DOWNLOAD PDF Cat DBT 7SFBH-56 Feeder Breaker Operation Manual

Operation Manual DBT-

Feeder Breaker Model 7SFBH-56

Doc. No.: A6474X234

DBT America 4041 Wurno Road Pulaski, VA 24301

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

Internet: www.dbtamerica.com

This manual is intended to provide GENERAL product information for the Model FSFBH-56 Feeder Breaker. The illustrations, descriptions and procedures contained in this publication apply only to this unit. 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 system.

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 2004 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 used.................................................1.5

2. Your safety Your safety ..................................................................................2.3 Personnel ................................................................................2.4 Operation.................................................................................2.4 Installation and repair..............................................................2.4 Operating conditions ...............................................................2.5 Intended use............................................................................2.5 Unauthorized use ....................................................................2.5 Safety instructions ...................................................................2.7 General rules:..........................................................................2.7 Storage and transport .............................................................2.8 Installation and start-up...........................................................2.8 Operation.................................................................................2.9 Maintenance and repair ..........................................................2.9 Overview of the safety instructions .......................................2.15

3. Storage and transport Storage and transport ................................................................3.3 Storage....................................................................................3.3 Storage of the machine and spare parts.................................3.3 Transport .................................................................................3.4 Load units; dimensions and weights .......................................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

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Table of Contents

Safety features........................................................................ 4.6 Overview of the feeder breaker .............................................. 4.9

5. Operation Operation .................................................................................... 5.3 How to operate the feeder breaker......................................... 5.3 Who is allowed to operate the feeder breaker?...................... 5.3 When can conveying be started? ........................................... 5.3 Controls and indicators ........................................................... 5.4 Operator’s station ................................................................... 5.4 Conveyor................................................................................. 5.9 Fire suppression ..................................................................... 5.9 Daily starting procedure........................................................ 5.11 Shut down procedure............................................................ 5.12 Electrical system................................................................... 5.13 Starter box ............................................................................ 5.13 Electrical components........................................................... 5.15 Hydraulic system .................................................................. 5.17 Hydraulic components .......................................................... 5.17 Mechanical assemblies......................................................... 5.21 Breaker assembly ................................................................. 5.21 Tail shaft ............................................................................... 5.22 Conveyor chain..................................................................... 5.23 Grease take-up ..................................................................... 5.24 Head shaft............................................................................. 5.25 Breaker power unit................................................................ 5.26 Instructions on the maintenance of the feeder breaker ........ 5.27 Important notes..................................................................... 5.27 Before maintenance.............................................................. 5.27 Lubrication and inspection .................................................... 5.29 Instructions on the adjustment procedures........................... 5.47 Conveyor chain..................................................................... 5.47 Breaker drive chain............................................................... 5.49 Breaker assembly adjustment .............................................. 5.51 Instructions on the replacement of wear parts...................... 5.53 Head shaft............................................................................. 5.53 Head shaft sprockets ............................................................ 5.56 Tail shaft ............................................................................... 5.58 Conveyor chain..................................................................... 5.63 Breaker assembly ................................................................. 5.67 Breaker drive chain............................................................... 5.76 Breaker power unit................................................................ 5.78

Model 7SFBH-56 Feeder Breaker

Table of Contents

6. Technical data Technical data.............................................................................6.3 Components of the feeder breaker .........................................6.3 Technical data sheet ...............................................................6.3 Tightening torques...................................................................6.5 Permissible media .................................................................6.11 Lubrication fluids and greases ..............................................6.11

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

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Table of Contents

Model 7SFBH-56 Feeder Breaker

1

About this manual

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 7SFBH-56 Feeder Breaker Serial No.: 54-2121 and is only permitted to be used for equipment of this type.

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.

new operation manual

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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1.3

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

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

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

1.4

service

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

safety

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

Model 7SFBH-56 Feeder Breaker

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

Try to memorize the symbols and their meanings.

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

WARNING! These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

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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1.5

Before starting to work

1.6

Model 7SFBH-56 Feeder Breaker

2

Your safety

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.

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. 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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2.3

Personnel

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

The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit.

Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the

mechanics, hydraulics and control engineering

and must be able to prove this knowledge.

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

Installation and repair work on:

safety components (pressure relief valves, extinguishers, etc.) the electrics (motors, controllers, etc.) the hydraulics (controls, cylinders, etc.)

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

2.4

Model 7SFBH-56 Feeder Breaker

Operating conditions

Operating conditions Intended use The feeder breaker has been designed and manufactured purely for 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 Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.

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

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

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2.5

Operating conditions

2.6

Model 7SFBH-56 Feeder Breaker

Safety instructions

Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

Inform your colleagues of:

safety equipment

your exact location. the work you are performing. the time that you will probably require.

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

Observe the acoustic and optical start-up warnings of the feeder breaker.

symbol plates emergency stop

lock-out

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:

cordon off working area moving parts

Cordon off your working area widely for the feeder breaker.

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

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maintenance work inspection work repair work

conveyor chains flights pivot points crusher shafts boom assemblies

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2.7

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

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

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

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

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

mobile handling equipment

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

Installation and start-up inclined face environmental acceptability

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

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

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

2.8

Model 7SFBH-56 Feeder Breaker

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

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

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

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

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

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

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

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

Protect your work area against falling rocks.

replacing components

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

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

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original DBT America spare parts.

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

For raising the feeder breaker use only:

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crib blocks with adequate load-holding capacity. hoists, jacks or cranes with adequate load-carrying capacity.

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2.9

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.

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

the hoses are not pinched or trapped. the hoses have no bubbles or blisters. the hose or outer sheathes of the hose are not abnormally rigid or hard. the outer sheath of the hoses is not damaged. the connectors are securely inserted into the sockets. the connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage in the whole system!

Flush out the hydraulic lines thoroughly before connecting.

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

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.

2.10

Model 7SFBH-56 Feeder Breaker

Safety instructions permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn o-rings.

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 2 years old, even if they have no visible signs of damage.

Fig. 1 Example: 4SP hydraulic hose, designation

1 2 3

manufacturer hose type date of manufacture 1st quarter 2000

4 5

nominal diameter 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. laying hydraulic hoses

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

Always lay hydraulic hoses so they:

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always have a little slack.

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2.11

Safety instructions Fig. 2 Laying hydraulic hoses, slack RIGHT

WRONG

are not twisted.

Fig. 3 Laying hydraulic hoses, twisting RIGHT

WRONG

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

Fig. 4 Laying hydraulic hoses, bending RIGHT

2.12

WRONG

Model 7SFBH-56 Feeder Breaker

Safety instructions

cannot chafe.

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.

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

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

Fig. 6 Laying hydraulic hoses, connections on moving parts RIGHT

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WRONG

2.13

Safety instructions

2.14

Model 7SFBH-56 Feeder Breaker

Overview of safety instructions

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

Chapter 3: Storage and transport 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.

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.

Use only approved lifting equipment!

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

Chapter 4: Installation DANGER! When using an additional pulling device (e.g. lifting tackle with adequate load limit) for coupling the ends of the conveyor chain, the chain ends must not be fitted and pulled with so-called C-links (chain link cut open).

The C-links could fracture under the load. You could be seriously injured or killed by the recoiling chain.

Use only approved lifting equipment for connecting pulling devices to the conveyor chain.

Working on chains which are under tension requires particular care. You or others could be seriously injured or killed by the recoiling chain!

During the tensioning procedure, ensure that all persons are kept out of the danger area and that the danger area is cordoned off widely!

Always work from alongside of the conveyor chain.

You could be injured or killed by a jumping hydraulic hose.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely.

Never use nails, wire or similar materials for securing.

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2.15

Overview of safety instructions Make sure that nobody is present in the danger area of the conveyor during the test run!

In this phase, a safe distance should be kept with respect to the conveyor as e.g. due to installation errors hazards may occur which would not occur during normal operation.

These hazards could cause severe injuries or even death!

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

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

The machine is equipped with a tail shaft cover plate to reduce the possibility of personnel stepping inside the gap between the tail shaft and the conveyor. The cover plate should not be removed during operation.

DANGER! Do not operate the machine with the tail shaft cover plate removed.

You or other personnel could be seriously injured from the rotating conveyor chain.

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.

2.16

Model 7SFBH-56 Feeder Breaker

Overview of safety instructions Chapter 5: Operation DANGER! Incorrect operation endangers yourself and others!

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

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

Should anything be unclear, please contact your immediate supervisor.

NOTICE! The fire suppression system must be recharged after it has been actuated from either actuator. (See Fire suppression system recharging in this chapter) The machine should not be restarted until the fire suppression system has been serviced and cleaned.

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

In the event the conveyor becomes jammed and it is necessary to reverse the chain, this may be done by setting the FWD/OFF/REV switch to the REV position on the starter box.

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.

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.

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2.17

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

DANGER! 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.

NOTICE! In the event that a sudden jam occurs which could damage the power unit, the breaker is protected by a shear pin. See Breaker power unit in this chapter for more information on the coupling.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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

Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

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

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

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.

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

2.18

Model 7SFBH-56 Feeder Breaker

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

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

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

DANGER! 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.

IMPORTANT! If the bearing has been allowed to fail completely, it may be necessary to cut the bearing from the shaft, using a torch. If a torch is required, care should be taken to prevent gauging or overheating of the shaft in the area of the bearing fit.

