DOWNLOAD PDF CAT Feeder Breaker 54-2180 Operation & Maintenance Manual BI629484

Operation Manual Bucyrus Feeder Breaker Model 7MFBM-48DD S/N 54-2180 Doc. No.: A6474X293

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 7MFBM-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..............................................2.23

3. Storage and transport Storage and transport ............................................................ 3.3 Storage ................................................................................ 3.3 Storage of the machine and spare parts......................... 3.3 Transport.............................................................................. 3.4 Load units, dimensions, and weights.............................. 3.4 Before transport .............................................................. 3.5

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

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VIVI/01

Table of contents _________________________________________________

Operation ................................................................................. 5.3 How to operate the feeder breaker ..................................... 5.3 Who is allowed to operate the feeder breaker ............... 5.3 When can conveying be started? ................................... 5.3 Controls and indicators ........................................................ 5.4 Operator’s station............................................................ 5.4 Control console ..............................................................5.11 VFD screens .............................................................5.12 VFD Bypass ........................................................................5.21 Starter enclosure.................................................................5.22 Fire suppression .................................................................5.23 Starting procedure ..............................................................5.25 Tramming............................................................................5.27 Conveyor motor start - forward ...........................................5.28 Conveyor motor start - reverse ...........................................5.30 Shutdown (tram/breaker motor)..........................................5.32 Conveyor motor stop - forward ...........................................5.34 Electrical system .................................................................5.37 Electrical component locator..........................................5.38 Electrical component layout ...........................................5.39 Control console ..............................................................5.40 Starter enclosure............................................................5.42 Variable frequency drive enclosure ...............................5.52 Belt slip/sequence board................................................5.52 Major electrical components ..........................................5.53 Electrical schematic .......................................................5.54 Interconnection diagram ................................................5.55 Hydraulic system.................................................................5.57 Hydraulic component locator .........................................5.58 Major hydraulic components .........................................5.59 Hydraulic schematic.......................................................5.61 Mechanical assemblies.......................................................5.63 Head shaft......................................................................5.63 Tail shaft.........................................................................5.64 Breaker shaft..................................................................5.65 Breaker power unit.........................................................5.66 Conveyor power unit ......................................................5.67 Conveyor chain .............................................................5.68 Crawler assemblies........................................................5.69 Roof anchor assembly ...................................................5.70 Outrigger (stabilizer) assembly ......................................5.70 Tailpiece.........................................................................5.71 Instructions on the maintenance of the feeder ..................5.73 Important notes .............................................................5.73 Before maintenance ......................................................5.73 Lubrication and inspection ............................................5.74 Specific lubrication and maintenance procedures ........5.78 Every 8 hours of operation .......................................5.78 Weekly .....................................................................5.81 Monthly .....................................................................5.85 Every 2500 hours (6 months)....................................5.88

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker

Bucyrus America, Inc.

5. Operation

________________________________________________ Table of contents Inspection of the feeder ..................................................... 5.93 Inspection of wear parts on the feeder .............................. 5.94 Inspection of the fire suppression system .......................... 5.95 Recharge of the fire suppression system........................... 5.97 Instructions on the adjustment procedures ....................... 5.99 Conveyor chain adjustment .......................................... 5.99 Crawler track adjustment .............................................. 5.101 Primary valve bank relief pressure setting .................... 5.103 Instructions on the replacement of wear parts .................. 5.107 Head shaft .................................................................... 5.107 Head shaft sprockets .................................................... 5.110 Tail shaft ....................................................................... 5.113 Conveyor chain ............................................................. 5.118 Crawler track ................................................................ 5.121 Crawler assembly ......................................................... 5.124 Conveyor power unit...................................................... 5.131 Breaker assembly.......................................................... 5.140 Breaker bit ..................................................................... 5.144 Breaker power unit ........................................................ 5.145 Tailpiece ........................................................................ 5.153 Troubleshooting.................................................................. 5.159 © Bucyrus America, Inc.

6. Technical data Technical data ......................................................................... 6.3 Components of the feeder breaker ...................................... 6.3 Tightening torques................................................................ 6.8 Permissible data ................................................................. 6.11 Lubrication fluids and greases....................................... 6.11

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

________________________________________________________________ A6474X293

VIVI/01

Bucyrus America, Inc.

Table of contents _________________________________________________

_________________________________________________________________ BUC – Model 7MFBM-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: 7MFBM-48DD Feeder Serial No.: 54-2180 and is only permitted to be used for equipment of this type.

© Bucyrus America, Inc.

new operation manual

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

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

Who is this operating manual intended for?

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

This includes persons who: ■

are in charge of transport

■

perform assembly/disassembly work

■

operate the machine

■

eliminate faults

■

perform daily routine work on the face or in the entry

■

perform maintenance work

■

perform repair work

supervisory personnel who: ■

initiate and/or supervise the activities just indicated.

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

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

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

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

safety

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

© Bucyrus America, Inc.

service

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder 1.4

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

Try to memorize the symbols and their meanings.

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

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

© 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.

______________________________________________________________ A6474X293 VIVI/01 1.5

© Bucyrus America, Inc.

Before starting to work ________________________________________

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder 1.6

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2

Your safety

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__________________________________________________ Personnel

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

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

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

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

© Bucyrus America, Inc.

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

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine,

■

of the mine inspector, and

■

of the mining supervisory authorities.

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

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Personnel ___________________________________________________ Personnel Operation training

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

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

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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

Installation and repair work on ■

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

■

the electrics (motors, controllers, etc.), and

■

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.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder 2.4

© Bucyrus America, Inc.

Installation and repair

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

Intended uses include: ■

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

Unauthorized use

© Bucyrus America, Inc.

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

■

the transport of persons

■

the transport of objects of any kind (such as 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 __________________________________________

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 2.6

___________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

Inform your colleagues of:

© Bucyrus America, Inc.

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 acoustic and optical start-up warnings of the machine.

symbol plates emergency stop (panic strip)

lock-out

cordon off working area

Observe the symbol plates on the machine.

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

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

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

______________________________________________________________ A6474X293 VIVI/01 2.7

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

conveyor chains

■

flights

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pivot points

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boom assemblies

■

crawler assemblies

■

breaker shaft assemblies

© Bucyrus America, Inc.

moving parts

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 2.8

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

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

© Bucyrus America, Inc.

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.

______________________________________________________________ A6474X293 VIVI/01 2.9

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

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

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

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

Maintenance and repair

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

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

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

Protect your work area against falling rocks.

replacing components

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

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

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original 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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 2.10

© 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 the safety procedures of each particular mine when performing maintenance.

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

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

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

the hoses are not pinched or trapped,

■

the hoses have no bubbles or blisters,

■

the hose or outer sheaths of the hose are not abnormally rigid or hard,

■

the outer sheaths of the hoses are not damaged,

■

the connectors are securely inserted into the sockets, and

■

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 to 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.

______________________________________________________________ A6474X293 VIVI/01 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.

Never try to repair damaged hydraulic hoses.

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

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting Right

Wrong

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 2.12

© Bucyrus America, Inc.

Replace hydraulic hoses at the first suspicion of damage.

___________________________________________ Safety instructions ■

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

Fig. 3: Laying hydraulic hoses, bending Right

■

Wrong

cannot chafe.

Fig. 4: Laying hydraulic hoses, crossing

© Bucyrus America, Inc.

Right

■ ■ ■ ■

Wrong

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

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

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

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

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

© Bucyrus America, Inc.

Right

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 2.14

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

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

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

© Bucyrus America, Inc.

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

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

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

Use only suitable load handling devices.

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

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

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

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

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

______________________________________________________________ A6474X293 VIVI/01 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! 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.

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.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 2.16

© Bucyrus America, Inc.

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

________________________________ Overview of safety instructions NOTICE! All valve bank handles are spring loaded/center return with the exception of the far right valve bank section that operates the oil tank jet fill and flow diversion to the secondary valve bank. Spring loaded/center return means the valve bank handle will return to the neutral position when released and the hydraulic function will stop.

WARNING! Before operating either tram control lever, ensure that all personnel are completely clear of the machine, that the roof anchors are completely retracted, the trailing cable has sufficient slack, and that the conveyor and the breaker have been turned off.

© 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.

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

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.

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

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

IMPORTANT! Setting changes (Screens 2, 3, 4, and 8) can only be made when the machine is not running (breaker and conveyor motors off).

Changes can only be made by a qualified person with proper password clearance.

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.

______________________________________________________________ A6474X293 VIVI/01 2.17

Overview of safety instructions _________________________________ IMPORTANT! The machine will not start if the primary valve bank levers are not in the neutral position and the neutral start mechanism is not engaged (covering the levers so that they cannot be moved from the neutral position).

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

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 must be taken to ensure that the operator’s feet do not get under the crawler tracks while the feeder breaker is moving.

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

IMPORTANT! The tram/breaker motor does not have to be running for the conveyor to start in the reverse direction.

IMPORTANT! The conveyor will only run in reverse as long as the start button is held in (there is no holding circuit). Once the button is released, the conveyor motor will shutdown.

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 to clean out the return line before shutting the machine down.

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

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 2.18

© Bucyrus America, Inc.

WARNING! Before operating either tram control lever, ensure that all personnel are completely clear of the machine, that the roof anchors are completely retracted, that the trailing cable has sufficient slack, that not electrical or water lines are in the path of travel, and that the conveyor has been turned off.

________________________________ Overview of safety instructions 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.

© Bucyrus America, Inc.

WARNING! The frame lift and tilt cylinders have counterbalance valve cartridges which serve as load holding valves. DO NOT replace these cylinders with different style cylinders or the machine may fall.

You or other personnel could be seriously injured or killed by the falling machine or the machine could be damaged.

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.

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

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

WARNING! 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! 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.

______________________________________________________________ A6474X293 VIVI/01 2.19

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

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

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

CAUTION! A special button head grease fitting is installed in the electric motor and gear reducer shaft lubrication central manifolds for the purpose of preventing over greasing by the mechanic. The special grease button fitting requires the proper grease gun adapter in order to transfer grease. Do not replace the button head grease fitting with a standard grease fitting or machine damage may occur.

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.

CAUTION! Do not cut holes in or remove the fill cap strainer. If the strainer is missing or damaged, the hydraulic component warranty will be voided.

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

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

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

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 2.20

© Bucyrus America, Inc.

CAUTION! Each grease line for the breaker and conveyor electric motors and reducers may have to be purged of air before the first use.

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

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

DANGER! 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.

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

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

© 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.

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 to perform this adjustment as it is unsafe. Failure to adhere to this warning 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 valve handle from the same half of the valve bank as the pressure relief valve is being operated. To resolve this issue, ensure that the valve bank function is from the same half of the valve bank as the relief pressure adjustment screw.

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

CAUTION! The feeder tailpiece or a roof anchor cylinder will move during this step and it must be ensured that all standard safety procedures are adhered to avoid personnel injury and equipment damage.

______________________________________________________________ A6474X293 VIVI/01 2.21

Overview of safety instructions _________________________________ 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 valve handle from the same half of the valve bank as the pressure relief valve is being operated. To resolve this issue, ensure that the valve bank function is from the same half of the valve bank as the relief pressure adjustment screw.

NOTICE! It is not necessary to remove the conveyor power unit in order to remove the headhsaft.

IMPORTANT! Adhere to all weld specifications shown on Fig. 100. Failure to do so may result in sprocket failure and machine damage.

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

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

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

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

IMPORTANT! The breaker shaft assemlby floats left to right. Do not alter the pivot mount lugs if, during assembly, alignment is difficult.

Simply shift the breaker shaft until alignment is obtained.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 2.22

© Bucyrus America, Inc.

CAUTION! The feeder tailpiece or a roof anchor cylinder will move during this step and it must be ensured that all standard safety procedures are adhered to avoid personnel injury and equipment damage.

________________________________ Overview of safety instructions CAUTION! An approximate 5/16” gap must be observed per Fig. 118 in order for the element to expand under loading conditions. Failure to have this gap will result in accelerated element failure.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures may require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all electrical work performed.

© Bucyrus America, Inc.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall. Machine damage or injury to personnel may result.

WARNING! Never check for hydraulic leaks with your hands. Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Do not attempt to locate hydraulic leaks by feeling around hoses and fittings with bare hands. Check for leaks with a piece of cardboard.

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

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

NOTICE! Use only lubrication fluids and greases approved by 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.

______________________________________________________________ A6474X293 VIVI/01 2.23

Overview of safety instructions _________________________________ 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.

© Bucyrus America, Inc.

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 2.24

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3

Storage and transport

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________________________________________________________________

_________________________________________________________________

________________________________________ Storage and transport

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

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

Storage corrosion protection

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

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

Storage of the machine and spare parts

© Bucyrus America, Inc.

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.

______________________________________________________________ A6474X293 VIVI/01 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.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder 3.4

© 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 (11’ 10” W X 36’ 6-1/2” L X 6’ 8” H),

■

weight (110,000 lbs), and

■

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.

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.

______________________________________________________________ A6474X293 VIVI/01 3.5

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

Lift point

© Bucyrus America, Inc.

Lift point

Lift point Lift point

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder 3.6

________________________________________ 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 are taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

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

© Bucyrus America, Inc.

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 suitable packaging.

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

______________________________________________________________ A6474X293 VIVI/01 3.7

© Bucyrus America, Inc.

Storage and transport _________________________________________

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder 3.8

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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.

© Bucyrus America, Inc.

Work on: ■

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

■

the electrical equipment (control units, signaling devices, etc.), and

■

the hydraulic equipment (cylinders, directional control valves, hoses etc.)

should only be carried out by 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

______________________________________________________________ A6474X293 VIVI/01 4.3

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder 4.4

__________________________________________________ Installation Pre-installation check list

© Bucyrus America, Inc.

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

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

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

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

■

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

■

check tension of conveyor chain

■

check the condition on fire suppression system (if equipped)

■

check that the tail shaft cover plate (if equipped) is in place and that the bolts are tight

■

check that the power unit shrouds and guards are in place

■

on the power units: ■ check the flange coupling hub to shaft bolts ■ check the electric motor to connecting tube bolts ■ check the gear box to connecting tube bolts

■

check the head shaft bearing retainer bolts

■

check the breaker shaft bolts

■

on the crawlers: ■ check the retainer bolts on the vertical guide retainers on the lift guide weldment ■ check the bolts on the side plate

■

jog the breaker motor to check for correct rotation of breaker

■

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

■

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

■

check the operation of the remote start pushbuttons

■

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

■

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

■

check hydraulic system pressures (see the hydraulic schematic in the Bucyrus parts book for your machine)

■

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

______________________________________________________________ A6474X293 VIVI/01 4.5

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

emergency stop pull cord switch

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

guards and covers

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

DANGER! Do not operate the machine with any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts.

“STOP CONV./BKR.” stop switch

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

fire suppression

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

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

neutral start mechanism

The feeder breaker 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.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder 4.6

© Bucyrus America, Inc.

Safety features include: (Reference Fig. 7)

__________________________________________________ Installation Fig. 7: Safety features on the feeder breaker Fire suppression actuator

© Bucyrus America, Inc.

“STOP CONV/ BKR” button

Emergency pull cord

Neutral start mechanism

Stop button

Fire suppression actuator

______________________________________________________________ A6474X293 VIVI/01 4.7

Installation___________________________________________________ Fig. 8: Overview of the feeder breaker Anchor arm (2)

Control case)

Tailpiece assembly © Bucyrus America, Inc.

Operator’s station

Conveyor power unit

Stabilizer (foot) cylinder (2)

Breaker power unit

Crawler assembly (typical both sides)

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder 4.8

__________________________________________________ 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.

To tow the feeder breaker proceed as follows:

© Bucyrus America, Inc.

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 retain 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.

______________________________________________________________ A6474X293 VIVI/01 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 retain 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.

© Bucyrus America, Inc.

Fig. 9: Torque hub disengagement

Retaining bolts (2)

Normal tram position

End cap button pointing outward

Retaining bolts (2)

End cap button pointing inward Freewheel position

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder 4.10

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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. It also includes instructions on the replacement of wear parts. Read this chapter carefully and thoroughly. In particular, observe the safety instructions in Chapter 2 “Your safety”.

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

© Bucyrus America, Inc.

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.

______________________________________________________________ A6474X293 VIVI/01 5.3

Operation____________________________________________________ Controls and indicators Operator’s station The primary controls for the machine are located over the crawler on the left hand side of the machine. The operator’s station (Fig. 10) consists of the following controls and indicators: two primary valve banks, main system pressure gauges, control console, panic bar, and fire suppression actuator.

NOTICE! All valve bank handles are spring loaded/center return with the exception of the far right section of the primary valve bank that operates the oil tank jet fill and flow diversion to the secondary valve bank. Spring loaded/center return means the valve bank handle will return to the neutral position when released and the hydraulic function will stop.

Fig. 10: Operator’s station Main system pressure gauges

Emergency stop button

Secondary valve bank

Primary valve bank

Power fill ball valve

© Bucyrus America, Inc.

Control console

Fire suppression actuator

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.4

___________________________________________________Operation Primary valve bank

© Bucyrus America, Inc.

The primary valve bank (Fig. 11) consists of the following hydraulic controls: “FRAME TILT”

The first lever from the operator’s left controls the movement of the cylinders mounted to the underside of 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.

“LH FRAME LIFT”

The second 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.

WARNING! Before operating either tram control lever, ensure that all personnel are completely clear of the machine, that the roof anchors are completely retracted, the trailing cable has sufficient slack, and that the conveyor and the breaker have been turned off.

“LEFT TRAM”

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

“RIGHT TRAM”

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

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

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

______________________________________________________________ A6474X293 VIVI/01 5.5

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

“RH FRAME LIFT”

The fifth 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.

“TANK FILL/AUX VB”

The sixth lever from the operator’s left has two (2) functions, it controls oil flow for the power fill function and to the secondary valve bank. See the procedure below to operate the power fill. To de-energize the 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.

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.

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

Turn the handle of the ball valve that is attached to the power fill motor 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 sucked thru the power fill motor and fill the hydraulic system oil tank.

Once the tank is filled to desired level, pull power fill lever on valve bank to 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 and store suction hose on top of the oil tank.

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.6

© 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.

___________________________________________________Operation Fig. 11: Primary valve bank “FRAME TILT”

“LH FRAME LIFT”

“LEFT TRAM”

“RIGHT TRAM”

“RH FRAME LIFT”

“TANK FILL/ AUX VB”

© Bucyrus America, Inc.

Neutral start mechanism

neutral start mechanism

The neutral start mechanism is a guard that covers the primary valve bank levers, while in neutral position, during start-up (see Start-up procedure in this chapter). The guard must be in place in order for the conveyor electric motor to start.

power fill ball valve

The power fill ball valve (Fig. 12) is located on the left hand side at the operator’s station and is used to control the flow of hydraulic fluid from the power fill pump.

Fig. 12: Power fill ball valve Power fill ball valve

______________________________________________________________ A6474X293 VIVI/01 5.7

Operation____________________________________________________ Secondary valve bank The secondary valve bank (Fig. 13) consists of the following hydraulic controls:

“RH ROOF”

The first lever from the operator’s left controls the movement of the left roof anchor assembly. To raise the roof anchor, slowly push the control lever away from the operator. To lower the roof anchor, slowly pull the control lever towards the operator.

The second lever from the operator’s left controls the movement of the right roof anchor assembly. To raise the roof anchor, slowly push the control lever away from the operator. To lower the roof anchor, slowly pull the control lever towards the operator.

“LH FOOT”

The third lever from the operator’s left controls the movement of the left foot cylinder. To lower the foot, slowly push the control lever away from the operator. To raise the foot, slowly pull the control lever towards the operator.

“RH FOOT”

The fourth lever from the operator’s left controls the movement of the right foot cylinder. To lower the foot, slowly push the control lever away from the operator. To raise the foot, slowly pull the control lever towards the operator.

“TAIL STEER”

The fifth lever from the operator’s left controls the direction of the tailpiece. To move the tailpiece away from the operator, push the control lever away from the operator. To move the tailpiece toward the operator, pull the control lever toward the operator.

“TAIL TILT”

The sixth lever from the operator’s left tilts the tailpiece up or down. To tilt the tailpiece up, push the control lever away from the operator. To tilt the tailpiece down, pull the control lever toward the operator.

Fig. 13: Secondary valve bank

“LH ROOF”

“RH ROOF”

“LH FOOT”

“RH FOOT”

“TAIL STEER”

“TAIL TILT”

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.8

© Bucyrus America, Inc.

“LH ROOF”

___________________________________________________Operation system pressure gauges

Located to the left of the primary valve bank are two pressure gauges (Fig. 14), which indicate the hydraulic system pressure. The top gauge displays pressure for the functions on the left hand side of the primary valve bank (“FRAME TILT”, “LH FRAME LIFT”, and “LEFT TRAM”).

The bottom gauge displays pressure for the functions on the right hand side of the primary valve bank (“RIGHT TRAM”, “RH FRAME LIFT”, and “TANK FILL/AUX VB”).

The normal operating pressure for any valve function is 2,250 psi. If either gauge reading exceeds 2,750 psi, shutdown the machine (see Shutdown procedure in this chapter) and call maintenance.

Fig. 14: System pressure gauges

© Bucyrus America, Inc.

System pressure gauges

fire suppression actuator (s)

There are two fire suppression actuators (Fig. 15) located on the feeder breaker: one is located at the operator’s station and the other is below the starter box. To actuate the fire suppression system from either of the 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. (Also, see the Fire suppression system section in this chapter.)

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

Fig. 15: Fire suppression actuator locations Fire suppression actuator

Fire suppression actuator

______________________________________________________________ A6474X293 VIVI/01 5.9

Operation____________________________________________________ emergency stop button

The emergency stop button (Fig. 16) is located on the control console to the left of operator’s station. The emergency stop button is used to break the control circuit in emergency situations. To actuate emergency stop button, press the button. When the emergency stop button is pushed, all machine functions should immediately shutdown.

Fig. 16: Emergency stop button

There are two methods of disabling the primary valve bank during tramming: the 6-way diversion valve and the mechanical disconnect.

6-way diversion valve

During tram operation, the 6-way diversion valve (Fig. 17) handle is positioned to allow flow to the primary valve bank. During conveyor operation, the valve is positioned to divert flow straight to tank. The purpose of diverting the fluid during tramming is to eliminate pressure drop, the help the hydraulic system run cooler, and to prevent accidental machine movement when the outby belt is attached to the feeder breaker roller.

mechanical disconnect

The mechanical disconnect is a coupling located between the breaker shaft electric motor and the gear pump. During tram operation, the coupling halves are bolted together to allow transmission of electric motor torque, which powers the gear pump, producing hydraulic flow and pressure. The mechanical disconnect can be used instead of the diversion valve.

Fig. 17: Diversion valve and mechanical disconnect Mechanical disconnect

Diversion valve

Motor

Motor hub Connecting tube

Pump

Pump hub

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.10

© Bucyrus America, Inc.

Emergency stop button

___________________________________________________Operation Control Console The control console (Fig. 18), located to the left of the primary and secondary valve banks.

Fig. 18: Control console Lens - panel view

“FWD-REV SWITCH”

“LOW-MED-HIGH SWITCH”

“LOCALREMOTE SWITCH”

© Bucyrus America, Inc.

“MAN/AUTO SWITCH”

“FUNCTION” button

“UP TIME” button

“DOWN TIME”

“ACKNOWLEDGE”

lens assembly

“ACKNOWLEDGE ALL”

“E-STOP” button

The lens assembly, located in the middle of the console, provides viewing access to the panel view mounted behind the lens assembly. The panel view has seven screens (Screens 1 through 7) that are available with all passwords and an eighth screen (Screen 8: VFD Bypass Screen) that is only available with specific passwords. To toggle from one screen to the next, press the “ACKNOWLEDGE” push button.

Note that if a fault occurs while the display is on a screen other than Screen 1, the display will automatically return to Screen 1 to display the fault.

IMPORTANT! Setting changes (Screens 2, 3, 4, and 8) can only be made when the machine is not running (breaker and conveyor motors off).

Changes can only be made by a qualified person with proper password clearance.

______________________________________________________________ A6474X293 VIVI/01 5.11

Operation____________________________________________________ Screen 1: Status & Alarms Screen 1 (Fig. 19), the “Status & Alarms Screen”, is the default power up screen. Active faults are displayed on this screen in white text against a red background. This screen will remain active until all faults are acknowledged by pushing either the “ACKNOWLEDGE” or “ACKNOWLEDGE ALL” pushbutton. If there are no “Active Faults” being displayed, the “ACKNOWLEDGE” pushbutton can be used to step through the other screens.

Screen 2: Timer Preset Screen 1 Screen 2 (Fig. 20) is a timer preset screen. It displays three timers: pick break (F1), conveyor motor (F2), and conveyor run (F3). Each timer can have it’s preset time adjusted from this screen.

