaker shaft bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 35) 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 breaker shaft grease return manifold fittings located on the left side of the machine.

Outboard breaker bearing (if applicable)

Lubricate the outboard breaker bearing (if applicable) with Spec. 100-3 through the grease fitting located on the central lubrication panel (Fig. 35) located on the left side of the receiving section. Pump six (6) - (8) pumps of grease into the fitting.

tail shaft and slide tube bearings

Lubricate the tail shaft and slide tube bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 35) 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.

Fig. 35: Central lubrication panel

“TAIL SHAFT”

“BREAKER SHAFT” & outboard bearing (if applicable)

“HEAD SHAFT”

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.38

© DBT AMERICA 2005

Every 8 hours of operation:

________________________________________________ Maintenance reducer input and output shafts

Lubricate the reducer input and output shafts with Spec. 100-3 through the grease fittings located on the lubrication panel (Fig. 36) located on the right side of the machine. Pump six (3) - (4) pumps of grease into the fittings.

Fig. 36: Reducer input and output shaft lubrication

Reducer input shaft

© DBT AMERICA 2005

hydraulic oil tank

Reducer input shaft

Check the hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 37). 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. 37: Hydraulic tank oil level

Sight glass

charge filter (s)

Check the charge filter’s pop-up style dirt alarm ( Fig. 38) located on the top of each filter housing. If the alarm indicates the filter element is dirty, replace element.

pressure filter (auxiliary circuit)

Check the auxiliary circuit pressure filter’s pop-up style dirt alarm (Fig. 38) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

return filter

Check the return filter’s pop-up style dirt alarm (Fig. 38) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

pressure filter (s) (hydrostatic)

Check the hydrostatic pressure filter’s pop-up style dirt alarm (Fig. 38) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

______________________________________________________________ A6474X246 VPVR / 01 5.39

Maintenance _________________________________________________ Fig. 38: Filter location Charge filters

Power fill filter

bits (breaker)

Pressure filter (auxiliary circuit)

Hydrostatic pressure filters

Check the breaker bits to see if they will rotate in their holders and for damaged or missing bits (Fig. 39). 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. 39: Breaker bit inspection Breaker bits (24)

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.40

© DBT AMERICA 2005

Return filter

________________________________________________ Maintenance panic strip

Check the panic strip located on the left side of the machine (Fig. 40).

Start the machine and strike the panic strip to be certain it is operating properly, tripping the machine circuit breaker and shutting down the machine.

“E-STOP” button

Check the “E-STOP” button located on the front cover of the starter enclosure (Fig. 40). Start the machine and strike the “E-STOP” button to be certain it is operating properly, tripping the machine circuit breaker and shutting down the machine.

Fig. 40: Panic strip and “E-STOP’ button location “E-STOP”

© DBT AMERICA 2005

Panic strip

______________________________________________________________ A6474X246 VPVR / 01 5.41

Maintenance _________________________________________________ Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 41) 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

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

fasteners

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: ■

breaker reducer mounting bolts

■

breaker drive motor mounting bolts

■

breaker shaft side plate bolts

■

under speed detector driveshaft bolts

■

head shaft bearing bolts

■

conveyor drive motor mounting bolts

■

tail shaft retainer hold down bolts

■

all cover and guard retaining bolts

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.42

© DBT AMERICA 2005

Fig. 41: Crawler track take-up lubrication

________________________________________________ Maintenance electrical cables, conduits and glands

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.

hydraulic system pressure (s)

Check the hydraulic system pressure (s) by visually looking at the pressure gauges (Fig. 42). Refer to the hydraulic schematic in your parts manual for correct pressure (s).

Fig. 42: Hydraulic system pressure gauges (s) location Conveyor circuit charge pressure gauge

Tram system circuit pressure gauge Tram circuit charge pressure gauge

© DBT AMERICA 2005

Conveyor system circuit pressure gauge

Conveyor speed pressure gauge

Tram circuit system pressure gauge

breaker reducer

Check oil level in the breaker drive reducer (Fig. 43). Oil level should be visible inside the top sight glass on the side of the reducer when it is in operation. If the oil level is low, add oil through the fill port located on the side of the reducer. The oil should be changed after the first 500 hours of operation and every six (6) months afterwards. Use a high grade AGMA #5 mild extreme pressure lubricant (Spec. 100-6).

Fig. 43: Breaker reducer oil level Full sight glass

Fill port / breather

Low sight glass

______________________________________________________________ A6474X246 VPVR / 01 5.43

Maintenance _________________________________________________ tram reducer (s)

Check the oil level in both tram reducer torque hubs (Fig. 44): ) 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 Spec. 100-2 oil through the fill plug hole until it begins to flow out of the check hole. ) Do not overfill the reducer.

Fig. 44: Tram reducer oil level

Check plug location

Drain plug location

strainer (dust system)

Clean the strainer mounted inside the dust suppression system. Open ball valve (Fig. 45) 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. 45: Dust suppression system strainer location Strainer

Ball valve Short hose

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.44

© DBT AMERICA 2005

Fill plug location

________________________________________________ Maintenance breaker drive chain

Lubricate the breaker drive chain with a good quality chain lube (Fig. 46).

Fig. 46: Breaker drive chain location

© DBT AMERICA 2005

Breaker drive chain

______________________________________________________________ A6474X246 VPVR / 01 5.45

Maintenance _________________________________________________ Every 2 weeks charge filter (s) pressure filter (auxiliary circuit) return filter

Change the charge filter’s element (Fig. 47). If the element is extremely dirty, a more frequent interval may be required.

Change the pressure filter’s element (Fig. 47). If the element is extremely dirty, a more frequent interval may be required.

Change the return filter’s element (Fig. 47). If the element is extremely dirty, a more frequent interval may be required.

pressure filter (s) (hydrostatic)

Change the hydrostatic pressure filter’s element (Fig. 47). If the element is extremely dirty, a more frequent interval may be required.

return filter

Change the hand pump filter element (Fig. 47). If the element is extremely dirty, a more frequent interval may be required.

Fig. 47: Filter location

Power fill filter

Return filter

Pressure filter (auxiliary circuit)

Hydrostatic pressure filters

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.46

© DBT AMERICA 2005

Charge filters

________________________________________________ Maintenance Monthly conveyor lift and tilt cylinders

Lubricate grease fittings on the rod ends of the conveyor lift and tilt cylinders with Spec. 100-3 (Fig. 48). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 48: Conveyor lift and tilt cylinder lubrication

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

© DBT AMERICA 2005

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

crawler anchor pins

Lubricate grease fittings on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 49). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 49: Crawler anchor pin (s) lubrication Crawler anchor pin grease fitting located inside crawler frame

______________________________________________________________ A6474X246 VPVR / 01 5.47

Maintenance _________________________________________________ Every 3 months electric motor (breaker)

Lubricate the electric breaker motor with Spec. 100-3 (Fig. 50): ) Clean dirt and debris from around the two plugs, one is located on each end of motor. ) Remove the plugs. ) Install grease fittings and grease sparingly. ) Remove grease fittings, clean and reinstall plugs.

NOTICE! The plugs must always be reinstalled in the electric motors.

Incorrect grease or over greasing may occur and cause serious damage to the motor.

Grease fitting

Grease fitting

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.48

© DBT AMERICA 2005

Fig. 50: Breaker motor lubrication

________________________________________________ Maintenance Every 6 months hydraulic oil tank

Change the hydraulic fluid in the oil tank (Fig. 51). ) 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 oil as required via the power fill system until fluid is visible in sight glass. ) Install fill cap. ) Start the machine and allow the hydraulic pump to run in order to purge air from the system. ) Shut down the machine and recheck the oil level. Add oil if necessary.

© DBT AMERICA 2005

Fig. 51: Hydraulic oil tank

Sight glass

Drain plug (not shown)

______________________________________________________________ A6474X246 VPVR / 01 5.49

Maintenance _________________________________________________ tram reducer

Change oil in the tram reducer (Fig. 52). ) 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 Spec 100-2 through the fill hole until fluid begins to flow from the check plug. ) When filling the reducer, allow enough time for all cavities inside the reducer to fill. ) Install level and fill plugs. ) Do not overfill reducer. © DBT AMERICA 2005

Fig. 52: Tram reducer oil change

Fill plug location

Check plug location

Drain plug location

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.50

________________________________________________ Maintenance breaker reducer

Change the oil in the breaker drive reducer (Fig. 53). ) Clean all dirt and debris from and around the level/fill plug, breather and drain plug. ) Remove the drain plug and allow the oil to completely drain. ) Clean and reinstall drain plug. ) Add oil spec 100-2 oil 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 level/fill plug. ) Do not overfill reducer.

© DBT AMERICA 2005

Fig. 53: Breaker reducer oil change Full sight glass

Fill port / breather

Drain plug

Low sight glass

______________________________________________________________ A6474X246 VPVR / 01 5.51

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

Prior to each shift the following points should be inspected: ) Clean and remove any foreign material from the operator’s station. ) Inspect all electrical cables, conduits, hydraulic hoses, fittings and warning devices for signs of wear or damage. ) Visually inspect the condition and readability of all tags, labels and reflectors. ) Check the panic strip and “E-STOP” button for correct operation. ) Check the hydraulic oil level 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 all electrical and hydraulic components for condition. ) 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.

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) Check oil level in the breaker reducer.

________________________________________________ Maintenance Inspection of wear parts on the feeder breaker

© DBT AMERICA 2005

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: ■

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

■

the breaker drive chain

■

the breaker drive sprockets

______________________________________________________________ A6474X246 VPVR / 01 5.53

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. 54). ) 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.

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

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) Check pressure relief vent in fill opening threads for obstruction.

________________________________________________ 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.

© DBT AMERICA 2005

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

______________________________________________________________ A6474X246 VPVR / 01 5.55

Maintenance _________________________________________________ Recharge of fire suppression system on the feeder breaker To return your fire suppression system to service after use (Fig. 54). ) Pull ring on safety valve to relieve actuator system pressure. ) Disconnect actuation system hose at cartridge receiver/actuator assembly. ) Open bursting disc union assembly. ) Remove extinguisher from bracket. ) Replace ruptured bursting disc with new disc. (Full disc side must face extinguisher). ) Fill extinguisher to rated capacity with Ansul dry chemical specified on nameplate.

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

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) Clean fill opening threads and gasket seating surface.

________________________________________________ Maintenance Recharge inspection of fire suppression system on the feeder breaker To provide maximum assurance that your fire suppression system will operate effectively and safely after recharging, the following points should be inspected weekly (Fig. 54). ) Make certain that extinguisher is in its designated place. ) Note general appearance for mechanical damage or corrosion. ) Check nameplate (s) for readability. ) Remove fill cap assembly. ) Make certain that extinguisher is filled with free flowing dry chemical to a level of not more than 3” from the bottom of the fill opening.

© DBT AMERICA 2005

) Secure fill cap, hand tighten. ) Remove cartridge from extinguisher and examine disc. Seal should be unruptured. ) Return cartridge to cartridge receiver/actuator assembly, hand tighten. ) Check hoses, fittings and nozzles for mechanical damage and cuts. ) Remove cartridge from remote actuator and examine disc. Disc should be unruptured. ) Return cartridge to remote actuator assembly, hand tighten. ) Replace any broken or missing lead and wire seals. ) Record date of inspection.

______________________________________________________________ A6474X246 VPVR / 01 5.57

Maintenance _________________________________________________ Fig. 54: Fire suppression system Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Nozzle

Breaker coupling

Operator’s station

Nozzle Nozzle Breaker motor Nozzle

Nozzle

Oil tank LP expellant © DBT AMERICA 2005

LP canister

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.58

_______________________________________ 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.

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 55):

© DBT AMERICA 2005

) Close the stop valve on manifold assembly securely. ) Attach a grease gun to the grease fitting located on the manifold and apply grease. The auto-relief indicator will vent grease when the required pressure is attained. ) The check valve will maintain pressure. ) 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.

______________________________________________________________ A6474X246 VPVR / 01 5.59

Adjustment procedures ________________________________________ ) Store any unused shims under cover plate.

Fig. 55: Conveyor chain adjustment Grease fitting Stop valve Auto relief indicator

Spare shims located under cover

© DBT AMERICA 2005

Tail shaft retainer

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.60

_______________________________________ 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. 56): ) 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. ) Chain sag should be 1 3/4” at the center of the crawler.

© DBT AMERICA 2005

To increase or decrease tension on the crawler track with the take-up cylinder proceed as follows (Fig. 56): ) 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.

______________________________________________________________ A6474X246 VPVR / 01 5.61

Adjustment procedures ________________________________________ 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.

Fig. 56: Crawler track adjustment

Idler assembly

Take-up cylinder

Grease fitting

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

Needle valve

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Access cover

_______________________________________ Adjustment procedures Breaker drive chain The breaker drive chain should be checked for correct tension at regular intervals.

To adjust tension on the breaker drive chain with the take-up cylinder proceed as follows (Fig. 57): ) Remove the covers from the power unit. ) Loosen the eight (8) power unit adjustment bolts located in the bottom of the mounting base, bolts do not have to be removed. ) Close the needle valve securely. ) Attach a grease gun to the grease fitting and apply grease. Pump grease into the grease fitting until the correct tension is attained.

© DBT AMERICA 2005

) After correct tension is attained, insert or remove the required amount of shims between the mounting base and machine frame to maintain correct tension. ) After adding or removing shims, slowly open the needle valve to release grease pressure from the cylinder, allowing shims to maintain tension.

WARNING! Due to grease cylinder 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. ) Tighten all adjustment bolts. ) Store and secure any unused shims. ) Install power unit covers.

Fig. 57: Breaker drive chain adjustment

Adjustment bolts (8) located in bottom of mounting base Shim location Take-up cylinder

Needle valve Shim storage

Grease fitting

Bleeder valve

______________________________________________________________ A6474X246 VPVR / 01 5.63

Adjustment procedures ________________________________________ Breaker assembly adjustment The breaker assembly can be adjusted in one inch increments.

To raise or lower the breaker assembly proceed as follows (Fig. 58): ) Remove the covers and guards from both ends of the breaker shaft. ) Release tension on the breaker drive chain. (See Breaker drive chain adjustment in this chapter). ) Remove the twelve (12) bolts, nuts, and lock washers (6 per side) that secure the cross over cover and remove cover. ) Attach an appropriate lifting device around the breaker shaft assembly and apply just enough lift to remove the sixteen (16) remaining bolts, nuts, and lock washers (8 per side) that secure the breaker assembly to the frame.

) With the aid of the lifting device, raise or lower the breaker assembly to the desired position. ) Secure the breaker with the sixteen (16) bolts, nuts, and lock washers (8 per side) and securely tighten. ) Place cross over cover in place and secure with the remaining twelve (12) bolts, nuts, and lock washers (6 per side). ) Check drive chain tension and adjust if required. (See Breaker drive chain adjustment in this chapter). ) Install covers and guards.

Fig. 58: Breaker assembly adjustment Cross over cover

Drive chain

Adjustment and mounting bolts

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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.

____________________________________ 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. 59) transmits the torque of the hydraulic motors 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.

© DBT AMERICA 2005

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

drive shaft

■

sprockets

■

bearings

■

hydraulic motors

Fig. 59: Head shaft main components Head shaft

Sprocket (2) & key (2)

Bearing (2)

Hydraulic motor (2)

______________________________________________________________ A6474X246 VPVR / 01 5.65

Replacement of wear parts _____________________________________ How to remove the head shaft To remove the head shaft assembly from the discharge boom proceed as follows (Fig. 60): ) 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 (s). (See Hydraulic motor removal in this chapter and hydraulic motor manual from supplier). ) Disconnect, tag and cap the central lubrication hoses on both 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. 60): ) 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. ) Connect the central lubrication hoses on both head shaft bearings. ) Install the hydraulic motor (s). (See Hydraulic motor installation in this chapter and hydraulic motor manual from supplier). ) 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.

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) Remove the four (4) nuts, bolts, and lock washers from each of the head shaft bearings.

____________________________________ 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. 60: head shaft removal and installation

© DBT AMERICA 2005

See hydraulic motor removal in this chapter and hydraulic motor manual from supplier

Sprocket guard

Conveyor chain

See hydraulic motor removal in this chapter and hydraulic motor manual from supplier

Head shaft

Sprocket guard

______________________________________________________________ A6474X246 VPVR / 01 5.67

Replacement of wear parts _____________________________________ Head shaft sprockets The head shaft sprocket transmits the torque of the hydraulic motors 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. 61): ) 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. ) Remove the two (2) set screws from each sprocket.

) 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. 61): ) 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.

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) Slide both sprockets from the drive shaft.

____________________________________ 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. 61): 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. ) Remove damaged sprockets and keys from head shaft. Old sprockets may require cutting to remove. © DBT AMERICA 2005

) Remove the two (2) sprocket guards located on the end of the discharge boom. ) Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease. ) Insert new key into shaft keyway. ) Install both sprocket halves with shims onto shaft and secure with the eight (8) cap screws. ) Align sprocket with conveyor chain and tighten set screws. ) Connect conveyor chain. (See Conveyor chain replacement in this chapter). ) Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

Fig. 61: Head shaft sprocket removal and installation

Head shaft

Bearing (2)

Shim Set screws Cap screws Split sprocket

Sprocket (2) & key (2)

Hydraulic motor (2)

______________________________________________________________ A6474X246 VPVR / 01 5.69

Replacement of wear parts _____________________________________ Tail shaft The tail shaft (Fig. 62) 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.

■

shaft

■

roller (2)

■

slide plate

■

key (2)

■

set screw (2)

■

roller bearing (2)

■

piston rod adapter (2)

■

grease fitting (2)

Fig. 62: Tail shaft main components Tail shaft Roller (2)

Key (2) Set screw (2)

Grease fitting (2)

Slide plate

Roller bearing (2) Piston rod adapter (2)

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The tail shaft assembly consists of the following main components:

____________________________________ Replacement of wear parts How to remove the tail shaft To remove the tail shaft assembly from the receiving boom proceed as follows (Fig. 63): ) 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).

© DBT AMERICA 2005

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

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

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 63): ) 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.

______________________________________________________________ A6474X246 VPVR / 01 5.71

Replacement of wear parts _____________________________________ Fig. 63: Tail shaft removal and installation

Tail shaft retainer plates (2)

© DBT AMERICA 2005

Tail shaft

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.72

____________________________________ Replacement of wear parts How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 64): ) 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 rollers and slid rollers from the shaft. ) Remove the tail shaft from the slide plate. ) Visually inspect all components for damage or wear and replace as necessary.

How to assemble the tail shaft

© DBT AMERICA 2005

To assemble the tail shaft assembly proceed as follows (Fig. 64): ) 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 rollers 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. ) 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).

