DOWNLOAD PDF CAT Feeder Breaker 54-2184 Operation & Maintenance Manual BI629488

Operation and Maintenance Manual Bucyrus - Feeder Breaker Model 7MFBH-48A

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

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

Internet: www.bucyrus.com

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

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

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

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

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

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

© BUCYRUS AMERICA , INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

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

2. Your safety

© BUCYRUS AMERICA, INC.

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

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

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

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VISV / 02

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 Starter enclosure............................................................. 5.9 Daily starting procedure .................................................5.12 Shutdown procedure......................................................5.15 Electrical system ............................................................5.17 Hydraulic system............................................................5.31 Mechanical assemblies..................................................5.35 Instructions on the maintenance of the feeder breaker 5.41 Important notes ........................................................5.41 Before maintenance .................................................5.41 Lubrication and inspection .......................................5.43 Specific lubrication and maintenance procedures ........5.44 Every 8 hours of operation ............................................5.46 Weekly .....................................................................5.48 Every 2 weeks ..........................................................5.51 Monthly .....................................................................5.52 Every 3 months ........................................................5.53 Every 2500 hours ......................................................5.54 Every 6 months ........................................................5.55 Inspection of the feeder ................................................5.57 Inspection of wear parts on the feeder breaker ............5.58 Inspection of the fire suppression system......................5.59 Recharge of the fire suppression system ......................5.61 Instructions on the adjustment procedures ...................5.63 Instructions on the replacement of wear parts ..............5.77 Troubleshooting .............................................................5.115

6.

Technical data Technical data ......................................................................... 6.3 Components of the feeder breaker ...................................... 6.3 Tightening torques ............................................................... 6.5 Permissible data .................................................................. 6.7 Lubrication fluids and greases ........................................ 6.7

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

_________________________________________________________________ Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

5. Operation

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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 7MFBH-48A Feeder Breaker Serial No.: 54-2168 and 54-2184 and is only permitted to be used for this equipment.

© 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. ______________________________________________________________ A6474X258 VISV / 02 1.3

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

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

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

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

safety

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

© BUCYRUS AMERICA, INC.

service

_________________________________________________________________ 1.4 Bucyrus – Model 7MFBH-48A Feeder Breaker

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

Try to memorize the symbols and their meanings.

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

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

© BUCYRUS AMERICA, INC.

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

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

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

■

Items in lists are marked with bullets.

–

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

ts 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.

______________________________________________________________ A6474X258 VISV / 02 1.5

© BUCYRUS AMERICA, INC.

Before starting to work ________________________________________

_________________________________________________________________ 1.6 Bucyrus – Model 7MFBH-48A Feeder Breaker

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Your safety

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__________________________________________________ Personnel

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine,

■

of the 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

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

_________________________________________________________________ 2.4 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

and must be able to prove this knowledge.

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

Intended uses include: ■

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

Unauthorized use

© BUCYRUS AMERICA, INC.

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

■

the transport of persons

■

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

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

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© BUCYRUS AMERICA, INC.

Operating conditions __________________________________________

_________________________________________________________________ 2.6 Bucyrus – Model 7MFBH-48A Feeder Breaker

___________________________________________ Safety instructions Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

© BUCYRUS AMERICA, INC.

Inform your colleagues of:

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

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

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

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

maintenance work

■

inspection work

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repair work

Cordon off your working area widely for the machine.

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

conveyor chains

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flights

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pivot points

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boom assemblies

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crawler assemblies

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breaker shaft assemblies

© BUCYRUS AMERICA, INC.

moving parts

_________________________________________________________________ 2.8 Bucyrus – Model 7MFBH-48A Feeder Breaker

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

© BUCYRUS AMERICA, INC.

means of attachment

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

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

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

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

mobile handling equipment

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

Installation and start-up inclined face

environmental acceptability

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

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

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

inspection maintenance instruction and safety tags

operator’s area

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

Verify that all maintenance has been performed.

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

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

Clean any foreign material from the operator’s area.

______________________________________________________________ A6474X258 VISV / 02 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

_________________________________________________________________ 2.10 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Be sure to observe the prescribed maintenance and inspection intervals.

___________________________________________ Safety instructions handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

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

maintenance, repair

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

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

Always replace damaged or lost decals and metal instruction plates.

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

© BUCYRUS AMERICA, INC.

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

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

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

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

the hoses are not pinched or trapped

■

the hoses have no bubbles or blisters

■

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

■

the outer sheath of the hoses is not damaged

■

the connectors are securely inserted into the sockets

■

the connections are leak-tight

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

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

______________________________________________________________ A6474X258 VISV / 02 2.11

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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

Replace hydraulic hoses at the first suspicion of damage.

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

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© BUCYRUS AMERICA, INC.

Never try to repair damaged hydraulic hoses.

___________________________________________ Safety instructions ■

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting Right

© BUCYRUS AMERICA, INC.

■

Wrong

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

Fig. 3: Laying hydraulic hoses, bending

■

always have a little slack.

Fig. 4: Laying hydraulic hoses, crossing

______________________________________________________________ A6474X258 VISV / 02 2.13

Safety instructions ____________________________________________ ■ ■ ■ ■

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

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

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

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

Fig. 5: Laying hydraulic hoses, connections on moving parts Wrong © BUCYRUS AMERICA, INC.

Right

_________________________________________________________________ 2.14 Bucyrus – Model 7MFBH-48A Feeder Breaker

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

Use only suitable load handling devices.

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

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

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

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

______________________________________________________________ A6474X258 VISV / 02 2.15

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

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

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

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

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

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.

_________________________________________________________________ 2.16 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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© BUCYRUS AMERICA, INC.

WARNING! Before removing the cover from the starter enclosure and attempting any maintenance or troubleshooting on the machine, the visible disconnect handle must be moved to the “OFF” position.

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

WARNING! If only one side of the machine is raised during maintenance, be careful and only move the control lever for that particular side.

Moving the wrong control lever could cause the machine to move and fall off its supports. You could be seriously injured or even killed by falling loads.

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

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.

______________________________________________________________ A6474X258 VISV / 02 2.19

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

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

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

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

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

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

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

_________________________________________________________________ 2.20 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

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Storage and transport

________________________________________________________________

________________________________________________________________

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________________________________________ Storage and transport

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

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

Storage corrosion protection

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

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

© BUCYRUS AMERICA, INC.

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

dirt and moisture

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

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

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

short-term storage

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

long-term storage

If the equipment is to be stored more than six months, the following lubrication and corrosion inhibiting procedures must be followed: ■

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

■

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

■

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

■

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

■

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

______________________________________________________________ A6474X258 VISV / 02 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

HFA fluids

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.

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

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

Long-term storage of spare components hydraulic components

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

miscellaneous components

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

motors

plastic deformation

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

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

_________________________________________________________________ 3.4 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Storage and transport _________________________________________

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

dimensions,

■

weight, and

■

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

© 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. lifting points

The feeder breaker has four (4) lifting points (Fig. 6) for loading and unloading the machine. LIFTING DEVICE MUST BE CAPABLE OF LIFTING A MAXIMUM OF 34,020 KG (75,000 LBS).

–

Left and right hopper end - chain hook must be securely hooked in notch located under frame on each corner.

–

Left and right discharge end - chains must be located to the inside of the discharge frame and hooks must be securely hooked in notch located in the bottom plate on each side.

______________________________________________________________ A6474X258 VISV / 02 3.5

Storage and transport _________________________________________

© BUCYRUS AMERICA, INC.

Fig. 7: Lifting points on the feeder breaker

_________________________________________________________________ 3.6 Bucyrus – Model 7MFBH-48A Feeder Breaker

________________________________________ Storage and transport Before transport temperatures below freezing

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

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

© BUCYRUS AMERICA, INC.

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

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging. The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

______________________________________________________________ A6474X258 VISV / 02 3.7

© BUCYRUS AMERICA, INC.

Storage and transport _________________________________________

_________________________________________________________________ 3.8 Bucyrus – Model 7MFBH-48A Feeder Breaker

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Installation

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________________________________________________________________

_________________________________________________________________

__________________________________________________ Installation

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

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

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

© BUCYRUS AMERICA, INC.

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

General tools are required to put the feeder breaker into service. In addition, various items of auxiliary equipment and machines may be required at the point of installation.

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

______________________________________________________________ A6474X258 VISV / 02 4.3

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

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

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

© BUCYRUS AMERICA, INC.

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

_________________________________________________________________ 4.4 Bucyrus – Model 7MFBH-48A Feeder Breaker

__________________________________________________ Installation Pre-installation check list

© BUCYRUS AMERICA, INC.

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

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

perform daily maintenance

■

visually inspect all cylinders, gear boxes, tanks, and hydraulic components for leaks or damage

■

visually inspect all electric motors, cables, and electric components for damage.

■

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

■

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

■

check tension of conveyor chain

■

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

■

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

■

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

■

jog the breaker motor to check for correct rotation of breaker

■

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

■

check operation of alarm (s) and lighting

■

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

■

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

■

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

______________________________________________________________ A6474X258 VISV / 02 4.5

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

emergency stop pull cord switch

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

guards and covers

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

DANGER! Do not operate the machine any of the guards or covers removed.

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

“E-STOP” switch (starter enclosure)

This “E-STOP” switch is located on the left hand side of the machine, on the starter enclosure cover. Depressing the “E-STOP” switch button will shutdown all machine functions immediately.

“E-STOP” switches (machine)

The machine is equipped with four (4) “E-STOP” switches, two are located on each side of the machine. Depressing either one of the “STOP” switch buttons will shutdown all machine functions immediately.

“START”/“E-STOP” switch (operator’s station)

The machine is equipped with a “START”/”E-STOP” switch located at the operator’s station. Depressing the “STOP” switch button will shutdown all machine functions immediately.

“START” switch (remote)

The machine is equipped with two (2) remote “START” switches.

These “START” switches allows the operator to start and reset the conveyor when it has timed out from a remote location.

fire suppression

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

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

_________________________________________________________________ 4.6 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Safety features include (reference Fig. 7):

© BUCYRUS AMERICA, INC.

__________________________________________________ Installation flashing warning light

The machine is equipped with a flashing warning light located on top of the unit. The light provides a continuous pre-start warning alert to other personnel before the electrical supply is connected to the main motor.

The visual indication is automatically energized at initial start up and will also flash when the conveyor is running and the machine is being trammed.

siren

The machine is equipped with a audible siren located on the right side of the unit. The siren provides a audible pre-start warning alert to other personnel before the electrical supply is connected to the main motor.

The siren will automatically shut off after thirty (30) seconds.

area lights

The machine is equipped with two (2) area lights located on each side of the machine. The area lights are automatically energized at initial start up of the machine.

headlights

The machine is equipped with four (4) headlights, two (2) are located on the discharge end and two (2) are located in the center of the machine.

The headlights are automatically energized at initial start up of the machine.

circuit breaker disconnect handle

The machine is equipped with a circuit breaker disconnect located on the left side of the discharge end of the machine. The disconnect allows the operator a means of disconnecting power from the main power source when performing maintenance procedures on the machine.

Fig. 7: Safety features on the feeder breaker “E-STOP” switch (remote) “E-STOP” switch

Headlight

Emergency stop pull cord switch

Headlight

Flashing warning light

Area light

Fire suppression actuator location

Headlight

“START/E-STOP” switch

Circuit breaker disconnect handle

“E-STOP” switch (remote)

“START” switch (remote)

Headlight “E-STOP” switch (remote) Fire suppression actuator

Siren

Area light

“E-STOP” switch (remote)

______________________________________________________________ A6474X258 VISV / 02 4.7

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

Power unit

Discharge section Starter enclosure

Hydraulic oil tank

Breaker assembly

L.H. crawler assembly R.H. crawler assembly

Torque hub

Ratio chains

Conveyor chain

Emergency pull cord stop

Receiving section

Tail shaft take-ups Tail shaft

_________________________________________________________________ 4.8 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Operator’s area

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

______________________________________________________________ A6474X258 VISV / 02 4.9

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

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

Retaining bolts (2)

Normal tram position

© BUCYRUS AMERICA, INC.

Fig. 9: Torque hub disengagement

End cap button pointing outward

Retaining bolts (2)

End cap button pointing inward Freewheel position

_________________________________________________________________ 4.10 Bucyrus – Model 7MFBH-48A Feeder Breaker

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Operation

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___________________________________________________Operation

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

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

How to operate the feeder breaker

© BUCYRUS AMERICA, INC.

DANGER! Incorrect operation endangers yourself and others!

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

Who is allowed to operate the feeder breaker?

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

This also includes: ■

what safety devices are installed on the machine,

■

where these safety devices are located, 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.

______________________________________________________________ A6474X258 VISV / 02 5.3

Operation____________________________________________________ Controls and indicators Operator’s station The primary controls for the machine are located at the operator’s station on the left hand side of the machine (Fig. 10).

Fig. 10: Operator’s station Starter enclosure

“E-STOP” switch

Visible disconnect

Fire suppression actuator

Auxiliary function pressure gauges

Valve bank

“START/E-STOP” switch

Conveyor speed pressure gauge

“TRAM/CONVEYOR” control valve

Conveyor speed and direction control valve

_________________________________________________________________ 5.4 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Oil Level sight gauge

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

The valve bank (Fig. 12) consists of the following hydraulic controls: “TANK FILL”

The first lever from the operator’s right controls the “TANK FILL” and oil flow for the machine. To operate the power fill, turn ball valve handle located on top of the oil tank to the open position and push the control lever on the valve bank. To de-energize power fill pump, move control lever to the centered position and turn ball valve handle to closed position. See Operating procedures for tank fill (power fill) procedure.

© BUCYRUS AMERICA, INC.

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

“FRAME LIFT” right

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

“RIGHT TRAM”

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

“LEFT TRAM”

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

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

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

______________________________________________________________ A6474X258 VISV / 02 5.5

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

“FRAME LIFT” left

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

“FRAME TILT”

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

© BUCYRUS AMERICA, INC.

Fig. 11: Primary valve bank

“TILT” “TANK FILL”

“LEFT LIFT”

auxiliary function pressure gauges

“LEFT TRAM”

“RIGHT TRAM”

“RIGHT LIFT”

The auxiliary function pressure gauges (Fig. 12) are high pressure gauge (6,000 psi) located to the left of the tram control levers. These gauges give the operator a constant reading of the auxiliary system pressures. The left hand gauge is for the three functions on the left side of the valve bank and the right hand gauge is for the three functions on the right side of the valve bank.

“CONVEYOR PRESSURE GAUGE”

The conveyor speed pressure gauge (Fig. 12) is a low pressure gauge (600 psi) located to the left of the conveyor direction control lever. This gauge gives the operator a constant reading of the conveyor speed pressure in the forward direction only.

two position conveyor direction and speed control valve

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

_________________________________________________________________ 5.6 Bucyrus – Model 7MFBH-48A Feeder Breaker

___________________________________________________Operation

© BUCYRUS AMERICA, INC.

There are two (2) pressure gauges located on the right side of the discharge end of the machine that give the operator constant pressure reading for system and charge pressures. See below for a brief description of each gauge.

“SYSTEM PRESSURE GAUGE”

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

“CHARGE PRESSURE” gauge

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

oil level sight gauge

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

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

power fill ball valve

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

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators (Fig. 12). One is located adjacent to the operator’s station on the left side of the machine. The other is located adjacent to the crawler on the right side of the machine. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

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

“E-STOP” switches

The machine is equipped with four (4) “E-STOP” switches (Fig. 12) two (2) are located on each side of the machine. Depressing either one of the “STOP” switch buttons will shutdown all machine functions immediately.

“START”/“E-STOP” switch

The machine is equipped with a “START”/”E-STOP” switch (Fig. 12) located at the operator’s station. Depressing the “START” switch button will energize the machine by closing the contact at the power center and depressing the “STOP” switch button will turn off main power to the machine (open the contact at the power center).

remote “START” switches

The machine is equipped with two (2) remote “START” switches (Fig. 12). Depressing either of the remote “START” switch buttons will energize the machine.

circuit breaker disconnect handle

The machine is equipped with a circuit breaker disconnect (Fig. 12) located on the left side of the discharge end of the machine. The disconnect allows the operator a means of disconnecting power from the main power source when performing maintenance procedures on the machine.

______________________________________________________________ A6474X258 VISV / 02 5.7

Operation____________________________________________________ “TRAM/CONVEYOR” control valve

The “TRAM/CONVEYOR” control valve (Fig. 12) allows the operator to select either “TRAM” or “CONVEYOR” mode. Push the control lever down for conveyor mode and pull the control lever up for tram mode.

Fig. 12: Controls and indicators “E-STOP” switch (remote)

Conveyor speed pressure gauge

Auxiliary function pressure gauges

Power fill ball valve

Oil level sight glass

“START” switch (remote)

“TRAM/CONVEYOR” control valve

“E-STOP” switch (remote)

“E-STOP” switch (remote)

Circuit breaker disconnect handle

Conveyor speed and direction control valve

“TRAM” circuit system and “CHARGE” pressure gauges

Fire suppression actuator

© BUCYRUS AMERICA, INC.

