DOWNLOAD PDF CAT Feeder Breaker 54-2173 Operation & Maintenance Manual BI629479

Operation Manual Bucyrus - Feeder Breaker Model - 7MFBHM-48DD Doc. No.:

A6474X280

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

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

Internet: www.bucyrus.com

__________________________________________________________

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

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

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

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

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

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

© BUCYRUS AMERICA , INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

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

2. Your safety

© BUCYRUS AMERICA, INC.

Your safety .............................................................................. 2.3 Personnel............................................................................. 2.4 Operation ........................................................................ 2.4 Installation and repair...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use ................................................................... 2.5 Unauthorized use............................................................ 2.5 Safety instructions................................................................ 2.7 General rules: ................................................................. 2.7 Storage and transport ..................................................... 2.9 Installation and start-up................................................... 2.9 Operation .......................................................................2.10 Maintenance and repair .................................................2.10 Overview of the safety instructions .....................................2.15 Chapter 3: Storage and transport ..................................2.15 Chapter 4: Installation ....................................................2.15 Chapter 5: Operation .....................................................2.16 Chapter 6: Technical data..............................................2.26

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

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

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Table of contents _________________________________________________

Operation ................................................................................. 5.3 How to operate the feeder breaker ..................................... 5.3 Who is allowed to operate the feeder breaker ............... 5.3 When can conveying be started?.................................... 5.3 Controls and indicators ........................................................ 5.4 Primary operator’s station ............................................... 5.4 Secondary operator’s station .........................................5.10 Left side of machine .......................................................5.13 Right center of machine .................................................5.13 Starter enclosure ............................................................5.14 Control features..............................................................5.16 “REGULAR” mode starting procedure ................................5.17 “TRAM ONLY” mode starting procedure.............................5.18 Shutdown procedure ...........................................................5.19 Conveyor .............................................................................5.20 Infrared pump motor controls ..............................................5.21 Electrical system .................................................................5.23 Starter enclosure ............................................................5.24 Hydraulic system.................................................................5.31 Major hydraulic components ....................................5.32 Mechanical assemblies .......................................................5.37 Crawler assembly (s) ....................................................5.37 Conveyor chain .............................................................5.38 Grease take-up .............................................................5.38 Head shaft .....................................................................5.39 Conveyor power unit .....................................................5.40 Tail shaft ........................................................................5.40 Breaker and breaker power unit assembly ....................5.41 Tailpiece assembly.........................................................5.43 Instructions on the maintenance of the feeder ...................5.45 Important notes .............................................................5.45 Before maintenance ......................................................5.45 Lubrication and inspection ............................................5.50 Specific lubrication and maintenance procedures .............5.52 Every 8 hours of operation ............................................5.52 Weekly ...........................................................................5.55 Every 2 weeks ...............................................................5.59 Monthly ..........................................................................5.59 Every 3 months .............................................................5.61 Every 2500 hours ...........................................................5.64 Every 6 months .............................................................5.65 Inspection of the feeder ......................................................5.67 Inspection of wear parts on the feeder ...............................5.68 Inspection of the fire suppression system...........................5.69 Recharge of the fire suppression system............................5.71 Instructions on the adjustment procedures ........................5.73 Conveyor chain adjustment ...........................................5.73 Crawler track adjustment ..............................................5.75 Under speed sensor calibration .....................................5.77 Hydrostatic pump relief valve adjustment ......................5.79 Hydrostatic pump charge pressure adjustment .............5.81 Loop flushing valve adjustment......................................5.84

_________________________________________________________________ Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

5. Operation

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© BUCYRUS AMERICA, INC.

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

6. Technical data Technical data ......................................................................... 6.3 Components of the feeder breaker ...................................... 6.3 Tightening torques................................................................ 6.7 Permissible data ................................................................... 6.9 Lubrication fluids and greases......................................... 6.9

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

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© BUCYRUS AMERICA, INC.

Table of contents _________________________________________________

_________________________________________________________________ Bucyrus – Model 7MFBHM-48DD Feeder Breaker

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1

About this manual

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_______________________________________ Before starting to work

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

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: Bucyrus – Model 7MFBHM-48DD Feeder Breaker Serial No.: 54-2173, 54-2174, and 54-2177 and is only permitted to be used for equipment of this type.

© BUCYRUS AMERICA, INC.

new operation manual

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

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

Who is this operating manual intended for?

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

This includes persons who: ■

are in charge of transport

■

perform assembly/disassembly work

■

operate the machine

■

eliminate faults

■

perform daily routine work on the face or in the entry

■

perform maintenance work

■

perform repair work

and supervisory personnel who: ■

initiate and/or

■

supervise the activities just indicated.

______________________________________________________________ A6474X280 VRVI/O1 1.3

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

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

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

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

safety

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

© BUCYRUS AMERICA, INC.

service

_________________________________________________________________ 1.4 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

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

Try to memorize the symbols and their meanings.

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

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

© BUCYRUS AMERICA, INC.

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

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

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

■

Items in lists are marked with bullets.

–

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

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

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

______________________________________________________________ A6474X280 VRVI/O1 1.5

© BUCYRUS AMERICA, INC.

Before starting to work ________________________________________

_________________________________________________________________ 1.6 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

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2

Your safety

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__________________________________________________ Personnel

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

Observe the safety and accident prevention regulations of

further operating manuals

■

the mine,

■

the mine inspector, and

■

the mining supervisory authorities.

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

______________________________________________________________ A6474X280 VRVI/O1 2.3

Personnel ___________________________________________________ Personnel Operation training

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

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

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

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© BUCYRUS AMERICA, INC.

and must be able to prove this knowledge.

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

Intended uses include: ■

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

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

© BUCYRUS AMERICA, INC.

Unauthorized uses include: ■

the transport of persons

■

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

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

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© BUCYRUS AMERICA, INC.

Operating conditions __________________________________________

_________________________________________________________________ 2.6 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

___________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

© BUCYRUS AMERICA, INC.

Inform your colleagues of

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

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

Observe the optical start-up warnings of the machine.

symbol plates panic strip

lock-out

cordon off working area

Observe the symbol plates on the machine.

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

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

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

______________________________________________________________ A6474X280 VRVI/O1 2.7

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

conveyor chains

■

flights

■

pivot points

■

crawler assemblies

■

breaker shaft assemblies

© BUCYRUS AMERICA, INC.

moving parts

_________________________________________________________________ 2.8 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

© BUCYRUS AMERICA, INC.

means of attachment

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

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

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

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

mobile handling equipment

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

Installation and start-up inclined face

environmental acceptability

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

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

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

inspection maintenance instruction and safety tags

operator’s area

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

Verify that all maintenance has been performed.

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

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

Clean any foreign material from the operator’s area.

______________________________________________________________ A6474X280 VRVI/O1 2.9

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

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

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

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

Maintenance and repair

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

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

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

Protect your work area against falling rocks.

replacing components

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

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

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

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

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

For raising the feeder breaker use only: ■

crib blocks with adequate load-holding capacity

■

hoists, jacks or cranes with adequate load-carrying capacity

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© BUCYRUS AMERICA, INC.

Be sure to observe the prescribed maintenance and inspection intervals.

___________________________________________ Safety instructions handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

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

maintenance, repair

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

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

Always replace damaged or lost decals and metal instruction plates.

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

© BUCYRUS AMERICA, INC.

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

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

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

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

the hoses are not pinched or trapped

■

the hoses have no bubbles or blisters

■

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

■

the outer sheaths of the hoses are not damaged

■

the connectors are securely inserted into the sockets

■

the connections are leak-tight

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

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

______________________________________________________________ A6474X280 VRVI/O1 2.11

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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

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

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

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting

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© BUCYRUS AMERICA, INC.

Never try to repair damaged hydraulic hoses.

___________________________________________ Safety instructions ■

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

Fig. 3: Laying hydraulic hoses, bending Right

© BUCYRUS AMERICA, INC.

■

Wrong

always have a little slack.

Fig. 4: Laying hydraulic hoses, crossing Right

■ ■ ■ ■

Wrong

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

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

______________________________________________________________ A6474X280 VRVI/O1 2.13

Safety instructions ____________________________________________

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

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

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

© BUCYRUS AMERICA, INC.

Right

_________________________________________________________________ 2.14 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

Use only suitable load handling devices.

Chapter 4: Installation CAUTION! Serious damage can be caused to the feeder breaker as a result of incorrect installation. The unit should only be installed under the instruction of specialists from Bucyrus America, Inc. IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

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

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

______________________________________________________________ A6474X280 VRVI/O1 2.15

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

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

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

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

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

Chapter 5: Operation DANGER! Incorrect operation endangers yourself and others! Incorrect operation of the machine is often the cause of very serious accidents! Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual. Should anything be unclear, please contact your immediate supervisor.

NOTICE! Once a hydraulic control valve handles is released by the operator, the lever will automatically return to the centered (neutral) position except for the “POWER FILL/SECONDARY” lever.

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© BUCYRUS AMERICA, INC.

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

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

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

© BUCYRUS AMERICA, INC.

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

WARNING! The “POWER FILL/SECONDARY” lever is the only lever on the valve bank that does not spring return to neutral when released.

When not in use, the valve should be manually returned to the neutral position. Failure to do so could result in unexpected machine movement if the secondary valve bank is energized and a lever on the secondary valve bank is inadvertently moved or machine overheating if the power fill pump is left energized. Unexpected machine movement could result in serious injury to personnel or damage equipment.

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

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

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

CAUTION! The “POWER FILL/SECONDARY” lever is the only lever on the primary valve bank that does not spring return to neutral when released. When the fill operation is complete, the lever must be manually returned to the neutral position. Failure to return the lever to neutral will result in the machine overheating.

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

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

______________________________________________________________ A6474X280 VRVI/O1 2.17

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

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

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

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

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

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

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

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

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

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© BUCYRUS AMERICA, INC.

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load may fall, causing damage to the machine or serious injury or death to you or other workers. Do not rely on counterbalance valves to hold the load. Always block or place a mechanical lock on the load.

Follow all Federal and mine safety standards for blocking the load.

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

______________________________________________________________ A6474X280 VRVI/O1 2.19

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

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

WARNING! Do not enter the hopper unless power center is locked and tagged out and machine main circuit breaker is in the “OFF” position. If these procedures are not followed, serious injury or death can result.

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

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

CAUTION! The oil tank must contain a minimum of 20 gallons ( 76 liters) of oil to operate the power fill function. This is to ensure that the hydraulic pumps are not run dry, causing sever damage to the pump.

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

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

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

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

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

2.20

Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

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

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

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

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

______________________________________________________________ A6474X280 VRVI/O1 2.21

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

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

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

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

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

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

______________________________________________________________ A6474X280 VRVI/O1 2.23

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

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

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

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

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

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

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

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

Use only approved lifting equipment for connecting pulling devices to the crawler track.

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

© BUCYRUS AMERICA, INC.

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

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers WARNING! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the take-up, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the take-up.

WARNING! When using a pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the conveyor chain, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable. Use only approved lifting equipment for connecting pulling devices to the conveyor chain.

IMPORTANT! If old conveyor chain is still on machine, installation can be facilitated by connecting the new conveyor chain to the old conveyor chain via the chain connectors and pulling it through the bottom conveyor pan.

______________________________________________________________ A6474X280 VRVI/O1 2.25

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

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

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

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

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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3

Storage and transport

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________________________________________ Storage and transport

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

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

Storage corrosion protection

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

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

© BUCYRUS AMERICA, INC.

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

dirt and moisture

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

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

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

short-term storage

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 following lubrication and corrosion inhibiting procedures must be followed: ■

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

■

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

■

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

■

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

■

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

______________________________________________________________ A6474X280 VRVI/O1 3.3

■

Coat exposed valve bank valve spools with rust inhibitor.

■

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

■

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

machine electrics

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

random sample inspection

After a storage period of approximately two years, a random sample inspections must be performed to determine whether the measures taken and the method of storage has prevented damage. On request, the inspection can be carried out by Bucyrus.

natural aging

Even with proper storage, seals and hoses are subject to natural aging.

Do not use these parts if they have been stored for more than two years.

HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in Chapter 6 of this manual.

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

Long-term storage of spare components hydraulic components

If a component is to be stored more than six months, the hydraulic component must be completely filled with a corrosion inhibiting fluid. Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow, then seal the ports with plastic or steel plugs.

miscellaneous components

Store the electrical equipment, electronic components, spare parts of rubber or plastic (such as seals and hoses) and hydraulic fluids only in closed rooms at temperatures of 60 °F (15 °C) to 77 °F (25 °C).

motors

plastic deformation

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

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

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

© BUCYRUS AMERICA, INC.

Storage and transport _________________________________________

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

dimensions,

■

weights,

■

lifting points, etc. (See Fig. 6 for lifting point locations)

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

© BUCYRUS AMERICA, INC.

Fig. 6: Lifting points on the feeder breaker

Lifting point (typical 2 places) looking in at the machine: Insert hook into slot and route the chain under the frame and into the conveyor discharge area.

Horizontal (lengthwise) center of gravity

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

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

______________________________________________________________ A6474X280 VRVI/O1 3.5

Storage and transport _________________________________________ Before transport temperatures below freezing

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

Transport of equipment at temperatures between -6° F (-21° C) and 40° F (-40° C) is only permissible when certain measures were taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

electronic components

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

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

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

© BUCYRUS AMERICA, INC.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport.

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4

Installation

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__________________________________________________Installation

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

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

Work on the safety components (pressure relief valves, fire extinguishing equipment, etc.),

© BUCYRUS AMERICA, INC.

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

Which tools are required for installation? tool box

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

Various items of auxiliary equipment and machines may be required at the point of installation.

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

______________________________________________________________ A6474X280 VRVI/O1 4.3

Installation___________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the feeder breaker as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc. installation plan

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

© BUCYRUS AMERICA, INC.

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

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

__________________________________________________Installation Pre-installation check list

© BUCYRUS AMERICA, INC.

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

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

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

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

■

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

■

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

■

check tension of conveyor chain

■

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

■

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

■

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

■

jog the breaker motor to check for correct rotation of breaker

■

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

■

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

■

check the operation of the remote start pushbuttons

■

start the machine and allow the hydraulic system to warm up for five (5) to ten (10) minutes

■

check hydraulic system pressures (see spare parts manual for hydraulic schematic)

■

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

______________________________________________________________ A6474X280 VRVI/O1 4.5

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

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

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

“PICK BREAK STOP” switch (starter enclosure)

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

“PUMP MOTOR STOP” switch (starter enclosure)

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

panic strip

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

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators. One is located adjacent to the primary operator’s station on the right side of the machine and one is located at the secondary operator’s station. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

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

neutral start mechanism

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

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

© BUCYRUS AMERICA, INC.

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.

__________________________________________________Installation Fig. 7: Safety features on the feeder breaker

“PUMP MOTOR STOP” switch

© BUCYRUS AMERICA, INC.

“PICK BREAK STOP” switch

Panic strip

Fire suppression actuator location Neutral start mechanism

Fire suppression actuator

______________________________________________________________ A6474X280 VRVI/O1 4.7

Installation___________________________________________________ Fig. 8: Overview of the feeder breaker

Tail shaft Receiving section

Tilt cylinder (2)

    

    

    

    

           

    

Tail shaft take-up

Crawler assembly (2)

Breaker assembly

Roof cylinder (2)

Torque hub

Frame lift cylinder (2) U .S.A.

Hydraulic oil tank

Conveyor chain

       

     

       

      

Conveyor power unit

Conveyor power unit

Stabilizer foot (2)

Starter enclosure Discharge section

Tailpiece steering cylinder (2) Tailpiece tilt cylinder (2)

Feeder head shaft

Secondary operator’s station

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

© BUCYRUS AMERICA, INC.

Primary operator’s station

Ratio chains

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

______________________________________________________________ A6474X280 VRVI/O1 4.9

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

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

Retaining bolts (2)

Normal tram position

© BUCYRUS AMERICA, INC.

Fig. 9: Torque hub disengagement

End cap button pointing outward

Retaining bolts (2)

End cap button pointing inward Freewheel position

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

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5

Operation

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___________________________________________________Operation

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

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

How to operate the feeder breaker

© BUCYRUS AMERICA, INC.

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

Who is allowed to operate the feeder breaker?

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

This also includes: ■

what safety devices are installed on the machine,

■

where these safety devices are located, and

■

how these safety devices are to be operated.

When can conveying be started?

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

______________________________________________________________ A6474X280 VRVI/O1 5.3

Operation____________________________________________________ Controls and indicators Primary operator’s station The primary controls for the machine are located on the right hand side of the machine at the primary operator’s station. The primary operator’s station (Fig. 10) consists of the following controls and indicators: primary valve bank, auxiliary function pressure gauges, conveyor speed pressure gauge, conveyor speed control valve, conveyor direction control valve, starter enclosure, oil level sight gauge, tram/conveyor mode control valve, and fire suppression actuator.

Fig. 10: Primary operator’s station Primary valve bank

Fire suppression actuator

Conveyor speed and direction control valve

Pressure gauge panel

Tram/conveyor mode control valve

Primary valve bank The primary valve bank (Fig. 11) consists of the following hydraulic controls: NOTICE! Once a hydraulic control valve handles is released by the operator, the lever will automatically return to the centered (neutral) position except for the “POWER FILL/SECONDARY” lever.

“LEFT FRAME LIFT”

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

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

© BUCYRUS AMERICA, INC.

Panic strip

___________________________________________________Operation “RIGHT FRAME LIFT”

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

“LEFT TRAM”

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

“RIGHT TRAM”

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

© BUCYRUS AMERICA, INC.

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

The tram/steering control levers are used for tramming and positioning the machine. To tram the machine forward in a straight direction (towards the receiving end), push both tram control levers forward and to tram the machine in a straight direction in reverse (towards the discharge end), pull back on both tram control levers. To steer left in the direction of the receiving end, push the right tram control lever towards the machine while the left tram control lever is in the neutral position or for tighter turns, pull the left tram control lever towards the operator. To steer right in the direction of the receiving end, push the left tram control lever towards the machine while the right tram control lever is in the neutral position or for tighter turns, pull the right tram control lever towards the operator.

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

“FRAME TILT”

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

“POWER FILL” and “SECONDARY”

The sixth lever from the operator’s left has two (2) functions, it controls the “POWER FILL” and “SECONDARY” oil flow for the machine. To operate the power fill, turn ball valve handle located on the left side of the discharge section to the open position and push the control lever.

To de-energize power fill pump, move control lever to the centered position and turn ball valve handle to closed position. Pull the control lever towards the operator to energize the secondary valve bank.

______________________________________________________________ A6474X280 VRVI/O1 5.5

Operation____________________________________________________ WARNING! The “POWER FILL/SECONDARY” lever is the only lever on the valve bank that does not spring return to neutral when released.

When not in use, the valve should be manually returned to the neutral position. Failure to do so could result in unexpected machine movement if the secondary valve bank is energized and a lever on the secondary valve bank is inadvertently moved or machine overheating if the power fill pump is left energized. Unexpected machine movement could result in serious injury to personnel or damage equipment. power fill procedure

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

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

Oil from the valve bank will now drive the power fill motor and a suction force will be created in the suction line. Oil from the new oil supply will be drawn through the power fill motor to the hydraulic oil tank.  Once the tank is filled to the desired level, pull the power fill lever on the valve bank to the neutral (center) position.  Turn the ball valve handle 90° to close the ball valve.  Remove the suction hose from the new oil supply.  Clean and install hose plug into suction hose. Store the suction hose on top of the oil tank.

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

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

© BUCYRUS AMERICA, INC.

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

___________________________________________________Operation Fig. 11: Primary valve bank

© BUCYRUS AMERICA, INC.

“LEFT LIFT”

“RIGHT LIFT”

“LEFT TRAM”

“RIGHT TRAM”

“TILT”

“POWER FILL” and “SECONDARY”

two position conveyor direction and speed control valve

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

tram/conveyor mode control valve

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

panic strip

The panic strip (Fig. 12) is used to break the control circuit in emergency situations. Striking the panic strip with a small amount of force will actuate the panic strip: all machine functions are shutdown immediately.

fire suppression

The machine fire suppression (remote) actuators (Fig. 12) is used to activate the fire suppression system on the machine. The fire suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

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

______________________________________________________________ A6474X280 VRVI/O1 5.7

Operation____________________________________________________ Fig. 12: Controls and indicators Panic strip

© BUCYRUS AMERICA, INC.

Fire suppression actuator

“TRAM/CONVEYOR” mode control valve

“CONVEYOR” speed and direction

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

___________________________________________________Operation Gauge panel

© BUCYRUS AMERICA, INC.

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

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

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

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

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

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

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

“CHARGE PRESSURE”

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

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

“FILTER SVC INDICATOR #1”

“CHARGE PRESSURE”

“AUXILIARY PRESSURE #2”

“AUXILIARY PRESSURE “3

“FILTER SVC INDICATOR #2”

‘FILTER SVC INDICATOR #3”

______________________________________________________________ A6474X280 VRVI/O1 5.9

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

Fig. 14: Secondary operator’s station

Fire suppression actuator

diversion valves

Diversion valves

Tank fill hand pump

Power fill ball valve

There are two diversion valves mounted on the frame below the secondary valve bank (Fig. 15). The diversion valve is used to control hydraulic oil flow between the roof cylinders and the foot cylinders. There is a diversion valve for each side of the machine (left and right).

To operate the roof cylinder, the diversion valve must be pulled out.

To operate the foot cylinder, the diversion valve must be pushed in.

Fig. 15: Diversion valves

Left side diversion valve

Right side diversion valve

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

© BUCYRUS AMERICA, INC.

Secondary valve bank

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

© BUCYRUS AMERICA, INC.

The secondary valve bank (Fig. 16) consists of the following hydraulic controls: “STEERING”

The “STEERING” control lever controls the direction of the tailpiece. To move the tailpiece away from the operator, push the control lever forward. To move the tailpiece toward the operator, pull the control lever back.

“TILT”

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

“LH ROOF CYLINDER LH FOOT CYLINDER”

The “LH ROOF CYLINDER/LH FOOT CYLINDER” controls the roof or foot cylinder on the left side of the machine, depending on the position of the diversion valve. To extend the cylinder (roof or foot), push the control lever forward. To retract the cylinder (roof or foot), pull the control lever back.

“RH ROOF CYLINDER RH FOOT CYLINDER”

The “RH ROOF CYLINDER/RH FOOT CYLINDER” controls the roof or foot cylinder on the right side of the machine, depending on the position of the diversion valve. To extend the cylinder (roof or foot), push the control lever forward. To retract the cylinder (roof or foot), pull the control lever back.

Fig. 16: Secondary valve bank

“STEERING”

“TILT”

“LH ROOF CYLINDER LH FOOT CYLINDER”

“RH ROOF CYLINDER RH FOOT CYLINDER”

______________________________________________________________ A6474X280 VRVI/O1 5.11

Operation____________________________________________________ foot cylinder locking pin

There is a mechanical locking pin on the foot cylinder (Fig. 17) that must be installed after the feeder is set in the dump position and the foot is planted. The locking pin will hold the cylinder in the extended position in the event that the foot cylinder counterbalance valve fails or is removed. Remove the pin before attempting to retract the cylinder.

Fig. 17: Foot cylinder mechanical locking pin

power fill ball valve

The power fill ball valve (Fig. 18) is used to open the hydraulic flow to the power fill pump. To operate the power fill, the ball valve must be opened, handle in line with the hydraulic line. Then the control handle on the primary valve bank (6th handle from the operator’s left is moved to the “POWER FILL” position (handle pushed forward). To deenergize the power fill pump, move the control lever to the centered position and turn ball valve handle to closed position.

CAUTION! The “POWER FILL/SECONDARY” lever is the only lever on the primary valve bank that does not spring return to neutral when released. When the fill operation is complete, the lever must be manually returned to the neutral position. Failure to return the lever to neutral will result in the machine overheating.

tank fill hand pump

The tank fill hand pump (Fig. 18) is used to manually fill the hydraulic oil tank. To operate the hand pump, release the handle latch and pump the handle up and down. When the filling operation is complete, return the handle to the upright position and latch in place.

Fig. 18: Power fill ball valve and tank fill hand pump

Power fill ball valve Tank fill hand pump

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

© BUCYRUS AMERICA, INC.

Locking pin storage tube

___________________________________________________Operation fire suppression actuator

The machine fire suppression (remote) actuators (Fig. 14) is used to activate the fire suppression system on the machine. The fire suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

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

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

The hydraulic oil level sight glass (Fig. 19) is located on the hydraulic oil tank on the left side of the machine. The oil level should not be allowed to drop below the bottom of the sight glass.

© BUCYRUS AMERICA, INC.

Fig. 19: Oil level sight glass

Oil level sight glass

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

The dust suppression system regulator (Fig. 20) is used to control the flow of water to the six spray nozzles located in the hose crossover tray in the breaker shaft. The water pressure to the nozzles is monitored by the dust suppression system pressure gauge (Fig. 20). To increase pressure, turn the regulator handle in (cw). To decrease pressure, turn the regulator handle out (ccw).

dust suppression system pressure gauge

The dust suppression system pressure gauge (Fig. 20) is used to monitor the water pressure to the spray nozzles. The gauge should read between 5 and 125 psi.