IMPORTANT! Apply a coat of Permatex gasket sealer to each seal washer prior to installation. Torque bearing end cap bolts to 140 - 150 ft-lbs and secure with locking wire (item 7).

IMPORTANT! If the bearing has been allowed to fail completely, it may be necessary to cut the bearing from the shaft, using a torch. If a torch is required, care should be taken to prevent gauging or overheating of the shaft in the area of the bearing fit.

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.

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2.19

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.

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.

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.

2.20

Model 7SFBH-56 Feeder Breaker

3

Storage and transport

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 gear boxes, hydraulic oil tank, etc. are filled to their maximum fill point.

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

dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic – such as seals and hoses – and hydraulic fluids only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).

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

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

short-term storage

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

long-term storage

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

Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow.

Then seal the ports with plastic or steel plugs.

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

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3.3

Storage and transport plastic deformation

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

random sample inspection

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

On request, the inspection can be carried out by 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.

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.

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.

3.4

Model 7sfbh-56 Feeder Breaker

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/frost-proofing 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.

electronic components

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

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

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3.5

Storage and transport

3.6

Model 7sfbh-56 Feeder Breaker

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 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

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

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4.3

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

These include i.e.:

hoists with adequate lifting capacity means of attachment with adequate lifting capacity impact wrenches, including accessories jacks with adequate lifting capacity

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.

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

4.4

Model 7SFBH-56 Feeder Breaker

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

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

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perform daily maintenance visually inspect all hydraulic hoses and electrical cables for damage 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 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 (if equipped) 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

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4.5

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

Safety features include: (Reference Fig. 7) emergency stop button

The emergency stop buttons are located on the left and right hand sides of the machine. Striking with a small amount of force will actuate either button. The emergency stop buttons are used to break the control circuit in emergency situations. When either button 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.

stop switch

The stop switch is located on the right hand side of the machine on the controller box cover. Depressing the stop switch button will shutdown all machine functions 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 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 inward 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.

tail shaft cover plate

The machine is equipped with a tail shaft cover plate to reduce the possibility of personnel stepping inside the gap between the tail shaft and the conveyor. The cover plate should not be removed during operation.

DANGER! Do not operate the machine with the tail shaft cover plate removed.

You or other personnel could be seriously injured from the rotating conveyor chain.

4.6

Model 7SFBH-56 Feeder Breaker

Installation pendulum switch

The machine is equipped with a pendulum switch for remote starting of the machine. If used, it should be located, by the customer, at the most convenient location.

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.

Fig. 7: Safety features of the feeder breaker

Emergency stop push-button

Fire suppression actuator Left hand side of machine

Note: emergency stop pull cord switch, not shown.

Emergency stop push-button

Covers and guards

Pendulum switch

Tail shaft cover plate

Fire suppression actuator Right hand side of machine

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4.7

Installation

4.8

Model 7SFBH-56 Feeder Breaker

Overview of the feeder breaker Overview of the feeder breaker Fig. 8: Overview of the feeder breaker

Head shaft

Breaker power unit

Right hand side of machine Starter box

Conveyor chain and flights

Oil Tank

Left hand side of machine Operator’s station

Ratio chains not shown

Breaker assembly

Pendulum switch

Tail shaft cover

Receiving end of machine

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4.9

Overview of the feeder breaker

4.10

Model 7SFBH-56 Feeder Breaker

5

Operation

How to operate the feeder breaker

Operation This chapter contains important information on the operation and maintenance of the feeder breaker. 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 feeder breaker and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the feeder breaker?

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

This also includes: what safety devices are installed on the machine. where these safety devices are located. how these safety devices are to be operated.

When can conveying be started?

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

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How to operate the feeder breaker Controls and indicators Operator’s station The primary controls for the machine are located on the left hand discharge end of the machine (Fig. 9). The operator’s station consists of the following controls and indicators: main system pressure gauges, starter box, and fire suppression actuator.

Fig. 9: Operator’s station

Pressure gauges

Fire suppression actuator

Starter box

5.4

Model 7SFBH-56 Feeder Breaker

How to operate the feeder breaker pressure gauge bank

Located to the operator’s left is the pressure gauge bank (Fig. 10), which indicates hydraulic system pressures. The two gauges are high pressure gauges that show the main system operating pressures. One gauge represents the pressure for the conveyor pump and the other represents the charge pressure for the conveyor pump.

Fig. 10: Pressure gauge bank

System pressure

Charge pressure

fire suppression actuator (s)

The machine is equipped with two (2) fire suppression actuators (Fig. 11); one is located at the operator’s station and the other at the receiving end on the right hand side. 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. (See Fire suppression system in this chapter) NOTICE! The fire suppression system must be recharged after it has been actuated from either actuator. (See Fire suppression system recharging in this chapter) The machine should not be restarted until the fire suppression system has been serviced and cleaned.

Fig. 11: Fire suppression actuators

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5.5

How to operate the feeder breaker starter box

5.6

The starter box (Fig. 12) located on the left hand side of the machine , consists of the following machine’s electrical functions:

Power on indicator light – This red light will be illuminated anytime the machine has electrical power connected to the machine.

High pressure indicator light – This yellow light will be illuminated when the system pressure is operating properly. In the event that the light is not illuminated the machine will shutdown. Before the machine will restart, the system pressure must be brought up to the proper pressure and then perform the daily starting procedure.

High temperature indicator light – This yellow light will be illuminated when the fluid in the primary oil tank on the machine is operating at its proper operating temperature. In the event that the light is not illuminated, the machine will shut down. Before the machine will restart, the machine must be allowed to cool to its proper operating temperature and then perform the daily starting procedure.

Low oil indicator light – This yellow light will be illuminated when the fluid in the primary oil tank is at its proper operating level. In the event that the light is not illuminated, the machine will shut down.

Before the machine will restart, the oil level must be re-established to its proper operating level and then perform the daily starting procedure.

Start push-button – This green push-button starts the electric motor that drives the breaker and hydraulic pump on the machine.

Stop push-button – This red push-button stops the electric motor that drives the breaker and hydraulic pump on the machine.

Auto/manual selector switch – In the manual position (rotated clockwise CW) and with the breaker motor running, the conveyor may be started from any of the remote start push-buttons. Hold the push-button for approximately ten (10) seconds, and the conveyor will run until a remote stop push-button is actuated. In the auto position (rotated counter clockwise CCW), once the conveyor motor is started from any of the remote start push-buttons, the conveyor will run for the time programmed into the PLC in the starter box.

Pilot test push-button – This red push-button is used to test the pilot circuit between the machine and the power center. If this circuit is interrupted the machine will not operate.

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

Model 7SFBH-56 Feeder Breaker

How to operate the feeder breaker

Speed pot – This rotary switch determines the desired speed of the conveyor chain. To increase speed, rotate the switch clockwise (CW) and to decrease speed, rotate the switch counter clockwise (CCW).

Forward/reverse selector switch – This selector switch determines the direction of conveyor travel. In the forward position the conveyor chain will travel from the receiving end to the discharge end and in the reverse position the conveyor chain will travel from the discharge end to the receiving end.

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

Fig. 12: Starter box electrical functions

HIGH PRESSURE

POWER ON

HIGH TEMP

START

STOP

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SPEED POT

LOW OIL

CIRCUIT BREAKER RESET

PILOT TEST OFF AUTO MAN

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E-STOP

NEUTRAL FORWARD REVERSE

5.7

How to operate the feeder breaker emergency stop button (s)

The emergency stop buttons (Fig. 13) are located on the left and right hand sides of the receiving end of the machine. Striking with a small amount of force will actuate either button. The emergency stop buttons are used to break the control circuit in emergency situations. When either button 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 (Fig. 13). One is located adjacent to the operator’s station on the left side of the machine. The other is located on the receiving section 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 inward 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.

Fig. 13: Emergency stop buttons and fire suppression actuators

Emergency stop push-button

Fire suppression actuator Left hand side of machine Emergency stop push-button

Fire suppression actuator

Right hand side of machine

5.8

Model 7SFBH-56 Feeder Breaker

How to operate the feeder breaker

Conveyor Perform daily start-up procedure. The conveyor may be started utilizing the push-buttons at the starter box or the remote start stations, if equipped.

The running time for the conveyor is controlled by a timer in the starter box. This timer is set for the conveyor to operate for five (5) minutes.

Each time the conveyor is started, the timer resets, thereby allowing the conveyor to empty before shutting down.

In the event the conveyor becomes jammed and it is necessary to reverse the chain, this may be done by setting the FWD/OFF/REV switch to the REV position on the starter box.

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.

Fire suppression The machine is equipped is equipped with a fixed nozzle dry chemical fire suppression system (Fig. 14). 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 discharge 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.

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.

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.

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5.9

How to operate the feeder breaker Fig. 14: Fire suppression LP Expellant

LP Expellant

LP Canister Remote actuator

Hopper end LP Canister Nozzle

Starter box

Nozzle Operator’s station

Conveyor coupling Nozzle

Oil tank

Nozzle Nozzle Remote actuator

Breaker coupling

Conveyor motor Nozzle

Nozzle

Breaker motor Nozzle Pump

5.10

Model 7SFBH-56 Feeder Breaker

How to operate the feeder breaker

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

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

) Check conveyor for any foreign material or objects. ) Check that all other personnel are within a safe distance of the machine.

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

) Set Auto-Off-Man switch on control console to the “Auto” position. ) Push and hold in the breaker start button for approximately ten (10) seconds.