“START/E-STOP” switch

Fire suppression actuator

“START” switch (remote)

“E-STOP” switch (remote)

_________________________________________________________________ 5.8 Bucyrus – Model 7MFBH-48A Feeder Breaker

___________________________________________________Operation Starter enclosure The starter enclosure (Fig. 13) is located on the left hand side of the machine and consists of the following machine’s electrical functions: “NORMAL”/”MAINTENANCE” switch

© BUCYRUS AMERICA, INC.

“START”

The “NORMAL”/”MAINTENANCE” switch is a two (2) position rotary switch. The switch must be in the “NORMAL” position for operating feeder breaker. “MAINTENANCE” mode is used for procedures that do not require dust suppression or the outby belt to be running. These operations are normally specific maintenance and troubleshooting procedures. This mode is not for use during routing maintenance of the machine.

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

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

“E/STOP”

The “E/STOP” pushbutton (when depressed) is used to stop the machines electric motor.

“110V E/L TEST”

The “110V E/L TEST” pushbutton (when depressed) is used to test the 110V earth leakage.

“12V E/L TEST”

The “12V E/L TEST” pushbutton (when depressed) is used to test the 12V earth leakage.

“110V / 12V E/L RESET”

The “110V / 12V E/L RESET” pushbutton (when depressed) is used to reset the 110V and 12V earth leakage.

“O/L RESET”

The “O/L RESET” pushbutton (when depressed) is used to reset the overload circuit breaker.

hour meter

The hour meter is a digital meter that gives the operator and maintenance person a constant reading of the total hours of machine operation.

circuit breaker reset lever

This lever is used to reset the circuit breaker when it has tripped or to disconnect power from the main power source while performing maintenance procedures. If the breaker has tripped, the reset lever must be moved to the “RESET” position first and then to the “ON” position.

“110V POWER ON” indicating light

This red indicating light will be on when the 110VAC is healthy.

“12V POWER ON” indicating light

This red indicating light will be on when the 12VAC power is healthy.

Also, 12VAC will be available to the flashing light and headlights.

“CRUSHER RUNNING” indicating light

This green indicating light will be on when the pick breaker has came up to speed.

______________________________________________________________ A6474X258 VISV / 02 5.9

Operation____________________________________________________

“MOTOR OIL TEMP. HEALTHY” light

This green indicating light will be on when the hydraulic oil level, temperature and overpressure is healthy.

This green indicating light will be on when the hydraulic oil temperature is healthy.

“HYDR OIL LEVEL HEALTHY” light

This green indicating light will be on when the hydraulic oil level is healthy.

“SPRAY WATER PROVED” light

This green indicating light will be on when water flow and pressure switches are being operated.

“WATER FLOW” light

This green indicating light will be on when water flow switch is being operated.

“OUT BY CONVEYOR RUNNING” indicating light

This green indicating light will be on when the out-by conveyor is running.

“NORMAL OPERATION” light

This red indicating light will be on when normal operation is selected.

“SEQ & WATER MONITORING” light

This green indicating light will be on when machine maintenance is selected to indicate belt sequence and water monitoring are being overrode.

“110V E/L TRIPED” light

This green indicating light will be off if 110VAC is healthy and on when the circuit trips.

“12 E/L TRIPED” light

This green indicating light will be off if 12VAC is healthy and on when the circuit trips.

“O/L TRIPED” light

This green indicating light is normally on. It will turn off if the motor overload has tripped.

_________________________________________________________________ 5.10 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

“HYDR OIL HEALTHY” light

___________________________________________________Operation Fig. 13: Starter enclosure controls and indicators Circuit breaker reset lever

2

3

4

5

6

7

8

9

10

11

12

© BUCYRUS AMERICA, INC.

1

13

14

15 16

22

1. Hour meter 2. “110V POWER ON” 3. “12V POWER ON” 4. “CRUSHER RUNNING” 5. “HYDR OIL HEALTH” 6. Mode of operation switch 7. “NORMAL OPERATION” 8. “MOTOR OIL TEMP HEALTH” 9. “SEQ & WATER MONITORING” 10. HYDR OIL LEVEL HEALTHY” 11. SPRAY WATER PROVED”

21

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12. “110V E/L TRIPED” 13. “O/L RESET” 14. “OUTBY CONVEYOR RUNNING” 15. “O/L TRIPED” 16. “12 E/L TRIPED: 17. “O/L RESET” 18. “START” 19. “E/STOP” 20. “12V E/L TEST” 21. “110V/12V E/L RESET” 22. 110V E/L TEST”

______________________________________________________________ A6474X258 VISV / 02 5.11

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

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

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.  Operate all valve control levers to ensure that they are free and in neutral position.

 Check that all other personnel are within a safe distance of the machine and discharge boom.

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

Starting the feeder breaker  Apply power to the machine. (Line side of the main circuit breaker)  Set main circuit breaker located on the side of the starter enclosure by first moving the circuit breaker lever to the “RESET” position and then to the “ON” position.

–

Area lights will come on. (If the two (2) 6A circuit breakers are on)

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“POWER ON” light will be on.

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“110V E/L TRIPED” light will be off.

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“12 E/L TRIPED” light will be off.

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“110V POWER ON” light will be on.

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“12V POWER ON” light will be on. (12VAC available to flashing light, headlights and siren).

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“CRUSHER RUNNING” light will be off.

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“HYDR OIL HEALTHY” light will be on.

_________________________________________________________________ 5.12 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Check conveyor (s) for any foreign material or objects.

___________________________________________________Operation –

“MOTOR OIL TEMP HEALTHY” light will be on.

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“HYDR OIL LEVEL HEALTHY” light will be on.

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“SPRAY WATER PROVED” light will be off.

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“WATER FLOW” light will be off.

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“OUT BAY CONVEYOR RUNNING” light will be on.

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“NORMAL OPERATION” light will be on.

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“SEQ & WATER MONITORING” light will be off.

To start the motor  Ensure that the “NORMAL/MAINTENANCE” switch located on the door of the starter enclosure is in the “NORMAL” position.

© BUCYRUS AMERICA, INC.

 Ensure the water to the mist spray system is in the “OFF” position.  Push and release the “START” pushbutton located on the starter enclosure door.  Pre-start warning consisting of a flashing light and siren will operate for the period set by timer TR4. (Adjustable from 0-30 seconds)  Provided all other control systems are healthy the motor will start immediately following the completion of the pre-start warning period below.

NOTICE: The crusher scroll is directly coupled to the motor. TR5 will also be energized (adjustable 0-30 seconds) normally set at 7 secs, temporarily overriding the rotational under speed sensor. If the rotational speed is not achieved during this period, the motor will shut down.

To start the discharge conveyor  Turn on the water supply. Both water monitoring switches will operate.  Push and release one of the remote “START” pushbuttons or the “START’ pushbutton on the starter enclosure door. The conveyor will now run for the preset period set by TR3 timer. Operating a remote “START” pushbutton or the “START” pushbutton on the door of the starter enclosure will reset the TR3 timer.  If the mist spray fails to reach the preset parameters set within the monitoring switches the conveyor will stop after the TR1 timer (adjustable from 0-30 seconds) usually set at 3 seconds times out.

______________________________________________________________ A6474X258 VISV / 02 5.13

Operation____________________________________________________ To start the feeder breaker in the maintenance mode WARNING? This operating mode is provided to allow the machine to be operated by PROPERLY TRAINED AUTHORIZED PERSONNEL ONLY during specific maintenance and troubleshooting procedures.

This mode is not intended to be used during routine maintenance of the machine. Failure to follow this warning could cause serious injury or death to you or other workers.   Turn the “NORMAL/MAINTENANCE” selector switch to the “MAINTENANCE” mode, this will bypass the waterflow/pressure switches and the outby belt sensor.  Start the motor as covered in the previous instructions.

Tram only mode

 Pull the “TRAM/CONVEYOR” control lever up to the “TRAM” position.  Operate tram control levers to the desired direction of travel.

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.

_________________________________________________________________ 5.14 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Move the “Conveyor” direction control lever to the neutral position.

___________________________________________________Operation Shutdown procedure There are several methods of shutting down the feeder breaker. Some methods will remove the main incoming power and other methods will only stop the 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 and clean out the return line before shutting the machine down.

© BUCYRUS AMERICA, INC.

The feeder breaker can be shutdown using any one of the following:  Depress either of the remote pushbutton stations “STOP” buttons.

This will stop the crusher motor.   Depress either of the onboard pushbutton stations “E-STOP” buttons. This will remove the main incoming power.  Engage the pull cord switch located across the receiving end.

This will remove the main incoming power.  Depress the E-STOP pushbutton located on the cover of the starter enclosure. This will stop the crusher motor.  Move the conveyor directional control handle to the centered “NEUTRAL” position.  Move the “TRAM/CONVEYOR” control handle to the centered “NEUTRAL” position.

______________________________________________________________ A6474X258 VISV / 02 5.15

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

_________________________________________________________________ 5.16 Bucyrus – Model 7MFBH-48A Feeder Breaker

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

WARNING! This section is intended 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.

© BUCYRUS AMERICA, INC.

The electrical system is designed to operate on a 1,100V, three (3) phase, 50 HZ supply that is supplied by the controlling GEB (Gate End Box). Earth fault monitoring of the 1,100 volt circuits is provided at the GEB. Short circuit protection of the 1,100V circuit is provided by the circuit breaker (150A) located in the right hand end of the starter enclosure.

The 150 KW motor is has a suitable rated over-load system which trips the supply to the main motor under abnormal loading conditions by deenergizing the motor contactor (M1). Earth-fault trip protection for both the 110VAC and the 12VAC circuits is provided with test pushbuttons which are located on the door of the starter enclosure.

Area lighting is provided by two (2) area lamps (1,10V AC) located on each side of the machine. Four (4) headlamps are provided, two (2) are mounted over the crusher and two (2) are mounted on the discharge end of the machine. Indicator lamps, mounted behind the starter enclosure’s door provide information and diagnostic aids to the operators.

WARNING! Before removing the cover from the starter enclosure and attempting any maintenance or troubleshooting on the machine, the circuit breaker handle must be moved to the “OFF” position.

Electrical control features The feeder breaker is provided with suitably located Exd approved latching emergency stop pushbuttons which, when operated, open the controlling GEB’s pilot circuit, thus removing the incoming 1,100V supply. The hopper end is supplied with an Exd approved pull-cord switch which, when operated, opens the controlling GEB’s pilot circuit, removing the incoming 1,100V supply. An Exd approved start/stop station provides the controlling point of the incoming supply. An emergency stop pushbutton and a start pushbutton, mounted on the left cover of the starter enclosure, provide an on/off for the motor.

Both visual (Exd approved flashing light) and audible (Exd approved siren) pre-start warnings alert the operator before the electrical supply is connected to the main motor. The visual indication is also operated when the conveyor is running and when the feeder breaker is being trammed.

_____________________________________________________________ A6474X258 VISV / 02 5.17

Electrical system _____________________________________________ The hydraulic oil reservoir has a combined oil level and temperature monitoring switch. If either parameter is out of range, the motor is stopped under fault conditions and local indication is given on the main enclosure door (indicator lights will turn off).

The crusher scroll rotational speed is monitored via a proximity sensor to ensure that full speed is obtained within a pre-set time period. Failure to do so stops the motor and local indication is provided on the starter enclosure door.

Both water monitoring and sequence monitoring may be overridden by turning the mode of operation selector switch on the starter enclosure door to “MAINTENANCE”. This is to facilitate periods of specific maintenance or troubleshooting. This is not intended for use during routine machine maintenance. Turning the switch to “MAINTENANCE” mode while feeder breaker is running will shut down the motor. Local indication is provided on the starter enclosure door.

Two remotely mounted start pushbuttons are provided which allow the conveyor to be restarted after it has timed out . The conveyor timer is adjustable from 10 to 180 seconds and is usually set at 180 seconds (3 minutes).

Electrical safety features ■

To be able to apply power to the feeder breaker from the GEB using a start/stop pushbutton installed in the pilot circuit.

■

Before the motor starts both the flasher unit and siren will be activated for up to 30 seconds.

■

Whenever the conveyor is running the flasher unit is also flashing.

■

Emergency stops, which operate the GEB’s pilot circuit, are located at the front and back on both sides of the machine.

■

An emergency pull cord switch which operates the GEB’s pilot circuit is suspended over the hopper.

■

Area lights are mounted on both sides of the feeder breaker.

■

Conveyor can only continue to operate when sufficient water pressure and flow is proven following a 0-30 second override time (TR2).

■

Hydraulic oil under level and over temperature switches which stop the motor.

_________________________________________________________________ 5.18 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

When in “NORMAL” mode of operation, the out-by conveyor is monitored via a proximity sensor which prevents the conveyor from running until the out-by belt is running. Local indication is provided on the starter enclosure door. When in “NORMAL” mode of operation, water pressure and flow are monitored and the conveyor is stopped under fault conditions if either parameter is out of range. Local indication is provided on the starter enclosure door.

____________________________________________ Electrical system Fig. 14: Electrical component locator Area light

“START/E-STOP” switch

© BUCYRUS AMERICA, INC.

“START” switch (remote)

“E-STOP” switch (remote)

Emergency pull cord switch

Flashing light

Headlight

Headlight

Headlight Electric motor

“START” switch (remote)

“E-STOP” switch (remote)

Headlight Circuit breaker reset handle Starter enclosure

Siren

Area light

“E-STOP” switch (remote)

“E-STOP” switch (remote)

_____________________________________________________________ A6474X258 VISV / 02 5.19

Electrical system _____________________________________________

© BUCYRUS AMERICA, INC.

Fig. 15: Electrical layout

_________________________________________________________________ 5.20 Bucyrus – Model 7MFBH-48A Feeder Breaker

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

WARNING! Before removing the cover from the starter enclosure and attempting any maintenance or troubleshooting on the machine, the circuit breaker handle must be moved to the “OFF” position.

© BUCYRUS AMERICA, INC.

Fig. 16: Starter enclosure

_____________________________________________________________ A6474X258 VISV / 02 5.21

Electrical system _____________________________________________ Door panel The door of the enclosure (Fig. 17) houses the indicator lights, operation pushbuttons, mode of operation selector switch, and hour meter, all of which are visible on the outside of the door. In addition, there are timers and relays mounted across the bottom of the door.

Fig. 17: Starter enclosure door Serial number 54-2184

© BUCYRUS AMERICA, INC.

Serial number 54-2168

_________________________________________________________________ 5.22 Bucyrus – Model 7MFBH-48A Feeder Breaker

____________________________________________ Electrical system Fig. 18: Starter enclosure door Serial number 54-2168 Door panel components 1

6

7

2

8

3

9

4

© BUCYRUS AMERICA, INC.

5

1.

2.

3.

4.

5.

6.

7.

8.

Indicator lights Mode of operation switch Indicator lights Hour meter Overload reset button Start button Emergency stop button 12V Earth leakage test button 9. 12V/110V Earth leakage reset button 10. 110V Earth leakage test button 11. “CR7” 12. “TR3” 13. “CR6” 14. “TR5” 15. “TR4” 16. “TR2” 17. “RR” 18. “CR5” 19. “CR3” 20. “CR4” 21. “TR1” 22. “TR6” 23. “CR1”

10

23

22

21

20

19

18

17

16

15

14

13

12

11

Serial number 54-2184

4

3

6

7

2

8

9

1

10

5

23

20

19

22

21

18

17

16

15

14

13

12

11

_____________________________________________________________ A6474X258 VISV / 02 5.23

Electrical system _____________________________________________ indicator lights

The indicator lights are used to inform the operator of the overall status of the machine. For indicator light functions and descriptions, see the Operation section of this chapter.

mode of operation switch

The mode of operation switch is used to put the machine in “NORMAL” or “MAINTENANCE” mode.

hour meter

The digital hour meter displays the number of hours the pump motor has operated.

overload reset button

The overload reset button, labeled “O/L RESET” on the front of the panel, is used to reset the overload relay when it trips.

The start button, labeled “START” on the front of the panel, is used to start the machine’s electric motor.

emergency stop button

The emergency stop button, labeled “E/STOP” on the front of the panel, is used to stop the machine’s electric motor.

12V earth leakage test button

The 12V earth leakage test button, labeled “12V E/L TEST” on the front of the panel, is used to test the earth leakage relay on the 12V circuit.

earth leakage reset button

The earth leakage reset button, labeled “110V/12V E/L RESET” on the front of the panel, is used to reset the 12V and 110V earth leakage relays after they have tripped.

110V earth leakage test button

The 110V earth leakage test button, labeled “110V E/L TEST” on the front of the panel, is used to test the earth leakage relay on the 110V circuit.

“TR1”

“TR1” is a time delay on dropout timer for the spray water. If the water flow and/or pressure drop below preset values for longer than three (3) seconds, the conveyor will shut off.

“TR2”

“TR2” is a time delay on dropout timer for the water monitoring functions. Upon startup, “TR2” will override “TR1” for three (3) seconds.