Fig. 20: Dust suppression system regulator and pressure gauge Regulator handle Gauge

Regulator

______________________________________________________________ A6474X280 VRVI/O1 5.13

Operation____________________________________________________ Starter enclosure

“POWER ON” light

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

“HIGH TEMP” light

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

“LOW OIL” light

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

“SEQ SW” light

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

“PRESSURE SWITCH” light

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

“UNDERSPEED” light

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

“SAFETY RELAY” light

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

“OL1” light

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

“OL2” light

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

“LIGHT SWITCH”

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

“PUMP MOTOR START”

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

“PUMP MOTOR STOP”

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

“CB2 RESET”

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

“PICK BREAK START”

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

“PICK BREAK STOP”

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

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

© BUCYRUS AMERICA, INC.

The starter enclosure (Fig. 21) is located on the right hand side of the machine. The controls and indicators on the front of the starter enclosure are:

___________________________________________________Operation “REGULAR/OFF/TRAM ONLY” selector switch

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

“REGULAR” - run the machine during normal operations.

–

“OFF” - removes power from the motors.

–

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

Fig. 21: Starter enclosure cover

© BUCYRUS AMERICA, INC.

“PRESSURE SWITCH”

“UNDERSPEED”

“SAFETY RELAY”

“REGULAR/OFF/ TRAM ONLY” switch

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

“OL1”

“OL2”

“LIGHT SWITCH”

“PICK BREAK START”

“PICK BREAK STOP”

“CB-2 RESET”

“PUMP MOTOR START”

“PUMP MOTOR STOP”

______________________________________________________________ A6474X280 VRVI/O1 5.15

Operation____________________________________________________ Control features

high temperature switch

There is a high temperature switch for the feeder breaker located at the oil tank. If a high temperature (greater than 150 °F) is detected, both motors will be turned off and a light (“HIGH TE MP”) will be illuminated on the starter enclosure (Fig. 21).

low oil cut off switch

There is a low oil cut off switch for the feeder breaker, located at the oil tank. If it detects a low oil issue (oil level below the sight glass) at the oil tank, the motor will be turned off and a light (“LOW OIL)) will be illuminated on the starter enclosure (Fig. 21).

under speed sensor

The under speed sensor detects whether or not the pick break is turning at normal operating speed. If the pick break slows below a preset speed for longer than 3 seconds, or if the pick break stops, both motors will shut down and a light (“UNDERSPEED”) will be illuminated on the starter enclosure (Fig. 21).

motor overloads (OL1 and OL2)

There is an overload on each of the motors (pick break & pump motor) if either one of these overloads detects an over current condition, it will trip and both motors will be stopped. These overloads will also detect a phase unbalance (10%) and will trip and stop both motors. A light will illuminate on the starter enclosure (Fig. 21) is either overload is tripped.

high pressure switch

There is a high pressure switch for the feeder breaker that detects a high pressure situation (greater than 4,800 psi) with the hydraulic system. If the switch detects high pressure, the pump motor will shutdown and the “PRESSURE SWITCH” light on the starter enclosure (Fig. 21) will be illuminated.

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

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

© BUCYRUS AMERICA, INC.

The following is a list of control features that could affect the running of the feeder breaker.

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

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

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

© BUCYRUS AMERICA, INC.

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

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

WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the machine.  Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET” position and then to the “ON” position.  Turn the “REGULAR/OFF/TRAM ONLY” selector switch located on the cover of starter enclosure to the “REGULAR” position.  Engage the “PICK BREAK START” pushbutton located on the cover of the starter enclosure.  The contactor M1 will energize and the pick break motor will start.  Engage the “PUMP MOTOR START” pushbutton located on the cover of the starter enclosure.  The contactor M2 will energize and the pump motor will start.

______________________________________________________________ A6474X280 VRVI/O1 5.17

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

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

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

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

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

WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the machine.  Turn the main circuit breaker to the “ON” position.  Turn the “REGULAR/OFF/TRAM ONLY” selector switch located in the cover of the starter enclosure to the “TRAM ONLY” position.  Engage the “PUMP MOTOR START” pushbutton located on the cover of the starter enclosure.  The contactor M2 will energize and the pump motor will start.

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

© BUCYRUS AMERICA, INC.

 Operate all primary and secondary valve bank control levers to ensure that they are free and in neutral position.

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

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

To shutdown the feeder breaker in “REGULAR” mode:  Engage the “PICK BREAK STOP” pushbutton located on the starter enclosure. This will stop the pick break motor and the pump motor.

© BUCYRUS AMERICA, INC.

 Turn the circuit breaker reset switch to the “OFF” position .

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

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

______________________________________________________________ A6474X280 VRVI/O1 5.19

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

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

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

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

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

© BUCYRUS AMERICA, INC.

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

___________________________________________________Operation Infrared pump motor controls An infrared transmitter can be used to start and stop the pump motor on the machine. The feeder breaker is equipped with two (2) infrared receivers located on top of the machine (Fig. 22).

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

Fig. 22: Infrared transmitter and receiver

© BUCYRUS AMERICA, INC.

Infrared receiver (2)

Infrared transmitter (remote control)

______________________________________________________________ A6474X280 VRVI/O1 5.21

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

Fig. 23: Major electrical component locator Tape switch Starter enclosure

Conveyor motor

Pick break motor

_____________________________________________________________ A6474X280 VRVI/O1 5.23

Electrical system _____________________________________________ Starter enclosure The starter enclosure (Fig. 24), located on the right side of the machine, houses the primary electrical control components.

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

© BUCYRUS AMERICA, INC.

Fig. 24: Starter enclosure

Starter enclosure cover

Swing panel - front

Back panel

Swing panel - back

Bottom panel

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

____________________________________________ Electrical system Starter enclosure cover The cover of the starter enclosure (Fig. 25) consists of indicator lights and switches (see Indicator and controls section in this chapter for a description of the lights and switches). All indicator lights on the cover panel are normally off.

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

Fig. 25: Starter enclosure cover

© BUCYRUS AMERICA, INC.

“PRESSURE SWITCH”

“UNDERSPEED”

“SAFETY RELAY”

“REGULAR/OFF/ TRAM ONLY” switch

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

“OL1”

“OL2”

“LIGHT SWITCH”

“PICK BREAK START”

“PICK BREAK STOP”

“CB-2 RESET”

“PUMP MOTOR START”

“PUMP MOTOR STOP”

_____________________________________________________________ A6474X280 VRVI/O1 5.25

Electrical system _____________________________________________ Swing panel - front side The swing panel (Fig. 26) is accessed by opening the cover on the enclosure. Located on the swing panel are: indicator lights, relays, timers, and a circuit breaker reset.

Immediately adjacent to the swing panel is the main circuit breaker, CB1, for the feeder breaker.

Fig. 26: Swing panel (front side) and main circuit breaker

“IS#1”

“IS#2”

“IS#3”

“IS#4”

“TR1”

Indicator lights “CB1”

“CR4” “SR” “CR1”

“CR2”

“CR3”

“CR5”

“CB1”

“CB2”

“CR6”

“RR”

“TR2”

“TR3”

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

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

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

© BUCYRUS AMERICA, INC.

Swing panel retaining bolt

© BUCYRUS AMERICA, INC.

____________________________________________ Electrical system “IS#1” and “CR1”

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

“IS#2” and “CR2”

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

“IS#3” and “CR3”

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

“IS#4” and “CR4”

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

“SR”

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

“CR5”

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

“CR6”

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

“CB-2”

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

“TR1”

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

“TR2”

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

“TR3”

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

_____________________________________________________________ A6474X280 VRVI/O1 5.27

Electrical system _____________________________________________ Swing panel - back side The back side of the swing panel (Fig. 27) is accessed by removing the swing panel retaining bolt and swinging the panel out. Located on the panel are relays, a switch, and the infrared receiver board.

Fig. 27: Swing panel - back side “IS#5”

Swing panel retaining bolt location

“CR7”

“IS#5” and “CR7”

“IS RELAY”

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

“IS RELAY”

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

infrared receiver board

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

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

© BUCYRUS AMERICA, INC.

Infrared receiver board

____________________________________________ Electrical system Back panel The back panel (Fig. 28) is accessed by removing the swing panel retaining bolt located in the upper left hand corner of the swing panel and swinging the panel out. Located on the back panel are two vacuum contactors, two overload relays, and the control transformer.

Fig. 28: Back panel

© BUCYRUS AMERICA, INC.

“T1”

“M1”

“OL2”

“M2”

“OL1”

“T1”

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

“M1”

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

“M2”

“M2” is the vacuum contactor for the pump motor.

“OL1”

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

“OL2”

“OL2” is the overload relay for the pump motor. If the pump motor is overloaded, the relay will shutdown the pump motor.

_____________________________________________________________ A6474X280 VRVI/O1 5.29

Electrical system _____________________________________________ Bottom panel The bottom panel (Fig. 29) is located in the bottom of the starter enclosure, directly under the back panel. The bottom panel is accessed by opening the swing panel.

Pick break sensor control board

Barrier

barrier

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

pick break sensor control board

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

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

© BUCYRUS AMERICA, INC.

Fig. 29: Bottom panel

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

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

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

© BUCYRUS AMERICA, INC.

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

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

Fig. 30: Hydraulic component locator feeder breaker

4,21,23

18,19

6

11

7

24

20,25

21,23,28 15

16,17

2

13,14,22 3

26,27 8

5

30 10 9

6

1.

2.

3.

4.

5.

6.

7.

oil tank hydrostatic pump tandem pump, gear w/ piggyback primary valve bank secondary valve bank tilt and lift cylinders tram motor

11

7

29

1

10

9

23. filter, in-line, non-bypass 24. return manifold 25. flow control, heat exchanger 26. tank fill hand pump 27. check valve 28. logic check valve 29. loop flushing valve 30. diversion valve _____________________________________________________________

A6474X280

8. conveyor motor 9. belt lift cylinder 10. tail pulley cylinder 11. roof anchor cylinder 12. foot cylinder (not shown) 13. flow divider, power fill 14. ball valve 15. dual relief manifold

6

VRVI/O1

16. pressure gauge (6,000 psi) 17. pressure gauge (600 psi) 18. 6-way selector valve 19. proportional detented valve 20. heat exchanger 21. filter (pressure, charge, aux pressure, return) 22. tank fill filter

5.31

Hydraulic system _____________________________________________ Major hydraulic components

hydraulic oil tank

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

hydrostatic pump

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

gear pump

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

primary valve bank

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

secondary valve bank

The secondary valve bank, located at the head shaft on the right hand side of the machine, is used to control tailpiece steering and tilt, the roof cylinders, and the foot cylinders.

tank fill pump

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

tank fill hand pump

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

tilt hydraulic cylinders

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

lift hydraulic cylinders

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

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

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

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

© BUCYRUS AMERICA, INC.

(Reference Fig. 30)

____________________________________________ Hydraulic system

© BUCYRUS AMERICA, INC.

tram motors

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

conveyor motor

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

loop flushing valve

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

oil/water heat exchanger

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

proportional conveyor speed/direction control valve

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

charge filter

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

pressure filter (s)

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

return filter

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

tank fill filter

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

pressure filter (hydrostatic)

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

conveyor pressure gauge (6,000 psi)

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

auxiliary function pressure gauges

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

_____________________________________________________________ A6474X280 VRVI/O1 5.33

Hydraulic system _____________________________________________ charge pressure gauge (600 psi)

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

filter service indicator gauges (6,000 psi)

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

Table 1: Corresponding pressure gauges Pressure gauge

Corresponding filter service indicator gauge

“AUXILIARY PRESSURE #2”

“FILTER SVC INDICATOR #2”

“AUXILIARY PRESSURE #3”

“FILTER SVC INDICATOR #3”

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

© BUCYRUS AMERICA, INC.

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

____________________________________________ Hydraulic system

© BUCYRUS AMERICA, INC.

Fig. 31: Hydraulic schematic feeder breaker

_____________________________________________________________ A6474X280 VRVI/O1 5.35

© BUCYRUS AMERICA, INC.

Hydraulic system _____________________________________________

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

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

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

Crawler assembly (s)

© BUCYRUS AMERICA, INC.

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

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

Fig. 32: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

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

_____________________________________________________________ A6474X280 VRVI/O1 5.37

Mechanical assemblies ________________________________________ Conveyor chain The feeder breaker is equipped with a conveyor chain assembly (Fig. 33) that carries mined material along the conveyor trough from the receiving section and out through the discharge end. The conveyor chain is made up of one basic chain assembly, which repeats sequentially along the entire chain loop. (See Maintenance section in this chapter for Conveyor chain maintenance.)

Fig. 33: Conveyor chain components

Roll pin

© BUCYRUS AMERICA, INC.

Chain link section

Flight bar

Grease take-up The feeder breaker is equipped with two (2) conveyor chain grease take-up assemblies (Fig. 34) that provide ease of adjustment for the conveyor chain. The take-up assemblies provide constant tension on the tail shaft around which the conveyor chain rides at the receiving end of the machine. (See Conveyor chain adjustment procedure in the Adjustment Procedure section of this chapter) Fig. 34: Grease take-up main components

Stop valve (2)

Grease manifold

Grease fitting (2)

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

_______________________________________ Mechanical assemblies Head shaft The feeder breaker is equipped with a head shaft (Fig. 35) located on the discharge end of the conveyor. The head shaft is driven from the right hand side via a hydraulic motor and gearbox that is directly mounted to the head shaft.

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

© BUCYRUS AMERICA, INC.

Fig. 35: Head shaft main components

Bearing (2)

Sprocket (2)

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

Gearbox

Hydraulic motor

_____________________________________________________________ A6474X280 VRVI/O1 5.39

Mechanical assemblies ________________________________________ Conveyor power unit The conveyor power unit drives the hydraulic pump (s) and pick breaker reducer (Fig. 36). It consists of a 125 HP electric motor coupled a hydrostatic pump and piggyback gear pump. The power unit has been assembled as a unit and can be removed as a unit or as individual components (see Replacement of wear parts section of this chapter).

Fig. 36: Conveyor power unit main components

Connecting tube

Motor (125 HP)

Hydrostatic pump

Gear pump

Tail shaft The feeder breaker is equipped with a tail shaft (Fig. 37) located on the receiving end of the conveyor. The tail shaft is an idler shaft that is driven by the tension of the conveyor chain. There is a slide plate arrangement attached to the tail shaft, which fills the gap between the receiving impact plate and the shaft.

Fig. 37: Tail shaft components Set screw (2)

Slide plate

Adapter (2)

Key (2)

Sprocket (2)

Head shaft

Bearing (2)

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

© BUCYRUS AMERICA, INC.

Coupling

_______________________________________ Mechanical assemblies Breaker and breaker power unit assembly The breaker and breaker power unit (Fig. 38) are assembled so that they can be installed as a unit. The power unit can be removed as a separate, complete assembly. To remove the breaker shaft, the breaker power unit and breaker shaft must be removed as an assembly.

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

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

© BUCYRUS AMERICA, INC.

Breaker shaft

Under speed sensor Breaker power unit

_____________________________________________________________ A6474X280 VRVI/O1 5.41

Mechanical assemblies ________________________________________ Breaker assembly The breaker assembly (Fig. 39) on the machine has a 32” (813 mm) pick circle with a 5 point star arrangement. It has a 10” (254 mm) shaft diameter turned down to 8” (203 mm) thru the bearings.

Fig. 39: Breaker assembly main components Bearing housing Bit (requires 2 retainer rings each) End cap Key Bearing housing

Side plate

Breaker shaft

Breaker end cap

Side plate

Breaker power unit The breaker power unit (Fig. 40) drives the pick breaker. It consists of a 150 HP electric motor coupled to a reducer. The power unit has been assembled as a unit and can be removed as a unit or as individual components (see Replacement of wear parts section of this chapter).

Fig. 40: Breaker power unit Flexible coupling Taper lok bushing

Electric motor Taper lok bushing

Reducer

Companion flange

Torque limiter

Connecting tube

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

© BUCYRUS AMERICA, INC.

Gear reducer spacer

_______________________________________ Mechanical assemblies Tailpiece assembly The tailpiece assembly (Fig. 41) attaches to the discharge end of the feeder breaker frame. It consists of a return belt pulley, an impact bed, and tilt and steering cylinders. The belt runs around the belt pulley and over the impact bed.

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

The tailpiece assembly, when attached to the feeder breaker, provides a means for quickly advancing and tensioning the belt.

© BUCYRUS AMERICA, INC.

Fig. 41: Tailpiece assembly

Impact bed

Steering cylinder Tilt cylinder

Belt pulley

_____________________________________________________________ A6474X280 VRVI/O1 5.43

© BUCYRUS AMERICA, INC.

Mechanical assemblies ________________________________________

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

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

Important notes

© BUCYRUS AMERICA, INC.

Please observe the following: ■

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

■

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

■

Use only suitable and approved tools for maintenance work.

■

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

■

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

■

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

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

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

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

■

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

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person. ______________________________________________________________ A6474X280

VRVI/O1

5.45

Maintenance _________________________________________________ ■

During maintenance or servicing, if either of the tram drives are to be run, the side that is to be run must be jacked clear of the ground and securely blocked. Follow all Federal and mine safety standards for blocking the machine.

■

Do not perform maintenance on a hydraulic cylinder while there is a load resting on the hydraulic cylinder. Loads must be securely blocked if maintenance is to be performed with a load on the hydraulic cylinder. Follow all Federal and mine safety standards for blocking the load.

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

■

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

■

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

■

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

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

© BUCYRUS AMERICA, INC.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load may fall, causing damage to the machine or serious injury or death to you or other workers. Do not rely on counterbalance valves to hold the load. Always block or place a mechanical lock on the load.

Follow all Federal and mine safety standards for blocking the load.

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

Table 2: Lubrication and maintenance schedule Item

© BUCYRUS AMERICA, INC.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19 20

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

Places

Lubricant

Specification

2 2 2 4 1 1 2 1 1 Inspect

Spec. 100-3

2 1 Inspect Inspect Inspect 2

Spec. 100-3

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

Spec. 100-2 or Spec. 100-13

1 1 1 2

34

Breaker reducer (check) Dust system strainer (check) Charge filter (change) Tailpiece bearing Every 2 weeks Pressure filter (auxiliary circuit) (change) Return filter (change) Pressure filter (hydrostatic) (change) Monthly Power fill filter (check/change as required) Conveyor tilt cylinders (rod and base) Conveyor lift cylinders (rod and base) Crawler anchor pin (s) Foot cylinder Every 3 months Breaker electric motor Conveyor electric motor Breaker reducer Torque limiter (check clutch wear) First 500 hours then every 2500 hours **Breaker reducer (Change) Every 6 months Hydraulic oil tank (change)

1

Spec. 100-1

35

Tram reducer (change oil)

2

Spec. 100-2 or Spec. 100-13

21 22 23 24 25 26 27 28 29 30 31 32 33

Century 220

Spec. 100-3

2 1 1 1 4 4 2 4

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

2 2 2 1 1

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

Century 220

______________________________________________________________ A6474X280 VRVI/O1 5.47

Maintenance _________________________________________________ Table 2 Continued: Lubrication and maintenance schedule Item

36 37 38 39 40 41 42

Description

Places

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

Lubricant

Specification

2 1

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

Location

Specification

Approximate capacity

Hydraulic oil tank Breaker reducer Tram reducer

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

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

Grease points

Notes

As required

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

© BUCYRUS AMERICA, INC.

Table 3: Lubricants: Fluids and capacities

26

     

31

41,42

5,34 6,8,9,19, 22,23,37

   

    

   

    

  

   

  

40

U.S.A.

3

30     

27      

10     

© BUCYRUS AMERICA, INC.

________________________________________________ Maintenance

Fig. 42: Lubrication chart

12

4

25

11

29 7,21,36

32

16,35

17,33

39

18

28

24

20

1,2

38

______________________________________________________________ A6474X280 VRVI/O1 5.49

Maintenance _________________________________________________ Lubrication and inspection Maintenance includes: ■

lubrication of the machine in accordance with the lubrication schedule.

■

inspection of the machine for faults and proper function.

■

inspection of wear parts.

Lubrication

central lubrication manifold

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

head shaft bearing seal lubrication manifold

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

tailpiece belt pulley lubrication manifold

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

conveyor motor lubrication manifold

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

breaker motor lubrication manifold

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

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

© BUCYRUS AMERICA, INC.

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

________________________________________________ Maintenance Fig. 43: Lubrication manifold locations Breaker motor lubrication manifold Central lubrication manifold

© BUCYRUS AMERICA, INC.

Head shaft bearing seal lubrication manifold

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

  

     

  

    

 

PR OU DLY M ADE I N THE

   

  

    

    

U.S. A.

Conveyor motor lubrication manifold Tailpiece pulley bearing lubrication manifold

______________________________________________________________ A6474X280 VRVI/O1 5.51

Maintenance _________________________________________________ Specific lubrication and maintenance procedures

head shaft bearings

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

head shaft bearing seals

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

tail shaft and slide tube bearings

Lubricate the feeder breaker tail shaft and slide tube bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 44) located on the right side of the receiving section.

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

breaker bearings

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

Fig. 44: Lubrication panels

Head shaft bearing (right side)

Head shaft bearing (left side)

Head shaft bearing seal (right side)

Breaker shaft (right side)

Head shaft bearing seal (right side)

Breaker shaft (left side)

Tail shaft bearing (right side)

Tail shaft (right side)

Tail shaft bearing (left side)

Breaker shaft grease return (2)

Tail shaft (left side)

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

© BUCYRUS AMERICA, INC.

Every 8 hours of operation

________________________________________________ Maintenance hydraulic oil tank

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

Fig. 45: Hydraulic tank oil level

Oil level sight glass

© BUCYRUS AMERICA, INC.

charge filter

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

pressure filter (auxiliary circuit)

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

return filter

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

pressure filter (hydrostatic)

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

Fig. 46: Filter locations

Hydrostatic pressure filter

Charge pressure filter

Return pressure filter

Auxiliary pressure filter

Auxiliary pressure filter

______________________________________________________________ A6474X280 VRVI/O1 5.53

Maintenance _________________________________________________ breaker bits

Check the breaker bits (Fig. 47) to see if they will rotate in their holders and for damaged or missing bits. The bits may be inspected by looking into the receiving end of the machine. If bits need to be replaced, see Bit replacement in the Replacement of wear parts section of this chapter.

WARNING! Do not enter the hopper unless power center is locked and tagged out and machine main circuit breaker is in the “OFF” position. If these procedures are not followed, serious injury or death can result.

Fig. 47: Breaker bits

© BUCYRUS AMERICA, INC.

Breaker bits

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

________________________________________________ Maintenance Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 48) with Spec. 100-3. The fittings (one per side) may be reached through the slot in the end of the crawler frame on the outside of each crawler.

Pump grease into the fitting until new grease can be observed coming out of the bearings.

Fig. 48: Crawler track take-up lubrication

© BUCYRUS AMERICA, INC.

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

conveyor chain tension

Check the conveyor chain tension. With the machine running, visually inspect tail shaft to ensure shaft is turning and conveyor chain 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:

electrical cables, conduits and glands hydraulic hoses and fittings

■

head shaft bearing bolts

■

breaker shaft side plate bolts

■

conveyor drive motor mounting bolts

■

tail shaft retainer hold down bolts

■

all cover and guard retaining bolts

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

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

______________________________________________________________ A6474X280 VRVI/O1 5.55

Maintenance _________________________________________________ charge filter

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

Fig. 49: Hydraulic charge filter

Charge filter

tram reducer (s)

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

Fig. 50: Tram reducer oil level

Fill plug location

Drain plug location

Check plug location

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

© BUCYRUS AMERICA, INC.

Charge pressure filter

________________________________________________ Maintenance breaker reducer

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

Fig. 51: Breaker reducer

© BUCYRUS AMERICA, INC.

Sight glass

dust system strainer

Clean the strainer mounted inside the dust suppression system. Open ball valve (Fig. 52) and allow water to flow from the short attached hose. The flowing water will flush out the filter strainer.

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

Fig. 52: Dust system

Regulator

Dust system pressure gauge

Strainer

Ball valve

Short hose

______________________________________________________________ A6474X280 VRVI/O1 5.57

Maintenance _________________________________________________ tailpiece bearing (belt pulley)

Grease the tailpiece bearing (2 places) through the grease manifold (Fig. 53) located on the right hand side of the machine with Spec. 1003. Pump new grease into the fitting until old grease can be observed coming out of the bearing.

Fig. 53: Tailpiece bearing (belt pulley)

© BUCYRUS AMERICA, INC.

Grease manifold

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

________________________________________________ Maintenance Every 2 weeks pressure filter (auxiliary circuit)

Change the two (2) pressure filter’s element (Fig. 54). If the element is extremely dirty, a more frequent interval may be required.

return filter

Change the return filter’s element (Fig. 54). If the element is extremely dirty, a more frequent interval may be required.

pressure filter (hydrostatic)

Change the hydrostatic pressure filter’s element (Fig. 54). If the element is extremely dirty, a more frequent interval may be required.

Fig. 54: Filter location

© BUCYRUS AMERICA, INC.

Charge pressure filter

Hydrostatic pressure filter

Auxiliary pressure filter

Return pressure filter

Auxiliary pressure filter

Monthly power fill filter

Check the power fill filter element (Fig. 55) and change as necessary depending on the frequency of tank fill system. If the element is extremely dirty, a more frequent interval may be required.