To change a preset time, use the “FUNCTION” pushbutton to select the timer you want to change and then use the “UP TIME” or “DOWN TIME” push button to increase or decrease the time. The timers are set at the following: ■ The pick break timer is preset at five (5) seconds and has a maximum setting of seven (7) seconds and a minimum of three (3) seconds.

■ The conveyor motor timer is preset at five (5) seconds and has a maximum setting of seven (7) seconds and a minimum of three (3) seconds.

■ The conveyor run timer is preset at two and a half (2 1/2) minutes (150 seconds) with a maximum of five (5) minutes (300 seconds) and a minimum setting of one (1) minute (60 seconds).

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.12

© Bucyrus America, Inc.

Fig. 19: Screen 1: Status and Alarms Screen

___________________________________________________Operation Fig. 19: Screen 2: Pre-set timer screen

© Bucyrus America, Inc.

Screen 3: Timer Preset Screen 2 Screen 3 (Fig. 21) is a timer preset screen. It displays two timers: the reverse (F1) and forward (F2) timers and it will display which timer is selected. Each timer can have it’s preset time adjusted from this screen when the machine is not running (breaker and conveyor motors off).

To change a preset time, use the “FUNCTION” pushbutton to select the timer you want to change and then use the “UP TIME” or “DOWN TIME” push button to increase or decrease the time. The timers are set at the following: ■ The reverse timer is preset at five (5) seconds and has a maximum setting of ten (10) seconds and a minimum of two (2) seconds.

■ The forward timer is preset at thirty (30) seconds with a maximum setting of sixty (60) seconds and a minimum of ten (10) seconds.

Fig. 21: Screen 3: Timer Preset Screen 2

______________________________________________________________ A6474X293 VIVI/01 5.13

Operation____________________________________________________ Screen 4: VFD Speed Preset Screen Screen 4 (Fig. 22) is the VFD speed preset screen for the conveyor low (Preset 1), medium (Preset 2), and high (Preset 3) ranges.

To rate of speed for each range can be changed by using the “FUNCTION” pushbutton to select the range you want to change and then use the “UP TIME” or “DOWN TIME” push button to increase or decrease the percentage.

The three speeds are set at the following: ■ Preset No. 1, “LOW” speed, is set at 10%.

■ Preset No. 2, “MEDIUM” speed, is set at 50% ■ Preset No. 3, “HIGH” speed, is set at 100%.

See the description of the “LOW”/”MED”/”HIGH” switch in this section for further information on conveyor speed.

© Bucyrus America, Inc.

Fig. 22: Screen 4: VFD Speed Preset Screen

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.14

___________________________________________________Operation Screen 5: VFD Status Screen Screen 5 (Fig. 23) is the VFD status screen. It displays the following information from the VFD: ■ frequency (Hz) ■ current (amps) ■ voltage (volts) ■ voltage on the DC Bus (volts) ■ power (Kw)

© Bucyrus America, Inc.

■ temperature (expressed as a % of the maximum allowed) The maximum operating temperature is 100% (55 °C, 131 °F). As soon as the Temp % reading goes above 100%, the drive will automatically shutdown. To avoid shutdown, whenever the Temp % reads 90 %, cooling system maintenance is required (check the fan, the pump, the coolant level, etc.).

■ fault codes active on the VFD Fig. 23: Screen 5: VFD Speed Status Screen

______________________________________________________________ A6474X293 VIVI/01 5.15

Operation____________________________________________________ Screen 6: Breaker Status Screen Screen 6 (Fig. 24) is the pick breaker status screen. It displays the current draw by the pick breaker in amps.

Screen 7: Password Screen Screen 7 (Fig. 25) is the password screen used to access Screen 8: VFD Bypass Screen. The password is four digits. Use the “FUNCTION” push button to select each digit and then use the “UP TIME” or “DOWN TIME” push buttons to change the value of the digit.

Fig. 25: Screen 5: Password Screen

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.16

© Bucyrus America, Inc.

Fig. 24: Screen 6: Breaker Status Screen

___________________________________________________Operation Screen 8: VFD Bypass Screen Screen 8 (Fig. 26), the VFD bypass screen, is visible when a password with a high enough clearance is entered. Press the “FUNCTION” push button to select with or without VFD. See the VFD Bypass section in this chapter for manually bypassing the VFD. To bypass the VFD, selecting the VFD Bypass option on Screen 8 and manually bypassing (jumping) the VFD must be completed.

© Bucyrus America, Inc.

Fig. 26: Screen 8: VFD Bypass Screen

______________________________________________________________ A6474X293 VIVI/01 5.17

Operation____________________________________________________ “UP TIME”

The “UP TIME” push button is the third button from the operator’s left on the middle row of controls on the console and is used to increase the value of a selected parameter (see the VFD Screen descriptions for further details). To increase the value of the parameter selected, push the “UP TIME” button until the desired value is displayed on the screen then release the button.

“DOWN TIME”

The “DOWN TIME” push button is the first button on the operator’s left on the bottom row of controls on the console and is used to decrease the value of a selected parameter (see the VFD Screen descriptions for further details). To decrease the value of a parameter, push the “DOWN TIME” button until the desired value is displayed on the screen then release the button.

“ACKNOWLEDGE”

The “ACKNOWLEDGE” push button is the second button from the left on the bottom row of controls on the console and has two functions:

■ After a fault or faults has appeared on the alarm screen (Screen 1) and has been cleared, push the “ACKNOWLEDGE” button to release and clear the screen of any alarm messages.

“ACKNOWLEDGE ALL”

The “ACKNOWLEDGE ALL” push button is the third button from the left on the bottom row of controls on the console. Pushing this button will clear multiple alarms on Screen 1.

“E-STOP”

The emergency stop, “E-STOP”, button is the fourth button from the operator’s left on the bottom row of controls on the console. When the button is pushed, all machine functions should immediately shutdown.

“MAN”/”AUTO”

The conveyor manual or automatic function switch, “MAN”/”AUTO”, is the first switch from the operator’s right on the middle row of controls on the console. When the selector switch is rotated counterclockwise (ccw) and is pointing at the “MAN” tag, the switch is manual position.

When in manual position, the following occur: ■ The sequence switch is by-passed, allowing the conveyor to run in the forward direction without the outby belt conveyor running. The breaker motor, however, must be running.

■ The conveyor can be jogged in reverse. This is a jog function only, the conveyor cannot run in reverse continuously. The breaker motor does not have to be running to jog the conveyor in reverse.

When the selector switch is rotated clockwise (cw) and is pointing at the “AUTO” tag, the switch is in the automatic position. In this position, the outby belt has to be running to run the conveyor. If the outby belt stops, the conveyor will stop. The breaker motor must be running to run the conveyor in “AUTO” mode.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.18

© Bucyrus America, Inc.

■ If there are no faults shown on the alarm banner screen (Screen 1), the button can be used to scroll between screens.

___________________________________________________Operation

Optional radio control of the feeder breaker is accessed via the “LOCAL”/”REMOTE” switch, which is the first switch from the operator’s left on the top row of controls on the console. If the machine does not have a radio, the switch must be rotated counterclockwise (ccw) to the “LOCAL” position in order to operate the machine.

“FWD”/”REV”

The conveyor forward or reverse direction selector switch, “FWD”/ ”REV”, is the second switch from the operator’s left on the top row of controls on the console. When the switch is in the forward, “FWD”, position, the conveyor chain will travel from the receiving end to the discharge end of the machine. When the switch is in the reverse, “REV”, position, the conveyor chain will travel from the discharge end to the receiving end of the machine.

“FUNCTION”

The “FUNCTION” push button is the second button from the right on the middle row of controls on the console. It is used to access different parameters on a screen (see VFD Screen descriptions for operation of the “FUNCTION” button on each screen).

© Bucyrus America, Inc.

“LOCAL”/”REMOTE (spare)”

______________________________________________________________ A6474X293 VIVI/01 5.19

Operation____________________________________________________ “LOW”/”MED”/”HIGH”

The conveyor speed control switch, “LOW”/”MED”/”HIGH”, is the third switch from the operator’s left on the top row of controls on the console and is used to select the speed of the conveyor. The rate of speed for each range, low, medium, and high, can be adjusted by using the “UP TIME” and “DOWN TIME” push buttons.

−

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

−

If the current increases above 125% FLA and stays at that level for five seconds, the conveyor will reverse and will run in the reverse direction for five seconds (adjustable from two to ten seconds) at 10% speed and then will run forward for thirty seconds (adjustable from ten to sixty seconds) at 10% speed.

−

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

−

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

−

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

−

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.20

© Bucyrus America, Inc.

Once the desired speed has been selected, the conveyor will continue to run at that speed unless one of the following occurs:

___________________________________________________Operation VFD By-pass In the event that the VFD fails, it can be by-passed. To by-pass the VFD (Fig. 27): Remove power from the machine by turning the circuit breaker, located on the left cover of the starter enclosure, to the “OFF” position.

Disconnect the lines going into the VFD on the motor side.

Disconnect the lines going into the line reactor from the main enclosure.

Bolt phase A to phase A, phase B to phase B, and phase C to phase C. Tape the connections.

Restore power to the machine by resetting the circuit breaker.

© Bucyrus America, Inc.

Enter the password on Screen 7 to allow access to the VFD Bypass Screen (Screen 8).

On Screen 8, use the “FUNCTION” push button to select the VFD bypass option.

Press the “ACKNOWLEDGE” button to toggle to another screen, thereby locking Screen 8 (VFD Bypass Screen).

Fig. 27: VFD enclosure

VFD

Line reactor

Chill plate

A

B

C

A

B

C

______________________________________________________________ A6474X293 VIVI/01 5.21

Operation____________________________________________________ Starter enclosure The starter enclosure (Fig. 28) is located on the left hand side of the machine and has a right and left cover. The left cover contains the circuit breaker reset lever while the right contains the motor start and stop buttons and a lens for viewing input and output lights on the PLC.

“START BREAKER”

The first button on the operator’s left is the “START BREAKER” button.

This push button is used to start the electric motor that drives the breaker and the hydraulic pump on the feeder breaker.

“STOP CONV/BKR”

The second button from the operator’s left is the “STOP CONV/BKR” button. This button is used to stop both the conveyor and the breaker electric motors.

“START CONVEYOR”

The third button from the operator’s left is the “START CONVEYOR” button. This button is used to start the electric motor that drives the conveyor.

lens cover

Located to the right of the push buttons is a lens that is used to view input and output lights on the PLC. On the left side of the starter enclosure:

circuit breaker reset lever

The circuit breaker reset is located on the left starter enclosure cover and is used to reset the circuit breaker, located inside the starter box, when it has tripped. When the lever is fully up, the circuit breaker is “ON”. When the circuit breaker is fully down, it is “OFF”. If the circuit breaker is in the middle between “OFF” and “ON”, it has tripped. To reset the circuit breaker, push the lever down past the “OFF” position and then up to “ON”.

Fig. 28: Starter enclosure Circuit breaker reset lever

“START BREAKER”

“STOP CONV/BKR”

“START CONVEYOR”

Lens cover

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.22

© Bucyrus America, Inc.

On the right side of the starter enclosure:

___________________________________________________Operation Fire suppression The feeder breaker is equipped with a fixed nozzle, dry chemical fire suppression system (Fig. 29). The system consists of three major components: storage canister, actuation device, and delivery system. The system is actuated manually by two pneumatic actuators: one located at the operator’s station and the other is located at the hopper end near the starter enclosure.

The dry chemical is Ansul FORAY (monoammonium phosphate base), which is effective on Class A, B, and C fires. The dry chemical is stored in a tank and is delivered to the strategic areas of the machine through hydraulic hoses and pre-set nozzles. The dry chemical is pressurized through the use of a gas expellant cartridge.

© Bucyrus America, Inc.

Actuation line valves are used at the branches to each actuation device to improve system reliability and , if necessary, to increase the overall effective lineal length of the actuation line. These check valves eliminate the possibility of the pressure from one actuator triggering or damaging another actuator, hindering the proper disbursement of the dry chemical.

To actuate the fire suppression system, pull the safety pin on the actuator and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine.

______________________________________________________________ A6474X293 VIVI/01 5.23

Operation____________________________________________________ Fig. 29: Fire suppression system

Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Nozzle

Breaker coupling

Operator’s station

Nozzle Nozzle Breaker motor Nozzle

Nozzle

Oil tank LP expellant © Bucyrus America, Inc.

LP canister

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.24

___________________________________________________Operation Daily starting procedure (tram/breaker motor) 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.

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

© Bucyrus America, Inc.

Ensure that the neutral start mechanism is covering the primary valve bank control handles and is fully engaged.

IMPORTANT! The machine will not start if the primary valve bank levers are not in the neutral position and the neutral start mechanism is not engaged (covering the levers so that they cannot be moved from the neutral position).

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

Apply power to the machine. (Line side of the main circuit breaker.)

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

Regular mode (conveying) Switch the “LOCAL”/”REMOTE” selector switch (Fig. 30) on the control console to the “LOCAL” position.

______________________________________________________________ A6474X293 VIVI/01 5.25

Operation____________________________________________________ Fig. 30: “LOCAL”/”REMOTE” selector switch

“LOCAL-REMOTE SWITCH”

Local Mode With the “LOCAL”/”REMOTE” switch in the “LOCAL” position, turn the “AUTO”/”MAN” switch to the “MAN” position (belt not running) or “AUTO” position (belt running).

Press and release the “START BREAKER” push button located on the right cover of the starter enclosure (Fig. 31).

Fig. 31: “START BREAKER” push button, starter enclosure (local)

“START BREAKER”

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.26

© Bucyrus America, Inc.

Start the tram/breaker motor by:

___________________________________________________Operation Tramming the feeder breaker The feeder breaker can be trammed in the “LOCAL” mode with the primary valve bank controls.

WARNING! Before operating either tram control lever, ensure that all personnel are completely clear of the machine, that the roof anchors are completely retracted, that the trailing cable has sufficient slack, that not electrical or water lines are in the path of travel, and that the conveyor has been turned off.

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 must be taken to ensure that the operator’s feet do not get under the crawler tracks while the feeder breaker is moving.

© Bucyrus America, Inc.

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

Local mode (Reference Fig. 32) To tram in the direction of the receiving end, slowly push the “LEFT TRAM” and “RIGHT TRAM” control levers (located on the primary valve bank) away from the operator at the same time.

To tram in the direction of the discharge end, slowly pull the “LEFT TRAM” and “RIGHT TRAM” control levers (located on the primary valve bank) toward the operator at the same time.

To steer right in the direction of the receiving end, pull the right tram control lever towards the machine while the left tram control lever is in the neutral position or, for tighter turns, push the left tram control lever away from the operator.

To steer left in the direction of the receiving end, pull the left tram control lever towards the machine while the right tram control lever is in the neutral position or, for tighter turns, push the right tram control lever away from the operator.

Fig. 32: Primary valve bank - tram levers

“LEFT TRAM”

“RIGHT TRAM”

______________________________________________________________ A6474X293 VIVI/01 5.27

Operation____________________________________________________ Conveyor motor start - forward direction To start the conveyor motor in the forward direction (Reference Fig. 33): Turn the “MAN”/”AUTO” selector switch, located on the control console, to either the “AUTO” (belt sequence) or “MAN” (no belt sequence) position.

Turn the “LOCAL”/”REMOTE” selector switch, located on the control console, to the “LOCAL” position.

Turn the “FWD”/”REV” selector switch, located on the control console, to the “FWD” position.

Start the tram/breaker motor (see Start up procedure (tram/breaker motor) section in this chapter).

“FWD-REV SWITCH”

“MAN/AUTO SWITCH”

“LOCAL-REMOTE SWITCH”

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.28

© Bucyrus America, Inc.

Fig. 33: Start conveyor controls - control console

___________________________________________________Operation Start the conveyor motor by: Push the “START CONVEYOR” push button located on the right cover of the starter enclosure (Fig. 34), or Push the “ON” button located on the cover of the infrared transmitter (Fig. 35).

Note: There will be a 14 second delay between pushing the button and the conveyor starting the first time the conveyor is started after power is applied to the machine.

Fig. 34: “START CONVEYOR” - starter cover

© Bucyrus America, Inc.

“START CONVEYOR”

Fig. 35: Conveyor start - infrared control

Conveyor “ON” button

______________________________________________________________ A6474X293 VIVI/01 5.29

Operation____________________________________________________ Conveyor motor start - reverse direction To start the conveyor motor in the reverse direction (Reference Fig. 36) : Turn the “MAN”/”AUTO” selector switch, located on the control console, to either the “AUTO” (belt sequence) or “MAN” (no belt sequence) position.

Turn the “LOCAL”/”REMOTE” selector switch, located on the control console, to the “LOCAL” position.

Turn the “FWD”/”REV” selector switch,, located on the control console, to the “REV” position.

IMPORTANT! The tram/breaker motor does not have to be running for the conveyor to start in the reverse direction.

“FWD-REV SWITCH”

“MAN/AUTO SWITCH”

“LOCAL-REMOTE SWITCH”

To start the conveyor motor in reverse, do either of the following: Push and hold the “START CONVEYOR” push button located on the right cover of the starter enclosure (Fig. 37), or Push and hold the “ON” button on the infrared transmitter (Fig. 38).

IMPORTANT! The conveyor will only run in reverse as long as the start button is held in (there is no holding circuit). Once the button is released, the conveyor motor will shutdown.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.30

© Bucyrus America, Inc.

Fig. 36: Start conveyor controls - control console

___________________________________________________Operation Fig. 37: “START CONVEYOR” - starter cover “START CONVEYOR”

© Bucyrus America, Inc.

Fig. 38: Conveyor start - infrared controls

Conveyor “ON” button

______________________________________________________________ A6474X293 VIVI/01 5.31

Operation____________________________________________________ Shutdown procedure (tram/breaker motor) To shutdown the tram/breaker motor: 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 to clean out the return line before shutting the machine down.

For local mode: Push and release the “STOP CONV/BKR” push button located on the right cover of the starter enclosure (Fig. 39), or Turn the “LOCAL”/”REMOTE” switch located on the cover of the control console (Fig. 40) to the center (off) position.

© Bucyrus America, Inc.

Fig. 39: “STOP CONV/BKR” push button “START CONV/BKR”

Fig. 40: “LOCAL - REMOTE SWITCH”

“LOCAL-REMOTE SWITCH”

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.32

___________________________________________________Operation The feeder breaker can also be shutdown in manual or radio remote (if equipped) by either of the following methods: Pull the pull cord (Fig. 41) located over the hopper end of the machine, or Pressing the “E STOP” button located on the cover of the control console (Fig. 41).

Fig. 41: Pull cord and emergency stop button locations

© Bucyrus America, Inc.

Pull cord

Emergency stop button

______________________________________________________________ A6474X293 VIVI/01 5.33

Operation____________________________________________________ Conveyor motor stop - forward direction To stop the conveyor motor when the conveyor is running in the forward direction, use any of the following methods: Push the “STOP CONV/BKR” push button located on the starter enclosure (Fig. 42), or Push the “STOP” button located on the infrared transmitter (Fig. 43), or Let the conveyor time out. The conveyor will time out and shutdown in 2 1/2 minutes if a start function is not engaged within that 2 1/1 minutes. If a start function is engaged, the timer will reset to 0 and will start timing again.

Shutdown the breaker/tram motor (see Shutdown procedure breaker/tram motor in this chapter).

Fig. 42: “STOP CONV/BKR” push button location

“START CONV/BKR”

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.34

© Bucyrus America, Inc.

Turn any of the following switches to the center (off) position): “LOCAL”/”REMOTE”, “FWD”/”REV”, or “MAN”/”AUTO” (Fig. 44).

___________________________________________________Operation Fig. 43: Stop button - infrared transmitter

Conveyor “STOP” button

© Bucyrus America, Inc.

Fig. 44: Control console

“FWD-REV SWITCH”

“MAN/AUTO SWITCH”

“LOCAL-REMOTE SWITCH”

______________________________________________________________ A6474X293 VIVI/01 5.35

© Bucyrus America, Inc.

Operation____________________________________________________

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.36

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

The machine receives electrical power through a heavy-duty trailing cable. Be sure that the packing gland 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 electrical components of the feeder breaker. All electrical maintenance should be performed only by a qualified electrician with the knowledge of the function of the components involved.

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

_____________________________________________________________ A6474X293 VIVI/01 5.37

Electrical system _____________________________________________ Fig. 45: Electrical component locator Tram/breaker motor (200 hp)

Oil float and temperature switches

Conveyor motor (150 hp)

Water solenoid (not shown) Pull cord switch

Junction box (belt slip/ sequence switch)

Control console

Solenoids (valves)

Neutral start mechanism

Speed switch

VFD cooling motor (5 hp)

Starter enclosure

VFD enclosure

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.38

© Bucyrus America, Inc.

Infrared receiver (not shown) (2)

____________________________________________ Electrical system Fig. 46: Electrical layout 16 3

1

5

10 13

14

15 11

© Bucyrus America, Inc.

7

12

9

10 4

1.

2.

3.

4.

5.

6.

7.

8.

Conveyor motor (150 hp, 460 VAC) Breaker/tram motor (200 hp, 460 VAC) Starter assembly Control console Pull cord switch Speed switch Water solenoid (optional) Oil float switch

6

2

8

9. Temperature switch 10. Infrared receiver assembly 11. Connection box with slip/sequence switch 12. Infrared transmitter 13. VFD coolant motor (5 hp) 14. Variable frequency drive (VFD) enclosure 15. Magnetic switch (neutral start) 16. Trailing cable (customer supplied)

_____________________________________________________________ A6474X293 VIVI/01 5.39

Electrical system _____________________________________________ Control console The cover of the control console (Fig. 47) consists of a lens assembly for viewing the panel view, six push buttons for navigating through and changing parameters on the panel view, and operating switches (see the Controls and indicators section of this chapter for a description of the functions of these buttons and switches).

Fig. 47: Control console cover Lens - panel view

“LOCAL-REMOTE SWITCH”

“LOW-MED-HIGH SWITCH”

“FUNCTION” button “MAN/AUTO SWITCH”

“UP TIME” button

“E-STOP” button

“DOWN TIME”

“ACKNOWLEDGE”

“ACKNOWLEDGE ALL”

Located behind the control console cover is the panel view and a push button assembly for the emergency stop, “E-STOP”, switch. For a detailed description on the functions accessible with the panel view, see the Controls and indicators section of this chapter.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.40

© Bucyrus America, Inc.

“FWD-REV SWITCH”

____________________________________________ Electrical system

© Bucyrus America, Inc.

Fig. 48: Control console wiring diagram

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Electrical system _____________________________________________ Starter enclosure The starter enclosure (Fig. 49) located on the left hand side of the discharge end 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 out at the main power center.

Starter enclosure left cover

Starter enclosure left panel

Starter enclosure right cover

Starter enclosure right panel

Starter enclosure swing panel

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.42

© Bucyrus America, Inc.

Fig. 49: Starter enclosure cover

____________________________________________ Electrical system Starter enclosure cover The cover of the starter enclosure consists of a right and a left cover (Fig. 50). The left cover assembly contains 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.

The right cover contains the conveyor motor and tram/breaker motor start and stop switches. These are labeled and control the start and stop functions for the electric motors.

For a detailed description on how to operate these switches, see the Controls and indicators section of this chapter.

Also located on the cover is a lens for viewing input and output displays on the PLC. Fig. 50: Starter enclosure cover

© Bucyrus America, Inc.

Left cover

Circuit breaker reset lever

Right cover

“START BREAKER”

“STOP CONV/BKR”

“START CONVEYOR”

PLC display lens cover

_____________________________________________________________ A6474X293 VIVI/01 5.43

Electrical system _____________________________________________ Starter enclosure swing panel The starter enclosure swing panel (Fig. 51) houses the Programmable Logic Controller (PLC). The PLC is comprised of the device net card, an analog input module, input module #1, input module #2, and the output module. The PLC inputs and outputs control the VFD and all motors.

Programmable Logic Controller (PLC)

Inputs and outputs on the PLC device net card

The device net card communicates with the variable frequency drive (VFD).

analog input module

The analog input module is used for 4 to 20 mA signals and has eight inputs.

input modules #1 and #2 output module

Input module #1 and #2 contain 16 inputs each.

Output module - 8 outputs

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.44

© Bucyrus America, Inc.

Fig. 51: Starter enclosure swing panel

____________________________________________ Electrical system

© Bucyrus America, Inc.

Fig. 52: Swing panel wiring diagram

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Electrical system _____________________________________________ Starter enclosure - left panel The left panel of the starter enclosure (Fig. 53) is accessed by opening the cover of the left side of the starter enclosure. Mounted on the left panel are a circuit breaker, vacuum contactors, fuses, and an overload relay module.