“TR3”

“TR3” is a time delay on pick-up timer for conveyor run. After the conveyor has been started, “TR3” will allow it to run for two and a half (2.5) minutes without operator input. If there is no operator input (the start button on the machine or the remote start button is not pushed) during that 2.5 minutes, the conveyor will shutdown. If there is operator input during the 2.5 minutes, the timer will reset and begin the count again.

“TR4”

“TR4” is a time delay on pick-up timer for the pre-start warning horn.

Once the start button is pushed to start the electric motor, a warning horn will sound for a preset amount of time. After this time has passed, the motor will start.

“TR5”

“TR5” is a timer that is used to override the underspeed sensor during start-up for a preset amount of time.

_________________________________________________________________ 5.24 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

start button

© BUCYRUS AMERICA, INC.

____________________________________________ Electrical system “TR6”

If the oil level, oil temperature, or oil pressure exceeds it preset value for longer than three (3) seconds, “TR6” will shut down the pump motor.

“CR1”

“CR1” is the control relay for the breaker underspeed sensor.

“RR”

“RR” is the reset relay for timer “T3”. It is activated by pushing the start button on the front of the enclosure or on the remote.

“CR3”

“CR3” is the belt sequence switch relay. If the outby belt stops, the sequence switch will shutdown the conveyor.

“CR4”

“CR4” in the normal operation relay. When the machine mode of operation switch on the front of the enclosure is in the “NORMAL” position, the machine is ready for normal operation.

“CR5”

“CR5” is the maintenance mode relay. When the machine mode of operation switch on the front of the enclosure is in the “MAINTENANCE” position, “CR5” will override water monitoring and belt sequence monitoring and will allow the pump motor to be started.

“CR6”

“CR6” is the conveyor solenoid relay.

“CR7”

“CR7” will turn on a flashing light when the alarm horn is sounding, when the conveyor solenoid is energized, and when the machine is being trammed.

_____________________________________________________________ A6474X258 VISV / 02 5.25

Electrical system _____________________________________________ Left side of starter enclosure The left side of the enclosure (Fig. 19) houses the contactor, control transformer, earth leakage relays, power supplies, intrinsically safe barriers, and resistors.

Fig. 19: Left side of starter enclosure

“M1”

“F1”

“F2”

© BUCYRUS AMERICA, INC.

“OL1”

IS barriers: “MTL1”, “MTL2”, and “MTL3’

Conveyor solenoid power supply

IS barrier power supply

“ELRC1”

Resistor/ diode

“ELRC2”

“E/LR”

Control transformer

Resistors

_________________________________________________________________ 5.26 Bucyrus – Model 7MFBH-48A Feeder Breaker

____________________________________________ Electrical system “OL1”

“OL1” is the overload relay for the pump motor. If the overload relay trips, the pushbutton, “O/L RESET”, located on the front of the enclosure must be pressed before the pump motor can be restarted.

“M1”

“M1” is the contactor for the pump motor.

“F1” and “F2” control transformer

© BUCYRUS AMERICA, INC.

resistors

“F1” and “F2” are 6A fuses on the primary (1,100V) side of the transformer.

The control transformer steps the current down from 1,100V to 120/12V. The resistors are used in the earth leakage test circuit.

“E/LR”

“E/LR” is the earth leakage relay. When this relay opens, power is removed from the 12V and 120V circuits.

“ELRC1”

“ELRC1” is the 120V circuit earth leakage relay and is used in conjunction with “E/LR”

“ELRC2”

“ELRC2” is the 12V circuit earth leakage relay and is used in conjunction with “E/LR”

power supplies

The power supplies are 120/24VDC power supplies for the IS barrier and the conveyor solenoid.

There are three IS barriers stacked together:

“MTL1”

“MTL1” is the oil temp and oil level intrinsically safe barrier.

“MTL2”

“MTL2” is the hydraulic oil pressure and tram pressure healthy intrinsically safe barrier.

“MTL3”

“MTL3” is the water flow and pressure intrinsically safe barrier.

30 ohm resistor/diode

The 30 ohm resistor/diode allows the machine operator to energize the power center contactor from the machine.

_____________________________________________________________ A6474X258 VISV / 02 5.27

Electrical system _____________________________________________ Right side of starter enclosure The right side of the enclosure (Fig. 20) houses the main circuit breaker, the BMI board, fuses, and the core balancers.

Fig. 20: Right side of starter enclosure

Fuses

“MCB”

BMI board

core balancers

The core balancers detect an imbalance in the control current and trip the earth leakage relay, “ELR”. Thee is one core balancer for the 120V circuit and one for the 12V circuit.

“MCB”

“MCB” is the main circuit breaker for the machine. The circuit breaker is reset with the reset handle located on the right side of the starter enclosure. Te reset the circuit breaker, push the switch down, passed off, and then up to the on position.

There are seven circuit breakers located in the enclosure:

“CB1” and “CB2”

“CB1” and “CB2” are 6A breakers for the 120V control circuit.

“CB3” and “CB4”

“CB3” and “CB4” are 32A breakers for the 12V circuit.

“CB5” and “CB6”

“CB5” and “CB6” are 6A breakers for the area lights.

“CB” BWI board

“CB” is a 6A breaker for the 24V conveyor solenoid circuit.

The BWI board is a dual channel circuit board that controls the belt sequence switch and the breaker underspeed sensor. This board also houses the belt sequence and breaker underspeed barriers.

_________________________________________________________________ 5.28 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Core balancers

____________________________________________ Electrical system Electrical main components electric motor (feeder breaker)

The machine has a 150 kW (200 hp) internal cooled electric drive motor that drives the pick breaker and hydraulic pump for the feeder breaker.

emergency stop pull cord switch

The emergency stop pull cord switch is located on the receiving end of the machine. To actuate the switch, pull the cord that is across the conveyor. When the cord is pulled, the incoming power is turned off.

“START/E-STOP” switch

© BUCYRUS AMERICA, INC.

“START” switch remote

The machine is equipped with a “START/E-STOP” switch located at the operator’s station. The “START/E-STOP” switch allows the operator to pull in the contactor at the power center from the machine.

The machine is equipped with two (2) remote “START” switches.

These “START” switches allows the operator to start and reset the conveyor when it has timed out from a remote location.

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

belt sequence sensor and pick breaker sensor

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

oil level and high temperature switch

The oil level and high temperature switches for the feeder breaker are located onboard the machine at the oil tank. If either one detects a high temperature or low oil level at the oil tank the motor will shutdown. The two indicating lights (“MOTOR OIL TEMP. HEALTHY” and “HYDR OIL LEVEL HEALTHY”) located on the starter enclosure will go out.

“E-STOP” switches (machine)

The machine is equipped with four (4) “E-STOP” switches, two are located on each side of the machine. Depressing either one of the “STOP” switch buttons will turn off the main power to machine (open contactor at power center).

flashing warning light

The machine is equipped with a flashing warning light located on top of the unit. The light provides a continuous pre-start warning alert to other personnel before the electrical supply is connected to the main motor.

The visual indication is automatically energized at initial start up and will also flash when the conveyor is running and the machine is being trammed.

area lights

The machine is equipped with two (2) area lights located on each side of the machine. The area lights are automatically energized at initial start up of the machine.

_____________________________________________________________ A6474X258 VISV / 02 5.29

Electrical system _____________________________________________ The machine is equipped with a audible siren located on the right side of the unit. The siren provides a audible pre-start warning alert to other personnel before the electrical supply is connected to the main motor.

The siren will automatically shut off after thirty (30) seconds.

headlights

The machine is equipped with four (4) headlights, two (2) are located on the discharge end and two (2) are located ion the center of the machine. The headlights are automatically energized at initial start up of the machine.

© BUCYRUS AMERICA, INC.

siren

_________________________________________________________________ 5.30 Bucyrus – Model 7MFBH-48A Feeder Breaker

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

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

© BUCYRUS AMERICA, INC.

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

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

Fig. 21: Hydraulic component locator

1.

2.

3.

4.

5.

6.

7.

8.

tram/conveyor control valve conveyor direction/speed valve primary valve bank tram motor RH tram motor LH Auxiliary pressure gauges loop flushing valve tank fill filter

9. tank fill pump 10. charge/system pressure gauges 11. heat exchanger 12. auxiliary pressure filters 13. charge filter 14. hydrostatic filter 15. return filter

16. solenoid valve 17. oil tank 18. conveyor motor 19. tilt and lift cylinders 20. tandem gear pump 21. hydrostatic pump 22. conveyor pressure gauge

_____________________________________________________________ A6474X258 VISV / 02 5.31

Hydraulic system _____________________________________________ Major hydraulic components

hydraulic oil tank

The hydraulic oil tank located on the left hand side of the machine has a 175 gallon (662 L) capacity. It is equipped with an oil level sight glass and oil level/high temperature switches.

hydrostatic pump

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

tandem gear pump

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

primary valve bank

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

tank fill pump

The tank fill pump is located on the left hand side of the discharge section of the machine on top of the oil tank and is used to replenish fluid to the hydraulic tank from an external source. The pump is capable of delivering approximately 5 gallons (19 L) of fluid per 30 seconds.

tilt hydraulic cylinders

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

lift hydraulic cylinders

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

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

tram motors

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

conveyor motor

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

_________________________________________________________________ 5.32 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

(Reference Fig. 21)

____________________________________________ Hydraulic system loop flushing valve

heat exchanger

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

conveyor direction/speed control valve

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

charge filter

The charge filter located under the gear pump on the right hand side of the machine is used to filter the charge fluid. The filter removes hot oil from the circuit, allowing the charge pump to replenish the circuit with cooler oil.

pressure filter (s)

© BUCYRUS AMERICA, INC.

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

Two (2) pressure filter (s) are located above the crawler on the left hand side of the machine and are used to filter fluid on the pressure side of the circuit.

return filter

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

tank fill filter

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

pressure filter (hydrostatic)

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

ball valve

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

“TRAM/CONVEYOR” control valve

The tram/conveyor control valve allows the operator to select either “TRAM” or “CONVEYOR” mode. Push the control lever down for conveyor mode and pull the control lever up for tram mode.

tram circuit system pressure gauge

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

tram circuit charge pressure gauge

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

auxiliary function pressure gauges

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

_____________________________________________________________ A6474X258 VISV / 02 5.33

© BUCYRUS AMERICA, INC.

Hydraulic system _____________________________________________

_________________________________________________________________ 5.34 Bucyrus – Model 7MFBH-48A Feeder Breaker

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

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

Crawler assembly (s)

© BUCYRUS AMERICA, INC.

The feeder breaker is trammed by two (2) hydraulically driven crawlers (Fig. 22); one is located on each side of the machine. The complete drive assemblies are housed in crawler frames which enclose, guide and support the tram components. Each tram drive is independently controlled by the operator for moving the machine forward, backward and for making turns.

The crawlers on the machine are hydraulic driven through torque hub gear reducers. Attached to the torque hub is a single sprocket that engages the crawler tracks directly. The crawler track loops around the take-up roller assembly located on the opposite end of the crawler assembly. The idler assembly, along with a grease take-up is used to adjust the tension on the crawler tracks. (See Maintenance section in this chapter for Crawler track adjustment procedure) Fig. 22: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

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

_____________________________________________________________ A6474X258 VISV / 02 5.35

Mechanical assemblies ________________________________________ Conveyor chain The feeder breaker is equipped with a conveyor chain assembly (Fig. 23) that carries mined material along the conveyor trough from the receiving section and out through the discharge end. The conveyor chain is made up of one basic chain assembly, which repeats sequentially along the entire chain loop. See Maintenance section in this chapter for Conveyor chain maintenance.

Fig. 23: Conveyor chain components

Roll pin

© BUCYRUS AMERICA, INC.

Chain link section

Flight bar

Grease take-up (s) The feeder breaker is equipped with two (2) conveyor chain grease take-up assemblies (Fig. 24) that provides ease of adjustment for the conveyor chain. The take-up assembly provides constant tension on the tail shaft around which the conveyor chain rides at the receiving end of the machine. (See Conveyor chain adjustment in this chapter) Fig. 24: Grease take-up main components Stop valve (2)

Grease manifold

Grease fitting (2)

_________________________________________________________________ 5.36 Bucyrus – Model 7MFBH-48A Feeder Breaker

_______________________________________ Mechanical assemblies Head shaft The feeder breaker is equipped with a head shaft (Fig. 25 and 26) located on the discharge end of the conveyor. The head shaft is driven from the left hand side via a hydraulic motor that is directly connected to the head shaft.

Fig. 25: Head shaft main components Sprocket (2)

Head shaft

© BUCYRUS AMERICA, INC.

Key (2)

Bearing (2)

Fig. 26: Conveyor torque arm and hydraulic motor

Torque arm

Coupling

Hydraulic motor

_____________________________________________________________ A6474X258 VISV / 02 5.37

Mechanical assemblies ________________________________________ Power unit The power unit drives the hydraulic pump (s) and pick breaker reducer (Fig. 27). It consists of a 200 HP electric motor, coupled to a reducer, hydrostatic pump and piggyback gear pump. The power unit has been assembled as a unit and can be removed as a unit or as individual components.

Fig. 27: Power unit main components Sprocket

Coupling Motor (200 HP) Connecting tube

Gear pump

Reducer

Mounting base Hydrostatic pump

Tail shaft The feeder breaker is equipped with a tail shaft (Fig. 28) located on the receiving end of the conveyor. The tail shaft is an idler shaft that is driven by the tension of the conveyor chain. There is a slide plate arrangement attached to the tail shaft, which fills the gap between the receiving impact plate and the shaft.

Fig. 28: Tail shaft components Roller (2)

Key (2) Set screw (2)

Tail shaft

Slide plate

Roller bearing (2) Piston rod adapter (2)

_________________________________________________________________ 5.38 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Coupling

_______________________________________ Mechanical assemblies Breaker assembly The breaker assembly (Fig. 29) on the machine has a 25” (635 mm) pick circle with a 4 point star arrangement. It has a 8” shaft diameter turned down to 6 3/16” (157 mm) thru the bearings. The breaker has a under speed sensor mounted on the left hand side that will shutdown the machine should the breaker be stalled due to a jam.

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

Fig. 29: Breaker assembly main components Side plate

Seal housing

Bearing housing

© BUCYRUS AMERICA, INC.

Bearing retainer

Under speed sensor mount

Bearing backing ring

Bearing

Bearing housing

Bearing backing ring

Pick (25)

Breaker shaft

Side plate

Bearing backing ring Bearing

Seal housing

Bearing retainer

Bearing housing Shear hub

_____________________________________________________________ A6474X258 VISV / 02 5.39

© BUCYRUS AMERICA, INC.

Mechanical assemblies ________________________________________

_________________________________________________________________ 5.40 Bucyrus – Model 7MFBH-48A Feeder Breaker

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

Important notes

© BUCYRUS AMERICA, INC.

Please observe the following: ■

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

■

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

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus 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 from 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 from 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.

______________________________________________________________ A6474X258 VISV / 02 5.41

Maintenance _________________________________________________ ■

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

■

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

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

■

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

■

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

■

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

_________________________________________________________________ 5.42 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

________________________________________________ Maintenance Lubrication and inspection Maintenance includes ■

Lubrication of the machine in accordance with the lubrication schedule.

■

Inspection of the machine for faults and proper function.

■

Inspection for wear parts.

© BUCYRUS AMERICA, INC.

Table 1: Lubricants: Fluids and capacities Location

Specification

Approximate capacity

Hydraulic oil tank

Spec. 100-1

162 gal (613 L)

Breaker reducer

Spec. 100-6

10 gal (38 L)

Tram Reducer

Spec. 100-2 or Spec. 100-13

2.5 gal per side (10 L per side)

Grease points

Spec. 100-3

As required

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

Central lubrication system The central lubrication manifold (Fig. 30) is located on the left hand side of the receiving end of the feeder breaker. This allows the following to be easily lubricated from a central point; head shaft, breaker shaft and tail shaft.

Fig. 30: Central lubrication Note: Outboard bearing port used only if applicable on machine.

Tail shaft

Outboard bearing

Breaker

Head shaft

______________________________________________________________ A6474X258 VISV / 02 5.43

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 19 20 21 22 23 24 25 26 27

28 29 30 31

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

Places 2 2 4 1 1 2 1 1 Inspect

Lubricant

Spec. 100-3 Spec. 100-3 Spec. 100-3 Plantoflux AT/68 S

2 1 Inspect Inspect

Spec. 100-3

Inspect Check 2

Breaker drive chain Breaker reducer (Check) Dust system strainer (Check) Charge filter (change) Every 2 weeks Pressure filter (auxiliary circuit) (change) Return filter (change) Pressure filter (hydrostatic) (change) Monthly Conveyor tilt and lift cylinders Crawler anchor pin (s) Every 3 months Power fill filter (change) Electric motor

1 1 1 1

Breaker reducer Every 2500 hours ** Breaker reducer (Change) Every 6 months Hydraulic oil tank (change) Tram reducer (change oil)

2

Specification

Spec. 100-2 or Spec. 100-13 Chain lube Century 220

2 1 1 8 2

Spec. 100-3 Spec. 100-3

1 2

Spec. 100-14 or Spec. 100-16 Spec. 100-3

1

Century 220

1 2

Plantoflux AT/68 S Spec. 100-2 or Spec. 100-13

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

_________________________________________________________________ 5.44 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Item

________________________________________________ Maintenance

© BUCYRUS AMERICA, INC.