Fig. 55: Power fill filter

Power fill filter

______________________________________________________________ A6474X280 VRVI/O1 5.59

Maintenance _________________________________________________ conveyor tilt cylinders

Lubricate grease fittings on the rod and base ends of the conveyor tilt cylinders with Spec. 100-3 (Fig. 56). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 56: Conveyor tilt cylinders

conveyor lift cylinders

Lubricate grease fittings on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 57). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 57: Conveyor lift cylinders Lift cylinder (2) (grease fitting located on rod and base end)

crawler anchor pins

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

Fig. 58: Crawler anchor pins

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

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

© BUCYRUS AMERICA, INC.

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

________________________________________________ Maintenance foot cylinder

Grease the foot cylinder (2) through the fittings located on the rod and cylinder eye (4 places) (Fig. 59) with Spec. 100-3. Pump new grease into the fitting until old grease can be observed coming out of the bushing.

Fig. 59: Foot cylinder grease points

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

Every 3 months

© BUCYRUS AMERICA, INC.

breaker electric motor

Lubricate the breaker power unit electric motor with Spec. 100-3 through the two (2) grease fittings located on the lubrication manifold (Fig. 60) located on the right side of the machine. Pump only one or two pumps of grease into each fitting.

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

Fig. 60: Breaker electric motor

Electric motor central lubrication panel

______________________________________________________________ A6474X280 VRVI/O1 5.61

Maintenance _________________________________________________ conveyor electric motor

Lubricate the conveyor power unit electric motor with Spec. 100-3 through the two (2) grease fittings located on the lubrication manifold (Fig. 61) located on the right side of the machine. Pump only one or two pumps of grease into each fitting.

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

Electric motor central lubrication panel

reducer

Lubricate the reducer with Spec. 100-3 through the three (3) grease fittings located on the reducer (Fig. 62) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

Fig. 62: Reducer lubrication

Grease fitting

Grease fitting (2)

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

© BUCYRUS AMERICA, INC.

Fig. 61: Conveyor electric motor

________________________________________________ Maintenance torque limiter

Check torque limiter clutch disk wear as shown. Clutch disk must be changed when 3.46” is measured as shown in Fig. 63.

Fig. 63: Torque limiter clutch wear

© BUCYRUS AMERICA, INC.

3.55” New thickness 3.46” Worn thickness

______________________________________________________________ A6474X280 VRVI/O1 5.63

Maintenance _________________________________________________ Every 2500 hours breaker drive reducer

Change the oil in the breaker drive reducer (Fig. 64). The reducer oil should be changed after the first 500 hours of operation and ever 2500 hours afterwards.

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

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

Fig. 64: Breaker reducer Inspection cover (fill access)

Fill plug (alternate)

Sight glass

Drain plug

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

© BUCYRUS AMERICA, INC.

Remove the drain plug and allow the oil to completely drain.

________________________________________________ Maintenance Every 6 months hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank (Fig. 65).  Clean all dirt and debris from around the fill cap and drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and reinstall drain plug.  Remove the fill cap and pour 20 gallons (76 L) of oil (Spec. 100-1) through the fill cap strainer to avoid cavitating the pumps with the power fill unit.

© BUCYRUS AMERICA, INC.

CAUTION! The oil tank must contain a minimum of 20 gallons ( 76 liters) of oil to operate the power fill function. This is to ensure that the hydraulic pumps are not run dry, causing severe damage to the pump.  Add oil Spec 100-1 as required via the power fill system until fluid is visible in sight glass.  Install fill cap.  Start the machine and allow the hydraulic pump to run in order to purge air from the system.  Shut down the machine and recheck the oil level. Add oil if necessary.

Fig. 65: Hydraulic tank oil level

Drain plug (not shown)

Oil level sight glass

______________________________________________________________ A6474X280 VRVI/O1 5.65

Maintenance _________________________________________________ tram reducer

Change oil in the tram reducer (Fig. 66).  Clean all dirt and debris from and around the level and fill plugs.  Rotate reducer until drain plug is at the 6 o’clock position and remove drain plug and allow the oil to completely drain.  Clean and reinstall drain plug.  Rotate reducer until plugs are at the 12 o’clock and 3 o’clock positions.  Add oil (80W-90) through the fill hole until fluid begins to flow from the check plug.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Install level and fill plugs. © BUCYRUS AMERICA, INC.

 Do not overfill reducer.

Fig. 66: Tram reducer oil change

Fill plug location when at 12 o’clock

Check plug location when at 3 or 9 o’clock

To drain, position a plug at 6 o’clock

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

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

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

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X280 VRVI/O1 5.67

Maintenance _________________________________________________ Inspection of wear parts on the feeder breaker

■

the conveyor chain

■

the conveyor chain flights

■

the conveyor drive sprockets

■

the conveyor tail shaft

■

the conveyor wear plates

■

the crawler pads

■

the crawler drive sprockets

■

the crawler idler rollers

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

© BUCYRUS AMERICA, INC.

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

________________________________________________ Maintenance Inspection of fire suppression system on the feeder breaker To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 67).  Note general appearance for mechanical damage or corrosion.  Check nameplate for readability, corrosion or looseness.  Remove fill cap assembly.  Examine gaskets for elasticity, clean and coat lightly with a good grade of high heat resistant grease.  Inspect threads on fill cap and in fill opening for nicks, burrs, cross threading, rough or feathered edges.

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X280 VRVI/O1 5.69

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

© BUCYRUS AMERICA, INC.

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

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

________________________________________________ Maintenance Recharge of fire suppression system on the feeder breaker To return your fire suppression system to service after use (Fig. 67).  Pull ring on safety valve to relieve actuator system pressure.  Disconnect actuation system hose at cartridge receiver/actuator assembly.  Open bursting disc union assembly.  Remove extinguisher from bracket.  Replace ruptured bursting disc with new disc. (Full disc side must face extinguisher).

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X280 VRVI/O1 5.71

Maintenance _________________________________________________ Fig. 67: Fire suppression system

Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Breaker coupling Nozzle

Operator’s station

Nozzle Nozzle Breaker motor Nozzle

Oil tank LP canister

LP expellant

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

© BUCYRUS AMERICA, INC.

Nozzle

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

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

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

Conveyor chain adjustment

© BUCYRUS AMERICA, INC.

The conveyor chain is a complete assembly and should be checked for correct tension at regular intervals.

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

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 68):  Close the needle valve on manifold assembly securely.  Attach a grease gun to the grease fitting located on the manifold and apply grease until the required pressure is attained. Sight across the bottom of the head shaft sprocket. The chain should sag 1 1/2” to 2” below the bottom of the head shaft sprocket.  After tensioning chain, remove the allen head bolts from the tail shaft retainers and lift out retainers.  Insert shims over cylinder rod to maintain gap between bearing and end plate of box. Measure the exposed rod length on the grease take-up cylinders and make sure they are within 1/4” of each other.

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

Incorrect tension or adjustment can cause premature wear of sprockets and chain. Measure the exposed rod length on the grease take-up cylinders and make sure they are within 1/4” of each other.  Allow tail shaft pressure to rest completely on shims.  Replace retainers.  Release pressure on the take-up cylinders by opening the top valve to vent grease. After grease has vented, close valve.

______________________________________________________________ A6474X280 VRVI/O1 5.73

Adjustment procedures ________________________________________ WARNING! Due to grease cylinders being under high pressure, do not stand in direct line of grease fitting or needle valve when releasing pressure. You could be seriously injured from high pressure grease.  Store any unused shims under cover plate.

Fig. 68: Conveyor chain adjustment

Shims

Needle valve (2)

Grease fitting (2)

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

© BUCYRUS AMERICA, INC.

Shim storage

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

To adjust tension on the crawler track with the take-up cylinders proceed as follows (Fig. 69):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

© BUCYRUS AMERICA, INC.

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

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

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

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

______________________________________________________________ A6474X280 VRVI/O1 5.75

Adjustment procedures ________________________________________ Fig. 69: Crawler track adjustment

Access cover

© BUCYRUS AMERICA, INC.

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

Cylinder retainer bar/ shim retainer plate mount

Retainer plate

Grease fitting

Needle valve

Take-up cylinder

Shims (located behind retainer plate)

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

_______________________________________ Adjustment procedures Underspeed sensor calibration To calibrate the underspeed sensor (Fig. 70), proceed as follows:  Start the feeder breaker (see Startup procedure in this chapter).  Start the conveyor belt and run at the slowest normal operating speed expected.

IMPORTANT! Calibration should be performed with the conveyor belt running the slowest normal operating speed expected to avoid nuisance shutdowns.  Turn Speed 1 control switch left (ccw) until it stops (approximately 7 o’clock).

© BUCYRUS AMERICA, INC.

 Hold test/set switch (SW1) in the set position to engage relay (RY1).  Turn Speed 1 control switch right (cw) slowly until critical speed LED (LED 3) stays on continuously.

IMPORTANT! For all speed adjustments, the critical speed LED (LED 3) must stay on continuously.  Continue turning Speed 1 control right (cw) until margin LED (LED 4) begins to blink.  The control relay will drop out with the above at a 15% slow down.  For a 20% margin, adjust the Speed 1 control so that the margin light (LED 4) is continuously on.  For a 10% margin, turn the Speed 1 control left (ccw) until the margin light (LED 4) turns off.  After the relay status LED is illuminated, return the test/set switch to the run position.  A momentary test position is provided to simulate the loss of sensor signal, which releases the relay.

______________________________________________________________ A6474X280 VRVI/O1 5.77

Adjustment procedures ________________________________________ Fig. 70: Under speed senor calibration

© BUCYRUS AMERICA, INC.

Bottom panel - starter enclosure

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

_______________________________________ Adjustment procedures Hydrostatic pump relief valve adjustment The hydrostatic pump used to drive the conveyor chain on the feeder breaker has two main pressure relief valves and one charge relief valve (Fig. 71). The main relief valves are preset at 5,000 psi and the charge relief valve at 350 psi.

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

© BUCYRUS AMERICA, INC.

 1. Locate the forward direction pressure port on the hydrostatic pump (Fig. 71) and remove the forward pressure hose from the pump. Plug the hose end and cap the pump fitting.

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

IMPORTANT! Do not run the pump for a long period of time while setting the reliefs as all of the flow will be going over the relief. Excessive pump operation with the lines plugged will result in overheating and the eventual failure of the pump.  3. Two people are required to adjust pressure settings. One person must move the conveyor direction valve handle to the forward direction, monitor the pressure gauges, relay pressure gauge readings to the mechanic making the adjustments, and be ready to shutdown the machine via the panic bar, if necessary. The second person will perform the actual pressure adjustment at the hydrostatic pump (Fig. 71).

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

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

If the system pressure gauge does read 5,000 psi during the conveyor forward relief pressure test, then proceed to Step 8.  4. Locate the corresponding relief pressure adjustment valve for the forward pressure port (Fig. 71).

______________________________________________________________ A6474X280 VRVI/O1 5.79

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

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

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

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

© BUCYRUS AMERICA, INC.

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

_______________________________________ Adjustment procedures Hydrostatic pump charge pressure adjustment WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.  1. Start the machine (see Start-up procedure in this chapter).  2. The charge pressure gauge (Fig. 72) should read 350 psi while the machine is at idle, the conveyor direction valve handle is in neutral, and the oil temperature is between 90°F and 110°F. Locate the charge pressure adjustment screw (Fig. 71).

© BUCYRUS AMERICA, INC.

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

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

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

______________________________________________________________ A6474X280 VRVI/O1 5.81

Adjustment procedures ________________________________________ Fig. 71: Pump relief valves Charge pressure relief adjustment System pressure relief adjustment, forward: located directly across from forward system pressure port

System pressure port, forward

System pressure port, reverse

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

© BUCYRUS AMERICA, INC.

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

_______________________________________ Adjustment procedures Fig. 72: Valve banks

Lift, right

Tram, left

Tram, right

Lift, left

Tilt

© BUCYRUS AMERICA, INC.

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

Auxiliary system pressure gauge

Charge pressure gauge

Auxiliary system pressure gauge

______________________________________________________________ A6474X280 VRVI/O1 5.83

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

The loop flushing valve (Fig. 73) is mounted on the frame behind the breaker power unit. The valve is preset from the factory at 290 psi, which is measured by the charge pressure gauge while the conveyor is running.

If an adjustment is required:

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

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

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

© BUCYRUS AMERICA, INC.

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

_______________________________________ Adjustment procedures Fig. 73: Loop flushing valve Jam nut and adjustment hex

© BUCYRUS AMERICA, INC.

Loop flushing valve

Charge pressure gauge

______________________________________________________________ A6474X280 VRVI/O1 5.85

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

The dual relief manifold (Fig. 74) is mounted on the frame behind the breaker power unit. The purpose of the two relief valves is to limit the maximum pressure to each of the inlet sections on the primary valve bank. The design pressure setting is 2,250 psi. The setting for each relief is read from the corresponding auxiliary pressure gauge while deadheading a function. The top relief cartridge (2) limits the pressure into the first inlet section (both left sections and left tram) while the bottom relief cartridge (1) limits pressure to the mid-inlet section (right tram, tilt, and power fill).

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

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

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

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

© BUCYRUS AMERICA, INC.

To adjust relief cartridge 2:

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

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

© BUCYRUS AMERICA, INC.

 Measure the setting of cartridge 1 by fully extending or retracting (deadheading) the tilt cylinders, then reading the pressure on “AUXILIARY PRESSURE #3” gauge while the cylinders are deadheaded. The reading should be 2,250 psi.

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

______________________________________________________________ A6474X280 VRVI/O1 5.87

Adjustment procedures ________________________________________ Fig. 74: Dual relief manifold Relief cartridge 2

Dual relief manifold

© BUCYRUS AMERICA, INC.

Relief cartridge 1

“AUXILIARY PRESSURE #2”

“AUXILIARY PRESSURE #3”

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

_______________________________________ Adjustment procedures Secondary valve bank relief adjustment The secondary valve bank (Fig. 75) is fitted with a relief in the inlet section. The designed setting is 2,250 psi.  Two people are required to adjust the pressure setting. One person must operate a foot cylinder valve handle on the secondary valve bank and adjust the relief valve cartridge. The second person will relay pressure gauge readings to the mechanic making the adjustment and will be ready to shutdown the machine via the panic bar, if necessary.

© BUCYRUS AMERICA, INC.

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

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

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

______________________________________________________________ A6474X280 VRVI/O1 5.89

Adjustment procedures ________________________________________ Fig. 75: Secondary valve bank adjustment

Adjustment screw

Roof/foot cylinder valve handle, right

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

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

“AUXILIARY PRESSURE #3”

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

© BUCYRUS AMERICA, INC.

Roof/foot cylinder valve handle, left

_______________________________________ Adjustment procedures Flow control valve adjustment This flow control valve (Fig. 76) is used to control the heat exchanger fan speed by limiting the flow allowed to the heat exchanger motor.

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

______________________________________________________________ A6474X280 VRVI/O1 5.91

Adjustment procedures ________________________________________

Heat exchanger motor

Flow control valve

Flow control valve adjustment

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

© BUCYRUS AMERICA, INC.

Fig. 76: Flow control valve adjustment

____________________________________ Replacement of wear parts

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

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

Head shaft

© BUCYRUS AMERICA, INC.

The head shaft (Fig. 77) transmits the torque of the hydraulic motor to the conveyor chain assembly. It is part of a complete assembly. As soon as any component is worn, the component or complete head shaft must be replaced. Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

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

drive shaft

■

sprockets

■

bearings

■

hydraulic motor

Fig. 77: Head shaft main components

Sprocket (2)

Head shaft Key (2)

Sprocket (4)

Bearing (2)

______________________________________________________________ A6474X280 VRVI/O1 5.93

Replacement of wear parts _____________________________________ How to remove the head shaft To remove the head shaft assembly from the feeder breaker proceed as follows (Fig. 78):  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Remove the two (2) sprocket guards located over the head shaft sprockets.  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the last cover on the right hand side of the machine.  Remove the last cover’s support post.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads. Unpin and fold down tailpiece tilt cylinders. It is not necessary to remove hydraulic hoses. Remove the tailpiece hoppers (2) and head shaft filler plates (2) using appropriate lifting equipment.

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

CAUTION! The hydraulic motor is heavy. Use proper lifting techniques.  Disconnect, tag, and cap all hydraulic hoses.  Remove the five bolts from the end of the motor.  Remove the conveyor gear reducer (see Conveyor gear reducer removal/installation procedure in this chapter). The conveyor gear reducer may remain on the shaft if the frame is equipped with a notch to allow for the passage of the reducer housing.  Disconnect, tag and cap the central lubrication hoses on both head shaft bearings and head shaft bearing seals.

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

© BUCYRUS AMERICA, INC.

 Block and secure tailpiece.

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

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

How to install the head shaft

© BUCYRUS AMERICA, INC.

To install the head shaft assembly proceed as follows (Fig. 78):  Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the feeder breaker. The gear reducer may be installed on shaft and installed into feeder if the feeder frame is equipped with an access notch.  Reinstall bearing shims, if applicable, back into the same location as they were removed from. Make sure to install the shims of the same thickness and quantity.  Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) nuts, bolts, and lock washers. Torque bolts to 645 ft-lbs.

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

______________________________________________________________ A6474X280 VRVI/O1 5.95

Replacement of wear parts _____________________________________

  Install cover support post and cover.  Connect conveyor chain. (See Conveyor chain replacement in this chapter).  Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

Fig. 78: Head shaft removal and installation

Conveyor chain (not shown) Nut 1”

Male clevis Swivel bearing

Female clevis

Cotter pin Head shaft Pin Hydraulic motor

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

Splined adapter Flat washer

Shaft retainer

Retaining bolt M20 X 2.5 X 100 10.9

Reducer end cover

Access notch

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

© BUCYRUS AMERICA, INC.

Lock washer

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

How to remove the head shaft sprockets To remove the sprockets from the head shaft assembly proceed as follows (Fig. 79):  Remove the head shaft assembly from the feeder (see Head shaft removal in this chapter).  Remove the two (2) bearings from the head shaft.

© BUCYRUS AMERICA, INC.

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

See parts manual for replacement parts list.

How to install the head shaft sprockets To install the sprockets on the head shaft proceed as follows (Fig. 79):  Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.  Insert one of the keys into the shaft keyway and slide first sprocket onto shaft (see Fig. 80 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 79 for weld spcifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.  Insert the other key into the shaft keyway and slide second sprocket onto shaft (see Fig. 79 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 80 for weld spcifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.  Install bearings on shaft (ss Bearing installation procedure in this chapter). Note that the bearing housing must be installed on shaft so that the Taconite seal is facing the middle of the shaft. One of the bearings must have the internal spacer remvoed to allow the shaft to float and not be in a bind.  Install the drive shaft assembly in the feeder breaker. (See Drive shaft installation in this chapter.) ______________________________________________________________ A6474X280

VRVI/O1

5.97

Replacement of wear parts _____________________________________ How to install the head shaft split sprockets To install the split sprockets on the head shaft proceed as follows (Fig. 79): IMPORTANT! Adhere to all weld specifications shown on Fig. 79. Failure to do so may result in sprocket failure and machine damage.  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the two (2) sprocket guards located on the end of the feeder breaker.

 Thoroughly clean and degrease the drive shaft.  Insert key into shaft keyway.  Install both sprocket halves onto shaft and tack weld in place (see Fig. 79 for location). Ensure sprocket alignment and proper spacing with conveyor chain.  Preheat sprocket weld joint to 600°F .  Weld sprocket halves together and do not exceed 800°F maximum interpass temperature. Ensure that the weld is smooth in the tooth area to prevent damage to the conveyor chanin bushings during chain operation.  If possible, cover sprocket with insulating blanket and allow weld to coolt to a maximum of 100°F before uncovering. If this is not possible, then post weld heat to 800°F.  Connect conveyor chain. (See Conveyor chain replacement in this chapter).  Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

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

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Fig. 79: Head shaft sprocket removal and installation Bearing (2)

Head shaft

3/8 X 45° weld chamfer

Sprocket guard

3/8 X 45° weld chamfer

Split sprocket (typical)

© BUCYRUS AMERICA, INC.

Sprocket (2) & key (2)

Hydraulic motor

General notes: 1.

2.

3.

Conveyor chain

4.

Do not mix and match halves with other sprockets.

Install sprocket and keys on head shaft.

OK to temporarily tack weld sprocket halves to head shaft until welding is complete.

Blend and smooth welds to avoid chain roller damage.

Weld notes: 1.

2.

3.

4.

5.

6.

7.

All welds chamfers are 1/2 X 45° except as noted above.

Preheat sprocket weld joint 600°F - 800°F. Maintain preheat temperature during entire welding process.

Max interpass temperature not to exceed 800°F. Use low hydrogen rod (E7018) or weld wire (Class E71T Spec AWS A5.20).

Post weld heat sprocket joint 600°F - 800°F. If possible/practical, bury sprocket in dirt or wrap with a welding blanket for a minimum of 8 hours or until sprocket temp reaches 100°F.

Taconite seal Taconite seal

(optional for one piece sprockets)

(optional for one piece sprockets)

______________________________________________________________ A6474X280 VRVI/O1 5.99

Replacement of wear parts _____________________________________ Tail shaft The tail shaft (Fig. 80) allows for even adjustments and friction free transition to the conveyor chain assembly. As soon as any component of the tail shaft is worn the component or complete tail shaft assembly must be replaced. Due to the high abrasion forces the tail shaft is subject to a very high level of wear.

■

shaft

■

sprocket (2)

■

slide plate weldment

■

key

■

sprocket set screw

■

take-up bearing (2)

■

piston rod adapter (2)

■

take-up bearing set screw (4)

© BUCYRUS AMERICA, INC.

The tail shaft assembly consists of the following main components:

Fig. 80: Tail shaft main components

Sprocket set screw

Slide plate

No key

Piston rod adapter (2)

Key

Set screw

Set screw

Set screw

Set screw

Sprocket (2)

Tail shaft

No set screw

Bearing (2)

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

____________________________________ Replacement of wear parts How to remove the tail shaft To remove the tail shaft assembly from the receiving end of the feeder breaker proceed as follows (Fig. 81):  Remove the RTV silicone from five (5) bolt heads and remove the bolts from each end of the tail shaft retainers and lift out the retainers.  Release tension on the conveyor chain by removing the tail shaft shims. (See Conveyor chain adjustment in this chapter).  Disconnect, tag and cap the central lubrication hoses to the tail shaft.  Separate conveyor chain and fold back to clear tail shaft. (See Conveyor chain replacement in this chapter).

© BUCYRUS AMERICA, INC.

 It may be necessary to unpin the take-up cylinders from the feeder frame and remvoe the cylinder rod from the take-up bearing.  Attach an appropriate lifting device to the tail shaft assembly and and slowly lift from machine.

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

How to install the tail shaft To install the tail shaft assembly into the receiving end of the feeder breaker proceed as follows (Fig. 81):  With an appropriate lifting device, insert tail shaft into the receiving end of the feeder breaker. Center the tail shaft in the feeder breaker frame, ensuring that the slots of the take-up bearing are aligned witht the guide bars and that the bearings are fully seated on the guide bars.  Install the take-up cylinder rod into the take-up bearing and insert take-up cylinder pin throught the mounting clevis on the frame. It may be necessary to loosen the set screws of the bearing retainer coolars and reposition the bearings so that the bearing slots are aligned with the frame guide bars.  Fold the conveyor chain over tail shaft.  Connect conveyor chain (see Conveyor chain replacement in this chapter.  Connect central lubrication hoses and lubricate the tail shaft slide plate and take-up bearings with Spec. 100-3 grease.

______________________________________________________________ A6474X280 VRVI/O1 5.101

Replacement of wear parts _____________________________________

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

Fig. 81: Tail shaft removal and installation

Cover

Shims Take-up cylinder Tail shaft slide plate

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

Take-up bearing

Swivel grease fitting

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

© BUCYRUS AMERICA, INC.

Tail shaft retainer plates (2)

____________________________________ Replacement of wear parts How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 82):  Remove the tail shaft assembly from the feeder breaker. (See How to remove the tail shaft in this chapter).  Loosen the set screws (2 per bearing assembly) and slide both take-up bearings and piston rod adapters from the tail shaft.  Loosen the set screw from the tail shaft sprocket and slide sprockets from the shaft. Note that heat may be required to loosen set screw as Loctite was used during installation.  Remove the tail shaft from the slide plate.  Visually inspect all components for damage or wear and replace as necessary.

© BUCYRUS AMERICA, INC.

How to assemble the tail shaft To assemble the tail shaft assembly proceed as follows (Fig. 82):  Thoroughly clean all parts that will be installed.  Grease tail shaft with Spec. 100-3 grease.  Slide tail shaft into the slide plate.  Insert key into keyway on tail shaft.

WARNING! Only install a key for one sprocket. If a key is installed for both sprockets, the chain could bind due to slight length variances in the conveyor chain.  Slide both sprockets onto tail shaft, one on each end.  Apply Loctite 242 (blue) on set screw and install set screw into the sprocket with the key, ensuring that the sprockets and tail shaft slide plate are centered on tail shaft.  Tighten set screw and torque to 100 ft-lb.  Install both take-up bearings onto the tail shaft, flush with the ends of the shaft.  Apply Loctite 242 (blue) to the set screw and install. Tighten and torque to 100 ft-lb.  Install swivel grease fittings in the ends of the shaft and the 90° grease hose elbows into the take-up bearings.  Install tail shaft into machine. (See How to install the tail shaft in this chapter). ______________________________________________________________ A6474X280 VRVI/O1 5.103

Replacement of wear parts _____________________________________ Fig. 82: Tail shaft disassembly and assembly

Sprocket set screw

Slide plate

No key

Piston rod adapter (2)

Key

Set screw

Set screw

Set screw

Set screw

Tail shaft

No set screw

Bearing (2)

© BUCYRUS AMERICA, INC.