Fig. 53: Starter enclosure - left panel

Control transformer

circuit breaker, “CB”

Vacuum contactor (F1)

Vacuum contactor (R1)

Current transformer (CT)

“CB” is a 600 amp circuit breaker and is the main circuit breaker for the feeder breaker. The circuit breaker reset switch on the front of the left starter enclosure panel is used to control the circuit breaker when the starter enclosure cover is in place.

When looking directly at “CB”, the circuit breaker is on when the switch is in the fully up position and off when it is down. When the circuit breaker has tripped, the switch will be in the middle, between off and on. To reset the circuit breaker, the switch must be moved down past off, the up to on.

vacuum contactor, “F1“

Vacuum contractor “F1” is the forward contactor for the conveyor motor.

It feeds power to the VFD to run the conveyor in the forward direction.

vacuum contactor, “R1“

Vacuum contactor “R1” is the reverse contactor for the conveyor motor.

It feed power to the VFD to run the conveyor in the reverse direction.

Vacuum contactors “F1” and “R1” are auxiliary contactors. If the VFD fails, these contactors can be used to manually by-pass the VFD so that the conveyor motor can be operated.

special function module

The special function module is a jam module used during manual bypass of the VFD. If the conveyor jams and the conveyor motor drags, the module will shutdown the conveyor motor.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.46

© Bucyrus America, Inc.

Circuit breaker (CB)

____________________________________________ Electrical system fuses , “F1” and “F2”

Fuses “F1” and “F2” are 6 amp, 600 volt fuses that protect the high side (480V) of the control transformer.

overload relay, “OL2”

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

The current transformer is a 300:5 ratio transformer which converts high current to low current for overload protection.

control transformer

The control transformer converts 480V to 120V.

© Bucyrus America, Inc.

current transformer

_____________________________________________________________ A6474X293 VIVI/01 5.47

Electrical system _____________________________________________

© Bucyrus America, Inc.

Fig. 54: Starter enclosure - left panel wiring diagram

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.48

____________________________________________ Electrical system Starter enclosure - right panel The right panel of the starter enclosure (Fig. 55) is accessed by opening the cover of the right side of the starter enclosure and opening the swing panel. Mounted on the right panel are a relays, modules, a power supply, the infrared receiver board, and fuses.

Fig. 55: Starter enclosure - right panel Special function module

IS relay “IS3”

IS relay “IS1”

IS relay “IS2”

Terminal strip

IEC Contactor “CP”

Power supply

Infrared receiver board

Fuse “F4”

Control relay

Fuse “F3”

© Bucyrus America, Inc.

Overload relay (“ OL1 “)

Overload relay (“OL2”)

Overload relay (“OL3“)

Vacuum contactor (“M1“)

Special function module located under OL3

overload relay, “OL1” special function module current transformer

Current transducer

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

Provides redundant motor protection.

The four current transformers are located on the vacuum contactor, “M1”. One transformer feeds the current transducer and the other three feed overload relay, “OL1”.

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Electrical system _____________________________________________ IS relay, “ IS2 “

The intrinsically safe relay “IS2” is the low hydraulic oil relay.

IS relay, “ IS1 “

The intrinsically safe relay “IS1” is the high temperature relay for the hydraulic oil.

The power supply is a 120/24V power supply for the panel view.

infrared receiver board

The infrared receiver board picks up signal from the infrared remote and convert the signal to open or close relays. The infrared remote can be used to start and stop the conveyor motor.

overload relay, “OL3 “

“OL3” is the VFD coolant pump motor overload. If the 5 hp motor that drives the coolant pump is overloaded, “OL3” will shutdown the motor.

vacuum contactor, “M1“

Vacuum contactor “M1” is the pick break motor contactor.

IS relay, “IS3“

The intrinsically safe relay “IS3” is the neutral start relay.

IEC contactor “CP”

The IEC contactor “CP” is the contactor for the VFD cooling pump motor.

current transducer

The current transducer converts a reading from the current transformer into a 4 to 20 mA signal that it sends to the PLC, which in turns controls the conveyor speed.

The control relay consists of five different relays:

master control relay, “MCR”

The master control relay, “MCR”, is the relay for the pull chord and the emergency stop. If this relay is open (if the pull chord is pulled or the emergency stop is pushed), nothing on the machine will run.

control relay, “CRWS”

The control relay for the optional water solenoid, “CRWS”, is a 0:5/3 relay.

control relay, “CR1”

Control relay “CR1” is the high temperature control relay. This relay works in conjunction with intrinsically safe relay “IS1”.

control relay, “CR2”

Control relay “CR2” is the low oil control relay. This relay works in conjunction with intrinsically safe relay “IS2”.

control relay, “CR3”

Control relay “CR3” is the neutral start relay. This relay works in conjunction with intrinsically safe relay “IS3”.

fuse, “F4”

Fuse “F4” is a 5 amp fuse for the AC/DC converter for the panel view.

fuse, “F3”

Fuse “F5” is a 15 amp fuse for the 120V control circuit.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.50

© Bucyrus America, Inc.

power supply

____________________________________________ Electrical system

© Bucyrus America, Inc.

Fig. 56: Starter enclosure - right panel wiring diagram

_____________________________________________________________ A6474X293 VIVI/01 5.51

Electrical system _____________________________________________ Variable Frequency Drive (VFD) enclosure The variable frequency drive (VFD) enclosure (Fig. 57) houses the VFD, a line reactor, and a chill plate.

Fig. 57: VFD enclosure Line reactor

Chill plate

Belt slip/sequence board The belt slip/sequence board (Fig. 58), located beside the control console on the left hand side of the machine to the left of the operator’s station, is the belt slip and sequence timers circuit board. The timers are embedded in the programming.

Fig. 58: Belt slip/sequence board

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.52

© Bucyrus America, Inc.

VFD

____________________________________________ Electrical system

© Bucyrus America, Inc.

Major electrical components tram/breaker electric motor

The machine has a 200 hp/460VAC electric drive motor that drives the pick breaker and the hydraulic pump for the feeder breaker.

emergency stop pull cord switch

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

belt sequence sensor

These sensors are used to detect the state of the belt conveyor (running or not running). If the selector switch (“MANUAL/OFF/ AUTOMATIC”) is in the “AUTOMATIC” position and the conveyor belt that is used to convey the coal from the feeder breaker stops, then the motor will be shut down. If this selector switch is turned to the “MANUAL” position, the belt sequence sensor is not in the circuit.

high temperature switch

The high temperature switch for the feeder breaker is located onboard the machine at the oil tank. If a high temperature at the oil tank is detected, a message will be displayed on the panel view

low oil cut off switch

The low oil cut off switch for the feeder breaker is located onboard the machine at the oil tank. If a low oil issue is detected, a message will be displayed on the panel view.

infrared receiver (2)

There are two infrared receivers mounted on either side of the hopper.

The infrared transmitter can be used to start and stop the conveyor motor.

conveyor electric motor

The machine has a 150 hp/460VAC electric motor that drives the conveyor.

VFD cooling motor

There is a 5 hp electric motor on that drives the cooling pump for the Variable Frequency Drive (VFD).

water solenoid (optional)

The water solenoid (optional) controls the feeder breaker water sprays.

neutral start magnetic switch

There is a magnetic switch located on the primary valve bank at the operator’s station. The purpose of the magnetic switch is to ensure that all valve levers on the primary valve bank are in the neutral position before the machine is started. In order to start the machine, all valve levers must be in neutral and the guard must be in place over the levers. Placing the guard over the levers closes the magnetic switch.

emergency stop button

The emergency stop button is located at the control station and is activated by pressing the panic bar. Pressing the panic bar will shutdown the machine.

_____________________________________________________________ A6474X293 VIVI/01 5.53

Electrical system _____________________________________________

© Bucyrus America, Inc.

Fig. 59: Schematic diagram

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.54

____________________________________________ Electrical system

© Bucyrus America, Inc.

Fig. 60: Interconnection diagram

_____________________________________________________________ A6474X293 VIVI/01 5.55

© Bucyrus America, Inc.

Electrical system _____________________________________________

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.56

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

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

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

© 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 will fall causing damage to the machine or serious injury or death to you or other workers.

_____________________________________________________________ A6474X293 VIVI/01 5.57

Hydraulic system _____________________________________________ Fig. 61: Hydraulic component locator

20

13

10

© Bucyrus America, Inc.

12

13

1

16

3

2

6

9

7, 11

4 5

14

1.

2.

3.

4.

5.

6.

7.

primary valve bank secondary valve bank pressure filters (2) system pressure gauge (lh) system pressure gauge (rh) 6 way diversion valve flow divider (jet fill)

3

8. return filter 9. heat exchanger 10. hydraulic oil tank 11. ball valve 12. gear pump 13. tram motor (2) 14. frame tilt cylinder (2)

8

15

19

17

18

15. frame lift cylinder (2) 16. roof anchor arm cylinder (2) 17. tailpiece steering cylinder (2) 18. tailpiece tilt cylinder (2) 19. floor stabilizer cylinder 20. mechanical disconnect

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.58

____________________________________________ Hydraulic system Major hydraulic components (Reference Fig. 61) The primary valve bank, located at the operator’s station on the left hand side of the machine, is used to control the machine’s frame tilt, frame lift, tram, and power fill functions. It also is used to energize the secondary valve bank. All sections of the valve bank are spring return (self centering) except for the power fill/secondary valve bank section, which is detented.

secondary valve bank

The secondary valve bank, located below the primary valve bank at the operator’s station on the left hand side of the machine, is used to control the roof and foot anchor cylinders and the tailpiece positioning cylinders (steering and tilt).

pressure filters (2)

There are two filters located below the valve banks at the operator’s station on the left hand side of the machine. The filters are used to filter the hydraulic fluid on the pressure side of the hydraulic system.

system pressure gauges (2)

There are two pressure gauges located to the left of the primary valve bank at the operator’s station o the left hand side of the machine. The top gauge is the left hand system pressure gauge and the bottom gauge is the right hand system pressure gauge.

© Bucyrus America, Inc.

primary valve bank

The left hand system pressure gauge displays the system pressure when any of the functions on the left hand side of the primary valve bank are energized. These functions are: “FRAME TILT”, “LEFT FRAME LIFT”, and “LEFT TRAM”.

The right hand system pressure gauge displays the system pressure when any of the functions on the right hand side of the primary valve bank are energized. These functions are: “RIGHT TRAM”, “RIGHT FRAME LIFT”, and “TANK FILL/AUX VB”.

6-way diversion valve

This diversion valve is used to divert flow to either the primary valve bank or straight to tank. During tram operation, the valve handle is positioned to allow flow to the valve bank. During conveyor operation, the valve handle is positioned to allow flow straight to tank.

flow divider (jet fill)

The flow divider is to pull oil from a new oil source and direct it into the return side of the hydraulic system to fill up the hydraulic tank.

return filter

The return filter is located to the right of the operator’s station on the left hand side of the machine.

heat exchanger

The heat exchanger, located on the left hand side of the discharge section, removes heat from the hydraulic oil prior to dumping the oil back to tank.

hydraulic oil tank

The hydraulic oil tank, located on the discharge end of the right hand side of the machine, has a 110 gallon capacity and is equipped with a sight glass (within the sight glass is a thermometer), a low oil level switch, and a high temperature switch.

_____________________________________________________________ A6474X293 VIVI/01 5.59

power fill ball valve

The power fill ball valve is used to control hydraulic oil flow to the power fill pump.

gear pump

The gear pump is driven by the breaker motor. It drives the tram motors and sends pressure to the valve banks to work the hydraulic cylinders.

tram motors (2)

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

frame tilt cylinders (2)

The frame tilt 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 feeder breaker. Both cylinders are controlled by one section of the primary valve bank.

frame lift cylinders (2)

The frame lift 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 feeder breaker. Each cylinder is individually controlled by separate sections of the primary valve bank.

WARNING! The frame lift and tilt cylinders have counterbalance valve cartridges which serve as load holding valves. DO NOT replace these cylinders with different style cylinders or the machine may fall.

You or other personnel could be seriously injured or killed by the falling machine or the machine could be damaged.

roof anchor arm cylinders (2)

The two roof anchor hydraulic cylinders are located on each roof anchor assembly. The cylinders are used to raise and lower the roof anchors.

Each cylinder is controlled individually by separate sections of the secondary valve bank.

tailpiece steering cylinders (2)

The tailpiece steering cylinders are mounted on each side of the tailpiece and are used to adjust the alignment of the tailpiece with the outby belt. The two cylinders are controlled by one section of the secondary valve bank.

tailpiece tilt cylinders (2)

The tailpiece tilt cylinders are mounted on each side of the tailpiece and are used to adjust the height of the tailpiece when aligning with the outby belt. The two cylinders are controlled by one section of the secondary valve bank.

foot cylinders (2)

The foot cylinders are mounted under the discharge end of the feeder breaker on the stabilizer foot assembly and are used to raise and lower the stabilizer foot. Each cylinder is controlled individually by separate sections of the secondary valve bank.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.60

© Bucyrus America, Inc.

Hydraulic system _____________________________________________

____________________________________________ Hydraulic system

© Bucyrus America, Inc.

Fig. 62: Hydraulic schematic

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© Bucyrus America, Inc.

Hydraulic system _____________________________________________

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.62

_______________________________________ 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.

Headshaft The feeder breaker is equipped with a headshaft (Fig. 63) located on the discharge end of the conveyor. The headshaft is driven from the right hand side via a 150 hp electric motor, which drives a gear reducer directly connected to the head shaft.

Fig. 63: Headshaft main components

© Bucyrus America, Inc.

Bearing

Sprocket

Key

Headshaft

Key

Sprocket

Bearing

Coupling half

_____________________________________________________________ A6474X293 VIVI/01 5.63

Mechanical assemblies ________________________________________ Tailshaft The feeder breaker is equipped with a tailshaft (Fig. 64) located on the receiving end of the conveyor. The tailshaft is an idler shaft that is driven by the tension of the conveyor chain. There is a slide plate arrangement attached to the tailshaft which fills the gap between the receiving impact plate and the shaft.

Fig. 64: Tail shaft components

Key (2) Set screw (2)

Tail shaft

Slide plate

Bearing (2)

Piston rod adapter (2)

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.64

© Bucyrus America, Inc.

Sprocket (2)

_______________________________________ Mechanical assemblies Breaker shaft The feeder breaker is equipped with a breaker shaft (Fig. 65) that has a 32 inch pick circle arrangement with a 10 inch shaft diameter turned down to 8 inches through the bearings.

Fig. 65: Breaker shaft main components 33 29

31

28 26 25 19

20

22

34

18

32 31

15

© Bucyrus America, Inc.

9

4

5

10

11

24

16

23

13

27

21

6 17

3

14

2 1

12

8 7

1. End cap 2. Coupling half 3. Spacer ring 4. Seal housing 5. Back-up ring 6. O-ring 7. Seal 8. Spiral retainer ring 9. Side plate 10. Bearing housing 11. Seal ring 12. Bearing 13. O-ring 14. Bearing retaining ring 15. Seal 16. Bearing backing ring 17. Key

18. Breaker shaft 19. Bit (25) 20. Bearing backing ring 21. Seal 22. Bearing retaining ring 23. O-ring 24. Bearing 25. Seal ring 26. Bearing housing 27. Side plate 28. Spiral retainer ring 29. Seal 30. O-ring 31. Back-up ring 32. Seal housing 33. End cap 34. Underspeed senor mount

_____________________________________________________________ A6474X293 VIVI/01 5.65

Mechanical assemblies ________________________________________ Breaker power unit The breaker power unit (Fig. 66) drives the breaker assembly and the hydraulic pump. It consist of a 200 hp electric motor coupled to a gear reducer via a flexible coupling and a torque limiter. The power unit is assembled as a unit and can be removed as a unit or as individual components The power unit is supported by the breaker shaft and a pivot pin in the electric motor/gear reducer connecting tube. (See Breaker power unit removal and installation in this chapter)

© Bucyrus America, Inc.

Fig. 66: Breaker power unit

1. Gear box 2. Pilot adapter 3. Hi-collar lock washer, 7/8” (12) 4. Socket head cap screw, 7/8X2” (12) 5. Connecting tube weldment 6. Lock washer, 1-1/8” (14) 7. Hex head cap screw, 1-1/8X3” (14) 8. Motor, 200 hp 9. Hex head bolt, 7/8X3-1/4” (16) 10. Lock washer, 7/8” (16) 11. Hex nut, 7/8” (16) 12. Companion flange 13. Torque limiter 14. Taper lock bushing

15. Flexible coupling 16. Cup point set screw, 1/2-13X1/2” (4) 17. Motor hub 18. Drive pin (2) 19. Pump hub 20. Cup point set screw, 3/8X3/8” (2) 21. Connecting tube 22. Lock washer, 5/8” (12) 23. Hex head cap screw, 5/8X2” (8) 24. Pump 25. Lock washer, 1/2” (4) 26. Hex head bolt, 1/2”X1-1/4” (4) 27. Connecting tube cover plate 28. Hex head bolt, 5/8X1” (4)

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.66

_______________________________________ Mechanical assemblies Conveyor power unit The conveyor power unit (Fig. 67) drives the headshaft assembly, which drives the conveyor chain and consists of a 150 hp electric motor coupled to a gear reducer via a flexible coupling and a torque limiter.

The power unit is assembled as a unit and can be removed as a unit or as individual components (see Conveyor power unit removal and installation in this chapter).

© Bucyrus America, Inc.

Fig. 67: Conveyor power unit

1. Gear box 2. Adapter plate 3. Hi-collar lock washer, 3/4” (qty 12) 4. Socket head cap screw, 3/4-10X2-1/2” (qty 12) 5. Companion flange 6. Cup point set screw, 1/2-13X1/2” (qty 6) 7. Torque limiter 8. Flexible coupling 9. Connecting tube 10. Motor, 150 hp, 460 VAC

11. Lockwasher, 1-1/8” (qty 11) 12. Hex head bolt, N.C. 1-1/8X3” (qty 11) 13. Lockwasher, 7/8” (qty 16) 14. Hex head bolt, 7/8X3-3/4” (qty 16) 15. Hex nut, 7/8” (qty 16) 16. Connecting tube cover plate 17. Lockwasher, 5/8” (qty 8) 18. Hex head bolt, N.C. 5/8X1” (qty 8) 19. Motor shaft guard

_____________________________________________________________ A6474X293 VIVI/01 5.67

Mechanical assemblies ________________________________________ Conveyor chain The conveyor chain (Fig. 68) carries mined material along the conveyor trough from the receiving section, through the breaker, and out the discharge end. The conveyor chain is made up on one basic chain assembly which repeats sequentially along the entire chain loop.

Fig. 68: Conveyor chain Chain section

Spiral pin

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.68

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Flight bar

_______________________________________ Mechanical assemblies Crawler assemblies The feeder breaker is trammed by two hydraulically driven crawlers (Fig. 69) 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 assembly, is used to adjust the tension on the crawler tracks (see Crawler track adjustment procedure I this chapter).

Fig. 69: Crawler assembly main components Sprocket

© Bucyrus America, Inc.

Hydraulic motor (not shown) Cat pad assembly

Torque hub Take-up cylinder and shims Take-up roller assembly grease point

_____________________________________________________________ A6474X293 VIVI/01 5.69

Mechanical assemblies ________________________________________ Roof anchor assemblies The two roof anchor assemblies (Fig. 70), located between each crawler, are used to stabilize the machine during crushing and conveying operations.

Fig. 70: Roof anchor assemblies Anchor arm pin

Anchor arm pullout

Anchor arm cylinder

Outrigger (stabilizer) support assemblies The two outrigger support assemblies (Fig. 71), located underneath the machine, are used to stabilize the machine during crushing and conveying operations. The lock pin must be installed whenever the outrigger foot is down.

Fig. 71: Outrigger (stabilizer) support assemblies Lock pin (installed location)

Outrigger (stabilizer) arm

Lock pin (stored location)

Outrigger (stabilizer) cylinder

Outrigger (stabilizer) foot

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.70

© Bucyrus America, Inc.

Anchor arm weldment

_______________________________________ Mechanical assemblies Tailpiece assembly The tailpiece assembly (Fig. 72), attaches to the discharge end of the feeder breaker frame. It consists of a return belt pulley, an impact bed, steering cylinders, and tilt cylinders. The belt runs around the pulley and over the impact bed.

The steering and tilt 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. 72: Tailpiece assembly

Tilt cylinder (2) Steering cylinder (2)

Belt pulley

Impact bed

_____________________________________________________________ A6474X293 VIVI/01 5.71

© Bucyrus America, Inc.

Mechanical assemblies ________________________________________

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.72

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

Important notes

© Bucyrus America, Inc.

Please observe the following: ■

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

■

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

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus 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.

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

■

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

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

______________________________________________________________ A6474X293 VIVI/01 5.73

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.

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

■

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

■

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

■

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

Lubrication and inspection Table 1: Lubricants and fluids capacities Location

Specification

Approx. Capacity

Hydraulic oil tank

100-1

110 gal

VFD cooling tank

50/50 Water/ Antifreeze

25 gal

Grease points

100-3

As required

1

Electric motors

100-14

As required

2

Breaker reducer

100-6

11 gal

Conveyor reducer

100-6

11 gal

100-2 or 100-13

2.5 gal EACH SIDE

Tram reducer

Notes

Notes: 1. Pump grease into the fitting until grease can be observed coming out of the fitting unless otherwise noted.

2. Do not over-grease electric motors; motor damage may result.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.74

© Bucyrus America, Inc.

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

________________________________________________ Maintenance Maintenance of the feeder breaker includes: ■

Lubrication of the machine in accordance with the lubrication schedule.

■

Inspection of the machine for faults and proper function.

■

Inspection of wear parts.

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

© Bucyrus America, Inc.

Central lubrication system There are two central lubrication manifolds. The lubrication manifold for the head shaft, tail shaft, and breaker (Fig. 73) is located on the left hand side of the receiving end of the feeder breaker, below the control console. The lubrication manifold for the electric motors and reducers (Fig. 74) is located to the right of the operator’s station, below the diversion valve and flow divider.

Fig. 73: Head shaft, tail shaft, and breaker central lubrication

Tail shaft

Breaker

Head shaft

Fig. 74: Electric motor and reducer central lubrication Breaker power unit

Conveyor power unit

______________________________________________________________ A6474X293 VIVI/01 5.75

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Description Every 8 hours of operation Head shaft bearings Breaker bearings Tail shaft and slide tube bearings Hydraulic oil level (check) Pressure filter (check) Return filter (check) Bits (breaker) Tailpiece bearings (pulley) Weekly Crawler track take-up bearings Conveyor chain tension Fasteners (nuts, bolts and screws) Electrical cables, conduits and glands Hydraulic hoses and connections Hydraulic system pressures Tram reducer (s) (check oil level) Breaker reducer (check oil level) Conveyor reducer (check oil level) Dust system strainer (clean)

Places

Lubricant

Specification

2 2 4 1 2 1 Inspect 2

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

2 1 Inspect Inspect Inspect Check 2 1 1 1

Spec. 100-3

Spec. 100-3

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

Monthly 19 20 21 22

Conveyor lift cylinders Conveyor tilt cylinders Crawler anchor pin (s) Roof anchor cylinders

4 4 2 4

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

23

Breaker electric motor

2

Spec. 100-14

24 25 26 27

Conveyor electric motor Breaker reducer (grease) Conveyor reducer (grease) Coolant motor

2

Spec. 100-14 Spec. 100-3 Spec. 100-3 Spec. 100-14

1

Every 6 months or every 2500 hours 28 29 30 31 32 33

** Breaker reducer (change oil) Hydraulic oil tank (change oil) Tram reducer (change oil) Pressure filter element Return filter element Conveyor reducer (change)

1 1 2 Change Change 1

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

Spec. 100-6

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.76

© Bucyrus America, Inc.

Item

________________________________________________ Maintenance Fig. 75: Lubrication and maintenance chart 16, 28

4, 29

17

© Bucyrus America, Inc.

27

19

1,2,3

20

22

14

10

6,32

9 5, 31

15, 30

21

8

23, 24 25, 26

______________________________________________________________ A6474X293 VIVI/01 5.77

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

Lubricate the feeder breaker head shaft bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 76) located on the left side of the receiving section. Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

tail shaft and slide tube bearings

Lubricate the feeder breaker tail shaft and slide tube bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 76) located on the left 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. 76) located on the left side of the receiving section. Pump grease into the fittings until new grease can be observed coming out of the bearing return lines.

Central lubrication panel

Tail shaft

Breaker

Head shaft

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.78

© Bucyrus America, Inc.

Fig. 76: Central lubrication panel

________________________________________________ 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. 77). The oil level should not be allowed to drop below the bottom of the sight glass. If the hydraulic oil level is low, add oil Spec. 100-1 via the power fill system.

Fig. 77: Hydraulic tank oil level

Oil level sight glass

© Bucyrus America, Inc.

pressure filters

return filter

There are two system pressure filters located at the operator’s station (Fig. 78). Check the dirt alarm located on the base of each filter and, if indicated, replace the element.