) Start conveyor motor.

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5.11

How to operate the feeder breaker

Shut down procedure ) 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 box. ) Turn the Auto/Man switch to the “OFF” position. ) Move the Forward/Reverse switch to the “NEUTRAL” position. ) Turn the Speed Pot switch to the lowest speed (counter clockwise).

5.12

Model 7SFBH-56 Feeder Breaker

Electrical system on the feeder breaker 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.

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 box and attempting any maintenance or troubleshooting on the machine, the main power must be disconnected and locked out at the main power center.

Starter box The starter box (Fig. 15) located on the left hand side of the discharge end of the machine. It houses the primary electrical control components for the machine.

On the left hand 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 conveyor, and the start and stop functions for the breaker. Located on the right hand 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.

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5.13

Electrical system on the feeder breaker Fig. 15: Starter box location

Right cover Left cover

Fig. 16: Panel board components

1.

2.

3.

4.

5.

6.

7.

8.

9.

circuit breaker w/shunt and line barrier, 400 amp 50VA control transformer .500KVA control transformer 3/10 amp fuse, 600 volt 1.5 amp fuse, 600 volt circuit breaker, ½ amp circuit breaker, 5 amp overload relay 300.5 current transducer

5.14

10.

11.

12.

13.

14.

15.

16.

17.

18.

vacuum contactor, 320 amp auxiliary contact limit switch isolator relay 33 KDHM resistor relay turk timer starter, 110 volt coil timer

Model 7SFBH-56 Feeder Breaker

Electrical system on the feeder breaker Electrical components electric motor

The machine has one (200 hp, 460 vac) electric drive motor (Fig. 17) that drives the breaker and hydraulic pump.

emergency stop button

The machine has two (2) emergency stop push-buttons (Fig. 17) located on the left and right hand sides of the receiving section. The pushbuttons are used to break the control circuit in emergency situations, stopping the electric motor. Striking with a small amount of force will actuate either emergency stop button.

motion switch

The machine has two (2) micro mini motion switches (Fig. 17). One is located on the non-drive end of the breaker assembly and functions as the breaker under speed sensor. The other switch is located on the customer belt conveyor to function as the feeder breaker / belt conveyor sequence switch.

pump solenoid

The pump solenoid (Fig. 17) located on the closed loop hydraulic conveyor pump strokes the pump swash plate varying the output flow to the hydraulic conveyor motor which varies the conveyor chain speed.

The solenoid input signal is varied by turning the potentiometer on the front of the starter enclosure.

pendulum switch

The pendulum switch (Fig. 17) located at the receiving end of the machine is used to start the machine remotely. The switch (when used) is located in an area where the haulage equipment operator can activate it without leaving their equipment.

temperature switch

The machine is equipped with a temperature switch (Fig. 17) located on the primary oil tank. It is used to monitor the temperature of the fluid inside the primary oil tank.

pressure switch

The machine is equipped with a pressure switch (Fig. 17) located on the primary oil tank. It is used to monitor the hydraulic system pressure of the machine.

oil level switch

The machine is equipped with a oil level switch (Fig. 17) located inside the primary oil tank. It is used to monitor the level of the fluid inside the primary oil tank.

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Electrical system on the feeder breaker Fig. 17: Electrical layout

5.16

Model 7SFBH-56 Feeder Breaker

Hydraulic system on the feeder breaker 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.

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.

DANGER! 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.

Hydraulic components hydraulic oil tank

The hydraulic oil tank (Fig. 19) located on the left hand side of the machine has a 100 gallon capacity and is equipped with oil level sight glass and oil level switch.

conveyor pump

The conveyor pump (Fig. 19) located on the breaker power unit assembly is used to supply the required flow of hydraulic fluid to the hydraulic motor.

loop flush valve

The loop flush valve (Fig. 19) located within the conveyor circuit is used to dump approximately 30% of the charge oil to the low pressure side of the circuit.

charge filter

The charge filter (Fig. 19) located within the conveyor circuit is used to filter the charge fluid. This removes hot oil from the circuit allowing the charge pump to replenish the circuit with cooler oil.

return filter

The return filter (Fig. 19) located within the conveyor circuit is used to filter the hydraulic fluid from the case drains of the conveyor pump and motor.

conveyor motor

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The conveyor motor (Fig. 19) located on the left side of the head shaft is a radial piston motor that receives hydraulic fluid from the hydraulic pump. It is used to drive the conveyor chain assembly.

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5.17

Hydraulic system on the feeder breaker

needle valve

The two (2) needle valves (Fig. 19) located with each pressure gauge are used to shut off line pressure to the pressure gauge in the case that a pressure gauge may malfunction.

5000 psi pressure gauge

The 5000 psi pressure gauge (Fig. 19) located to left of the operator’s station is used to give the operator a continuous reading of the system pressure.

600 psi pressure gauge

The 600 psi pressure gauge (Fig. 19) located to left of the operator’s station is used to give the operator a continuous reading of the charge pressure.

heat exchanger

The heat exchanger (Fig. 19) located within the conveyor circuit is used to remove heat from the hydraulic circuit prior to dumping into tank.

5.18

Model 7SFBH-56 Feeder Breaker

Hydraulic system on the feeder breaker Fig. 18: Hydraulic schematic

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5.19

Hydraulic system on the feeder breaker

Fig. 19: Conveyor circuit

1.

2.

3.

4.

5.

5.20

oil tank conveyor pump loop flush valve charge filter conveyor motor

6.

7.

8.

9.

10.

needle valve 5000 psi gauge 600 psi gauge return filter heat exchanger

Model 7SFBH-56 Feeder Breaker

Hydraulic system on the feeder breaker

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5.21

Mechanical assemblies on the feeder breaker 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 The breaker assembly (Fig. 20) on the machine has a 38” pick circle with a 6 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 right hand side that will shutdown the machine should the breaker be stalled due to a jam.

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

Fig. 20: Breaker assembly components

Bearing (2)

Pick (46) Not shown

Breaker

Shear hub Bearing retainer (2)

Breaker side plate (2) Bearing housing (2)

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Magnetic cut-off assembly

5.21

Mechanical assemblies on the feeder breaker Tail shaft The machine is equipped with a tail shaft (Fig. 21) 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. 21: Tail shaft components

Roller (2)

Key (2) Set screw (2)

5.22

Tail shaft

Slide plate

Grease fitting (2)

Roller bearing (2) Piston rod adapter (2)

Model 7SFBH-56 Feeder Breaker

Mechanical assemblies on the feeder breaker Conveyor chain The conveyor chain assembly (Fig. 22) 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.

Fig. 22: Conveyor chain components

6 Link chain section

Flight bar

6 Link chain section Lock nut (4)

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5.23

Mechanical assemblies on the feeder breaker Grease take-up The machine is equipped with a conveyor chain grease take-up assembly (Fig. 23) 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. 23: Grease take-up components

1.

2.

3.

4.

5.

6.

7.

8.

9.

5.24

manifold stop valve (2) union (4) r. h. hose assembly l .h. hose assembly take-up cylinder (2) tee grease fitting auto relief indicator

10.

11.

12.

13.

14.

15.

16.

17.

18.

adapter (2) check valve cap screw (2) retainer pin (2) washer (flat) (2) cotter pin (2) washer (lock) (2) nut (hex) (2) shim set (2)

Model 7SFBH-56 Feeder Breaker

Mechanical assemblies on the feeder breaker Head shaft The feeder breaker is equipped with a head shaft (Fig. 24) located on the discharge end of the conveyor. The head shaft is driven from the left hand side via a hydraulic motor which is directly connected to the head shaft.

Fig. 24: Head shaft assembly components

Hydraulic motor Sprocket

Sprocket

Head shaft Bearing

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Bearing

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5.25

Mechanical assemblies on the feeder breaker Breaker power unit The breaker power unit drives the breaker assembly and hydraulic pump (Fig. 25). It consists of a 200 HP electric motor, coupled to a Link-Belt (Model LC250) right angle gear reducer, via a flexible coupling. 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. 25: Breaker power unit components

Pump mounting pedestal

Electric motor

Sprocket

Hydraulic pump

Gear reducer Mounting base

5.26

Coupling

Model 7SFBH-56 Feeder Breaker

Instructions on the maintenance of the feeder breaker 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 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.

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 start.

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

Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

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5.27

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

5.28

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.

Model 7SFBH-56 Feeder Breaker

Instructions on the maintenance of the feeder breaker 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.

Central lubrication system The central lubrication system (Fig. 26) 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. 26: Central lubrication piping

Tail shaft Tail shaft

Breaker Breaker shaft

Head shaft Head shaft

Central lubrication manifold

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Instructions on the maintenance of the feeder breaker Table 1: Lubrication and maintenance schedule Lube point 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 4 5 6 13

5.30

Description Every 8 hours of operation Head shaft bearings Breaker bearings Tail shaft and slide tube bearings Hydraulic oil tank: Check oil level Charge filter Return filter Bits (breaker) Weekly Conveyor chain tension Fasteners (Nuts, bolts and screws) Electrical cables and glands Hydraulic hoses and connections Hydraulic system pressure Breaker reducer Check oil level Breaker drive chain Every (3) months Electric Motor (breaker) Every 6 months or 2500 hours Hydraulic oil tank: Change Charge filter: Change element Return filter: Change element Breaker reducer: Change oil

Places

Lubricant

Specification

2 2 3 1

Exxon Lidok EP-2 Exxon Lidok EP-2 Exxon Lidok EP-2 NUTO H68

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

1 1 Inspect 1 Inspect Inspect Inspect Check 1 1

AGMA #5 mild extreme pressure Chain lube

1

Exxon Unirex N-2

1

NUTO H68

Spec. 100-1

1 1 1

AGMA #5 mild extreme pressure

Model 7SFBH-56 Feeder Breaker

Instructions on the maintenance of the feeder breaker Specific lubrication and maintenance procedures Every 8 hours of operation: head shaft bearings

Lubricate the head shaft bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 27) 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. 27) located on the left side of the receiving section. Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

tail shaft

Lubricate the tail shaft and slide tube bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 27) 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. 27: Central lubrication points

HEADSHAFT

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TAILSHAFT

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Instructions on the maintenance of the feeder breaker hydraulic oil tank

Check the hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 28). 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 through the fill cap located on top of the tank.