Sprocket (2)

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

____________________________________ Replacement of wear parts Conveyor chain The conveyor chain (Fig. 83) is made up of one basic chain assembly which repeats sequentially along the entire chain loop. As soon as any component of the conveyor chain is worn the component or complete conveyor chain assembly must be replaced.

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

6 link chain section

■

flight bar

■

spiral pin

© BUCYRUS AMERICA, INC.

Fig. 83: Conveyor chain main components

6 link chain section Spiral pin Flight bar

______________________________________________________________ A6474X280 VRVI/O1 5.105

Replacement of wear parts _____________________________________ How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 84):  Lay conveyor chain sections on a clean flat surface.  Insert connector pins through flight end and align holes in spiral pin with holes in flight bar.  Insert spiral pin.  Drive spiral pin in with a hammer and punch. Ensure that spiral pin is recessed on both sides of flight bar.  Repeat the previous assembly instructions until the complete chain has been assembled.

Extended pin connecting link Spiral pin (4)

Block link assembly

Flight bar

Side bar

6 link chain section

How to remove the conveyor chain assembly To remove the conveyor chain assembly proceed as follows:  Release tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).  At the chain disassembly/assembly point, raise the chain a minimum of 3” high and block it under the flight.

Note: There are notches in the frame on both sides of the conveyor deck. The notches are to provide access to the conveyor chain during disassembly and assembly. This is the chain disassembly/assembly point.

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

© BUCYRUS AMERICA, INC.

Fig: 84: Conveyor chain assembly

____________________________________ Replacement of wear parts  Separate conveyor chain by removing spiral pins and connecting links in one section of the chain.  Connect a pulling device (e.g. winch or lifting tackle with adequate load limit), or the new conveyor chain, to either end of the old conveyor chain and slowly pull the old conveyor chain completely out of the machine.

WARNING! When using a pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the conveyor chain, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable. Use only approved lifting equipment for connecting pulling devices to the conveyor chain.

How to install the conveyor chain assembly To install the conveyor chain assembly proceed as follows:

© BUCYRUS AMERICA, INC.

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

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

IMPORTANT! If old conveyor chain is still on machine, installation can be facilitated by connecting the new conveyor chain to the old conveyor chain via the chain connectors and pulling it through the bottom conveyor pan.  Fold conveyor chain back over the tail shaft and drive shaft and slowly pull the chain along the conveyor ensuring that the chain is under the chain hold downs.  Ensure that the chain is properly meshed with the sprockets on the head and tail shafts.  Connect conveyor chain (see How to assemble the conveyor chain sections in this chapter for proper connection).  Adjust tension on the conveyor chain (see Conveyor chain adjustment procedure in this chapter.  With machine running, visually inspect tail shaft to ensure that the conveyor chain is properly engaged with the tail shaft sprockets.

______________________________________________________________ A6474X280 VRVI/O1 5.107

Replacement of wear parts _____________________________________ Crawler track The crawler track (Fig. 85) assembly (left and right) carries the machine via torque received from the tram drive reducer. The crawler track is made up of one basic crawler pad assembly, which repeats sequentially along the entire pad loop. As soon as any component of the crawler track is worn the component or complete crawler track assembly must be replaced.

Each crawler track consists of the following main components: ■

crawler pad

■

connector pin

■

t-pin

Fig. 85: Crawler track main components

© BUCYRUS AMERICA, INC.

Crawler pad

Connector pin and T-pin

_________________________________________________________________ 5.108 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

____________________________________ Replacement of wear parts How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 85):  Lay crawler track pads on a clean flat surface.  Align pads with chain connecting holes centered.  Insert connector into center of crawler pad connecting holes.  Drive T-pin through connecting pin and bend end to secure.  Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly

© BUCYRUS AMERICA, INC.

To remove the crawler track pad assembly proceed as follows (Fig. 85):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

To separate the crawler pads proceed as follows (Fig. 85) IMPORTANT! Heating or cutting connections with a torch or chisel may be required to ease the removal of T- pins.  Drive or cut T-pin from crawler pad connection using hammer and punch.  Separate crawler track assembly.  Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the crawler track assembly and slowly pull the crawler track completely out from under the machine.

______________________________________________________________ A6474X280 VRVI/O1 5.109

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

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

How to install the crawler track pad assembly To install the crawler track pad assembly proceed as follows (Fig. 85):

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Check to ensure that crawler track tension cylinder is completely retracted (see Crawler track adjustment in this chapter).  Slide crawler track pad assembly under crawler assembly.  Fold pad assembly over both ends of crawler assembly. Ensure that pad assembly meshes with drive sprocket and idler roller.  Connect crawler track pad assembly (see How to assemble crawler track pad assembly in this chapter for proper connection).  Adjust tension on the crawler track pad assembly (see Crawler track pad adjustment procedure in this chapter for proper adjustment).

_________________________________________________________________ 5.110 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Crawler assembly The crawler assembly (Fig. 86) consists of a take-up assembly and drive assembly that transmits torque to the crawler track via a hydraulic drive motor coupled to the tram drive torque hub. As soon as any component of the drive assembly is worn or damaged, the component must be replaced.

© BUCYRUS AMERICA, INC.

The crawler assembly consists of the following main components: ■

hydraulic drive motor

■

tram drive torque hub

■

cat pad assembly

■

take-up roller assembly

■

grease take-up assembly

■

drive sprocket

Fig. 86: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

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

______________________________________________________________ A6474X280 VRVI/O1 5.111

Replacement of wear parts _____________________________________ How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 87):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

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

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

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

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

_________________________________________________________________ 5.112 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

 Securely block under the crawler frame.

____________________________________ Replacement of wear parts How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 87):  Remove old take-up assembly (see previous section, How to remove crawler take-up assembly).

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

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X280 VRVI/O1 5.113

Replacement of wear parts _____________________________________ Fig. 87: Crawler take-up removal and installation

Tilt cylinder mounting bracket Crawler take-up

_________________________________________________________________ 5.114 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Tilt cylinder

____________________________________ Replacement of wear parts How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 88):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

© BUCYRUS AMERICA, INC.

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

CAUTION! Do not bump hydraulic motor or hydraulic motor fittings when removing the motor from the machine.  Remove the adapter plate and motor from the torque hub as an assembly.  If not replacing the hydraulic motor, it is not necessary to separate the adapter plate from the hydraulic motor. If replacing the hydraulic motor, remove the four (4) nuts and lock washers that secure the hydraulic motor to the adapter plate. And remove adapter plate.

______________________________________________________________ A6474X280 VRVI/O1 5.115

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

How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 88):  Remove old crawler drive assembly (see previous section, How to remove crawler drive assembly).

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

 Place sprocket onto torque hub and secure with the twenty (20) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

■ ■ ■

Step 1: 70 ft-lb Step 2: 140 ft-lb Step 3: 210 ft-lb

 Thoroughly clean and degrease the adapter plate and mating faces of the torque hub and hydraulic tram motor.   Apply Loctite 518 gasket eliminator or equivalent to the adaptor plate. Be sure to apply the sealant completely around all bolt holes to prevent leakage.  Place hydraulic motor gasket onto motor adapter plate.  Apply Loctite 518 to the second side of the motor gasket.  Install adapter plate and gasket onto hydraulic motor and secure with the four (4) nuts and lock washers. Apply Loctite 242 (blue) to nuts.  Apply Loctite 518 to the adapter plate gasket.  Place adapter plate gasket onto the adapter plate.  Apply Loctite 518 gasket eliminator or equivalent to the second side of the adaptor plate gasket. Be sure to apply the sealant completely around all bolt holes to prevent leakage.  Install motor and adapter plate assembly onto torque hub, being careful not to damage motor shaft or gasket. Secure with the (4) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows. _________________________________________________________________

5.116

Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts ■ ■ ■

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

 If using a motor adapter plate that does not have the keepers already installed, weld four (4) keepers against the motor flanges to prevent motor movement.  Clean all dirt and debris from mounting area of crawler frame.

© BUCYRUS AMERICA, INC.

 Attach an appropriate lifting device to the torque hub and slide complete assembly into crawler frame.   Secure torque hub assembly to frame with the twelve (12) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

■ ■ ■ ■

Step 1: 50 ft-lb Step 2: 140 ft-lb Step 3: 280 ft-lb Step 4: 420 ft-lb

 Connect hydraulic hoses to drive motor.  Install and connect crawler and track pad assembly (see How to install the crawler track pad assembly in this chapter).  Install the removable side plate and secure with the six (6) bolts and lock washers. Torque incrementally as follows.

■ ■ ■

Step 1: 300 ft-lb Step 2: 600 ft-lb Step 3: 905 ft-lb

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

______________________________________________________________ A6474X280 VRVI/O1 5.117

Replacement of wear parts _____________________________________

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

10.

11.

12.

13.

14.

15.

16.

17.

18.

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

19.

20.

21.

22.

23.

24.

25.

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

_________________________________________________________________ 5.118 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 88: Crawler drive disassembly and assembly

____________________________________ Replacement of wear parts Breaker shaft and breaker power unit It is recommended that the breaker power unit (Fig. 89) and the breaker shaft assembly (Fig. 90) be removed and installed as a single assembly.

The power unit consists of the following main components: ■

motor (150 hp)

■ reducer/motor coupling ■

reducer

■

torque limiter

■

connecting tube

© BUCYRUS AMERICA, INC.

Fig. 89: Breaker power unit main components Taperlock bushing Taperlock bushing

Torque limiter

Reducer

Motor (150 HP) Flexible coupling

Companion flange Connecting tube

______________________________________________________________ A6474X280 VRVI/O1 5.119

Replacement of wear parts _____________________________________ Fig. 90: Breaker shaft and breaker power unit assembly removal/installation

Breaker shaft

© BUCYRUS AMERICA, INC.

Breaker power unit

_________________________________________________________________ 5.120 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

____________________________________ Replacement of wear parts How to remove the breaker shaft and breaker power unit To remove the breaker shaft and breaker power unit as a complete assembly proceed as follows (Fig. 90).  Turn the machine main circuit breaker (CB1) to the “OFF” position.  Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

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

© BUCYRUS AMERICA, INC.

 Remove the roof anchor cylinder and roof cylinder mount weldment as an assembly (see roof anchor cylinder removal/installation procedure in this section).  Remove the central grease manifold from the cover support weldment. It is not necessary to remove the grease hoses from the manifold.  Remove the area light from the cover support weldment. It is not necesssary to remove the area light electrical cable.  Remove all power unit covers.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Remove the primay operator’s station mounting hardware from the cover support structure and remove the junction box access panel of the electric motr. Disconnect the cable leads from the motor leads. Tag for assembly purposes.  Remove and cap all grease lines from the breaker shaft, gear reducer, and electric motor.   Remove the power unit support structure.  Remove the under speed sensor and shaft guard.  Attach an appropriate lifting device to the breaker shaft and power unit assembly. Take all slack out of the lifting device in order to support the assembly when mounting hardward is removed.  Remove the hardware from the breaker side plates and the power unit reaction pin.  Lift the breaker shaft and power unit out of the machine as an assembly.

______________________________________________________________ A6474X280 VRVI/O1 5.121

Replacement of wear parts _____________________________________ How to install the breaker shaft and breaker power unit To install the breaker shaft and breaker power unit as a complete assembly proceed as follows (Fig. 91).  Attach an appropriate lifting device to the complete unit and slowly lift the unit onto the machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Install the power unit reaction pin and the hardware into the breaker side plates.  Install the shaft guard and under speed sensor on the gear box.

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

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Turn the machine circuit breaker on.  Unlock and remove tags from electric power at the power center.  Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.

_________________________________________________________________ 5.122 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

 Remove caps and install all grease lines to the breaker shaft, gear box, and electric motor.

____________________________________ Replacement of wear parts How to disassemble the breaker power unit To disassemble the breaker power unit proceed as follows (Fig. 91):  Remove complete unit from machine. (See breaker shaft and breaker power unit removal/installation procedure in this section.)  Cut the bolt safety wire from the end of the three cap retainer bolts.  Remove the end cap bolts, lockwashers, and end caps.  Attach an appropriate lifting device to the breaker shaft and remove from the hollow output shaft of the gear reducer.

© BUCYRUS AMERICA, INC.

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

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

______________________________________________________________ A6474X280 VRVI/O1 5.123

Replacement of wear parts _____________________________________ How to assemble the breaker power unit To assemble the breaker power unit proceed as follows (Fig. 91):  Install 1/2” key in keyway of high speed shaft of the gear reducer.  Install 2 3/8” taper lock bushing and companion flange onto high speed shaft of the gear reducer. See Fig. 92 for correct orientation and location on shaft. Torque bolts to 104 ft-lbs.  Install torque limiter onto companion flange using twelve 7/16” UNF bolts and lockwashers. Torque to 67 ft-lbs.  Install 7/8” key into motor shaft.  Install flexible coupling and taperlock bushing onto motor shaft.

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

 Install electric motor, flexible coupling, and taperlock bushing subassembly onto connecting tube using eight bolts. Torque to 379 ftlbs.  Bolt the flexible coupling onto the torque liimiter using eight M12 bolts and lockwashers. Torque to 379 ft-lbs.  Refer to Fig. 92 for correct clearance between flex coupling jaws and coupling element.  If clearance is incorrect, loosen the taper lock bushing bolts and reposition the taperlock bushing accordingly. Retorque the bolts to 90 ft-lbs.  Install the connecting tube access cover.  Apply Never Seez to breaker shaft end and install key into keyway.  Install breaker shaft into hollow gear reducer low speed shaft.  Install end cap, lockwashers, bolts, and safety wire.  Install shaft guard onto gear reducer.

_________________________________________________________________ 5.124 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Fig. 91: Breaker shaft and power unit disassembly and assembly Breaker shaft

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

© BUCYRUS AMERICA, INC.

End cap (located behind weldment)

Shaft guard weldment

______________________________________________________________ A6474X280 VRVI/O1 5.125

Replacement of wear parts _____________________________________ Fig. 91: Breaker shaft and breaker power unit disassembly and assembly (continued) Connecting tube access cover Taper lock busing

Flexible coupling

Taper lock bushing

Electric motor

Torque limiter

Companion flange

Gear reducer

Socket head bolt (8) M12 X 1.75 X 35

Socket head bolt (3) 1/2”-13 X 1 1/2”

Hex bolt (12) 3/4” X 2”

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

Socket head bolt (3) 1/2”-13 X 1 1/2”

_________________________________________________________________ 5.126 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

Hex bolt (8) 3/4” X 2”

____________________________________ Replacement of wear parts Conveyor power unit The conveyor power unit (Fig. 92) has been assembled as a unit and can be removed and installed as a unit.

The power unit consists of the following main components: ■

electric motor (125 hp)

■ connecting tube ■

coupling

■

hydrostatic pump

■

piggyback gear pump

Fig. 92: Conveyor power unit main components

© BUCYRUS AMERICA, INC.

Electric motor

Connecting tube

Coupling

Case drain

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

Gear pump Hydrostatic pump

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

Hex bolt (4) 3/4 X 2 NC

______________________________________________________________ A6474X280 VRVI/O1 5.127

Replacement of wear parts _____________________________________ How to remove the conveyor power unit (Fig. 92)  Turn the main circuit breaker on the feeder breaker to the “OFF” position.  Lock and tag out the power to the feeder breaker at the main power center. Follow all Federal, State, and mine rules.

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

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or devices and keep a safe distance from suspended loads.  Disconnect, tag, and cap all hydraulic hoses.  Disconnect grease lines to conveyor electric motor.  Remove access cover on junction box of conveyor and motor and remove the cable leads from the motor leads.  Reinstall junction box cover.  Remove the four bolts that secure the motor to the frame.  Lift power unit assembly from machine.

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

_________________________________________________________________ 5.128 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

© BUCYRUS AMERICA, INC.

 Attach an appropriate lifting device to the power unit. Take up the slack in the lifting device so that the power unit is supported and wont’ tilt and fall when unbolted from the frame.

____________________________________ Replacement of wear parts How to install the conveyor power unit (Fig. 92)  Attach an appropriate lifting device to the power unit and lift the power unit into the machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or devices and keep a safe distance from suspended loads.  Align the electric motor foot bolt holes with the mounting plate bolt hoes.  Install the four 3/4” diameter hex bolts, washers, and nuts. Torque to 380 ft-lbs.

© BUCYRUS AMERICA, INC.

 Connect hydraulic hoses.  Ensure that the hydrostatic pump is primed. To prime the hydrostatic pump, remove the case drain fitting (see Fig. 92) and pour hydraulic fluid (Spec. 100-1) until the pump housing is full.  Connect grease lines to the electric motor.  Remove junction box cover.  Attach motor leads to cable leads and seal junction box cover. Follow all Federal, State, and mine regulations.  Install machine covers.

______________________________________________________________ A6474X280 VRVI/O1 5.129

Replacement of wear parts _____________________________________ How to disassemble the conveyor power unit (Fig. 92) WARNING! Before removing each pump and the connecting tube be sure to properly support the component. Failure to properly support the component may result in damage to the component or injury to personnel.

WARNING! Remove all fittings from the pumps and plug the ports before removal. Failure to remove fittings and plug ports could result in damage to the pumps.  Remove four bolts, lock washers, and flat washers and remove gear pump. Save the o-ring and splined pump insert from the rear of the hydrostatic pump.

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

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

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

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts How to assemble the conveyor power unit (Fig. 92)  Install the key in the electric motor shaft.  Apply Never Seez to the electric motor shaft and install the coupling hub onto the electric motor shaft. Roughly position the hub even with the end of the shaft. Do not tighten the set screw as final positioning of the hub will be determined at the end of assembly.  Install the element onto the coupling hub on the electric motor.  Apply Never Seez onto the hydrostatic pump splined shaft. Install the remaining coupling hub onto the hydrostatic pump splined shaft (refer to Fig. 93 for dimensions).

© BUCYRUS AMERICA, INC.

 Clean all mating surfaces on the connecting tube and the electric motor.  Apply Loctite 242 (blue) to the eight bolts and install bolts, flat washers, and lock washers into the connecting tube Torque incrementally and evenly to 170 ft-lbs as follows: ■ ■ ■

Step 1: 50 ft-lbs Step 2: 100 ft-lbs Step 3: 170 ft-lbs

IMPORTANT! It is extremely important that the connecting tube pulls up evenly on the electric motor. If the connecting tube is cocked, misalignment between the pump and the electric motor will occur and the coupling will fail.   Install the hydrostatic pump. Align the pilot hub on the pump with the pilot bore of the connecting tube while simultaneously engaging the jaws of the Rotex coupling halves.  Install four bolts, flat washers, and lock washers and torque incrementally and evenly to 280 ft-lbs as follows: ■ ■ ■

Step 1: 90 ft-lbs Step 2: 200 ft-lbs Step 3: 280 ft-lbs

Refer to Figure 93 to verify distance between the coupling jaws and the coupling element of 0.18”. This distance must be maintained to avoid element failure. Adjust the gap as required by repositioning the hub on the electric motor shaft as required.  Check coupling half alignment by using a straight edge across the two coupling halves (see Fig. 93). Rotate the electric motor and measure the spacing in at least two places to ensure the electric motor and pump shafts are aligned. If there is misalignment, the connecting tube may be cocked or the mating surfaces may not be clean. This misalignment must be corrected before proceeding with assembly.

______________________________________________________________ A6474X280 VRVI/O1 5.131

Replacement of wear parts _____________________________________ IMPORTANT! The coupling halves must be aligned before proceeding with assembly. If the coupling haves are not aligned, component failure may occur.   Apply Loctite 242 (blue) to the set screw on the coupling hub of the electric motor shaft and torque to 275 in-lbs.  Remove the end plate from the hydrostatic pump in order to install the piggy back gear pump by removing the four bolts.  Verify that the o-ring and splined pump insert are pre-installed by the pump manufacturer. If not, the o-ring and splined pump insert that were removed during disassembly can be reused or replaced with a new o-ring and splined insert (see your Bucyrus America, Inc. parts manual that shipped with your machine).

 Install the gear pump being careful to properly align the splines and not cut the o-ring.  Install the four bolts, lock washers, and flat washers in the gear pump. Torque incrementally and evenly to 80 ft-lbs as follows: ■ ■ ■

Step 1: 20 ft-lbs Step 2: 50 ft-lbs Step 3: 80 ft-lbs

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

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Fig. 93: Conveyor power unit disassembly/assembly

© BUCYRUS AMERICA, INC.

Electric motor to coupling mating surface

Place straight edge along this edge to determine alignment

______________________________________________________________ A6474X280 VRVI/O1 5.133

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

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

How to install the breaker bit

 Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.  Install the external retaining rings (two per bit) on the shank end of the bit with a pair of external retaining ring pliers. Ensure that the retaining ring is completely seated inside grooved area of the bit.

Fig. 94: Breaker bit removal and installation

Retaining rings Bit holder

Breaker bit

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

© BUCYRUS AMERICA, INC.

To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 94):

____________________________________ Replacement of wear parts Installing the tailpiece To install the tailpiece on the feeder breaker (Reference Fig. 95: Tailpiece installation): WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Install spacer blocks (Item 14) into the underside of the tailpiece weldment (Item 6).  Make sure that bolts (Item 37) will pass through the bearing spacers and the tailpiece weldment.  Tack weld bearing spacer blocks (Item 14) to tailpiece weldment (Item 6).

© BUCYRUS AMERICA, INC.

 Install belt pulley assembly (Item 15) using hex bolts, flat washers, hex nuts, and lock washers (Items 37, 36, 35, and 22).  Bolt impact bed assembly (Item 13) to tailpiece weldment (Item 6) using flat washers, lock washers, hex nuts, and bolts (Items 31, 32, 33, and 34).  Install slider assembly (Item 18) using flat washers, lock washers, hex nuts, and bolts (Items 27, 28, 29, and 30).  Install knuckle piece (Item 4) to tailpiece weldment (Item 6) using tailpiece swivel pin, flat washer, hex nut, keeper pin, and cotter pin (Items 7, 38, 39, 40, 43).  Tighten the hex nut (Item 39) onto the tailpiece swivel pin (Item 7) then weld the pin keeper (Item 40) across the flat of the tailpiece swivel pin (Item 7) on three sides.  Position the assembled knuckle joint and the tailpiece frames to the main frame. (Reference Figure 10 for placement). Install pins (Item 5).  Install the tailpiece hopper weldments (Items 8 and 9) on the main frame using flat washers, lock washers, hex nuts and bolts (Items 23, 24, 25, and 26) and flat washers, lock washers, hex nuts, and bolts (Items 27, 28, 29, and 30).  Install tailpiece tilt cylinders (Item 12) into the tailpiece hopper weldments (Items 8 and 9) and the tailpiece weldment (Item 6) using the swivel clevis weldments, pins, and cotter pins (Items 11, 16, and 41).  Install the steering cylinders (Item 10) between the tailpiece frame (Item 6) and the knuckle joint weldment using pins and cotter pins (Items 16 and 41).

______________________________________________________________ A6474X280 VRVI/O1 5.135

Replacement of wear parts _____________________________________  Refer to the hydraulic schematic (Fig. 96) for hydraulic installation of the cylinders. Route all hoses, avoiding pinch points, so that hose damage does not occur.

© BUCYRUS AMERICA, INC.

Fig. 95: Tailpiece installation

4. knuckle piece 5. pin 6. tailpiece weldment 7. tailpiece swivel pin 8. tailpiece hopper weldment 9. tailpiece hopper weldment 10. steering cylinder 11. swivel clevis weldment 12. tailpiece tilt cylinder 13. impact bed assembly

14. spacer block 15. belt pulley assembly 16. pin 18. slider assembly 22. lock washer 23. flat washer 24. lock washer 25. hex nut 26. bolt 27. flat washer

28. lock washer 29. hex nut 30. bolt 31. flat washer 32. lock washer 33. hex nut 34. bolt 35. hex nut 36. flat washer 37. bolt

38. flat washer 39. hex nut 40. keeper pin 41. cotter pin 43. cotter pin

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

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 95: Tailpiece installation (continued)

Detail A

______________________________________________________________ A6474X280 VRVI/O1 5.137

Replacement of wear parts _____________________________________

© BUCYRUS AMERICA, INC.

Fig. 96: Hydraulic schematic

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

____________________________________ Replacement of wear parts Roof cylinder and roof cylinder mount weldment removal and installation To remove the roof cylinder (reference Fig. 97):   Fully retract the roof cylinder.  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

© BUCYRUS AMERICA, INC.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.  Attach an appropriate lifting device to the roof cylinder and roof cylinder mounting weldment.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  Disconnect, tag, and cap the hydraulic hoses going to the cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.   Remove the sixteen bolts, two rows of four on each side of the mounting weldment, that attach the mounting weldment to the frame. NOTE: It is not necessary to remove the mount weldment if the roof cylinder only is being replaced. If the roof cylinder is being replaced, skip this step.  Lift the cylinder and weldment off of the feeder breaker. NOTE: If the roof cylinder only is being replaced, skip this step.  Remove the eight bolts, four on each side of the cylinder, that attach the roof cylinder to the mounting weldment.