Check the return filter’s dirt alarm (Fig. 70) located on the top of the filter housing. If indicated, replace the element Fig. 78: Filter locations Return filter

Pressure filter

Pressure filter

______________________________________________________________ A6474X293 VIVI/01 5.79

Maintenance _________________________________________________ breaker bits

Check the breaker bits to see if they will rotate in their holders and for damaged or missing bits (Fig. 79). The bits may be inspected by looking into the receiving end of the machine. If bits need to be replaced, see Bit replacement in this chapter.

Fig. 79: Breaker bits

Bit holder

tailpiece bearings

Lubricate the tailpiece bearings with Spec. 100-3 through the two fittings on the grease block located on the side of the tailpiece (Fig. 80).

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

Fig. 80: Tailpiece bearing lubrication

Tailpiece bearing lubrication block

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.80

© Bucyrus America, Inc.

Breaker bit

________________________________________________ Maintenance Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 81) 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.

© Bucyrus America, Inc.

Fig. 81: Crawler track take-up lubrication

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

conveyor chain tension

With the machine off, check the conveyor chain tension at the head shaft end. (Fig. 82). When the conveyor chain is properly tensioned, there will be approximately 2 inches (50 mm) of droop on the bottom side of the head shaft sprockets. With the machine running, visually inspect tail shaft to ensure shaft is turning and conveyor chain is engaging the tail shaft sprockets properly. If adjustment is necessary, see Conveyor chain adjustment procedure in this chapter.

Fig. 82: Conveyor chain tension

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

______________________________________________________________ A6474X293 VIVI/01 5.81

Maintenance _________________________________________________

electrical cables, conduits and glands hydraulic hoses and fittings

Due to the machine being subjected to continual shock loading and vibration, close attention to all mounting bolts and screws is required.

Loose fasteners will cause premature wear and failure to bearings, couplings, etc. Inspect and tighten as required the following fasteners: ■

breaker reducer mounting bolts

■

breaker drive motor mounting bolts

■

breaker shaft side plate bolts

■

underspeed sensor driveshaft bolts

■

head shaft bearing bolts

■

conveyor drive motor mounting bolts

■

conveyor drive reducer mounting bolts

■

conveyor flight fixing bolts

■

tail shaft retainer hold down bolts

■

all cover and guard retaining bolts

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.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.82

© Bucyrus America, Inc.

fasteners

________________________________________________ Maintenance tram reducer (s)

Check the oil level in both tram reducer torque hubs (Fig. 83): Oil level/fill plug should be at the 3 o’clock position and the drain plug at the 6 o’clock position.

Remove the oil level/fill plug. The oil level should be kept at the level of the level/fill plug.

Should it be necessary to add oil, add oil (Spec. 100-2 or 100-13) through the fill plug hole until it begins to flow out of the check hole.

Do not overfill the reducer.

Replace the oil level/fill plug.

Fig. 38: Tram reducer oil level

© Bucyrus America, Inc.

Fill/check plug location

Drain plug location

breaker reducer

Check oil level in the breaker drive reducer (Fig. 84). Oil level should be maintained inside the sight glass on the side of the reducer when it is in operation. Add oil, Spec. 100-6, as necessary. The oil should be changed after the first 500 hours of operation.

Fig. 84: Breaker reducer Breather

Inspection cover

Sight glass (fill to this level)

Drain plug

______________________________________________________________ A6474X293 VIVI/01 5.83

Maintenance _________________________________________________ conveyor reducer

Check oil level in the conveyor drive reducer (Fig. 85). Oil level should be maintained inside the sight glass on the side of the reducer when it is in operation. Add oil, Spec. 100-6, as necessary. The oil should be changed after the first 500 hours of operation.

Fig. 85: Conveyor reducer

Drain plug

dust system strainer

Inspection cover

Sight glass (fill to this level)

Clean the strainer mounted inside the dust suppression system. Open ball valve (Fig. 86) 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. 86: Dust system strainer Strainer

Strainer (located behind enclosure)

Ball valve Short drain hose

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.84

© Bucyrus America, Inc.

Breather

________________________________________________ Maintenance Monthly conveyor lift cylinder

Lubricate grease fittings on the rod and base ends of the conveyor lift and tilt cylinders with Spec. 100-3 (Fig. 87). Pump grease into the fittings until new grease can be observed coming out of the pins.

conveyor tilt cylinders

Lubricate grease fittings on the rod and base ends of the conveyor lift and tilt cylinders with Spec. 100-3 (Fig. 87). Pump grease into the fittings until new grease can be observed coming out of the pins.

crawler anchor pins

Lubricate grease fittings on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 87). Pump grease into the fittings until new grease can be observed coming out of the pins.

roof anchor cylinders

Lubricate the roof anchor cylinders with Spec. 100-3 through the grease fittings located on each end of the cylinders (Fig. 87). Pump grease into each fitting until new grease can be observed coming out of the bushing and pin.

© Bucyrus America, Inc.

Fig. 87: Cylinder and crawler anchor pin lubrication points

Roof anchor cylinder (2) (rod and base end)

Conveyor lift cylinder (2) (rod and base end)

Crawler anchor pin (2)

Conveyor tilt cylinder (2) (rod and base end)

______________________________________________________________ A6474X293 VIVI/01 5.85

Maintenance _________________________________________________ CAUTION! Each grease line for the breaker and conveyor electric motors and reducers may have to be purged of air before the first use.

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

breaker electric motor

Lubricate the breaker electric motor with Spec. 100-14 through the two (2) button head grease fittings located on the central lubrication panel (Fig. 88) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

conveyor electric motor

Lubricate the conveyor electric motor with Spec. 100-14 through the two (2) button head grease fittings located on the central lubrication panel (Fig. 88) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

conveyor reducer

Lubricate the conveyor reducer with Spec. 100-3 through the two (2) button head grease fittings located on the central lubrication panel (Fig. 88) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

breaker reducer

Lubricate the conveyor reducer with Spec. 100-3 through the two (2) button head grease fittings located on the central lubrication panel (Fig. 88) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.86

© Bucyrus America, Inc.

CAUTION! A special button head grease fitting is installed in the electric motor and gear reducer shaft lubrication central manifolds for the purpose of preventing over greasing by the mechanic. The special grease button fitting requires the proper grease gun adapter in order to transfer grease. Do not replace the button head grease fitting with a standard grease fitting or machine damage may occur.

________________________________________________ Maintenance Fig. 88: Electric motor and reducer lubrication

© Bucyrus America, Inc.

Electric motor and reducer lubrication panel

Breaker power unit

Conveyor power unit

______________________________________________________________ A6474X293 VIVI/01 5.87

Maintenance _________________________________________________ Every 2500 hours (every six months) breaker reducer

Change the oil in the breaker drive reducer (Fig. 89). The reducer oil should be changed after the first 500 hours of operation and every 2500 hours afterwards.

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

Clean and reinstall drain plug.

Add oil (Spec. 100-6) as required (approximately 11 gallons) until fluid is visible in sight glass or begins to flow from the check plug that is slightly below the center line of the input shaft.

When filling the reducer, allow enough time for all cavities inside the reducer to fill.

Install level/fill plug.

Do not overfill reducer.

Breather

Inspection cover

Sight glass (fill to this level)

Drain plug

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.88

© Bucyrus America, Inc.

Fig. 89: Breaker reducer

________________________________________________ Maintenance hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank (Fig. 90).

Clean all dirt and debris from and around the fill cap and drain plug.

Remove the drain plug and allow the oil tank to completely drain.

Clean and reinstall drain plug.

Remove the fill cap and pour 20 gallons (76 L) through the fill cap strainer to avoid cavitating the pumps with the power fill unit.

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

© Bucyrus America, Inc.

CAUTION! Do not cut holes in or remove the fill cap strainer. If the strainer is missing or damaged, the hydraulic component warranty will be voided.

Add oil Spec 100-1 as required (approximately 205 gallons) via the power fill system until fluid is visible in sight glass (see procedure in Operation section of this chapter).

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. 90: Hydraulic oil tank

Drain plug (located underneath)

Sight glass

______________________________________________________________ A6474X293 VIVI/01 5.89

Maintenance _________________________________________________ tram reducer

Change oil in the tram reducer (Fig. 91).

Rotate the reducer until the fill/check plug is located in the 3 o’clock or 9 o’clock position and the drain plug is located at the 6 o’clock position.

Clean all dirt and debris from and around the level and fill plugs.

Remove both the fill/check plug and the drain plug. Allow the oil to completely drain from the unit.

Clean and reinstall drain plug.

Add oil (Spec. 100-2 or 100-13) through the fill hole until fluid begins to flow from the fill/check plug hole (approximately 2.5 gallons PER SIDE).

When filling the reducer, allow enough time for all cavities inside the reducer to fill.

Clean and install fill/check plug.. © Bucyrus America, Inc.

Do not overfill reducer.

Fig. 91: Tram reducer oil change

Drain plug location

Fill/check plug location

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.90

________________________________________________ Maintenance pressure filters

Change the two pressure filter elements (Fig. 92). If the elements are extremely dirty, a more frequent change interval may be required.

return filter

Change the return filter element (Fig. 92). If the element is extremely dirty, a more frequent change interval may be required.

Fig. 92: Filter locations

© Bucyrus America, Inc.

Return filter

Pressure filter

Pressure filter

______________________________________________________________ A6474X293 VIVI/01 5.91

Maintenance _________________________________________________ conveyor reducer

Change the oil in the conveyor drive reducer (Fig. 93). The reducer oil should be changed after the first 500 hours of operation and every 2500 hours afterwards.

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

Clean and reinstall drain plug.

Add oil (Spec. 100-6) as required (approximately 11 gallons) until fluid is visible in sight glass or begins to flow from the check plug that is slightly below the center line of the input shaft.

When filling the reducer, allow enough time for all cavities inside the reducer to fill.

Install level/fill plug.

Do not overfill reducer.

Breather

Inspection cover

Drain plug Sight glass (fill to this level)

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.92

© Bucyrus America, Inc.

Fig. 93: Conveyor reducer

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

Prior to each shift the following points should be inspected: Clean and remove any foreign material from the operator’s station.

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

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

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

© Bucyrus America, Inc.

Check the hydraulic oil resevoir 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.

Check oil level in the breaker shaft gear reducer using the bottom sight glass.

Inspect all electrical and hydraulic components for condition.

Check for proper conveyor chain tensioning.

Check for proper breaker shaft drive 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.

Clean and remove any foreign materials from around the head shaft bearings.

Check the breaker shaft for missing or damaged bits.

______________________________________________________________ A6474X293 VIVI/01 5.93

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

Inspect: the conveyor chain

■

the conveyor chain flights

■

the conveyor drive sprockets

■

the conveyor tail shaft

■

the conveyor wear plates

■

the crawler pads

■

the crawler drive sprockets

■

the crawler idler rollers © Bucyrus America, Inc.

■

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.94

________________________________________________ Maintenance Inspection of fire suppression system To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 94).

Note general appearance for mechanical damage or corrosion.

Check nameplate for readability, corrosion or looseness.

Remove fill cap assembly.

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

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

Check pressure relief vent in fill opening threads for obstruction.

© Bucyrus America, Inc.

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 or blow off caps.

Check remote actuator (dashboard type).

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

______________________________________________________________ A6474X293 VIVI/01 5.95

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.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.96

________________________________________________ Maintenance Recharge of fire suppression system To return your fire suppression system to service after use (Fig. 94).

Pull ring on safety valve to relieve actuator system pressure.

Disconnect actuation system hose at cartridge receiver/actuator assembly.

Open bursting disc union assembly.

Remove extinguisher from bracket.

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

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

Clean fill opening threads and gasket seating surface.

© Bucyrus America, Inc.

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.

______________________________________________________________ A6474X293 VIVI/01 5.97

Maintenance _________________________________________________ Fig. 94: Fire suppression system Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Nozzle

Breaker coupling

Operator’s station

Nozzle Nozzle Breaker motor Nozzle

Nozzle

Oil tank LP expellant © Bucyrus America, Inc.

LP canister

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.98

_______________________________________ Adjustment procedures Instructions on the adjustment procedures It is essential that adjustments be made periodically to the conveyor chain, breaker drive chain and crawler tracks, as otherwise damage can be caused to other parts of the machine or to the assembly itself.

Inspect the adjustments at regular intervals.

Conveyor chain adjustment The conveyor chain is a complete assembly and should be checked for correct tension at regular intervals (see Weekly Maintenance section in this chapter).

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

© Bucyrus America, Inc.

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 95): Close the stop valves on manifold assembly securely by turning clockwise.

Attach a grease gun to the grease fittings located on the manifold and apply grease until the required pressure is attained.

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 of grease cylinder.

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

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

Replace retainers.

Release pressure on the take-up cylinders by opening the valves (turn counter clockwise) to vent grease, allowing tail shaft pressure to rest completely on shims. Do not close valve.

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

Store any unused shims under cover plate at the tail shaft area..

______________________________________________________________ A6474X293 VIVI/01 5.99

Adjustment procedures ________________________________________

Grease fitting, left hand grease cylinder

Grease fitting, right hand grease cylinder

Stop valve, left hand grease cylinder

Shim storage

Stop valve, right hand grease cylinder

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.100

© Bucyrus America, Inc.

Fig. 95: Conveyor chain adjustment

_______________________________________ 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. 96): Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

© Bucyrus America, Inc.

Chain sag should be 2” to 3” (50 mm to 75mm) 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 2” to 3” (50 mm to 75mm) at the center of the crawler.

Turn needle valve knob clockwise (CW) to close.

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

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

Run crawler in forward direction for 3 minutes at slow speed.

Run crawler in reverse direction for 3 minutes at slow speed.

Shutdown machine.

If necessary, re-adjust chain sag.

Add or remove required amount of shims to maintain correct tension.

Release grease pressure in the cylinder by loosening the grease fitting and turning the valve knob counter clockwise, allowing the shims to maintain the correct tension. Tighten the grease fitting once grease has stopped coming out around the grease fitting.

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.

______________________________________________________________ A6474X293 VIVI/01 5.101

Adjustment procedures ________________________________________ Fig. 96: Crawler track adjustment

When properly tensioned, chain sag should be 1 3/4” (44.5 mm) at center of crawler.

Idler assembly

© Bucyrus America, Inc.

Access cover

Take-up cylinder

Grease fitting

Needle valve

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.102

_______________________________________ Adjustment procedures Primary valve bank relief pressure setting WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.

Note: The primary valve bank (Fig. 97) has two relief adjustment screws located at the inlet section and the mid-inlet section. The required primary system pressure is 2,250 psi.

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

© Bucyrus America, Inc.

2. Operate a hydraulic cylinder function (Fig. 97) from the inlet section of the valve bank until the cylinder is completely bottomed out and no further movement of the cylinder is observed.

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 to perform this adjustment as it is unsafe. Failure to adhere to this warning may result in serious injury or death.

3. Refer to the corresponding auxiliary system pressure gauge (Fig. 97) for that half of the valve bank and observe the pressure value while holding the valve bank handle in the operating position chosen to bottom out the hydraulic cylinder. If the pressure reading is not 2,250 psi, adjustment is required.

4. Release the valve bank handle to allow it to return to the neutral position.

5. Loosen the locking hex collar of the corresponding pressure relief valve for the inlet valve bank section.

6. Insert a large flat blade screwdriver into the pressure adjustment screw slot and turn the screwdriver clockwise to increase the relief pressure setting and counterclockwise to decrease the relief pressure setting. Repeat Step 3 until 2,250 psi is indicated on the corresponding inlet pressure gauge.

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.

______________________________________________________________ A6474X293 VIVI/01 5.103

Adjustment procedures ________________________________________ NOTICE! While adjusting the relief pressure, if the system pressure gauge reading is not changing, it must be determined that the valve handle from the same half of the valve bank as the pressure relief valve is being operated. To resolve this issue, ensure that the valve bank function is from the same half of the valve bank as the relief pressure adjustment screw.

7. Maintain the position of the adjustment screw by holding with the screwdriver while turning the hex lock collar clockwise to increase the relief pressure setting and counterclockwise to decrease the relief pressure setting. Repeat Step 3 until 2,250 psi is indicated on the corresponding pressure gauge.

8. Return to Step 2 and repeat the same adjustments for the midinlet section of the primary valve bank.

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

Note: The hydraulic source of the secondary valve bank is from the far right hand valve bank section of the primary valve bank. The primary valve bank relief adjustment must be performed first before the relief adjustment of the secondary valve bank can be preformed. The required secondary system relief pressure is 2,250 psi for both the primary and secondary valve banks.

1. Turn the machine on. Refer to the corresponding section of this manual for start up procedures if necessary.

2. Pull the far right hand handle of primary valve bank towards the operator to send hydraulic fluid to the secondary valve bank.

The far right hand section of the primary valve bank has a detent action handle and will remain in an operating position until it is manually placed back into neutral.

3. Operate a hydraulic cylinder function from the secondary valve bank until the cylinder is completely bottomed out and no further movement of the cylinder is observed.

CAUTION! The feeder tailpiece or a roof anchor cylinder will move during this step and it must be ensured that all standard safety procedures are adhered to avoid personnel injury and equipment damage.

4. Refer to the corresponding auxiliary system pressure gage for that half of the primary valve bank from which the secondary valve bank is fed and observe the pressure value while holding the valve bank handle in the operating position chosen to bottom the hydraulic cylinder. Adjustment will be required if the pressure gage does not read 2,250 psi.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.104

© Bucyrus America, Inc.

Secondary valve bank relief pressure setting

_______________________________________ Adjustment procedures 5. Release the valve bank handle to allow it to return to the neutral position.

6. Loosen the locking hex collar of the pressure relief valve.

7. Insert a large flat blade screwdriver into the pressure adjustment screw slot and turn the screwdriver clockwise to increase the relief pressure setting and counterclockwise to decrease the relief pressure setting. Repeat Step 3 until 2,250 psi is indicated on the corresponding pressure gage used to set the relief pressure on the mid inlet of the primary valve bank.

© 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 system.

8. Lock the pressure adjustment screw in place by turning the hex collar clockwise while still holding the pressure adjustment screw with the screwdriver so as not to alter the desired pressure setting. Once the hex collar is snugged down, Repeat Step 3 to ensure the relief pressure setting was not accidentally changed during the tightening of the hex collar. If the relief pressure setting has changed, loosen the hex collar and readjust the pressure adjustment screw.

9. Turn off the machine.

______________________________________________________________ A6474X293 VIVI/01 5.105

Adjustment procedures ________________________________________ Fig. 97: Valve banks Hydraulic cylinder function - left lift

Tram, left

Tram, right

Hydraulic cylinder function - right lift

Auxiliary system pressure gauges

Primary valve bank inlet relief used for the 3 valve bank sections to the right

Primary valve bank mid-inlet relief used for the 3 valve bank sections to the right

Secondary valve bank inlet relief

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.106

© Bucyrus America, Inc.

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

____________________________________ Replacement of wear parts

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

Head shaft The head shaft (Fig. 98) transmits the torque of the hydraulic motor to the conveyor chain assembly. It is part of a complete assembly. As soon as any component is worn, the component or complete head shaft must be replaced. Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

© Bucyrus America, Inc.

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

drive shaft

■

sprockets

■

bearings

■

hydraulic motor

Fig. 98: Head shaft main components Sprocket (2)

Head shaft Key (2)

Bearing (2)

______________________________________________________________ A6474X293 VIVI/01 5.107

Replacement of wear parts _____________________________________ How to remove the head shaft To remove the head shaft assembly from the feeder breaker proceed as follows (Fig. 99): 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 head shaft. (See Conveyor chain replacement in this chapter).

Remove head shaft safety guard located on the left hand side of the feeder, behind the conveyor motor.

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

Unpin from the tailpiece hoppers 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 eight (8) bolts located in the coupling between the head shaft and the conveyor reducer.

NOTICE! It is not necessary to remove the conveyor power unit in order to remove the headhsaft.

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

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

Attach an appropriate lifting device to the head shaft and slide out towards the rear of the frame.

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.108

© Bucyrus America, Inc.

Block and secure tailpiece.

____________________________________ Replacement of wear parts How to install the head shaft To install the head shaft assembly proceed as follows (Fig. 99): Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the feeder breaker.

Align the coupling halves on the headshaft and the output shaft of the conveyor drive gear reducer. Install new bolts, lock washers, and hex nuts. Torque incrementally and evenly in a crossing pattern as follows: 1st step: Snug 2nd step: 215 ft-lb 3rd step: 430 ft-lb 4th step: 645 ft-lb Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) 7/8” nuts, bolts, flat washers, and lock washers. Torque bolts to 645 ft-lbs.

© Bucyrus America, Inc.

Install the left and right sprocket guards, head shaft filler plates, tailpiece hoppers, and tailpiece tilt cylinders (see Tailpiece installation procedure in this chapter).

Connect the central lubrication hoses on both head shaft bearings.

Install head shaft safety guard over the coupling (see Conveyor power unit installation in this chapter).

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

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

Fig. 99: Head shaft removal and installation Lubrication hose connection, typical 2 places

Conveyor chain (not shown)

Bolt (4) Flat washer (4) Lock washer (4) Nut (4)

Head shaft Sprocket (2) Head shaft bearing (2)

Head shaft coupling half (2)

Frame slot (2) ______________________________________________________________ A6474X293 VIVI/01 5.109

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. 100): Remove the head shaft assembly from the feeder breaker (see Drive shaft removal in this chapter).

Remove the two (2) bearings from the head shaft.

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

Remove old keys.

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

See parts manual for replacement parts list.

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

Insert one of the keys into the shaft keyway and slide first sprocket onto shaft.

Insert the other key into the shaft keyway and slide second sprocket onto shaft.

Slide both bearings onto shaft.

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.110

© Bucyrus America, Inc.

Slide both sprockets from the head shaft.

____________________________________ 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. 100): IMPORTANT! Adhere to all weld specifications shown on Fig. 100. 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.

© Bucyrus America, Inc.

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

Thoroughly clean and degrease the drive shaft.

Insert key into shaft keyway.

Install both sprocket halves onto shaft and tack weld in place.

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 cool 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).

______________________________________________________________ A6474X293 VIVI/01 5.111

Replacement of wear parts _____________________________________ Fig. 100: Head shaft sprocket removal and installation 3/8 X 45° weld chamfer Head shaft

Bearing (2)

Sprocket guard 3/8 X 45° weld chamfer

Split sprocket Hydraulic motor

Conveyor chain

Sprocket (2) & key (2)

1.

2.

3.

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.

20.34

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.

58.50 HOLD

3.97

41.88 HOLD

26.50

10.19

82.81 _________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.112

© Bucyrus America, Inc.

General notes:

____________________________________ Replacement of wear parts Tail shaft The tail shaft (Fig. 101) tail shaft function is to provide a means for adjusting the conveyor chain and to redirect conveyor chain direction.

The tail shaft assembly or any tail shaft component must be replaced as soon as inspection shows advanced wear. Due to the high abrasion forces, the tail shaft is subject to a very high level of wear.

© Bucyrus America, Inc.

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

shaft

■

sprocket (2)

■

slide plate

■

key (2)

■

set screw (2)

■

roller bearing (2)

■

piston rod adapter (2)

■

grease fitting (2)

Fig. 101: Tail shaft main components Sprocket (2)

Key (2) Set screw (2)

Tail shaft

Slide plate

Grease fitting (2)

Roller bearing (2) Piston rod adapter (2)

______________________________________________________________ A6474X293 VIVI/01 5.113

Replacement of wear parts _____________________________________ How to remove the tail shaft To remove the tail shaft assembly from the feeder proceed as follows (Fig. 102): Release tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

Clean the silicone from the five (5) socket head bolts and remove the bolts from each of the tail shaft retainers and lift out the retainers.

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

Remove the tail shaft shims and swivel grease fittings.

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

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

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 102): With an appropriate lifting device, insert tail shaft into receiving boom.

Fold the conveyor chain over tail shaft.

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

Install swivel grease fittings.

Connect central lubrication hoses and lubricate tail shaft and slide plate bearings with Spec. 100-3 grease.

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

Install the tail shaft retainers with the five (5) bolts in each side.

With machine running, inspect tail shaft to ensure that the shaft is turning and conveyor chain is engaging the tail shaft sprockets properly.

Fill the socket head bolts with silicone. _________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.114

© Bucyrus America, Inc.

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

____________________________________ Replacement of wear parts Fig. 102: Tail shaft removal and installation

Cover

Tail shaft retainer plates (2)

Shims

© Bucyrus America, Inc.

Take-up cylinder

Shim storage (typical both sides)

Tail shaft

Sprocket (2) Swivel grease fitting (2)

______________________________________________________________ A6474X293 VIVI/01 5.115

Replacement of wear parts _____________________________________ How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 103): Remove the tail shaft assembly from the feeder. (See How to remove the tail shaft in this chapter).