______________________________________________________________ A6474X246 VPVR / 01 5.73

Replacement of wear parts _____________________________________ Fig. 64: Tail shaft disassembly and assembly Tail shaft Roller (2)

Slide plate

Roller bearing (2) Piston rod adapter (2)

© DBT AMERICA 2005

Key (2) Set screw (2)

Grease fitting (2)

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.74

____________________________________ Replacement of wear parts Conveyor chain The conveyor chain (Fig. 65) 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

© DBT AMERICA 2005

Fig. 65: Conveyor chain main components

6 link chain section Spiral pin Flight bar

______________________________________________________________ A6474X246 VPVR / 01 5.75

Replacement of wear parts _____________________________________ How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 66): ) Lay conveyor chain sections on a clean flat surface. ) Insert connector pins through flight end and align holes in spiral pin with holes in flight bar. ) Insert spiral pin. ) Drive spiral pin in with a hammer and punch. Ensure that spiral pin is recessed on both sides of flight bar. ) Repeat the previous assembly instructions until the complete chain has been assembled.

Extended pin connecting link Spiral pin (4)

Block link assembly

Flight bar

Side bar

6 link chain section

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Fig 66: Conveyor chain assembly

____________________________________ 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.

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.

© DBT AMERICA 2005

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.

______________________________________________________________ A6474X246 VPVR / 01 5.77

Replacement of wear parts _____________________________________ Crawler track The crawler track (Fig. 67) 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. 67: Crawler track main components Crawler pad

© DBT AMERICA 2005

Connector pin and T-pin

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.78

_______________________________________ Adjustment procedures How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 67): ) 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 To remove the crawler track pad assembly proceed as follows (Fig. 67):

© DBT AMERICA 2005

) 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. 67) 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.

______________________________________________________________ A6474X246 VPVR / 01 5.79

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 sprockets 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. 67): ) Remove old crawler track pad assembly (see previous section, How to remove crawler track pad assembly.

) 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 sprockets and idler roller. ) Connect crawler track pad assembly (see How to assemble crawler track pad assembly in this chapter for proper connection). ) Adjust tension on the crawler track pad assembly (see Crawler track pad adjustment procedure in this chapter for proper adjustment).

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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.

____________________________________ Replacement of wear parts Crawler assembly The crawler assembly (Fig. 68) 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.

© DBT AMERICA 2005

The crawler assembly consists of the following main components: ■

hydraulic drive motor

■

tram drive torque hub

■

cat pad assembly

■

take-up roller assembly

■

grease take-up assembly

■

drive sprocket

Fig. 68: Crawler assembly main components Cat pad assembly Hydraulic motor (not shown)

Take-up roller assembly

Sprocket

Torque hub

Grease take-up assembly

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Replacement of wear parts _____________________________________ How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 69): ) 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. ) Securely block under the crawler frame.

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 four (4) bolts from the tilt cylinder mounting block. ) Remove the tilt cylinder pin and remove tilt cylinder. ) Remove the eight (8) bolts from the tilt cylinder mounting bracket and remove bracket. ) Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to the take-up assembly and slowly pull the assembly out of the crawler frame.

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

Use only approved lifting equipment for connecting pulling devices to the take-up. ) Inspect all components for wear or damage.

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

____________________________________ Replacement of wear parts How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 69): ) 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.

© DBT AMERICA 2005

) Install and connect crawler and track pad assembly, see How to install the crawler track pad assembly in this chapter. ) Install the tilt cylinder mounting bracket and secure with the eight (8) bolts, washers and nuts. ) Install the tilt cylinder and secure the cylinder block with the four (4) bolts. ) Install tilt cylinder pin. ) Connect hydraulic hoses to tilt cylinder. ) Purge hydraulic system of air. ) Adjust crawler track pad tension, see How to adjust crawler track pad tension in this chapter.

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Replacement of wear parts _____________________________________ Fig. 69: Crawler take-up removal and installation

Tilt cylinder mounting bracket

© DBT AMERICA 2005

Tilt cylinder mounting block

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 5.84

____________________________________ Replacement of wear parts How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 70): ) 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. ) Disconnect, cap and tag all hydraulic hoses to hydraulic motor.

© DBT AMERICA 2005

) Remove slotted nut, roll pin and washer from lift cylinder anchor pin. ) Slide anchor pin out of crawler frame and tilt cylinder. ) 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.

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Replacement of wear parts _____________________________________ How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 70): ) 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.

■

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.

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) 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.

____________________________________ 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.

© DBT AMERICA 2005

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

■

step 1 – 300 ft-lb

■

step 2 – 600 ft-lb

■

step 3 – 905 ft-lb

) 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. 70: Crawler drive removal and installation

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crawler frame crawler pad (s) torque hub gasket (adapter plate) adapter plate gasket (hydraulic motor) drive sprocket removable side plate pin (crawler anchor)

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bushing bushing keeper pin keeper (hydraulic motor) flat washer castle nut cotter pin lock washer cap screw

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lock washer cap screw flat washer lock washer nut bolt lock washer bolt

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Replacement of wear parts _____________________________________ Breaker assembly The breaker assembly (Fig. 71) is assembled as a complete unit and should be removed as a unit for repairs except for the replacement of the bits. As soon as any component of the breaker assembly is worn or damaged, the component or complete assembly must be replaced.

The breaker assembly consists of the following main components: Fig. 71: Breaker assembly main components Shims Seal

Back-up ring

Seal housing

O-ring

Sealing ring Seal

Pick and roll pin

Bearing backing ring

Bearing

Bearing housing

Sprocket

End cap

Retainer cap Breaker shaft

Side plate

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Snap ring

____________________________________ Replacement of wear parts How to remove the breaker assembly To remove the breaker assembly from the machine proceed as follows (Fig. 72): ) Remove the covers and guards from both ends of the breaker shaft. ) Release tension on the breaker drive chain and remove chain.

(See Breaker drive chain adjustment in this chapter). ) Disconnect, tag and cap the bearing central lubrication hoses. ) Remove the twelve (12) bolts, nuts, and lock washers (6 per side) that secure the cross over cover and remove cover.

© DBT AMERICA 2005

) Attach an appropriate lifting device around the breaker shaft assembly and apply just enough lift to remove the sixteen (16) remaining bolts, nuts, and lock washers (8 per side) that secure the breaker assembly to the frame.

NOTE: During disassembly, note the location of shim locations and thicknesses for installation purposes.

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. 72): ) With the aid of the lifting device, slowly lift the breaker assembly into the frame and align mounting holes. ) Install shims between breaker side plates and feeder frame to establish a .050” - .110” gap between bearing backing ring and bearing housing on each end of the breaker shaft. ) Secure the breaker with the sixteen (16) bolts, nuts, and lock washers (8 per side) and securely tighten. ) Place cross over cover in place and secure with the remaining twelve (12) bolts, nuts, and lock washers (6 per side). ) Install breaker drive chain and adjust tension. (See Breaker drive chain adjustment in this chapter).

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Replacement of wear parts _____________________________________

) Connect the central lubrication hoses. ) Install covers and guards.

Fig. 72: Breaker assembly removal and installation

Shim location

Mounting bolts

Bearing housing Backing ring

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© DBT AMERICA 2005

Shim location

____________________________________ Replacement of wear parts How to disassemble the breaker assembly To disassemble the breaker assembly proceed as follows (Fig. 73): ) Remove the breaker assembly from the machine. (See How to remove the breaker assembly in this chapter).

Note: Disassembly procedure is for the right side. Both sides of the breaker assembly are identical except for the drive sprocket installed on the right side. ) Remove the three (3) bolts and lockwashers (items 21 and 22) from shaft and remove end cap (item 20). ) Remove the eight (8) bolts and lockwashers (items 16 and 17) from seal housing (item 8).

© DBT AMERICA 2005

) Remove seal housing (item 8), seal (item 9), snap ring (item (10), back-up ring (Item 11) and o-ring (item 12) as an assembly from shaft. ) Remove back-up ring (item 11) and o-ring (item 12) from seal housing (item 8). ) Remove snap ring (item 10) and seal (item 9) from seal housing (item 8). ) Remove bearing housing (item 6) from shaft. ) Remove bearing (item 3) and seal half (item 5) from shaft. ) Remove remaining seal half (item 5) and bearing backing ring (item 2) from shaft. ) Visually inspect all components for wear or damage and replace as necessary.

______________________________________________________________ A6474X246 VPVR / 01 5.91

Replacement of wear parts _____________________________________ How to assemble the breaker assembly To assemble the breaker assembly proceed as follows (Fig. 73): ) Thoroughly clean all components with dry and lint free cloth prior to assembly. ) Apply Loctite gasket eleminator 518 to the 1 1/2” radius of the shaft before installing bearing backing ring (item 2). ) Install bearing backing ring (item 2). ) Install bearing (item 3) and sealing ring (item 4) with bearing tool (P/ N 323334). Seat bearing with 60 tons of force. Do not heat bearing to install. ) After installing bearing, apply Isopropyl 12: alcohol to each housing bore.

) Slide bearing housing (item 6) over bearing (item 3).

IMPORTANT! Apply a light coat of grease to seal (item 9), back-up ring (item 11), o-ring (item 12) and sprocket (item 18) to aid installation. ) Intalll seal (Item 9) into seal housing (item 8) as shown (Fig. 73, Detail “B”) with the single lip toward the bearing and dual lips toward atmosphere. Use forming tool (P/N 333685) to aid installation. ) Install snap ring (item 10) into seal housing (item 8). ) Install back-up ring (item 11) and o-ring (item 12) onto seal housing (item 8).

IMPORTANT! Ensure that 1/4” pipe plug (item 7) installed in face of bearing housing (item 6) is flush or below face of housing. ) Install assembled seal housing (item 8) and secure with the eight bolts (item 14) and lockwashers (item 13). ) If required, install sprocket (item 18). ) Install end cap (item 20) for left side or retainer cap (item 19) for right side and secure with three (3) bolts (item 22) and lockwashers (item 21). Torque bolts (item 22) to 140 -150 ft-lb and install retaining wire (item 23).

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) Wipe each metallic face of seal (item 5) with lint free cloth. Do not use grease or oil on rubber. Apply SAE 30 oil to metallic faces only and install metallic face seal (item 5).

Replacement of wear parts _____________________________________ ) Install completed assembly onto machine.

IMPORTANT! Remove outboard 1/2” and 1/4 plugs only, install grease lines in 1/4” NPT ports and fill with grease until grease appears at the outboard unplugged port. Rotate shaft by hand ten (10) revolutions to seat metal faces of seal (item 5). Re-attach 1/2” grease return lines.

© DBT AMERICA 2005

Fig. 73: Breaker shaft disassembly and assembly

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breaker shaft bearing backing ring bearing sealing ring seal bearing housing pipe plug 1/4” seal housing seal snap ring, internal

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back-up ring o-ring lockwasher bolt breaker side plate lockwasher bolt sprocket retainer cap end cap

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30.

lockwasher bolt retaining wire pick spirol roll pin pipe plug 1/2” shim, .25” shim, .13” shim, .06” shim, .03”

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Replacement of wear parts _____________________________________ How to remove the breaker bit (s) To remove the breaker bit (s) proceed as follows (Fig. 74): ) Remove the spirol roll pin from the shank end of the bit with a hammer and punch. ) 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 (s) To install the breaker bit (s) in the breaker shaft bit holder proceed as follows (Fig. 74):

) Install the spirol roll pin in the shank end of the bit with a hammer.

Fig. 74: Breaker bit removal and installation

Spirol roll pin

Bit holder

Breaker bit

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) Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.

____________________________________ Replacement of wear parts Breaker power unit The breaker power unit (Fig. 75) 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 breaker power unit consists of the following main components: Fig. 75: Breaker power unit main components

Bearing Coupling

© DBT AMERICA 2005

Gear pump

Sprocket

Tandem pump

Mounting bracket Connecting tube Motor (200 HP)

Connecting tube

Gear reducer Mounting base

Flexible coupling

Torque limiter

Bushing (Taperlock)

______________________________________________________________ A6474X246 VPVR / 01 5.95

Replacement of wear parts _____________________________________ How to remove the breaker drive unit To remove the breaker drive unit as a complete assembly proceed as follows (Fig. 76). ) Remove breaker drive 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. ) Disconnect, cap and tag reducer input and output shaft lubrication hoses.

) Remove breaker drive chain. (See How to remove the breaker drive chain in this chapter). ) Attach an appropriate lifting device to the complete unit and slowly lift until just enough pressure is relieved to allow removal of the eight (8) mounting base adjustment bolts.

WARNING! Breaker drive unit should be supported with an appropriate lifting device before removing any bolts from unit. 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) mounting base adjustment bolts. ) With the aid of the lifting device, slowly lift the complete unit from the machine

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) Disconnect, cap and tag reducer outboard shaft bearing lubrication hose.

____________________________________ Replacement of wear parts How to install the breaker drive unit To install the breaker drive unit as a complete assembly proceed as follows (Fig. 76). ) With the aid of the lifting device, slowly lift the complete breaker drive assembly onto the machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads. ) Align mounting base adjustment holes with holes in frame and install the eight (8) adjustment bolts. ) Install and adjust tension on the breaker drive chain. (See How to install the breaker drive chain in this chapter) ) Connect the reducer input and output shaft lubrication hoses.

© DBT AMERICA 2005

) Connect the reducer outboard shaft lubrication hose. ) Connect all hydraulic hoses to the hydraulic pumps. ) Connect all electrical wiring to the drive motor. ) Install breaker drive covers. ) Purge hydraulic system of air.

Fig. 76: Breaker drive unit removal and installation Mounting base

Mounting base adjustment bolts

______________________________________________________________ A6474X246 VPVR / 01 5.97

Replacement of wear parts _____________________________________ How to disassemble the breaker drive unit To disassemble the breaker drive unit proceed as follows (Fig. 78): ) Remove complete unit from machine. (See How to remove the breaker drive unit in this chapter) ) Remove the four (4) bolts (item 41) and lockwashers (item 42) from gear pump (item 32) and remove pump. ) Open access cover on connecting tube (item 29) and loosen the two (2) set screws on each end of the coupling. ) Remove the two (2) bolts (item 37) and six (6) bolts (item 36) from tandem pump mounting brackets (items 33 and 34) and remove brackets.

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 (item 38) and lockwashers (item 30) from connecting tube (item 29) and remove connecting tube. ) Remove coupling (item 28) and key (item 45) from motor shaft. ) Remove access cover on connecting tube (item 2) and loosen the four (4) set screws (item 40) on flexible coupling (item 18). ) Remove the fourteen (14) bolts (item 27) and lockwashers (item 47) from motor. With the aid of a lifting device, slowly pull motor from flexible coupling (item 18) and remove key (item 46). ) Remove the twelve (12) bolts (item 25) and lockwashers (item 3) from connecting tube (item 2) and remove connecting tube. ) Remove the eight (8) bolts (item 39) and lockwashers (item 35) from flexible coupling (item 18) and remove coupling. ) Remove the twelve (12) bolts (item 17) and lockwashers (item 16) from companion flange (item 15) and remove torque limiter (item 8). ) Remove the three (3) bolts that secure the taper lock onto motor shaft. ) Insert two (2) of the bolts removed from taper lock into the two (2) jack screw threaded holes located in the end of the taper lock (Fig. 77). Tighten both screws equally until the taper lock is free from motor shaft.

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) Remove the four (4) bolts (item 43) and lockwashers (item 44) from tandem pump. With the aid of a lifting device, slowly pull pump from coupling (item 28).

____________________________________ Replacement of wear parts Fig. 77: Taper lock removal and installation

Jack screw holes (2) for bushing removal

Bolt holes (3) for bushing installation

) Remove taper lock (item 14), companion flange (item 15) and motor shaft key (item 12). ) Remove the four (4) bolts (item 24), nuts (item 48) and lockwashers (item 9) from outboard bearing (item 23). Slide bearing from reducer shaft.

© DBT AMERICA 2005

) Loosen set screw in sprocket (item 7) and slide sprocket from reducer shaft. ) Remove shaft key (item 11) from reducer shaft. ) Remove the eight (8) bolts (item 10), nuts (item 22) and lockwashers (item 49) from reducer (item 1). With the aid of a lifting device, slowly lift reducer from mounting base (item 5). ) Visually inspect all components for wear or damage and replace if necessary.

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Adjustment procedures ________________________________________ How to assemble the breaker drive unit To assemble the breaker drive unit proceed as follows (Fig. 78): ) With the aid of a lifting device, slowly lift the reducer (item 5) onto the mounting base (item 5) and align mounting holes in reducer with mounting holes of mounting base.

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 reducer to mounting base with eight (8) bolts (item 10), nuts (item 22) and lockwashers (item 49). Torque bolts to 460 ft-lb. ) Insert key (item 11) into reducer output shaft.

) Install outboard bearing (item 23) onto reducer output shaft and secure to mounting base with four (4) bolts (item 24), nuts (item 48) and lockwashers (item 9). Torque bolts to 460 ft-lb. ) Insert key (item 12) into reducer input shaft. ) Install companion flange (item 15) and taper lock bushing (item 14) on reducer input shaft. Locate flange so that taper lock bushing is flush with the end of the reducer shaft. Secure the taper lock bushing with the three (3) bolts supplied with taper lock bushing.

Torque bolts to 85 ft-lb. ) Bolt torque limiter (item 8) to the companion flange (item 15) with twelve (12) bolts (item 17) and lockwashers (item 16). ) Bolt the connecting tube (item 2) to the reducer (item 1) with twelve (12) bolts (item 25) and lockwashers (item 3). Torque bolts to 280 ft-lb. ) Insert key (Item 46) into motor shaft. ) Install motor half of flexible coupling (item 18) onto motor shaft.

Locate coupling so the motor shaft end is 1.43” from the edge of the coupling hub bore. Apply Loctite 242 blue to set screws (item 40) and tighten to lock coupling (item 18) into position. ) Bolt the coupling flange (item 18) to torque limiter (item 8) with eight (8) bolts (item 39) and lockwashers (item 35). ) Insert the flexible coupling element into the coupling into the coupling flange bolted to the torque limiter (item 8).

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) Install sprocket (item 7) onto reducer output shaft and tighten set screw to secure.

____________________________________ Replacement of wear parts ) With the aid of a lifting device, slowly lift the motor (item 4) and insert it into the connecting tube (item 2). Use caution not to pinch the flexible coupling element. Secure motor to the connecting tube with fourteen (14) bolts (item 27) and lockwashers (item 47).

Torque bolts to 460 ft-lb. ) Check the gap between the flexible coupling element and the mating coupling components. There should be a .300” gap between the face of the flexible element and the coupling hub on each side of the element. (See Detail “A” in Fig. 78) ) If the gap is too wide or too close, loosen the motor coupling half and reposition it until the gap is correct. ) Insert key (Item 45) into motor shaft. ) Install motor half of coupling (item 28) on motor shaft. ) Bolt connecting tube (item 29) to motor (item 4) with eight (8) bolts (item 38) and lockwashers (item 30). Torque bolts to 170 ft-lb.