______________________________________________________________ A6474X280 VRVI/O1 5.139

Replacement of wear parts _____________________________________ To install the roof cylinder (reference Fig. 97):  Attach an appropriate lifting device to the roof cylinder and position the roof cylinder in the mounting weldment.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.   Install the eight bolts, four on each side of the cylinder, to secure the roof cylinder to the mounting weldment.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  Position the cylinder and mounting weldment on the feeder breaker. NOTE: If the roof cylinder only is being replaced, omit this step.   Install the sixteen bolts, two rows of four on each side of the mounting weldment, that attach the mounting weldment to the frame.

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

Fig. 97: Roof cylinder removal and installation

Roof cylinder

Cylinder mounting bolts (8)

Roof cylinder mounting weldment

Mounting weldment bolts (16)

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

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Foot cylinder removal and installation To remove a foot cylinder (reference Fig. 98):  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

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

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.  Remove the cotter pin from the outrigger arm pin, remove the castle nut, and washer and pull the outrigger arm pin.  Remove the two cotter pins from the cylinder eye pin and pull the cylinder eye pin.

To install a foot cylinder (reference Fig. 98):  Mount the cylinder eye to the outrigger mount plate.  Position the cylinder eye in the outrigger mount plate clevis.  Insert the cylinder eye pin through the cylinder eye and outrigger mount plate clevis.  Install the two cotter pins through the cylinder eye pin.  Position the foot clevis on the rod eye and align the rod eye in the outrigger arm weldment.  Install the outrigger arm pin through the outrigger arm weldment, foot, and rod eye. Install the washer and castle nut on the end of the pin.  Reconnect the hydraulic hoses to the cylinder.  Reconnect power to the machine.  Purge the hydraulic system of air.

______________________________________________________________ A6474X280 VRVI/O1 5.141

Replacement of wear parts _____________________________________ Fig. 99: Foot cylinder removal and installation

Washer

Outrigger arm pin

Cotter pin

Foot cylinder

See detail A

Cotter pin (2)

Outrigger arm

Cylinder pin

Outrigger mount plate

Detail A

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

© BUCYRUS AMERICA, INC.

Outrigger foot

Castle nut

____________________________________ Replacement of wear parts Tilt cylinder removal and installation To remove a tilt cylinder (reference Fig. 99):  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

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

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.  Attach an appropriate lifting device to the tilt cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  Pull a cotter pin out of the pin through the cylinder eye and remove the pin.  Pull a cotter pin out of the pin through the rod eye and remove the pin.

To install a tilt cylinder (reference Fig. 99):  Attach an appropriate lifting device to the tilt cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  Align the cylinder in the mounting clevises on the machine.  Install the pin through the cylinder eye and secure with a cotter pin.  Install the pin through the rod eye and secure with a cotter pin.

______________________________________________________________ A6474X280 VRVI/O1 5.143

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

© BUCYRUS AMERICA, INC.

Fig. 99: Tilt cylinder removal and installation

Pin (2 places)

Cotter pin (4) (2 per pin)

Tilt cylinder (2)

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

____________________________________ Replacement of wear parts Lift cylinder removal and installation To remove a lift cylinder (reference Fig. 100):  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

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

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.  Attach an appropriate lifting device to the lift cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  Pull a cotter pin out of the pin through the cylinder eye and remove the pin.  Pull a cotter pin out of the pin through the rod eye and remove the pin.

To install a lift cylinder (reference Fig. 100):  Attach an appropriate lifting device to the lift cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  Align the cylinder in the mounting clevises on the machine.  Install the pin through the cylinder eye and secure with a cotter pin.  Install the pin through the rod eye and secure with a cotter pin.

______________________________________________________________ A6474X280 VRVI/O1 5.145

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

Cotter pin (4) (2 per pin)

Pin (2 places)

Lift cylinder (2)

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

© BUCYRUS AMERICA, INC.

Fig. 100: Lift cylinder removal and installation

____________________________________ Replacement of wear parts

Tailpiece tilt cylinder removal and installation To remove a tailpiece tilt cylinder (reference Fig. 101):  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

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

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.  Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  Pull cotter pin out of the pin through the cylinder eye.  Pull cotter pin out of the pin through the rod eye.

To install a tailpiece tilt cylinder (reference Fig. 101):  Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  Align the cylinder in the mounting clevises on the machine.  Install the pin through the cylinder eye and secure with a cotter pin.  Install the pin through the rod eye and secure with a cotter pin.

______________________________________________________________ A6474X280 VRVI/O1 5.147

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

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

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

© BUCYRUS AMERICA, INC.

Fig. 101: Tailpiece tilt cylinder removal and installation

____________________________________ Replacement of wear parts

Tailpiece steering cylinder removal and installation To remove a tailpiece steering cylinder (reference Fig. 102):  Shutdown the feeder breaker (see Shutdown procedure in this chapter).  Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

© BUCYRUS AMERICA, INC.

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

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on it, the load will fall, causing damage to the machine or serious injury or death to personnel.  Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  Pull cotter pin out of the pin through the cylinder eye.  Pull cotter pin out of the pin through the rod eye.

To install a tailpiece steering cylinder (reference Fig. 102):  Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.  Align the cylinder in the mounting clevises on the machine.  Install the pin through the cylinder eye and secure with a cotter pin.  Install the pin through the rod eye and secure with a cotter pin.

______________________________________________________________ A6474X280 VRVI/O1 5.149

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

Pin (2) Tailpiece steering cylinder

Cotter pin (4) (2 per eye)

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

© BUCYRUS AMERICA, INC.

Fig. 102: Tailpiece steering cylinder removal and installation

_______________________________________________________________

6

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Model 7MFBHM-48DD Feeder Breaker. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

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

Customer specials may not be listed.

Components of the feeder breaker Technical data sheet Overall length: without tailpiece ................................ approx. 33’ (9,992 mm) with tailpiece ..................................... approx. 36’ 6” (11,134 mm) Overall width: .......................................... approx. 10” 7” (3232 mm) Tramming height (min.):.......................... approx. 48” (1,199 mm) Ground clearance (min.): ........................ approx. 7” (190 mm) Ground clearance (max.): ....................... approx. 24” (622 mm) Receiving height (min.): .......................... approx. 13” (330 mm) Discharge height (max.).......................... approx. 48” (1,199 mm) Operating height (max.): ......................... approx. 74” (1,864 mm) Level hopper capacity: ............................ approx. 370 ft³ (10.5 m3) Capacity (w/ optional 12” sideboards): ... approx. 420 ft³ (12 m3) Receiving impact plate:........................... HRS + CCO wear plate Breaker impact plate: .............................. T1 + CCO wear plate Coal line material: ................................... HRS + CCO wear plate Return line material:................................ HRS + CCO wear plate Mainframe side plates:............................ HRS + CCO wear plate Weight (machine only): ........................... approx: 80,000 lbs (36,288 kg)

performance

Material input size (max.):....................... approx. 1’ x 2’ x 3’ (305 mm x 610 mm x 915 mm) Maximum material strength: ................... approx. 30,000 psi (207 N/mm2) Nominal output size: ............................... approx. 8” (203 mm) (one dimension)

© BUCYRUS AMERICA, INC.

general

approx. 1” (25.4 mm) (pick to flight clearance) Discharge rate (max.): ............................ approx. 1,225 TPH @ 135 fpm (1.1E6 kg/hr @ 39.6 m/min) Material to be broken: ............................. Coal @ 65 lb/ft³ (1,041 kg/m3)

______________________________________________________________ A6474X280 VRVI/O1 6.3

Technical data ________________________________________________

head shaft

tail shaft

Conveyor width: ................................approx. 48” (1,232 mm) Number of strands: ...........................2 @ 280,000 psi/strand (1,931 N/m2) Ultimate Strength Chain pitch: .......................................approx. 3 .75” (95.25 mm) Chain pin diameter:...........................approx. 1.13” (28.7 mm) Flights:...............................................2 3/4” X 5” (70 mm x 127 mm) solid alloy steel Flight attachment ..............................Cross pin, not bolted w/ optional stainless steel roll pins Conveyor speed (max):.....................approx. 130 fpm (39.6 m/min) Shaft diameter:..................................5” (127 mm) Bearings ............................................2 pillow block assemblies Bearing bore: ....................................4 15/16” (125.4 mm) Overload protection:..........................Hydraulic relief Shaft diameter:..................................3 15/16” (100 mm) Bearing bore: ....................................3 15/16” (100 mm) Take-up: ............................................Grease cylinders w/locking shims

conveyor drive

Drive motor: ......................................125 hp/1050v/AC/3ph/50Hz/MSHA Reducer:............................................Hydro-mechanical w/ 29:1 reduction Overload protection:..........................Hydraulic relief Motor speed control: .........................Hydraulic displacement Motor/shaft coupling:.........................Splined

breaker drive

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

breaker

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

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

© BUCYRUS AMERICA, INC.

conveyor chain

© BUCYRUS AMERICA, INC.

_______________________________________________ Technical data crawlers

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

hydraulic

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

Electrical

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

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

by Customer

______________________________________________________________ A6474X280 VRVI/O1 6.5

Technical data ________________________________________________ ■

Head shaft is removable horizontally as a unit.

■

Breaker and tailshaft are removable vertically as a unit.

■

8 point Ansul dry chemical fire suppression system.

■

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

■

Manual centralized lubrication system. Optional automatic lubrication system.

■

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

■

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

■

Fairfield Torque Hubs have a freewheel to allow towing.

© BUCYRUS AMERICA, INC.

features

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

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

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

Set screws Table 4: Set screws (Socket standard steel) Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

© BUCYRUS AMERICA, INC.

Nominal diameter

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

Table 5: Hex and socket head cap screws, coarse thread (Grade 8) Nominal diameter ¼” 5/16” 3/8” 7/16” ½” 9/16” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting (lubed) 8 ft-lbs 16 ft-lbs 28 ft-lbs 45 ft-lbs 70 ft-lbs 99 ft-lbs 135 ft-lbs 240 ft-lbs 390 ft-lbs 545 ft-lbs 830 ft-lbs 1,160 ft-lbs 1,525 ft-lbs 2,030 ft-lbs

Recommended torque setting (dry) 13 ft-lbs 26 ft-lbs 47 ft-lbs 75 ft-lbs 115 ft-lbs 165 ft-lbs 225 ft-lbs 400 ft-lbs 645 ft-lbs 905 ft-lbs 1,380 ft-lbs 1,935 ft-lbs 2,540 ft-lbs 3,380 ft-lbs

______________________________________________________________ A6474X280 VRVI/O1 6.7

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

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15 10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 6: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

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

© BUCYRUS AMERICA, INC.

Table 6: Untreated screw, black finish (Coarse thread, continued)

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© BUCYRUS AMERICA, INC.

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

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

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

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

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

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

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

______________________________________________________________ A6474X280 VRVI/O1 6.9

Permissible media ____________________________________________ Approved suppliers:

Supplier

Brand name

1

Amoco Oil Company

Amoco AW oil No.68

2

Gulf oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hyldraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

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

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

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

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

©© BUCYRUS AMERICA, INC.

Table 7: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 8: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

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

6

Unocal 76

7

Shell Oil company

8

Century Lubricating Oils, Inc.

9

Texaco Lubricants Company

Hulbest EP-7 Powergear 460 Meropa 680

10

Exxon

Spartan EP 460

11

Pennzoil

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

12

Lubricating Engineers

13

Conoco Inc.

608 Almosal Vari-Purpose Gear Lubricant Gear oil 460

14

Hydrotex

933 Industrial Gear Lubricant

15

Phillips

16

Miners Oil

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

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

______________________________________________________________ A6474X280 VRVI/O1 6.11

Permissible media ____________________________________________

Supplier

Brand name

1

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

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 10: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century oils Limited Hydrotex Pennzoil Unocal Exxon

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

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

©© BUCYRUS AMERICA, INC.

Table 9: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ Permissible media Table 11: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

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

5 6

Cincinnati – Vulcon Company Cities Service Oil company

7 8

10 11

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

12 13 14 15 16 17

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

18

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

© BUCYRUS AMERICA, INC.

9

19 20 21

22 23

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

24 25

Wynn Oil company Lubrication Engineers

26

Hydrotex

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

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

______________________________________________________________ A6474X280 VRVI/O1 6.13

Permissible media ____________________________________________

Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

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

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

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

©© BUCYRUS AMERICA, INC.

Table 12: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 13: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) Supplier Brand name 1

Amoco Oil Company

American Industrial Oil No. 68

2

Gulf oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy – Medium

4

Chevron U.S.A.

5

Sun Oil Company

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

6

Unocal 76

7

Shell Oil Company

Unax RX68 or Turbine Oil 68 Turbo 68

8

Century Lubricating Oils, Inc.

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

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

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

______________________________________________________________ A6474X280 VRVI/O1 6.15

Permissible media ____________________________________________

1

Amoco Oil Company

American Industrial oil No. 150

2

Gulf Oil

Harmony 150

3

Mobil Oil Corporation

DTE Oil EX. Heavy

4

Chevron U.S.A.

5

Sun Oil Company

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

6

Unocal 76

7

Shell Oil company

Unax RX 700 or Turbine Oil 700 Turbo 150

8

Century Lubricating Oils, Inc.

Centraulic R&O 150

9

Atlantic Richfield Company

10

Texaco Lubricants Company

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

11

Exxon

Teresstic 150

12

Pennzoil

Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15

Conoco Inc.

Dectol R&O 76

16

Hydrotex

System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Table 15: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier Brand name 1 Amoco Oil Company Cylinder oil No. 1000 2 Mobil Oil Corporation Extra Hecla Super Cylinder Oil 3 Chevron U.S.A. Chevron Cylinder Oil W ISO 1000 4 Sun Oil Company Sun Steam Cylinder Oil 5 Unocal 76 Worm gear Lube 250 or Stevalc 6 Century Lubricating Oils, Inc. Garwal 680 7 Atlantic Richfield Company Modoc 195 8 Texaco Lubricants Company 650 T Cylinder Oil 1000 9 Exxon Cylesstic TK-1000 10 Pennzoil Cylinder Oil #1000 11 Conoco Inc. Inca Oil 1000

_________________________________________________________________ 6.16 Bucyrus – Model 7MFBHM-48DD Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 14: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 16: 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 17: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 18: Multi-purpose tractor hydraulic fluid (Spec. 100-12)

1 2 3 4

Supplier Exxon / Mobil Century / Fuchs Shell Chevron

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid

5 6 7

BP Lubricants Quaker State Conoco

Tractran UTH Quaker State FCI HD Powertran Fluid

______________________________________________________________ A6474X280 VRVI/O1 6.17

___________________________________________ Permissible media Table 19: Synthetic EP gear lubricants (Spec. 100-13) Brand name Powergear H680

© BUCYRUS AMERICA, INC.

1

Supplier Fuchs

______________________________________________________________ A6474X280 VRVI/O1 6.18

_______________________________________________________________

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.

© BUCYRUS AMERICA, INC.

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

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

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

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

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

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

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

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

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

______________________________________________________________ A6474X280 VRVI/O1 7.3

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

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

© BUCYRUS AMERICA, INC.

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

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

CONTENTS

saue Series 90

Axial Piston Pumps Technical Information

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

The latter is infinitely adjustable between zero and maximum displacement.

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

●

The Series 90 - Advanced Technology Today

●

8 Sizes of Variable Displacement Pumps

●

Complete Family of Control Systems

●

Proven Reliability and Performance

●

Optimum Product Configurations

●

Compact and Lightweight

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

Printed in Germany.

2

F000 539

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Technical Features A Complete Family to Meet Market Needs

The Latest Technology

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

● Unique Product Features ● High Power Density

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

● Design Provides for Reduced Operating Costs

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

High Performance

Reliability

● Speeds to 5 000 min-1 (rpm)

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

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

World Product

Worldwide Support

● Designed for Worldwide Markets

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

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

● Serviced by a Worldwide Network of Authorized Service Centers

3

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

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

Options • • • • • • • • • •

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

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

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

4

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

Dimensions • • • • • • • •

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

• • • • • • •

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

5

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

Control handle

Displacement control valve Heat exchanger bypass valve Reservoir

Orificed check valve

Vacuum gauge Heat exchanger

Purge relief valve

Charge pressure relief valve Reversible variable displacement pump

Servo control cylinder

Multi-function valve

Fixed displacement motor

To pump case Servo pressure relief valves

Charge pump Input shaft

Output shaft Multi-function valve

Pump swashplate Servo control cylinder

Pump

Motor swashplate Loop flushing valve

Motor

P001 004E

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

6

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

Servo Piston Feed Back

Cradle Bearing

Cradle

Cradle Leveler

Cradle Guide

Charge Pump

P001 413E

Name Plate

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

Neumünster, Germany Typ

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

Model Number Serial Number

Model Code

Ident Nr

687459 N – 88 – 26 – 67890

Identification Number

Serial No. Fabr Nr MADE IN GERMANY

Place of Manufacture 7

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Type Designation and Order Code R

MODEL CODE

M

P J G N

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

R

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

8

100 130 180 250

= = = =

100 130 180 250

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

M

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

P

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

030 042 055 075 100 130 180 250 ●

●

●

●

●

●

●

●

J

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

G

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

N

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

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

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

Frame Size

030 042 055 075 100 130 180 250 ● ❍

● ❍

● ❍

● ❍

● ❍

● ❍

●

-

-

-

-

-

-

-

-

❍

❍

❍

❍ ❍

❍ ❍

❍ ❍

❍ ❍

❍ ❍

-

-

❍

❍

-

●

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Type Designation and Order Code (Continued) F

L

H

T

W

Y

Z

K

X X

Data Sheet Code On Request

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

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

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

= See Port “B” 030 ● -

042 ● -

055 ● -

075 ● -

100 130 ● ● -

180 ●

250 ●

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

❍ ❍ ❍ ●

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

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

Frame Size

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

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

042 ❍ ● ❍

055 ❍ ● ❍ ❍

075 ❍ ● ❍ ❍

100 ❍ ● ❍ ❍

130 ❍ ❍ ● ❍

180 ❍ ● ❍

250 ❍ ● ❍

030 ❍ ● ❍ -

042 ● ❍ ❍ -

055 ● ● ❍ -

075 ● ● ❍ -

100 ● ❍ +● ❍ -

130 ● ❍ ❍

180 ● +❍ -

250 ● +❍ -

F Displacement Limitation 3 4

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

❍ ❍ ❍ ❍

● ❍

● = Standard ❍ = Option - = not available

+ = not recommended for front pump in tandem configurations 9

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

M3

Clockwise (CW) Rotation

Hydraulic Parameters A

M1

System Pressure Range, Input p1 (see page 12)

M2

B L1

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

= = = = = =

S

L2

P001 008E

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

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

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

420 bar 480 bar

(6 000 psi) (7 000 psi)

Case Pressure Max. Rated: Intermittent pressure:

(see page 12) 3 bar 5 bar

(40 psi) (75 psi)

Cold start

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

(see page 12)

Type of Mounting

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

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

Temperature Range1)

Pipe Connections

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

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

Direction of Rotation

(see page 12) intermittent, cold start intermittent

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

Fluid Viscosity Limits

Clockwise or counterclockwise (unidirectional).

Installation Position Installation position discretionary.

The housing must always be filled with hydraulic fluid.

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

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

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

10

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

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

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Technical Data Table 1

Dimension

030

042

055

Frame Size 075

cm3

30

42

55

75

100

130

180

250

in3

1.83

2.56

3.35

4.57

6.10

7.93

10.98

15.25

min-1 (rpm)

500

500

500

500

500

500

500

500

min-1 (rpm)

4 200

4 200

3 900

3 600

3 300

3 100

2 600

2 300

min-1 (rpm)

4 600

4 600

4 250

3 950

3 650

3 400

2 850

2 500

Max. min-1 (rpm) Attainable *

5 000

5 000

4 700

4 300

4 000

3 700

3 150

2 750

Nm/bar in lb/1000 psi

0.48 290

0.67 410

0.88 530

1.19 730

1.59 970

2.07 1 260

2.87 1 750

3.97 2 433

Mass moment of inertia of the int. rotating parts

kg m2 lb • ft2

0.0023 0.0546

0.0039 0.0926

0.0060 0.1424

0.0096 0.2280

0.0150 0.3560

0.023 0.5460

0.0380 0.9020

0.0650 1.5430

Weight (with MA Control)

kg lb

28 62

34 75

40 88

49 108

68 150

88 195

136 300

154 340

100

130

180

250

Displacement

Minimum Input Rated * speed Maximum *

Theoretical Torque

* General Technical Specifications, see page 12

Determination of Nominal Pump Size Inch-System:

Metric-System: PD • PS • EV

Pump Q = output flow

Description: Vg • n • hv

gpm 231

Pump Qe = output flow

l/min 1 000 Vg • ∆p

PD • p Input torque

PT =

lbf•in 2 • π • ET

Input torque

Me =

PD • PS • p Input power

p

=

Qe • ∆p

Me • n hp

396 000 • ET

Nm 20 • π • hmh

Input power

Pe =

= 9 550

kW 600 • ht

Inch-System: PD = Pump displacement per rev.

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

in3 rpm psi

cm3 bar

11

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

General Technical Specifications Speed Range

Case Pressure

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

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

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

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

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

Braking Warning !

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Charge Pressure

12

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

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options Reservoir

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

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

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

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

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

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

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

Figure 5: Charge pressure filtration

Screen

Hydraulic fluid reservoir Adjustable Charge pressure relief valve

The reservoir inlet (fluid return) should be positioned so that the flow to the reservoir is discharged below the normal fluid level, and also directed into the interior of the reservoir for maximum dwell and efficient deaeration.

Suction Filtration - Option S The suction filter is placed in the circuit between the reservoir and the inlet to the charge pump, as shown in Figure 4. For closed loop transmissions with controlled reservoir ingression a filter having a Beta 10 ratio of 1.5 to 2 has been shown to provide acceptable performance.

Charge pump

to low pressure side and control

To pump case

Filter P000 798E

The use of a filter contamination monitor is recommended.

Displacement Limiter - Option 4

Figure 4: Suction filtration

All Series 90 pumps are designed with optional mechanical displacement (stroke) limiters (Figure 6).

ManoVacuummeter

The maximum displacement of the pump can be set using the hexagon adjustment screw.

Hydraulic fluid reservoir

Figure 6: Displacement limiter Filter

Displacement limiter

Charge pump

to low pressure side and control

Adjustable Charge pressure relief valve

To pump case

Servo cylinder P000 797E

Servo piston

P000 799E

13

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Multi-function Valve Both the pressure limiter sensing valves and relief valves are built into the multi-function valves located in the pump endcap. The sequenced pressure limiter/high pressure relief valve system in the Series 90 provides an advanced design of overpressure protection.

The pressure limiter avoids system overheating associated with relief valves and the sequenced relief valves are available to limit pressure spikes which exist in severe operating conditions.

Because the relief valves open only during extremely fast pressure spike conditions, heat generation is minimized during the short time that they might be open.

For some applications, such as dual path vehicles, the pressure limiter function may be defeated such that only the relief valve function remains. The relief response is approximately 20 ms whether used with or without the pressure limiter function.

Figure 7: Circuit diagram M4 M5

M3

Clockwise (CW) Rotation

M1

A

M2

B L1

S

L2

P001 008E

Overpressure Protection The Series 90 pumps are designed with a sequence pressure limiting system and high pressure relief valves (Figure 8). When the preset pressure is reached, the pressure limiter system acts to rapidly destroke the pump so as to limit the system pressure. Typical response is less than 90 ms. For unusually rapid load application, the high pressure relief valve is available to also limit the pressure level. The pressure limiter sensing valve acts as the pilot for the relief valve spool, such that the relief valve is sequenced to operate above the pressure limiter level.

Pressure Limiter Operation Referring to Figure 8 when set pressure is exceeded the pressure sensing valve (A) flows oil through passage (B) and across an orifice in the control spool raising pressure on the servo which was at low pressure. Servo pressure relief valves (C) limit servo pressure to appropriate levels.

The pressure limiter action cancels the input command of the displacement control and tends to equalize servo pressure. Swashplate moments assist to change the displacement as required to maintain system pressure at the set point.

Figure 8: Multi-function valve, pressure limiter, pressure regulation, option 1 To control Multifunction valve

A Servo piston

Bypass hex adjustment

Port "A" B Servo pressure relief valves Port "B"

C

Servo piston Charge pressure relief valve

Multifunction valve

14

P000 800E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Bypass Function

Speed Sensor

In some applications it is desirable to bypass fluid around the variable displacement pump when pump shaft rotation is either not possible or not desired. For example, a “down” vehicle may be moved to a service or repair location or winched on a trailer without operating the prime mover.

Series 90 pumps are available with an optional speed sensor for direct measurement of pump input speed.

Series 90 pumps are designed with a bypass function. The bypass is operated by mechanically rotating the bypass hex on both multi-function valves three (3) turns counterclockwise (CCW). Refer to figures 8 on page 14.

This connects working loop A and B and allows fluid to circulate without rotating the pump and prime mover.

Caution !

Bypass valves are intended for moving a machine or vehicle for very short distances at very slow speeds.

They are NOT intended as “tow” valves.