Loosen the set screws in the bearing retainer collors and slide both roller bearings and piston rod adapters from the tail shaft.

Loosen the set screws from both tail shaft sprockets and slide rollers from the shaft.

Remove the tail shaft from the slide plate weldment.

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

How to assemble the tail shaft

Thoroughly clean all parts that will be installed.

Grease tail shaft with Spec. 100-3 grease.

Slide tail shaft into the slide plate.

Insert keys into keyways on tail shaft.

Slide both sprockets onto tail shaft, one on each end.

Apply Loctite 242 (blue) and install set screws into both sprockets, ensuring that rollers and tail shaft slide plate are centered on tail shaft.

Tighten set screws (torque to 100 ft-lb).

Apply Never Seez to the outside and inside diamters of the piston rod adapter and install into the tailshaft take-up bearing.

Install both roller bearings and piston rod adapter on tail shaft, one on each end.

Apply Loctite 242 (blue) to the set screws of the take up bearing and install into the bearing retainer collars. Torque to 100 ft-lbs.

Install swivel grease fittings into each end of shaft.

Install assembled tail shaft into machine. (See How to install the tail shaft in this chapter).

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.116

© Bucyrus America, Inc.

To assemble the tail shaft assembly proceed as follows (Fig. 103):

____________________________________ Replacement of wear parts Fig. 103: Tail shaft disassembly and assembly

Key (2) Set screw (2)

Sprocket (2) Tail shaft

Swivel grease fitting (2)

© Bucyrus America, Inc.

Roller bearing (2) Piston rod adapter (2)

Slide plate

______________________________________________________________ A6474X293 VIVI/01 5.117

Replacement of wear parts _____________________________________ Conveyor chain The conveyor chain (Fig. 104) 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. 104: Conveyor chain main components

6 link chain section Spiral pin Flight bar

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.118

____________________________________ Replacement of wear parts How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 105): Lay conveyor chain sections on a clean flat surface.

Insert connector pins through flight end and align holes in spiral pin with holes in flight bar.

Insert spiral pin.

Drive spiral pin in with a hammer and punch. Ensure that spiral pin is recessed on both sides of flight bar.

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

© Bucyrus America, Inc.

Fig. 105: Conveyor chain assembly

Extended pin connecting link Spiral pin (4)

Block link assembly

Flight bar

Side bar

6 link chain section

______________________________________________________________ A6474X293 VIVI/01 5.119

Replacement of wear parts _____________________________________ How to remove the conveyor chain assembly To remove the conveyor chain assembly proceed as follows: Release tension on the conveyor. (See Conveyor chain adjustment in this chapter).

Separate conveyor chain by removing T pins and connecting links in the section of the chain that is aligned with the knockout areas located in the receiving hopper. .

Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the conveyor chain and slowly pull the conveyor chain completely out of the machine.

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

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

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

If not retracted, see Conveyor chain adjustment in this chapter.

Run a cable or pull rope with an adequate load limit through the bottom conveyor pan and connect to the conveyor chain.

Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to the other end of the cable or pull rope and slowly pull the conveyor chain completely through the bottom conveyor pan.

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

Fold conveyor chain back over the tail shaft and drive shaft and slowly pull the chain along the conveyor ensuring that the chain is under the chain hold downs.

Ensure that the chain is properly meshed with the drive sprockets and aligned with the tail shaft sprockets.

Connect conveyor chain (see How to assemble the conveyor chain sections in this chapter for proper connection).

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

With machine running, visually inspect tail shaft to ensure that that the shaft is turning and conveyor chain is engaging tail shaft sprockets properly. _________________________________________________________________

5.120

BUC – Model 7MFBM-48DD Feeder Breaker

© Bucyrus America, Inc.

How to install the conveyor chain assembly

____________________________________ Replacement of wear parts Crawler track The crawler track (Fig. 106) 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. 106: Crawler track main components

© Bucyrus America, Inc.

Crawler pad

Connector pin and T-pin

______________________________________________________________ A6474X293 VIVI/01 5.121

Replacement of wear parts _____________________________________ How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 107): Lay crawler track pads on a clean flat surface.

Align pads with chain connecting holes centered.

Insert connector into center of crawler pad connecting holes.

Drive T-pin through connecting pin and bend end to secure.

Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly

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

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

Crawler track tension must be released (see Crawler track adjustment in this chapter).

Lift and block the crawler pad to expose a connecting pin at the drive sprocket area (Fig. 109).

Separate the crawler pads.

To separate the crawler pads proceed as follows (Fig. 108) 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.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.122

© Bucyrus America, Inc.

To remove the crawler track pad assembly proceed as follows (Fig. 107):

____________________________________ 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. 107):

© Bucyrus America, Inc.

Remove old crawler track pad assembly (see previous section, How to remove crawler track pad assembly.

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

Check to ensure that crawler track tension cylinder is completely retracted (see Crawler track adjustment in this chapter).

Slide crawler track pad assembly under crawler assembly.

Fold pad assembly over both ends of crawler assembly. Ensure that pad assembly meshes with drive sprocket and idler roller.

Connect crawler track pad assembly at the drive sprocket location (Fig. 65) (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).

______________________________________________________________ A6474X293 VIVI/01 5.123

Replacement of wear parts _____________________________________ Crawler assembly The crawler assembly (Fig. 107) consists of a take-up assembly and drive assembly that transmits torque to the crawler track via a hydraulic drive motor coupled to the tram drive torque hub. As soon as any component of the drive assembly is worn or damaged, the component must be replaced.

■

hydraulic drive motor

■

tram drive torque hub

■

cat pad assembly

■

take-up roller assembly

■

grease take-up assembly

■

drive sprocket © Bucyrus America, Inc.

The crawler assembly consists of the following main components:

Fig. 107: Crawler assembly main components

Cat pad assembly

Recommended crawler chain separation point

Drive sprocket

Hydraulic motor (not shown)

Torque hub Take-up cylinder & shims Take-up roller assembly and grease point

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.124

____________________________________ Replacement of wear parts How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 108): Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

Crawler track tension must be released (see Crawler track adjustment in this chapter.

Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear take-up.

Securely block under the crawler frame.

© Bucyrus America, Inc.

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.

______________________________________________________________ A6474X293 VIVI/01 5.125

Replacement of wear parts _____________________________________ How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 108): 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.

Grease the take-up assembly thru the grease fitting located in the end of the roller pin. Ensure that there is a grease fitting in each end of the roller pin and that grease completely fills the bearing housing and appears between the roller wheels and the bearing housing.

Attach appropriate lifting device to take-up assembly and slide assembly completely into the end of crawler frame.

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).

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© Bucyrus America, Inc.

Clean all dirt and debris from inside crawler frame.

____________________________________ Replacement of wear parts Fig. 108: Crawler take-up removal and installation

Crawler take-up assembly

Tilt cylinder Tilt cylinder mounting bracket

© Bucyrus America, Inc.

Crawler frame

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Replacement of wear parts _____________________________________ How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 109): Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

Crawler track tension must be released (see Crawler track adjustment in this chapter).

Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear sprocket.

Remove slotted nut, roll pin, and washer from tiltcylinder anchor pin.

Slide anchor pin out of crawler frame and swing tilt cylinder free of the crawler frame.

Remove the six (6) bolts and lock washers that secure the removable side plate to crawler frame and remove side plate.

Remove the twelve (12) bolts and lock washers that secure the torque hub to the crawler frame.

Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.

Remove the four (4) bolts and lock washers that secure the hydraulic motor and adapter plate to the torque hub.

Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.

Slide adapter plate and motor off of torque hub.

Remove adapter plate gasket.

Remove the four (4) nuts and lock washers that secure the hydraulic motor to the adapter plate and remove adapter plate.

Remove the twenty (20) bolts and lock washers that secure the sprocket to the torque hub and separate hub and sprocket.

Inspect all components for wear or damage.

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© Bucyrus America, Inc.

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

____________________________________ Replacement of wear parts How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 109): Remove old crawler drive assembly (see previous section, How to remove crawler drive assembly).

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

Inspect all components for wear or damage prior to installation.

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:

© Bucyrus America, Inc.

■ ■ ■

Step 1: 70 ft-lb Step 2: 140 ft-lb Step 3: 210 ft-lb

Apply Loctite 518 gasket eleiminator 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.

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

Place adapter plate gasket onto torque hub.

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.

Install motor and adapter plate assembly onto torque hub, being careful not to damage motor shaft or gasket. Secure with the (4) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows: ■ ■ ■

Step 1: 25 ft-lb Step 2: 50 ft-lb Step 3: 70 ft-lb

If using a motor adaptor plate that does not have the keepers already installed, then weld four (4) keepers at each corner of the motor flanges to prevent motor movement Clean all dirt and debris from mounting area of crawler frame.

Attach an appropriate lifting device to the torque hub and slide complete assembly into crawler frame.

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Replacement of wear parts _____________________________________ 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 or Never Seez to anchor pin and slide pin through crawler frame and tilt cylinder. Secure pin with slotted nut, washer and roll pin.

Purge hydraulic system of air.

Adjust crawler track pad tension (see How to adjust crawler track pad tension in this chapter).

Fig. 109: Crawler drive disassembly and assembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

10.

11.

12.

13.

14.

15.

16.

17.

18.

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

19.

20.

21.

22.

23.

24.

25.

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

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© Bucyrus America, Inc.

■ ■ ■

____________________________________ Replacement of wear parts Conveyor power unit The conveyor power unit (Fig. 110) has been assembled as a unit and can be removed as a unit or as individual components. As soon as any component of the power unit is worn or damaged, the component must be replaced.

The power unit consists of the following main components: ■

motor (150 hp)

■

gear reducer with coupling half

■

companion flange

■

flexible coupling

■

connecting tube

■

torque limiter

© Bucyrus America, Inc.

Fig. 110: Conveyor power unit main components Gear reducer with coupling half

Adapter plate

Connecting tube cover plate

Flexible coupling

Connecting tube

Companion flange Motor (150 HP) Torque limiter

Motor shaft guard

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Replacement of wear parts _____________________________________ How to remove the conveyor power unit To remove the power unit as a complete assembly proceed as follows (Fig. 111): Remove power unit covers from the machine.

Remove the headshaft coupling guard.

Disconnect and tag all electrical wiring to the drive motor.

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

Attach an appropriate lifting device to the complete unit and slowly lift the unit from the machine until the weight is removed from the two mounting pins.

Remove the two (2) mounting pins.

Remove the eight (8) bolts from the headshaft/gear reducer coupling.

Countinue to lift the conveyor power unit from the machine.

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

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

To install the power unit as a complete assembly proceed as follows (Fig. 111): Attach an appropriate lifting device to the complete unit and slowly lift the unit onto the machine. Align the gear recuer output shaft with the headshaft. Align the gear reducer output shaft with the headshaft. Align the bolt holes of the coupling halves and install new bolts, lock washers, and hex nuts. Torque incrementally and evenly in a crossing pattern as follows: 1st step: Snug 2nd step: 215 ft-lbs 3rd step: 430 ft-lbs 4th step: 645 ft-lbs

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© Bucyrus America, Inc.

Disconnect, cap, and tag grease lines to the electric motor and gearbox.

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

Align the pin holes in the gear reducer adapter plate with the mounting lugs on the machine frame.

Install mounting pins and cotter pins.

Connect all electrical wiring to the drive motor.

Connect all grease lines to the drive motor and gearbox.

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

Install headshaft coupling guard.

Install breaker drive covers.

© Bucyrus America, Inc.

Fig. 111: Conveyor power unit removal and installation

Power unit

Mounting bolts (8)

Mounting pins (2)

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Replacement of wear parts _____________________________________ How to disassemble the conveyor power unit To disassemble the power unit proceed as follows (Fig. 113): Remove complete unit from machine. (See How to remove the drive unit in this chapter) Open the access cover on the connecting tube by removing the four (4) 5/8” hex bolts and lock washers.

Attach a lifting device to the electric motor.

Remove the sixteen (16) 7/8” bolts, lock washers, and hex nuts.

Slowly separate the electric motor from the connecting tube. Use caution when guiding the motor shaft out of the tube as half of the flexible coupling will still be attached to the motor shaft.

Loosen the four (4) 1/2-13 set screws located in the half of the flexible coupling attached to the motor shaft, applying heat to the set screws as necessary to liquify the thread locker.

Remove the flexible coupling half and shaft key.

Attach a lifting device to the connecting tube.

Remove the eleven (11) 1-1/8 hex bolts and lock washers from the connecting tube.

Slowly separate the connecting tube from the gear reducer adapter plate. Use caution as the flexible coupling half, torque limiter, and companion flange are still attached to the reducer input shaft.

Remove the flexible coupling element from the jaws of the coupling half that is still bolted to the torque limiter.

Remove the eight (8) M12X1.75X35 socket head caps screws and lock washers from the remaing flexible coupling half, applying heat to the bolts if necessary to liquify the thread locker.

Remove the twelve (12) 7/16-20X1” socket head cap screw and lock washers form the companion flange. Ensure the torque limiter is secured so as not to fall off of the companion flange.

Remove the two (2) 1/2-13 set screws from the companion flange, applying heat to the set screws if necessary to liquify the thread locker.

Slide the companion flange from the reducer input shaft and remove the key.

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© 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.

____________________________________ Replacement of wear parts Remove the four (4) 5/8 bolts and lock washers from the fan end of the motor and separate the shaft guard from the electric motor.

Inspect all parts for wear and damage, especially the torque limiter and the flexible coupling element.

Refer to Fig. 112 for torque limiter thickness measurement to determine if clutch rebuild is necessary.

Attach a lifting device to the reducer adapter plate and remove the twelve (12) 3/4-10X2-1/2 socket head cap screws and lock washer from the reducer. Slowly separate the adapter plate from the reducer. Caution must be used to avoid damage to the cooling fan on the gear reduceer.

© Bucyrus America, Inc.

Fig. 112: Torque limiter thickness measurement

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Replacement of wear parts _____________________________________ How to assemble the conveyor power unit To assemble the power unit proceed as follows (Fig. 113): Clean the mating surfaces of the gear reducer and adapter plate.

Check for surface defects and adpater plate flatness.

With the aid of a lifting device, slowly lift the adapter plate onto the pilot fit end of the input side of the gear reducer. Be careful to damaging the fan with the adaptor plate. Install the twelve (12) 3/410X2-1/2 socket head cap screws and lock washers and torque incrementally and evenly in a crossing pattern as follows: 1st step: snug 2nd step: 90 ft-lbs 3rd step: 180 ft-lbs 4th step: 270 ft-lbs

Attach the shaft guard to the electric motor fan end with four (4) 5/8” bolts.

Install the gear reducer input shaft key.

Install the coupling flange onto the gear reducer input shaft until the counter bore on the torque limiter side is flush with the end of the shaft. Apply Loctite 242 (blue) to the two (2) 1/2-13 set screws and torque to 140 ft-lbs.

Align the pilot on the torque limiter with the coupling flange pilot counterbore and index the tapped holes on the torque limiter with the bolt hole pattern on the coupling flange.

Apply Loctite 242 (blue) thread locker to the threads of the twelve (12) 7/16-20X1” socket head cap screws.

Install twelve (12) 7/16-20X1” socket head cap screws and lock washers (note that one (1) hole every 90° will be left empty) and torque incrementally and evenly in a crossing pattern as follows: 1st step: snug 2nd step: 30 ft-lbs 3rd step: 75 ft-lbs 4th step: 100 ft-lbs Apply Loctite 242 (blue) thread locker to the threads of the eight (8) M12X1.75X35 socket head cap screws.

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© 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.

____________________________________ Replacement of wear parts Align the flexible coupling half with the pilot on the torque limiter and index the bolt holes. Install eight (8) M12X1.75X35 socket head cap screws and lock washers and torque incrementally and evenly in a crossing pattern as follows: 1st step: snug 2nd step: 30 ft-lbs 3rd step: 60 ft-lbs 4th step: 115 ft-lbs With the aid of a lifting device, align the connecting tube counterbore and the adapter plate.

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.

© Bucyrus America, Inc.

Install eleven (11) 1-1/8 hex bolts and lock washers and torque incrementally and evenly in a crossing pattern as follows: 1st step: snug 2nd step:460 ft-lbs 3rd step: 920 ft-lbs 4th step: 1,380 ft-lbs Install the remaining flexible coupling half, the coupling element, and the key onto the electric motor shaft. Do not tighten the set screws at this point.

With the aid of a lifting device, slowly mate the electric motor and the flexible coupling half with the connecting tube and flexible coupling half aready installed on the torque limiter. Carefully align the coupling jaws and the coupling element to avoid damage to either component. Secure with sixteen (16) 7/8” hex bolts and lock washers and torque incrementally and evenly in a crossing pattern as follows: 1st step: snug 2nd step:150 ft-lbs 3rd step: 300 ft-lbs 4th step: 460 ft-lbs Apply Loctite 242 (blue) to four (4) 1/2-13 set screws and install in flexible coupling half on electric motor shaft. Torque to 140 ft-lbs.

Install conencting tube access door and secure with four (4) 5/8” hex bolts and lock washers.

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

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

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Replacement of wear parts _____________________________________

© Bucyrus America, Inc.

Fig. 113: Conveyor power unit disassembly and assembly

1. Gear box 2. Adapter plate 3. Hi-collar lock washer, 3/4” (qty 12) 4. Socket head cap screw, 3/4-10X2-1/2” (qty 12) 5. Companion flange 6. Cup point set screw, 1/2-13X1/2” (qty 6) 7. Torque limiter 8. Flexible coupling 9. Connecting tube 10. Motor, 150 hp, 460 VAC

11. Lockwasher, 1-1/8” (qty 11) 12. Hex head bolt, N.C. 1-1/8X3” (qty 11) 13. Lockwasher, 7/8” (qty 16) 14. Hex head bolt, 7/8X3-3/4” (qty 16) 15. Hex nut, 7/8” (qty 16) 16. Connecting tube cover plate 17. Lockwasher, 5/8” (qty 8) 18. Hex head bolt, N.C. 5/8X1” (qty 8) 19. Motor shaft guard

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____________________________________ Replacement of wear parts

© Bucyrus America, Inc.

Fig. 113: Conveyor power unit disassembly and assembly (continued)

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Replacement of wear parts _____________________________________ Breaker assembly The breaker assembly (Fig. 114) is assembled as a complete unit and should be removed as a unit for repairs except for the replacement of bits or the under speed sensor. As soon as any component of the breaker assembly is worn or damaged, the component or complete assembly must be replaced.

■

breaker shaft

■

bearing housing (2)

■

bearing (2)

■

bits (25)

■

bearing retainer (2)

■

under speed sensor

■

breaker side plate (2)

■

retaining cap (2)

■

dust cover (2)

© Bucyrus America, Inc.

The breaker assembly consists of the following main components:

Fig. 114: Breaker assembly main components Under speed sensor

Bearing (2)

Breaker shaft

Bearing retainer

Dust cover Retainer cap

Bearing retainer

Retainer cap Dust cover Breaker side plate (2)

Bearing housing (2) Bit (25)

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.140

____________________________________ Replacement of wear parts How to remove the breaker assembly To remove the breaker assembly from the machine proceed as follows (Fig. 115): Remove covers and guards as required to gain access to the breaker assembly.

Attach a suitable lifting device to the breaker shaft gear reducer and apply enough tension to the chain to maintain the position of the power unit once the breaker shaft and gear reducer are separated at the coupling halves.

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.

© Bucyrus America, Inc.

Disconnect, tag, and cap the bearing central lubrication hoses.

Attach an appropriate lifting device around the breaker shaft assembly and apply just enough lift to remove the twenty-four (24) bolts, nuts, and washers (12 per side) that secure the breaker assembly to the frame.

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

Remove the eight (8) 7/8” hex bolts, lock washers, and hex nuts from the coupling halves that join the gear reducer output shaft and the breaker shaft.

Remove enough breaker bits to clear the feeder frame support tubes (see Breaker bit removal procedure in this chapter).

With the aid of the lifting device, slowly lift the complete assembly out 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.

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Replacement of wear parts _____________________________________ How to install the breaker assembly To install the breaker assembly into the machine proceed as follows (Fig. 115): With the aid of the lifting device, slowly lift the breaker assembly into the frame and align mounting holes.

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 breaker bits that were removed in order to clear the feeder frame support tubes (see Breaker bit installation procedure in this chapter).

Install the eight (8) 7/8” bolts, lock washers, and hex nuts into the coupling halves that mate the reducer output shaft to the breaker shaft. Torque incrementally and evenly in a crossing pattern as follows: Step 1: Snug Step 2: 215 ft-lbs Step 3: 430 ft-lbs Step 4: 645 ft-lbs IMPORTANT! The breaker shaft assemlby floats left to right. Do not alter the pivot mount lugs if, during assembly, alignment is difficult.

Simply shift the breaker shaft until alignment is obtained.

Connect the bearing central lubrication hoses.

Remove lifting devices from the gear reducer and the breaker shaft.

Install covers and guards.

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© Bucyrus America, Inc.

Secure the breaker with the twenty-four (24) bolts, nuts, and washers (12 per side) and securely tighten. Torque bolts to 900 ftlb.

____________________________________ Replacement of wear parts

© Bucyrus America, Inc.

Fig. 115: Breaker assembly removal and installation

1.

2.

3.

4.

5.

Breaker assembly Lock washer, 1-1/4” (24) Hex nut, 1-1/4” (24) Hex head bolt, 1-1/4”X4-1/2” (24) Breaker power unit

6. Pivot lug weldment 7. Pivot lug mounting plate 8. Power unit reaction pin 9. Hex head bolt, 7/8”X4” (8) 10. Lockwasher, 7/8” (8)

11. Hex nut, 7/8” (8) 12. Lock washer, 1” (4) 13. Hex head bolt, 1”X2” (4) 14. Cotter pin, 3/8”X4” (2) 15. Shaft guard assembly

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Replacement of wear parts _____________________________________ How to remove the breaker bit To remove the breaker bit from the breaker shaft bit holder proceed as follows (Fig. 116): Remove the external retaining rings (2) from the shank end of the bit with a pair of external retaining ring pliers.

Remove the bit from its holder.

How to install the breaker bit To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 116): Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.

© Bucyrus America, Inc.

Install the external retaining rings (2) 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. 116: Breaker bit removal and installation

Retaining rings

Bit holder

Breaker bit

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.144

____________________________________ Replacement of wear parts Breaker power unit removal and installation How to remove the breaker power unit (Reference Fig. 115) WARNING! The following procedure requires the use of lifting and blocking devices. You could be seriously injured or killed by fallings loads.

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

Remove the power from the machine. Follow all local, State, Mine, and Federal lockout/tagout procedures.

Block the crawlers to prevent machine movement.

Remove covers and guards.

Disconnect, tag, and cap all grease and hydraulic hoses.

© Bucyrus America, Inc.

Open the electric motor junction box and disconnect and tag the electric motor leads.

Attach a suitable lifting device to the electric motor and gear reducer in a manner such that it will be safe to lift and the assembly will be balanced and stable and so that components will not be damaged.

Apply tension to the lifting device to remove any visible slack.

Position blocking devices under the power unit assembly in case the assembly falls.

Remove the eight (8) 7/8” hex bolts, lock washers, and hex nuts from the reducer output shaft/breaker shaft flanged coupling. Discard the hardware.

Remove the cotter pins and reaction pin from the reaction pivot mount.

Slowly separate the power unit from the rest of the machine and lower it to the ground. Use caution to avoid bumping and damaging the hydraulic pump.

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Replacement of wear parts _____________________________________ How to install the breaker power unit (Reference Fig. 115) WARNING! The following procedure requires the use of lifting and blocking devices. You could be seriously injured or killed by fallings loads.

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

Attach a suitable lifting device to the electric motor and gear reducer in a manner such that it will be safe to lift and the assembly will be balanced and stable and so that components will not be damaged. Slowly position the power unit in the machine using caution to avoid bumping and damaging the hydraulic pump.

Install the cotter pins and reaction pin in the reaction pivot mount.

Step 1: Snug Step 2: 215 ft-lbs Step 3: 430 ft-lbs Step 4: 645 ft-lbs Open the electric motor junction box and connect the electric motor leads.

Reconnect all grease and hydraulic hoses.

Replace covers and guards.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.146

© Bucyrus America, Inc.

Install eight (8) 7/8” hex bolts, lock washers, and hex nuts through the reducer output shaft/breaker shaft flanged coupling. Torque incremtnally and evenly in a crossing pattern as follows:

____________________________________ Replacement of wear parts Breaker power unit disassembly To disassemble the breaker power unit reference Fig. 117. During the disassembly procedure, lifting and blocking devices will be used. Always observe the safe working load limits of all lifting and blocking devices.

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

Remove the breaker power unit assembly from the machine (see Breaker power unit assembly removal procedure in this chapter).

With the aid of a lifting device, place the unit on a solid surface and support with blocks so the unit is stable during the disassembly process.