Fig. 28: Hydraulic oil tank

Breather

Fill cap

Sight glass

5.32

Model 7SFBH-56 Feeder Breaker

Instructions on the maintenance of the feeder breaker charge filter

Check the charge filter’s pop-style dirt alarm (Fig. 29) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

Fig. 29: Charge filter

Dirt alarm

Element

return filter

Check the return filter’s pop-up style dirt alarm (Fig. 30) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

Fig. 30: Return filter

Dirt alarm

Element

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Instructions on the maintenance of the feeder breaker bits (breaker)

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

Fig. 31: Breaker bit inspection

Breaker bits (46)

Breaker assembly

5.34

Model 7SFBH-56 Feeder Breaker

Instructions on the maintenance of the feeder breaker Weekly: 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 conveyor drive reducer mounting bolts conveyor flight fixing bolts tail shaft retainer hold down bolts all cover and guard retaining bolts

electrical cables 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

Check the hydraulic system pressure by visually looking at the pressure gauges located at the operator’s station. Refer to the hydraulic schematic in your parts manual for correct pressure.

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Instructions on the maintenance of the feeder breaker breaker reducer

Check oil level in the breaker drive reducer (Fig. 32). Oil level should be maintained inside the sight glass on the side of the reducer when it is in operation. If the reducer does not have a sight glass, a pipe plug will be installed in the side of the reducer slightly below the input shaft center line. This is the level that the fluid should be maintained at. The oil should be changed after the first 500 hours of operation. Use a high grade AGMA #5 mild extreme pressure lubricant (Spec. 100-6).

Fig. 32: Breaker reducer

Inspection cover

Breather

Grease fitting

Drain plug

Breaker drive chain

5.36

Lubricate the breaker drive chain with a good quality chain lube.

Model 7SFBH-56 Feeder Breaker

Instructions on the maintenance of the feeder breaker Every 3 months: electric motor (breaker)

Lubricate the electric breaker motor with Spec. 100-3 (Fig. 33):

) 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.

Fig. 33: Breaker motor lubrication Grease fitting

Grease fitting

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Instructions on the maintenance of the feeder breaker Every 6 months: hydraulic oil tank

Change the hydraulic fluid in the oil tank (Fig. 34).

) 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 until fluid is visible in sight glass. ) Install fill cap. ) Start the machine and allow the hydraulic pump to run in order to purge air from the system.

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

Fig. 34: Hydraulic oil tank

Breather

Fill cap

Sight glass

Drain plug

5.38

Model 7SFBH-56 Feeder Breaker

Instructions on the maintenance of the feeder breaker charge filter

Change the charge filter’s element (Fig. 35) . If the element is extremely dirty, a more frequent interval may be required.

Fig. 35: Charge filter

Dirt alarm

Element

return filter

Change the return filter’s element (Fig. 36) . If the element is extremely dirty, a more frequent interval may be required.

Fig. 36: Return filter

Dirt alarm

Element

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Instructions on the maintenance of the feeder breaker breaker reducer

Change the oil in the breaker drive reducer (Fig. 37).

) 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 100-6 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.

Fig. 37: Breaker reducer

Inspection cover

Breather

Grease fitting

Drain plug

5.40

Model 7SFBH-56 Feeder Breaker

Instructions on the maintenance of the feeder breaker 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 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 breaker reducer. ) Inspect all electrical and hydraulic components for condition. ) Check for proper conveyor 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.

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

Inspect:

) the conveyor chain ) the conveyor chain flights ) the conveyor drive sprockets ) the conveyor tail shaft ) the conveyor wear plates

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Instructions on the maintenance of the feeder breaker 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. 38).

) Note general appearance for mechanical damage or corrosion. ) Check nameplate for readability, corrosion or looseness. ) Remove fill cap assembly. ) Examine gaskets for elasticity, clean and coat lightly with a good

grade of high heat resistant grease. ) Inspect threads on fill cap and in fill opening for nicks, burrs, cross threading, rough or feathered edges. ) Check pressure relief vent in fill opening threads for obstruction. ) Make certain extinguisher is filled with free flowing Ansul dry chemical to a level of not more than 3” from bottom of fill opening. ) Secure fill cap, hand tight. ) Remove extinguisher cartridge guard assembly. ) 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. ) Disengage bursting disc union and open bracket clamp. ) 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). ) 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.

5.42

Model 7SFBH-56 Feeder Breaker

Instructions on the maintenance of the feeder breaker ) Seal ring pin to puncture lever with lead and wire seal. Return cartridge to remote actuator, hand tighten.

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

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Instructions on the maintenance of the feeder breaker Recharge of fire suppression system on the feeder breaker To return your fire suppression system to service after use (Fig. 38).

) Pull ring on safety valve to relieve actuator system pressure. ) Disconnect actuation system hose at cartridge receiver/actuator

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

5.44

Model 7SFBH-56 Feeder Breaker

Instructions on the maintenance of the feeder breaker 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. 38).

) 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.

) 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.

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Instructions on the maintenance of the feeder breaker Fig. 38: Fire suppression system LP Expellant

LP Expellant

LP Canister Remote actuator

Hopper end LP Canister Nozzle

Starter box

Nozzle Operator’s station

Conveyor coupling Nozzle

Oil tank

Nozzle Nozzle Remote actuator

Breaker coupling

Conveyor motor Nozzle

Nozzle

Breaker motor Nozzle Pump

5.46

Model 7SFBH-56 Feeder Breaker

Adjustment procedures on the feeder breaker 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 breaker assembly 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 The conveyor chain is a complete assembly and should be checked for correct tension at regular intervals.

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 39):

) Close the top valve securely. ) Attach a grease gun to the grease fitting located at the bottom of 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, raise tail shaft cover. ) Remove the three (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 and lower tail shaft cover. ) 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.

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Adjustment procedures on the feeder breaker Fig. 39: Conveyor chain adjustment

Top valve Auto-relief indicator

Grease fitting Grease take-up

Tail shaft cover

5.48

Model 7SFBH-56 Feeder Breaker

Adjustment procedures on the feeder breaker 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. 40):

) Remove the covers from the power unit. ) Remove the breaker drive chain guard. ) Loosen the power unit adjustment bolts located in the bottom and on the side of the power unit 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. ) 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 needle valve when releasing pressure. You could be seriously injured from high pressure grease.

) Tighten all adjustment bolts. ) Install breaker drive chain guard. ) Install power unit covers.

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Adjustment procedures on the feeder breaker

Fig. 40: Breaker drive chain adjustment (Typical power unit shown)

Main frame

Shim location

Grease fitting

Power unit mounting base

Needle valve Adjustment bolts

5.50

Take-up cylinder

Model 7SFBH-56 Feeder Breaker

Adjustment procedures on the feeder breaker Breaker assembly adjustment The breaker assembly can be adjusted in 1one inch increments.

To raise or lower the breaker assembly proceed as follows (Fig. 41):

) 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)

) Attach an appropriate lifting device around the breaker shaft

assembly and apply just enough lift to remove the twenty four (24) bolts, nuts, and lock washers (12 per side) that secure the breaker assembly to the frame.

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

Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

) With the aid of the lifting device, raise or lower the breaker assembly to the desired position.

) Secure the breaker with the twenty four (24) bolts, nuts, and lock washers (12 per side) and securely tighten.

) Remove the lifting device. ) Check drive chain tension and adjust if required. (See Breaker drive chain adjustment in this chapter) ) Install covers and guards.

Fig. 41: Breaker adjustment

Mounting bolt location

Breaker side plate (Typical on both sides of machine)

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Adjustment procedures on the feeder breaker

5.52

Model 7SFBH-56 Feeder Breaker

Instructions on the 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. 42) transmits the torque of the hydraulic motor to the conveyor chain assembly. It is part of a complete assembly. As soon as any component is worn, the component or complete head shaft must be replaced. Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

The head shaft assembly consists of the following main components:

drive shaft sprockets bearings

Fig. 42: Head shaft main components

Sprocket

Head shaft

Bearing

Sprocket

Bearing

Hydraulic motor (Ref.)

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Instructions on the replacement of wear parts How to remove the head shaft To remove the head shaft assembly from the discharge boom proceed as follows (Fig. 43):

) 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) covers located on the end of the discharge boom. ) Remove the hydraulic motor. (See Hydraulic motor removal in this chapter) ) Disconnect the central lubrication hoses on both head shaft bearings and cap ends of the hoses. ) Remove the four (4) nuts, bolts, and lock washers from each of the head shaft bearings. ) Attach an appropriate lifting device to the head shaft and slide out towards the rear of the frame.