© DBT AMERICA 2005

) Install pump half of coupling (item 28) on pump shaft. ) With the aid of a lifting device, slowly lift the pump (item 33) and insert it into the connecting tube (item 29). Secure pump to the connecting tube (item 29) with four (4) bolts (item 43) and lockwashers (item 44). ) Reach through opening in connecting tube and insert coupling element into coupling. Adjust both coupling halves until a 1/8” gap is achieved between metal faces of both coupling halves. Tighten the two (2) set screws on each coupling half to lock into position. ) Install pump mounting brackets (items 33 and 34) and secure with two (2) bolts (item 37) and six (6) bolts (item 36). Torque bolts to 80 ft-lb. ) Install gear pump (item 32) onto tandem pump (item 31) and secure with four (4) bolts (item 41) and lockwashers (item 42). ) Install completed breaker drive unit onto machine. (See How to install the breaker drive unit in this chapter)

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Replacement of wear parts _____________________________________ Fig. 78: Breaker drive unit disassembly and assembly

© DBT AMERICA 2005

1/8” Gap between metal faces

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reducer connecting tube lockwasher electric motor mounting base access cover sprocket torque limiter lockwasher bolt key (reducer output)

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key (reducer input) flat washer taper lock bushing companion flange lockwasher bolt flexible coupling flat washer bolt nut nut

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bearing bolt bolt bolt bolt coupling connecting tube lockwasher tandem pump gear pump mounting bracket (rh)

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mounting bracket (lh) lockwasher bolt bolt bolt bolt set screw bolt lockwasher bolt lockwasher

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48.

49.

key (motor) key (motor) lockwasher nut lockwasher

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____________________________________ Replacement of wear parts Conveyor drive motor (s) The conveyor drive motor (s) 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 and install the conveyor drive motor (s)

© DBT AMERICA 2005

Refer to the supplier manual located in your parts manual for removal and installation instructions on the conveyor drive motor.

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Replacement of wear parts _____________________________________

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6

Technical data

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________________________________________________________________

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_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Model 7MFBH-56AL 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

© DBT AMERICA 2005

general

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

Discharge height at 42 1/4” operating height: Operating height (max.): Level hopper capacity: Capacity (w/ optional 6” sideboards): Receiving impact plate: Breaker impact plate: Coal line material: Return line material: Mainframe side plate: Weight:

performance

Material input size (max.): Material strength: Nominal output size: Discharge rate (max.):

Material to be broken:

approx. 34’ approx. 11’ 3” approx. 28 5/8” approx. 31” approx. 2” approx. 14” approx. 14 7/8” approx. 30 1/2” approx. 22 5/8” approx. 50” approx. 279 ft³ approx. 331 ft³ HRS + CCO wear plate 1 1/2” T1 CCO wear plate HRS + CCO wear plate HT AR400 HT AR400 approx: 73,000 lbs approx. 2’ X 3’ X 4’ approx. 30,000 psi approx. 8” (one dimension) approx. 920TPH @ 135 fpm (1” pick to flight clearance) coal @ 65 lb/ft³

______________________________________________________________ A6474X246 VPVR / 01 6.3

conveyor chain

Conveyor width: Number of strands:

Conveyor speed:

approx. 56’ 2 @ 200,000 lb/strand ultimate approx. 3 1/2” approx. 15/16” 2 1/2” X 5” solid alloy steel approx. 0 - 135 fpm

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 motors:

2 radial piston hydraulic Low speed high torque 382 in³/rev splined direct mount On head shaft hydraulic relief

Chain pitch: Chain pin diameter: Flights:

head shaft

tail shaft

conveyor drive

Total motor displacement: Mounting: Overload protection: breaker

Shaft diameter: Bearing bore: Pick circle diameter: Running pick force: Pick force (max.): Overload protection: Underspeed protection: Breaker speed: Height setting: Breaker bits and holders:

breaker drive

Drive motor: Reducer: Coupling: Drive chain:

8” 6 3/16” approx. 19” approx. 8,550 lbs approx. 78,950 lbs torque limiting coupling magnetic sensor 97 rpm Manually adjustable 2” increments Heavy duty, rock type Bits with carbide insert 200HP/575v/AC/3ph/ 60Hz/TEFC right angle, 10:1 ratio Link-Belt torque limiting coupling ASA-180-2

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 6.4

© DBT AMERICA 2005

Technical data ________________________________________________

_______________________________________________ Technical data crawlers

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

hydraulic

Conveyor/tram drive pumps:

Cylinder circuit pump: Tram motors: Lift cylinders: Tilt cylinders: © DBT AMERICA 2005

Filters: Reservoir: Heat exchanger: Hydraulic fittings: Hydraulic PTO: Electrical

Breaker motor: Starter: Contactor: Panic switch: Belt sequence switch: Remote start switches: Trailing cable (by customer):

approx. 47 fpm Fairfield W12 torque hub grease cylinder w/locking shims approx. 89 5/8” approx. 70 3/4” approx. 18” approx. 27.4 psi (2) axial piston Variable displacement electronic displacement control gear pump Char Lynn 4000 series 19in³/rev Double acting 12” stroke, 6” bore Double acting 12” stroke, 6” bore (3) 10 micron pressure line 80 gal. capacity with low oil level switch air to oil type JIC (standard) 15 gpm @ 2000 psi 200HP/575v/AC/3ph/ 60Hz/1750 rpm/TEFC 200 hp/single/575v/AC 3ph/60Hz/dust tight IP65 vacuum type “tape switch” magnetic sensor with 50’ cable (3) photo eyes #4/0 GGC round

______________________________________________________________ A6474X246 VPVR / 01 6.5

features

■

Head shaft is removable horizontally as a unit.

■

Breaker and tailshaft are removable vertically as a unit.

■

Emergency stop pull cord switch over hopper.

■

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

■

Breaker drive is mounted on sliding base with grease cylinder for adjusting drive chain tension, locking shims included.

■

Locking shims included for tailshaft 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.

■

3/8” sectionalized covers over power units.

■

Extra heavy duty chain hold-downs at breaker transition.

■

6 point water spray dust suppression system, with “pendulum” valve.

■

Manual zone lubrication system.

■

8 point Ansul dry chemical fire suppression system.

■

Radio remote control of tram and cylinder functions. Battery charger for remote control will be mounted inside an enclosure on the feeder breaker.

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 6.6

© DBT AMERICA 2005

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

© DBT AMERICA 2005

Table 2: 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

Table 3: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

______________________________________________________________ A6474X246 VPVR / 01 6.7

Tightening torques ____________________________________________

Nominal diameter

Recommended torque setting

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” 1 ¾” 2” 2 ¼” 2 ½” 2 ¾” 3”

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

Table 5: 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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 6.8

© DBT AMERICA 2005

Table 4: FSR hex bolts (SAE 5 and 325 steel)

___________________________________________ Tightening torques Table 6: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Table 7: Untreated screw, black finish (Coarse thread, continued)

© DBT AMERICA 2005

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

______________________________________________________________ A6474X246 VPVR / 01 6.9

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 10: Untreated screw, black finish (Fine thread, continued) 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 11: 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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 6.10

© DBT AMERICA 2005

Property class

___________________________________________ Tightening torques Table 12: 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

© DBT AMERICA 2005

Table 13: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nm

36

Ft-lbs

26

42

54

89

126

169

Nm

83

132

200

275

390

530

Ft-lbs

61

97

147

202

287

390

58

88

Nominal diameter M18

M20

M22

121

171

230

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 14: 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

______________________________________________________________ A6474X246 VPVR / 01 6.11

Tightening torques ____________________________________________ Table 15: 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 16: Electrically zinc plated (Fine thread, continued)

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 17: 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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 6.12

© DBT AMERICA 2005

Property class

___________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Use only lubrication fluids and greases approved by DBT America! These fluids and greases have been tested at DBT America and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

© DBT AMERICA 2005

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! DBT America 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.

______________________________________________________________ A6474X246 VPVR / 01 6.13

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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 6.14

© DBT AMERICA 2005

Table 18: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© DBT AMERICA 2005

Table 19: 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

______________________________________________________________ A6474X246 VPVR / 01 6.15

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 21: 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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 6.16

© DBT AMERICA 2005

Table 20: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ Permissible media Table 22: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

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

5 6

Cincinnati – Vulcon Company Cities Service Oil company

7 8

10 11

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

12 13 14 15 16 17

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and chemical Co. Pennzoil Quaker Chemical Company

18

Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

© DBT AMERICA 2005

9

19 20 21 22 23

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

24 25

Wynn Oil company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion fire resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant hydraulic Fluid HY-Guard

______________________________________________________________ A6474X246 VPVR / 01 6.17

Permissible media ____________________________________________

Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil company

Omala 75

8

Century 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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 6.18

© DBT AMERICA 2005

Table 23: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media

© DBT AMERICA 2005

Table 24: 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

______________________________________________________________ A6474X246 VPVR / 01 6.19

Permissible media ____________________________________________

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 26: 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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 6.20

© DBT AMERICA 2005

Table 25: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

___________________________________________ Permissible media

© DBT AMERICA 2005

Table 27: 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 28: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

______________________________________________________________ A6474X246 VPVR / 01 6.21

© DBT AMERICA 2005

Permissible media ____________________________________________

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 6.22

_______________________________________________________________

7

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.

© DBT AMERICA 2005

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

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Oak Hill, WV P.O. Box 60 Oak Hill, WV 25901

Paonia, CO P.O. Box 566 Paonia, CO 81428

Price, UT 1814 North 1500 West P.O. Box 1016 Price, UT 84501 Phone: (435) 637-3930 Fax: (435) 637-9754

719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846 Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

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

______________________________________________________________ A6474X246 VPVR / 01 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

© DBT AMERICA 2005

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

_________________________________________________________________ DBT – 7MFBH-56AL Feeder Breaker 7.4

CONTENTS

saue Series 90

Axial Piston Pumps Technical Information

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

General Description Series 90 axial piston variable displacement pumps are of cradle swashplate design with variable displacement, and are intended for closed circuit applications.

The flow rate is proportional to the pump input speed and displacement.

The latter is infinitely adjustable between zero and maximum displacement.

Flow direction is reversed by tilting the swashplate to the opposite side of the neutral (zero displacement) position.

●

The Series 90 - Advanced Technology Today

●

8 Sizes of Variable Displacement Pumps

●

Complete Family of Control Systems

●

Proven Reliability and Performance

●

Optimum Product Configurations

●

Compact and Lightweight

Front page: Option - electric displacement control (EDC) Copyright 1987-1996, SAUER-SUNDSTRAND COMPANY All rights reserved. Contents subject to change.

Printed in Germany.

2

F000 539

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Technical Features A Complete Family to Meet Market Needs

The Latest Technology

● Eight (8) Different Sizes 30 cm3 (1.83 in3) to 250 cm3 (15.25 in3)

● Unique Product Features ● High Power Density

● Wide Range of Installation Options ● Designed to Lower Installation Costs ● Control System Flexibility Manual, Hydraulic, and Electrical Controls

● Design Provides for Reduced Operating Costs

● High Power Auxiliary Pads for Multiple Pump Configurations ● Closed Circuit Installations

High Performance

Reliability

● Speeds to 5 000 min-1 (rpm)

● Designed to Rigorous Standards, and Proven in Laboratory and Field

● Pressure to 480 bar (6 960 psi) ● Manufactured to Rigid Quality Standards ● High Overall Efficiency ● Long Service Life ● Low Noise Levels ● Input Shaft Bearings provide for Large External Shaft Loads

World Product

Worldwide Support

● Designed for Worldwide Markets

● Sales and Technical Support in All Industrialized Countries of the World

● Identical Product Manufactured Worldwide ● Mobile, Industrial, and Stationary Markets

● Serviced by a Worldwide Network of Authorized Service Centers

3

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Contents (Continued Next Page) Description • • • • • • • •

General Description ................................................................................................................. 2 Technical Features .................................................................................................................. 3 System Circuit Description ...................................................................................................... 6 Sectional View ......................................................................................................................... 7 Type Designation and Order Code ...................................................................................... 8, 9 Technical Specifications - Variable Displacement Pump ...................................................... 10 Technical Data ....................................................................................................................... 11 Determination of Nominal Pump Size .................................................................................... 11

General Technical Specifications • Speed Range, System Pressure Range, Case Pressure, Hydraulic Fluids, Temperature Limits, Charge Pressure .................................................................................. 12

Options • • • • • • • • • •

Reservoir ............................................................................................................................... 13 Filtration ................................................................................................................................. 13 Displacement Limiter ............................................................................................................. 13 Multi-function Valve ............................................................................................................... 14 Bypass Function .................................................................................................................... 15 Speed Sensor ........................................................................................................................ 15 Charge Pump ........................................................................................................................ 16 Charge Pump Maps ............................................................................................................... 17 Shaft Availability and Torque Ratings .................................................................................... 18 Auxiliary Mounting Pads ........................................................................................................ 19

External Load Limits • Shaft Loads ........................................................................................................................... 20 • Mounting Flange Loads ......................................................................................................... 21

Efficiency Graphs • Efficiency Graphs .................................................................................................................. 22

4

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Contents (Continued Previous Page) Description Controls - Circuit Diagram, Nomenclature and Description • • • • •

3-Position (FNR) Electric Control - Options DC, DD ...................................................... 24, 25 Electric Displacement Control (EDC) - Options KA, KP ................................................. 26, 27 Hydraulic Displacement Control (HDC) - Option HF ...................................................... 28, 29 Manual Displacement Control (MDC) - Options MA, MB ............................................... 29, 30 Non-Linear Manual Displacement Control (MDC) - Option NA ...................................... 30, 31

Dimensions • • • • • • • •

Variable Displacement Pump - Frame Size 030 ............................................................... 32,33 Variable Displacement Pump - Frame Size 042 ............................................................... 34,35 Variable Displacement Pump - Frame Size 055 .................................................. 36, 37, 38, 39 Variable Displacement Pump - Frame Size 075 .................................................. 40, 41, 42, 43 Variable Displacement Pump - Frame Size 100 .................................................. 44, 45, 46, 47 Variable Displacement Pump - Frame Size 130 ........................................................ 48, 49, 50 Variable Displacement Pump - Frame Size 180 .................................................. 52, 53, 54, 55 Variable Displacement Pump - Frame Size 250 .................................................. 56, 57, 58, 59

• • • • • • •

Displacement Limiter ............................................................................................................. 60 Cover Plate - Option CA ....................................................................................................... 60 3-Position (FNR) Electric Control - Options DC, DD ............................................................ 60 Electric Displacement Control (EDC) - Options KA, KP ....................................................... 61 Hydraulic Displacement Control (HDC) - Option HF ............................................................ 61 Manual Displacement Controls (MDC) - Options MB, NA .................................................... 62 Filtration ................................................................................................................................. 63

5

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

System Circuit Description Working loop (high pressure) Working loop (low pressure) Suction line Control fluid Case drain fluid

Control handle

Displacement control valve Heat exchanger bypass valve Reservoir

Orificed check valve

Vacuum gauge Heat exchanger

Purge relief valve

Charge pressure relief valve Reversible variable displacement pump

Servo control cylinder

Multi-function valve

Fixed displacement motor

To pump case Servo pressure relief valves

Charge pump Input shaft

Output shaft Multi-function valve

Pump swashplate Servo control cylinder

Pump

Motor swashplate Loop flushing valve

Motor

P001 004E

Figure 1 shows a hydrostatic transmission using a series 90 axial piston variable displacement pump and a series 90 fixed displacement motor.

6

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Sectional View Figure 2: Variable displacement pump Slider Block Servo Arm Servo Valve Cradle Hold Down

Servo Piston Feed Back

Cradle Bearing

Cradle

Cradle Leveler

Cradle Guide

Charge Pump

P001 413E

Name Plate

saue Ames, Iowa, U.S.A. Model Code

Neumünster, Germany Typ

90L055 KA 1 N 6 S 3 C6 C 03 NNN 35 35 24 Model No.