© Bucyrus America, Inc.

Remove the bolt from the small connecting tube door and open the door.

Loosen the two 1/2” set screw in the pump hub. Apply heat if necessary to liquify the Loctite 242 (blue).

Remove the four 5/8” hex head cap screws and lock washers from the pump and separate the pump from the small connecting tube.

Use caution as the pump weighs approximately 80 pounds.

Remove the eight hex head cap screws and lock washer from the connecting tube and separate the connecting tube from the electric motor. Use caution as the connecting tube weighs approximately 60 pounds.

Remove the two drive pins from the motor hub and pump hub assembly and separate the pump hub from the motor hub.

Loosen the two 1/2” set screws from the motor hub. Apply heat if necessary to liquify the Loctitee 242 (blue).

Separate the motor hub from the electric motor shaft.

Remove the access door on the large connecting tube by removing the four bolts and lock washer securing it.

Attach a lifting device to the electric motor and apply tension to remove any slack in order to prevent the motor from moving/falling during further disassembly.

CAUTION! The following step is a two person job. While one person is separating the components, the other person should look through the open access door to ensure that the flexible coupling half jaws and the coupling element are not damaged.

______________________________________________________________ A6474X293 VIVI/01 5.147

Replacement of wear parts _____________________________________ Separate the electric motor and the first half of the coupling and the taper lock bushing from the connecting tube, remove the sixteen 7/8” hex head cap screws, lock washers, and nuts from the connecting tube.

Using the lifting device, place the electric motor on a solid surface and block it up to prevent moving/falling during further disassembly.

Remove the three socket head cap screws from the taper lock bushing. Apply heat if necessary to liquify the Loctite 242 (blue).

Clean any remaining Loctite from the threads of two of the socket head cap screws.

Install the two cleaned socket head cap screws into the threaded jacking holes of the taper lock bushing and tighten in even increments to remove the taper lock bushing from the electric motor shaft and flexible coupling half. Use caution as the parts weigh approximately 40 pounds.

Attach a lifting device to the large connecting tube and apply tension to remove any slack.

Remove the twelve 1-1/8” hex head cap screws and lock washers from the connecting tube and slowly separate the tube from the gear reducer adapter plate. Use caution so as not to damage the torque limiter during this disassembly step.

Remove the eight M12X1.75X35 socket head cap screws and lock washers from the second flexible coupling half. Apply heat if necessary to liquify the Loctite 242 (blue).

Separate the second half of the flexible coupling from the torque limiter. Use caution as this part weighs approximately 40 pounds.

Remove the twelve 7/16” socket head cap screws, applying heat if necessary to liquify the thread locker, and lock washers from the companion flange and separate the torque limiter from the companion flange. Use caution as this part weighs approximately 80 pounds.

Loosen the two (2) 1/2-13X1/2” set crews from the companion flange. Apply heat if necessary to liquify the thread locker.

Slide the companion flange from the gear reducer input shaft. Use caution as this part weighs approximately 30 pounds.

Attach a lifting device to the gear reducer adapter plate and apply tension until any slack is removed.

Remove the twelve 3/4” socket head cap screws and lock washers from the adapter plate.

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© Bucyrus America, Inc.

Remove the flexible coupling element from the jaws of the second flexible coupling half that is still inside the connecting tube.

____________________________________ Replacement of wear parts Slowly separate the adapter plate from the reducer using caution to avoid damage to the cooling fan on the reducer input shaft.

Inspect all parts for damage and wear. Inspect for torque limiter friction disc wear by measuring the torque limiter thickness as shown in Fig. 117 (continued page).

© Bucyrus America, Inc.

Fig. 117: Breaker power unit disassembly and assembly

1. Gear reducer 2. Reducer plate 3. Hi-collar lock washer, 3/4” (12) 4. Socket head cap screw, 3/4X2” (12) 5. Connecting tube weldment 6. Lock washer, 1-1/8” (14) 7. Hex head cap screw, 1-1/8X3” (14) 8. Motor, 200 hp 9. Hex head bolt, 7/8X3-1/4” (16) 10. Lock washer, 7/8” (16) 11. Hex nut, 7/8” (16) 12. Companion flange 13. Torque limiter 14. Taper lock bushing

15. Flexible coupling 16. Cup point set screw, 1/2-13X1/2” (4) 17. Motor hub 18. Drive pin (2) 19. Pump hub 20. Cup point set screw, 3/8X3/8” (2) 21. Connecting tube 22. Lock washer, 5/8” (12) 23. Hex head cap screw, 5/8X2” (8) 24. Pump 25. Lock washer, 1/2” (4) 26. Hex head bolt, 1/2”X1-1/4” (4) 27. Connecting tube cover plate 28. Hex head bolt, 5/8X1” (4)

______________________________________________________________ A6474X293 VIVI/01 5.149

Replacement of wear parts _____________________________________

© Bucyrus America, Inc.

Fig. 117 (continued): Breaker power unit disassembly and assembly

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.150

____________________________________ Replacement of wear parts Breaker power unit assembly To assemble the breaker power unit assembly reference Fig. 117. During the assembly procedure, lifting and blocking devices will be used.

Always observe the safe working load limits of all lifting and blocking devices.

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.

Clean mating surfaces of gear reducer and gear reducer/ connecting tube adapter plate.

Check flatness of the adapter plate with a straight edge.

© Bucyrus America, Inc.

Attach a lifting device to the adapter plate and slowly position it on the gear reducer. Refer to Fig. 110 for proper orientation. Use caution to avoid damaging the fan during this step.

Install the twelve 3/4-10 socket head cap screws and hi-collar lockwashers through the adapter plate into the reducer. Torque incrementally and evenly in a crossing pattern as follows: Step 1: Snug Step 2: 130 ft-lbs Step 3: 260 ft-lbs Step 4: 400 ft-lbs Install the key and companion flange onto the gear reducer input shaft. Refer to Fig. 117 for correct orientation and position of the companion flange along the input shaft.

Apply Loctite 242 (blue) to the two 1/2-13X1/2” set screws and torque to 115 ft-lbs.

Apply Loctite 242 (blue) to the threads of the twelve 7/16-20X1” socket head cap screws.

Align the torque limiter with the companion flange and install the twelve 7/16-20X1” socket head cap screws and lock washers.

Note that four holes spaced evenly every 90° will be left blank as there is no corresponding hole tapped in the torque limiter. Torque the bolts incrementally and evenly in a cross pattern as follows: Step 1: Snug Step 2: 25 ft-lbs Step 3: 50 ft-lbs Step 4: 75 ft-lbs

______________________________________________________________ A6474X293 VIVI/01 5.151

Replacement of wear parts _____________________________________ Apply Loctite 242 (blue) to the threads of the eight M12X1.75X35 socket head cap screws.

Align the first half of the flexible coupling with the torque limiter and install the eight M12X1.75X35 socket head cap screws and lock washer through the coupling half into the torque limiter. Torque incrementally and evenly in a crossing pattern as follows: Step 1: Snug Step 2: 30 ft-lbs Step 3: 60 ft-lbs Step 4: 90 ft-lbs Install the flexible coupling element into the jaws of the coupling half installed on the torque limiter.

Attach a lifting device to the large connecting tube and slowly mate it to the gear reducer adapter plate. Refer to Fig. 117 for proper orientation of the access door. Use caution to avoid damaging the torque limiter.

Install the twelve 1-1/8” hex head cap screws and lock washers through the connecting tube and into the adapter plate. Torque incrementally and evenly in a crossing pattern as follows: Step 1: Snug Step 2: 460 ft-lbs Step 3: 920 ft-lbs Step 4: 1380 ft-lbs Install the taper lock busing and the remaining half of the flexible coupling onto the electric motor shaft. Refer to Fig. 117 for location along the shaft. Make a reference mark on the shaft with a piece of tape or a paint pen.

Apply Loctite 242 (blue) to the threads of three (3) 1/2-13 socket head cap screws and install the three screws and hi-collar lock washers into the taper lock bushing. Torque incrementally and evenly in a crossing pattern as follows: Step 1: Snug Step 2: 40 ft-lbs Step 3: 80 ft-lbs Step 4: 115 ft-lbs Check the reference mark on the shaft of the electric motor to ensure that the taper lock bushing has not moved. Loosen the socket head cap screws and reposition if movement has occurred.

Clean and inspect the mating surfaces of the connecting tube and electric motor.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.152

© Bucyrus America, Inc.

Inspect the mating surface of the connecting tube to ensure proper engagement with the adapter plate.

____________________________________ Replacement of wear parts Refer to Fig. 117 for proper electric motor orientation. Attach a lifting device to the electric motor assembly and slowly mate surfaces of the connecting tube and electric motor. Use a helper to ensure that the jaws of the flexible coupling halves and the coupling element are indexed and aligned to avoid damage to these parts.

Recheck all measurements and refer to Fig. 117 to ensure proper position of the companion flange, torque limiter, and flexible coupling.

CAUTION! An approximate 5/16” gap must be observed per Fig. 117 in order for the element to expand under loading conditions. Failure to have this gap will result in accelerated element failure.

© Bucyrus America, Inc.

Install the sixteen 7/8” hex head cap screws, lock washers, and hex nuts through the connecting tube and electric motor mounting flanges. Torque incrementally and evenly in a crossing pattern as follows: Step 1: Snug Step 2: 215 ft-lbs Step 3: 430 ft-lbs Step 4: 645 ft-lbs Install the large connecting tube access door with the four 5/8X1” hex head cap screws and lock washers.

Refer to Fig. 117 to measure and mark the placement location for the electric motor hub with paint pen or tape on the electric motor shaft.

Install the key and electric motor hub onto the electric motor shaft.

Apply Loctite 242 (blue) to the two 1/2-13X1/2” set screws and install into the electric motor hub. Torque to 115 ft-lbs.

Align the pump hub with electric motor hub and install the two drive pins.

Clean and inspect the mating surfaces of the electric motor and the small connecting tube. Attach the small connecting tube to the electric motor with eight 5/8” hex head cap screws and lock washers. Torque incrementally and evenly in a crossing pattern as follows: Step 1: Snug Step 2: 75 ft-lbs Step 3: 150 ft-lbs Step 4: 225 ft-lbs

______________________________________________________________ A6474X293 VIVI/01 5.153

Replacement of wear parts _____________________________________ Clean and inspect the mating surfaces of the small connecting tube and the gear pump. Install the key onto the pump shaft and attach the pump to the connecting tube with four 5/8” hex head cap screws and lock washers. Torque incrementally and evenly in a crossing pattern as follows: Step 1: Snug Step 2: 75 ft-lbs Step 3: 150 ft-lbs Step 4: 225 ft-lbs Open the access door on the small connecting tube.

Apply Loctite 242 (blue) to the threads of the two 1/2-13 set screws and install into the pump hub. Torque to 115 ft-lbs.

© Bucyrus America, Inc.

Close the small connecting tube access door and secure with hex head cap screws and lock washers.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.154

____________________________________ Replacement of wear parts How to remove the tailpiece To remove the tailpiece from the feeder breaker (reference Fig. 118): 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 steering cylinders from between the tailpiece weldment and the knuckle joint weldment by removing the pins and cotter pins.

Remove the tailpiece tilt cylinders from the tailpiece hopper weldments and the tailpiece weldment by removing the pins, and cotter pins.

© Bucyrus America, Inc.

Remove the tailpiece hopper weldments from the main frame by removing the flat washers, lock washers, hex nuts and bolts and flat washers, lock washers, hex nuts, and bolts.

Remove the pins that secure the knuckle joint and the tailpiece frames to the main frame.

Remove the pin keeper from the hex nut and then remove the tailpiece swivel pin.

Remove the knuckle piece from the tailpiece weldment by removing the tailpiece swivel pin, flat washer, hex nut, keeper pin, and cotter pin.

Remove the slider assembly by removing the flat washers, lock washers, hex nuts, and bolts.

Unbolt the impact bed assembly from the tailpiece weldment by removing the flat washers, lock washers, hex nuts, and bolts).

Remove the belt pulley assembly by removing the hex bolts, flat washers, hex nuts, and lock washers.

______________________________________________________________ A6474X293 VIVI/01 5.155

Replacement of wear parts _____________________________________ How to install the tailpiece To install the tailpiece on the feeder breaker (Reference Fig. 118): 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 belt pulley assembly using hex bolts, flat washers, hex nuts, and lock washers.

Bolt impact bed assembly to tailpiece weldment using flat washers, lock washers, hex nuts, and bolts.

Install slider assembly using flat washers, lock washers, hex nuts, and bolts.

Install knuckle piece to tailpiece weldment using tailpiece swivel pin, flat washer, hex nut, keeper pin, and cotter pin.

Position the assembled knuckle joint and the tailpiece frames to the main frame. Install pins.

Install the tailpiece hopper weldments on the main frame using flat washers, lock washers, hex nuts and bolts.

Install tailpiece tilt cylinders into the tailpiece hopper weldments and the tailpiece weldment using the swivel clevis weldments, pins, and cotter pins.

Install the steering cylinders between the tailpiece frame and the knuckle joint weldment using pins and cotter pins.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.156

© Bucyrus America, Inc.

Tighten the hex nut onto the tailpiece swivel pin then weld the pin keeper across the flat of the tailpiece swivel pin on three sides.

____________________________________ Replacement of wear parts Refer to the hydraulic schematic for hydraulic installation of the cylinders. Route all hoses, avoiding pinch points, so that hose damage does not occur.

© Bucyrus America, Inc.

Fig. 118: Tailpiece removal and installation

1. Clevis (4) 2. Knuckle joint weldment 3. Pin, 2X5-3/4” (4) 4. Tailpiece weldment 5. Tailpiece swivel pin 6. Flat washer, 1-3/4” 7. Castle hex nut, 1-3/4-5 8. Pulley assembly 9. Flat washer, 1-1/2” (8) 10.Lock washer, 1-1/2” (8) 11.Hex nut, 1-1/2” (8) 12.Headshaft filler weldment, LH 13.Headshaft filler weldment, RH 14.Tailpiece hopper weldment, RH 15.Tailpiece hopper weldment, LH 16.Flat washer, 3/4” (16) 17.Lock washer, 3/4” (18) 18.Hex nut, 3/4” (16) 19.Hex head bolt, 3/4X2-1/2” (8) 20.Hex head bolt, 3/4X3-1/4” (8)

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

Slider saddle assembly Impact bed assembly Steering cylinder (2) Knuckle clevis weldment (4) Tilt cylinder (2) Pin, 1-1/4X3-3/4” (12) Flat washer, 1/2” (14) Lock washer (14) Hex nut, 1/2” (6) Hex head bolt, 1/2X5-1/2” (6) Grease manifold weldment Grease fitting, 1/4” (2) Hex head bolt, 3/4X1-1/4” (2) Rubber skirt (2) Rubber skirt bar (2) Hex head bolt, 1/2X1” (8) Discharge skirt weldment, LH Coal line discharge skirt weldment Discharge skirt weldment, RH

______________________________________________________________ A6474X293 VIVI/01 5.157

____________________________________ Replacement of wear parts

© Bucyrus America, Inc.

Fig. 118: Tailpiece installation (continued)

______________________________________________________________ A6474X293 VIVI/01 5.158

_____________________________________________ Troubleshooting Troubleshooting procedures The following section lists problems that may be encountered when servicing the feeder breaker and can aid in locating and correcting these problems.

For machine wiring diagrams, electrical schematics, and hydraulic schematics, please consult the Bucyrus America, Inc. parts manual that shipped with your machine.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures may require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all electrical work performed.

© Bucyrus America, Inc.

For maintenance procedures and tests that DO NOT require the controller to be energized, precautions include: ■

Before removing the controller cover, remove the power from the system by disconnecting the trailing cable. Follow all local, state, Federal, and mine lockout/tag out procedures.

For maintenance procedures that DO require the controller be energized while the cover is off: ■

At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be in the “OFF” position.

During any maintenance, observe the following: ■

Use insulated gloves and tools where possible.

■

All connections must be tight and care must be taken to prevent bolts, nuts, washers, or other small metal fasteners from being dropped or lost inside the controller. These fasteners could cause electrical shorts inside the controller.

_____________________________________________________________ A6474X293 VIVI/01 5.159

Troubleshooting ______________________________________________ Hydraulic troubleshooting WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall. Machine damage or injury to personnel may result.

WARNING! Never check for hydraulic leaks with your hands. Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Do not attempt to locate hydraulic leaks by feeling around hoses and fittings with bare hands. Check for leaks with a piece of cardboard.

Typical hydraulic problems

■

contaminated oil or poor oil quality

■

low or insufficient oil in the system

■

using the wrong type of oil or wrong viscosity grade

■

air in the hydraulic system

■

internal or external leakage of the hydraulic system

■

improper mechanical adjustments, such as relief valves

■

mechanical or structural damage leading to component failure

■

components by-passing (internal leaking or inability to hold pressure), which leads to erosion of bushings, valve spools, and other critical components

The greatest aid to troubleshooting a hydraulic system is the confidence of knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles. Every component has an intended purpose and the operating characteristics of each component should be clearly understood before attempting to troubleshoot the machine. Before troubleshooting this machine, familiarize yourself with the hydraulic schematic in the Bucyrus America, Inc. parts book that shipped with your machine.

It is important to know the capabilities of the system. Each component in the system has a maximum rated speed, flow, torque, or pressure. If the system is loaded beyond the specifications, the possibility of failure is greatly increased. The correct operating pressures of the system must be know and must always be checked and set with a pressure gauge. When in doubt, always assume that the correct pressure is the lowest pressure that will allow adequate performance of the system functions while remaining below the maximum rating of the machine’s components.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.160

© Bucyrus America, Inc.

The most common cause of improper hydraulic function are:

_____________________________________________ Troubleshooting Contaminants in hydraulic systems The primary cause of hydraulic component failure is system contamination. Cleanliness must be a high priority when servicing the hydraulic system. Even very small particles can damage system components be scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this operation manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are listed below for your information.

1. Ensure that bulk oils are at acceptable cleanliness levels.

© Bucyrus America, Inc.

Areas where Bucyrus America, Inc. customers have made improvements in the past include: –

implement ISO Cleanliness Code standards for bulk hydraulic oils

–

evaluate bulk oil shipments for cleanliness by conducting particle counts and maintain records

–

minimize drum usage by utilizing tote tanks and five gallon pails

–

use plastic versus steel storage tanks, if possible

–

install desiccant breathers on all bulk tanks

–

use sealed plastic containers for adding oil to small sumps

–

locate bulk tanks near equipment and pump directly to reservoirs

–

use filter carts to maintain oil cleanliness standards

–

properly train personnel on the importance of clean oil and best practices for storage and handling

–

monitor your program closely and look for continuous improvement

2. Eliminate contamination source through “clean” maintenance practices. This is best achieved by understanding the primary sources of contamination during maintenance and troubleshooting.

–

always clean the area around the component that is to be removed and inspected

–

store components in a plastic bag after inspection and prior to replacement on the machine

–

cap off all hoses/fittings

_____________________________________________________________ A6474X293 VIVI/01 5.161

Troubleshooting ______________________________________________ –

never touch a filter with bare hands when installing it in the machine

–

pay close attention to the filler/breather cap and replace it when damaged or at the recommended interval

Following are general tables, listed in a cause/remedy format, to assist in troubleshooting the feeder breaker. Before performing troubleshooting, safely shutdown and disconnect the machine as follows: Lower or mechanically secure (block) all suspended loads.

Relieve any pressure in the system.

Isolate the electrical power supply.

© Bucyrus America, Inc.

Refer to the Shutdown procedure listed in this chapter for a detailed shutdown procedure.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.162

_____________________________________________ Troubleshooting Table 3: Troubleshooting excessive noise

Pump Noisy Cause

Motor Noisy Remedy

Cause

Cavitation

A

Coupling misaligned

Air in fluid

B

Motor or coupling worn or damaged

Coupling misaligned

C

Pump worn or damaged

E

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

C

Setting too low or too close to another valve setting

D

Worn poppet and seat

E

Remedies

© Bucyrus America, Inc.

A. Any or all of the following: replace dirty filters wash strainers in solvent compatible with system fluid clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed check fluid temperature B. Any or all of the following: tighten leaky inlet connections fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir bleed air from system replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following: align unit check condition of seals, bearings, and coupling D.

install and/or adjust pressure gauge

E.

overhaul or replace defective parts

_____________________________________________________________ A6474X293 VIVI/01 5.163

Troubleshooting ______________________________________________ Table 4: Troubleshooting excessive heat Pump Heated

Motor Heated Cause

Remedy

Relief Valve Heated

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

Fluid heated

See Fluid Heated

Fluid heated

See Fluid Heated

Cavitation

A

Excessive load

C

Valve setting incorrect

D

Fluid dirty or low supply

F

Air in fluid

B

Worn or damaged motor

E

Worn or damaged valve

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve, motor, cylinder, or other component

E

Fluid heated

A. Any or all of the following: replace dirty filters clean clogged inlet line clean reservoir breather vent change system fluid change to proper pump drive motor speed

F.

change filters check system fluid viscosity; change if necessary fill reservoir to proper level

G.

clean cooler and/or strainer repair or replace cooler

B. Any or all of the following: tighten leaky inlet connections fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir bleed air from system replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following: align unit check condition of seals, bearings, and coupling locate and correct mechanical binding check for workload in excess of circuit design D.

adjust setting on valve

E.

overhaul or replace defective parts

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.164

© Bucyrus America, Inc.

Remedies

_____________________________________________ Troubleshooting Table 5: Troubleshooting incorrect flow No Flow

© Bucyrus America, Inc.

Cause

Low Flow Remedy

Cause

Excessive Flow Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies A. Any or all of the following: replace dirty filters clean clogged inlet line clean reservoir breather vent fill reservoir to proper level

F. Any or all of the following check position of manually operated controls G.

reverse rotation

H.

replace with correct unit

B. Any or all of the following: tighten leaky inlet connections bleed air from system C. All of the following: check for damaged pump or pump drive replace and align coupling D.

adjust setting on valve

E.

overhaul or replace part

_____________________________________________________________ A6474X293 VIVI/01 5.165

Troubleshooting ______________________________________________ Table 6: Troubleshooting incorrect pressure No Pressure

Low Pressure

Cause

Remedy

Cause

Remedy

No flow

See Table 5

Pressure relief path exists

See Table 5

Damaged pump, motor, or cylinder

E

Erratic Pressure Cause

Remedy

Air in fluid

B

Worn relief valve

E

Contamination in fluid

A

Worn pump, motor, or cylinder

E

A.

replace dirty filters and system fluid

B.

tighten leaky connections fill reservoir to proper level and bleed air from system

C.

gas valve for leakage charge to correct pressure overhaul if defective

D.

adjust valve

E.

overhaul or replace part

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.166

© Bucyrus America, Inc.

Remedies

_____________________________________________ Troubleshooting Table 7: Troubleshooting faulty operation No Movement Cause

© Bucyrus America, Inc.

No flow or pressure

Slow Movement

Remedy

Cause

See Table Low flow 5

Erratic Movement

Excessive Speed or Movement

Remedy

Cause

Remedy

See Table 5

Erratic pressure

See Table Excessive flow 6

See Table 5

Air in fluid

See Table Overriding work 3 load

G

Limit or sequence device (mechanical, electrical, or hydraulic) inoperative or misadjusted

D

Fluid viscosity too high

A

Mechanical bind

B

Insufficient control pressure for valves

See Table 6

No lubrication of machine ways or linkage

F

Worn or damaged cylinder or motor

D

No lubrication of machine ways or linkage

F

Sticking valve

C

Sticking valve

C

Worn or damaged cylinder or motor

D

Worn or damaged cylinder or motor

D

Pilot filter clogged

See Table 5

Cause

Remedy

Remedies A.

check fluid temperature check system fluid viscosity; change if necessary

B.

locate bind and repair

C.

clean and adjust or replace part check condition of system fluid and filters

D.

overhaul or replace part

E.

repair command console or interconnecting wires

F.

lubricated

G.

adjust, repair, or replace counterbalance valve

_____________________________________________________________ A6474X293 VIVI/01 5.167

Troubleshooting ______________________________________________ Hydraulic system (general)

Trouble or symptom dirty oil

foaming oil

moisture in oil

overheating of system

prolonged operation of a function at pressures above normal idle condition

Probable cause

Test, check and/or remedy

Components not properly cleaned during servicing.

Disassemble components and reclean parts.

Air breather left off.

Add breather.

Hose lines not properly covered when servicing machine.

Keep hose ends protected from contamination while disconnected.

Clean hose lines before reconnecting.

Filter elements not replaced at proper intervals or when indicated.

Replace elements at proper intervals.

Tank return lines not below fluid level.

Check oil level.

Oil contaminated with incompatible foreign matter.

Drain out oil and replace with clean oil and change filter.

Suction leak to pump aerating oil.

Replace or tighten fittings and lines.