A special magnetic speed ring is pressed onto the outside diameter of the cylinder block and a Hall effect sensor is located in the pump housing. The sensor accepts supply voltage and outputs a digital pulse signal in response to the speed of the ring. The output changes its high/low state as the north and south poles of the permanently magnetized speed ring pass by the face of the sensor. The digital signal is generated at frequencies suitable for microprocessor based controls.

This sensor will operate with a supply voltage of 4.5 to 15 VDC, and requires a current of 12 mA at 5.0 VDC under no load. Maximum operating current is 30 mA at 1 kHz. Maximum operating frequency is 15 kHz. Output voltage in “High State” (VOH) is sensor supply voltage minus 0.5 VDC, minimum. Output voltage in “Low State” (VOL) is 0.5 VDC, maximum.

The sensor is available with a Packard Weather-Pack 3 or 4-pin sealed connector or a Turck Eurofast M12x1 4-pin connector.

Table 2: Pulse frequency

-

Frame Size

030

042

055

075

Pulses per revolution

43

48

52

58

Frame Size

100

130

180

250

Pulses per revolution = not available

63

69

-

-

Figure 11: Speed sensor SAUER-SUNDSTRAND Mating Parts Kit Part No. K08620 (3 pin) Part No. K03384 (4 pin)

Packard Weather-Pack 3 or 4 Pin Shroud Connector Red White Black Green

A B C D

Supply Voltage + Speed Signal Gnd Common Direction (Option)

SAUER-SUNDSTRAND Mating Parts Kit Part No. K14956 or Ident. No. 500724 (straight) Part No. K14957 or Ident. No. 500725 (right angle)

Turck Eurofast 4 Pin Connector Pin 2 Direction (Option)

Keyway (Ref) Pin 1 Supply Voltage +

"Y" Pin 3 Speed Signal P001 459E

Pin 4 Gnd Common 12.7 [0.50] Wrench Flats View "Y"

15

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Charge Pump Charge flow is required on all Series 90 pumps applied in closed circuit installations to make up internal leakage, maintain a positive pressure in the main circuit, provide flow for cooling, filtration, replace any leakage losses from external valving or auxiliary systems and provide flow and pressure for the control system.

Rated charge pressure must be maintained at its specified pressure under all conditions of operation to prevent damage to the transmission.

Many factors influence the charge flow requirements and the resulting charge pump size selection. These factors include system pressure, pump speed, pump swashplate angle, type of fluid, temperature, size of heat exchanger, length and size of hydraulic lines, control response characteristics, auxiliary flow requirements, hydrostatic motor type, etc. When initially sizing and selecting hydrostatic units for an application, it is frequently not possible to have all the information necessary to accurately evaluate all aspects of charge pump size selection.

The following procedure will assist the designer in arriving at an initial charge pump size selection for a typical application, it is emphasized that unusual application conditions may require a more detailed review of charge pump sizing.

Testing is recommended to verify that adequate charge pressure is maintained under actual operating conditions.

Charge Pump Sizing / Selection The first step in approximating the proper size charge pump is to determine the charge flow requirements for the total system under different modes of operation.

The total charge flow requirements must include the flow requirements of the pump/ motor(s) and all auxiliary components which remove fluid from the system.

The charge pump sizing must consider the pump and motor(s) operating at their maximum operating pressure and also when the pump is operating at minimum speed.

A) Charge Flow Requirement - Pump Determine the pump speed, minimum and operating, and maximum system pressure at these speeds. If the pump speed is less than 1 000 min -1, use the data published for 1 000 min-1 .

Referring to the figure 12 on page 17, “Charge Flow Requirement - Pump,” determine the flow factor Fp at the desired flow requirement for the pump:

Fp x Frame Size x 3.785 = l/min, Charge Flow Requested - Pump 75 Fp x Frame Size Qp = = gpm, Charge Flow Requested - Pump 75 Qp =

Frame Size in (cm3/rev)

16

B) Charge Flow Requirements - Motor Determine the motor speeds and maximum system pressure. Referring to the accompanying figure 13, “Charge Flow Requirement - Motor”, determine the flow factor of the motor Fm. Using the following equation, determine charge flow requirements for the motor Qm. Qm = Fm x Frame Size x 3.785 = l/min, Charge Flow Requested - Motor 75 Fm x Frame Size Qm = = gpm, Charge Flow Requested - Motor 75 C) Total Charge Flow Requirements The total charge flow requirements Qt is the sum of the flow requirements of each of the components in system; namely: Qt= Qp + Qm1 + Qm2 + Qaux = l/min, (Tot. Charge Flow Req.) D) Determine Required Charge Pump Size ● Referring to the accompanying figure 14, “Charge Pump Flow”, select the correct charge pump requirements determined above and the pump input speed. ● Refer to the “Charge Pump Size/ Availability and Speed Limits” chart to verify that the maximum speed limit of the selected charge pump is not be exceeded. ● If the desired size noted in the chart is not available, always select the next size larger charge pump. ● If the standard size charge pumps are not adequate to meet the flow requirements of the system, a Gear Pump can be mounted to the auxiliary mounting pad to provide the necessary additional flow.

System features and conditions which may invalidate the above calculations include (but not limited to): ● continuous operation at low input speeds (< 1 500 min-1 ) ● high shock loadings ● excessively long system lines (> 3 m [9.8 ft]) ● auxiliary flow requirements ● use of high torque low speed motors If any of the above conditions exist, contact SAUERSUNDSTRAND Application Engineering.

Table 3: Available charge pump sizes and speed limits Charge pump size cm3 (in3) A 8 (0.50) B 11 (0.69) C 14 (0.86) D 17 (1.03) E 20 (1.20) F 26 (1.60) F 26 (1.60) H 34 (2.07) J 47 (2.82) K 65 (3.90)

Rated speed min-1 (rpm) 4 200 4 200 4 200 3 900 3 600 3 300 3 100 (130 pump) 3 100 2 600 2 300

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Charge Pump Maps Charge Pressure : Case Drain: Reservoir Temperature:

20 bar (290 psi) 80 °C (8.2 cSt) 180 °F (53 SUS) 70 °C (11 cSt) 160 °F (63 SUS)

Figure 12: Charge flow requirements - pump

Figure 13: Charge flow requirements - motor

42 00 m m in - in -1 1 (rp (rp m m ) )

6

5

5

)

00

-1 (

3

in

4

Flow Factor Fm

36

Flow Factor Fp

(rp

) in m pm 00 -1 (r 30 in m) m rp 00 -1 ( 20 min 00 10

4

2

00

1000 0

2000

3000

4000

100 200 System Pressure

5000

300

)

pm

-1 (r

3

in 0m

0

36

2 3000

6000 ∆p psi

0

∆p bar

0

400

m

42

1000

2000

3000

min

)

-1 (rpm

) -1 (rpm

2000

min

1000

min

1

1

0

)

m

rp

m

-1

)

-1 (rpm

5000 6000 ∆p psi

4000

400 ∆p bar

300

100 200 System Pressure

P001 010E

P001 011E

Figure 14: Charge pump output flow

v

6

v

.9 i

/Re

•3

3

ev

.9 i n

3

2.0

/R in 3

in 3 /R ev

.60

.2 3 •

ev

3 /R

•1

3

26

cm

3

•1

.07

20

cm

•2 cm 3

3.0

2

1

10

4.0

3

HP

9

5.0

1.

cm 3 •2

in

47

v

Re

3 /

03

34

in

kW

20

.

•1

4

ev 3 /R 3 • ev cm in 0 6 3 /R 2 cm .8 in 9 17 3 • 0 0.6 cm 3 • ev 14 cm in3 /R 1 3 • 0.5 1 m c 8 3

gallons/min

l/min

30

cm 3

.6 0 •1

3

cm 26

2

12

65

.07 •2

3

cm 34

6.0 v Re

3 /

15

50 40

5

in 3 /R ev

ev

n 3/ Re

v

•2 cm 3

60

7.0

ev

18

in 3 /R

65 c

70

in 3 /R

21

.9

80

47

m3•

24

90

in 3 /Re

3.9 in 3/ Re

v

Figure 15: Charge pump power requirements

03

1.

in

ev

3 /R

in

ev

6 3 /R cm 0.8 in 17 3 • .69 cm 3 • 0 14 cm 11 v Re n3 / .5 i 3•0 m 8c

1.0

1 0

0 0

500 1000 Speed

P000 802E

2000 min -1 (rpm)

3000

4000 4500

0

500 1000 Speed

2000

3000

4000 4500

min -1 (rpm) P000 803E

17

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Shaft Availability and Torque Ratings Figure 16: Torques for auxiliary mounting pads

Third Stage

Second Stage

First Stage

Me1 for the first pump

Me2 for the second pump

Me Input Torque

Me3 for the next pump P001 407E

Table 4: Shaft availability and torque ratings Shaft Description

Option Code

Frame Size Availability Rated Torque [Nm (lbf•in)] 030

042

055

075

100

130

180

250

13 teeth 16/32 pitch Spline

C2

260 (2 300)

—

—

—

—

—

—

—

15 teeth 16/32 pitch Spline

C3

530 (4 700)

530 (4 700)

—

—

—

—

—

—

19 teeth 16/32 pitch Spline

C5

—

900 (8 000)

—

—

—

—

—

—

21 teeth 16/32 pitch Spline

C6

—

—

1 130 (10 000)

—

—

—

—

—

23 teeth 16/32 pitch Spline

C7

—

—

—

1 580 (14 000)

1 580 (14 000)

—

—

—

27 teeth 16/32 pitch Spline

C8

—

—

—

—

—

2 938 (26 000)

2 938 (26 000)

3 600 (32 000)

13 teeth 8/16 pitch Spline

F1

—

—

—

—

1 810 (16 000)

1 810 (16 000)

+

+

14 teeth 12/24 pitch Spline

S1

—

—

735 (6 500)

735 (6 500)

— + 18

= Shaft option not available = not recommended for front pump in tandem configurations

+

735 (6 500)

—

1 810 (16 000) —

1 810 (16 000) —

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Auxiliary Mounting Pads Table 5: Auxiliary mounting pad specifications Mounting Pad Size

Option Code

Internal Spline Size

Spline Engagement min. mm (in.)

Rated Torque Nm (lbf•in)

SAE A

A

9 teeth 16/32 pitch

13.5 (.53)

107 (950)

SAE B

B

13 teeth 16/32 pitch

14.2 (.56)

256 (2 200)

SAE B-B

V

15 teeth 16/32 pitch

16.1 (.63)

347 (2 990)

SAE C

C

14 teeth 12/24 pitch

18.3 (.72)

663 ❊ (5 700)❊

SAE D

D

13 teeth 8/16 pitch

20.8 (.82)

1 186 (10 500)

SAE E

E

13 teeth 8/16 pitch

20.8 (.82)

1 637 (14 500)

SAE H

H

27 teeth 16/32 pitch

27.0 (1.06)

22 362 (19 805)

❊ For the 055 pump the rated torque is limited to 445 Nm (3 830 lbf•in)

Mating Auxiliary Pumps

Pump mounting flanges and shafts with the dimensions noted below are compatible with the auxiliary mounting pads on the Series 90 pumps.

Figure 17

D

Coupling

B max.

(+.000) (-.002)

Spline engagement for rated torque

0

F min.

ø P (Dia) -0.05

E Mounting Flange (Ref)

0.8 (.03) R Preferred P001 462E

Table 6: Auxiliary Pump Dimensions [mm (in.)]

Flange

øP

B

Size

Dia

max.

D

E

F min.

SAE

82.55

7.4

32

13.5

A

(3.250)

(.29)

(1.26)

(.53)

SAE

101.6

10.7

41

14.2

B

(4.000)

(.42)

(1.61)

(.56)

SAE

101.6

10.7

46

B-B

(4.000)

(.42)

(1.81)

SAE

127.0

14.3

56

C

(5.000)

(.56)

(2.20)

16.1 See Dimensions

The accompanying drawing provides the dimensions for the auxiliary pump mounting flange and shaft.

(.63) 18.3 (.72)

SAE

152.4

14.3

75

D

(6.000)

(.56)

(2.95)

(.82)

20.8

SAE

165.1

18.0

75

20.8

E

(6.500)

(.71)

(2.95)

(.82)

SAE

165.1

18.0

75

27.0

H

(6.500)

(.71)

(2.95)

(1.06)

19

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

External Load Limits Shaft Loads Figure 18: External shaft load orientation

Normal bearing B10 life in hours is indicated in the accompany table at a continuous differential pressure of 240 bar (3 500 psi), 1 800 min-1 (rpm) shaft speed, maximum displacement, and no external shaft side load. The data below is based on a 50 % forward, 50 % reverse duty cycle, standard charge pump size, and standard charge pressure.

L 0° Re

Re 90° Re

270° Re T out

T in

Table 7: Bearing life Frame Size

Bearing Life - B10 hrs

030

10 040

042

18 060

055

22 090

075

22 970

100

22 670

130

17 990

180

16 150

250

12 020

180° Re

Pump swashplate

P000 801E

Maximum Allowable Radial Side Load, Re = Me / L All external shaft loads will have an effect on bearing life. In applications where external shaft loads can not be avoided, the impact on bearing life may be minimized by orientating the load to the 90 or 270 degree position.

Please contact Sauer-Sundstrand Application Engineering for an evaluation of unit bearing life if:

Series 90 pumps are designed with bearings that can accept external radial and thrust loads. The external radial shaft load limits are a function of the load position and orientation, and the operating conditions of the unit.

The maximum allowable radial side load (Re), based on the maximum external moment (Me) and the distance (L) from the mounting flange to the load, may be determined from the table and diagram below. Thrust (axial) load limits are also shown.

•

continuously applied external loads exceed 25 % of the maximum allowable radial side load, Re.

•

the pump swashplate is positioned on one side of center all or most of the time.

•

the unit bearing life (B10) is critical.

Tapered input shafts or “clamp-type” couplings are recommended for applications where radial shaft side loads are present.

Table 8: External shaft load Frame Size

030

042

055

075

100

130

180

250

Max. Allowable External Loads 1) External Moment (Me)

Nm lbf•in

112 991

126 1 114

101 893

118 1 043

126 1 114

140 1 238

161 1 424

176 1 556

2) Max. Shaft Thrust in (T in)

N lbf

2 900 652

2 635 592

3 340 750

4 300 966

5 160 1 160

5 270 1 184

7 000 1 573

7 826 1 759

3) Max. Shaft Thrust out (T out)

N lbf

1 330 299

1 020 229

910 204

930 209

1 000 224

688 154

1 180 265

1 693 380

20

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

External Load Limits (Continued) Mounting Flange Loads Adding tandem mounted auxiliary pumps and/or subjecting pumps to high shock loads may result in excessive loading of the mounting flange. The overhung load moment for multiple pump mounting may be estimated as shown in the accompanying figure.

Figure 19: Overhung load moments

CG Pump 2

Auxiliary Pad

Mounting Flange

CG Pump 1

Estimating Overhung Load Moments W = L =

Weight of pump [kg] Distance from mounting flange to pump center of gravity (refer to pump installation drawings) [m] MR = GR (W1L1 + W2L2 + ... + WnLn) MS = GS (W1L1 + W2L2 + ... + WnLn)

Where: MR MS GR GS

L1 L2

= = = =

Rated load moment [Nm] Shock load moment [Nm] Rated (vibratory) acceleration ("g"s) * [m/s2 ] Maximum shock acceleration ("g"s) * [m/s2]

P001 290E

* Calculations will be carried out by multiphying the gravity (g = 9.81 m/s2 ) with a given factor.

This factor depends on the application.

Allowable overhung load moment values are shown in the accompanying table. Exceeding these values will require additional pump support.

Table 9: Allowable overhung load moments Frame Size

Rated Moment MR

Shock Load Moment MS

Nm

lbf•in

Nm

lbf•in

030

860

7 600

3 020

26 700

042

860

7 600

3 020

26 700

055

1 580

14 000

5 650

50 000

075

1 580

14 000

5 650

50 000

100

1 580

14 000

5 650

50 000

130

3 160

28 000

10 730

95 000

180

6 070

54 000

20 600

182 000

250

6 070

54 000

20 600

182 000

21

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Efficiency Graphs Figure 20 shows typical overall and volumetric efficiencies for series 90 pump with system pressures of 210 and 420 bar (3 000 and 6 000 psi) speed corresponding to rated speed, and a fluid viscosity of 8 mm2/s (cSt) {50 SUS}.

Figure 20: Overall efficiency and volumetric efficiency at maximum displacement 100 η v = 210 bar (3000 psi)

95

000

ar (3

η t = 210 b

i)

0 ps

600

90

Efficieny %

psi)

r( 0 ba

2

ηv = 4

i)

0 ps

600

r( 0 ba

η t = 42 85

80 0

50

25

75

100 P000 791E

Speed % of Rated Continuous Speed

The following performance maps show typical overall efficiencies for series 90 pumps with system pressures of 70 to 420 bar (1 000 to 6 000 psi) and at 2/3 of its rated speed varying between 1/4 to maximum displacement (Figure 22).

These efficiency maps can be used for all frame sizes.

Figure 22: Pump overall efficiency at 2/3 rated speed

420

6000

350

92% 210

2000

140

93% bar

psi

3000

1000

70

0

0 0

P000 793E

22

25 50 75 Speed % of Rated Continuous Speed

100

psi

System Pressure

280

4000

6000

420

5000

350

4000

280

85

η t

=

0.

η t=

90%

3000

bar

5000

0.6

85%

η t= 0 η .65 t= η 0.7 t= 0.7 5 η t= 0.8

Figure 21: Overall efficiency at max. displ. of pump

9

η t

=

0.

210

2000

140

0

0 0

25 75 50 Displacement in percent of maximum displacement

100

P000 794E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Notes

23

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description 3-Position (FNR) Electric Control, Options DC, DD The 3-Position (FNR) control uses an electric input signal to switch the pump to a full stroke position.

Table 10: Electric input signal direct current Configuration

b

DC

12 VDC

DD

24 VDC

Figure 23.1: 3-Position electric control hydraulic schematic "B"

"0"

"A" Figure 24: Solenoid Connector

To Servo Piston S1

Solenoid plug face for DIN 43650 Connector

S2

a

SAUER-SUNDSTRAND Mating Parts Kit Part No. K09129

b

not connected

T P From Charge

S1 = Servo Side 1 S2 = Servo Side 2

P001 409E

Figure 23.2: Pump displacement vs electrical signal 100 % Displacement

b

Voltage VDC "0"

-b

100 % P001 408E

24

1

2

Voltage between terminals 1 and 2 P001 473E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) 3-Position (FNR) Electric Control, Options DC, DD (Continued) Response Time

Table 12: Pump output flow direction vs. control voltage

The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

Input Shaft Rotation

A range of orifice sizes is available for the Series 90 Electric Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

CW

CCW

Signal at Magnet

a

b

a

b

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations

Typical response times between neutral and full flow at the following conditions: ∆p = Temperature = Charge Pressure =

210 bar 50 °C 24 bar

(3 000 psi) (122 °F) (340 psi)

Table 11: Typical response times Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 1.0

25

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Electric Displacement Control (EDC), Options KA, KP The electric displacement control uses an electrohydraulic Pressure Control Pilot valve to control the pilot pressure.

The Pressure Control Pilot valve converts an electrical input signal to a hydraulic input signal to operate a 4-way servo valve, which ports hydraulic pressure to either side of a double acting servo piston. The servo piston tilts the cradle swashplate, thus varying the pump´s displacement from full displacement in one direction to full displacement in the opposite direction. The control has a mechanical feedback mechanism which moves the servo valve in relation to the input signal and the angular position of the swashplate. The electrical displacement control is designed so the angular rotation of the swashplate (pump displacement) is proportional to the electrical input signal.

Due to normal operating force changes, the swashplate tends to drift from the position preset by the machine operator. Drift, sensed by feedback linkage system connecting the swashplate to the control valve, will activate the valve and supply pressure to the servo piston, maintaining the swashplate in its preset position.

Figure 25: Electric displacement control hydraulic schematic Manual Override To Servo Piston

S2

S1

Swashplate Feedback

"B"

"0"

X2 X1

T P From Charge

Features and Benefits of the Electric Control: • The electric displacement control is a high gain control: With only a small change of the input current, the servo valve moves to a full open position thus porting maximum flow to the servo cylinder.

• Oil filled pilot valve case lengthens control life by preventing moisture ingression and dampening component vibrations.

P000 810E

Figure 26: Cross-section of electric displacement control valve

• All electrical displacement controls are equipped with dual coil pilot valves. The user has the option of using a single coil or both coils (in series or parallel).

• Internal mechanical stops on the servo valve allow rapid changes in input signal voltages without damaging the control mechanism.

"A"

X2

Electric Input Signal

P C P X1

• Precision parts provide repeatable accurate displacement settings with a given input signal.

• The swashplate is coupled to a mechanism. The control valve hydraulically connects the ends of the servo piston to drain when an electric input signal is not present.

• These features result in: - Simple, low cost design.

- Pump will return to neutral after prime mover shuts down.

- Pump returns to neutral if external electrical input signal fails or if there is a loss of charge pressure.

26

T S2 P S1 T

S1 = Servo Side 1 S2 = Servo Side 2

P000 809

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Electric Displacement Control (EDC), Options KA, KP (Continued) Table 13 Coil Configuration

a mA

b mA

Single coil Dual coil

14 ± 5 7±3

85 ± 18 43 ± 9

A & B or C & D A&D

85 ± 18

(C B Common) AC&BD

in series Dual coil parallel

14 ± 5

Pin Connections

Maximum input current under any condition: 250 mA Coil resistance at 24 °C (75 °F): A - B coil → 20 Ω C - D coil → 16 Ω Figure 27: Pump displacement vs electrical signal current

Displacement

100 %

-b

Response Time The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

A range of orifice sizes is available for the Series 90 Electric Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Typical response times between neutral and full flow at the following conditions: ∆p = 210 bar (3 000 psi) Temperature = 50 °C (122 °F) Charge Pressure = 24 bar (340 psi) Table 14: Typical response times

-a

Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 1.0

Current mA "0" a

b

100 % P001 015E

Figure 28: Connectors

Table 15: Pump output flow direction vs. control current EDC using a Single Coil or Dual Coils in Parallel (A and C Common, B and D Common)

MS Connector (Option EA) MS 3102C-14S-2P D C

A B

SAUER-SUNDSTRAND Mating Parts Kit Part No. K08106 or Ident. No. 615062

Packard Weather-Pack (Option EP) 4-way shroud connector

CW

Input Shaft Rotation

CCW

Positive Current to Term.

A or C

B or D

A or C

B or D

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

EDC using Dual Coils in Series (B and C Common)

B C D

CW

Input Shaft Rotation

A SAUER-SUNDSTRAND Mating Parts Kit Part No. K03384 (Female Terminals)

P001 464E

CCW

Positive Current to Term.

A

D

A

D

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations 27

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Hydraulic Displacement Control (HDC), Option HF The hydraulic displacement control uses a hydraulic input signal to operate a 4-way servo valve, which ports hydraulic pressure to either side of a double acting servo piston. The servo piston tilts the cradle swashplate, thus varying the pump´s displacement from full displacement in one direction to full displacement in the opposite direction. The control has a mechanical feedback mechanism which moves the servo valve in relation to the input signal and the angular rotation of the swashplate. The hydraulic displacement control is designed so the angular position of the swashplate (pump displacement) is proportional to the hydraulic input signal pressure. Due to normal operating force changes, the swashplate tends to drift from the position preset by the machine operator. Drift, sensed by feedback linkage system connecting the swashplate to the control valve, will activate the valve and supply pressure to the servo piston, maintaining the swashplate in its preset position.

Figure 30: Cross-section of hydraulic displacement control valve Hydraulic Signal Inputs X1

X2

T S2 P S1 T P000 807

S1 = Servo Side 1 S2 = Servo Side 2 Control Signal Requirements Maximum allowable signal pressure is 60 bar (870 psi).

Features and Benefits of the Hydraulic Control: • The hydraulic displacement control is a high gain control: With only small change of the input signal, the servo valve moves to a full open position porting maximum flow to the servo cylinder.

• Internal mechanical stops on the servo valve allows rapid changes in input signal pressure without damaging the control mechanism.

Table 16: Hydraulic signal pressure range 3 ± 0.5 bar 11 ± 0.5 bar

a b

Figure 31: Pump displacement vs input signal pressure 100 % Displacement

• Precision parts provide repeatable, accurate displacement settings with a given input signal.

• The swashplate is coupled to a mechanism. The control valve hydraulically connects the ends of the servo piston to drain when an electric input signal is not present.

• These features result in: - Simple - low cost design.

- Pump will return to neutral after prime mover shuts down.

- Pump returns to neutral if there is a loss of input signal pressure or if there is a loss of charge pressure.

43 ± 6 psi 160 ± 6 psi

-b

-a

Signal Pressure

"0" a

b

Figure 29: Hydraulic displacement control hydraulic schematic 100 %

To Servo Piston S2

X1

Input Signal Pressure Swashplate Feedback

P001 014E

S1 Input Signal Pressure

Table 17: Pump output flow direction vs. control pressure X2

T P From Charge

Input Shaft Rotation

CW

CCW

Control Pressure to Port

X2

X1

X2

X1

Port A Flow

In

Out

Out

In

Port B Flow

Out

In

In

Out

Refer to dimensions for port locations P000 808E

28

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Hydraulic Displacement Control (HDC), Option HF (Continued) Response Time The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

A range of orifice sizes is available for the Series 90 Hydraulic Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Typical response times between neutral and full flow at the following conditions: ∆p = 210 bar (3 000 psi) Temperature = 50 °C (122 °F) Charge Pressure = 24 bar (340 psi)

Table 18: Typical response times Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 1.0

Manual Displacement Control (MDC), Options MA, MB The manual displacement control device converts a mechanical input signal to a hydraulic signal that tilts the cradle swashplate through an angular rotation varying the pump`s displacement from full displacement in one direction to full displacement in the opposite direction.