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

Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

How to install the head shaft To install the head shaft assembly proceed as follows (Fig. 43):

) 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.

) Connect the central lubrication hoses on both head shaft bearings. ) Install the hydraulic motor. (See Hydraulic motor installation in this chapter)

) Install the two (2) covers on the end of the discharge boom. ) Connect conveyor chain. (See Conveyor chain replacement in this chapter).

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

5.54

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts Fig. 43: Head shaft removal and installation

Sprocket

Sprocket Head shaft

Bearing mounting bolts (8)

Bearing (2)

Hydraulic motor (Ref.) Discharge boom covers

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Instructions on the replacement of wear parts Head shaft sprockets The head shaft sprocket transmits the torque of the hydraulic 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. 44):

) 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 set screws from each sprocket. ) Slide both sprockets from the drive shaft. ) Remove old keys. ) Inspect all components of the drive shaft for wear and damage. See parts manual for replacement parts list.

How to install the head shaft sprockets To install the sprockets on the head shaft assembly proceed as follows (Fig. 44):

) 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 and tighten the two set screws to secure the sprocket.

) Slide the long spacer onto the shaft. ) Insert the other key into the shaft keyway and slide second sprocket onto shaft and tighten the two set screws to secure the sprocket. ) Slide both bearings onto shaft. ) Install the drive shaft assembly in the discharge boom. (See drive shaft installation in this chapter)

5.56

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts

Fig. 44: Head shaft sprocket removal and installation

Sprocket (2) Bearing (2)

Key (1) per sprocket

Set screw (2 ) per sprocket

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Instructions on the replacement of wear parts Tail shaft The tail shaft (Fig. 45) 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.

The tail shaft assembly consists of the following main components:

shaft roller (2) slide plate key (2) set screw (2) roller bearing (2) piston rod adapter (2) grease fitting (2)

Fig. 45: Tail shaft main components

Roller (2)

Key (2) Set screw (2)

5.58

Tail shaft

Slide plate

Grease fitting (2)

Roller bearing (2) Piston rod adapter (2)

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts How to remove the tail shaft To remove the tail shaft assembly from the receiving boom proceed as follows (Fig. 46):

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

) Lift up the tail shaft cover plate. ) Disconnect, tag, and cap the central lubrication hoses to the tail shaft.

) Remove the three (3) bolts and lock washers from each of the tail shaft retainers and lift out the retainers. ) Remove the tail shaft shims. ) Separate conveyor chain and fold back to clear tail shaft. (See Conveyor chain replacement in this chapter) ) Lift out the tail shaft and repair as required.

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 46):

) Insert tail shaft into receiving boom. ) Fold the conveyor chain back over tail shaft. ) Connect conveyor chain (see Conveyor chain replacement in this

chapter). ) Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter). ) Install the tail shaft retainers with the three (3) bolts and lock washers in each side. ) Connect central lubrication hoses and lubricate tail shaft and slide plate bearings with Spec. 100-3 grease. ) With machine running, visually inspect tail shaft to ensure that the shaft is turning and conveyor chain is not sliding across tail shaft.

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Instructions on the replacement of wear parts

Fig. 46: Tail shaft removal and installation

Tail shaft retainers (Located under cover plate)

Tail shaft cover plate

Tail shaft (Located under cover plate)

5.60

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 47):

) 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 both keys from 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 To assemble the tail shaft assembly proceed as follows (Fig. 47):

) Thoroughly clean any parts that will be re-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)

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Instructions on the replacement of wear parts

Fig. 47: Tail shaft disassembly and assembly

Roller (2)

Key (2) Set screw (2)

5.62

Tail shaft

Slide plate

Grease fitting (2)

Roller bearing (2) Piston rod adapter (2)

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts Conveyor chain The conveyor chain (Fig. 48) 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:

chain connecting link flight nut (lock) retainer collar Fig. 48: Conveyor chain components

Flight bar

Nut (lock)

Connecting link

Retainer collar

Chain assembly

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Instructions on the replacement of wear parts How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 48):

) Lay conveyor chain sections on a clean flat surface. ) Insert connector through retainer collar and through flight end. ) Install locknut on connector.

IMPORTANT! Use a thin walled socket, universal and impact wrench to tighten locknut.

) Tack weld locknut to pin.

CAUTION! Do not use elastic stop nut on chain connector pins. Damage to the machine or conveyor chain could occur due to the elastic nuts vibrating off.

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

5.64

Model 7SFBH-56 Feeder Breaker

Instructions on the 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).

) Lift up tail shaft cover plate. ) Separate conveyor chain by removing nuts and chain connectors

from each side of conveyor 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.

DANGER! 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.

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Instructions on the replacement of wear parts 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.

) 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.

DANGER! 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.

) 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. ) Align chain connection point with access holes in conveyor side plates. ) Connect conveyor chain (see How to assemble the conveyor chain sections in this chapter for proper connection). ) Adjust tension on the conveyor chain (see Conveyor chain adjustment procedure in this chapter). ) With machine running, visually inspect tail shaft to ensure that that the shaft is turning and conveyor chain is not sliding across tail shaft.

5.66

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts Breaker assembly The breaker assembly (Fig. 49) is assembled as a complete unit and should be removed as a unit for repairs except for the replacement of the shear hub assembly, bits and magnetic cutoff assembly. As soon as any component of the breaker assembly is worn or damaged, the component or complete assembly must be replaced.

The breaker assembly consists of the following main components:

breaker shear hub assembly bearing housing (2) bearing (2) bits (46) bearing retainer (2) magnetic cutoff assembly seal washer (3) breaker side plate (2) retaining cap dust cover shims

Fig. 49: Breaker assembly components

1.

2.

3.

4.

5.

6.

breaker shaft shear hub assembly bearing housing (2) bearing (2) bit (46) retaining ring (46)

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7.

8.

9.

10.

11.

bearing retainer (2) magnetic cutoff assembly sealwasher (3) cap screw 2 ½” (3) breaker side plate (2)

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12.

13.

14.

15.

16.

19 gauge wire retaining cap dust cover (2) shim .25” (2) shim .12” (2)

17.

18.

19.

20.

21.

shim .06” (2) cap screw 1 ¾” (160 cap screw 1” (8) cap screw 2 ¼” (6) lockwasher 1” (6)

5.67

Instructions on the replacement of wear parts How to remove the breaker assembly To remove the breaker assembly from the machine proceed as follows (Fig. 50):

) Remove covers and guards as required to gain access to the breaker assembly.

) Disconnect electrical wiring to the magnetic cutoff assembly. ) Disconnect, tag and cap the two (2) bearing central lubrication hoses.

) Attach an appropriate lifting device to support the breaker assembly.

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 breaker drive chain. (See Breaker drive chain replacement in this chapter)

) Ensure that the breaker assembly is adequately supported and

remove the bolts and lock washers that secure the breaker side plates, twelve (12) per side. ) 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. 50):

) Attach an appropriate lifting device to the breaker assembly and slowly lift the assembly into 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.

) Align mounting holes in the side plates with the desired holes in the frame of machine.

) Secure breaker assembly with the breaker side plate mounting bolts and lock washers, twelve (12) per side.

) Install the breaker drive chain. (See Breaker drive chain adjustment in this chapter)

) Connect electrical wiring to the magnetic cutoff assembly. ) Connect the two (2) bearing central lubrication hoses. ) Install all covers and guards that were removed.

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Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts

Fig. 50: Breaker assembly removal and installation Mounting bolt location (Quantity of 6 per side)

Mounting bolt location (Quantity of 6 per side)

Breaker assembly

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Breaker side plate (Typical on both sides of machine)

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5.69

Instructions on the replacement of wear parts How to disassemble the breaker assembly To disassemble the breaker assembly proceed as follows (Fig. 51):

) Remove the breaker assembly from the machine. (See How to remove the breaker assembly in this chapter)

To disassemble the drive side of the breaker assembly proceed as follows (Fig. 51):

) Remove the retaining cap (item 13) from the shaft by removing the

locking wire (item 7), three bolts (item 10) and seal washers (item 9).

) Remove the shear hub assembly (item 2) from the breaker shaft. ) Remove grease fitting from bearing housing (item 3). ) Remove the breaker side plate (item 11) from the shaft by removing the three bolts (item 20) and lock washers (item 21).

) Remove bearing retainer (item 7) from the shaft by removing the

eight bolts (item 18). ) Remove bearing housing (item 3) by removing the four bolts (item 19). ) Remove the bearing assembly (item 4). The bearing has a loose cone and cup fit, which should allow the bearing to slide off the shaft without the use of a press.

IMPORTANT! If the bearing has been allowed to fail completely, it may be necessary to cut the bearing from the shaft, using a torch. If a torch is required, care should be taken to prevent gauging or overheating of the shaft in the area of the bearing fit.

) Remove dust cover (item 14). ) Visually inspect all components for damage or wear and replace as necessary.