Soluble oil solution splashing into poorly sealed tank gasket or fill holes left open.

Drain out and refill with clean oil.

Check fill pipes to see if they are properly closed.

Moisture in cans of replacement oil.

Replace with new cans of oil.

Extreme temperature differential in certain geographical locations.

Store oil in an area that protects against exposure to frequent extreme temperature changes.

Fluid viscosity too high.

Check fluid specifications.

Excessive slippage or internal leakage past pump or cylinders.

Fluid viscosity too low. Test components for specified flow or bypass conditions.

Oil level too low.

Check/add oil.

Improper air circulation around reservoir.

Check to see if the area around the reservoir is clear.

System relief valve set too high or too low.

Reset the relief valve to specifications.

Sticking selector or other control valve.

Isolate circuits/components and identify fault.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.168

© Bucyrus America, Inc.

Table 8: Hydraulic system (general) troubleshooting

_____________________________________________ Troubleshooting Table 8 (continued): Hydraulic system (general) troubleshooting Trouble or symptom

Test, check and/or remedy

Sealing compound (pipe dope, Teflon tape).

Clean or replace seals. Drain and replace oil as necessary.

Tank or component ports left open to atmosphere.

Cap or plug properly. Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.

Lines left unprotected or dirty repaired components.

Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.

Repair parts not properly protected while stored.

Check and clean parts thoroughly before installation. Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.

© Bucyrus America, Inc.

foreign matter sources in the circuit

Probable cause

_____________________________________________________________ A6474X293 VIVI/01 5.169

Troubleshooting ______________________________________________ Brakes Table 9: Brakes troubleshooting

brakes won’t release

brakes will not release completely

no brakes

Probable cause

Test, check and/or remedy

Brake release controls not functioning properly.

Inspect brake shuttle valves. Repair/replace components as required.

Pressure too low.

Check release pressure.

Defective brakes.

Check brake assemblies and repair/replace as required.

Damaged line or connections in circuit.

Repair or replace as required.

Valve (s) in any branch of this circuit contaminated or damaged.

Isolate circuits to locate the source of the leak and clean or replace as required.

Defective brakes.

Check brakes for proper operation (release pressure).

Air in brakes.

Bleed brakes.

Brake release controls not functioning properly.

Inspect brake shuttle valves.

Pressure too low.

Check release pressure.

Broken or mashed brake line.

Check lines for breaks or mashed condition.

Defective or worn brakes.

Check brake lining wear.

Valve (s) in any branch of this circuit contaminated or damaged.

Isolate circuits to locate the source of the leak and clean or replace as required.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.170

© Bucyrus America, Inc.

Trouble or symptom

_____________________________________________ Troubleshooting Hydraulic cylinders Table 10: Hydraulic cylinder troubleshooting Trouble or symptom cylinder drifts

Probable cause

Test, check and/or remedy

Piston seal leak.

Repair seals or replace cylinder.

Control cartridge by-passing.

Replace cartridge or cylinder as required.

Correct leaks.

Other circuit leaks. cylinder fails to move the load when actuated

Pressure too low.

Check pressure of circuit controls and cylinder to insure designed system pressure is attained.

Piston seal leak.

Repair seals or replace cylinder.

Piston rod broken internally.

Repair as required or replace cylinder.

© Bucyrus America, Inc.

Contamination in hydraulic system resulting in scored cylinder bore. erratic or chatter in operation

Replace cylinder. Check oil cleanliness and change as required.

Excessive friction due to misalignment and/or side loading.

Inspect cylinder installation for proper operation and/or for foreign objects that inhibit the normal operation of the cylinder.

Air in circuit.

Cycle cylinder to full stop positions to purge air.

Excessive system pressure due to over adjustment.

Check and correct pressure adjustment to rated limits.

Excessive friction due to misalignment and/or side loading.

Inspect cylinder installation for proper operation and/or for foreign objects that inhibit the normal operation of the cylinder.

Excessive pressure.

Check and correct pressure adjustment to rated limits.

Seal is pinched or extruded.

Replace seal and/or cylinder as required.

Seal deterioration (soft or gummy).

Check for contamination of fluids (incompatibility). Flush system and refill with correct fluid. Replace seal and/or cylinder as required.

Dirt has scored the piston or the rod.

Replace cylinder.

piston freezes to the tube

Scoring in the piston.

Replace cylinder.

packing and gasket leaks develop

Excessive heat/wear.

Replace seal and/or cylinder as required.

excessive or rapid piston seal wear

cylinder body seal leak

piston is leaking

_____________________________________________________________ A6474X293 VIVI/01 5.171

Troubleshooting ______________________________________________ Hydraulic pump Trouble or symptom pump makes excessive noise

seal leak

Probable cause

Test, check and/or remedy

Vacuum leaks in suction line.

Check for leaks in fittings or damaged suction lines.

Vacuum leaks in the pump shaft seal.

Check pump shaft seal for signs of brittleness or damage due to excessive heat. Replace seal as required.

Poor alignment with drive mechanism.

Check pump shaft and motor shaft insert, as well as pilot engagement, for interference.

Incorrect fluid in system.

Check fluid specifications - change fluid if necessary.

System relief settings.

Pressure adjustment too low or cartridge fouled with foreign material. Readjust to correct setting and/ or clean foreign material from cartridge.

Pump cavitation.

Check fluid level for proper level.

Check for aeration of fluid reservoir.

Check for vacuum leaks in suction lines. Repair all faults as required and/or replace pump as required.

Worn or damaged gears/ housing.

Replace pump.

Worn or faulty bearing.

Replace pump.

Reversed rotation.

Check pump motor wiring.

Plugged or restricted suction line or suction strainer.

Clean by removing the foreign material blocking oil flow.

Plugged reservoir filter breather.

Clean or replace filter breather as required.

Torn or worn seals.

Replace seal.

Gland bearing worn.

Excessive gland bearing wear will likely require pump replacement.

Seal deterioration (soft or gummy).

Check oil for fluid compatibility.

Drain oil tank and replace oil as required or if questionable. Replace seals.

Seal deterioration (hardened or loss of elasticity).

Replace seal.

Seal deterioration (flat spots on I.D.).

Check pump shaft for possible bearing wear. Replace seal.

Loose or worn pump parts.

Replace worn pump parts. _________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.172

© Bucyrus America, Inc.

Table 11: Hydraulic pump troubleshooting

_____________________________________________ Troubleshooting Table 11 (continued): Hydraulic pump troubleshooting Trouble or symptom

© Bucyrus America, Inc.

pump fails to deliver oil

oil leakage around pump

excessive pump wear

Probable cause

Test, check and/or remedy

Low oil level in reservoir.

Fill to proper level.

Oil intake hose suction strainer plugged.

Clean or replace strainer.

Air leak in suction line preventing priming.

Tighten or replace suction lines.

Pump shaft turning too slowly.

Check pump motor and controls to insure proper pump speed is attained.

Oil viscosity too high.

Replace with recommended oil.

Wrong shaft rotation.

Check pump motor wiring.

Pump shaft or parts broken.

Replace shaft or broken parts.

Pump damaged due to contamination.

Change pump, drain and replace oil in the reservoir and replace filter elements.

Shaft seal worn.

Replace seals.

Hose connections leaking.

Tighten flange bolts or adapters and hose connections as required. Replace hose, adapters, and/or seals as required.

Pump housing bolts loose or improperly torqued.

Tighten bolts to correct torque and/or replace pump if correct performance cannot be attained.

Contaminated hydraulic oil being circulated through the system.

Drain oil from the reservoir and replace it with clean hydraulic oil. Replace filter elements and implement frequent element changes until the desired cleanliness of the system is attained.

Oil viscosity too low.

Replace with recommended oil and change filter elements.

Excessive pump loads.

Check relief valve adjustment.

Reset to correct setting.

_____________________________________________________________ A6474X293 VIVI/01 5.173

Troubleshooting ______________________________________________ Table 11 (continued): Hydraulic pump troubleshooting Trouble or symptom pump parts inside the housing are broken

Probable cause Seizure due to lack of oil.

Excessive system pressure above maximum pump rating.

Excessive torque to housing bolts.

Solid matter being drawn in from reservoir and wedged in pump.

Test, check and/or remedy Check oil level and refill to design level for proper operation. Replace pump and filter elements.

Replace pump and filter elements.

Minimize the relief pressure adjustment before starting the new pump.

Replace relief valve if correct adjustment cannot be obtained.

Replace pump and filter elements.

© Bucyrus America, Inc.

Replace pump and filter elements, suction strainer, and suction hoses to insure that no foreign material can damage new pump.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.174

_____________________________________________ Troubleshooting Valves Table 12: Valve troubleshooting Trouble or symptom

© Bucyrus America, Inc.

operating pressure cannot be changed

Probable cause

Test, check and/or remedy

Valve spring broken.

Replace the spring, valve cartridge, or valve assembly as required.

Open valve in the system.

Locate and repair the open valve condition.

valve piston sticks

Dirt in the system.

Remove the valve and clean it thoroughly; flush the system as necessary. Replace valve as required and replace filter elements.

certain passages are blocked or pressure fluctuates

Dirt in the system.

Remove the valve and clean it thoroughly; flush the system as necessary. Replace valve as required and replace filter elements.

the pressure fluctuates and there is extreme noise in the valve

Air in the system.

Check for leaks and other points that may allow air into the system.

Repair as required.

Pressure or volume too high.

Check for correct pressure and/or volume adjustments and reset as required.

Valve piston and body worn.

Replace the valve.

valve leaks internally

Check and replace filter elements as required. excessive leakage or sticking pistons occurs

Valve excessively hot.

Check for proper pressure and/or volume adjustments and reset as required.

Remove the valve and clean it thoroughly; flush the system as necessary.

oil leaks between sections

Dirt in the system.

Drain and replace the oil in the reservoir. Check and replace all filter elements.

Pinched, blown or missing section seal.

Replace section seal.

Stud fasteners not correctly torqued.

Replace section seals and retorque.

Mounting plate not level.

Loosen mounting bolts and shim as required.

Contamination/butts on seal.

Clean seal groove and replace section seal.

_____________________________________________________________ A6474X293 VIVI/01 5.175

Troubleshooting ______________________________________________ Table 12 (continued): Valve troubleshooting

oil leaks at either end of spool

spring centered spools do not return to neutral

load will not hold

load drops when spool moved from neutral

no motion, slow, or erratic system operation

Probable cause

Test, check and/or remedy

Over-pressurized tank core.

Correct high back pressure condition.

Worn or damaged spool seals.

Replace seals and seal retainers.

Broken centering spring.

Replace centering spring.

Misalignment of operating linkage.

Check linkage for mechanical binding.

Foreign particles in system.

Clean valve and system.

Cylinder leaking or worn.

Check cylinder, repair as needed.

Port relief valve not holding.

Remove and clean or replace.

Spool or housing scored or worn excessively.

Replace section.

Dirt or foreign particles lodged between check valve poppet and seat.

Disassemble, clean, and reassemble.

Scored or sticking check valve poppet.

Replace poppet.

Worn pump.

Check flow and pressure.

Defective cylinder or motor.

Repair or replace.

Low reservoir oil level.

Add oil to specifications.

Clogged suction strainer.

Clean or replace.

Suction line restricted.

Check lines.

Relief valve not properly set.

Check pressure setting.

Relief valve poppet or seat scored and sticking open.

Replace relief valve.

Valve spool not shifted full stroke.

Check spool linkage travel.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.176

© Bucyrus America, Inc.

Trouble or symptom

_____________________________________________ Troubleshooting Bearings

© Bucyrus America, Inc.

Table 13: Bearing troubleshooting Trouble, symptom or cause

Probable cause

overheating bearing

Wrong type of grease or oil.

Consult the lubrication chart for the proper lubricant.

Low oil level; loss of lubricant through seal; excessive grease.

Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.

Insufficient clearance in bearing.

Replacement bearing should be identical to original equipment to ensure proper internal clearance.

Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

Shaft out of line.

Correct alignment and be sure shafts are coupled in a straight line.

Insufficient clearance in bearing.

Replacement bearing should be identical to original equipment to ensure proper internal clearance.

Foreign matter acting as abrasive.

Clean bearing housing and replace worn seals.

Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.

Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.

Shaft and other parts of bearing assembly distorted.

Replace bearing, shaft and other parts as needed.

Enlarged housing bore causing spinning of outer ring in housing.

Re-bore housing and press steel bushing in bore, then machine bore to correct size.

Foreign matter acting as abrasive.

Clean bearing housing and replace worn seals.

Unbalanced loading.

Check balance of rotating parts and rebalance as needed.

Chip in bearing housing; insufficient clearance in bearing; Ball or roller dented from extreme loading.

Replace with OEM bearing; do not hammer on any part of bearing; clean housing and use fresh lube.

noisy bearing

vibrating bearing

unsatisfactory performance

Test, check and/or remedy

_____________________________________________________________ A6474X293 VIVI/01 5.177

Troubleshooting ______________________________________________ Electrical system troubleshooting Table 14: Electrical system troubleshooting

motor contactor chatter

pump/breaker motor will not start

pump motor starts but will not keep running conveyor motor will not start

Probable cause

Test, check and/or remedy

Low voltage.

Check supply voltage, especially during start-up.

Loose connections.

Check connection from terminal block #33 to contactor coil and from terminal block #33 to O:5/2.

Three phase power not present at contactor M1.

Check for three phase input to contactor.

MCR circuit not energized.

Check pull cord switch and emergency stop pushbutton. Verify that MCR relay is energized. Check input light at I:3/10.

IS selector switches not in correct position.

Verify that the “MANUAL-AUTO” switch is in the “MANUAL” position and that the “LOCAL-REMOTE” switch is in the “LOCAL” position.

Check processor light (next to “RUN” and key position.

Verify that the key is in the run position and that the light is on. If the key is in run and the light is not on, call for PLC support. If the “FAULT” light is lit, call for PLC support.

Start circuit in PLC not healthy.

Check the input lights (see Table 15).

Overload (OL1) tripped.

Check light on overload, it should be green and flashing, red indicates tripped overload. Check I:3/2 light.

Hold in circuit.

Check input I:3/5 light (See Table 15).

Three phase power not present at contactor (F1).

Check for three phase input to the contactor.

No output from PLC.

Check output light O:5/0. Check connection from terminal block #31 to output card and from terminal block #31 to F1 coil.

Pump/breaker motor not running.

Start pump/breaker motor.

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.178

© Bucyrus America, Inc.

Trouble or symptom

_____________________________________________ Troubleshooting Table 14: Electrical system troubleshooting Trouble or symptom conveyor motor will not start

Probable cause

Test, check and/or remedy

Selector switch not in correct position.

“MANUAL-AUTO” switch must be in the “AUTO” position if the outby conveyor is running. The “LOCALREMOTE” switch must be in the ”LOCAL” position. The “FWD-REV” switch must be in the “FWD” position for forward operation or “REV” for reverse operation..

Overload (OL2) tripped.

Check light on overload, should be green and flashing, red indicates tripped overload. Check input lightI:3/3.

Start circuits in PLC not healthy.

Check the following inputs lights (see Table 15).

© Bucyrus America, Inc.

Table 15: Input light designations Breaker motor input lights Light

Description

Conveyor motor input lights Light

Description

I:3/2

OL1 & OL3 healthy.

I:4/7

Conveyor stop pick breaker N.C./infrared remote stop N.C.

I:3/10

Master control relay healthy.

I:3/5

M1 & CP AUX healthy.

I:3/8

High temperature OK.

I:4/6

Pick breaker stop N.C.

I:3/9

Low oil OK.

I:3/10

Master control relay healthy.

I:3/13

Local mode on selector switch.

I:3/12

Auto mode or I:3/11 manual.

I:4/4

Magnetic switch closed.

I:3/4

Belt sequence, if in auto.

I:3/12

Auto mode on selector switch (preferred).

I:3/15

Conveyor forward selector switch.

I:3/11

Manual mode on selector switch.

I:5/10

Will not be on until start push button is engaged and contactor F1 is in.

I:4/6

Pick breaker stop N.C.

I:3/2

OL1 & OL3 healthy.

Note: Lights are normally on. Light off indicates possible fault situation.

_____________________________________________________________ A6474X293 VIVI/01 5.179

© Bucyrus America, Inc.

Troubleshooting ______________________________________________

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 5.180

_______________________________________________________________

6

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Model 7MFBM-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

© Bucyrus America, Inc.

general

Overall length (w/out tailpiece): Overall length (with tailpiece): Overall width: Tramming height (min.): Ground clearance (min.) (with tailpiece): Ground clearance (max.) (with tailpiece): Receiving height (min.): Discharge height of belt: Operating height (max): Level hopper capacity: Capacity (w/ optional 12” sideboards): Receiving impact plate: Breaker impact plate: Coal line material: Return line material: Frame side plates: Weight (w/out tailpiece, roof anchors, or floor stabilizers):

performance

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

conveyor chain

approx. 33’ approx. 36’ 6-1/2” approx. 11’ 7-11/16” approx. 69-9/16” approx. 3” approx. 19-13/16” approx. 14” approx. 38-1/8” approx. 93” approx. 370ft³ approx. 440 ft³ HRS + CCO wear plate T-1 + CCO wear plate HT AR400 + CCO wear plate HT AR400 HT AR400 approx: 90,000 lbs approx. 1’ x 2’ x 3’ approx. 30,000 psi approx. 8” approx. 1” pick to flight clearance approx. 1,210TPH @ 149 fpm coal @ 65 lb/ft³

approx. 48” 2 @ 200,000 lb/strand ultimate Chain pitch: approx. 3-1/2” Chain pin diameter: approx. 15/16” Flights: 2-1/2” x 5-1/2” Solid alloy steel Flight attachment Cross pin, not bolted Conveyor speed (max): approx. fpm ______________________________________________________________ A6474X293

Conveyor width: Number of strands:

VIVI/01

6.3

Technical data ________________________________________________ Shaft diameter: Head shaft bearings: Bearing bore: Overload protection: tail shaft

conveyor drive

Shaft diameter: Bearing bore: Take-up:

3-15/16” 3-15/16” Grease cylinders w/locking shims

Drive motor:

150 hp/460VAC/3ph/ 60Hz/MSHA Variable frequency drive (VFD) LC280,31.5:1 reduction, Link Belt

Motor speed control: Reducer:

breaker drive

Reducer housing: Reducer/shaft coupling: Overload Protection:

Fabricated steel Flanged type Torque limiting coupling

Drive motor:

200 hp/460VAC/3ph/ 60 Hz/MSHA LC315, 25:1 reduction, Link Belt Fabricated steel Jaw type, coupled to torque limiter Flanged type PT Tech Torque Limiter

Reducer: Reducer Housing: Motor/reducer coupling: Reducer/shaft coupling: Overload protection: breaker

5” Two pillow block assemblies 4-15/16” Torque limiting coupling

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

approx. 10” approx. 8” approx. 32” approx. 11,480 lbs approx. 54,000 lbs PT Tech Torque Limiter Motor amp monitoring 71 rpm Manually adjustable 2” increments Kennametal tapered shank bit w/ hard face Star

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 6.4

© Bucyrus America, Inc.

head shaft

_______________________________________________ Technical data crawlers

Tram speed: Drive: Take-up: Center-to-center distance: Pad width: Ground pressure: Maximum tractive force:

hydraulic

Pump: Tram motors: Frame lift/tilt and roof cylinders: Tailpiece tilt/steer cylinders:

© Bucyrus America, Inc.

Floor cylinders: Filters (4): Reservoir: Heat exchanger: electrical

Breaker motor: Conveyor motor: Conveyor drive: Starter: Contactor: Coolant Motor:

approx. 39 fpm W16 Fairfield torque hub Grease cylinder approx. 91-5/16” approx. 20” approx. 29.2 psi @ 106,500 lb GVW approx. 98,078 lbs @ 3500 psi system pressure 2 stage, 5.1 in³/section, gear pump, 3500 psi max pressure rating Char Lynn 4000 series 24 in³/rev Double acting 17” stroke, 6” bore Double acting 12” stroke, 3” bore Double acting 9” stroke, 6” bore (2) Pressure, (1) return, (1) tank fill 110 gal capacity Oil to air type 200 hp/460VAC/3 ph/ 60 Hz/1750 rpm/MSHA 150 hp/460 VAC/3 ph/ 60 Hz/1750 rpm/MSHA Variable frequency 200 hp/150hp/dual/ 460VAC/3 ph/60 Hz/ MSHA Vacuum type 5 hp/460VAC/3 ph/ 60 Hz/1750 rpm/MSHA

______________________________________________________________ A6474X293 VIVI/01 6.5

© Bucyrus America, Inc.

Technical data ________________________________________________

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 6.6

___________________________________________ 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.

© Bucyrus America, Inc.

Table 16: Hex head and socket head cap screws, coarse thread (Grade 8) Nominal diameter

Recommended torque setting

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

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

Table 17: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

______________________________________________________________ A6474X293 VIVI/01 6.7

Tightening torques ____________________________________________

Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

Table 19: Socket, flat & button head cap screws (Steel only) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 6.8

© Bucyrus America, Inc.

Table 18: Set screws (Socket standard steel)

___________________________________________ Tightening torques Table 20: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M33 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

© Bucyrus America, Inc.

Table 20: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nm

36

Ft-lbs

26

42

54

89

126

169

Nm

83

132

200

275

390

530

Ft-lbs

61

97

147

202

287

390

58

88

Nominal diameter M18

M20

M22

121

171

230

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 20: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

______________________________________________________________ A6474X293 VIVI/01 6.9

Tightening torques ____________________________________________ Table 21: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

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

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

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 21: Electrically zinc plated (Fine thread, continued)

8.8 10.9 12.9

Torque Ma

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 21: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 6.10

© Bucyrus America, Inc.

Property class

___________________________________________ Permissible media Permissible media Lubrication fluids and greases 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.

© Bucyrus America, Inc.

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.

______________________________________________________________ A6474X293 VIVI/01 6.11

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.

Hydraulic 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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 6.12

© Bucyrus America, Inc.

Table 22: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© Bucyrus America, Inc.

Table 23: 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

______________________________________________________________ A6474X293 VIVI/01 6.13

Permissible media ____________________________________________

1

Supplier Amoco Oil Company

2 3 4

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

5 6 7 8

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

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

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

Table 25: 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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 6.14

© Bucyrus America, Inc.

Table 24: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ Permissible media Table 26: 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

Henry 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

______________________________________________________________ A6474X293 VIVI/01 6.15

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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 6.16

© Bucyrus America, Inc.

Table 27: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media

© Bucyrus America, Inc.

Table 28: 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

______________________________________________________________ A6474X293 VIVI/01 6.17

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 30: 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

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 6.18

© Bucyrus America, Inc.

Table 29: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

___________________________________________ Permissible media

© Bucyrus America, Inc.

Table 31: 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 32: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 33: 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

______________________________________________________________ A6474X293 VIVI/01 6.19

Permissible media ____________________________________________ Table 34: High emulsibility extreme pressure gear oil (Spec. 100-13) 1

Supplier Fuchs

Brand name Powergear H680

Table 35: Synthetic lithium complex grease for electric motor bearings (Spec. 100-14)

1 2 3

Supplier Mobil Conoco-Phillips Shell

Brand name Mobilith SHC 100 Triton 100 Albida EMS 2

1

Supplier Conoco

Brand name GLW Gear Oil 220

_________________________________________________________________ BUC – Model 7MFBM-48DD Feeder Breaker 6.20

© Bucyrus America, Inc.

Table 36: High demulsibility extreme pressure gear oil (Spec. 100-15)

_______________________________________________________________

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

______________________________________________________________ A6474X293 VIVI/01 7.3

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

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

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

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Installation and Operating Instructions for HANSEN UniMineR-P4 Gear Reducers 2.1 Mounting: Foot mounted units must be positioned horizontally within from end to end and side to side unless specifically ordered for another mounting position.

Avoid overloading shafts, bearings and housings by using a rigid flat support foundation such as a HANSEN Transmissions supplied baseplate, and providing accurate initial alignment. All housing feet must rest firmly on supports before being bolted down. Use the proper size mounting bolts with a flat washer under the head of each bolt.

Mounting bolts must be tightened only after the unit, motor and / or other auxiliary equipment has been carefully aligned. Care should be taken to ensure that the drive rests properly on the foundation and that the input and output shafts are aligned in accordance with the coupling manufacturer’s specifications with the corresponding shafts of the driving and driven equipment.

1. General: UniMineR-P4 Speed Reducers were designed primarily for the demanding mine environment but can also be used for other applications.

Standard features include flippable housing arrangement, grease o purgeable seal arrangement, and 3 tilting angle in any direction without lubrication modifications.

This manual is written to help the users of UniMineR-P4 reducers install, operate and maintain this equipment with the same care given to it in the factory. If you have questions that are not answered in this manual, please contact HANSEN Transmissions.

All speed reducers are factory tested.