Model Number Serial Number

Model Code

Ident Nr

687459 N – 88 – 26 – 67890

Identification Number

Serial No. Fabr Nr MADE IN GERMANY

Place of Manufacture 7

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Type Designation and Order Code R

MODEL CODE

M

P J G N

9 0 Series or Product 90 = Series 90, Closed Circuit

R

Design and Rotation L = Pump, Left Hand (CCW) R = Pump, Right Hand (CW) Frame Size Displacement per revolution cm3 (in3) 030 = 30 (1.83) 042 = 42 (2.56) 055 = 55 (3.35) 075 = 75 (4.57)

8

100 130 180 250

= = = =

100 130 180 250

(6.10) (7.93) (10.99) (15.25)

M

Controls Frame Size 030 042 055 075 100 130 180 250 CA = Cover plate (without feedback link) ● ● ● ● ● ● DC = Electric 3-Position (FNR) Solenoid (12 VDC) ❍ ❍ ❍ ❍ ❍ ❍ DD = Electric 3-Position (FNR) Solenoid (24 VDC) ❍ ❍ ❍ ❍ ❍ KA = Electric Displacement (EDC) MS-Connector ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ KP = Electric Displacement (EDC) Packard-Connector ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ HF = Hydraulic Displacement (HDC) 3—11 bar (44—160 psi) ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ MA = Manual Displacement (MDC) ● ● ● ● ● ● ● ● MB = Manual Displacement with Neutral Start Switch (NSS) - ❍ ❍ ❍ ❍ ❍ ❍ ❍ NA = Non-Linear Manual Displacement ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍

P

Pressure Regulation Frame Size 1 = Pressure limiter (PL) in Port " A " and " B "

030 042 055 075 100 130 180 250 ●

●

●

●

●

●

●

●

J

Auxiliary Mounting Pad A = SAE A with sealed cover B = SAE B with sealed cover C = SAE C with sealed cover D = SAE D with sealed cover E = SAE E with sealed cover H = SAE H with sealed cover V = SAE B-B with sealed cover N = No Auxiliary Mounting Pad

G

Endcap Ports (SAE J518c Code 62) Frame Size 030 042 055 075 100 130 180 250 3 = Twin ports with shuttle valve in high press. circuit for pressure override valve - - ● 6 = Side ports - ● ● ● 8 = Twin ports, radial ● ● ● ● ● ● ❍ ●

N

Filtration S = Suction filtration R = Remote pressure - without filter T = Remote pressure - without filter P = Integral pressure filter - with spin-on filter (short) L = Integral pressure filter - with spin-on filter (long)

Frame Size ( 9 teeth, 16/32 pitch) (13 teeth,16/32 pitch) (14 teeth,12/24 pitch) (13 teeth, 8/16 pitch) (13 teeth, 8/16 pitch) (27 teeth,16/32 pitch) (15 teeth,16/32 pitch)

030 042 055 075 100 130 180 250 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ - ❍ ❍ ❍ ❍ ❍ ❍ - ❍ ❍ ❍ - ❍ ❍ - ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ● ● ● ● ● ● ● ●

Frame Size

030 042 055 075 100 130 180 250 ● ❍

● ❍

● ❍

● ❍

● ❍

● ❍

●

-

-

-

-

-

-

-

-

❍

❍

❍

❍ ❍

❍ ❍

❍ ❍

❍ ❍

❍ ❍

-

-

❍

❍

-

●

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Type Designation and Order Code (Continued) F

L

H

T

W

Y

Z

K

X X

Data Sheet Code On Request

K Charge Pressure Setting 18 = 18 bar (260 psi) ❍ 24 = 24 bar (350 psi) ● 30 = 30 bar (435 psi) ❍ 20 = 20 bar (290 psi) ❍ 28 = 28 bar (410 psi) ❍

Z High Pressure Setting, Port “B” 00 = no pressure 20 = 200 bar (2 900 psi) ❍ 32 = 320 bar (4 640 psi) ❍ regulating valves ❍ 23 = 230 bar (3 330 psi) ❍ 35 = 350 bar (5 070 psi) ❍ 14 = 140 bar (2 030 psi) ❍ 26 = 260 bar (3 770 psi) ❍ 38 = 380 bar (5 510 psi) ❍ 17 = 170 bar (2 460 psi) ❍ 29 = 290 bar (4 200 psi) ❍ 42 = 420 bar (6 090 psi) ●

Y High Pressure Setting, Port “A” W Special Hardware Features Frame Size GBA NNN

= See Port “B” 030 ● -

042 ● -

055 ● -

075 ● -

100 130 ● ● -

180 ●

250 ●

T Control Feed Orifice in Control Inlet 00 = no orifice 01 = ø 0.46 mm (.018 in.Dia) 02 = ø 0.66 mm (.026 in.Dia) 03 = ø 0.81 mm (.032 in.Dia)

❍ ❍ ❍ ●

H Charge Pump Displacement Frame Size A = 8 cm3 (0.50 cu.in./Rev.) B = 11 cm3 (0.69 cu.in./Rev.) C = 14 cm3 (0.86 cu.in./Rev.) D = 17 cm3 (1.03 cu.in./Rev.) E = 20 cm3 (1.20 cu.in./Rev.) F = 26 cm3 (1.60 cu.in./Rev.) H = 34 cm3 (2.07 cu.in./Rev.) J = 47 cm3 (2.82 cu.in./Rev.) K = 65 cm3 (3.90 cu.in./Rev.) L = external charge pump with internal relief valve

L Shaft Configuration C2 = C3 = C5 = C6 = C7 = C8 = F1 = S1 = T1 = T2 = T3 = T4 =

Frame Size

13 Teeth 16/32 pitch 15 Teeth 16/32 pitch 19 Teeth 16/32 pitch 21 Teeth 16/32 pitch 23 Teeth 16/32 pitch 27 Teeth 16/32 pitch 13 Teeth 8/16 pitch 14 Teeth 12/24 pitch 1.375 in. tapered 1.500 in. tapered 1.000 in. tapered 1.750 in. tapered

04 = ø 1.02 mm (.040 in.Dia) 05 = ø 1.37 mm (.054 in.Dia) 06 = ø 1.57 mm (.062 in.Dia) 09 = ø 2.34 mm (.092 in.Dia) 030 ❍ ● ❍

042 ❍ ● ❍

055 ❍ ● ❍ ❍

075 ❍ ● ❍ ❍

100 ❍ ● ❍ ❍

130 ❍ ❍ ● ❍

180 ❍ ● ❍

250 ❍ ● ❍

030 ❍ ● ❍ -

042 ● ❍ ❍ -

055 ● ● ❍ -

075 ● ● ❍ -

100 ● ❍ +● ❍ -

130 ● ❍ ❍

180 ● +❍ -

250 ● +❍ -

F Displacement Limitation 3 4

= no limiters = variable, limitation both sides ( factory set at max. displ.)

❍ ❍ ❍ ❍

● ❍

● = Standard ❍ = Option - = not available

+ = not recommended for front pump in tandem configurations 9

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Technical Specifications - Variable Displacement Pump Circuit Diagram and Nomenclature Variable displacement pump Figure 3: Variable displacement pump with charge pump and manual displacement control MA, clockwise rotation M4 M5

M3

Clockwise (CW) Rotation

Hydraulic Parameters A

M1

System Pressure Range, Input p1 (see page 12)

M2

B L1

Ports: A, B S L1, L2 M1, M2 M3 M4, M5

= = = = = =

S

L2

P001 008E

Main pressure lines Suction line - charge pump Case drain lines Gauge port for port "A“ and "B“ Gauge port - charge pressure Gauge port - servo pressure

Variable displacement pump: Charge pressure = see order code on page 9 Charge pump input pressure: Min. rated pressure = 0.7 bar (20.6 in Hg) absolute Min. allowable pressure, intermittent = 0.2 bar (5.9 in Hg) absolute

System Pressure Range, Output p 2(see page 12) Rated pressure : Max. Pressure :

420 bar 480 bar

(6 000 psi) (7 000 psi)

Case Pressure Max. Rated: Intermittent pressure:

(see page 12) 3 bar 5 bar

(40 psi) (75 psi)

Cold start

Design Hydraulic Fluid Axial piston pump of cradle swashplate design with variable displacement.

(see page 12)

Type of Mounting

Refer to SAUER-SUNDSTRAND publication, BLN-9887 or 697581. Refer to ATI-9101E for information relating to biodegradable fluids.

SAE flange, Size B, C, D, E (SAE J 744) mounting pad

Temperature Range1)

Pipe Connections

ϑ min = - 40 °C (- 40 °F) ϑ nenn = 104 °C (220 °F) ϑ max = 115 °C (240 °F)

Main pressure ports: SAE-Flange Twin ports, radial (all Frame Sizes) SAE-Flange Side ports, radial (055 / 075 / 100) Remaining ports: SAE straight thread O-ring boss

Direction of Rotation

(see page 12) intermittent, cold start intermittent

at the hottest point, e.g. drain line 1) Hydraulic fluid viscosity has to be considered

Fluid Viscosity Limits

Clockwise or counterclockwise (unidirectional).

Installation Position Installation position discretionary.

The housing must always be filled with hydraulic fluid.

mm2 /s (1 mm2/s = 1 cSt) ν min = 7 ν nenn = 12 - 60 ν max = 1 600

SUS (Saybolt Universal Second) 47 intermittent 66 - 278 rated viscosity 7 500 intermittent, cold start

Filtration Flow Direction See tables 12, 15, 17, 19, 20 on pages 25, 27, 28, 30, and 31.

10

Required cleanliness level: ISO 4406 Code 18/13 or better.

Refer to SAUER-SUNDSTRAND publication BLN-9887 or 697581 and ATI-9201E.

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Technical Data Table 1

Dimension

030

042

055

Frame Size 075

cm3

30

42

55

75

100

130

180

250

in3

1.83

2.56

3.35

4.57

6.10

7.93

10.98

15.25

min-1 (rpm)

500

500

500

500

500

500

500

500

min-1 (rpm)

4 200

4 200

3 900

3 600

3 300

3 100

2 600

2 300

min-1 (rpm)

4 600

4 600

4 250

3 950

3 650

3 400

2 850

2 500

Max. min-1 (rpm) Attainable *

5 000

5 000

4 700

4 300

4 000

3 700

3 150

2 750

Nm/bar in lb/1000 psi

0.48 290

0.67 410

0.88 530

1.19 730

1.59 970

2.07 1 260

2.87 1 750

3.97 2 433

Mass moment of inertia of the int. rotating parts

kg m2 lb • ft2

0.0023 0.0546

0.0039 0.0926

0.0060 0.1424

0.0096 0.2280

0.0150 0.3560

0.023 0.5460

0.0380 0.9020

0.0650 1.5430

Weight (with MA Control)

kg lb

28 62

34 75

40 88

49 108

68 150

88 195

136 300

154 340

100

130

180

250

Displacement

Minimum Input Rated * speed Maximum *

Theoretical Torque

* General Technical Specifications, see page 12

Determination of Nominal Pump Size Inch-System:

Metric-System: PD • PS • EV

Pump Q = output flow

Description: Vg • n • hv

gpm 231

Pump Qe = output flow

l/min 1 000 Vg • ∆p

PD • p Input torque

PT =

lbf•in 2 • π • ET

Input torque

Me =

PD • PS • p Input power

p

=

Qe • ∆p

Me • n hp

396 000 • ET

Nm 20 • π • hmh

Input power

Pe =

= 9 550

kW 600 • ht

Inch-System: PD = Pump displacement per rev.

PS = Hydrostatic pump speed p = Differential hydraulic pressure EV = Pump volumetric efficiency ET = Pump mechanical - hydraulic (Torque) efficiency Metric-System: Vg = Pump displacement per rev. ∆p = pHD - pND hv = Pump volumetric efficiency hmh = Pump mechanical -

in3 rpm psi

cm3 bar

11

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

General Technical Specifications Speed Range

Case Pressure

The Rated Speed is the highest speed recommended at full power condition at which normal life can be expected.

Under normal operating conditions, the maximum continuous case pressure must not exceed 3 bar (40 psi).

All other operating conditions (e.g. fluid viscosity and temperature, charge pressure) must be within recommended ranges.

Maximum allowable intermittent case pressure during cold start must no exceed 5 bar (75 psi).

Hydraulic Fluids Maximum Speed is the highest operating speed permitted and cannot be exceeded without reduction in the life of the product or risking immediate failure and loss of driveline power (which may create a safety hazard).

Braking Warning !

The loss of hydrostatic driveline power in any mode (e.g. acceleration, deceleration, or neutral mode of operation) may cause a loss of braking capacity. A braking system which is independent of the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop.

Maximum Attainable Speed requires approval from SAUER-SUNDSTRAND Application Engineering. Special unit hardware and/or special operating conditions may be required.

System Pressure Range System pressure is a dominant operating variable affecting hydraulic unit life. High pressure, which results from high load, reduces expected life in a manner similar to many mechanical assemblies such as engines and gearboxes.

The maximum pressure is the highest intermittent pressure allowed. It is determined by the max. machine load demand.

Ratings and data for Series 90 products are based on operating with premium hydraulic fluids containing oxidation, rust and foam inhibitors.

The following are suitable: - Premium turbine oils - API CD engine oils per SAE J183 - M2C33F or G automatic transmission fluids (ATF) - Dexron II (ATF) meeting Allison C3 or Caterpillar TO-2 - Certain agricultural tractor fluids (STOU) - Hydraulic fluids per DIN 51524, part 2 (HLP) - Hydraulic fluids per DIN 51524, part 3 (HVLP) Fire resistant fluids are also suitable at modified operating conditions. For more information see Sauer-Sundstrand publication BLN-9887 or 697581.

Refer to publication ATI-9101E for information relating to biodegradable fluids.

While fluids containing anti-wear additives are not necessary for the satisfactory performance of the Series 90 units, they are often required for associated equipment. These fluids must possess good thermal and hydrolytic stability to prevent wear, erosion and corrosion of the internal components.

It is not permissible to mix hydraulic fluids. Contact SauerSundstrand Application Engineering for more information.

Temperature Limits For petroleum based fluids, see page 10 for maximum allowable temperatures.

These temperature limits apply at the hottest point of the transmission, which is normally the case drain.

Maximum pressure is assumed to occur a small percentage of operating time, usually less than 2 % of the total.

Heat exchangers should be sized to keep the fluid within the limits.

Maximum pressure is normally the pressure relief valve setting. It is desirable to have a machine duty cycle with the percentage of time at various loads and speeds. An appropriate design pressure can be calculated by our application department from this information. This method of selecting operating pressure is recommended whenever duty cycle information is available.

Charge Pressure

12

The charge pressure setting listed in the Model Code is based on the charge flow across the charge pressure relief valve at fluid temperature of 50 °C (120 °F). The motor charge relief valve pressure setting is the pressure generated at a charge flow of 15 l/min (4 gpm).

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options Reservoir

Charge Pressure Filtration - Option R, T, P, L

The function of the reservoir is to remove air and to provide make up fluid for volume changes associated with fluid expansion or contraction, possible cylinder flow, and minor leakage.

The pressure filter can be integrally mounted directly on the pump or mounted remotely, Figure 5, for ease of servicing.

A 200 mesh screen, located in the reservoir or the charge inlet line, is recommended when using charge pressure filtration. This system requires a filter capable of withstanding charge pressure.

The reservoir should be designed to accommodate maximum volume changes during all system operating modes and to promote deaeration of the fluid as it passes through the tank.

A suggested minimum reservoir volume equal to 1/2 charge pump flow/min. This allows 30 seconds fluid dwell for removing entrained air at the maximum return flow. This is usually adequate to allow for a closed reservoir (no breather) in most applications. The reservoir outlet to the charge pump inlet should be above the bottom of the reservoir to take advantage of the gravity separation and prevent large foreign particles from entering the charge inlet line.

Pressure filters with Beta 10 ratio of 10-20 have been shown to provide acceptable performance.

Figure 5: Charge pressure filtration

Screen

Hydraulic fluid reservoir Adjustable Charge pressure relief valve

The reservoir inlet (fluid return) should be positioned so that the flow to the reservoir is discharged below the normal fluid level, and also directed into the interior of the reservoir for maximum dwell and efficient deaeration.

Suction Filtration - Option S The suction filter is placed in the circuit between the reservoir and the inlet to the charge pump, as shown in Figure 4. For closed loop transmissions with controlled reservoir ingression a filter having a Beta 10 ratio of 1.5 to 2 has been shown to provide acceptable performance.

Charge pump

to low pressure side and control

To pump case

Filter P000 798E

The use of a filter contamination monitor is recommended.

Displacement Limiter - Option 4

Figure 4: Suction filtration

All Series 90 pumps are designed with optional mechanical displacement (stroke) limiters (Figure 6).

ManoVacuummeter

The maximum displacement of the pump can be set using the hexagon adjustment screw.

Hydraulic fluid reservoir

Figure 6: Displacement limiter Filter

Displacement limiter

Charge pump

to low pressure side and control

Adjustable Charge pressure relief valve

To pump case

Servo cylinder P000 797E

Servo piston

P000 799E

13

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Multi-function Valve Both the pressure limiter sensing valves and relief valves are built into the multi-function valves located in the pump endcap. The sequenced pressure limiter/high pressure relief valve system in the Series 90 provides an advanced design of overpressure protection.

The pressure limiter avoids system overheating associated with relief valves and the sequenced relief valves are available to limit pressure spikes which exist in severe operating conditions.

Because the relief valves open only during extremely fast pressure spike conditions, heat generation is minimized during the short time that they might be open.

For some applications, such as dual path vehicles, the pressure limiter function may be defeated such that only the relief valve function remains. The relief response is approximately 20 ms whether used with or without the pressure limiter function.

Figure 7: Circuit diagram M4 M5

M3

Clockwise (CW) Rotation

M1

A

M2

B L1

S

L2

P001 008E

Overpressure Protection The Series 90 pumps are designed with a sequence pressure limiting system and high pressure relief valves (Figure 8). When the preset pressure is reached, the pressure limiter system acts to rapidly destroke the pump so as to limit the system pressure. Typical response is less than 90 ms. For unusually rapid load application, the high pressure relief valve is available to also limit the pressure level. The pressure limiter sensing valve acts as the pilot for the relief valve spool, such that the relief valve is sequenced to operate above the pressure limiter level.

Pressure Limiter Operation Referring to Figure 8 when set pressure is exceeded the pressure sensing valve (A) flows oil through passage (B) and across an orifice in the control spool raising pressure on the servo which was at low pressure. Servo pressure relief valves (C) limit servo pressure to appropriate levels.

The pressure limiter action cancels the input command of the displacement control and tends to equalize servo pressure. Swashplate moments assist to change the displacement as required to maintain system pressure at the set point.

Figure 8: Multi-function valve, pressure limiter, pressure regulation, option 1 To control Multifunction valve

A Servo piston

Bypass hex adjustment

Port "A" B Servo pressure relief valves Port "B"

C

Servo piston Charge pressure relief valve

Multifunction valve

14

P000 800E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Bypass Function

Speed Sensor

In some applications it is desirable to bypass fluid around the variable displacement pump when pump shaft rotation is either not possible or not desired. For example, a “down” vehicle may be moved to a service or repair location or winched on a trailer without operating the prime mover.

Series 90 pumps are available with an optional speed sensor for direct measurement of pump input speed.

Series 90 pumps are designed with a bypass function. The bypass is operated by mechanically rotating the bypass hex on both multi-function valves three (3) turns counterclockwise (CCW). Refer to figures 8 on page 14.

This connects working loop A and B and allows fluid to circulate without rotating the pump and prime mover.

Caution !

Bypass valves are intended for moving a machine or vehicle for very short distances at very slow speeds.

They are NOT intended as “tow” valves.

A special magnetic speed ring is pressed onto the outside diameter of the cylinder block and a Hall effect sensor is located in the pump housing. The sensor accepts supply voltage and outputs a digital pulse signal in response to the speed of the ring. The output changes its high/low state as the north and south poles of the permanently magnetized speed ring pass by the face of the sensor. The digital signal is generated at frequencies suitable for microprocessor based controls.

This sensor will operate with a supply voltage of 4.5 to 15 VDC, and requires a current of 12 mA at 5.0 VDC under no load. Maximum operating current is 30 mA at 1 kHz. Maximum operating frequency is 15 kHz. Output voltage in “High State” (VOH) is sensor supply voltage minus 0.5 VDC, minimum. Output voltage in “Low State” (VOL) is 0.5 VDC, maximum.

The sensor is available with a Packard Weather-Pack 3 or 4-pin sealed connector or a Turck Eurofast M12x1 4-pin connector.

Table 2: Pulse frequency

-

Frame Size

030

042

055

075

Pulses per revolution

43

48

52

58

Frame Size

100

130

180

250

Pulses per revolution = not available

63

69

-

-

Figure 11: Speed sensor SAUER-SUNDSTRAND Mating Parts Kit Part No. K08620 (3 pin) Part No. K03384 (4 pin)

Packard Weather-Pack 3 or 4 Pin Shroud Connector Red White Black Green

A B C D

Supply Voltage + Speed Signal Gnd Common Direction (Option)

SAUER-SUNDSTRAND Mating Parts Kit Part No. K14956 or Ident. No. 500724 (straight) Part No. K14957 or Ident. No. 500725 (right angle)

Turck Eurofast 4 Pin Connector Pin 2 Direction (Option)

Keyway (Ref) Pin 1 Supply Voltage +

"Y" Pin 3 Speed Signal P001 459E

Pin 4 Gnd Common 12.7 [0.50] Wrench Flats View "Y"

15

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Charge Pump Charge flow is required on all Series 90 pumps applied in closed circuit installations to make up internal leakage, maintain a positive pressure in the main circuit, provide flow for cooling, filtration, replace any leakage losses from external valving or auxiliary systems and provide flow and pressure for the control system.