5.70

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts To assemble the drive side of the breaker assembly proceed as follows (Fig. 51):

) Install dust cover (item 14) onto shaft. ) Install bearing assembly (item 4). The bearing should slide onto

shaft with a minimal amount of force. Do not press against the outer case of the bearing. If a slight force is required, press only on the wear ring that the lip of the bearing seal bears on. ) Install bearing housing (item 3) and secure with the four bolts (item 19). ) Install bearing retainer (item 7) and secure with the eight bolts (item 18). A .06” gap must be maintained between bearing retainer (item 7) and bearing housing (item 3). Shim as required with shims (items 15, 16, and 17). ) Install the breaker side plate (item 11) and secure with the three bolts (item 20) and lock washers (item 21). ) Install grease fitting in bearing housing (item 3). ) Install the shear hub assembly (item 2) on the shaft. ) Install the retaining cap (item 13) and secure with the three bolts (item 10) and seal washers (item 9). Apply a coat of Permatex gasket sealer to each seal washer prior to installation. Torque bolts to 140 - 150 ft-lbs and secure with locking wire (item 7).

IMPORTANT! Apply a coat of Permatex gasket sealer to each seal washer prior to installation. Torque bearing end cap bolts to 140 - 150 ft-lbs and secure with locking wire (item 7).

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5.71

Instructions on the replacement of wear parts To disassemble the magnetic cutoff side of the breaker assembly proceed as follows (Fig. 51):

) Remove the magnetic sensor (item 8) from it’s mounting bracket ) Remove the magnetic sensor mount and retaining cap (item 13) from the shaft by removing the locking wire (item 7), three bolts (item 10) and seal washers (item 9). ) Remove grease fitting from bearing housing (item 3). ) Remove the breaker side plate (item 11) from the shaft by removing the three bolts (item 20) and lock washers (item 21). ) Remove bearing retainer (item 7) from the shaft by removing the eight bolts (item 18). ) Remove bearing housing (item 3) by removing the four bolts (item 19). ) Remove the bearing assembly (item 4). The bearing has a loose cone and cup fit, which should allow the bearing to slide off the shaft without the use of a press.

IMPORTANT! If the bearing has been allowed to fail completely, it may be necessary to cut the bearing from the shaft, using a torch. If a torch is required, care should be taken to prevent gauging or overheating of the shaft in the area of the bearing fit.

) Remove dust cover (item 14). ) Visually inspect all components for damage or wear and replace as necessary.

5.72

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts To assemble the magnetic cutoff side of the breaker assembly proceed as follows (Fig. 51):

) Install dust cover (item 14) onto shaft. ) Install bearing assembly (item 4). The bearing should slide onto

shaft with a minimal amount of force. Do not press against the outer case of the bearing. If a slight force is required, press only on the wear ring that the lip of the bearing seal bears on. ) Install bearing housing (item 3) and secure with the four bolts (item 19). ) Install bearing retainer (item 7) and secure with the eight bolts (item 18). A .06” gap must be maintained between bearing retainer (item 7) and bearing housing (item 3). Shim as required with shims (items 15, 16, and 17). ) Install the breaker side plate (item 11) and secure with the three bolts (item 20) and lock washers (item 21). ) Install grease fitting in bearing housing (item 3). ) Install the magnetic sensor mount and retaining cap (item 13) and secure with the three bolts (item 10) and seal washers (item 9).

Apply a coat of Permatex gasket sealer to each seal washer prior to installation. Torque bolts to 140 - 150 ft-lbs and secure with locking wire (item 7).

IMPORTANT! Apply a coat of Permatex gasket sealer to each seal washer prior to installation. Torque bearing end cap bolts to 140 - 150 ft-lbs and secure with locking wire (item 7).

) Install the magnetic sensor (item 8) into it’s mounting bracket

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5.73

Instructions on the replacement of wear parts Fig. 51: Breaker assembly and disassembly

1.

2.

3.

4.

5.

6.

5.74

breaker shaft shear hub assembly bearing housing (2) bearing (2) bit (46) retaining ring (46)

7.

8.

9.

10.

11.

bearing retainer (2) magnetic cutoff assembly sealwasher (3) cap screw 2 ½” (3) breaker side plate (2)

12.

13.

14.

15.

16.

19 gauge wire retaining cap dust cover (2) shim .25” (2) shim .12” (2)

17.

18.

19.

20.

21.

shim .06” (2) cap screw 1 ¾” (160 cap screw 1” (8) cap screw 2 ¼” (6) lockwasher 1” (6)

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts How to remove the breaker bit To remove the breaker bit from the breaker shaft bit holder proceed as follows (Fig. 52):

) Remove the external retaining ring from the shank end of the bit with a pair of external retaining ring pliers.

) Remove the bit from its holder. If the bit will not pull easily from its

holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.

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

How to install the breaker bit To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 52):

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

) Install the external retaining ring on the shank end of the bit with a

pair of external retaining ring pliers. Ensure that the retaining ring is completely seated inside grooved area of the bit.

Fig. 52: Breaker bit removal and installation

Breaker bit

Side view of breaker

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Retaining ring

5.75

Instructions on the replacement of wear parts Breaker drive chain The breaker drive chain (Fig. 53) is made up of one basic chain assembly, which repeats sequentially along the entire chain loop. As soon as the breaker chain is worn the complete chain assembly must be replaced.

Fig. 53: Breaker drive chain location

Breaker drive chain located behind cover

5.76

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts How to remove the breaker drive chain To remove the breaker drive chain proceed as follows.

) Remove breaker drive chain guard and breaker power unit cover. ) Release tension on the breaker drive chain. (See Breaker drive

chain adjustment in this chapter). ) Separate drive chain by removing cotter pins (can also be “T” pins) from any two (2) chain pins on a common link. Remove the side bar on the cottered side. Slide the chain link out from the side of the chain opposite the cottered side.

How to install the breaker drive chain To install the breaker drive chain proceed as follows.

) Loop drive chain completely around breaker drive sprocket and

reducer sprocket. ) Connect drive chain by sliding chain link thru both ends of chainand secure with side bar and cotter pins or “T” pins. ) Adjust tension on the breaker drive chain. (See Breaker drive chain adjustment in this chapter). ) Install breaker drive chain guard and breaker power unit cover.

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5.77

Instructions on the replacement of wear parts Breaker power unit The breaker power unit (Fig. 54) 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:

reducer drive motor coupling sprocket pump coupling mounting base pump pedestal hydraulic pump

Fig. 54: Breaker power unit main components

Pump mounting pedestal

Pump coupling

Drive motor

Sprocket

Hydraulic pump

Gear reducer Mounting base

5.78

Coupling

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts How to remove the breaker power unit To remove the breaker power unit as a complete assembly proceed as follows (Fig. 55):

) Remove breaker drive covers from the machine. ) Remove breaker drive chain guard. ) Disconnect and tag all electrical wiring to the drive motor. ) Disconnect, cap and tag all hydraulic hoses to the hydraulic motor. ) Release tension on the breaker drive chain. (See Breaker drive chain adjustment in this chapter).

) Separate drive chain. (See Breaker drive chain removal in this chapter).

) Remove the four (4) adjustment bolts and lock washers located on the side of the mounting base.

) Remove the take-up assembly. ) Attach an appropriate lifting device to the complete unit and slowly lift and remove unit from the machine.

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

Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

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5.79

Instructions on the replacement of wear parts How to install the breaker power unit To install the breaker power unit as a complete assembly proceed as follows (Fig. 55):

) Attach an appropriate lifting device to the complete unit and slowly lift the unit onto the machine.

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

Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

) Install the take-up assembly. ) Install the four (4) adjustment bolts and lock washers located on the

side of the mounting base. ) Connect drive chain. (See Breaker drive chain installation in this chapter). ) Adjust tension on the breaker drive chain. (See Breaker drive chain adjustment in this chapter). ) Connect all hydraulic hoses to the hydraulic motor. ) Connect all electrical wiring to the drive motor. ) Purge hydraulic system of air. ) Install breaker drive chain guard. ) Install breaker drive covers.

Fig. 55: Breaker power unit removal and installation

Breaker power unit covers

Adjustment bolts

Breaker power unit

5.80

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts How to remove the hydraulic pump To remove the hydraulic pump proceed as follows (Fig. 56):

) Disconnect, cap and tag all hydraulic hoses to the hydraulic pump. ) Attach an appropriate lifting device to the hydraulic pump.

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.

) Loosen clamping bolts on the pump side of pump coupling. ) Remove the four (4) bolts, lock washers and nuts that secure the pump to the pump mounting pedestal.

) With the aid of the lifting device, slowly pull the pump out of the pedestal and coupling.

) Visually inspect the pump coupling for wear or damage and replace if necessary.

How to install the hydraulic pump To install the hydraulic pump proceed as follows (Fig. 56):

) With the aid of the lifting device, slowly lift the pump and slide the shaft through the pump pedestal and into the pump coupling.

Ensure that the splines are aligned correctly and do not force the shaft into the coupling or damage to the coupling or pump could occur.

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 pump to the pump pedestal with the four (4) bolts, lock washers and nuts. ) Tighten clamping bolts on the pump side of pump coupling. ) Disconnect the lifting device from the hydraulic pump. ) Connect all hydraulic hoses to the hydraulic pump. ) Purge hydraulic system of air.

IMPORTANT! Pump case must be full of oil prior to starting the machine.

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5.81

Instructions on the replacement of wear parts How to remove the electric motor To remove the electric motor proceed as follows (Fig. 56):

) Disconnect and tag all electrical wiring to electric motor. ) Remove hydraulic pump. (See How to remove the hydraulic pump in this chapter) ) Remove the four (4) bolts, lock washers and nuts that secure the electric motor to the power unit mounting base. ) Loosen clamping bolts on the motor side of motor reducer coupling. ) Attach an appropriate lifting device to the electric motor.