Fig. 31: Lubrication chart

______________________________________________________________ A6474X258 VISV / 02 5.45

Maintenance _________________________________________________ Specific lubrication and maintenance procedures

head shaft bearings

Lubricate the feeder breaker head shaft bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 32) 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. 32) 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. 32) 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 bearing return Fig. 32: Central lubrication panel Central lubrication panel

hydraulic oil tank

Check the feeder breaker hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 33). 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 (Plantoflux AT/68 S) via the power fill system.

Fig. 33: Hydraulic tank oil level Oil level sight glass

_________________________________________________________________ 5.46 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Every 8 hours of operation:

________________________________________________ Maintenance

© BUCYRUS AMERICA, INC.

charge filter

Check the feeder breaker charge filter’s pop-up style dirt alarm ( Fig. 34) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

pressure filter (auxiliary circuit)

Check the feeder breakers two (2) auxiliary circuit pressure filter’s popup style dirt alarm (Fig. 34) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

return filter

Check the feeder breaker return filter’s pop-up style dirt alarm (Fig. 34) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

pressure filter (hydrostatic)

Check the feeder breaker hydrostatic pressure filter’s pop-up style dirt alarm (Fig. 34) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

breaker bits

Check the breaker bits to see if they will rotate in their holders and for damaged or missing bits (Fig. 34). 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. 34: Filter and breaker bit location Pressure filter (auxiliary circuit)

Pressure filter (auxiliary circuit)

Breaker bits

Return filter

Pressure filter (hydrostatic) Charge filter

______________________________________________________________ A6474X258 VISV / 02 5.47

Maintenance _________________________________________________ Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 35) with Spec. 100-3. The fittings (one per side) may be reached through the slot in the end of the crawler frame on the outside of each crawler.

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

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

conveyor chain tension

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

fasteners

Due to the machine being subjected continual shock loading and vibration, close attention to all mounting bolts and screws is required. Loose fasteners will cause premature wear and failure to bearings, couplings, etc. Inspect and tighten as required the following fasteners: ■

head shaft bearing bolts

■

breaker shaft side plate bolts

■

conveyor drive motor mounting bolts

■

tail shaft retainer hold down bolts

■

all cover and guard retaining bolts

electrical cables, conduits, glands, lights and siren

Visually inspect all electrical cables, conduits, glands. Lights and siren for signs of wear or damage.

hydraulic hoses and fittings

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

_________________________________________________________________ 5.48 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 35: Crawler track take-up lubrication

________________________________________________ Maintenance charge filter

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

hydraulic system pressure (s)

Check the hydraulic system pressure (s) by visually looking at the pressure gauges (Fig. 36). Refer to the hydraulic schematic in your parts manual for correct pressure (s).

Fig. 36: Hydraulic charge filter and system pressure gauges (s) location

© BUCYRUS AMERICA, INC.

Conveyor speed pressure gauge

Conveyor circuit charge pressure gauge

Tram system circuit pressure gauge

Tram system circuit pressure gauge

Charge filter

Conveyor system circuit pressure gauge

tram reducer (s)

Check the oil level in both tram reducer torque hubs (Fig. 37):  Oil level/fill plug should be at the 3 o’clock and 12 o’clock position.  Remove the oil level/fill plugs.  The oil level should be kept at the level of the level/fill plug.  Should it be necessary to add oil, add 80W-90 oil through the fill plug hole until it begins to flow out of the check hole.  Do not overfill the reducer.

Fig. 37: Tram reducer oil level Fill plug location

Check plug location

Drain plug location

______________________________________________________________ A6474X258 VISV / 02 5.49

Maintenance _________________________________________________ breaker drive chain breaker reducer

Lubricate the breaker drive chain with a good quality chain lube Check oil level in the breaker drive reducer (Fig. 38). Oil level should be maintained inside the sight glass on the side of the reducer when it is in operation. If the reducer does not have a sight glass, a pipe plug will be installed in the side of the reducer slightly below the input shaft center line. This is the level that the fluid should be maintained at. The oil should be changed after the first 500 hours of operation. Use Century 220 lubricant.

Fig. 38: Breaker reducer

Sight glass

dust system strainer

Drain plug

Breather

Drain plug

Clean the strainer mounted inside the dust suppression system. Open ball valve (Fig. 39) 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. 39: Dust system Ball valve

Strainer

Short hose location

_________________________________________________________________ 5.50 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Inspection cover/fill plug

________________________________________________ Maintenance Every 2 weeks pressure filter (auxiliary circuit)

Change the two (2) pressure filter’s element (Fig. 40). If the element is extremely dirty, a more frequent interval may be required.

return filter

Change the return filter’s element (Fig. 40). If the element is extremely dirty, a more frequent interval may be required.

pressure filter (hydrostatic)

Change the hydrostatic pressure filter’s element (Fig. 40). If the element is extremely dirty, a more frequent interval may be required.

Fig. 40: Filter location

© BUCYRUS AMERICA, INC.

Pressure filter (auxiliary circuit)

Pressure filter (auxiliary circuit)

Return filter

Pressure filter (hydrostatic) Charge filter

______________________________________________________________ A6474X258 VISV / 02 5.51

Maintenance _________________________________________________ Monthly conveyor lift and tilt cylinders

Lubricate grease fittings on the rod and base ends of the conveyor lift and tilt cylinders with Spec. 100-3 (Fig. 41). 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. 41). Pump grease into the fittings until new grease can be observed coming out of the pins.

Crawler anchor pin (s) (grease fitting located inside crawler frame) Lift cylinder (s) (grease fitting located on rod and base end) Tilt cylinder (s) (grease fitting located on rod and base end)

_________________________________________________________________ 5.52 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 41: Cylinder and anchor pin lubrication point location

________________________________________________ Maintenance Every 3 months electric motor

Lubricate the feeder breaker’s electric motor with Spec. 100-14 or 10016 through the two (2) grease fittings located on each end of the motor (Fig. 42) . Pump only one or two pumps of grease into each fitting.

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

reducer

power fill filter

Lubricate the reducer with Spec. 100-3 through the two (2) grease fittings located on the central lubrication panel (Fig. 42) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

Change the power fill filter element (Fig. 42). If the element is extremely dirty, a more frequent interval may be required.

© BUCYRUS AMERICA, INC.

Fig. 42: Electric motor and reducer lubrication

Power fill filter

Reducer lubrication panel Electric motor central lubrication panel

______________________________________________________________ A6474X258 VISV / 02 5.53

Maintenance _________________________________________________ Every 2500 hours reducer

Change the oil in the breaker drive reducer (Fig. 43). The reducer oil should be changed after the first 500 hours of operation and ever 2500 hours afterwards. Remove the drain plug and allow the oil to completely drain. Clean and reinstall drain plug.

Do not overfill reducer.

Fig. 43: Breaker reducer Inspection cover/ fill plug

Drain plug

Breather

Sight glass

Drain plug

_________________________________________________________________ 5.54 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

________________________________________________ Maintenance Every 6 months hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank (Fig. 44).  Clean all dirt and debris from and around the fill cap and drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and reinstall drain plug.  Add oil (Plantoflux AT/68 S) as required via the fill cap on top of the oil tank until fluid is visible in sight glass.

NOTICE! Do not puncture or remove dirt screen from fill cap. Contamination can enter oil tank and cause premature wear of components if dirt screen is punctured or removed.

© BUCYRUS AMERICA, INC.

 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 thru the power fill system.

Fig. 44: Hydraulic oil tank Sight glass

Drain plug (located under oil tank)

______________________________________________________________ A6474X258 VISV / 02 5.55

Maintenance _________________________________________________ tram reducer

Change oil in the tram reducer (Fig. 45).  Clean all dirt and debris from and around the level and fill plugs.  Rotate reducer until drain plug is at the 6 o’clock position and remove drain plug and allow the oil to completely drain.  Clean and reinstall drain plug.  Rotate reducer until plugs are at the 12 o’clock and 3 o’clock positions.  Add oil (Spec. 100-2 or Spec. 100-13) through the fill hole until fluid begins to flow from the check plug.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.

 Do not overfill reducer.

Fig. 45: Tram reducer oil change Fill plug location

Check plug location

Drain plug location

_________________________________________________________________ 5.56 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Install level and fill plugs.

________________________________________________ Maintenance Inspection 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 “E-STOP” button (s) for correct operation.

© BUCYRUS AMERICA, INC.

 Check the hydraulic oil level in the by looking at the sight glass.

The oil level should be kept at the level of the top sight glass.  Check oil level in the crawler reducers.  Inspect all electrical and hydraulic components for condition.  Check for proper conveyor chain tensioning.  Check for proper crawler chain tensioning.  Lubricate per the lubrication schedule.  Check power input cable to power source insuring that the voltage and breaker settings are correct.  Check that the cable handling device is intact and oriented correctly.  Check that all covers are installed and secure.  Check the tightness of all connecting elements.  Check that area lights and head lamps are all working correctly.

______________________________________________________________ A6474X258 VISV / 02 5.57

Maintenance _________________________________________________ Inspection of wear parts

■

the conveyor chain

■

the conveyor chain flights

■

the conveyor drive sprockets

■

the conveyor tail shaft

■

the conveyor wear plates

■

the crawler pads

■

the crawler drive sprockets

■

the crawler idler rollers

■

the breaker drive chain and sprockets

_________________________________________________________________ 5.58 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

Inspect:

________________________________________________ Maintenance Inspection of fire suppression system To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 46).  Note general appearance for mechanical damage or corrosion.  Check nameplate for readability, corrosion or looseness.  Remove fill cap assembly.  Examine gaskets for elasticity, clean and coat lightly with a good grade of high heat resistant grease.  Inspect threads on fill cap and in fill opening for nicks, burrs, cross threading, rough or feathered edges.

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X258 VISV / 02 5.59

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

© BUCYRUS AMERICA, INC.

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

_________________________________________________________________ 5.60 Bucyrus – Model 7MFBH-48A Feeder Breaker

________________________________________________ Maintenance Recharge of fire suppression system To return your fire suppression system to service after use (Fig. 46).  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.

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X258 VISV / 02 5.61

Maintenance _________________________________________________ Fig. 46: Fire suppression system

Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Breaker coupling Nozzle

Operator’s station

Nozzle Nozzle Breaker motor Nozzle

Oil tank LP canister

LP expellant

_________________________________________________________________ 5.62 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Nozzle

_______________________________________ 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.

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. 47):  Close the stop valve on manifold assembly securely.  Attach a grease gun to the grease fitting located on the manifold and apply grease until 2” - 3” (50 mm - 75 mm) of sag is achieved underneath the head shaft sprockets.  After tensioning chain, remove the allen head bolts from the tail shaft retainers and lift out retainers.  Insert shims over cylinder rod to maintain gap between bearing and end plate of box.  Allow tail shaft pressure to rest completely on shims.

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

Incorrect tension or adjustment can cause premature wear of sprockets and chain.  Replace retainers.  Release pressure on the take-up cylinders by opening the top valve to vent grease. After grease has vented, close valve.

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

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Adjustment procedures ________________________________________ Fig. 47: Conveyor chain adjustment

Grease fitting

Stop valve

_________________________________________________________________ 5.64 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Chain sag should be 2” - 3” (50 mm - 75 mm) underneath head shaft sprockets

_______________________________________ 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. 48):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

© BUCYRUS AMERICA, INC.

 Chain sag should be 1 3/4” (44.5 mm) at the center of the crawler.  Remove the access cover located on the side of the crawler and locate the needle valve inside crawler frame. Turn valve knob counter clockwise (CCW) to open valve and pump grease into the fitting until the correct adjustment is achieved. Chain sag should be 1 3/4” (44.5 mm) at the center of the crawler.  Turn needle valve knob clockwise (CW) to close.

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

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

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

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Adjustment procedures ________________________________________ Fig. 48: Crawler track adjustment

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

Idler assembly

Access cover

Take-up cylinder

Needle valve © BUCYRUS AMERICA, INC.

Grease fitting

_________________________________________________________________ 5.66 Bucyrus – Model 7MFBH-48A Feeder Breaker

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

To adjust tension on the breaker drive chain with the take-up cylinder proceed as follows (Fig. 49):  Remove the covers from the power unit.  Loosen the power unit adjustment bolts located on each side of the mounting base, bolts do not have to be removed.  Close the needle valve securely.  Attach a grease gun to the grease fitting and apply grease. Pump grease into the grease fitting until 1” - 2” (25 mm - 50 mm) sag in lower section of chain is achieved.

© BUCYRUS AMERICA, INC.

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

WARNING! Due to grease cylinder being under high pressure, do not stand in direct line of grease fitting or bleeder valve when releasing pressure. You could be seriously injured from high pressure grease.  Tighten all adjustment bolts.  Store and secure any unused shims.  Install power unit covers.

Fig. 49: Breaker drive chain adjustment

Power unit

Bleeder valve and needle valve

Take-up assembly Adjustment bolts located in

Shim location

bottom of mounting base ______________________________________________________________ A6474X258 VISV / 02 5.67

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

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

The loop flushing valve (Fig. 50) is mounted on the frame behind the power unit. The valve is preset from the factory at 290 psi (20 bar), which is measured by the charge pressure gauge when the conveyor is running.

 Start the machine (See starting procedure in this chapter).  Operate the conveyor directional control lever to run the conveyor.  Loosen the jam nut on the adjustment stem by turning out (counterclockwise).  Turn the adjustment stem in (clockwise) to increase the setting or out (counterclockwise) to decrease the setting.  When the correct setting is obtained, tighten the jam nut on the adjustment stem by turning in (clockwise) while holding the adjustment stem in place.

_________________________________________________________________ 5.68 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

If an adjustment is required:

_______________________________________ Adjustment procedures Fig. 50: Loop flushing valve

Adjustment stem and jam nut

© BUCYRUS AMERICA, INC.

Loop flushing valve

“CHARGE PRESSURE” gauge

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

The valve bank reliefs are located in each inlet section of the valve bank (Fig. 51). The purpose of the two relief valves is to limit the maximum pressure of each inlet section. The design pressure setting is 2,250 psi. The setting for each relief is read from the corresponding auxiliary pressure gauge while deadheading a function. The first relief cartridge (Cartridge 1)) limits the pressure into the first inlet section (both left sections and left tram) while the second relief cartridge (Cartridge 2) limits pressure to the mid-inlet section (right tram, tilt, and power fill).

 Measure the setting of Cartridge 1 by fully extending or retracting (deadheading) one of the lift cylinders, then reading the pressure on “AUXILIARY PRESSURE #1” gauge while the cylinder is deadheaded. The reading should be 2,250 psi.

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

_________________________________________________________________ 5.70 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

To adjust relief Cartridge 1:

_______________________________________ Adjustment procedures To adjust relief Cartridge 2:  Measure the setting of cartridge 2 by fully extending or retracting (deadheading) the tilt cylinders, then reading the pressure on “AUXILIARY PRESSURE #2” gauge while the cylinders are deadheaded. The reading should be 2,250 psi.

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

© BUCYRUS AMERICA, INC.

 Turn the hex key adjustment in (cw) to increase the setting or out (ccw) to decrease the setting.  Once the desired setting is obtained, tighten the jam nut by turning in (cw) while hold the hex key in place.

Fig. 51: Relief valves Cartridge 1

“AUX SYSTEM PRESSURE 1” gauge (left cylinder)

Cartridge 2

“AUX SYSTEM PRESSURE 2” gauge (right cylinder)

“FRAME LIFT” (left cylinder)

“FRAME LIFT” (right cylinder

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Adjustment procedures ________________________________________ Flow control valve adjustment The flow control valve (Fig. 52) is used to control the heat exchanger fan speed by limiting the flow allowed to the heat exchanger motor.

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

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

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

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

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

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

_________________________________________________________________ 5.72 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

_______________________________________ Adjustment procedures

© BUCYRUS AMERICA, INC.

Fig. 52: Flow control valve adjustment

Heat exchanger motor

Flow control valve

Flow control valve adjustment

Pump and charge system reliefs The pump and charge system reliefs are non-adjustable. If settings are incorrect, the cartridges must be replaced. See the pump drawing in the Bucyrus parts book for your machine.

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Adjustment procedures ________________________________________ The BDI board is mounted on the floor of the right hand side of the starter enclosure (Fig. 53).

Note: Calibration should be performed with the belt running at normal speed.

To setup and test the breaker shaft underspeed sensor or belt sequence sensor:  Turn the speed control counterclockwise (left) until it stops (approximately 7 o’clock).  Hold the test/set switch in the set position to engage relay.  Turn the speed control counterclockwise (left) until the margin LED begins to blink.