Internal parts are coated with rust preventive run-in oil before shipment. Seals are grease lubricated. Shaft projections and hollow shaft bores are coated with protective coating.

Speed reducers are shipped from the factory without lubricating oil.

Alignment and leveling of the unit is accomplished by careful shimming between the mounting feet and foundation. Dowel pins or shear blocks should be provided on the mounting feet to maintain proper alignment.

Warning: Please read and follow the enclosed instructions. Your failure to adhere to these procedures may result in serious personal injury and cause equipment damage and may void the warranty.

If the reducer and other drive components are mounted on a Hansen Transmissions Steel Baseplate, recheck the factory alignment of all component shafts to insure nothing has been misaligned during shipment and installation.

2. Installation and Mounting: Warning: Safety is the basic factor to consider at all times, in the operation of these drives. Through the use of proper clothing and tools with proper application and methods of handling, you can prevent serious accidents and injury to yourself and your fellow workers.

Warning: For safe handling, use only proper lifting equipment such as crane or hoist, having ample load carrying capacity. Hand lifting is dangerous. Use the lifting eye on the reducer, where provided to lift reducer only.

When necessary to lift reducer and attached accessories, use proper placed slings of suitable capacity.

Warning: When the drive is connected to motor or driven equipment through the use of couplings, sprockets, gears or belt drive, proper guards meeting requirements of OSHA must be used to prevent personal injury or property damage.

Warning: Never operate drive at speeds, horsepowers, or loads higher than nameplate ratings, or personal injury can result. Consult HANSEN Transmissions if there is any change of operating conditions from that for which the unit was sold, as stamped on nameplate specifications. Failure to comply could result in personal injury and/or machinery damage.

1

2.1 continued: The protective coating on the shaft projections should be removed using a suitable non-flammable solvent.

farthest away. This will keep the force on the torque arm to a minimum.

2. It should be mounted so that the reaction force of the torque arm is in tension and not in compression.

Although some torque arm designs will work in compression, a better design is to have the torque arm in tension.

3. The torque arm mounting should be free to articulate and, if possible, adjustable.

There should be only one connection point to act as the reaction point.

Connections at more than one point may restrict free movement as the unit operates.

In the case of hollow shaft units, the protective coating must also be removed from the bore using a suitable nonflammable solvent. Under no circumstances should abrasive paper or cloth be used for this cleaning procedure. The hollow bore should be coated with an anti-seize type compound where a keyed connection is used. Shrink Disc connections must be absolutely dry and free of all lubricant for proper operation. Please refer to separate Shrink Disc installation instructions for this type of connection. Hollow shaft units with a keyway connection are to be secured against axial movement with a keeper plate bolted in place using the corresponding tapped holes in the mating shaft.

Caution: A rigidly mounted torque arm may preload parts of the speed reducer as well as the connecting frame and driven machinery, and could very well result in fatigue failure of the output shaft or driven shaft.

2.3 Mounting of Couplings, Sprockets or Sheaves:

With all shaft mounted reducers, a flexible torque arm must be provided to prevent counter rotation of the speed reducer.

Gears,

Caution: Only components that were specified and approved at the time the drive was ordered should be attached to the reducer shafts. The use of other components may cause personal injury or damage to the drive system. If other components must be used, contact HANSEN Transmissions for review and approval prior to installation.

Care must be taken to ensure that the unit is readily accessible, particularly the oil filler and drain plugs, the oil sight glass or dipstick, and the inspection cover. If the speed reducer is supplied with a cooling fan, there must be an unrestricted airflow over the reducer housing.

2.2 Torque Arms:

To prevent possible damage to reducer internal parts, avoid hammer blows when mounting couplings, gears, sprockets, sheaves etc. on the shaft projections.

These components should be mounted onto the shafts using proper shop practices. To facilitate this, the shafts can be greased and the taps in the shaft ends used for pulling components on. When a tight fit occurs, the component will slide on easily after preo o heating it in oil to 150 F to 200 F to expand its bore.

Warning: Both the components of the torque arm and the frame to which it is connected must be of proper size and material to withstand the applied loads or personal injury and machinery damage may occur.

Various design codes may dictate the safety factor that must be employed in torque arm and frame design. When supplying your own torque arm, the following describes typical design guidelines:

2.4 Speed Reducer Accessories: For units with other additional equipment, such as backstops, clutches, etc. refer to separate operating instructions.

1. It should be positioned far from L.S.S., no closer than the front of the reducer housing, so that the torque arm is 90 degrees to a line through the hollow shaft and to the point of attachment 2

2.5 Shrink Disc Installation and Removal Instructions

sequence till Shrink Disc can be moved on hub.

DO NOT remove locking screws completely.

2. Make sure any rust buildup in front of hub is removed before hub is pulled from shaft.

Shrink Discs are supplied ready for installation. However, prior to tightening of locking screws it is necessary to remove wooden spacers located between outer collars, which are used during shipment of Shrink Discs.

2.5.3 Re-Installation of Shrink Discs In relatively clean operating conditions, Shrink Discs can be re-used without prior cleaning.

Severe conditions, however, require thorough cleaning and re-lubrication with the following or similar lubricants:

2.5.1 Installation Important: Never tighten locking screws before shaft installation, since inner ring of Shrink Disc as well as hub bore can be permanently contracted even at relatively low tightening torques.

Tapers of inner rings and outer collar bores: Molykote 321R-spray or Molykote G RAPID- spray or paste

1. Clean hub O.D. and Shrink Disc Bore and lightly lubricate hub O.D. before assembly of Shrink Disc on hub.

2. Carefully clean shaft and hub bore from any lubricant prior to mounting hub onto shaft.

THIS STEP IS VERY IMPORTANT, since it will greatly affect the torque transmitting capability of a Shrink Disc connection.

3. After checking correct position of Shrink Disc and hub, handtighten 3 or 4 equally spaced locking screws and make sure that outer collars of Shrink Disc are in a parallel position.

Afterwards handtighten rest of locking screws.

4. Use torque wrench and equally tighten all screws one after another in a clock or counterclockwise sequence by approx.

1/4 turns (even if initially some screws will require a low tightening torque) until specified tightening torque MA is reached. NOTE: To compensate for torque reduction due to setting of screws adjacent to a screw just being torqued, a tightening torque approx. 5% higher than specified is recommended for the final round.

5. Reset torque wrench and make sure that no screw will turn at specified tightening torque TA. NOTE: It is not necessary to check tightening torque again after installation is completed or equipment has been in operation.

Screw threads and head contact area: Multipurpose grease such as Molykot BR-2

Damaged O-rings should be replaced.

LOCKING SCREW-TIGHTENING TORQUES “MA” SCREW SIZE M5 M6 M8 M10 M12 M16 M20

2.5.2 Removal 1. Loosen locking screws in several stages by using approx. 1/2 turns; following either a clock or counterclockwise 3

M24

M27

mm 8

10

13

17

19

24

30

36

41

MA (Nm) 5

12

29

58

100

240

470

800

1100

MA(ft. lb)3.6 8.7 21 42

73

174

340

593

795

2.6 Electrical Connections: (When using motor) Warning: Do not connect motor without making sure power supply is disconnected. Failure to comply can cause injury to personnel and / or damage to equipment.

2.

Do not connect motor without first determining that power supply (voltage, cycles and phase) corresponds to the motor nameplate specifications. Wiring, controls and overload devices must comply with National Electrical Code, local and OSHA requirements.

3.

If the reducer is equipped with an integral backstop, an arrow plate on the housing indicates the direction of rotation. Make certain the motor shaft rotation is correct before coupling the motor to the reducer. If necessary, reverse leads on motor to make shaft rotation conform to those shown.

Prior to starting the unit, check the oil level by removing the dipstick. Oil level must be located between two marks on the dipstick.

Adjust oil level, if necessary.

Warning: Speed reducers that are equipped with oil level fill plugs in place of dipsticks MUST be checked on a flat level surface with no degree of tilt. Oil is to be filled just until it begins to drain from the lower of the two fill plugs.

2.7 Check Direction of Rotation After determining compatibility of the motor, connect motor as shown on diagram on the motor nameplate.

To change rotation of three-phase motors, interchange any two line leads. Refer to motor manufacturer’s instructions for more detailed information.

Caution: If reducer is supplied with an integral backstop check for proper rotation of motor and reducer before connecting motor to reducer.

Speed reducers, which are not lubricated, may be operated only a few seconds without causing damage.

Caution: Never remove the breather, dipstick, or inspection cover while the unit is in operation, or personal injury may result.

3. Initial Start-Up UniMineR-P4 Parallel Shaft Reducers have been test-run at the factory. However, during initial start-up the following procedures are recommended: 1.

4.

Prime mover electrical starting equipment should be arranged to start unit slowly to avoid impact loads.

Across the line starting of motors should be applied with caution to prevent instantaneous gear loads that could greatly exceed the rating of the speed reducer or other components.

5.

4

Start the reducer under as light a load as possible. As the unit is brought up to normal operating speed, it should be checked for unusual noise, excessive vibrations, excessive heat and oil leakage. If any of these symptoms develop, the unit should be shut down immediately, and the cause determined and corrected. The unit should be run for a minimum of 4 hours with only partial load, and the load should be increased gradually.

After approximately 40 hours of operation, check all foundation bolts and mounting bolts and tighten as required.

Always recheck alignment after tightening.

3.3 Outdoor and Long Term Storage of Speed Reducers

3.1 On Site Storage When speed reducers are to be stored, full protection will best be obtained indoors in a clean, dry place, under relatively even, moderate temperatures.

When outdoor storage is unavoidable, provide adequate protection from the elements.

It is always preferable to store speed reducers indoors. When this is not possible, or when storage is for a period longer than one year, follow these instructions: 1.

Housing interiors and operating parts of the speed reducer are protected by a rust inhibitor.

Proper indoor storage of drives will permit protection for approximately six months against corrosion from condensation. For longer periods follow the Long Term Storage Instructions or consult HANSEN Transmissions.

2.

3.

Caution: Improper storage of drives may cause damage to internal parts. The storage procedure outlined in the following paragraphs must be followed; otherwise the standard warranty may be voided.

4.

3.2 Standby If the unit is taken out of operation for an extended period of time, it should be run for ½ hour minimum (with or without load), at rated speed every three (3) weeks, to maintain an oil film on all machined internal surfaces. If this is not possible, it must be retreated with a rust inhibitive agent and prepared for storage as noted in these instructions under Long Term Storage Procedures.

5.

6.

If the drive is to be stored for an extended period, one year or more, the Long Term Storage Procedure must be followed. If storage will be less than one year the breather on top of the housing should be replaced with a pipe plug to prevent escape of oil vapors and entrance of moisture until the drive is put into service. Storage should be indoors in a clean, dry atmosphere under even, moderate temperatures. If outdoor storage is necessary, the drive must be under cover with adequate protection from the elements. (Refer to Long Term Storage Procedure). Before putting the drive into service, replace the pipe plug with the breather provided, and fill with the proper type and quantity of oil. Proper storage will help protect against corrosion from condensation.

7.

8.

5

Reducers should never be exposed to the elements. They must be protected from the elements in some manner. If stored outdoors, cover with a tarp that can be secured to the base of the reducer housing.

Remove plug from breather hole and attach a sufficient length of pipe to extend above the highest part of the speed reducer.

Cap the pipe (pipe cap should be drilled and tapped for alemite fitting) and install alemite #317400 fitting to relieve potential internal pressure.

Fill reducer completely with a heavy rust inhibitor such as Gulf No-Rust Engine Oil, Grade 3, which conforms to Military Specification MIL-L-21260.

At least every three months rotate input shaft. Be sure the output shaft rotates more than one revolution. This is done to insure all internal parts are coated with fresh oil and that the shaft seals are free and the seal journals are coated with oil.

At least every three months check the speed reducer for water condensation by removing lowest drain plug and allowing small amount of oil to drain from the oil sump. All water that may have accumulated will be at the bottom of reducer housing and will drain out first.

Check all exposed fittings and shaft projections every three months for integrity of the protective coating.

Reapply coating if required, to prevent possible corrosion of shafts.

Use Cosmoline 1102 MIL-C-16173 Grade 2 or equivalent.

When standby unit or unit prepared for long term storage is put into service drain the preservative oil and refill with proper amount of lubricant listed in the lubrication instructions. Reinstall the supplied breather.

4. Lubrication

Table 3: *Approximate Oil Quantities – US Gallons

Proper lubrication and lubricant maintenance are very important factors that will result in a long, effective, trouble-free speed reducer operation.

Lubricant must be of proper viscosity, its level must be monitored and maintained, and it must be changed periodically. It must be free from dirt and water contamination.

Unit Size C D E F G

information should be used for oil ordering purposes. Proper level of oil is indicated by dipstick markings.

4.1 Initial Oil Change The oil used at initial start-up and operation of a new reducer should be thoroughly drained after 500 hours of operation. A thorough cleaning of the gear case using flushing oil should be performed to remove any foreign matter during the first oil change.

This is most important to insure trouble free, long life of the speed reducer. Under normal operating conditions, subsequent oil changes should be made every 1500 to 5000 hours of operation, depending on the severity of the application, or eighteen months, whichever occurs first.

Oil seals are grease lubricated through grease ports located on the outside of bearing retainers. Grease acts not only as a seal lubricant but also as a shield against outside contaminants.

For grease lubrication of oil seals use the following long fibered grease or its equivalent: Mobility SHC 220

In extremely dusty, dirty, corrosive atmospheres, or where there is a rapid rise and fall in temperature producing condensation, there may be a build-up of sludge, dust, dirt, chemicals, condensation, or fumes, in the oil sump, contaminating the oil. High sump temperatures will also result in accelerated oil breakdown. Under these conditions the oil should be changed at shorter intervals. Cleaning debris off the housing could extend the useful life of the oil. Oil sampling and analysis can be helpful in determining the correct oil change interval for your speed reducer.

Table 1: AGMA Lubricant Numbers Ambient Temperatures o o o o 32 F– 90 F 50 F–120 F Other 5EP 6EP Consult factory

Table 2: Typical Oils Meeting AGMA Recommendations Lubricant

AGMA Grade

MFG. 150 4 EP

220 5 EP

320 6 EP

Right Angle 5.3 8.2 10.6 15.3 21.1

*These quantities are approximate and the

Splash lubrication is the standard method of delivering oil to all internal components of UniMineR-P4 reducers.

Gears and low speed bearings are lubricated by immersion in the oil bath. Oil splash from gears fill oil pockets in the housing and by gravity feed the lubricant to all other bearings and internal components.

Mobil

Parallel 5 7.9 10 14.5 19.8

460 7 EP

Exxon

Spartan EP-150

Spartan EP-220 Spartan EP-320 Spartan EP-460

Mobile

Mobilgear 629

Mobilgear 630

Mobilgear 632

Mobilgear 634

Shell

Omala 150

Omala 220

Omala 320

Omala 460

Texaco

Meropa 100

Meropa 220

Meropa 320

Meropa 460

Rando Oil HDE100

6

When running under load the oil in the unit will warm up to its normal operating temperature which may be as high as 175o 200 F depending on the reducer size, ratio, and percent of full HP rating being transmitted. Higher operating temperatures can be avoided if special measures are taken, such as external cooling or the use of special lubricants.

Consult HANSEN Transmissions for details.

4.2 Draining the Oil

seal and a new grease collar is formed.

Foreign material, which may have accumulated in the seal area, will be forced out together with the old grease.

The oil should be drained while the reducer is at operating temperature.

All parts belonging to the lubrication system must be checked periodically to ensure they are functioning correctly and are properly sealed.

It is important that only the recommended grease or its equivalent be used for purging out the old grease. Lighter greases, such as bearing greases, may liquidify within the chamber and flow out, resembling an oil leak.

At each oil change, while the inspection cover is removed, inspect the internal assembly of the reducer – particularly the condition of the gear teeth. New sealing compound should be applied to the inspection cover each time it is removed.

The outside of the reducer housing should be cleaned at each oil change to maintain proper heat dissipation.

5. Backstops UniMineR-P4 backstops are designed to prevent reverse rotation of the driven equipment and holding back the load on such equipment as inclined conveyors, bucket elevators, fans, rotary pumps and kilns.

Warning: Backstops are not approved for use on systems that are designed for handling of people such as elevators, manlifts, ski tows and ski lifts.

UniMineR-P4 oil seal systems are initially grease lubricated in the factory prior to shipping reducers to the customer. The TM high-speed Oil-Guard seal system consists of two spring loaded lip seals, an oil deflector and a dynamic drain-back provision.

The low speed seal system consists of two spring loaded lip deals and a pressure relief passage. Both arrangements are additionally protected by a grease chamber, which excludes outside contaminants.

Warning: Do not use a backstop as a substitute for a brake. Do not use a backstop for indexing application.

Backstops are designed to prevent reverse rotation of five times or less in a period of eight hours. For more frequent operation consult HANSEN Transmissions.

When ordered from the factory, the backstop will be assembled to result in proper shaft rotation.

Caution: To avoid damage to the backstop, determine the proper direction of motor rotation prior to connecting motor coupling or drive to the reducer.

To remain effective, the protective grease must be purged periodically. The regreasing schedule should be based on the severity of the operational and environmental conditions.

In severe conditions the regreasing should be performed every 1 to 2 months. Under more favorable conditions regreasing schedule could be extended to 3 to 6 months.

With a grease gun, pump the recommended grease through a fitting located at the outside of the bearing retainer until the old grease is forced out in the area of the shaft

Manually rotate the shaft in the overrunning direction. Before connecting the motor, run it to determine that it rotates in the same direction as an overrunning direction of the input shaft of the speed reducer.

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5.1 To reverse backstop rotation:

Disconnect unit from driven equipment and from the motor. Drain the oil. When applicable, remove any external accessories such as pumps, coolers, strainers, etc.

Unbolt foot-mounted unit from the foundation. Remove dipstick, oil breather and two pipe plugs and change them from top to bottom. Use proper sealer to seal the pipe plugs. Refill the unit with the proper amount of oil.

Warning: Disconnect power to the motor. Disconnect reducer from the load and unload the backstop or serious personal injury or equipment damage may result.     



Unbolt backstop and clutch cover Remove backstop cover and outer race Remove retaining ring Remove the backstop, inner ring, and sprag assembly from the shaft by sliding it along the shaft Flip the inner race and sprag assembly so the side near the reducer is now outboard. The free wheel direction indicated on the sprag assembly will now point in the opposite direction.

Be sure to clean and apply sealant to both sides of the backstop outer race to prevent oil leaks.

6.2 Replacing Internal Parts: UniMineR-P4’s split housing design permits removal of all internal parts without disturbing the mounting or alignment of the reducer base.

Caution: Only experienced mechanics, knowledgeable in heavy machinery and especially gear reducer products, should attempt to replace internal parts of the UniMineR-P4 Reducers.

Field installation of the UniMineR-P4 backstops is possible. When installing a backstop to a unit, which was not originally furnished with one, additional parts will be required. Consult HANSEN Transmissions.

Such installation must be performed by an experienced service mechanic.

Warning: For safe handling, use only proper lifting equipment such as cranes and hoists having ample load carrying capacity.

Hand lifting is dangerous.

Drain the oil to the level below the lowest bearing bore.

Disconnect all external equipment as described in “Flipping” above.

Remove the capscrews that fasten the bearing retainers to the housing cover.

(Upper part of the housing). Loosen the capscrews that fasten the bearing retainers to the housing base. Remove the threaded studs, two dowel pins, which fasten the housing cover to housing base lift the cover from the base using slings and a hoist. If necessary, use a jack-off tap on the low end of the speed reducer. Inspect all internal parts for damage and wear.

If part replacement is required remove the complete shaft assembly from the unit, and remove bearings and gears as applicable using proper size pullers and presses.

Follow the backstop manufacturer installation and maintenance instructions furnished with the gearbox.

6. Disassembly and Reassembly: 6.1 Flipping: UniMineR-P4 Speed Reducers are designed to be flippable in the field. New units can be flipped by removing a dipstick, oil breather and two pipe plugs and changing them from top to bottom. Use proper sealer to seal the pipe plugs.

When unit in service needs to be flipped use the following procedure: Warning: Before beginning any work on the reducer, disconnect the driving means (lockout motor starter and unload brakes, backstops, etc.) to insure against accidental start-up that could cause personal injury.

NOTE: Refer to the appropriate parts drawing for the particular size and type drive on the following pages for parts location prior to disassembly to familiarize yourself with the internal parts of the speed reducer.

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Reassembly of parts should be made in the reverse order of disassembly.

Before replacing the housing cover, the mating surfaces of both the cover and base should be cleaned and new sealing compound applied.

6.3 Recommended Spare Parts: One set of spare parts is usually adequate for one to five identical reducers operating in the same general area, under average conditions, where a possible breakdown will affect only one reducer. Where continued operation is extremely vital and / or type of service is unusually severe, consideration should be given to carrying additional sets of spare parts.

For installations having five to ten identical reducers and where continued operation is extremely vital, and type of service is unusually severe, we recommend you carry a complete spare reducer, in addition to spare parts.

For installations having more than ten identical reducers or for large quantities of same size reducers regardless whether identical or not, consult HANSEN Transmissions for spare parts recommendation. State the exact nature of the application, its importance regarding continued operation, and any other factors, which will aid us in making proper recommendations.

One set of recommended spare parts for a HANSEN Transmissions UniMineR-P4 Reducer consists of: One high speed shaft and pinion, one set high speed shaft bearings, and one set of high speed and low speed oil seals.

Model: Serial Number: Installation Date:

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Bearing and Seal List

Bearing No. 1 2 3 4 5 6 7 8 9 10 11 S1 S2 S3 S4

Unit Size C D E F T2EDO45 32310 32312 32314 2-31311 2-31312 2-31314 2-31315 22312C-C3 22313E-C3 22315E-C3 22316E-C3 32312 32314 32316 22317E 32312 32314 32316B 22317E 32312 32314 32316 ZSL192317-C3 32312B 32314B 32316B 22317E 81211 22226E 22228 23034CC 23036CC 22226E 22228 23034CC 23036CC NCF2934V NCF2936V NCF2938V NCF2940V 45x60x8 50x65x8 60x75x8 70x90x10 50x65x8 55x70x8 65x85x10 70x90x10 130x160x12 140x170x15 170x200x15 180x210x15 170x200x15 180x210x15 190x220x15 200x230x15

Bearing Shimming Instructions: All Low Speed Bearings: .008" - .020" High Speed and Intermediate Speed Parallel: .003" - .005" High Speed and Intermediate Speed Right Angle: .000" - .002"

G 32316 2-31317 22318E-C3 22320E 22320E 22320E 22320E 81213 23040CC 23040CC NCF2952V 80x100x10 80x100x10 200x230x15 250x280x15

Part Drawing for MHP-2 UniMineR-P4 Parallel Shaft Speed Reducer

LOC LOC NO. NAME OF PART QTY. NO. NAME OF PART QTY. 1700 Housing Assembly 1 5706 Pump Ring 1 2106 Spacer / Shim 1 6502 Low Speed Seals 1 1905 High Speed Bearing Retainer 1 1922 Low Speed Split Cover 1 2601 Low Speed Shaft 1 2704 High Speed Pinion 1 1902 Low Speed Bearing Retainer 1 2703 High Speed Gear 1 1901 Low Speed Bearing Retainer 1 2702 Low Speed Pinion 1 6006 High Speed Bearing 1 2701 Low Speed Gear 1 6005 High Speed Bearing 1 6004 Intermediate Bearing 1 6003 Intermediate Bearing 1 Hardware Group 6001 Low Speed Bearing 1 Dipstick 1 6002 Low Speed Bearing 1 Breather 1 6506 High Speed Seal 1 Pipe Plugs (Set) 1 1907 High Speed Split Cover 1 Retainer Rings (Set) 1 Keys (Set) 1

Parts Drawing for MHR - UniMineR-P4 Right Angle Speed Reducer

LOC LOC NO. NAME OF PART QTY. NO. NAME OF PART 1700 Housing Assembly 1 6309 Pump Ring 2009 High Speed Bearing Cartridge 1 5909 Lock Nut 1909 High Speed Bearing Retainer 1 6502 Low Speed Seals 1903 Intermediate Speed Retainer 1 1922 Low Speed Split Cover 1902 Low Speed Bearing Retainer 1 2904 Bevel Pinion 1901 Low Speed Bearing Retainer 1 2903 Bevel Gear 6009 High Speed Bearings 1 2702 Low Speed Pinion 6010 High Speed Bearing 1 2701 Low Speed Gear 6004 Intermediate Bearing 1 2601 Low Speed Shaft 6003 Intermediate Bearing 1 Hardware Group 6001 Low Speed Bearing 1 Dipstick 6002 Low Speed Bearing 1 Breather 6509 High Speed Seal 1 Pipe Plugs (Set) 1929 High Speed Split Cover 1 Retainer Rings (Set) Keys (Set)

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1