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 pull the electric motor out of

the coupling until the motor shaft is completely clear of the coupling.

) Remove bushing and motor key. ) With the aid of the lifting device, slowly lift the electric motor out of

the machine. ) Inspect motor reducer coupling, bushing and all removed parts for wear or damage and replace if necessary.

How to install the electric motor To install the electric motor proceed as follows (Fig. 56):

) Install motor bushing and key onto electric motor shaft. ) With the aid of the lifting device, slowly lift the electric motor and

slide the shaft into the motor reducer coupling. Ensure that the splines are aligned correctly and do not force the shaft into the coupling or damage to the coupling or electric motor could occur.

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 motor mounting holes with the appropriate holes in power unit

mounting base and secure with the four (4) bolts, lock washers and nuts. ) Tighten clamping bolts on the motor side of motor reducer coupling. ) Install hydraulic pump. (See How to install the hydraulic pump in this chapter) ) Connect all electrical wiring to electric motor.

5.82

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts How to remove the breaker reducer To remove the breaker reducer proceed as follows (Fig. 56):

) Remove breaker drive chain. (See Breaker drive chain removal in this chapter)

) Remove the eight (8) bolts, lock washers and nuts that secure the reducer to the power unit mounting base.

) Loosen clamping bolts on the reducer side of motor reducer coupling.

) Attach an appropriate lifting device to the reducer.

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 pull the reducer out of the

coupling until the reducer shaft is completely clear of the coupling.

) Remove bushing and reducer key. ) With the aid of the lifting device, slowly lift the reducer out of the machine.

) Remove end cap from output shaft of reducer and remove sprocket. ) Visually inspect all components for wear or damage and replace if necessary.

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5.83

Instructions on the replacement of wear parts How to install the breaker reducer To install the breaker reducer proceed as follows (Fig. 56):

) Install key, sprocket and end cap on output shaft of reducer. ) Install reducer bushing and key onto reducer shaft. ) With the aid of the lifting device, slowly lift the reducer onto the

machine. Ensure that the splines are aligned correctly and do not force the shaft into the coupling or damage to the coupling or reducer could occur.

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 reducer mounting holes with the appropriate holes in power

unit mounting base and secure with the eight (8) bolts, lock washers and nuts. ) Tighten clamping bolts on the reducer side of motor reducer coupling. ) Install breaker drive chain. (See How to install the breaker drive chain in this chapter) ) Adjust tension on breaker drive chain. (See How to adjust the breaker drive chain tension in this chapter)

5.84

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts

Fig. 56: Breaker power unit component removal and installation

Sprocket key Pump mounting pedestal

Pump coupling, Motor key

Drive motor

Sprocket

End cap

Coupling

Hydraulic pump Mounting base

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Gear reducer Motor bushing and key

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Reducer bushing and key

5.85

Instructions on the replacement of wear parts How to remove the hydraulic motor and torque arm.

To remove the hydraulic motor and torque arm proceed as follows (Fig. 57):

) Disconnect, cap, and tag motor hydraulic hoses. ) Remove the six (6) bolts that secure the hydraulic motor cover and remove cover.

) Remove bolt in end of head shaft and remove end cap from shaft. ) Remove cotter key from connecting link pin on torque arm and

remove pin. ) Attach an appropriate lifting device to the hydraulic motor and slide motor and torque arm off of head shaft.

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 adapter from end of head shaft. ) Remove torque arm from hydraulic motor. ) Visually inspect all components for wear or damage and replace as necessary.

5.86

Model 7SFBH-56 Feeder Breaker

Instructions on the replacement of wear parts How to install the hydraulic motor and torque arm.

To install the hydraulic motor and torque arm proceed as follows (Fig. 57):

) Coat splines on hydraulic motor, adapter and head shaft with “Never Seize” at assembly.

) Slide motor adapter onto head shaft, ensure that splines are aligned. ) Install torque arm onto the back of the hydraulic motor. ) Attach an appropriate lifting device to the hydraulic motor and slide motor and torque arm onto head shaft. Ensure that splines are aligned. Do not force hydraulic motor onto shaft or damage to hydraulic motor, shaft or adapter may occur.

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.

) Insert end of torque arm into connecting link and secure with cotter key and pin.

) Install shaft end cap and secure with bolt. ) Install hydraulic motor cover and secure with the six (6) bolts. ) Connect hydraulic hoses. ) Purge hydraulic system of air.

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5.87

Instructions on the replacement of wear parts Fig. 57: Hydraulic motor and torque arm removal and installation Cotter key and pin Head shaft assembly

Motor adapter

Hydraulic motor Torque arm

Cotter key and pin

End cap and bolt

Hydraulic motor cover

Cover bolts (6)

5.88

Model 7SFBH-56 Feeder Breaker

6

Technical data

Components of the feeder breaker

Technical data This chapter contains the most important technical data on the 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.

Components of the feeder breaker Technical data sheet general

performance

conveyor chain

tail shaft

head shaft

conveyor drive

Overall length: Overall width: Overall height: Receiving height: Discharge height: Weight:

approx. 32’ 6” approx. 10’ 10 ¾” approx. 71 ½” approx. 25 ¾” approx. 42” approx. 70,000 lbs

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

approx. 2’ X 3’ X 4’ approx. 30,000 psi approx. 6” (one dimension) approx. 2,000 TPH @ 93 fpm salt @ 110 lb/ft³

Conveyor width: Number of strands: Chain pitch: Chain pin diameter: Flights: Conveyor speed:

approx. 56” 2 @ 200,000 lb/strand ultimate approx. 3 ½” approx. 15/16” 2 ½” X 5” solid alloy steel approx. 0 - 135 fpm

Shaft diameter: Bearing bore: Take-up:

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

Shaft diameter: Bearing bore: Overload protection:

approx. 5” approx. 4 15/16” hydraulic relief

Drive motor:

radial piston hydraulic low speed high torque direct mounted on head shaft splined shaft hydraulic relief

Mounting: Overload protection:

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6.3

Components of the feeder breaker breaker

breaker drive

hydraulic

Shaft diameter: Bearing bore: Pick circle diameter: Running pick force: Pick force (max.): Overload protection: Under speed protection Breaker speed: Height setting: Breaker bits: Breaker drive chain:

approx. 8” approx. 6 3/16” approx. 38” approx. 9,200 lbs approx. 45,000 lbs shear pin magnetic sensor approx. 45 rpm manually adjustable, 2” increments heavy duty, rock type bits with carbide Insert, holder is improved design alloy steel ASA-180-2

Drive motor: Reducer: Coupling: Drive chain:

200HP/480v/AC/3ph/60Hz/TEFC right angle, 10:1 reduction, Link Belt Rex Omega Elastomer Coupling ASA-180-2

Conveyor pump: Filters (2): Reservoir capacity:

axial piston, variable displacement 12 micron, Pressure Line approx. 150 gal. w/low oil level switch ISO 68 Mineral Oil oil to air type JIC (standard)

Hydraulic fluid: Heat exchanger: Hydraulic fittings: electrical

Breaker motor: Starter: Enclosure: Contactor: Belt sequence switch: Breaker under speed: Remote start:

6.4

200HP/480v/AC/3ph/60Hz/ 1750 rpm/TEFC 200HP/single/480v/AC/3ph/ 60Hz/mine duty IP65 rating, adequate for low Pressure water wash down vacuum type magnetic sensor w/50’ cable Hawkeye magnetic sensor Hawkeye Pendulum switch w/50’ cable

Model 7SFBH-56 Feeder Breaker

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

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

Table 2 : Set screws (Socket long-lok) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½”

Recommended torque setting 6 in-lbs 9 in-lbs 13 in-lbs 30 in-lbs 5 ft-lbs 8 ft-lbs 11 ft-lbs 16.7 ft-lbs

Table 3 : Set screws (Socket standard steel) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1”

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Recommended torque setting 9 in-lbs 16 in-lbs 30 in-lbs 6 ft-lbs 12 ft-lbs 18 ft-lbs 29 ft-lbs 43 ft-lbs 100 ft-lbs 146 ft-lbs 199 ft-lbs 262 ft-lbs

6.5

Tightening torques Table 4 : FSR hex bolts (SAE 5 and 325 steel) Nominal diameter ¼” 5/16” 3/8” 7/16” ½” 9/16” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½” 1 ¾” 2” 2 ¼” 2 ½” 2 ¾” 3”

Recommended torque setting 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 : Socket, flat and button head cap screws (Steel only) 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”

6.6

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

Model 7SFBH-56 Feeder Breaker

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

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended torque setting M3 M4 M5 0.60 1.37 2.70 0.44 1.01 1.99 1.37 3.10 6.15 1.01 2.29 4.54 1.92 4.40 8.55 1.42 3.25 6.38 2.30 5.25 10.4 1.70 3.87 7.6

Nominal diameter M6 4.5 3.3 10.5 7.7 15 11 18 13

M7 7.8 5.6 17.5 12.9 25 18.4 29 21.3

M8 11 8.1 26 19 36 26 43 31

M10 22 16 61 37 72 53 87 64

Table 7 : Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended torque setting M12 M14 M16 39 62 85 28 45 70 89 141 215 65 103 158 125 198 305 92 146 224 150 240 365 110 177 269