 For a 20% margin, adjust the speed control so that the margin light just turns on steady.  For a 10% margin, adjust the speed control counterclockwise so that the margin light just turns off.  For all speed adjustments, the critical speed LED must stay on continuously.  After the relay status LED is illuminated, return the test/set switch to the run position.  A momentary test position is provided to simulate the loss of sensor signal, which releases the relay.

Repeat for the other sensor.

_________________________________________________________________ 5.74 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

 The control relay will drop out with the above at 15% slow down.

_______________________________________ Adjustment procedures Fig. 53: BDI board

Critical speed LED (breaker shaft)

Critical speed LED (belt sequence)

© BUCYRUS AMERICA, INC.

Margin LED (breaker shaft)

Margin LED (belt sequence)

Breaker shaft underspeed sensor

Belt sequence sensor

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© BUCYRUS AMERICA, INC.

Adjustment procedures ________________________________________

_________________________________________________________________ 5.76 Bucyrus – Model 7MFBH-48A Feeder Breaker

____________________________________ Replacement of wear parts Instructions on the replacement of wear parts 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. 54) 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. 54: Head shaft main components

Sprocket (2)

Head shaft Key (2)

Bearing (2)

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Replacement of wear parts _____________________________________ How to remove the head shaft To remove the head shaft assembly from the feeder breaker discharge boom proceed as follows (Fig. 55):  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the two (2) sprocket guards located on the end of the discharge boom.  Remove the hydraulic motor. (See Hydraulic motor removal in this chapter).

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

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

How to install the head shaft To install the head shaft assembly proceed as follows (Fig. 55):  Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the discharge boom.  Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) nuts, bolts, and lock washers. Torque bolts to 645 ft-lbs.  Install the left and right covers to the end of the boom frame.  Connect the central lubrication hoses on both head shaft bearings.  Install the hydraulic motor. (See Hydraulic motor installation in this chapter).

_________________________________________________________________ 5.78 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

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

Fig. 55: Head shaft removal and installation

© BUCYRUS AMERICA, INC.

Conveyor chain (not shown)

Covers

See hydraulic motor removal in this chapter

Head shaft Sprocket guard (s)

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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. 56):  Remove the drive shaft assembly from the discharge boom (see Drive shaft removal in this chapter).  Remove the two (2) bearings from the head shaft.

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

See parts manual for replacement parts list.

How to install the head shaft sprockets To install the sprockets on the head shaft proceed as follows (Fig. 56):  Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.  Insert one of the keys into the shaft keyway and slide first sprocket onto shaft.  Insert the other key into the shaft keyway and slide second sprocket onto shaft.  Slide both bearings onto shaft.  Install the drive shaft assembly in the discharge boom. (See drive shaft installation in this chapter.

_________________________________________________________________ 5.80 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts How to install the head shaft temporary split sprockets To install the temporary split sprockets on the head shaft proceed as follows (Fig. 55): IMPORTANT! The split sprocket is designed for temporary use only and should be replaced during the first available maintenance shift.  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the two (2) sprocket guards located on the end of the discharge boom.

© BUCYRUS AMERICA, INC.

 Remove damaged sprockets and keys from head shaft. Old sprockets may require cutting to remove.  Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.  Insert new key into shaft keyway.  Install both sprocket halves and align sprockets with conveyor chain. Tack weld both halves together and pre-heat the weld joint to 600° - 800° F. Weld with low hydrogen wire or electrode.  Align sprocket with conveyor chain and tighten set screws.  Connect conveyor chain. (See Conveyor chain replacement in this chapter).  Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

Fig. 56: Head shaft sprocket removal and installation Head shaft

Bearing (2)

Sprocket guard

Set screws

Split sprocket

Hydraulic motor

Conveyor chain

Sprocket (2) & key (2)

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Replacement of wear parts _____________________________________ Tail shaft The tail shaft (Fig. 57) allows for even adjustments friction free transition to the conveyor chain assembly. As soon as any component of the tail shaft is worn the component or complete tail shaft assembly must be replaced. Due to the high abrasion forces the tail shaft is subject to a very high level of wear.

■

shaft

■

roller (2)

■

slide plate

■

key (2)

■

set screw (2)

■

roller bearing (2)

■

piston rod adapter (2)

■

grease fitting (2)

Fig. 57: Tail shaft main components Tail shaft Roller (2)

Key (2) Set screw (2)

Grease fitting (2)

Slide plate

Roller bearing (2) Piston rod adapter (2)

_________________________________________________________________ 5.82 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

The tail shaft assembly consists of the following main components:

____________________________________ Replacement of wear parts How to remove the tail shaft To remove the tail shaft assembly from the receiving boom proceed as follows (Fig. 58):  Release tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).  Remove the five (5) bolts and lock washers from each of the tail shaft retainers and lift out the retainers.  Disconnect, tag and cap the central lubrication hoses to the tail shaft.  Remove the tail shaft shims.  Separate conveyor chain and fold back to clear tail shaft. (See Conveyor chain replacement in this chapter).

© BUCYRUS AMERICA, INC.

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

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

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 58):  With an appropriate lifting device, insert tail shaft into receiving boom.  Fold the conveyor chain over tail shaft.  Connect conveyor chain (see Conveyor chain replacement in this chapter.  Connect central lubrication hoses and lubricate tail shaft and slide plate bearings with Spec. 100-3 grease.  Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).  Install the tail shaft retainers with the five (5) bolts and lock washers in each side.  With machine running, visually inspect tail shaft to ensure that the shaft is turning and conveyor chain is not sliding across tail shaft.

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Replacement of wear parts _____________________________________ Fig. 58: Tail shaft removal and installation

Cover Tail shaft retainer plates (2)

Shims

Tail shaft

_________________________________________________________________ 5.84 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Take-up cylinder

____________________________________ Replacement of wear parts How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 59):  Remove the tail shaft assembly from the receiving boom. (See How to remove the tail shaft in this chapter).  Slide both roller bearings and piston rod adapters from the tail shaft.  Remove the set screws from both tail shaft rollers and slid rollers from the shaft.  Remove the tail shaft from the slide plate.  Visually inspect all components for damage or wear and replace as necessary.

© BUCYRUS AMERICA, INC.

How to assemble the tail shaft To assemble the tail shaft assembly proceed as follows (Fig. 59):  Thoroughly clean all parts that will be installed.  Grease tail shaft with Spec. 100-3 grease.  Slide tail shaft into the slide plate.  Insert keys into keyways on tail shaft.  Slide both rollers onto tail shaft, one on each end.  Install set screws into both rollers, ensuring that rollers and tail shaft slide plate are centered on tail shaft.  Tighten set screws.  Install both roller bearings and adapter plates on tail shaft, one on each end.  Install grease fittings, if required.  Install assembled tail shaft into machine. (See How to install the tail shaft in this chapter).

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Replacement of wear parts _____________________________________ Fig. 59: Tail shaft disassembly and assembly Tail shaft Roller (2)

Slide plate

Roller bearing (2) Piston rod adapter (2)

© BUCYRUS AMERICA, INC.

Key (2) Set screw (2)

Grease fitting (2)

_________________________________________________________________ 5.86 Bucyrus – Model 7MFBH-48A Feeder Breaker

____________________________________ Replacement of wear parts Conveyor chain The conveyor chain (Fig. 60) 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. 60: Conveyor chain main components

6 link chain section Spiral pin Flight bar

______________________________________________________________ A6474X258 VISV / 02 5.87

Replacement of wear parts _____________________________________ How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 61):  Lay conveyor chain sections on a clean flat surface.  Insert connector pins through flight end and align holes in spiral pin with holes in flight bar.  Insert spiral pin.  Drive spiral pin in with a hammer and punch. Ensure that spiral pin is recessed on both sides of flight bar.  Repeat the previous assembly instructions until the complete chain has been assembled.

Extended pin connecting link Spiral pin (4)

Block link assembly

Flight bar

Side bar

6 link chain section

_________________________________________________________________ 5.88 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig 61: Conveyor chain assembly

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

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Replacement of wear parts _____________________________________ Crawler track The crawler track (Fig. 62) 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. 62: Crawler track main components

© BUCYRUS AMERICA, INC.

Crawler pad

Connector pin and T-pin

_________________________________________________________________ 5.90 Bucyrus – Model 7MFBH-48A Feeder Breaker

____________________________________ Replacement of wear parts How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 62):  Lay crawler track pads on a clean flat surface.  Align pads with chain connecting holes centered.  Insert connector into center of crawler pad connecting holes.  Drive T-pin through connecting pin and bend end to secure.  Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly

© BUCYRUS AMERICA, INC.

To remove the crawler track pad assembly proceed as follows (Fig. 62):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

To separate the crawler pads proceed as follows (Fig. 62) 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.

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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. 62):

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Check to ensure that crawler track tension cylinder is completely retracted (see Crawler track adjustment in this chapter).  Slide crawler track pad assembly under crawler assembly.  Fold pad assembly over both ends of crawler assembly. Ensure that pad assembly meshes with drive sprocket and idler roller.  Connect crawler track pad assembly (see How to assemble crawler track pad assembly in this chapter for proper connection).  Adjust tension on the crawler track pad assembly (see Crawler track pad adjustment procedure in this chapter for proper adjustment).

_________________________________________________________________ 5.92 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Crawler assembly The crawler assembly (Fig. 63) consists of a take-up assembly and drive assembly that transmits torque to the crawler track via a hydraulic drive motor coupled to the tram drive torque hub. As soon as any component of the drive assembly is worn or damaged, the component must be replaced.

© BUCYRUS AMERICA, INC.

The crawler assembly consists of the following main components: ■

hydraulic drive motor

■

tram drive torque hub

■

cat pad assembly

■

take-up roller assembly

■

grease take-up assembly

■

drive sprocket

Fig. 63: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

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

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Replacement of wear parts _____________________________________ How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 64):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

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

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

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

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

_________________________________________________________________ 5.94 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Securely block under the crawler frame.

____________________________________ Replacement of wear parts How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 64):  Remove old take-up assembly (see previous section, How to remove crawler take-up assembly).

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

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X258 VISV / 02 5.95

Replacement of wear parts _____________________________________ Fig. 64: Crawler take-up removal and installation

Tilt cylinder mounting bracket

Crawler frame

_________________________________________________________________ 5.96 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Tilt cylinder

____________________________________ Replacement of wear parts How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 65):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

© BUCYRUS AMERICA, INC.

 Disconnect, cap and tag all hydraulic hoses to hydraulic motor.  Remove slotted nut, roll pin and washer from lift cylinder anchor pin.  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.

______________________________________________________________ A6474X258 VISV / 02 5.97

Replacement of wear parts _____________________________________ How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 65):  Remove old crawler drive assembly (see previous section, How to remove crawler drive assembly).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Inspect all components for wear or damage prior to installation.

■

step 1 – 70 ft-lb

■

step 2 – 140 ft-lb

■

step 3 – 210 ft-lb

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

■

step 1 – 25 ft-lb

■

step 2 – 50 ft-lb

■

step 3 – 70 ft-lb

 Weld four (4) keepers across motor flanges to prevent motor movement.  Clean all dirt and debris from mounting area of crawler frame.  Attach an appropriate lifting device to the torque hub and slide complete assembly into crawler frame.  Secure torque hub assembly to frame with the twelve (12) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

_________________________________________________________________ 5.98 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Place sprocket onto torque hub and secure with the twenty (20) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

____________________________________ Replacement of wear parts ■

step 1 – 50 ft-lb

■

step 2 – 140 ft-lb

■

step 3 – 280 ft-lb

■

step 4 – 420 ft-lb

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

© BUCYRUS AMERICA, INC.

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

■

step 1 – 300 ft-lb

■

step 2 – 600 ft-lb

■

step 3 – 905 ft-lb

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

Fig. 65: Crawler drive disassembly and assembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

10.

11.

12.

13.

14.

15.

16.

17.

18.

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

19.

20.

21.

22.

23.

24.

25.

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

______________________________________________________________ A6474X258 VISV / 02 5.99

Replacement of wear parts _____________________________________ Power unit The power unit (Fig. 66) has been assembled as a unit and can be removed as a unit or as individual components. As soon as any component of the power unit is worn or damaged, the component must be replaced.

The power unit consists of the following main components: ■

gear pump

■

hydrostatic pump

■

pump coupling

■

motor (200 hp)

■

reducer

■

sprocket

■

connecting tube

Fig. 66: Power unit main components Sprocket Reducer Coupling Motor (200 HP) Connecting tube Coupling Hydrostatic pump Mounting base Gear pump

_________________________________________________________________ 5.100 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

■ reducer/motor coupling

____________________________________ Replacement of wear parts How to remove the power unit To remove the power unit as a complete assembly proceed as follows (Fig. 67.  Remove power unit covers from the machine.  Disconnect and tag all electrical wiring to the drive motor.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.  Disconnect, cap and tag all hydraulic hoses to the hydraulic pumps.  Remove the ten (10) mounting base bolts.

© BUCYRUS AMERICA, INC.

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

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

How to install the power unit To install the power unit as a complete assembly proceed as follows (Fig. 67).  Attach an appropriate lifting device to the complete unit and slowly lift the unit onto the machine and align mounting base holes with holes in the frame.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Secure mounting base to frame with the ten (10) base bolts, lockwashers, flatwashers and nuts previously removed.  Connect all hydraulic hoses to the hydraulic pumps.  Connect all electrical wiring to the drive motor.  Connect the drive chain. (See Breaker drive chain installation and adjustment in this chapter).  Install breaker drive covers.

______________________________________________________________ A6474X258 VISV / 02 5.101

Replacement of wear parts _____________________________________ Fig. 67: Power unit removal and installation

Power unit

© BUCYRUS AMERICA, INC.

Mounting bolts

_________________________________________________________________ 5.102 Bucyrus – Model 7MFBH-48A Feeder Breaker

____________________________________ Replacement of wear parts How to disassemble the breaker power unit To disassemble the power unit proceed as follows (Fig. 69):  Remove complete unit from machine. (See How to remove the drive unit in this chapter)  Remove the four (4) bolts and lockwashers from gear pump (item 17) and remove pump.  Open access cover on connecting tube (item 8) and loosen the two (2) bolts on the pump end and set screw on the motor end of the coupling.

© BUCYRUS AMERICA, INC.

 Remove the four (4) bolts and lockwashers from hydrostatic pump (item 12). With the aid of a lifting device, slowly pull pump from coupling (item 7) and connecting tube (item 8).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Remove the eight (8) bolts and lockwashers from connecting tube (item 8) and remove connecting tube from motor (item 5).  Remove coupling (item 7) and key from motor shaft.  Remove the four (4) bolts and nuts from motor base and the eight (8) bolts, lockwashers and nuts from the reducer base. With the aid of a lifting device, slowly lift motor and reducer from mounting base (item 11).  Remove sprocket (item 6) and key from reducer shaft.  Separe motor and reducer coupling halfs by removing the twelve (12) bolts from around the center of coupling (item 3).  With the aid of a lifting device, slowly separate motor (item 5) and reducer (item 1).  Remove the bolt, lockwasher and end cap (item 22) the end of the reducer shaft.  Remove the three (3) bolts that secures the taper lock (item 2) to the reducer shaft.  Insert two (2) of the bolts removed from the taper lock into the jack screw threaded holes located in the end of the taper lock (Fig. 68).

Tighten both bolts equally until the taper lock is free from reducer shaft.  Remove the bolt, lockwasher and end cap (item 22) the end of the motor shaft.

______________________________________________________________ A6474X258 VISV / 02 5.103

Replacement of wear parts _____________________________________  Remove the three (3) bolts that secures the taper lock (item 4) to the motor shaft.  Insert two (2) of the bolts removed from the taper lock into the jack screw threaded holes located in the end of the taper lock (Fig. 68).

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

Fig. 68: Taper lock removal and installation

Jack screw holes (2) for bushing removal

© BUCYRUS AMERICA, INC.

Bolt holes (3) for bushing installation

_________________________________________________________________ 5.104 Bucyrus – Model 7MFBH-48A Feeder Breaker

____________________________________ Replacement of wear parts How to assemble the power unit To assemble the power unit proceed as follows (Fig. 69): NOTICE! Apply Loctite (blue) to all fasteners..  With the aid of a lifting device, slowly lift reducer onto mounting base (item 1) and align mounting holes. Secure reducer with the eight (8) bolts, lockwashers and nuts to mounting base. Torque bolts to 460 ft-lb.

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

© BUCYRUS AMERICA, INC.

 Slide reducer coupling element half (item 2) onto reducer shaft.  Slide taper lock (item 3) and shaft key onto reducer shaft. Locate reducer coupling element so that taper lock is flush with the end of the reducer shaft. Secure taper lock with the three (3) bolts supplied with taper lock. Torque bolts to 85 ft-lb.  Install end cap (item 21) onto reducer shaft and secure with bolt and lockwasher. Torque bolt to 80 ft-lb.  Slide motor coupling element half (item 4) onto motor shaft.  Slide taper lock (item 4) and shaft key onto motor shaft. Locate motor coupling element so that motor shaft has .5 inch (12.7 mm).