The manual displacement control has a mechanical feedback mechanism which moves a servo valve in the proper relationship to the input signal and the angular position of the swashplate.

The manual displacement control is designed so that the angular rotation of the swashplate is proportional to the mechanical input signal. The control is designed with an internal override mechanism which allows the mechanical input to be moved at a faster rate than the movement of the swashplate without damage to the control.

Features and Benefits of the Manual Control: • Precision parts provide repeatable, accurate displacement settings with a given input signal.

• The manual displacement control is a high gain control: With only small movement of the control handle (input signal), the servo valve moves to full open position porting max. flow to the servo cylinder. This is a high response system with low input force.

• The integral override mechanism allows rapid changes in input signal without damaging the control mechanism.

• Precision parts provide repeatable, accurate displacement settings with a given input signal.

• A double-acting servo piston is coupled to a spring centering mechanism. The servo control valve is spring centered such that with "no input signal" the servo valve is open centered and thus no fluid is ported to the servo cylinder.

• These features result in: - Pump will return to neutral after prime mover shuts down.

- Pump will return to neutral if external control linkage fails at the control handle or if there is a loss of charge pressure.

Figure 32: Manual displacement control hydraulic schematic "B"

"0"

"A"

To Servo Piston S2

Swashplate Feedback

S1

T P From Charge

P000 805E

Figure 33: Cross-section of manual displacement control valve

Control Handle Input Signal

T S2 P S1 T P000 804E

S1 = Servo Side 1 S2 = Servo Side 2 29

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Manual Displacement Control (MDC), Options MA, MB (Continued) External Control Handle Requirements Torque required to move handle to maximum displacement is 0.68 to 0.9 Nm (6 to 8 lbf•in).

Torque required to hold handle at given displacement is 0.34 to 0.57 Nm (3 to 5 lbf•in).

Torque required to overcome the override mechanism is 1.1 to 2.3 Nm (10 to 20 lbf•in) with the maximum torque required for full forward to full reverse movement.

Maximum allowable input torque is 17 Nm (150 lbf•in)

Figure 34: Pump displacement vs control lever rotation

Table 19: Pump output flow direction vs. control handle rotation

"A"

Input Shaft Rotation Handle Rotation

CW

CCW

Displacement

100 %

-24°÷ 30° *

-2° "0"

Lever Rotation 2°

-35° max.

35° max.

"B" 24°÷ 30° *

"A" (CCW) "B" (CW) "A" (CCW) "B" (CW)

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations 100 %

Response Time see next page.

* Actual angle see dimensions.

P001 013E

Non-linear Manual Displacement Control (MDC), Option NA The manual displacement control device converts a mechanical input signal to a hydraulic signal that tilts the cradle swashplate through an angular rotation varying the pump`s displacement from full displacement in one direction to full displacement in the opposite direction.

The manual displacement control has a mechanical feedback mechanism which moves a servo valve in the proper relationship to the input signal and the angular position of the swashplate.

The manual displacement control is designed so that the angular rotation of the swashplate is progressive to the mechanical input signal. The control is designed with an internal override mechanism which allows the mechanical input to be moved at a faster rate than the movement of the swashplate without damage to the control.

Figure 35: Non-linear manual displacement control hydraulic schematic "B" "0" "A" To Servo Piston S2

Swashplate Feedback

• These features result in: - Pump that is returned to neutral after prime mover shut down.

- Pump that is returned to neutral if external control linkage fails at the control handle.

S1

- If there is loss of charge pressure pump returns to neutral.

T P From Charge P001 412E

30

Features and Benefits of the Non-linear Manual Control: • The manual displacement control is a high gain control: With only small movement of the control handle (input signal), the servo valve moves to full open position porting max. flow to the servo cylinder. This is a high response system with low input force.

• Low spool dead band results in good down hill and braking capability.

• Smooth acceleration is possible.

• The integral override mechanism allows rapid changes in input signal without damaging the control mechanism.

• Precision parts provide repeatable, accurate displacement settings with a given input signal.

• A double-acting servo piston is coupled to a spring centering mechanism. The servo control valve is spring centered such that with "no input signal" the servo valve is open centered and thus no fluid is ported to the servo cylinder.

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Controls - Circuit Diagram, Nomenclature and Description (Continued) Non-linear Manual Displacement Control (MDC), Option NA (Continued) Figure 36: Cross-section of non-linear manual displacement control valve

Response Time (applies also for Option MA and MB) The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

A range of orifice sizes is available for the Series 90 Manual Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Control Handle Input Signal

T S2

P

S1

S1 = Servo Side 1 S2 = Servo Side 2

P001 410E

External Control Handle Requirements Torque required to move handle to maximum displacement is 0,68 to 0,9 Nm (6 to 8 lbf•in).

Maximum allowable input torque is 17 Nm (150 lbf•in).

Figure 37: Pump displacement vs control lever rotation

Displacement

100 %

"A"

-31°

"B" 3°

-33° max.

33° max.

Lever Rotation

-3° "0"

31°

Typical response times between neutral and full flow at the following conditions: ∆p = 210 bar (3 000 psi) Temperature = 50 °C (122 °F) Charge Pressure = 24 bar (340 psi)

Table 21: Typical response times Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 9.0

100 % P001 411E

Table 20: Pump output flow direction vs. control handle rotation Input Shaft Rotation Handle Rotation

CW

CCW

"A" (CCW) "B" (CW) "A" (CCW)

"B" (CW)

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations 31

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 030 mm (in.)

Figure 38: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8 101.8 (4.01) 38 (1.5)

Coupling may not protrude beyond this surface

25

length of full spline

7.9 (.98) (.31)

Splined Shaft Option C3

B

CCW

9.7 (.38) 12.2 (.48)

Ports A and B 1/2 -6000 psi Split Flange Boss per SAE J518 (Code 62) 5/16-18UNC-2B 20 (.787) min. Full Thread

91.55 (3.60) Port L2

40.49 (1.59)

Approx center of gravity

100 (3.94) 176.4 (6.94)

185.4 (7.29)

Gauge port M1 System pressure A 9/16-18UNF-2B

Gauge port M4 Servo pressure 9/16-18UNF-2B

"Z"

SHAFT SPLINE DATA: Pitch Dia = 23.813 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit 33.33 (1.31)

Coupling may not protrude beyond this surface

20

length of full spline

7.9 (.78) (.31)

Splined Shaft Option C2

79 (3.11)

42 (1.65)

ø21.72 (.85 Dia)

View "Y"

126 (4.96) 231.9 (9.13)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

"A" Max. Displacement

Woodruff key 6.35 x 22.22 (.250 x .875)

ø6.73 2x (.265 Dia)

Tapered Shaft Option T3

View "X" Charge Pressure Relief Valve

Multifunction Valve

73.55 (2.89)

View "W"

Port X3 (optional) External control supply 9/16-18UNF-2B

53.66 (2.11) 8.3 (.33)

Castle nut, 3/4-16UNF Wrench size: 27 (1.062) Torque nut to 150-190 Nm (110-146 lbf-ft) R 25.4 (R 1.0)

Port L2 Case drain 7/8-14UNF-2B 146 (5.75)

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 20,6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Coupling may not protrude beyond this surface

73 (2.875)

ø25.4 (1Dia)

Null position

24° min.

"B"

24° min.

Max. Displacement

45 (1.77)

Approx center of gravity

60 (2.36)

Gauge port M5 Servo pressure 9/16-18UNF-2B

35 (1.38)

Gauge port M3 Charge pressure 9/16-18UNF-2B

ø18.67 (.74 Dia)

Port L1 Case drain use highest port as outlet 7/8-14UNF-2B

ø15.3 (.602 Dia)

0

A

74 (2.91) 71.5 (2.81) Port L2

18.24 (.71)

ø21.34 (.84 Dia)

CW

(-.002)

ø101.6 -0.05 (4 Dia) (+.000)

51 (2.00)

15 (.59) ø25.4 (1Dia) ø60 max. (max. 2.36 Dia)

51 (2.00)

Rotation

"X"

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

32

"W"

141 (5.55)

Port S: Charge pump inlet 1-1/16-12UN-2B

100 (3.94 ) Port L1

124 (4.88)

Gauge port M2 System pressure B 9/16-18UNF-2B

View "Z"

Control MDC, Option MA 9.4 (.37)

"Y"

34.6 (1.36) 48.86 (1.92)

P001 359E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 030 (Continued) mm (in.)

Continued Figure 38: Auxiliary Mounting Pad - Options A, B, V View "X"

106.375 (4.188)

"X"

SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 32.5 (1.28)

4 Threads 3/8-16UNC-2B 17 (.67) deep

15.3 (.60)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

259.6 (10.22)

106.375 (4.188)

273.4 (10.76)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.5 (1.0)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

4 Threads 1/2-13UNC-2B 22 (.87) deep

19.6 (.77) 256.4 (10.09)

146 (5.75)

273.8 (10.78)

View "X"

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 15.2 (.598)

4 Threads 1/2-13UNC-2B 22 (.87) deep

29.9 (1.18) 256.4 (10.09)

146 (5.75)

273.8 (10.78) P001 360E

33

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 042 mm (in.)

Figure 39: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

Coupling may not protrude beyond this surface

25

length of full spline

7.9 (.98) (.31)

Splined Shaft Option C3

B

111 (4.37)

"W"

145 (5.71)

38 (1.5)

Rotation

"X"

Ports A and B 3/4 -6000 psi Split Flange Boss per SAE J518 (Code 62) 3/8-16UNC-2B 20 (.787) min. Full Thread

12.2 (2x) (.48) 114.5 (4.51) Port L2 130 (5.12) 207.8 (8.18)

50.8 (2.00) Approx center of gravity

ø15.3 (.602 Dia)

(-.002)

0

A

9.7 (.38)

CW

81.4 (3.20) 80 (3.15) Port L2

23.8 (.94)

ø21.34 (.84 Dia)

CCW

ø101.6 -0.05 (4 Dia) (+.000)

52 (2.047)

7.9 (.31) ø25.4 (1Dia) ø70 max. (max. 2.76 Dia)

52 (2.047)

129 (5.08)

86 (3.39)

Port S: Charge pump inlet 1-1/16-12UN-2B

108 (4.25) Port L1

View "Z"

Control MDC, Option MA 9.4 (.37)

"Y" Gauge port M2 System pressure B 9/16-18UNF-2B

"Z" 33 (1.30)

SHAFT SPLINE DATA: Pitch Dia = 23.813 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Approx center of gravity

Port L2 Case drain 7/8-14UNF-2B 146 (5.75)

73 (2.875)

View "X"

Gauge port M1 System pressure A 9/16-18UNF-2B

View "Y"

Gauge port M4 Servo pressure 9/16-18UNF-2B

Charge Pressure Relief Valve

83 (3.27)

41.6 (1.64)

Multifunction Valve

Gauge port M3 Charge pressure 9/16-18UNF-2B Multifunction Valve

Port L1 Case drain use highest port as outlet 7/8-14UNF-2B

Gauge port M5 Servo pressure 9/16-18UNF-2B

56.9 (2.24)

143.5 (5.65)

85.5 (3.4)

258 (10.16)

Manual Displacement Control Handle Dimensions

Coupling may not protrude beyond this surface

Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in)

"A" Max. Displacement

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Tapered Shaft Option T3

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

34

62.5 (2.46)

28° min.

Castle nut, 3/4-16UNF Wrench size: 27 (1.062) Torque nut to 150-190 Nm (110-146 lbf-ft)

ø25.4 (1Dia)

Null position

28° min.

"B"

Port X3 (optional) External control supply 9/16-18UNF-2B

53.7 (2.11) 8.3 (.33)

R 50.8 (R 2.0)

Max. Displacement

View "W"

34.6 (1.36) 38.6 (1.52)

126 (4.96)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 361E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 042 (Continued) mm (in.)

Continued Figure 39: Auxiliary Mounting Pad - Options A, B, V View "X"

106.375 (4.188)

"X"

SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 32.5 (1.28)

4 Threads 3/8-16UNC-2B 17 (.67) deep

18 (.71)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

288 (11.34)

106.375 (4.188)

301.85 (11.88)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.5 (1.0)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

4 Threads 1/2-13UNC-2B 22 (.87) deep

20.5 (.81) 282.92 (11.14)

146 (5.75)

300.37 (11.83)

View "X"

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 15.2 (.598)

4 Threads 1/2-13UNC-2B 22 (.87) deep

30.8 (1.21) 282.92 (11.14)

146 (5.75)

300.37 (11.83) P001 362E

35

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 055 mm (in.)

Figure 40: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Side Ports, Option 6

View "Z" Control MDC, Option MA

9.4 (.37)

Gauge port M2 System pressure B 9/16-18UNF-2B

133.9 (5.27) 121.9 (4.80) Port B 117.6 (4.63) Port L1

47.6 (1.88) 7.9 (.31)

Splined Shaft Option S1

Gauge port M1 System pressure A 9/16-18UNF-2B

243.7 (9.60) Port S

Port L1 Case drain use highest port as outlet 1-1/16-12UN-2B

288.8 (11.37)

33.8 (1.33)

27.76 (1.093)

72.9 (2.87) 168.9 (6.65) 23.9 (9.13)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

Max. Displacement

28° min.

A

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Coupling may not protrude beyond this surface Woodruff key 9.525 x 38.1 (.375 x 1.50)

88.9 (3.50) 86.2 (3.39) Port L2 Port S: Charge pump inlet 1-5/16-12UN-2B

96.85 (3.81)

View "W"

58.4 (2.30) Port X3 (optional) External control supply 9/16-18UNF-2B

66.9 (2.63) 6.6 (.26)

ø34,93 (1.375 Dia)

SAE J744c 47.8 (1.88) 62.02 (2.44)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

36

View "X" Charge Pressure Relief Valve

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 33.338 (1.3125) Pressure Angle = 30° Number of teeth = 21 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Tapered Shaft Option T1

(2x)

Gauge port M3 Charge pressure 9/16-18UNF-2B

Castle nut, 1-20UNEF Wrench size: 38 (1.496) Torque nut to 190-230 Nm (140-170 lbf-ft)

28° min.

Max. Displacement

114.5 (4.50)

Port L2 Case drain 1-1/16-12UN-2B

Multifunction Valve

ø28.7 (1.13 Dia) Gauge port M5 Servo pressure 7/16-20UNF-2B

(2x)

Splined Shaft Option C6

41.7 (1.64)

57.15(2.25)

Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

Approx center of gravity

57.25 (2.25)

length of full spline

ø34.42 (1.355 Dia)

7.9 (.31)

43.7 (1.72)

ø14.27 (.562 Dia)

Coupling may not protrude beyond this surface

47.6 (1.88)

Gauge port M4 Servo pressure 7/16-20UNF-2B

(-.002)

SHAFT SPLINE DATA: Pitch Dia = 29.633 (1.1667) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

120.4 (4.74) Port L2 152.4 (6.0)

View "Y"

0

"Z"

82.6 (3.25)

14.2 (.56)

Approx center of gravity

CW

65 (2.56)

"X"

CCW

ø127 -0.05 (5 Dia) (+.000)

17.8 (.70) ø31.14 (1.226Dia) ø84.8 max. (max. 3.34 Dia)

90.4 (3.56) Port A

Rotation

12.45 ±0.25 (.49) (±.01)

Null position

"W"

length of full spline

27.9 (1.10)

ø24.9 (.98 Dia)

B

110.7 (4.36)

93.7 (3.69)

Coupling may not protrude beyond this surface

149.9 (5.90)

"Y"

136.35 (5.37)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 385E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 055 (Continued) Continued Figure 40: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC)

mm (in.)

Endcap Twin Ports, Option 8 "Y"

Gauge port M2 System pressure B 9/16-18UNF-2B

Control MDC, Option MA

Port S: Charge pump inlet 1-5/16-12UN-2B

27.76 (1.093)

57.9 (2.28)

57.9 (2.28)

B

A

Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

57.15 (2.25)

Gauge port M1: System pressure A 9/16-18UNF-2B 232.2 (9.14) 247.1 (9.73)

85.1 (3.35) Port S

88.9 (3.54)

View "Y"

P001 386E

37

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 055 (Continued) mm (in.)

Continued Figure 40: Auxiliary Mounting Pad - Options A, B, C, V

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 37.13 (1.46)

View "X"

"X"

106.375 (4.188)

ø82.6 (3.252 Dia)

+ 0.13 0 (+.005) (- .000)

SAE A, Option A

4 Threads 3/8-16UNC-2B 22.8 (.89) deep

15.13 (.59)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

316.6 (12.46)

106.375 (4.188)

330.4 (13.01)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.51 (1.16)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

17.66 (.70)

4 Threads 1/2-13UNC-2B 22 (.87) deep

311.5 (12.26)

146 (5.75)

329 (12.95)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 18.97 (.747)

30.73 (1.21)

6 Threads 1/2-13UNC-2B 22 (.87) deep

314 (12.36) 331 (13.03)

114.5 (4.51) 181 (7.13) P001 387E

38

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 055 (Continued) mm (in.)

Continued Figure 40: Auxiliary Mounting Pad - Options A, B, C, V

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.43 (.96)

20.75 (.82)

4 Threads 1/2-13UNC-2B 22 (.87) deep

311.5 (12.26)

146 (5.75)

329 (12.95) P001 387E/1

39

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 075 mm (in.)

Figure 41: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Side Ports, Option 6 Control MDC, Option MA

99.3 (3.91)

9.4 (.37)

139.7 (5.50)

126 (4.96) Port B

Splined Shaft Option S1

Rotation

Port L1 Case drain use highest port as outlet 1-1/16-12UN-2B

View "Y"

306.1 (12.05)

41.6 (1.64)

27.76 (1.093)

A Max. Displacement

248.2 (9.77)

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

SHAFT SPLINE DATA: Pitch Dia = 36.513 (1.4375) Pressure Angle = 30° Number of teeth = 23 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Coupling may not protrude beyond this surface Woodruff key 9.525 x 38.1 (.375 x 1.50)

Tapered Shaft Option T2

View "X" Charge Pressure Relief Valve

Multifunction Valve

Port S: Charge pump inlet 1-5/16-12UN-2B

104 (4.09)

View "W"

65 (2.56) Port X3 (optional) External control supply 9/16-18UNF-2B

66.9 (2.63) 8.65 (.34)

ø38.1 (1.5 Dia)

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

40

(2x)

Multifunction Valve

Castle nut, 1-20UNEF Wrench size: 38 (1.496) Torque nut to 190-230 Nm (140-170 lbf-ft)

28° min.

28° min.

B Null position

81.3 (3.20) 172.2 (6.78)

R 50.8 (R 2.0)

Max. Displacement

114.5 (4.50)

A

Gauge port M5 Servo pressure 9/16-18UNF-2B

Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in)

Approx center of gravity

Port L2 Case drain 1-1/16-12UN-2B

(2x)

Gauge port M3 Charge pressure 9/16-18UNF-2B

ø31.8 (1.25 Dia)

Manual Displacement Control Handle Dimensions

93.7 (3.69) 91,7 (3.61) Port L2

(-.002)

Splined Shaft Option C7

57.15(2.25)

Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

57.25 (2.25)

length of full spline

34.8 (1.37)

ø37.59 (1.48 Dia)

7.9 (.31)

40.6 (1.60)

ø14.27 (.562 Dia)

Coupling may not protrude beyond this surface

47.6 (1.88)

Gauge port M4 Servo pressure 9/16-18UNF-2B

0

SHAFT SPLINE DATA: Pitch Dia = 29.633 (1.1667) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

84 (3.31)

262.6 (10.34) Port S

141.7 (5.58) Port L2 155.7 (6.13)

"Z"

12.45 ±0.25 (.49) (±.01)

71 (2.79)

Approx center of gravity

14.2 (.56)

ø127 -0.05 (5 Dia) (+.000)

3.8

Gauge port M1 System pressure A 9/16-18UNF-2B

CW

M4

94.5 (3.72) Port A

ø24.9 (.98 Dia)

(.15) ø31.14 (1.226Dia) ø94 max. (max. 3.70 Dia)

CCW

B

124.2 (4.89) Port L1

length of full spline

27.9 (1.10)

M5

"X"

"W"

Coupling may not protrude beyond this surface

47.6 (1.88) 7.9 (.31)

110.7 (4.36)

155.7 (6.13)

Gauge port M2 System pressure B 9/16-18UNF-2B

View "Z"

"Y"

47.8 (1.88) 62.02 (2.44)

141.1 (5.55)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 380E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 075 (Continued) Continued Figure 41: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC)

mm (in.)

Endcap Twin Ports, Option 8 "Y"

Gauge port M2 System pressure B 9/16-18UNF-2B

Control MDC, Option MA

Port S: Charge pump inlet 1-5/16-12UN-2B

27.76 (1.093)

61 (2.40)

93.77 (3.69)

61 (2.40)

B

A

57.15 (2.25) Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

Gauge port M1: System pressure A 9/16-18UNF-2B 242.4 (9.54) 247.9 (9.76)

92 (3.62)

View "Y"

P001 381E

41

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 075 (Continued) mm (in.)

Continued Figure 41: Auxiliary Mounting Pad - Options A, B, C, V COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 37.13 (1.46)

View "X" SAE A, Option A

B

M4

106.375 (4.188)

ø82.6 (3.252 Dia)

+ 0.13 0 (+.005) (- .000)

M5

"X"

A for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

4 Threads 3/8-16UNC-2B 22.8 (.89) deep

15.13 (.59) 333.93 (13.14)

106.375 (4.188)

347.8 (13.69)

M4

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

146 (5.75)

(- .000)

B

+ 0.13

View "X" SAE B, Option B M5

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.51 (1.16)

A

4 Threads 1/2-13UNC-2B 22 (.87) deep

17.66 (.70) 328.9 (12.95)

146 (5.75)

346.5 (13.64)

114.5 (4.51)

(- .000)

M4

+ 0.13

B

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C M5

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 18.97 (.747)

6 Threads 1/2-13UNC-2B 22 (.87) deep

30.73 (1.21) 331.4 (13.05) 348.4 (13.72)

A 114.5 (4.51) 181 (7.13)

P001 384E

42

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 075 (Continued) mm (in.)

Continued Figure 41: Auxiliary Mounting Pad - Options A, B, C, V

146 (5.75)

(- .000)

M4

+ 0.13

B

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V M5

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.43 (.96)

4 Threads 1/2-13UNC-2B 22 (.87) deep

22.75 (.896) 328.9 (12.95)

A 146 (5.75)

346.5 (13.64) P001 384E/1

43

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 100 mm (in.)

Figure 42: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Side Ports, Option 6

View "Z"

"Y"

Control MDC, Option MA

108.4 (4.27)

9.4 (.37)

148.7 (5.85) 143.3 (5.64) Port B 139.1 (5.48) Port L1

length of full spline

49.5 (1.95)

Splined Shaft Option F1

Gauge port M1 System pressure A 9/16-18UNF-2B

288 (11.34) Port S

Port L1 Case drain use highest port as outlet 1-1/16-12UN-2B

161 (6.34) Port L2

SHAFT SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

180.3 (7.10)

339 (13.35)

View "Y"

47.6 (1.88)

Gauge port M4 Servo pressure 9/16-18UNF-2B

38.9 (1.53)

27.76 (1.093)

Gauge port M5 Servo pressure 9/16-18UNF-2B 204.6 (8.06) 277.7 (10.93)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

"A" Max. Displacement

30° min.

Woodruff key 9.525 x 38.1 (.375 x 1.50)

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Tapered Shaft Option T2

114.6 (4.51)

View "W"

66 (2.60) Port X3 (optional) External control supply 9/16-18UNF-2B

66.9 (2.63) 9.54 (.38)

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

44

A Port S: Charge pump inlet 1-5/8-12UN-2B

ø38,1 (1.5 Dia)

Null position

Coupling may not protrude beyond this surface

Gauge port M3 Charge pressure 9/16-18UNF-2B

Multifunction Valve

Castle nut, 1-20UNEF Wrench size: 38 (1.496) Torque nut to 190-230 Nm (140-170 lbf-ft)

30° min.

Max. Displacement

Charge Pressure Relief Valve

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 36.513 (1.4375) Pressure Angle = 30° Number of teeth = 23 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

87.3 (3.44)

View "X"

Splined Shaft Option C7

ø32.3 (1.27 Dia) Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

Port L2 (2x) Case drain 1-1/16-12UN-2B 114.5 (2x) (4.50)

57.25 (2.25)

length of full spline

33 (1.30)

57.15(2.25)

Approx center of gravity

Coupling may not protrude beyond this surface

ø37.59 (1.48 Dia)

7.9 (.31)

42 (1.65)

ø14.27 (.562 Dia)

89.7 (3.53)

Approx center of gravity

76 (2.99)

"X"

107 (4.21) 100,37 (3.95) Port L2

"Z"

12.45 ±0.25 (.49) (±.01) 14.2 (.56)

CW

(-.002)

0

CCW

ø127 -0.05 (5 Dia) (+.000)

20.3 (.80) ø43.94 (1.73Dia) ø100.6 max. (max. 3.96 Dia)

99.0 (3.89) Port A

Rotation

ø34.5 (1.36 Dia)

"B"

"W"

Coupling may not protrude beyond this surface

66.7 (2.625) 7.9 (.31)

119.7 (4.71)

164.7 (6.48)

Gauge port M2 System pressure B 9/16-18UNF-2B

47.8 (1.88) 62.02 (2.44)

164.34 (6.47)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 377E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 100 (Continued) Continued Figure 42: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC)

mm (in.)