Nominal diameter M18 130 95 295 217 420 309 500 368

M20 184 135 420 308 690 435 710 523

M22 250 184 570 420 800 590 960 708

M24 315 232 725 634 1020 752 1220 899

Table 8 : Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

A6474X234

VUVE/01

Recommended torque setting M27 M30 470 635 346 468 1070 1450 789 1069 1510 2050 1113 1511 1810 2450 1334 1606

Nominal diameter M33 865 637 1970 1452 2770 2042 3330 2455

M36 1111 819 2630 1885 3560 2625 4280 3156

M39 1440 1062 3290 2428 4620 3407 5550 4093

6.7

Tightening torques Table 9 : Untreated screw, black finish (Fine thread) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25 27 52 95 19 38 70 38 73 135 28 53 99 45 88 160 33 64 118

Table 10 : Untreated screw, black finish (Fine thread, continued) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5 150 225 325 110 165 239 210 315 460 154 232 339 260 380 550 184 280 405

Table 11 : Untreated screw, black finish (Fine thread, continued) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

6.8

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399 610 780 449 575 640 860 1100 472 634 811 770 1050 1300 567 774 958

Model 7SFBH-56 Feeder Breaker

Tightening torques Table 12 ; Electrically zinc plated (Coarse thread) Property class 5.6 8.8

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended torque setting M33 M4 M5 0.56 1.28 2.50 0.41 0.94 1.84 1.28 2.90 5.75 0.94 2.14 4.24 1.80 4.10 8.10 1.33 3.02 5.97 2.15 4.95 9.70 1.59 3.65 7.15

Nominal diameter M6 4.3 3.1 9.9 7.3 14 10.3 16.5 12.1

M7 7.1 5.2 16.5 12.1 23 16.9 27 19.9

M8 10.5 7.7 24 17.7 34 25 40 29

M10 21 15 48 35 67 49 81 59

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

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended Nominal diameter torque setting M12 M14 M16 M18 M20 M22 36 58 88 121 171 230 26 42 54 89 126 169 83 132 200 275 390 530 61 97 147 202 287 390 117 185 285 390 550 745 86.2 136 210 287 405 549 140 220 340 470 660 890 103 162 250 346 486 656

Table 14 : Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

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Recommended Nominal diameter torque setting M24 M27 M30 295 435 590 800 1030 1340 217 320 435 590 759 988 675 995 1350 1830 2360 3050 497 733 995 1349 1740 2249 960 1400 1900 2680 3310 4290 708 1032 1401 1902 2441 3163 1140 1680 2280 3090 3980 5150 840 1239 1661 2278 2935 3798

6.9

Tightening torques Table 15 : Electrically zinc plated (Fine thread) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25 25 49 88 18 36 84 35 68 125 25 50 92 42 82 150 30 60 110

Table 16 : Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5 140 210 305 103 154 224 195 295 425 143 217 313 235 350 510 173 258 376

Table 17 : Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

6.10

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 425 570 720 313 420 531 600 800 1000 442 590 737 720 960 1200 531 708 885

Model 7SFBH-56 Feeder Breaker

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.

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.

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6.11

Permissible media Approved suppliers: Table 18 : Anti-wear hydraulic oil (Spec. 100-1) 1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18

6.12

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil company Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers Conoco Inc. Hydrotex Phillips Miners Oil

Brand name Amoco AW oil No.68 Harmony 68 AW Mobil DTE-16 Chevron hydraulic Oil Aw ISO 68 Sunvis 868 Unax AW 68 Shell Hydraulic Oil #33 Huldraulic AW 68 Duro AW S-315 Oil Texaco Rando Oil HD 68 Nuto 68 Pennzbell AW 68 Hydraulic Oil Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil Super Hydraulic oil 68 Systems 5K 68 Maginus A Oils 81350 Hydraulic Oil 68AW

Model 7SFBH-56 Feeder Breaker

Permissible media Table 19 : Extreme pressure gear oils (Spec. 100-2)

A6474X234

1 2 3

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation

4

Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8

Shell Oil company Century Lubricating Oils, Inc.

9 10 11

Texaco Lubricants Company Exxon Pennzoil

12

Lubricating Engineers

13 14 15

Conoco Inc. Hydrotex Phillips

16

Miners Oil

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

VUVE/01

6.13

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

6.14

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

Model 7SFBH-56 Feeder Breaker

Permissible media Table 22 : Invert emulsion hydraulic fluid (Spec. 100-5) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

A6474X234

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

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Cincinnati – Vulcon Company Vulcon FR Fluid #1 Cities Service Oil company Citgo Pacemaker Invert FR Fluid Century Oils limited Aquacent Light Fiske Bros. Refining Company Lubriplate HO-Retard Getty Oil company Veedol Auburn FRH (Veedol, Tidewater) Gulf Oil Company FR Fluid E.F. Houghton Houghto-Safe 5046 Houghto-Safe 5046W Century Lubricating Oils Hulsafe 600 Imperial Oil and Grease Astrol 587 Mobil Oil Corporation Pyrogard D National Oil and chemical Co. Erifon 1, 2, and 3 Pennzoil Maxmul FRP/G Quaker Chemical Company Quintolubric 958 Series Quintolubric 958 Series Henery E. Sanson and Sons Hydra-Mul Premium Emulsion MFGE Company Fluid Southwest Grease and Oil Invert Emulsion fire resistant Company, Inc. Hydraulic Fluid Southwest Petroleum Corp.

Swepco Fire Resistant Hydraulic oil #718 Standard Oil Company of Staysol FR Ohio (Boron Sohio) Sun Oil company Sunsafe F Tower Oil Company Safoil Anti-Wear Hydraulic Fluid Wynn Oil company Hydra-Safe heavy Medium Lubrication Engineers 6455 Monolec Fire Resistant hydraulic Fluid Hydrotex HY-Guard

VUVE/01

6.15

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

6.16

1 2 3 4

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

5 6 7 8 9 10 11 12

Sun Oil Company Unocal 76 Shell Oil company Century Lubricating Oils, Inc. Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13 14 15

Conoco Inc. Hydrotex Phillips

16 17 18 19 20

Atlantic Richfield Cities Service Pennzoil Miner Oil Texaco, Lubricants Company

Brand name Amoco Premagear EP 320 EP Lubricant HD 320 Mobil gear 632 Chevron gear compound EP ISO 320 Sunep 320 Extra Duty NL Gear Lube 6EP Omala 75 Hulbest EP-6 Meropa 320 Spartan EP 320 Super Maxol EP 220 Gear Lube 605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320 932 Industrial Gear Lube Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000 Citgo EP Compound 110 Pen Gear #320 Gear Oil EP220 Texaco Multigear EP 80W-90

Model 7SFBH-56 Feeder Breaker

Permissible media Table 24 : Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7)

A6474X234

1 2 3 4

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

5 6

Sun Oil Company Unocal 76

7 8 9 10 11 12 13

Shell Oil Company Century Lubricating Oils, Inc. Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14 15 16 17 18

Hydrotex Atlantic Richfield Cities Service Miner Oil Texaco, Lubricants Company

VUVE/01

Brand name American Industrial Oil No. 68 Harmony 68 DTE Heavy – Medium Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754 Unax RX68 or Turbine Oil 68 Turbo 68 Centraulic R&O 68 Regal Oil R&O N-68 Tresstic 68 Pennzbell RO 68 6120 Monolec Turbine Oil Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68 Duro 5.315 Citgo Pacemaker A/W68 Hydraulic Oil AW68 TDH 1893

6.17

Permissible media Table 25 : Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) 1 2 3 4

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

5 6

Sun Oil Company Unocal 76

7 8 9

Shell Oil company Century Lubricating Oils, Inc. Atlantic Richfield Company

10 11 12 13 14 15 16 17 18

Texaco Lubricants Company Exxon Pennzoil Cities Service Lubrication Engineers Conoco Inc. Hydrotex Phillips Miner Oil

Brand name American Industrial oil No. 150 Harmony 150 DTE Oil EX. Heavy Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961 Unax RX 700 or Turbine Oil 700 Turbo 150 Centraulic R&O 150 Duro 600 or S-700 Regal Oil R&O 150 Teresstic 150 Pennzbell RO 150 Citgo Pacemaker 150 6405 Monolec Turbine Oil Dectol R&O 76 System 1 150, System 5k 150 Magnus Oils 700 ISO 150

Table 26 : Worm gear lubricant, compounded cylinder oil (Spec. 1009)

6.18

1 2 3

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

4 5

Sun Oil Company Unocal 76

6 7 8 9 10 11

Century Lubricating Oils, Inc. Atlantic Richfield Company Texaco Lubricants Company Exxon Pennzoil Conoco Inc.

Brand name Cylinder oil No. 1000 Extra Hecla Super Cylinder Oil Chevron Cylinder Oil W ISO 1000 Sun Steam Cylinder Oil Worm gear Lube 250 or Stevalc Garwal 680 Modoc 195 650 T Cylinder Oil 1000 Cylesstic TK-1000 Cylinder Oil #1000 Inca Oil 1000

Model 7SFBH-56 Feeder Breaker

Permissible media 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

A6474X234

Supplier Century Lubricants Company

VUVE/01

Brand name Synthetic EP Gear Lubricants

6.19

Permissible media

6.20

Model 7SFBH-56 Feeder Breaker

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.

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

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

Oak Hill, WV P.O. Box 60 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

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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

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

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

7.4

Model 7SFBH-56 Feeder Breaker