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

Torque bolts to 85 ft-lb.  Install end cap (item 25) onto motor shaft and secure with bolt and lockwasher. Torque bolt to 80 ft-lb.  With the aid of a lifting device, slowly lift motor onto mounting base (item 11) and align mounting holes and coupling halfs. Secure reducer with the eight (8) bolts, lockwashers and nuts to mounting base. Torque bolts to 280 ft-lb.  Connect coupling (item 3) with the twelve (12) bolts supplied with coupling.  Insert key into slot of motor shaft and slide motor coupling half (item 7) onto motor shaft until shaft and coupling face are flush.  Tighten set screw in motor half of coupling.  Insert coupling element into motor half of coupling.  Align the 8 holes of connecting tube (item 8) with motor (item 5)and secure with the eight (8) bolts and lockwashers.

______________________________________________________________ A6474X258 VISV / 02 5.105

Replacement of wear parts _____________________________________  Slide pump half of coupling (item 7) onto hydrostatic pump shaft (item 12) until a .70” (17.78 mm) shaft end gap is acquired. Tighten the two (2) coupling half bolts.   With the aid of a lifting device, slowly lift hydrostatic pump (item 12) and carefully align pump half and motor half of coupling. Secure pump to connecting tube with four (4) bolts and lockwashers.

Coupling spacing should be .18” (4.5 mm) after pump mounting bolts are tightened.  Align mounting holes and shaft of gear pump (item 17) with hydrostatic pump (item 12) and secure with four (4) bolts and lockwashers.  Install completed power unit onto machine. (See How to install the power unit in this chapter)  Fill hydrostatic pump thru case drain port with system oil before running pump. © BUCYRUS AMERICA, INC.

Fig. 69: Power unit disassembly and assembly

_________________________________________________________________ 5.106 Bucyrus – Model 7MFBH-48A Feeder Breaker

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 69: Power unit disassembly and assembly (continued)

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

10.

11.

12.

13.

14.

15.

16.

17.

18.

bolt mounting base hydrostatic pump washer (flat) washer (lock) bolt bolt gear pump nut (lock)

19.

20.

21.

22.

23.

24.

25.

26.

27.

bolt washer (lock) nut (lock) end cap washer (lock) bolt end cap retainer bar retainer bar

28.

29.

30.

31.

retainer bar washer (lock) Bolt retainer

______________________________________________________________ A6474X258 VISV / 02 5.107

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

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

How to remove the conveyor drive motor To remove the conveyor drive motor proceed as follows (Fig. 70): WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Disconnect lifting device and remove the torque arm mounting bolts.  Remove torque arm from conveyor motor.  Slide coupling from headshaft.  Inspect all components for wear or damage.

_________________________________________________________________ 5.108 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts How to install the conveyor drive motor To install the conveyor drive motor proceed as follows (Fig. 70): WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.  Apply a coat of mineral oil to the splines of the headshaft, coupling and conveyor motor. Do not use never seez.  Slide coupling onto headshaft.  Install torque arm on conveyor motor with mounting bolts. Torque bolts to 400 ft-lb.

© BUCYRUS AMERICA, INC.

 Remove conveyor motor cover bolts and remove cover.  Attach an appropriate lifting device to two (2) of the conveyor motor torque arm mounting bolts and slowly lift and slide the the motor onto the coupling and headshaft.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Bolt conveyor motor to headshaft with torque mounting bolt located inside conveyor motor. Torque bolt to 280 ft-lb.  Install conveyor motor cover with cover bolts. Torque bolts to 59 ftlb.  Install torque arm connecting link with the two (2) pins and cotter keys.  Connect all hydraulic hoses to the conveyor motor.  Purge hydraulic system of air.

______________________________________________________________ A6474X258 VISV / 02 5.109

Replacement of wear parts _____________________________________ Fig. 70: Conveyor drive motor removal and installation Pin and cotter key (2 places) Connecting link

Head shaft

Torque arm

cover bolts (torque to 59 ft-lb)

Mounting bolt (torque to 280 ft-lb)

Mounting bolts (torque to 400 ft-lb)

_________________________________________________________________ 5.110 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Coupling

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

The breaker assembly consists of the following main components:

© BUCYRUS AMERICA, INC.

■ ■ ■ ■ ■ ■ ■ ■ ■ ■

breaker shaft shear hub assembly bearing housing (2) bearing (2) bits (25) bearing retainer (2) underspeed sensor breaker side plate (2) retaining cap (2) dust cover

Fig. 71: Breaker assembly main components Underspeed sensor mount

Breaker side plate (2)

Bearing (2)

Bearing housing (2)

Breaker

Shear hub

Retainer cap (2)

Pick (25)

______________________________________________________________ A6474X258 VISV / 02 5.111

Replacement of wear parts _____________________________________ How to remove the breaker assembly To remove the breaker assembly from the machine proceed as follows (Fig. 72):  Remove covers and guards as required to gain access to the breaker assembly.  Release tension on the breaker drive chain and remove chain.

(See Breaker drive chain removal in this chapter).  Disconnect, tag and cap the bearing central lubrication hoses.

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

How to install the breaker assembly To install the breaker assembly into the machine proceed as follows (Fig. 72):  With the aid of the lifting device, slowly lift the breaker assembly into the frame and align mounting holes.  Secure the breaker with the tweenty (20) bolts, nuts, and washers (10 per side) and securely tighten. Torque bolts to 900 ft-lb.  Install breaker drive chain and adjust tension. (See Breaker drive chain adjustment in this chapter).  Connect the bearing central lubrication hoses.  Install covers and guards.

_________________________________________________________________ 5.112 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 72: Breaker assembly removal and installation

1. breaker shaft assembly 2. lock washer 3. flat washer 4. bolt 5. nut

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

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

How to install the breaker bit

 Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.  Install the external retaining ring on the shank end of the bit with a pair of external retaining ring pliers. Ensure that the retaining ring is completely seated inside grooved area of the bit.

Fig. 73: Breaker bit removal and installation

Retaining ring Bit holder

Breaker bit

_________________________________________________________________ 5.114 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

 To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 73):

_____________________________________________ 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.

© BUCYRUS AMERICA, INC.

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.

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.

_____________________________________________________________ A6474X258 VISV / 02 5.115

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.

_________________________________________________________________ 5.116 Bucyrus – Model 7MFBH-48A Feeder Breaker

© 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

_____________________________________________________________ A6474X258 VISV / 02 5.117

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.

_________________________________________________________________ 5.118 Bucyrus – Model 7MFBH-48A Feeder Breaker

_____________________________________________ Troubleshooting Table 4: 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

_____________________________________________________________ A6474X258 VISV / 02 5.119

Troubleshooting ______________________________________________ Table 5: 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

_________________________________________________________________ 5.120 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Remedies

_____________________________________________ Troubleshooting Table 6: 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

_____________________________________________________________ A6474X258 VISV / 02 5.121

Troubleshooting ______________________________________________ Table 7: 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

Remedies

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

_________________________________________________________________ 5.122 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

A.  replace dirty filters and system fluid

_____________________________________________ Troubleshooting Table 8: Troubleshooting faulty operation No Movement Cause

© BUCYRUS AMERICA, INC.

No flow or pressure

Slow Movement

Remedy

Cause

See Table 5 Low flow

Erratic Movement

Excessive Speed or Movement

Remedy

Cause

Remedy

Cause

Remedy

See Table 5

Erratic pressure

See Table 6

Excessive flow

See Table 5

Air in fluid

See Table 3

Overriding work 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

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

_____________________________________________________________ A6474X258 VISV / 02 5.123

Troubleshooting ______________________________________________ Hydraulic system (general) Table 9: Hydraulic system (general) troubleshooting Probable cause

dirty oil 

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.

moisture in oil 

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.

foaming oil 



Moisture in cans of replacement 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.

overheating of system 

Replace with new cans of oil.



Excessive slippage or internal leak-  age past pump or cylinders.



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.

prolonged operation of a function at  pressures above normal idle condition

Fluid viscosity too low. Test components for specified flow or bypass conditions.

_________________________________________________________________ 5.124 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Trouble or symptom

_____________________________________________ Troubleshooting Table 9 (continued): Hydraulic system (general) troubleshooting Trouble or symptom

Probable cause

Test, check and/or remedy

foreign matter sources  in the circuit

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.

   

Repair parts not properly protected while stored.

 



Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.

Check and clean parts thoroughly before installation. Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.

© BUCYRUS AMERICA, INC.



Lines left unprotected or dirty repaired components.

_____________________________________________________________ A6474X258 VISV / 02 5.125

Troubleshooting ______________________________________________ Hydraulic cylinders Table 10: Hydraulic cylinder troubleshooting Probable cause

cylinder drifts 

Piston seal leak.

Test, check and/or remedy 

Repair seals or replace cylinder.



Replace cartridge or cylinder as required.



Correct leaks.



Control cartridge by-passing.



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.



Contamination in hydraulic system resulting in scored cylinder bore.



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 or rapid piston  seal wear

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). 

erratic or chatter in operation 



cylinder body seal leak 

piston is leaking 

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.

_________________________________________________________________ 5.126 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Trouble or symptom

_____________________________________________ Troubleshooting Hydraulic pump, general Table 11: Hydraulic pump troubleshooting, general Trouble or symptom

Probable cause

© BUCYRUS AMERICA, INC.

pump makes excessive noise 

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.

seal leak 

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).



Seal deterioration (flat spots on I.D.).



Replace seal.

Check pump shaft for possible bearing wear. Replace seal.

 Loose or worn pump parts.  Replace worn pump parts. _____________________________________________________________ A6474X258 VISV / 02 5.127

Troubleshooting ______________________________________________ Table 11 (continued): Hydraulic pump troubleshooting, general Probable cause

pump fails to deliver oil 

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.

excessive pump wear 

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.

oil leakage around pump 

_________________________________________________________________ 5.128 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Trouble or symptom

_____________________________________________ Troubleshooting Table 11 (continued): Hydraulic pump troubleshooting, general Trouble or symptom

Probable cause

pump parts inside  the housing are broken 

Test, check and/or remedy

Seizure due to lack of oil.



Check oil level and refill to design level for proper operation. Replace pump and filter elements.

Excessive system pressure above maximum pump rating.



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.



Replace pump and filter elements, suction strainer, and suction hoses to insure that no foreign material can damage new pump.

Excessive torque to housing bolts.



Solid matter being drawn in from reservoir and wedged in pump.

© BUCYRUS AMERICA, INC.



_____________________________________________________________ A6474X258 VISV / 02 5.129

Troubleshooting ______________________________________________ Hydrostatic transmission pump troubleshooting (closed loop system) The transmission pump used on Bucyrus closed loop feeder breakers is represented in Fig. 74. This is a 21 degree swash plate driven axial piston pump with hydraulic servo displacement control. Maximum displacement is 210cc/rev (12.8 Cubic Inches). Maximum service pressure is 400 Bar (6090 PSI). The hydrostatic pump requires a secondary flow from a separate gear pump for charging the transmission loop and for control oil. Charge pressure is limited by a charge relief set to crack open at 20 Bar (290 PSI). The charge pressure shown on the charge pressure gauge will be higher than 20 Bar (closer to 25 Bar) depending on the charge flow. The displacement control requires 20 Bar.

The pump includes high pressure relief valves on the hydrostatic loop.

These are direct operated, fast acting, and non-adjustable. The cracking set point is 350 Bar (5075 PSI). Due the direct operated design, the pressure drop across the relief increases with flow and, at maximum displacement, the system pressure gauges will reflect this higher pressure.

The direction of the hydrostatic loop is controlled by the displacement control. Pilot pressure to either ports Y or Z will control the pump displacement between 4 and 10 Bar (58 to 145 PSI). Pump output flow is proportional to this pilot pressure range. At 4 Bar, the pump will start producing flow. This output will increase in a straight line until 10 Bar pilot, at which point it is at the maximum displacement it is set for. If charge pressure to the displacement control is less than 10 Bar, the maximum output will not be achieved.

Reference Fig. 75 for the location of five factory adjustment points.  The large ring sets the control module set the pressure range of the displacement: this is where the 10 Bar maximum set point is determined. DO NOT ADJUST THESE. Pump output control will be compromised. If the adjustments have been tampered with, measure the two sides and set them at equal distances from the control body. When the control is actuated to maximum speed, adjust side opposite acting pilot pressure port counterclockwise if conveyor speed is too low. If conveyor speed is too fast, adjust the ring clockwise until desired speed is reached. Two ports are provided on top of the control for gauges to monitor pilot pressure during adjustment.

_________________________________________________________________ 5.130 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

The charge pump also provides anti-cavitation to the hydrostatic loop.

Check valves adjacent to the high pressure relief valves will port oil to any side of the loop which drops below 20 Bar. If system aeration is prevalent, there could be a condition where the charge pump is not keeping up with the hydrostatic loop. The most common cause for this is a failing charge pump or inoperative hot oil shuttle valve, which is elsewhere in the system.

_____________________________________________ Troubleshooting  The screws inside the large ring sets are recessed. These set the maximum displacement of the pump and have been factory adjusted. Unless a system adjustment is required, do not adjust these. The screw is locked with a seal nut. Any leakage at this control is due to a loose or faulty seal nut.

© BUCYRUS AMERICA, INC.

 The fifth adjustment is the neutral adjustment. This determines the centering of the control, so that with no pilot signal, there is no pump output. This is factory adjusted. If the pump is not centered in neutral, disconnect pilot pressure lines and recheck pump for “creep”. If creeping ceases, the pilot pressure system must be checked. If the pump continues to be off center, neutral adjustment is required. First, measure the distance from the top of the neutral adjust hex to the pump body: record this distance. It should be approximately 14.5mm. Loosen the spanner ring. Clear the conveyor area and carefully adjust the neutral adjust with no pilot signal to the pump. Adjust until creep stops. Continue adjusting until creep starts in opposite direction. Set adjustment in between these two points and relock spanner nut. If this does not resolve pump neutral problem, replace pump and return to factory for evaluation.

During installation of a new pump, it is critical that the pump case be filled before start up. It is often difficult to do this well underground, so start with filling and plugging the pump before taking underground.

Pumps stored on site should be filled with oil in any case. The large plug in the top middle of the control module can be used as “highest point” for case filling.

On installation, top up oil in pump case at highest case drain port. Jog pump motor at least ten (10) times before starting up. Immediate charge pressure at gauge on startup indicates the pump and the hydrostatic loop are filled. The pump sound will “smooth” at this point as well.

When the pump fails to deliver required conveyor speed, its efficiency must be determined. Unfortunately, the case flow checks used on open loop pumps do not apply to closed loop pumps because case flow is the charge pump flow. If the case flow is less than expected for the charge pump, replace the charge pump. If problem persists, investigate the high pressure loop for internal leak points. These will also be “hot spots” in the system. One of these points can be the high pressure relief valves, which are bypassing flow due to contaminant wear or debris: remove and examine the reliefs. If spare reliefs are available, replace and restart system.

It can also occur that pilot pressure is not adequate to maintain pump at desired stroke. Verify proper pilot pressure using a known accurate gauge.

If these checks fail to correct pump output, the pump is internally worn and must be replaced.

_____________________________________________________________ A6474X258 VISV / 02 5.131

Troubleshooting ______________________________________________ When removing the old pump, use plugs from replacement pump and duct tape to seal off all ports. This assures that cause of failure can be assessed at the factory and eliminates water ingression and damage to the pump internals. These units are economically repairable if returned in sealed condition.

© BUCYRUS AMERICA, INC.

Fig. 74: Pump schematic (typical)

Note: P and S = work ports Ms and Mp = gauge ports L and U = case drain ports F = charge supply port T = vent port Y and Z = pilot pressure port

_________________________________________________________________ 5.132 Bucyrus – Model 7MFBH-48A Feeder Breaker

_____________________________________________ Troubleshooting

© BUCYRUS AMERICA, INC.

Fig. 75: Pump

_____________________________________________________________ A6474X258 VISV / 02 5.133

Troubleshooting ______________________________________________ Valves Table 12: Valve troubleshooting Probable cause

operating pressure  cannot be changed

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 leaks internally 

Valve piston and body worn.



Replace the valve.



Check and replace filter elements as required.



Check for proper pressure and/or volume adjustments and reset as required.



excessive leakage or  sticking pistons occurs      

Valve excessively hot.

 

Remove the valve and clean it thoroughly; flush the system as necessary.

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.

oil leaks  between sections

_________________________________________________________________ 5.134 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Trouble or symptom

_____________________________________________ Troubleshooting Table 12 (continued): Valve troubleshooting Trouble or symptom

Probable cause

oil leaks at either  end of spool

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.

 spring centered spools  do not return to neutral   load will not hold 

© BUCYRUS AMERICA, INC.

Test, check and/or remedy

load drops when spool  moved from neutral

Dirt or foreign particles lodged be tween check valve poppet and seat.

Disassemble, clean, and reassemble.



Scored or sticking check valve pop-  pet.

Replace poppet.

no motion, slow, or erratic  system operation 

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.