Rated charge pressure must be maintained at its specified pressure under all conditions of operation to prevent damage to the transmission.

Many factors influence the charge flow requirements and the resulting charge pump size selection. These factors include system pressure, pump speed, pump swashplate angle, type of fluid, temperature, size of heat exchanger, length and size of hydraulic lines, control response characteristics, auxiliary flow requirements, hydrostatic motor type, etc. When initially sizing and selecting hydrostatic units for an application, it is frequently not possible to have all the information necessary to accurately evaluate all aspects of charge pump size selection.

The following procedure will assist the designer in arriving at an initial charge pump size selection for a typical application, it is emphasized that unusual application conditions may require a more detailed review of charge pump sizing.

Testing is recommended to verify that adequate charge pressure is maintained under actual operating conditions.

Charge Pump Sizing / Selection The first step in approximating the proper size charge pump is to determine the charge flow requirements for the total system under different modes of operation.

The total charge flow requirements must include the flow requirements of the pump/ motor(s) and all auxiliary components which remove fluid from the system.

The charge pump sizing must consider the pump and motor(s) operating at their maximum operating pressure and also when the pump is operating at minimum speed.

A) Charge Flow Requirement - Pump Determine the pump speed, minimum and operating, and maximum system pressure at these speeds. If the pump speed is less than 1 000 min -1, use the data published for 1 000 min-1 .

Referring to the figure 12 on page 17, “Charge Flow Requirement - Pump,” determine the flow factor Fp at the desired flow requirement for the pump:

Fp x Frame Size x 3.785 = l/min, Charge Flow Requested - Pump 75 Fp x Frame Size Qp = = gpm, Charge Flow Requested - Pump 75 Qp =

Frame Size in (cm3/rev)

16

B) Charge Flow Requirements - Motor Determine the motor speeds and maximum system pressure. Referring to the accompanying figure 13, “Charge Flow Requirement - Motor”, determine the flow factor of the motor Fm. Using the following equation, determine charge flow requirements for the motor Qm. Qm = Fm x Frame Size x 3.785 = l/min, Charge Flow Requested - Motor 75 Fm x Frame Size Qm = = gpm, Charge Flow Requested - Motor 75 C) Total Charge Flow Requirements The total charge flow requirements Qt is the sum of the flow requirements of each of the components in system; namely: Qt= Qp + Qm1 + Qm2 + Qaux = l/min, (Tot. Charge Flow Req.) D) Determine Required Charge Pump Size ● Referring to the accompanying figure 14, “Charge Pump Flow”, select the correct charge pump requirements determined above and the pump input speed. ● Refer to the “Charge Pump Size/ Availability and Speed Limits” chart to verify that the maximum speed limit of the selected charge pump is not be exceeded. ● If the desired size noted in the chart is not available, always select the next size larger charge pump. ● If the standard size charge pumps are not adequate to meet the flow requirements of the system, a Gear Pump can be mounted to the auxiliary mounting pad to provide the necessary additional flow.

System features and conditions which may invalidate the above calculations include (but not limited to): ● continuous operation at low input speeds (< 1 500 min-1 ) ● high shock loadings ● excessively long system lines (> 3 m [9.8 ft]) ● auxiliary flow requirements ● use of high torque low speed motors If any of the above conditions exist, contact SAUERSUNDSTRAND Application Engineering.

Table 3: Available charge pump sizes and speed limits Charge pump size cm3 (in3) A 8 (0.50) B 11 (0.69) C 14 (0.86) D 17 (1.03) E 20 (1.20) F 26 (1.60) F 26 (1.60) H 34 (2.07) J 47 (2.82) K 65 (3.90)

Rated speed min-1 (rpm) 4 200 4 200 4 200 3 900 3 600 3 300 3 100 (130 pump) 3 100 2 600 2 300

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Charge Pump Maps Charge Pressure : Case Drain: Reservoir Temperature:

20 bar (290 psi) 80 °C (8.2 cSt) 180 °F (53 SUS) 70 °C (11 cSt) 160 °F (63 SUS)

Figure 12: Charge flow requirements - pump

Figure 13: Charge flow requirements - motor

42 00 m m in - in -1 1 (rp (rp m m ) )

6

5

5

)

00

-1 (

3

in

4

Flow Factor Fm

36

Flow Factor Fp

(rp

) in m pm 00 -1 (r 30 in m) m rp 00 -1 ( 20 min 00 10

4

2

00

1000 0

2000

3000

4000

100 200 System Pressure

5000

300

)

pm

-1 (r

3

in 0m

0

36

2 3000

6000 ∆p psi

0

∆p bar

0

400

m

42

1000

2000

3000

min

)

-1 (rpm

) -1 (rpm

2000

min

1000

min

1

1

0

)

m

rp

m

-1

)

-1 (rpm

5000 6000 ∆p psi

4000

400 ∆p bar

300

100 200 System Pressure

P001 010E

P001 011E

Figure 14: Charge pump output flow

v

6

v

.9 i

/Re

•3

3

ev

.9 i n

3

2.0

/R in 3

in 3 /R ev

.60

.2 3 •

ev

3 /R

•1

3

26

cm

3

•1

.07

20

cm

•2 cm 3

3.0

2

1

10

4.0

3

HP

9

5.0

1.

cm 3 •2

in

47

v

Re

3 /

03

34

in

kW

20

.

•1

4

ev 3 /R 3 • ev cm in 0 6 3 /R 2 cm .8 in 9 17 3 • 0 0.6 cm 3 • ev 14 cm in3 /R 1 3 • 0.5 1 m c 8 3

gallons/min

l/min

30

cm 3

.6 0 •1

3

cm 26

2

12

65

.07 •2

3

cm 34

6.0 v Re

3 /

15

50 40

5

in 3 /R ev

ev

n 3/ Re

v

•2 cm 3

60

7.0

ev

18

in 3 /R

65 c

70

in 3 /R

21

.9

80

47

m3•

24

90

in 3 /Re

3.9 in 3/ Re

v

Figure 15: Charge pump power requirements

03

1.

in

ev

3 /R

in

ev

6 3 /R cm 0.8 in 17 3 • .69 cm 3 • 0 14 cm 11 v Re n3 / .5 i 3•0 m 8c

1.0

1 0

0 0

500 1000 Speed

P000 802E

2000 min -1 (rpm)

3000

4000 4500

0

500 1000 Speed

2000

3000

4000 4500

min -1 (rpm) P000 803E

17

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Shaft Availability and Torque Ratings Figure 16: Torques for auxiliary mounting pads

Third Stage

Second Stage

First Stage

Me1 for the first pump

Me2 for the second pump

Me Input Torque

Me3 for the next pump P001 407E

Table 4: Shaft availability and torque ratings Shaft Description

Option Code

Frame Size Availability Rated Torque [Nm (lbf•in)] 030

042

055

075

100

130

180

250

13 teeth 16/32 pitch Spline

C2

260 (2 300)

—

—

—

—

—

—

—

15 teeth 16/32 pitch Spline

C3

530 (4 700)

530 (4 700)

—

—

—

—

—

—

19 teeth 16/32 pitch Spline

C5

—

900 (8 000)

—

—

—

—

—

—

21 teeth 16/32 pitch Spline

C6

—

—

1 130 (10 000)

—

—

—

—

—

23 teeth 16/32 pitch Spline

C7

—

—

—

1 580 (14 000)

1 580 (14 000)

—

—

—

27 teeth 16/32 pitch Spline

C8

—

—

—

—

—

2 938 (26 000)

2 938 (26 000)

3 600 (32 000)

13 teeth 8/16 pitch Spline

F1

—

—

—

—

1 810 (16 000)

1 810 (16 000)

+

+

14 teeth 12/24 pitch Spline

S1

—

—

735 (6 500)

735 (6 500)

— + 18

= Shaft option not available = not recommended for front pump in tandem configurations

+

735 (6 500)

—

1 810 (16 000) —

1 810 (16 000) —

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Auxiliary Mounting Pads Table 5: Auxiliary mounting pad specifications Mounting Pad Size

Option Code

Internal Spline Size

Spline Engagement min. mm (in.)

Rated Torque Nm (lbf•in)

SAE A

A

9 teeth 16/32 pitch

13.5 (.53)

107 (950)

SAE B

B

13 teeth 16/32 pitch

14.2 (.56)

256 (2 200)

SAE B-B

V

15 teeth 16/32 pitch

16.1 (.63)

347 (2 990)

SAE C

C

14 teeth 12/24 pitch

18.3 (.72)

663 ❊ (5 700)❊

SAE D

D

13 teeth 8/16 pitch

20.8 (.82)

1 186 (10 500)

SAE E

E

13 teeth 8/16 pitch

20.8 (.82)

1 637 (14 500)

SAE H

H

27 teeth 16/32 pitch

27.0 (1.06)

22 362 (19 805)

❊ For the 055 pump the rated torque is limited to 445 Nm (3 830 lbf•in)

Mating Auxiliary Pumps

Pump mounting flanges and shafts with the dimensions noted below are compatible with the auxiliary mounting pads on the Series 90 pumps.

Figure 17

D

Coupling

B max.

(+.000) (-.002)

Spline engagement for rated torque

0

F min.

ø P (Dia) -0.05

E Mounting Flange (Ref)

0.8 (.03) R Preferred P001 462E

Table 6: Auxiliary Pump Dimensions [mm (in.)]

Flange

øP

B

Size

Dia

max.

D

E

F min.

SAE

82.55

7.4

32

13.5

A

(3.250)

(.29)

(1.26)

(.53)

SAE

101.6

10.7

41

14.2

B

(4.000)

(.42)

(1.61)

(.56)

SAE

101.6

10.7

46

B-B

(4.000)

(.42)

(1.81)

SAE

127.0

14.3

56

C

(5.000)

(.56)

(2.20)

16.1 See Dimensions

The accompanying drawing provides the dimensions for the auxiliary pump mounting flange and shaft.

(.63) 18.3 (.72)

SAE

152.4

14.3

75

D

(6.000)

(.56)

(2.95)

(.82)

20.8

SAE

165.1

18.0

75

20.8

E

(6.500)

(.71)

(2.95)

(.82)

SAE

165.1

18.0

75

27.0

H

(6.500)

(.71)

(2.95)

(1.06)

19

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

External Load Limits Shaft Loads Figure 18: External shaft load orientation

Normal bearing B10 life in hours is indicated in the accompany table at a continuous differential pressure of 240 bar (3 500 psi), 1 800 min-1 (rpm) shaft speed, maximum displacement, and no external shaft side load. The data below is based on a 50 % forward, 50 % reverse duty cycle, standard charge pump size, and standard charge pressure.

L 0° Re

Re 90° Re

270° Re T out

T in

Table 7: Bearing life Frame Size

Bearing Life - B10 hrs

030

10 040

042

18 060

055

22 090

075

22 970

100

22 670

130

17 990

180

16 150

250

12 020

180° Re

Pump swashplate

P000 801E

Maximum Allowable Radial Side Load, Re = Me / L All external shaft loads will have an effect on bearing life. In applications where external shaft loads can not be avoided, the impact on bearing life may be minimized by orientating the load to the 90 or 270 degree position.

Please contact Sauer-Sundstrand Application Engineering for an evaluation of unit bearing life if:

Series 90 pumps are designed with bearings that can accept external radial and thrust loads. The external radial shaft load limits are a function of the load position and orientation, and the operating conditions of the unit.

The maximum allowable radial side load (Re), based on the maximum external moment (Me) and the distance (L) from the mounting flange to the load, may be determined from the table and diagram below. Thrust (axial) load limits are also shown.

•

continuously applied external loads exceed 25 % of the maximum allowable radial side load, Re.

•

the pump swashplate is positioned on one side of center all or most of the time.

•

the unit bearing life (B10) is critical.

Tapered input shafts or “clamp-type” couplings are recommended for applications where radial shaft side loads are present.

Table 8: External shaft load Frame Size

030

042

055

075

100

130

180

250

Max. Allowable External Loads 1) External Moment (Me)

Nm lbf•in

112 991

126 1 114

101 893

118 1 043

126 1 114

140 1 238

161 1 424

176 1 556

2) Max. Shaft Thrust in (T in)

N lbf

2 900 652

2 635 592

3 340 750

4 300 966

5 160 1 160

5 270 1 184

7 000 1 573

7 826 1 759

3) Max. Shaft Thrust out (T out)

N lbf

1 330 299

1 020 229

910 204

930 209

1 000 224

688 154

1 180 265

1 693 380

20

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

External Load Limits (Continued) Mounting Flange Loads Adding tandem mounted auxiliary pumps and/or subjecting pumps to high shock loads may result in excessive loading of the mounting flange. The overhung load moment for multiple pump mounting may be estimated as shown in the accompanying figure.

Figure 19: Overhung load moments

CG Pump 2

Auxiliary Pad

Mounting Flange

CG Pump 1

Estimating Overhung Load Moments W = L =

Weight of pump [kg] Distance from mounting flange to pump center of gravity (refer to pump installation drawings) [m] MR = GR (W1L1 + W2L2 + ... + WnLn) MS = GS (W1L1 + W2L2 + ... + WnLn)

Where: MR MS GR GS

L1 L2

= = = =

Rated load moment [Nm] Shock load moment [Nm] Rated (vibratory) acceleration ("g"s) * [m/s2 ] Maximum shock acceleration ("g"s) * [m/s2]

P001 290E

* Calculations will be carried out by multiphying the gravity (g = 9.81 m/s2 ) with a given factor.

This factor depends on the application.

Allowable overhung load moment values are shown in the accompanying table. Exceeding these values will require additional pump support.

Table 9: Allowable overhung load moments Frame Size

Rated Moment MR

Shock Load Moment MS

Nm

lbf•in

Nm

lbf•in

030

860

7 600

3 020

26 700

042

860

7 600

3 020

26 700

055

1 580

14 000

5 650

50 000

075

1 580

14 000

5 650

50 000

100

1 580

14 000

5 650

50 000

130

3 160

28 000

10 730

95 000

180

6 070

54 000

20 600

182 000

250

6 070

54 000

20 600

182 000

21

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Efficiency Graphs Figure 20 shows typical overall and volumetric efficiencies for series 90 pump with system pressures of 210 and 420 bar (3 000 and 6 000 psi) speed corresponding to rated speed, and a fluid viscosity of 8 mm2/s (cSt) {50 SUS}.

Figure 20: Overall efficiency and volumetric efficiency at maximum displacement 100 η v = 210 bar (3000 psi)

95

000

ar (3

η t = 210 b

i)

0 ps

600

90

Efficieny %

psi)

r( 0 ba

2

ηv = 4

i)

0 ps

600

r( 0 ba

η t = 42 85

80 0

50

25

75

100 P000 791E

Speed % of Rated Continuous Speed

The following performance maps show typical overall efficiencies for series 90 pumps with system pressures of 70 to 420 bar (1 000 to 6 000 psi) and at 2/3 of its rated speed varying between 1/4 to maximum displacement (Figure 22).

These efficiency maps can be used for all frame sizes.

Figure 22: Pump overall efficiency at 2/3 rated speed

420

6000

350

92% 210

2000

140

93% bar

psi

3000

1000

70

0

0 0

P000 793E

22

25 50 75 Speed % of Rated Continuous Speed

100

psi

System Pressure

280

4000

6000

420

5000

350

4000

280

85

η t

=

0.

η t=

90%

3000

bar

5000

0.6

85%

η t= 0 η .65 t= η 0.7 t= 0.7 5 η t= 0.8

Figure 21: Overall efficiency at max. displ. of pump

9

η t

=

0.

210

2000

140

0

0 0

25 75 50 Displacement in percent of maximum displacement

100

P000 794E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Notes

23

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description 3-Position (FNR) Electric Control, Options DC, DD The 3-Position (FNR) control uses an electric input signal to switch the pump to a full stroke position.

Table 10: Electric input signal direct current Configuration

b

DC

12 VDC

DD

24 VDC

Figure 23.1: 3-Position electric control hydraulic schematic "B"

"0"

"A" Figure 24: Solenoid Connector

To Servo Piston S1

Solenoid plug face for DIN 43650 Connector

S2

a

SAUER-SUNDSTRAND Mating Parts Kit Part No. K09129

b

not connected

T P From Charge

S1 = Servo Side 1 S2 = Servo Side 2

P001 409E

Figure 23.2: Pump displacement vs electrical signal 100 % Displacement

b

Voltage VDC "0"

-b

100 % P001 408E

24

1

2

Voltage between terminals 1 and 2 P001 473E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) 3-Position (FNR) Electric Control, Options DC, DD (Continued) Response Time

Table 12: Pump output flow direction vs. control voltage

The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

Input Shaft Rotation

A range of orifice sizes is available for the Series 90 Electric Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

CW

CCW

Signal at Magnet

a

b

a

b

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations

Typical response times between neutral and full flow at the following conditions: ∆p = Temperature = Charge Pressure =

210 bar 50 °C 24 bar

(3 000 psi) (122 °F) (340 psi)

Table 11: Typical response times Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 1.0

25

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Electric Displacement Control (EDC), Options KA, KP The electric displacement control uses an electrohydraulic Pressure Control Pilot valve to control the pilot pressure.

The Pressure Control Pilot valve converts an electrical input signal to a hydraulic input signal to operate a 4-way servo valve, which ports hydraulic pressure to either side of a double acting servo piston. The servo piston tilts the cradle swashplate, thus varying the pump´s displacement from full displacement in one direction to full displacement in the opposite direction. The control has a mechanical feedback mechanism which moves the servo valve in relation to the input signal and the angular position of the swashplate. The electrical displacement control is designed so the angular rotation of the swashplate (pump displacement) is proportional to the electrical input signal.

Due to normal operating force changes, the swashplate tends to drift from the position preset by the machine operator. Drift, sensed by feedback linkage system connecting the swashplate to the control valve, will activate the valve and supply pressure to the servo piston, maintaining the swashplate in its preset position.

Figure 25: Electric displacement control hydraulic schematic Manual Override To Servo Piston

S2

S1

Swashplate Feedback

"B"

"0"

X2 X1

T P From Charge

Features and Benefits of the Electric Control: • The electric displacement control is a high gain control: With only a small change of the input current, the servo valve moves to a full open position thus porting maximum flow to the servo cylinder.