Endcap Twin Ports, Option 8 Gauge port M2 System pressure B 9/16-18UNF-2B

"Y"

Control MDC, Option MA

47.6 (1.88)

Port S: Charge pump inlet 1-5/8-12UN-2B

7.9 (.31)

30.5 (1.20)

Coupling may not protrude beyond this surface length of full spline

Splined Shaft Option S1

ø24.9 (.98 Dia)

A

Ports A and B 1 -6000 psi Split Flange Boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 (.83) min. Full Thread

57.15 (2.25)

Gauge port M1: System pressure A 9/16-18UNF-2B 277.9 (10.94) 280.5 (11.04)

ø31.14 (1.226Dia)

27.76 (1.093)

66.8 (2.63)

66.8 (2.63)

B

SHAFT SPLINE DATA: Pitch Dia = 29.634 (1.1667) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

99.8 (3.93) Port S

107.95 (4.25)

View "Y"

P001 378E

45

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 100 (Continued) Continued Figure 42: Auxiliary Mounting Pad - Options A, B, C, V

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 37.13 (1.46)

mm (in.)

View "X"

106.375 (4.188)

"X"

ø82.6 (3.252 Dia)

+ 0.13 0 (+.005) (- .000)

SAE A, Option A

A 4 Threads 3/8-16UNC-2B 22.8 (.89) deep

15.13 (.60)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

366.02 (14.41)

106.375 (4.188)

379.69 (14.95)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.51 (1.16)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

4 Threads 1/2-13UNC-2B 22 (.87) deep

17.66 (.70) 360.9 (14.21)

146 (5.75)

378.3 (14.89)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29,6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 18.97 (.747)

6 Threads 1/2-13UNC-2B 22 (.87) deep

30.73 (1.21) 363.47 (14.31) 380.27 (14.97)

A 114.5 (4.51) 181 (7.13)

P001 379E

46

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 100 (Continued) Continued Figure 42: Auxiliary Mounting Pad - Options A, B, C, V

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.43 (.96)

mm (in.)

4 Threads 1/2-13UNC-2B 22 (.87) deep

22.75 (.896) 360.9 (14.21)

146 (5.75)

378.3 (14.89) P001 379E/1

47

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 130 mm (in.)

Figure 43: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

View "Z"

"Y"

Control MDC, Option MA

110.5 (4.35)

9.4 (.37)

length of full spline

42.5 (1.67)

7.9 (.31)

Splined Shaft Option F1 (-.002)

0

"X" 14.6 (.57)

66.68 (2.63)

185 (7.28) 290 (11.42) 300 (11.81)

Gauge port M1 System pressure A 9/16-18UNF-2B

View "Y"

66.68 (2.63)

Gauge port M4 Servo pressure 9/16-18UNF-2B

42.5 (1.67)

48 (1.89) 209.3 (8.24) 370 (14.58)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

"A" Max. Displacement

30° min.

Woodruff key 10.074 x 50.67 (.397 x 1.995)

R 25.4 (R 1.0)

Tapered Shaft Option T4

75.95 (2.99) 12.27 (.48)

SAE J744c

ø6.73 2x (.265 Dia)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

48

Port X3 (optional) External control supply 9/16-18UNF-2B

View "W" 121.2 (4.8)

ø44.45 (1.75Dia)

Null position

Coupling may not protrude beyond this surface

Gauge port M3 Charge pressure 9/16-18UNF-2B

M3

"B"

Charge Pressure Relief Valve

Multifunction Valve

Castle nut, 1-1/4-18UNEF Wrench size: 46 (1.811) Torque nut to 370-430 Nm (270-317 lbf-ft)

30° min.

Max. Displacement

View "X"

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 42.8625 (1.6875) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

101.5 (3.99)

Port L2 (2x) Case drain 1-5/16-12UN-2B 161.6 (2x) (6.36)

Splined Shaft Option C8

111 (4.37)

Gauge port M5 Servo pressure 9/16-18UNF-2B

80.8 (3.18)

length of full spline

ø37 (1.46 Dia)

Port L1 Case drain use highest port as outlet 1-5/16-12UN-2B

Approx center of gravity

Coupling may not protrude beyond this surface

ø44.35 (1.75 Dia)

7.9 (.31)

48.8 (1.92)

ø20.6 (.81 Dia)

SHAFT SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

166 (6.54) Port L2 Approx center of gravity

"Z"

12.45 ±0.25 (.49) (±.01)

CW

91 (3.58)

Ports A and B 1- 1/4 -6000 psi Split Flange Boss per SAE J518 (Code 62) 1/2-13UNC-2B 23 (.906) min. Full Thread

CCW

111.6 (4.39) 109,81 (4.32) Port L2

ø34.04 (1.34 Dia) A

15 (.59) ø43.89 (1.73Dia) ø114 max. (max. 4.49 Dia)

Rotation

31.75 (1.25)

77 (3.03)

B

ø152.4 -0.05 (6 Dia) (+.000)

147.1 (5.79) Port L1 77 (3.03)

168.5 (6.63)

Port S: Charge pump inlet 1-5/8-12UN-2B

"W"

Coupling may not protrude beyond this surface

66.68 (2.63)

184.5 (7.26)

Gauge port M2 System pressure B 9/16-18UNF-2B

53.85 (2.12) 71.35 (2.81)

178.6 (7.03)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 373E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 130 (Continued) Continued Figure 43: Auxiliary Mounting Pad - Options A, B, C, D, V

mm (in.)

View "X"

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 22.4 (.88)

"X"

106.375 (4.188)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

(- .000)

SAE A, Option A

4 Threads 3/8-16UNC-2B 8 (.31) deep

15.6 (.61)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

400.89 (15.78)

106.375 (4.188)

414.56 (16.32)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

146 (5.75)

"X"

View "X" SAE B, Option B

(- .000)

+ 0.13

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 28.77 (1.1)

4 Threads 1/2-13UNC-2B 22 (.87) deep

18.2 (.72) 408 (16.06)

146 (5.75)

425.65 (16.76)

View "X"

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.97 (1.18) (- .000)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

114.5 (4.51)

+ 0.13

ø127.03 0 (5.001 Dia) (+.005)

"X"

SAE C, Option C

6 Threads 1/2-13UNC-2B 22 (.87) deep

31.4 (1.24) 411.05 (16.18) 427.75 (16.84)

114.5 (4.51) 181 (7.13)

P001 374E

49

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 130 (Continued) mm (in.)

Continued Figure 43: Auxiliary Mounting Pad - Options A, B, C, D, V View "X"

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.22 (.993)

"X"

161.6 (6.36)

+ 0.13

ø152.45 0 (6.002 Dia) (+.005)

(- .000)

SAE D, Option D

4 Threads 3/4-10UNC-2B 41 (1.6) deep

50.84 (2.00)

for O-Ring ø153 x 3.0 (6.02 Dia x 0.118)

415.62 (16.36)

161.6 (6.36)

439.22 (17,29)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.59 (.96)

4 Threads 1/2-13UNC-2B 22 (.87) deep

23.3 (.92) 408 (16.06)

146 (5.75)

425.65 (16.76) P001 375E

50

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Notes

51

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 Figure 44: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

View "Z"

"Y"

Control MDC, Option MA

Splined Shaft Option F1

B

201.5 (7.93)

length of full spline

42.5 (1.67)

Rotation

66.68 (2.63) Approx center of gravity

20 (.79)

186 (7.32) Port L2

200 (7.87) 321 (12.64) 326 (12.83)

Gauge port M1 System pressure A 9/16-18UNF-2B

Gauge port M4 Servo pressure 9/16-18UNF-2B

7.9 (.31)

42.5 (1.67)

0

(-.002)

View "X"

Charge Pressure Relief Valve

Splined Shaft Option C8 Multifunction Valve

56 (2.20)

138 (5.43)

108 Gauge port M5 (4.25) Servo pressure 9/16-18UNF-2B 228 (8.97)

Approx center of gravity

56 (2.20) Port L2 112.25 (2x) Case drain (4.42) 1-5/8-12UN-2B 224.5 (2x) (8.84)

length of full spline

Gauge port M3 Charge pressure 9/16-18UNF-2B

ø39 (1.54 Dia) Port L1 Case drain use highest port as outlet 1-5/8-12UN-2B

ø20.6 (.81 Dia)

Coupling may not protrude beyond this surface

ø44.35 (1.75 Dia)

View "Y"

"Z"

SHAFT SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

66.68 (2.63)

CW

143 (5.63) 142 (5.59) Port L2

15.5 ±0.25 (.61) (±.01)

ø165.1 -0.05 (6.5 Dia) (+.000)

31.75 (1.25)

93 (3.66)

Ports A and B 1- 1/4 -6000 psi Split Flange Boss per SAE J518 (Code 62) 1/2-13UNC-2B 23 (.906) min. Full Thread

ø34.04 (1.34 Dia)

A

12 (.47) ø43.89 (1.73Dia) ø114 max. (max. 4.49 Dia)

195 (7.68)

CCW

93 (3.66)

204 (8.03)

7.9 (.31)

181 (7.13) Port L1

"X"

"W"

Coupling may not protrude beyond this surface

66.68 (2.63) Port S: Charge pump inlet 1-5/8-12UN-2B

177 (6.97)

160 (6.30)

9.4 (.37)

Gauge port M2 System pressure B 9/16-18UNF-2B

mm (in.)

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 42.8625 (1.6875) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

View "W"

398 (15.67)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

Null position

"A" Max. Displacement

30° min.

"B"

30° min.

Max. Displacement

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

52

191 (7.52)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 376E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 (Continued) mm (in.)

Continued Figure 44: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

106.375 (4.188)

"X"

View "X" SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 17.8 (.70)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

4 Threads 3/8-16UNC-2B 17.8 (.70) deep

15 (.59) 429.3 (16.90)

106.375 (4.188)

442.9 (17.44)

View "X" SAE B, Option B

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.5 (1.16)

4 Threads 1/2-13UNC-2B 22 (.87) deep

17.5 (.69) 436.4 (17.18)

146 (5.75)

454.1 (17.88)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 22.1 (.87)

6 Threads 1/2-13UNC-2B 22 (.87) deep

30.5 (1.20) 439.4 (17.30) 456.1 (17.96)

114.5 (4.51) 181 (7.13)

P001 388E

53

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 (Continued) mm (in.)

Continued Figure 44: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

View "X"

A

161.6 (6.36)

(- .000)

+ 0.13

"X"

ø152.45 0 (6.002 Dia) (+.005)

B

SAE D, Option D

for O-Ring ø153 x 3.0 (6.02 Dia x 0.118)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

49.9 (1.96) 448.1 (17.64) 464.8 (18.30)

View "X" SAE E, Option E

224.5 (8.84)

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

"X"

46.5 (1.83)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

473.1 (18.63)

View "X" SAE H, Option H

224.5 (8.84) 46.5 (1.83)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

448.1 (17.64) 473.1 (18.63)

54

224.5 (8.84)

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

448.1 (17.64)

COUPLING SPLINE DATA: Pitch Dia = 42.862 (1.687) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 28.5 (1.12)

"X"

161.6 (6.36)

224.5 (8.84)

P001 469E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 (Continued) mm (in.)

Continued Figure 44: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.49 (.96)

4 Threads 1/2-13UNC-2B 22 (.87) deep

22.6 (.89) 436.4 (17.18)

146 (5.75)

454.1 (17.88)

P001 469E/1

55

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 mm (in.)

Figure 45: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

View "Z"

"Y" 9.4 (.37)

Control MDC, Option MA

length of full spline

42.5 (1.67)

Splined Shaft Option F1

B

201.5 (7.93)

212 max.

(8.35)

7.9 (.31)

Rotation

341 (13.43)

Ports A and B 1- 1/2 - 6000 psi Split Flange Boss per SAE J518 (Code 62) 5/8-11UNC-2B, 25 (.98) min.

Full Thread

331 (13)

210 (8.27)

(-.002)

0

"Z"

SHAFT SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Gauge port M4 Servo pressure 9/16-18UNF-2B

7.9 (.31)

56 (2.20)

Coupling may not protrude beyond this surface

System pressure B 9/16-18UNF-2B

Multifunction Valve

56 (2.20) 108 Gauge port M5 (4.25) Servo pressure 9/16-18UNF-2B 228 (8.98)

Charge Pressure Relief Valve

Splined Shaft Option C8

136 (5.35)

M2

Approx center of gravity

56 (2.20) Port L2 112.25 (2x) Case drain (4.42) 1-5/8-12UN-2B 224.5 (2x) (8.84)

length of full spline

Gauge port M3 Charge pressure 9/16-18UNF-2B

ø39 (1.54 Dia)

Port L1 Case drain use highest port as outlet 1-5/8-12UN-2B

ø20.6 (.81 Dia)

View "X" Gauge port M2 66.68 (2.63)

ø44.35 (1.75 Dia)

View "Y"

20 (.79)

186 (7.32) Port L2

79.38 (3.13) Approx center of gravity

CW

143 (5.63) 142 (5.59) Port L2

15.5 ±0,25 (.61) (±.01)

ø165.1 -0.05 (6.5 Dia) (+.000)

ø34.04 (1.34 Dia)

12 (.47) ø43.89 (1.73Dia) ø114 max. (max. 4.49 Dia)

69.85 (2.75) A

36.5 (1.44)

Port S: Charge Pump Inlet 1- 1/2 3000 psi Split Flange Boss per SAE J518 (Code 61) 1/2-13UNC-2B 24 (.94) min.

Full Thread

185.5 (7.30)

35.71 (1.41)

98 (3.86)

CCW

98 (3.86)

181 (7.13) Port L1

"X"

"W"

Coupling may not protrude beyond this surface

66.68 (2.63)

SHAFT SPLINE DATA: Pitch Dia = 42.8625 (1.6875) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

419 (16.5)

Multifunction Valve

Gauge port M10 Charge Pump Inlet 9/16-18UNF-2B

Gauge port M1 System pressure A 9/16-18UNF-2B

View "W"

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

Null position

"A" Max. Displacement

30° min.

"B"

30° min.

Max. Displacement

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

56

191 (7.52)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 465E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 (Continued) mm (in.)

Continued Figure 45: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

106.375 (4.188)

"X"

View "X" SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 17.8 (.70)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

4 Threads 3/8-16UNC-2B 17.8 (.70) deep

15 (.59) 450.30 (17.73)

106.375 (4.188)

463.90 (18.26)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.5 (1.16)

17.5 (.69)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

4 Threads 1/2-13UNC-2B 22 (.87) deep

457.4 (18.01)

146 (5.75)

475.1 (18.70)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 22.1 (.87)

6 Threads 1/2-13UNC-2B 22 (.87) deep

30.5 (1.20) 460.4 (18.13) 477.1 (18.78)

114.5 (4.51) 181 (7.13)

P001 466E

57

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 (Continued) Continued Figure 45: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

161.6 (6.36)

"X"

View "X" SAE D, Option D

(- .000)

+ 0.13

ø152.45 0 (6.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

for O-Ring ø153 x 3.0 (6.02 Dia x 0.118)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

49.9 (1.96) 469.1 (18.47)

224.5 (8.84) 494.1 (19.45)

SAE H, Option H

224.5 (8.84) 46.5 (1.83)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

469.1 (18,47) 494.1 (19.45)

58

224.5 (8.84)

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

469.1 (18,47)

COUPLING SPLINE DATA: Pitch Dia = 42.862 (1.687) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 28.5 (1.12)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

View "X"

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

SAE E, Option E

46.5 (1.83)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

"X"

161.6 (6.36)

485.8 (19.13)

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

"X"

mm (in.)

224.5 (8.84)

P001 467E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 (Continued) Continued Figure 45: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V View "X"

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.00 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.49 (.96)

mm (in.)

4 Threads 1/2-13UNC-2B 22 (.87) deep

22.6 (.89) 457.4 (18.01)

146 (5.75)

475.1 (18.70) P001 467E/1

59

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Controls, Displacement Limiter Figure 46: Cover Plate

C2

Option CA

View "W"

C1

C4 max.

C3

C1

C4 max.

Port M4

Displacement Limiter Option 4 Limitation both sides

Ports: M4, M5 = Servo Pressure 9/16-18UNF-2B O-Ring Boss

Port M5

"W"

P001 363E

Table 22: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100

C1 63.5 (2.50) 67.9 (2.67) 69.2 (2.72) 74.2 (2.92) 83.3 (3.28)

C2 140.5 (5.53) 129.5 (5.10) 179.4 (7.06) 185.7 (7.31) 183.3 (7.22)

C3 95.5 (3.76) 99.5 (3.92) 103.6 (4.08) 109.4 (4.31) 118.3 (4.66)

C4 max. [Option 4] 106 (4.17) 108 (4.25) 114 (4.48) 118 (4.65) 136 (5.35)

130 180 250

86.6 (3.41) -

209.3 (8.24) -

137.2 (5.40) -

141 (5.55) 184 (7.24) 184 (7.24)

Figure 47: 3-Position (FNR) Electric Control

View "W"

C5.2

C5 max.

C5.1

a

Option DC & DD

b

P001 399E

Table 23: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100 130 (Option DC only) 60

"W"

C5 max.

190.5 (7.50) 194.5 (7.66) 198.6 (7.82) 204.4 (8.05) 213.3 (8.40) 232.2 (9.14)

C5.1 110.2 (4.34) 110.2 (4.34) 110.2 (4.34) 110.2 (4.34) 101.6 (4.00) 116.6 (4.59)

C5.2 112.8 (4.44) 112.8 (4.44) 112.8 (4.44) 112.8 (4.44) 121.4 (4.78) 106.4 (4.19)

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Controls (Continued) Figure 48: Electric Displacement Control (EDC) with MS-Connector or Packard-Connector View "W"

C7

C6

C6

PackardConnector Option EP

Port X2

P001 403E

"W"

Frame Size 030 and 042 only

C7 (frame size 030 and 042 only)

Option KA & KP

Port X1

Ports: X1, X2 = 9/16-18UNF-2B O-Ring Boss

Table 24: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100

C6 95.3 (3.75) 95.3 (3.75) 95.3 (3.75) 105.2 (4.14) 114.0 (4.49)

C7 173.5 (6.83) 173.5 (6.83) 141.2 (5.56) 144.8 (5.70) 153.7 (6.05)

130 180 / 250

99.1 (3.90) 93.4 (3.68)

172.7 (6.80) 190.0 (7.48)

Figure 49: Hydraulic Displacement Control (HDC) C12

Port X1 Port X2

View "W"

Option HF

C8.1 (port X2)

C8.2 (port X1)

C10

C9

C11

Ports: X1, X2 = Control Pilot Pressure 9/16-18UNF-2B, O-Ring Boss

P001 372E

"W"

Table 25: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100 130 180 / 250

C8.1 135.0 (5.31) 139.0 (5.47) 143.0 (5.63) 148.9 (5.86) 158.0 (6.22) 176.7 (6.95) 194.0 (7.63)

C8.2 131.0 (5.15) 135.0 (5.31) 139.0 (5.47) 139.9 (5.50) 149.0 (5.86) 167.7 (6.60) 185.0 (7.28)

C9 71.0 (2.79) 71.0 (2.79) 71.0 (2.79) 68.2 (2.68) 76.8 (3.02) 61.8 (2.43) 54.0 (2.12)

C10 75.7 (2.98) 75.7 (2.98) 75.7 (2.98) 67.0 (2.63) 67.0 (2.63) 67.0 (2.63) 67.0 (2.63)

C11 77.6 (3.05) 89.6 (3.52) 105.6 (4.15) 121.8 (4.79) 127.9 (5.03) 142.1 (5.59) 148.6 (5.85)

C12 87.2 (3.43) 99.2 (3.90) 115.2 (4.53) 125.3 (4.93) 131.4 (5.17) 145.6 (5.73) 152.1 (5.99) 61

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Controls (Continued) Figure 50: Manual Displacement Control (MDC) with Neutral Start Switch C13

View "W"

C14

Option MB

Neutral Start Switch

P001 364E

"W"

Table 26: Dimensions [mm (in.)]

Frame Size 042 055 075

~ C13 0.4 (.016) 18.0 (.71) 25.0 (.98)

C14 96.0 (3.78) 100.0 (3.94) 106.9 (4.21)

100

31.0 (1.22)

115.8 (4.56)

130

45.0 (1.77)

134.5 (5.29)

180 250

52.0 (2.04) 52.0 (2.04)

151.8 (5.97) 151.8 (5.97)

Figure 51: Non-Linear Manual Displacement Control (MDC) "V" Option NA

View "W"

View "V"

R 50.8 (R 2.0)

"A" P001 404E

"W"

Max. Displacement

31° min.

Null position

31° min.

Max. Displacement

"B"

C15

Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in)

R 26.4 (R 1.04) ø8.26 2x (.325 Dia)

Table 27: Dimensions [mm (in.)]

Frame Size 075 100 130

62

C15 178.9 (7.04) 187.8 (7.39) 206.7 (8.14)

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Filtration Figure 52: Integral Pressure Filter View "X"

Option P & L

Gauge port M6 Charge pressure before filter 9/16-18UNF ø 94.2 max. (max. 3.71 Dia)

180°

"X"

180° Gauge port M3 Charge pressure after filter 9/16-18UNF

Required for removal

20.3 min. (.80 min.)

22.86 (.90)

F1 = short filter cartridge (Option P) F2 = long filter cartridge (Option L)

F4 max.

Frame Size030 - 130 = Option P Frame Size042 - 250 = Option L

F3

Figure 53: Remote Pressure - without filter View "X"

Option R & T

Port E from filter 7/8-14UNF (Option R) 1 1/16 -12UN (Option T)

5.6 (.22)

180°

5,6 (.22)

"X" 180°

Port D to filter 7/8-14UNF (Option R) 1 1/16 -12UN (Option T)

Gauge port M3 Charge pressure after filter 9/16-18UNF

F5 max.

F6 max.

Frame Size030 - 130 = Option R Frame Size180 + 250= Option T

F7 max.

28.5 (1.12) F3 P001 357E

Table 28: Dimensions [mm (in.)]

Frame Size

F1

F2

F3

F4 max.

F5 max.

F6 max.

F7 max.

030

174.5 (6.87)

-

176.8 (6.96)

203.0 (7.99)

107.7 (4.24)

147.7 (5.81)

163.0 (6.42)

042

174.5 (6.87) 262.6 (10.34) 201.4 (7.93)

208.0 (8.19)

112.7 (4.44)

152.7 (6.01)

168.0 (6.61)

055

174.5 (6.87) 262.6 (10.34) 240.9 (9.48)

209.6 (8.25)

114.3 (4.50)

154.3 (6.07)

169.6 (6.68)

075

174.5 (6.87) 262.6 (10.34) 270.5 (10.65) 214.4 (8.44)

119.1 (4.69)

159.1 (6.26)

174.4 (6.86)

100

174.5 (6.87) 262.6 (10.34) 280.7 (11.05) 223.0 (8.78)

127.7 (5.03)

167.7 (6.60)

183.0 (7.20)

130

174.5 (6.87) 262.6 (10.34) 299.9 (11.81) 233.0 (9.17)

137.7 (5.42)

177.7 (6.99)

193.0 (7.60)

180

-

-

327.8 (12.90)

-

182.0 (7.16)

236.8 (9.32)

259.2 (10.2)

250

-

-

342.8 (13.49)

-

182.0 (7.16)

236.8 (9.32)

259.2 (10.2) 63

CONTENTS

saue Hydraulic Power Systems SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide SAUER-SUNDSTRAND is a world leader in the design and manufacture of Hydraulic Power Systems. Research and development resources in both North America and Europe enable SAUER-SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology.

SAUER-SUNDSTRAND specializes in integrating a full range of system components to provide vehicle designers with the most advanced total-design system.

SAUER-SUNDSTRAND is Your World Source for Controlled Hydraulic Power Systems.

F000 691

F000 692

Heavy Duty Axial Piston Pumps and Motors

Heavy Duty Bent Axis Variable Motors F000 685 F000 688

Medium Duty Axial Piston Pumps and Motors

Cartridge Motors/ Compact Wheel Drives F000 690

Microcontrollers and Electrohydraulic Controls F000 689

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F000 686

F000 684

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F000 693

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Worldwide Service Support SAUER-SUNDSTRAND provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world.

Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.

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SAUER-SUNDSTRAND COMPANY 2800 East 13th Street Ames IA 50010 • U.S.A. Phone: (515) 239-6000 • FAX: (515) 239-6618

SAUER-SUNDSTRAND GMBH & CO. Postfach 2460 • D-24531 Neumünster Krokamp 35 • D-24539 Neumünster • Germany Phone: (04321) 871-0 • FAX: (04321) 871 122