_____________________________________________________________ A6474X258 VISV / 02 5.135

Troubleshooting ______________________________________________ Bearings Table 13: Bearing troubleshooting Probable cause

overheating bearing 

Test, check and/or remedy

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.

vibrating bearing 

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 

unsatisfactory performance 

_________________________________________________________________ 5.136 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Trouble, symptom or cause

_____________________________________________ Troubleshooting Electrical system troubleshooting If the feeder breaker will not start, check the following indicating lights: a. “L1” - Power on 110VAC - Normally On. If the light is off, check the high voltage fuses F1 and F2 on the control transformer. b. “L2” - Power on 110VAC (control power) - Normally On. If this light is off, check “CB-1” (6A) and “CB-2” (6A). If Ok, check that the earth leakage lights “EF1” and “EF2” are off. c.

“L3” - Power on 12VAC - Normally On. If this light is off, check “CB-3” (32A) and “CB-4” (32A). If OK, check that the earth leakage lights “EF1” and “EF2” are off.

© BUCYRUS AMERICA, INC.

d. “L5” - Hydraulic Oil Healthy - Normally On. If this light is off, check lights “L6” and “L7”. If these lights are on, the oil over pressure has tripped. e. “L6” - Hydraulic Oil Temp Healthy - Normally On. If this light is off, check light “L7”, which should be on and “L5”, which should be off.

If “L5” and “L6” are off, the high oil temperature has tripped. f.

“L7” - Hydraulic Oil Level Healthy - Normally On. If this light is off, along with “L5” and “L6”, then the low oil level switch has tripped.

g. “L8” - Spray Water Proved - Normally On. If this light is off and “L9” is on, the water pressure has dropped. h. “L9” - Water Flow Healthy - Normally On. If this light and light “L8” are off, then the water flow switch is open. i.

“O/L TRIPED” - Overload tripped - Normally On. If this light is off, the overload has tripped.

_____________________________________________________________ A6474X258 VISV / 02 5.137

© BUCYRUS AMERICA, INC.

Troubleshooting ______________________________________________

_________________________________________________________________ 5.138 Bucyrus – Model 7MFBH-48A Feeder Breaker

_______________________________________________________________

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Model 7MFBH-48A Feeder Breaker. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

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

Customer specials may not be listed.

Components of the feeder breaker Technical data sheet

© BUCYRUS AMERICA, INC.

general

performance

Overall length:...................................................... approx. 34’ 61/2” (10,528 mm) Overall width: ....................................................... approx. 10’ 4” (3,149 mm) Tramming height (min.):....................................... approx. 44” (1,118 mm) Ground clearance (min.): ..................................... approx. 7” (178 mm) Ground clearance (max.): .................................... approx. 24” (610 mm) Receiving height (min.): ....................................... approx. 13” (330 mm) Discharge height (max.)....................................... approx. 53” (1,346 mm) Operating height (max.): ...................................... approx. 78” (1,981 mm) Level hopper capacity: ......................................... approx. 440 ft³ (12.46 m³) Capacity (w/ optional 12” sideboards): ................ approx. 530 ft³ (15 m³) Receiving impact plate:........................................ HRS + CCO wear plate Breaker impact plate: ........................................... ASTM A514 + CCO wear plate Coal line material: ................................................ HRS + CCO wear plate Return line material:............................................. HRS + CCO wear plate Mainframe side plates:......................................... HRS + CCO wear plate Weight: ................................................................. approx: 70,000 lbs (31,752 kg) Material input size (max.): Discharge rate (max.): Material to be broken:

approx. 2’ x 3’ x 4’ (607mm x 914 mm x 1,219 mm) approx. 1,200 TPH @ 135 fpm (41 m/min) coal @ 65 lb/ft³ (1,041 kg/m³)

______________________________________________________________ A6474X258 VISV / 02 6.3

Technical data ________________________________________________ Conveyor width: ................................................... approx. 48” (1,219 mm) Number of strands: .............................................. 2 @ 200,000 lb (90,720 kg) strand ultimate Chain pitch: ............................................................approx. 3 1/2” (88.9 mm) Chain pin diameter:.............................................. approx. 15/16” (23.81 mm) Flights:.................................................................. 2 1/2” X 5 1/2” (63.5 mm x 140 mm) solid alloy steel Conveyor speed:.................................................. approx. 35 - 135 fpm (11 - 41m/min) Flight attachment ................................................. solid flight pin w/roll pin Flight spacing....................................................... approx. 21” (533 mm)

© BUCYRUS AMERICA, INC.

conveyor chain

_________________________________________________________________ 6.4 Bucyrus – Model 7MFBH-48A Feeder Breaker

___________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled. The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

IMPORTANT! Use a calibrated torque wrench for accuracy.

© BUCYRUS AMERICA, INC.

Table 15: Grade 8 bolt torque specifications (calculated at 75% proof load) Bolt size

Recommended torque setting (ft-lbs) (dry)

Recommended torque setting (ft-lbs) (wet)

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2

13 26 47 75 115 165 225 400 645 905 1,380 1,935 2,540 3,380

8 16 28 45 70 99 135 240 390 545 830 1,160 1,525 2,030

______________________________________________________________ A6474X258 VISV / 02 6.5

Tightening torques ____________________________________________

Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00 M7 X 1.00 M8 X 1.25 M10 X 1.50 M12 X 1.75 M14 X 2.00 M16 X 2.00 M18 X 2.50 M20 X 2.50 M22 X 2.50 M24 X 3.00 M27 X 3.00 M30 X 3.50 M33 X 3.50 M36 X 4.00

(54) (92) (156) (2250 37 65 104 161 222 314 428 543 796 1079 1468 1886

(41) (69) (116) (169) 28 49 78 121 167 235 321 407 597 809 1101 1415

(78) (133) (222) (333) 53 93 148 230 318 449 613 776 1139 1543 2101 2699

(59) (99) (167) (242) 40 69 111 172 238 337 460 582 854 1158 1576 2024

(91) (156) (260) (377) 62 108 173 269 372 525 716 908 1331 1804 2455 3154

(68) (116) (195) (284) 47 81 130 202 279 394 537 681 998 1353 1842 2366

_________________________________________________________________ 6.6 Bucyrus – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Table 16: Metric bolt torque specifications (calculated at 75% proof load)

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© BUCYRUS AMERICA, INC.

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

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

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

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

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

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

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

______________________________________________________________ A6474X258 VISV / 02 6.7

Permissible media ____________________________________________ Approved suppliers:

Supplier

Brand name

1

Amoco Oil Company

Amoco AW oil No.68

2

Gulf oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hyldraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

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

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

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

_________________________________________________________________ 6.8 Bucyrus – Model 7MFBH-48A Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 17: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 18: 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

______________________________________________________________ A6474X258 VISV / 02 6.9

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 20: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century oils Limited Hydrotex Pennzoil Unocal Exxon

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

_________________________________________________________________ 6.10 Bucyrus – Model 7MFBH-48A Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 19: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ Permissible media Table 21: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

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

5 6

Cincinnati – Vulcon Company Cities Service Oil company

7 8

10 11

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

12 13 14 15 16 17

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

18

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

© BUCYRUS AMERICA, INC.

9

19 20 21

22 23

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

24 25

Wynn Oil company Lubrication Engineers

26

Hydrotex

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

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

______________________________________________________________ A6474X258 VISV / 02 6.11

Permissible media ____________________________________________

Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

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

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

_________________________________________________________________ 6.12 Bucyrus – Model 7MFBH-48A Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 22: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 23: 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

______________________________________________________________ A6474X258 VISV / 02 6.13

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

_________________________________________________________________ 6.14 Bucyrus – Model 7MFBH-48A Feeder Breaker

©© BUCYRUS AMERICA, INC.

Table 24: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 26: 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 27: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 28: 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

______________________________________________________________ A6474X258 VISV / 02 6.15

Permissible media ____________________________________________ Table 29: Extreme pressure gear oil (Spec. 100-13)

1

Supplier Century Lubricants

Brand name Powergear H680

Table 30: High temperature lithium complex motor bearing grease (Spec. 100-14) 1 2 3

Supplier Mobil Conoco Phillips Shell

Brand name Mobilith SHC 100 Triton 100 Albida EMS 2

Table 31: High demulsibility EP gear oil gear oil (Spec. 100-15) Supplier Conoco

Brand name GLW Gear Oil 220

Table 32: Lithium complex semi-synthetic motor bearing grease (Spec. 100-16) 1

Supplier

Brand name

Fuchs

Renolit S2TX

_________________________________________________________________ 6.16 Bucyrus – Model 7MFBH-48A Feeder Breaker

©© BUCYRUS AMERICA, INC.

1

_______________________________________________________________

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

Paonia, CO P.O. Box 566 Paonia, CO 81428 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846 Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

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

______________________________________________________________ A6474X258 VISV / 02 7.3

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

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

© BUCYRUS AMERICA, INC.

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

_________________________________________________________________ 7.4 Bucyrus – Model 7MFBH-48A Feeder Breaker

CONTENTS

saue Series 90

Axial Piston Pumps Technical Information

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

The latter is infinitely adjustable between zero and maximum displacement.

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

●

The Series 90 - Advanced Technology Today

●

8 Sizes of Variable Displacement Pumps

●

Complete Family of Control Systems

●

Proven Reliability and Performance

●

Optimum Product Configurations

●

Compact and Lightweight

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

Printed in Germany.

2

F000 539

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Technical Features A Complete Family to Meet Market Needs

The Latest Technology

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

● Unique Product Features ● High Power Density

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

● Design Provides for Reduced Operating Costs

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

High Performance

Reliability

● Speeds to 5 000 min-1 (rpm)

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

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

World Product

Worldwide Support

● Designed for Worldwide Markets

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

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

● Serviced by a Worldwide Network of Authorized Service Centers

3

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

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

Options • • • • • • • • • •

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

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

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

4

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

Dimensions • • • • • • • •

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

• • • • • • •

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

5

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

Control handle

Displacement control valve Heat exchanger bypass valve Reservoir

Orificed check valve

Vacuum gauge Heat exchanger

Purge relief valve

Charge pressure relief valve Reversible variable displacement pump

Servo control cylinder

Multi-function valve

Fixed displacement motor

To pump case Servo pressure relief valves

Charge pump Input shaft

Output shaft Multi-function valve

Pump swashplate Servo control cylinder

Pump

Motor swashplate Loop flushing valve

Motor

P001 004E

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

6

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

Servo Piston Feed Back

Cradle Bearing

Cradle

Cradle Leveler

Cradle Guide

Charge Pump

P001 413E

Name Plate

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

Neumünster, Germany Typ

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

Model Number Serial Number

Model Code

Ident Nr

687459 N – 88 – 26 – 67890

Identification Number

Serial No. Fabr Nr MADE IN GERMANY

Place of Manufacture 7

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Type Designation and Order Code R

MODEL CODE

M

P J G N

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

R

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

8

100 130 180 250

= = = =

100 130 180 250

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

M

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

P

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

030 042 055 075 100 130 180 250 ●

●

●

●

●

●

●

●

J

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

G

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

N

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

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

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

Frame Size

030 042 055 075 100 130 180 250 ● ❍

● ❍

● ❍

● ❍

● ❍

● ❍

●

-

-

-

-

-

-

-

-

❍

❍

❍

❍ ❍

❍ ❍

❍ ❍

❍ ❍

❍ ❍

-

-

❍

❍

-

●

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Type Designation and Order Code (Continued) F

L

H

T

W

Y

Z

K

X X

Data Sheet Code On Request

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

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

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

= See Port “B” 030 ● -

042 ● -

055 ● -

075 ● -

100 130 ● ● -

180 ●

250 ●

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

❍ ❍ ❍ ●

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

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

Frame Size

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

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

042 ❍ ● ❍

055 ❍ ● ❍ ❍

075 ❍ ● ❍ ❍

100 ❍ ● ❍ ❍

130 ❍ ❍ ● ❍

180 ❍ ● ❍

250 ❍ ● ❍

030 ❍ ● ❍ -

042 ● ❍ ❍ -

055 ● ● ❍ -

075 ● ● ❍ -

100 ● ❍ +● ❍ -

130 ● ❍ ❍

180 ● +❍ -

250 ● +❍ -

F Displacement Limitation 3 4

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

❍ ❍ ❍ ❍

● ❍

● = Standard ❍ = Option - = not available

+ = not recommended for front pump in tandem configurations 9

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

M3

Clockwise (CW) Rotation

Hydraulic Parameters A

M1

System Pressure Range, Input p1 (see page 12)

M2

B L1

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

= = = = = =

S

L2

P001 008E

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

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

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

420 bar 480 bar

(6 000 psi) (7 000 psi)

Case Pressure Max. Rated: Intermittent pressure:

(see page 12) 3 bar 5 bar

(40 psi) (75 psi)

Cold start

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

(see page 12)

Type of Mounting

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

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

Temperature Range1)

Pipe Connections

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

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

Direction of Rotation

(see page 12) intermittent, cold start intermittent

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

Fluid Viscosity Limits

Clockwise or counterclockwise (unidirectional).

Installation Position Installation position discretionary.

The housing must always be filled with hydraulic fluid.

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

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

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

10

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

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

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Technical Data Table 1

Dimension

030

042

055

Frame Size 075

cm3

30

42

55

75

100

130

180

250

in3

1.83

2.56

3.35

4.57

6.10

7.93

10.98

15.25

min-1 (rpm)

500

500

500

500

500

500

500

500

min-1 (rpm)

4 200

4 200

3 900

3 600

3 300

3 100

2 600

2 300

min-1 (rpm)

4 600

4 600

4 250

3 950

3 650

3 400

2 850

2 500

Max. min-1 (rpm) Attainable *

5 000

5 000

4 700

4 300

4 000

3 700

3 150

2 750

Nm/bar in lb/1000 psi

0.48 290

0.67 410

0.88 530

1.19 730

1.59 970

2.07 1 260

2.87 1 750

3.97 2 433

Mass moment of inertia of the int. rotating parts

kg m2 lb • ft2

0.0023 0.0546

0.0039 0.0926

0.0060 0.1424

0.0096 0.2280

0.0150 0.3560

0.023 0.5460

0.0380 0.9020

0.0650 1.5430

Weight (with MA Control)

kg lb

28 62

34 75

40 88

49 108

68 150

88 195

136 300

154 340

100

130

180

250

Displacement

Minimum Input Rated * speed Maximum *

Theoretical Torque

* General Technical Specifications, see page 12

Determination of Nominal Pump Size Inch-System:

Metric-System: PD • PS • EV

Pump Q = output flow

Description: Vg • n • hv

gpm 231

Pump Qe = output flow

l/min 1 000 Vg • ∆p

PD • p Input torque

PT =

lbf•in 2 • π • ET

Input torque

Me =

PD • PS • p Input power

p

=

Qe • ∆p

Me • n hp

396 000 • ET

Nm 20 • π • hmh

Input power

Pe =

= 9 550

kW 600 • ht

Inch-System: PD = Pump displacement per rev.

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

in3 rpm psi

cm3 bar

11

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

General Technical Specifications Speed Range

Case Pressure

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

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

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

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

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

Braking Warning !

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Charge Pressure

12

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

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options Reservoir

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

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

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

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

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

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

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

Figure 5: Charge pressure filtration

Screen

Hydraulic fluid reservoir Adjustable Charge pressure relief valve

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

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

Charge pump

to low pressure side and control

To pump case

Filter P000 798E

The use of a filter contamination monitor is recommended.

Displacement Limiter - Option 4

Figure 4: Suction filtration

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

ManoVacuummeter

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

Hydraulic fluid reservoir

Figure 6: Displacement limiter Filter

Displacement limiter

Charge pump

to low pressure side and control

Adjustable Charge pressure relief valve

To pump case

Servo cylinder P000 797E

Servo piston

P000 799E

13

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

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

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

Figure 7: Circuit diagram M4 M5

M3

Clockwise (CW) Rotation

M1

A

M2

B L1

S

L2

P001 008E

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

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

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

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

A Servo piston

Bypass hex adjustment

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

C

Servo piston Charge pressure relief valve

Multifunction valve

14

P000 800E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Options (Continued) Bypass Function

Speed Sensor

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

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

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

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

Caution !

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

They are NOT intended as “tow” valves.