• Oil filled pilot valve case lengthens control life by preventing moisture ingression and dampening component vibrations.

P000 810E

Figure 26: Cross-section of electric displacement control valve

• All electrical displacement controls are equipped with dual coil pilot valves. The user has the option of using a single coil or both coils (in series or parallel).

• Internal mechanical stops on the servo valve allow rapid changes in input signal voltages without damaging the control mechanism.

"A"

X2

Electric Input Signal

P C P X1

• Precision parts provide repeatable accurate displacement settings with a given input signal.

• The swashplate is coupled to a mechanism. The control valve hydraulically connects the ends of the servo piston to drain when an electric input signal is not present.

• These features result in: - Simple, low cost design.

- Pump will return to neutral after prime mover shuts down.

- Pump returns to neutral if external electrical input signal fails or if there is a loss of charge pressure.

26

T S2 P S1 T

S1 = Servo Side 1 S2 = Servo Side 2

P000 809

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Electric Displacement Control (EDC), Options KA, KP (Continued) Table 13 Coil Configuration

a mA

b mA

Single coil Dual coil

14 ± 5 7±3

85 ± 18 43 ± 9

A & B or C & D A&D

85 ± 18

(C B Common) AC&BD

in series Dual coil parallel

14 ± 5

Pin Connections

Maximum input current under any condition: 250 mA Coil resistance at 24 °C (75 °F): A - B coil → 20 Ω C - D coil → 16 Ω Figure 27: Pump displacement vs electrical signal current

Displacement

100 %

-b

Response Time The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

A range of orifice sizes is available for the Series 90 Electric Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Typical response times between neutral and full flow at the following conditions: ∆p = 210 bar (3 000 psi) Temperature = 50 °C (122 °F) Charge Pressure = 24 bar (340 psi) Table 14: Typical response times

-a

Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 1.0

Current mA "0" a

b

100 % P001 015E

Figure 28: Connectors

Table 15: Pump output flow direction vs. control current EDC using a Single Coil or Dual Coils in Parallel (A and C Common, B and D Common)

MS Connector (Option EA) MS 3102C-14S-2P D C

A B

SAUER-SUNDSTRAND Mating Parts Kit Part No. K08106 or Ident. No. 615062

Packard Weather-Pack (Option EP) 4-way shroud connector

CW

Input Shaft Rotation

CCW

Positive Current to Term.

A or C

B or D

A or C

B or D

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

EDC using Dual Coils in Series (B and C Common)

B C D

CW

Input Shaft Rotation

A SAUER-SUNDSTRAND Mating Parts Kit Part No. K03384 (Female Terminals)

P001 464E

CCW

Positive Current to Term.

A

D

A

D

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations 27

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Hydraulic Displacement Control (HDC), Option HF The hydraulic displacement control uses a hydraulic input signal to operate a 4-way servo valve, which ports hydraulic pressure to either side of a double acting servo piston. The servo piston tilts the cradle swashplate, thus varying the pump´s displacement from full displacement in one direction to full displacement in the opposite direction. The control has a mechanical feedback mechanism which moves the servo valve in relation to the input signal and the angular rotation of the swashplate. The hydraulic displacement control is designed so the angular position of the swashplate (pump displacement) is proportional to the hydraulic input signal pressure. Due to normal operating force changes, the swashplate tends to drift from the position preset by the machine operator. Drift, sensed by feedback linkage system connecting the swashplate to the control valve, will activate the valve and supply pressure to the servo piston, maintaining the swashplate in its preset position.

Figure 30: Cross-section of hydraulic displacement control valve Hydraulic Signal Inputs X1

X2

T S2 P S1 T P000 807

S1 = Servo Side 1 S2 = Servo Side 2 Control Signal Requirements Maximum allowable signal pressure is 60 bar (870 psi).

Features and Benefits of the Hydraulic Control: • The hydraulic displacement control is a high gain control: With only small change of the input signal, the servo valve moves to a full open position porting maximum flow to the servo cylinder.

• Internal mechanical stops on the servo valve allows rapid changes in input signal pressure without damaging the control mechanism.

Table 16: Hydraulic signal pressure range 3 ± 0.5 bar 11 ± 0.5 bar

a b

Figure 31: Pump displacement vs input signal pressure 100 % Displacement

• Precision parts provide repeatable, accurate displacement settings with a given input signal.

• The swashplate is coupled to a mechanism. The control valve hydraulically connects the ends of the servo piston to drain when an electric input signal is not present.

• These features result in: - Simple - low cost design.

- Pump will return to neutral after prime mover shuts down.

- Pump returns to neutral if there is a loss of input signal pressure or if there is a loss of charge pressure.

43 ± 6 psi 160 ± 6 psi

-b

-a

Signal Pressure

"0" a

b

Figure 29: Hydraulic displacement control hydraulic schematic 100 %

To Servo Piston S2

X1

Input Signal Pressure Swashplate Feedback

P001 014E

S1 Input Signal Pressure

Table 17: Pump output flow direction vs. control pressure X2

T P From Charge

Input Shaft Rotation

CW

CCW

Control Pressure to Port

X2

X1

X2

X1

Port A Flow

In

Out

Out

In

Port B Flow

Out

In

In

Out

Refer to dimensions for port locations P000 808E

28

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Hydraulic Displacement Control (HDC), Option HF (Continued) Response Time The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

A range of orifice sizes is available for the Series 90 Hydraulic Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Typical response times between neutral and full flow at the following conditions: ∆p = 210 bar (3 000 psi) Temperature = 50 °C (122 °F) Charge Pressure = 24 bar (340 psi)

Table 18: Typical response times Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 1.0

Manual Displacement Control (MDC), Options MA, MB The manual displacement control device converts a mechanical input signal to a hydraulic signal that tilts the cradle swashplate through an angular rotation varying the pump`s displacement from full displacement in one direction to full displacement in the opposite direction.

The manual displacement control has a mechanical feedback mechanism which moves a servo valve in the proper relationship to the input signal and the angular position of the swashplate.

The manual displacement control is designed so that the angular rotation of the swashplate is proportional to the mechanical input signal. The control is designed with an internal override mechanism which allows the mechanical input to be moved at a faster rate than the movement of the swashplate without damage to the control.

Features and Benefits of the Manual Control: • Precision parts provide repeatable, accurate displacement settings with a given input signal.

• The manual displacement control is a high gain control: With only small movement of the control handle (input signal), the servo valve moves to full open position porting max. flow to the servo cylinder. This is a high response system with low input force.

• The integral override mechanism allows rapid changes in input signal without damaging the control mechanism.

• Precision parts provide repeatable, accurate displacement settings with a given input signal.

• A double-acting servo piston is coupled to a spring centering mechanism. The servo control valve is spring centered such that with "no input signal" the servo valve is open centered and thus no fluid is ported to the servo cylinder.

• These features result in: - Pump will return to neutral after prime mover shuts down.

- Pump will return to neutral if external control linkage fails at the control handle or if there is a loss of charge pressure.

Figure 32: Manual displacement control hydraulic schematic "B"

"0"

"A"

To Servo Piston S2

Swashplate Feedback

S1

T P From Charge

P000 805E

Figure 33: Cross-section of manual displacement control valve

Control Handle Input Signal

T S2 P S1 T P000 804E

S1 = Servo Side 1 S2 = Servo Side 2 29

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Manual Displacement Control (MDC), Options MA, MB (Continued) External Control Handle Requirements Torque required to move handle to maximum displacement is 0.68 to 0.9 Nm (6 to 8 lbf•in).

Torque required to hold handle at given displacement is 0.34 to 0.57 Nm (3 to 5 lbf•in).

Torque required to overcome the override mechanism is 1.1 to 2.3 Nm (10 to 20 lbf•in) with the maximum torque required for full forward to full reverse movement.

Maximum allowable input torque is 17 Nm (150 lbf•in)

Figure 34: Pump displacement vs control lever rotation

Table 19: Pump output flow direction vs. control handle rotation

"A"

Input Shaft Rotation Handle Rotation

CW

CCW

Displacement

100 %

-24°÷ 30° *

-2° "0"

Lever Rotation 2°

-35° max.

35° max.

"B" 24°÷ 30° *

"A" (CCW) "B" (CW) "A" (CCW) "B" (CW)

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations 100 %

Response Time see next page.

* Actual angle see dimensions.

P001 013E

Non-linear Manual Displacement Control (MDC), Option NA The manual displacement control device converts a mechanical input signal to a hydraulic signal that tilts the cradle swashplate through an angular rotation varying the pump`s displacement from full displacement in one direction to full displacement in the opposite direction.

The manual displacement control has a mechanical feedback mechanism which moves a servo valve in the proper relationship to the input signal and the angular position of the swashplate.

The manual displacement control is designed so that the angular rotation of the swashplate is progressive to the mechanical input signal. The control is designed with an internal override mechanism which allows the mechanical input to be moved at a faster rate than the movement of the swashplate without damage to the control.

Figure 35: Non-linear manual displacement control hydraulic schematic "B" "0" "A" To Servo Piston S2

Swashplate Feedback

• These features result in: - Pump that is returned to neutral after prime mover shut down.

- Pump that is returned to neutral if external control linkage fails at the control handle.

S1

- If there is loss of charge pressure pump returns to neutral.

T P From Charge P001 412E

30

Features and Benefits of the Non-linear Manual Control: • The manual displacement control is a high gain control: With only small movement of the control handle (input signal), the servo valve moves to full open position porting max. flow to the servo cylinder. This is a high response system with low input force.

• Low spool dead band results in good down hill and braking capability.

• Smooth acceleration is possible.

• The integral override mechanism allows rapid changes in input signal without damaging the control mechanism.

• Precision parts provide repeatable, accurate displacement settings with a given input signal.

• A double-acting servo piston is coupled to a spring centering mechanism. The servo control valve is spring centered such that with "no input signal" the servo valve is open centered and thus no fluid is ported to the servo cylinder.

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Non-linear Manual Displacement Control (MDC), Option NA (Continued) Figure 36: Cross-section of non-linear manual displacement control valve

Response Time (applies also for Option MA and MB) The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

A range of orifice sizes is available for the Series 90 Manual Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Control Handle Input Signal

T S2

P

S1

S1 = Servo Side 1 S2 = Servo Side 2

P001 410E

External Control Handle Requirements Torque required to move handle to maximum displacement is 0,68 to 0,9 Nm (6 to 8 lbf•in).

Maximum allowable input torque is 17 Nm (150 lbf•in).

Figure 37: Pump displacement vs control lever rotation

Displacement

100 %

"A"

-31°

"B" 3°

-33° max.

33° max.

Lever Rotation

-3° "0"

31°

Typical response times between neutral and full flow at the following conditions: ∆p = 210 bar (3 000 psi) Temperature = 50 °C (122 °F) Charge Pressure = 24 bar (340 psi)

Table 21: Typical response times Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 9.0

100 % P001 411E

Table 20: Pump output flow direction vs. control handle rotation Input Shaft Rotation Handle Rotation

CW

CCW

"A" (CCW) "B" (CW) "A" (CCW)

"B" (CW)

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations 31

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 030 mm (in.)

Figure 38: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8 101.8 (4.01) 38 (1.5)

Coupling may not protrude beyond this surface

25

length of full spline

7.9 (.98) (.31)

Splined Shaft Option C3

B

CCW

9.7 (.38) 12.2 (.48)

Ports A and B 1/2 -6000 psi Split Flange Boss per SAE J518 (Code 62) 5/16-18UNC-2B 20 (.787) min. Full Thread

91.55 (3.60) Port L2

40.49 (1.59)

Approx center of gravity

100 (3.94) 176.4 (6.94)

185.4 (7.29)

Gauge port M1 System pressure A 9/16-18UNF-2B

Gauge port M4 Servo pressure 9/16-18UNF-2B

"Z"

SHAFT SPLINE DATA: Pitch Dia = 23.813 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit 33.33 (1.31)

Coupling may not protrude beyond this surface

20

length of full spline

7.9 (.78) (.31)

Splined Shaft Option C2

79 (3.11)

42 (1.65)

ø21.72 (.85 Dia)

View "Y"

126 (4.96) 231.9 (9.13)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

"A" Max. Displacement

Woodruff key 6.35 x 22.22 (.250 x .875)

ø6.73 2x (.265 Dia)

Tapered Shaft Option T3

View "X" Charge Pressure Relief Valve

Multifunction Valve

73.55 (2.89)

View "W"

Port X3 (optional) External control supply 9/16-18UNF-2B

53.66 (2.11) 8.3 (.33)

Castle nut, 3/4-16UNF Wrench size: 27 (1.062) Torque nut to 150-190 Nm (110-146 lbf-ft) R 25.4 (R 1.0)

Port L2 Case drain 7/8-14UNF-2B 146 (5.75)

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 20,6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Coupling may not protrude beyond this surface

73 (2.875)

ø25.4 (1Dia)

Null position

24° min.

"B"

24° min.

Max. Displacement

45 (1.77)

Approx center of gravity

60 (2.36)

Gauge port M5 Servo pressure 9/16-18UNF-2B

35 (1.38)

Gauge port M3 Charge pressure 9/16-18UNF-2B

ø18.67 (.74 Dia)

Port L1 Case drain use highest port as outlet 7/8-14UNF-2B

ø15.3 (.602 Dia)

0

A

74 (2.91) 71.5 (2.81) Port L2

18.24 (.71)

ø21.34 (.84 Dia)

CW

(-.002)

ø101.6 -0.05 (4 Dia) (+.000)

51 (2.00)

15 (.59) ø25.4 (1Dia) ø60 max. (max. 2.36 Dia)

51 (2.00)

Rotation

"X"

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

32

"W"

141 (5.55)

Port S: Charge pump inlet 1-1/16-12UN-2B

100 (3.94 ) Port L1

124 (4.88)

Gauge port M2 System pressure B 9/16-18UNF-2B

View "Z"

Control MDC, Option MA 9.4 (.37)

"Y"

34.6 (1.36) 48.86 (1.92)

P001 359E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 030 (Continued) mm (in.)

Continued Figure 38: Auxiliary Mounting Pad - Options A, B, V View "X"

106.375 (4.188)

"X"

SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 32.5 (1.28)

4 Threads 3/8-16UNC-2B 17 (.67) deep

15.3 (.60)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

259.6 (10.22)

106.375 (4.188)

273.4 (10.76)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.5 (1.0)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

4 Threads 1/2-13UNC-2B 22 (.87) deep

19.6 (.77) 256.4 (10.09)

146 (5.75)

273.8 (10.78)

View "X"

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 15.2 (.598)

4 Threads 1/2-13UNC-2B 22 (.87) deep

29.9 (1.18) 256.4 (10.09)

146 (5.75)

273.8 (10.78) P001 360E

33

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 042 mm (in.)

Figure 39: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

Coupling may not protrude beyond this surface

25

length of full spline

7.9 (.98) (.31)

Splined Shaft Option C3

B

111 (4.37)

"W"

145 (5.71)

38 (1.5)

Rotation

"X"

Ports A and B 3/4 -6000 psi Split Flange Boss per SAE J518 (Code 62) 3/8-16UNC-2B 20 (.787) min. Full Thread

12.2 (2x) (.48) 114.5 (4.51) Port L2 130 (5.12) 207.8 (8.18)

50.8 (2.00) Approx center of gravity

ø15.3 (.602 Dia)

(-.002)

0

A

9.7 (.38)

CW

81.4 (3.20) 80 (3.15) Port L2

23.8 (.94)

ø21.34 (.84 Dia)

CCW

ø101.6 -0.05 (4 Dia) (+.000)

52 (2.047)

7.9 (.31) ø25.4 (1Dia) ø70 max. (max. 2.76 Dia)

52 (2.047)

129 (5.08)

86 (3.39)

Port S: Charge pump inlet 1-1/16-12UN-2B

108 (4.25) Port L1

View "Z"

Control MDC, Option MA 9.4 (.37)

"Y" Gauge port M2 System pressure B 9/16-18UNF-2B

"Z" 33 (1.30)

SHAFT SPLINE DATA: Pitch Dia = 23.813 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Approx center of gravity

Port L2 Case drain 7/8-14UNF-2B 146 (5.75)

73 (2.875)

View "X"

Gauge port M1 System pressure A 9/16-18UNF-2B

View "Y"

Gauge port M4 Servo pressure 9/16-18UNF-2B

Charge Pressure Relief Valve

83 (3.27)

41.6 (1.64)

Multifunction Valve

Gauge port M3 Charge pressure 9/16-18UNF-2B Multifunction Valve

Port L1 Case drain use highest port as outlet 7/8-14UNF-2B

Gauge port M5 Servo pressure 9/16-18UNF-2B

56.9 (2.24)

143.5 (5.65)

85.5 (3.4)

258 (10.16)

Manual Displacement Control Handle Dimensions

Coupling may not protrude beyond this surface

Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in)

"A" Max. Displacement

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Tapered Shaft Option T3

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

34

62.5 (2.46)

28° min.

Castle nut, 3/4-16UNF Wrench size: 27 (1.062) Torque nut to 150-190 Nm (110-146 lbf-ft)

ø25.4 (1Dia)

Null position

28° min.

"B"

Port X3 (optional) External control supply 9/16-18UNF-2B

53.7 (2.11) 8.3 (.33)

R 50.8 (R 2.0)

Max. Displacement

View "W"

34.6 (1.36) 38.6 (1.52)

126 (4.96)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 361E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 042 (Continued) mm (in.)

Continued Figure 39: Auxiliary Mounting Pad - Options A, B, V View "X"

106.375 (4.188)

"X"

SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 32.5 (1.28)

4 Threads 3/8-16UNC-2B 17 (.67) deep

18 (.71)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

288 (11.34)

106.375 (4.188)

301.85 (11.88)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.5 (1.0)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

4 Threads 1/2-13UNC-2B 22 (.87) deep

20.5 (.81) 282.92 (11.14)

146 (5.75)

300.37 (11.83)

View "X"

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 15.2 (.598)

4 Threads 1/2-13UNC-2B 22 (.87) deep

30.8 (1.21) 282.92 (11.14)

146 (5.75)

300.37 (11.83) P001 362E

35

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 055 mm (in.)

Figure 40: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Side Ports, Option 6

View "Z" Control MDC, Option MA

9.4 (.37)

Gauge port M2 System pressure B 9/16-18UNF-2B

133.9 (5.27) 121.9 (4.80) Port B 117.6 (4.63) Port L1

47.6 (1.88) 7.9 (.31)

Splined Shaft Option S1

Gauge port M1 System pressure A 9/16-18UNF-2B

243.7 (9.60) Port S

Port L1 Case drain use highest port as outlet 1-1/16-12UN-2B

288.8 (11.37)

33.8 (1.33)

27.76 (1.093)

72.9 (2.87) 168.9 (6.65) 23.9 (9.13)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

Max. Displacement

28° min.

A

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Coupling may not protrude beyond this surface Woodruff key 9.525 x 38.1 (.375 x 1.50)

88.9 (3.50) 86.2 (3.39) Port L2 Port S: Charge pump inlet 1-5/16-12UN-2B

96.85 (3.81)

View "W"

58.4 (2.30) Port X3 (optional) External control supply 9/16-18UNF-2B

66.9 (2.63) 6.6 (.26)

ø34,93 (1.375 Dia)

SAE J744c 47.8 (1.88) 62.02 (2.44)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

36

View "X" Charge Pressure Relief Valve

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 33.338 (1.3125) Pressure Angle = 30° Number of teeth = 21 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Tapered Shaft Option T1

(2x)

Gauge port M3 Charge pressure 9/16-18UNF-2B

Castle nut, 1-20UNEF Wrench size: 38 (1.496) Torque nut to 190-230 Nm (140-170 lbf-ft)

28° min.

Max. Displacement

114.5 (4.50)

Port L2 Case drain 1-1/16-12UN-2B

Multifunction Valve

ø28.7 (1.13 Dia) Gauge port M5 Servo pressure 7/16-20UNF-2B

(2x)

Splined Shaft Option C6

41.7 (1.64)

57.15(2.25)

Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

Approx center of gravity

57.25 (2.25)

length of full spline

ø34.42 (1.355 Dia)

7.9 (.31)

43.7 (1.72)

ø14.27 (.562 Dia)

Coupling may not protrude beyond this surface

47.6 (1.88)

Gauge port M4 Servo pressure 7/16-20UNF-2B

(-.002)

SHAFT SPLINE DATA: Pitch Dia = 29.633 (1.1667) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

120.4 (4.74) Port L2 152.4 (6.0)

View "Y"

0

"Z"

82.6 (3.25)

14.2 (.56)

Approx center of gravity

CW

65 (2.56)

"X"

CCW

ø127 -0.05 (5 Dia) (+.000)

17.8 (.70) ø31.14 (1.226Dia) ø84.8 max. (max. 3.34 Dia)

90.4 (3.56) Port A

Rotation

12.45 ±0.25 (.49) (±.01)

Null position

"W"

length of full spline

27.9 (1.10)

ø24.9 (.98 Dia)

B

110.7 (4.36)

93.7 (3.69)

Coupling may not protrude beyond this surface

149.9 (5.90)

"Y"

136.35 (5.37)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 385E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 055 (Continued) Continued Figure 40: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC)

mm (in.)

Endcap Twin Ports, Option 8 "Y"

Gauge port M2 System pressure B 9/16-18UNF-2B

Control MDC, Option MA

Port S: Charge pump inlet 1-5/16-12UN-2B

27.76 (1.093)

57.9 (2.28)

57.9 (2.28)

B

A

Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

57.15 (2.25)

Gauge port M1: System pressure A 9/16-18UNF-2B 232.2 (9.14) 247.1 (9.73)

85.1 (3.35) Port S

88.9 (3.54)

View "Y"

P001 386E

37

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 055 (Continued) mm (in.)

Continued Figure 40: Auxiliary Mounting Pad - Options A, B, C, V

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 37.13 (1.46)

View "X"

"X"

106.375 (4.188)

ø82.6 (3.252 Dia)

+ 0.13 0 (+.005) (- .000)

SAE A, Option A

4 Threads 3/8-16UNC-2B 22.8 (.89) deep

15.13 (.59)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

316.6 (12.46)

106.375 (4.188)

330.4 (13.01)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.51 (1.16)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

17.66 (.70)

4 Threads 1/2-13UNC-2B 22 (.87) deep

311.5 (12.26)

146 (5.75)

329 (12.95)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 18.97 (.747)

30.73 (1.21)

6 Threads 1/2-13UNC-2B 22 (.87) deep

314 (12.36) 331 (13.03)

114.5 (4.51) 181 (7.13) P001 387E

38

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 055 (Continued) mm (in.)

Continued Figure 40: Auxiliary Mounting Pad - Options A, B, C, V

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.43 (.96)

20.75 (.82)

4 Threads 1/2-13UNC-2B 22 (.87) deep

311.5 (12.26)

146 (5.75)

329 (12.95) P001 387E/1

39

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 075 mm (in.)

Figure 41: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Side Ports, Option 6 Control MDC, Option MA

99.3 (3.91)

9.4 (.37)

139.7 (5.50)

126 (4.96) Port B

Splined Shaft Option S1

Rotation

Port L1 Case drain use highest port as outlet 1-1/16-12UN-2B

View "Y"

306.1 (12.05)

41.6 (1.64)

27.76 (1.093)

A Max. Displacement

248.2 (9.77)

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

SHAFT SPLINE DATA: Pitch Dia = 36.513 (1.4375) Pressure Angle = 30° Number of teeth = 23 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Coupling may not protrude beyond this surface Woodruff key 9.525 x 38.1 (.375 x 1.50)

Tapered Shaft Option T2

View "X" Charge Pressure Relief Valve

Multifunction Valve

Port S: Charge pump inlet 1-5/16-12UN-2B

104 (4.09)

View "W"

65 (2.56) Port X3 (optional) External control supply 9/16-18UNF-2B

66.9 (2.63) 8.65 (.34)

ø38.1 (1.5 Dia)

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

40

(2x)

Multifunction Valve

Castle nut, 1-20UNEF Wrench size: 38 (1.496) Torque nut to 190-230 Nm (140-170 lbf-ft)

28° min.

28° min.

B Null position

81.3 (3.20) 172.2 (6.78)

R 50.8 (R 2.0)

Max. Displacement

114.5 (4.50)

A

Gauge port M5 Servo pressure 9/16-18UNF-2B

Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in)

Approx center of gravity

Port L2 Case drain 1-1/16-12UN-2B

(2x)

Gauge port M3 Charge pressure 9/16-18UNF-2B

ø31.8 (1.25 Dia)

Manual Displacement Control Handle Dimensions

93.7 (3.69) 91,7 (3.61) Port L2

(-.002)

Splined Shaft Option C7

57.15(2.25)

Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

57.25 (2.25)

length of full spline

34.8 (1.37)

ø37.59 (1.48 Dia)

7.9 (.31)

40.6 (1.60)

ø14.27 (.562 Dia)

Coupling may not protrude beyond this surface

47.6 (1.88)

Gauge port M4 Servo pressure 9/16-18UNF-2B

0

SHAFT SPLINE DATA: Pitch Dia = 29.633 (1.1667) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

84 (3.31)

262.6 (10.34) Port S

141.7 (5.58) Port L2 155.7 (6.13)

"Z"

12.45 ±0.25 (.49) (±.01)

71 (2.79)

Approx center of gravity

14.2 (.56)

ø127 -0.05 (5 Dia) (+.000)

3.8

Gauge port M1 System pressure A 9/16-18UNF-2B

CW

M4

94.5 (3.72) Port A

ø24.9 (.98 Dia)

(.15) ø31.14 (1.226Dia) ø94 max. (max. 3.70 Dia)

CCW

B

124.2 (4.89) Port L1

length of full spline

27.9 (1.10)

M5

"X"

"W"

Coupling may not protrude beyond this surface

47.6 (1.88) 7.9 (.31)

110.7 (4.36)

155.7 (6.13)

Gauge port M2 System pressure B 9/16-18UNF-2B

View "Z"

"Y"

47.8 (1.88) 62.02 (2.44)

141.1 (5.55)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 380E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 075 (Continued) Continued Figure 41: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC)

mm (in.)

Endcap Twin Ports, Option 8 "Y"

Gauge port M2 System pressure B 9/16-18UNF-2B

Control MDC, Option MA

Port S: Charge pump inlet 1-5/16-12UN-2B

27.76 (1.093)

61 (2.40)

93.77 (3.69)

61 (2.40)

B

A

57.15 (2.25) Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

Gauge port M1: System pressure A 9/16-18UNF-2B 242.4 (9.54) 247.9 (9.76)

92 (3.62)

View "Y"

P001 381E

41

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 075 (Continued) mm (in.)

Continued Figure 41: Auxiliary Mounting Pad - Options A, B, C, V COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 37.13 (1.46)

View "X" SAE A, Option A

B

M4

106.375 (4.188)

ø82.6 (3.252 Dia)

+ 0.13 0 (+.005) (- .000)

M5

"X"

A for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

4 Threads 3/8-16UNC-2B 22.8 (.89) deep

15.13 (.59) 333.93 (13.14)

106.375 (4.188)

347.8 (13.69)

M4

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

146 (5.75)

(- .000)

B

+ 0.13

View "X" SAE B, Option B M5

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.51 (1.16)

A

4 Threads 1/2-13UNC-2B 22 (.87) deep

17.66 (.70) 328.9 (12.95)

146 (5.75)

346.5 (13.64)

114.5 (4.51)

(- .000)

M4

+ 0.13

B

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C M5

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 18.97 (.747)

6 Threads 1/2-13UNC-2B 22 (.87) deep

30.73 (1.21) 331.4 (13.05) 348.4 (13.72)

A 114.5 (4.51) 181 (7.13)

P001 384E

42

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 075 (Continued) mm (in.)

Continued Figure 41: Auxiliary Mounting Pad - Options A, B, C, V

146 (5.75)

(- .000)

M4

+ 0.13

B

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V M5

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.43 (.96)

4 Threads 1/2-13UNC-2B 22 (.87) deep

22.75 (.896) 328.9 (12.95)

A 146 (5.75)

346.5 (13.64) P001 384E/1

43

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 100 mm (in.)

Figure 42: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Side Ports, Option 6

View "Z"

"Y"

Control MDC, Option MA

108.4 (4.27)

9.4 (.37)

148.7 (5.85) 143.3 (5.64) Port B 139.1 (5.48) Port L1

length of full spline

49.5 (1.95)

Splined Shaft Option F1

Gauge port M1 System pressure A 9/16-18UNF-2B

288 (11.34) Port S

Port L1 Case drain use highest port as outlet 1-1/16-12UN-2B

161 (6.34) Port L2

SHAFT SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

180.3 (7.10)

339 (13.35)

View "Y"

47.6 (1.88)

Gauge port M4 Servo pressure 9/16-18UNF-2B

38.9 (1.53)

27.76 (1.093)

Gauge port M5 Servo pressure 9/16-18UNF-2B 204.6 (8.06) 277.7 (10.93)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

"A" Max. Displacement

30° min.

Woodruff key 9.525 x 38.1 (.375 x 1.50)

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Tapered Shaft Option T2

114.6 (4.51)

View "W"

66 (2.60) Port X3 (optional) External control supply 9/16-18UNF-2B

66.9 (2.63) 9.54 (.38)

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

44

A Port S: Charge pump inlet 1-5/8-12UN-2B

ø38,1 (1.5 Dia)

Null position

Coupling may not protrude beyond this surface

Gauge port M3 Charge pressure 9/16-18UNF-2B

Multifunction Valve

Castle nut, 1-20UNEF Wrench size: 38 (1.496) Torque nut to 190-230 Nm (140-170 lbf-ft)

30° min.

Max. Displacement

Charge Pressure Relief Valve

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 36.513 (1.4375) Pressure Angle = 30° Number of teeth = 23 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

87.3 (3.44)

View "X"

Splined Shaft Option C7

ø32.3 (1.27 Dia) Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

Port L2 (2x) Case drain 1-1/16-12UN-2B 114.5 (2x) (4.50)

57.25 (2.25)

length of full spline

33 (1.30)

57.15(2.25)

Approx center of gravity

Coupling may not protrude beyond this surface

ø37.59 (1.48 Dia)

7.9 (.31)

42 (1.65)

ø14.27 (.562 Dia)

89.7 (3.53)

Approx center of gravity

76 (2.99)

"X"

107 (4.21) 100,37 (3.95) Port L2

"Z"

12.45 ±0.25 (.49) (±.01) 14.2 (.56)

CW

(-.002)

0

CCW

ø127 -0.05 (5 Dia) (+.000)

20.3 (.80) ø43.94 (1.73Dia) ø100.6 max. (max. 3.96 Dia)

99.0 (3.89) Port A

Rotation

ø34.5 (1.36 Dia)

"B"

"W"

Coupling may not protrude beyond this surface

66.7 (2.625) 7.9 (.31)

119.7 (4.71)

164.7 (6.48)

Gauge port M2 System pressure B 9/16-18UNF-2B

47.8 (1.88) 62.02 (2.44)

164.34 (6.47)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 377E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 100 (Continued) Continued Figure 42: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC)

mm (in.)

Endcap Twin Ports, Option 8 Gauge port M2 System pressure B 9/16-18UNF-2B

"Y"

Control MDC, Option MA

47.6 (1.88)

Port S: Charge pump inlet 1-5/8-12UN-2B

7.9 (.31)

30.5 (1.20)

Coupling may not protrude beyond this surface length of full spline

Splined Shaft Option S1

ø24.9 (.98 Dia)

A

Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

57.15 (2.25)

Gauge port M1: System pressure A 9/16-18UNF-2B 277.9 (10.94) 280.5 (11.04)

ø31.14 (1.226Dia)

27.76 (1.093)

66.8 (2.63)

66.8 (2.63)

B

SHAFT SPLINE DATA: Pitch Dia = 29.634 (1.1667) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

99.8 (3.93) Port S

107.95 (4.25)

View "Y"

P001 378E

45

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 100 (Continued) Continued Figure 42: Auxiliary Mounting Pad - Options A, B, C, V

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 37.13 (1.46)

mm (in.)

View "X"

106.375 (4.188)

"X"

ø82.6 (3.252 Dia)

+ 0.13 0 (+.005) (- .000)

SAE A, Option A

A 4 Threads 3/8-16UNC-2B 22.8 (.89) deep

15.13 (.60)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

366.02 (14.41)

106.375 (4.188)

379.69 (14.95)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.51 (1.16)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

4 Threads 1/2-13UNC-2B 22 (.87) deep

17.66 (.70) 360.9 (14.21)

146 (5.75)

378.3 (14.89)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29,6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 18.97 (.747)

6 Threads 1/2-13UNC-2B 22 (.87) deep

30.73 (1.21) 363.47 (14.31) 380.27 (14.97)

A 114.5 (4.51) 181 (7.13)

P001 379E

46

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 100 (Continued) Continued Figure 42: Auxiliary Mounting Pad - Options A, B, C, V

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.43 (.96)

mm (in.)

4 Threads 1/2-13UNC-2B 22 (.87) deep

22.75 (.896) 360.9 (14.21)

146 (5.75)

378.3 (14.89) P001 379E/1

47

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 130 mm (in.)

Figure 43: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

View "Z"

"Y"

Control MDC, Option MA

110.5 (4.35)

9.4 (.37)

length of full spline

42.5 (1.67)

7.9 (.31)

Splined Shaft Option F1 (-.002)

0

"X" 14.6 (.57)

66.68 (2.63)

185 (7.28) 290 (11.42) 300 (11.81)

Gauge port M1 System pressure A 9/16-18UNF-2B

View "Y"

66.68 (2.63)

Gauge port M4 Servo pressure 9/16-18UNF-2B

42.5 (1.67)

48 (1.89) 209.3 (8.24) 370 (14.58)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

"A" Max. Displacement

30° min.

Woodruff key 10.074 x 50.67 (.397 x 1.995)

R 25.4 (R 1.0)

Tapered Shaft Option T4

75.95 (2.99) 12.27 (.48)

SAE J744c

ø6.73 2x (.265 Dia)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

48

Port X3 (optional) External control supply 9/16-18UNF-2B

View "W" 121.2 (4.8)

ø44.45 (1.75Dia)

Null position

Coupling may not protrude beyond this surface

Gauge port M3 Charge pressure 9/16-18UNF-2B

M3

"B"

Charge Pressure Relief Valve

Multifunction Valve

Castle nut, 1-1/4-18UNEF Wrench size: 46 (1.811) Torque nut to 370-430 Nm (270-317 lbf-ft)

30° min.

Max. Displacement

View "X"

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 42.8625 (1.6875) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

101.5 (3.99)

Port L2 (2x) Case drain 1-5/16-12UN-2B 161.6 (2x) (6.36)

Splined Shaft Option C8

111 (4.37)

Gauge port M5 Servo pressure 9/16-18UNF-2B

80.8 (3.18)

length of full spline

ø37 (1.46 Dia)

Port L1 Case drain use highest port as outlet 1-5/16-12UN-2B

Approx center of gravity

Coupling may not protrude beyond this surface

ø44.35 (1.75 Dia)

7.9 (.31)

48.8 (1.92)

ø20.6 (.81 Dia)

SHAFT SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

166 (6.54) Port L2 Approx center of gravity

"Z"

12.45 ±0.25 (.49) (±.01)

CW

91 (3.58)

Ports A and B 1- 1/4 -6000 psi Split Flange Boss per SAE J518 (Code 62) 1/2-13UNC-2B 23 (.906) min. Full Thread

CCW

111.6 (4.39) 109,81 (4.32) Port L2

ø34.04 (1.34 Dia) A

15 (.59) ø43.89 (1.73Dia) ø114 max. (max. 4.49 Dia)

Rotation

31.75 (1.25)

77 (3.03)

B

ø152.4 -0.05 (6 Dia) (+.000)

147.1 (5.79) Port L1 77 (3.03)

168.5 (6.63)

Port S: Charge pump inlet 1-5/8-12UN-2B

"W"

Coupling may not protrude beyond this surface

66.68 (2.63)

184.5 (7.26)

Gauge port M2 System pressure B 9/16-18UNF-2B

53.85 (2.12) 71.35 (2.81)

178.6 (7.03)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 373E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 130 (Continued) Continued Figure 43: Auxiliary Mounting Pad - Options A, B, C, D, V

mm (in.)

View "X"

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 22.4 (.88)

"X"

106.375 (4.188)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

(- .000)

SAE A, Option A

4 Threads 3/8-16UNC-2B 8 (.31) deep

15.6 (.61)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

400.89 (15.78)

106.375 (4.188)

414.56 (16.32)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

146 (5.75)

"X"

View "X" SAE B, Option B

(- .000)

+ 0.13

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 28.77 (1.1)

4 Threads 1/2-13UNC-2B 22 (.87) deep

18.2 (.72) 408 (16.06)

146 (5.75)

425.65 (16.76)

View "X"

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.97 (1.18) (- .000)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

114.5 (4.51)

+ 0.13

ø127.03 0 (5.001 Dia) (+.005)

"X"

SAE C, Option C

6 Threads 1/2-13UNC-2B 22 (.87) deep

31.4 (1.24) 411.05 (16.18) 427.75 (16.84)

114.5 (4.51) 181 (7.13)

P001 374E

49

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 130 (Continued) mm (in.)

Continued Figure 43: Auxiliary Mounting Pad - Options A, B, C, D, V View "X"

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.22 (.993)

"X"

161.6 (6.36)

+ 0.13

ø152.45 0 (6.002 Dia) (+.005)

(- .000)

SAE D, Option D

4 Threads 3/4-10UNC-2B 41 (1.6) deep

50.84 (2.00)

for O-Ring ø153 x 3.0 (6.02 Dia x 0.118)

415.62 (16.36)

161.6 (6.36)

439.22 (17,29)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.59 (.96)

4 Threads 1/2-13UNC-2B 22 (.87) deep

23.3 (.92) 408 (16.06)

146 (5.75)

425.65 (16.76) P001 375E

50

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Notes

51

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 Figure 44: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

View "Z"

"Y"

Control MDC, Option MA

Splined Shaft Option F1

B

201.5 (7.93)

length of full spline

42.5 (1.67)

Rotation

66.68 (2.63) Approx center of gravity

20 (.79)

186 (7.32) Port L2

200 (7.87) 321 (12.64) 326 (12.83)

Gauge port M1 System pressure A 9/16-18UNF-2B

Gauge port M4 Servo pressure 9/16-18UNF-2B

7.9 (.31)

42.5 (1.67)

0

(-.002)

View "X"

Charge Pressure Relief Valve

Splined Shaft Option C8 Multifunction Valve

56 (2.20)

138 (5.43)

108 Gauge port M5 (4.25) Servo pressure 9/16-18UNF-2B 228 (8.97)

Approx center of gravity

56 (2.20) Port L2 112.25 (2x) Case drain (4.42) 1-5/8-12UN-2B 224.5 (2x) (8.84)

length of full spline

Gauge port M3 Charge pressure 9/16-18UNF-2B

ø39 (1.54 Dia) Port L1 Case drain use highest port as outlet 1-5/8-12UN-2B

ø20.6 (.81 Dia)

Coupling may not protrude beyond this surface

ø44.35 (1.75 Dia)

View "Y"

"Z"

SHAFT SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

66.68 (2.63)

CW

143 (5.63) 142 (5.59) Port L2

15.5 ±0.25 (.61) (±.01)

ø165.1 -0.05 (6.5 Dia) (+.000)

31.75 (1.25)

93 (3.66)

Ports A and B 1- 1/4 -6000 psi Split Flange Boss per SAE J518 (Code 62) 1/2-13UNC-2B 23 (.906) min. Full Thread

ø34.04 (1.34 Dia)

A

12 (.47) ø43.89 (1.73Dia) ø114 max. (max. 4.49 Dia)

195 (7.68)

CCW

93 (3.66)

204 (8.03)

7.9 (.31)

181 (7.13) Port L1

"X"

"W"

Coupling may not protrude beyond this surface

66.68 (2.63) Port S: Charge pump inlet 1-5/8-12UN-2B

177 (6.97)

160 (6.30)

9.4 (.37)

Gauge port M2 System pressure B 9/16-18UNF-2B

mm (in.)

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 42.8625 (1.6875) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

View "W"

398 (15.67)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

Null position

"A" Max. Displacement

30° min.

"B"

30° min.

Max. Displacement

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

52

191 (7.52)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 376E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 (Continued) mm (in.)

Continued Figure 44: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

106.375 (4.188)

"X"

View "X" SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 17.8 (.70)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

4 Threads 3/8-16UNC-2B 17.8 (.70) deep

15 (.59) 429.3 (16.90)

106.375 (4.188)

442.9 (17.44)

View "X" SAE B, Option B

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.5 (1.16)

4 Threads 1/2-13UNC-2B 22 (.87) deep

17.5 (.69) 436.4 (17.18)

146 (5.75)

454.1 (17.88)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 22.1 (.87)

6 Threads 1/2-13UNC-2B 22 (.87) deep

30.5 (1.20) 439.4 (17.30) 456.1 (17.96)

114.5 (4.51) 181 (7.13)

P001 388E

53

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 (Continued) mm (in.)

Continued Figure 44: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

View "X"

A

161.6 (6.36)

(- .000)

+ 0.13

"X"

ø152.45 0 (6.002 Dia) (+.005)

B

SAE D, Option D

for O-Ring ø153 x 3.0 (6.02 Dia x 0.118)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

49.9 (1.96) 448.1 (17.64) 464.8 (18.30)

View "X" SAE E, Option E

224.5 (8.84)

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

"X"

46.5 (1.83)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

473.1 (18.63)

View "X" SAE H, Option H

224.5 (8.84) 46.5 (1.83)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

448.1 (17.64) 473.1 (18.63)

54

224.5 (8.84)

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

448.1 (17.64)

COUPLING SPLINE DATA: Pitch Dia = 42.862 (1.687) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 28.5 (1.12)

"X"

161.6 (6.36)

224.5 (8.84)

P001 469E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 (Continued) mm (in.)

Continued Figure 44: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.49 (.96)

4 Threads 1/2-13UNC-2B 22 (.87) deep

22.6 (.89) 436.4 (17.18)

146 (5.75)

454.1 (17.88)

P001 469E/1

55

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 mm (in.)

Figure 45: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

View "Z"

"Y" 9.4 (.37)

Control MDC, Option MA

length of full spline

42.5 (1.67)

Splined Shaft Option F1

B

201.5 (7.93)

212 max.

(8.35)

7.9 (.31)

Rotation

341 (13.43)

Ports A and B 1- 1/2 - 6000 psi Split Flange Boss per SAE J518 (Code 62) 5/8-11UNC-2B, 25 (.98) min.

Full Thread

331 (13)

210 (8.27)

(-.002)

0

"Z"

SHAFT SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Gauge port M4 Servo pressure 9/16-18UNF-2B

7.9 (.31)

56 (2.20)

Coupling may not protrude beyond this surface

System pressure B 9/16-18UNF-2B

Multifunction Valve

56 (2.20) 108 Gauge port M5 (4.25) Servo pressure 9/16-18UNF-2B 228 (8.98)

Charge Pressure Relief Valve

Splined Shaft Option C8

136 (5.35)

M2

Approx center of gravity

56 (2.20) Port L2 112.25 (2x) Case drain (4.42) 1-5/8-12UN-2B 224.5 (2x) (8.84)

length of full spline

Gauge port M3 Charge pressure 9/16-18UNF-2B

ø39 (1.54 Dia)

Port L1 Case drain use highest port as outlet 1-5/8-12UN-2B

ø20.6 (.81 Dia)

View "X" Gauge port M2 66.68 (2.63)

ø44.35 (1.75 Dia)

View "Y"

20 (.79)

186 (7.32) Port L2

79.38 (3.13) Approx center of gravity

CW

143 (5.63) 142 (5.59) Port L2

15.5 ±0,25 (.61) (±.01)

ø165.1 -0.05 (6.5 Dia) (+.000)

ø34.04 (1.34 Dia)

12 (.47) ø43.89 (1.73Dia) ø114 max. (max. 4.49 Dia)

69.85 (2.75) A

36.5 (1.44)

Port S: Charge Pump Inlet 1- 1/2 3000 psi Split Flange Boss per SAE J518 (Code 61) 1/2-13UNC-2B 24 (.94) min.

Full Thread

185.5 (7.30)

35.71 (1.41)

98 (3.86)

CCW

98 (3.86)

181 (7.13) Port L1

"X"

"W"

Coupling may not protrude beyond this surface

66.68 (2.63)

SHAFT SPLINE DATA: Pitch Dia = 42.8625 (1.6875) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

419 (16.5)

Multifunction Valve

Gauge port M10 Charge Pump Inlet 9/16-18UNF-2B

Gauge port M1 System pressure A 9/16-18UNF-2B

View "W"

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

Null position

"A" Max. Displacement

30° min.

"B"

30° min.

Max. Displacement

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

56

191 (7.52)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 465E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 (Continued) mm (in.)

Continued Figure 45: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

106.375 (4.188)

"X"

View "X" SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 17.8 (.70)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

4 Threads 3/8-16UNC-2B 17.8 (.70) deep

15 (.59) 450.30 (17.73)

106.375 (4.188)

463.90 (18.26)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.5 (1.16)

17.5 (.69)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

4 Threads 1/2-13UNC-2B 22 (.87) deep

457.4 (18.01)

146 (5.75)

475.1 (18.70)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 22.1 (.87)

6 Threads 1/2-13UNC-2B 22 (.87) deep

30.5 (1.20) 460.4 (18.13) 477.1 (18.78)

114.5 (4.51) 181 (7.13)

P001 466E

57

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 (Continued) Continued Figure 45: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

161.6 (6.36)

"X"

View "X" SAE D, Option D

(- .000)

+ 0.13

ø152.45 0 (6.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

for O-Ring ø153 x 3.0 (6.02 Dia x 0.118)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

49.9 (1.96) 469.1 (18.47)

224.5 (8.84) 494.1 (19.45)

SAE H, Option H

224.5 (8.84) 46.5 (1.83)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

469.1 (18,47) 494.1 (19.45)

58

224.5 (8.84)

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

469.1 (18,47)

COUPLING SPLINE DATA: Pitch Dia = 42.862 (1.687) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 28.5 (1.12)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

View "X"

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

SAE E, Option E

46.5 (1.83)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

"X"

161.6 (6.36)

485.8 (19.13)

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

"X"

mm (in.)

224.5 (8.84)

P001 467E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 (Continued) Continued Figure 45: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V View "X"

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.00 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.49 (.96)

mm (in.)

4 Threads 1/2-13UNC-2B 22 (.87) deep

22.6 (.89) 457.4 (18.01)

146 (5.75)

475.1 (18.70) P001 467E/1

59

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Controls, Displacement Limiter Figure 46: Cover Plate

C2

Option CA

View "W"

C1

C4 max.

C3

C1

C4 max.

Port M4

Displacement Limiter Option 4 Limitation both sides

Ports: M4, M5 = Servo Pressure 9/16-18UNF-2B O-Ring Boss

Port M5

"W"

P001 363E

Table 22: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100

C1 63.5 (2.50) 67.9 (2.67) 69.2 (2.72) 74.2 (2.92) 83.3 (3.28)

C2 140.5 (5.53) 129.5 (5.10) 179.4 (7.06) 185.7 (7.31) 183.3 (7.22)

C3 95.5 (3.76) 99.5 (3.92) 103.6 (4.08) 109.4 (4.31) 118.3 (4.66)

C4 max. [Option 4] 106 (4.17) 108 (4.25) 114 (4.48) 118 (4.65) 136 (5.35)

130 180 250

86.6 (3.41) -

209.3 (8.24) -

137.2 (5.40) -

141 (5.55) 184 (7.24) 184 (7.24)

Figure 47: 3-Position (FNR) Electric Control

View "W"

C5.2

C5 max.

C5.1

a

Option DC & DD

b

P001 399E

Table 23: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100 130 (Option DC only) 60

"W"

C5 max.

190.5 (7.50) 194.5 (7.66) 198.6 (7.82) 204.4 (8.05) 213.3 (8.40) 232.2 (9.14)

C5.1 110.2 (4.34) 110.2 (4.34) 110.2 (4.34) 110.2 (4.34) 101.6 (4.00) 116.6 (4.59)

C5.2 112.8 (4.44) 112.8 (4.44) 112.8 (4.44) 112.8 (4.44) 121.4 (4.78) 106.4 (4.19)

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Controls (Continued) Figure 48: Electric Displacement Control (EDC) with MS-Connector or Packard-Connector View "W"

C7

C6

C6

PackardConnector Option EP

Port X2

P001 403E

"W"

Frame Size 030 and 042 only

C7 (frame size 030 and 042 only)

Option KA & KP

Port X1

Ports: X1, X2 = 9/16-18UNF-2B O-Ring Boss

Table 24: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100

C6 95.3 (3.75) 95.3 (3.75) 95.3 (3.75) 105.2 (4.14) 114.0 (4.49)

C7 173.5 (6.83) 173.5 (6.83) 141.2 (5.56) 144.8 (5.70) 153.7 (6.05)

130 180 / 250

99.1 (3.90) 93.4 (3.68)

172.7 (6.80) 190.0 (7.48)

Figure 49: Hydraulic Displacement Control (HDC) C12

Port X1 Port X2

View "W"

Option HF

C8.1 (port X2)

C8.2 (port X1)

C10

C9

C11

Ports: X1, X2 = Control Pilot Pressure 9/16-18UNF-2B, O-Ring Boss

P001 372E

"W"

Table 25: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100 130 180 / 250

C8.1 135.0 (5.31) 139.0 (5.47) 143.0 (5.63) 148.9 (5.86) 158.0 (6.22) 176.7 (6.95) 194.0 (7.63)

C8.2 131.0 (5.15) 135.0 (5.31) 139.0 (5.47) 139.9 (5.50) 149.0 (5.86) 167.7 (6.60) 185.0 (7.28)

C9 71.0 (2.79) 71.0 (2.79) 71.0 (2.79) 68.2 (2.68) 76.8 (3.02) 61.8 (2.43) 54.0 (2.12)

C10 75.7 (2.98) 75.7 (2.98) 75.7 (2.98) 67.0 (2.63) 67.0 (2.63) 67.0 (2.63) 67.0 (2.63)

C11 77.6 (3.05) 89.6 (3.52) 105.6 (4.15) 121.8 (4.79) 127.9 (5.03) 142.1 (5.59) 148.6 (5.85)

C12 87.2 (3.43) 99.2 (3.90) 115.2 (4.53) 125.3 (4.93) 131.4 (5.17) 145.6 (5.73) 152.1 (5.99) 61

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Controls (Continued) Figure 50: Manual Displacement Control (MDC) with Neutral Start Switch C13

View "W"

C14

Option MB

Neutral Start Switch

P001 364E

"W"

Table 26: Dimensions [mm (in.)]

Frame Size 042 055 075

~ C13 0.4 (.016) 18.0 (.71) 25.0 (.98)

C14 96.0 (3.78) 100.0 (3.94) 106.9 (4.21)

100

31.0 (1.22)

115.8 (4.56)

130

45.0 (1.77)

134.5 (5.29)

180 250

52.0 (2.04) 52.0 (2.04)

151.8 (5.97) 151.8 (5.97)

Figure 51: Non-Linear Manual Displacement Control (MDC) "V" Option NA

View "W"

View "V"

R 50.8 (R 2.0)

"A" P001 404E

"W"

Max. Displacement

31° min.

Null position

31° min.

Max. Displacement

"B"

C15

Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in)

R 26.4 (R 1.04) ø8.26 2x (.325 Dia)

Table 27: Dimensions [mm (in.)]

Frame Size 075 100 130

62

C15 178.9 (7.04) 187.8 (7.39) 206.7 (8.14)

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Filtration Figure 52: Integral Pressure Filter View "X"

Option P & L

Gauge port M6 Charge pressure before filter 9/16-18UNF ø 94.2 max. (max. 3.71 Dia)

180°

"X"

180° Gauge port M3 Charge pressure after filter 9/16-18UNF

Required for removal

20.3 min. (.80 min.)

22.86 (.90)

F1 = short filter cartridge (Option P) F2 = long filter cartridge (Option L)

F4 max.

Frame Size030 - 130 = Option P Frame Size042 - 250 = Option L

F3

Figure 53: Remote Pressure - without filter View "X"

Option R & T

Port E from filter 7/8-14UNF (Option R) 1 1/16 -12UN (Option T)

5.6 (.22)

180°

5,6 (.22)

"X" 180°

Port D to filter 7/8-14UNF (Option R) 1 1/16 -12UN (Option T)

Gauge port M3 Charge pressure after filter 9/16-18UNF

F5 max.

F6 max.

Frame Size030 - 130 = Option R Frame Size180 + 250= Option T

F7 max.

28.5 (1.12) F3 P001 357E

Table 28: Dimensions [mm (in.)]

Frame Size

F1

F2

F3

F4 max.

F5 max.

F6 max.

F7 max.

030

174.5 (6.87)

-

176.8 (6.96)

203.0 (7.99)

107.7 (4.24)

147.7 (5.81)

163.0 (6.42)

042

174.5 (6.87) 262.6 (10.34) 201.4 (7.93)

208.0 (8.19)

112.7 (4.44)

152.7 (6.01)

168.0 (6.61)

055

174.5 (6.87) 262.6 (10.34) 240.9 (9.48)

209.6 (8.25)

114.3 (4.50)

154.3 (6.07)

169.6 (6.68)

075

174.5 (6.87) 262.6 (10.34) 270.5 (10.65) 214.4 (8.44)

119.1 (4.69)

159.1 (6.26)

174.4 (6.86)

100

174.5 (6.87) 262.6 (10.34) 280.7 (11.05) 223.0 (8.78)

127.7 (5.03)

167.7 (6.60)

183.0 (7.20)

130

174.5 (6.87) 262.6 (10.34) 299.9 (11.81) 233.0 (9.17)

137.7 (5.42)

177.7 (6.99)

193.0 (7.60)

180

-

-

327.8 (12.90)

-

182.0 (7.16)

236.8 (9.32)

259.2 (10.2)

250

-

-

342.8 (13.49)

-

182.0 (7.16)

236.8 (9.32)

259.2 (10.2) 63

CONTENTS

saue Hydraulic Power Systems SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide SAUER-SUNDSTRAND is a world leader in the design and manufacture of Hydraulic Power Systems. Research and development resources in both North America and Europe enable SAUER-SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology.

SAUER-SUNDSTRAND specializes in integrating a full range of system components to provide vehicle designers with the most advanced total-design system.

SAUER-SUNDSTRAND is Your World Source for Controlled Hydraulic Power Systems.

F000 691

F000 692

Heavy Duty Axial Piston Pumps and Motors

Heavy Duty Bent Axis Variable Motors F000 685 F000 688

Medium Duty Axial Piston Pumps and Motors

Cartridge Motors/ Compact Wheel Drives F000 690

Microcontrollers and Electrohydraulic Controls F000 689

Open Circuit Axial Piston Pumps

F000 686

F000 684

Hydrostatic Transmission Packages F000 687

Gear Pumps and Motors

F000 693

Genuine Service Parts

Worldwide Service Support SAUER-SUNDSTRAND provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world.

Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.

saue TI-SPV90E • 04/96 • 369 108A BLN-10029 • Rev. D • May 1996

SAUER-SUNDSTRAND COMPANY 2800 East 13th Street Ames IA 50010 • U.S.A. Phone: (515) 239-6000 • FAX: (515) 239-6618

SAUER-SUNDSTRAND GMBH & CO. Postfach 2460 • D-24531 Neumünster Krokamp 35 • D-24539 Neumünster • Germany Phone: (04321) 871-0 • FAX: (04321) 871 122