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

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

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

Table 2: Pulse frequency

-

Frame Size

030

042

055

075

Pulses per revolution

43

48

52

58

Frame Size

100

130

180

250

Pulses per revolution = not available

63

69

-

-

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

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

A B C D

Supply Voltage + Speed Signal Gnd Common Direction (Option)

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

Turck Eurofast 4 Pin Connector Pin 2 Direction (Option)

Keyway (Ref) Pin 1 Supply Voltage +

"Y" Pin 3 Speed Signal P001 459E

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

15

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

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

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

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

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

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

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

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

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

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

Frame Size in (cm3/rev)

16

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

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

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

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

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

Figure 12: Charge flow requirements - pump

Figure 13: Charge flow requirements - motor

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

6

5

5

)

00

-1 (

3

in

4

Flow Factor Fm

36

Flow Factor Fp

(rp

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

4

2

00

1000 0

2000

3000

4000

100 200 System Pressure

5000

300

)

pm

-1 (r

3

in 0m

0

36

2 3000

6000 ∆p psi

0

∆p bar

0

400

m

42

1000

2000

3000

min

)

-1 (rpm

) -1 (rpm

2000

min

1000

min

1

1

0

)

m

rp

m

-1

)

-1 (rpm

5000 6000 ∆p psi

4000

400 ∆p bar

300

100 200 System Pressure

P001 010E

P001 011E

Figure 14: Charge pump output flow

v

6

v

.9 i

/Re

•3

3

ev

.9 i n

3

2.0

/R in 3

in 3 /R ev

.60

.2 3 •

ev

3 /R

•1

3

26

cm

3

•1

.07

20

cm

•2 cm 3

3.0

2

1

10

4.0

3

HP

9

5.0

1.

cm 3 •2

in

47

v

Re

3 /

03

34

in

kW

20

.

•1

4

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

gallons/min

l/min

30

cm 3

.6 0 •1

3

cm 26

2

12

65

.07 •2

3

cm 34

6.0 v Re

3 /

15

50 40

5

in 3 /R ev

ev

n 3/ Re

v

•2 cm 3

60

7.0

ev

18

in 3 /R

65 c

70

in 3 /R

21

.9

80

47

m3•

24

90

in 3 /Re

3.9 in 3/ Re

v

Figure 15: Charge pump power requirements

03

1.

in

ev

3 /R

in

ev

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

1.0

1 0

0 0

500 1000 Speed

P000 802E

2000 min -1 (rpm)

3000

4000 4500

0

500 1000 Speed

2000

3000

4000 4500

min -1 (rpm) P000 803E

17

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

Third Stage

Second Stage

First Stage

Me1 for the first pump

Me2 for the second pump

Me Input Torque

Me3 for the next pump P001 407E

Table 4: Shaft availability and torque ratings Shaft Description

Option Code

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

042

055

075

100

130

180

250

13 teeth 16/32 pitch Spline

C2

260 (2 300)

—

—

—

—

—

—

—

15 teeth 16/32 pitch Spline

C3

530 (4 700)

530 (4 700)

—

—

—

—

—

—

19 teeth 16/32 pitch Spline

C5

—

900 (8 000)

—

—

—

—

—

—

21 teeth 16/32 pitch Spline

C6

—

—

1 130 (10 000)

—

—

—

—

—

23 teeth 16/32 pitch Spline

C7

—

—

—

1 580 (14 000)

1 580 (14 000)

—

—

—

27 teeth 16/32 pitch Spline

C8

—

—

—

—

—

2 938 (26 000)

2 938 (26 000)

3 600 (32 000)

13 teeth 8/16 pitch Spline

F1

—

—

—

—

1 810 (16 000)

1 810 (16 000)

+

+

14 teeth 12/24 pitch Spline

S1

—

—

735 (6 500)

735 (6 500)

— + 18

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

+

735 (6 500)

—

1 810 (16 000) —

1 810 (16 000) —

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

Option Code

Internal Spline Size

Spline Engagement min. mm (in.)

Rated Torque Nm (lbf•in)

SAE A

A

9 teeth 16/32 pitch

13.5 (.53)

107 (950)

SAE B

B

13 teeth 16/32 pitch

14.2 (.56)

256 (2 200)

SAE B-B

V

15 teeth 16/32 pitch

16.1 (.63)

347 (2 990)

SAE C

C

14 teeth 12/24 pitch

18.3 (.72)

663 ❊ (5 700)❊

SAE D

D

13 teeth 8/16 pitch

20.8 (.82)

1 186 (10 500)

SAE E

E

13 teeth 8/16 pitch

20.8 (.82)

1 637 (14 500)

SAE H

H

27 teeth 16/32 pitch

27.0 (1.06)

22 362 (19 805)

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

Mating Auxiliary Pumps

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

Figure 17

D

Coupling

B max.

(+.000) (-.002)

Spline engagement for rated torque

0

F min.

ø P (Dia) -0.05

E Mounting Flange (Ref)

0.8 (.03) R Preferred P001 462E

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

Flange

øP

B

Size

Dia

max.

D

E

F min.

SAE

82.55

7.4

32

13.5

A

(3.250)

(.29)

(1.26)

(.53)

SAE

101.6

10.7

41

14.2

B

(4.000)

(.42)

(1.61)

(.56)

SAE

101.6

10.7

46

B-B

(4.000)

(.42)

(1.81)

SAE

127.0

14.3

56

C

(5.000)

(.56)

(2.20)

16.1 See Dimensions

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

(.63) 18.3 (.72)

SAE

152.4

14.3

75

D

(6.000)

(.56)

(2.95)

(.82)

20.8

SAE

165.1

18.0

75

20.8

E

(6.500)

(.71)

(2.95)

(.82)

SAE

165.1

18.0

75

27.0

H

(6.500)

(.71)

(2.95)

(1.06)

19

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

L 0° Re

Re 90° Re

270° Re T out

T in

Table 7: Bearing life Frame Size

Bearing Life - B10 hrs

030

10 040

042

18 060

055

22 090

075

22 970

100

22 670

130

17 990

180

16 150

250

12 020

180° Re

Pump swashplate

P000 801E

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

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

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

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

•

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

•

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

•

the unit bearing life (B10) is critical.

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

Table 8: External shaft load Frame Size

030

042

055

075

100

130

180

250

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

Nm lbf•in

112 991

126 1 114

101 893

118 1 043

126 1 114

140 1 238

161 1 424

176 1 556

2) Max. Shaft Thrust in (T in)

N lbf

2 900 652

2 635 592

3 340 750

4 300 966

5 160 1 160

5 270 1 184

7 000 1 573

7 826 1 759

3) Max. Shaft Thrust out (T out)

N lbf

1 330 299

1 020 229

910 204

930 209

1 000 224

688 154

1 180 265

1 693 380

20

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

Figure 19: Overhung load moments

CG Pump 2

Auxiliary Pad

Mounting Flange

CG Pump 1

Estimating Overhung Load Moments W = L =

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

Where: MR MS GR GS

L1 L2

= = = =

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

P001 290E

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

This factor depends on the application.

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

Table 9: Allowable overhung load moments Frame Size

Rated Moment MR

Shock Load Moment MS

Nm

lbf•in

Nm

lbf•in

030

860

7 600

3 020

26 700

042

860

7 600

3 020

26 700

055

1 580

14 000

5 650

50 000

075

1 580

14 000

5 650

50 000

100

1 580

14 000

5 650

50 000

130

3 160

28 000

10 730

95 000

180

6 070

54 000

20 600

182 000

250

6 070

54 000

20 600

182 000

21

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

95

000

ar (3

η t = 210 b

i)

0 ps

600

90

Efficieny %

psi)

r( 0 ba

2

ηv = 4

i)

0 ps

600

r( 0 ba

η t = 42 85

80 0

50

25

75

100 P000 791E

Speed % of Rated Continuous Speed

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

These efficiency maps can be used for all frame sizes.

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

420

6000

350

92% 210

2000

140

93% bar

psi

3000

1000

70

0

0 0

P000 793E

22

25 50 75 Speed % of Rated Continuous Speed

100

psi

System Pressure

280

4000

6000

420

5000

350

4000

280

85

η t

=

0.

η t=

90%

3000

bar

5000

0.6

85%

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

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

9

η t

=

0.

210

2000

140

0

0 0

25 75 50 Displacement in percent of maximum displacement

100

P000 794E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Notes

23

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

Table 10: Electric input signal direct current Configuration

b

DC

12 VDC

DD

24 VDC

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

"0"

"A" Figure 24: Solenoid Connector

To Servo Piston S1

Solenoid plug face for DIN 43650 Connector

S2

a

SAUER-SUNDSTRAND Mating Parts Kit Part No. K09129

b

not connected

T P From Charge

S1 = Servo Side 1 S2 = Servo Side 2

P001 409E

Figure 23.2: Pump displacement vs electrical signal 100 % Displacement

b

Voltage VDC "0"

-b

100 % P001 408E

24

1

2

Voltage between terminals 1 and 2 P001 473E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

Table 12: Pump output flow direction vs. control voltage

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

Input Shaft Rotation

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

CW

CCW

Signal at Magnet

a

b

a

b

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations

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

210 bar 50 °C 24 bar

(3 000 psi) (122 °F) (340 psi)

Table 11: Typical response times Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 1.0

25

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

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

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

S2

S1

Swashplate Feedback

"B"

"0"

X2 X1

T P From Charge

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

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

P000 810E

Figure 26: Cross-section of electric displacement control valve

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

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

"A"

X2

Electric Input Signal

P C P X1

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

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

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

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

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

26

T S2 P S1 T

S1 = Servo Side 1 S2 = Servo Side 2

P000 809

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

a mA

b mA

Single coil Dual coil

14 ± 5 7±3

85 ± 18 43 ± 9

A & B or C & D A&D

85 ± 18

(C B Common) AC&BD

in series Dual coil parallel

14 ± 5

Pin Connections

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

Displacement

100 %

-b

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

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

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

-a

Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 1.0

Current mA "0" a

b

100 % P001 015E

Figure 28: Connectors

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

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

A B

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

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

CW

Input Shaft Rotation

CCW

Positive Current to Term.

A or C

B or D

A or C

B or D

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

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

B C D

CW

Input Shaft Rotation

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

P001 464E

CCW

Positive Current to Term.

A

D

A

D

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations 27

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

X2

T S2 P S1 T P000 807

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

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

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

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

a b

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

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

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

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

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

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

43 ± 6 psi 160 ± 6 psi

-b

-a

Signal Pressure

"0" a

b

Figure 29: Hydraulic displacement control hydraulic schematic 100 %

To Servo Piston S2

X1

Input Signal Pressure Swashplate Feedback

P001 014E

S1 Input Signal Pressure

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

T P From Charge

Input Shaft Rotation

CW

CCW

Control Pressure to Port

X2

X1

X2

X1

Port A Flow

In

Out

Out

In

Port B Flow

Out

In

In

Out

Refer to dimensions for port locations P000 808E

28

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

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

Table 18: Typical response times Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 1.0

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

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

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

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

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

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

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

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

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

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

Figure 32: Manual displacement control hydraulic schematic "B"

"0"

"A"

To Servo Piston S2

Swashplate Feedback

S1

T P From Charge

P000 805E

Figure 33: Cross-section of manual displacement control valve

Control Handle Input Signal

T S2 P S1 T P000 804E

S1 = Servo Side 1 S2 = Servo Side 2 29

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

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

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

Figure 34: Pump displacement vs control lever rotation

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

"A"

Input Shaft Rotation Handle Rotation

CW

CCW

Displacement

100 %

-24°÷ 30° *

-2° "0"

Lever Rotation 2°

-35° max.

35° max.

"B" 24°÷ 30° *

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

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations 100 %

Response Time see next page.

* Actual angle see dimensions.

P001 013E

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

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

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

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

Swashplate Feedback

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

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

S1

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

T P From Charge P001 412E

30

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

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

• Smooth acceleration is possible.

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

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

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

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

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

Control Handle Input Signal

T S2

P

S1

S1 = Servo Side 1 S2 = Servo Side 2

P001 410E

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

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

Figure 37: Pump displacement vs control lever rotation

Displacement

100 %

"A"

-31°

"B" 3°

-33° max.

33° max.

Lever Rotation

-3° "0"

31°

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

Table 21: Typical response times Frame Size

Maximum Time Seconds (Smallest Orifice) Option 01

Minimum Time Seconds (No Orifice) Option 00

030 042 055 075 100 130 180 250

1.5 1.9 3.6 3.7 4.8 7.5 7.5 9.0

0.60 0.22 0.27 0.32 0.42 0.70 0.55 9.0

100 % P001 411E

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

CW

CCW

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

"B" (CW)

Port A Flow

Out

In

In

Out

Port B Flow

In

Out

Out

In

Refer to dimensions for port locations 31

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 030 mm (in.)

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

Coupling may not protrude beyond this surface

25

length of full spline

7.9 (.98) (.31)

Splined Shaft Option C3

B

CCW

9.7 (.38) 12.2 (.48)

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

91.55 (3.60) Port L2

40.49 (1.59)

Approx center of gravity

100 (3.94) 176.4 (6.94)

185.4 (7.29)

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

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

"Z"

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

Coupling may not protrude beyond this surface

20

length of full spline

7.9 (.78) (.31)

Splined Shaft Option C2

79 (3.11)

42 (1.65)

ø21.72 (.85 Dia)

View "Y"

126 (4.96) 231.9 (9.13)

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

"A" Max. Displacement

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

ø6.73 2x (.265 Dia)

Tapered Shaft Option T3

View "X" Charge Pressure Relief Valve

Multifunction Valve

73.55 (2.89)

View "W"

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

53.66 (2.11) 8.3 (.33)

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

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

Multifunction Valve

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

Coupling may not protrude beyond this surface

73 (2.875)

ø25.4 (1Dia)

Null position

24° min.

"B"

24° min.

Max. Displacement

45 (1.77)

Approx center of gravity

60 (2.36)

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

35 (1.38)

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

ø18.67 (.74 Dia)

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

ø15.3 (.602 Dia)

0

A

74 (2.91) 71.5 (2.81) Port L2

18.24 (.71)

ø21.34 (.84 Dia)

CW

(-.002)

ø101.6 -0.05 (4 Dia) (+.000)

51 (2.00)

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

51 (2.00)

Rotation

"X"

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

32

"W"

141 (5.55)

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

100 (3.94 ) Port L1

124 (4.88)

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

View "Z"

Control MDC, Option MA 9.4 (.37)

"Y"

34.6 (1.36) 48.86 (1.92)

P001 359E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

106.375 (4.188)

"X"

SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

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

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

15.3 (.60)

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

259.6 (10.22)

106.375 (4.188)

273.4 (10.76)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

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

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

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

19.6 (.77) 256.4 (10.09)

146 (5.75)

273.8 (10.78)

View "X"

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

SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

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

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

29.9 (1.18) 256.4 (10.09)

146 (5.75)

273.8 (10.78) P001 360E

33

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 042 mm (in.)

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

Coupling may not protrude beyond this surface

25

length of full spline

7.9 (.98) (.31)

Splined Shaft Option C3

B

111 (4.37)

"W"

145 (5.71)

38 (1.5)

Rotation

"X"

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

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

50.8 (2.00) Approx center of gravity

ø15.3 (.602 Dia)

(-.002)

0

A

9.7 (.38)

CW

81.4 (3.20) 80 (3.15) Port L2

23.8 (.94)

ø21.34 (.84 Dia)

CCW

ø101.6 -0.05 (4 Dia) (+.000)

52 (2.047)

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

52 (2.047)

129 (5.08)

86 (3.39)

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

108 (4.25) Port L1

View "Z"

Control MDC, Option MA 9.4 (.37)

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

"Z" 33 (1.30)

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

Approx center of gravity

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

73 (2.875)

View "X"

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

View "Y"

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

Charge Pressure Relief Valve

83 (3.27)

41.6 (1.64)

Multifunction Valve

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

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

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

56.9 (2.24)

143.5 (5.65)

85.5 (3.4)

258 (10.16)

Manual Displacement Control Handle Dimensions

Coupling may not protrude beyond this surface

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

"A" Max. Displacement

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Tapered Shaft Option T3

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

34

62.5 (2.46)

28° min.

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

ø25.4 (1Dia)

Null position

28° min.

"B"

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

53.7 (2.11) 8.3 (.33)

R 50.8 (R 2.0)

Max. Displacement

View "W"

34.6 (1.36) 38.6 (1.52)

126 (4.96)

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

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

106.375 (4.188)

"X"

SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

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

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

18 (.71)

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

288 (11.34)

106.375 (4.188)

301.85 (11.88)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

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

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

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

20.5 (.81) 282.92 (11.14)

146 (5.75)

300.37 (11.83)

View "X"

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

SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

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

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

30.8 (1.21) 282.92 (11.14)

146 (5.75)

300.37 (11.83) P001 362E

35

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 055 mm (in.)

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

View "Z" Control MDC, Option MA

9.4 (.37)

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

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

47.6 (1.88) 7.9 (.31)

Splined Shaft Option S1

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

243.7 (9.60) Port S

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

288.8 (11.37)

33.8 (1.33)

27.76 (1.093)

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

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

Max. Displacement

28° min.

A

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

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

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

96.85 (3.81)

View "W"

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

66.9 (2.63) 6.6 (.26)

ø34,93 (1.375 Dia)

SAE J744c 47.8 (1.88) 62.02 (2.44)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

36

View "X" Charge Pressure Relief Valve

Multifunction Valve

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

Tapered Shaft Option T1

(2x)

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

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

28° min.

Max. Displacement

114.5 (4.50)

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

Multifunction Valve

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

(2x)

Splined Shaft Option C6

41.7 (1.64)

57.15(2.25)

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

Approx center of gravity

57.25 (2.25)

length of full spline

ø34.42 (1.355 Dia)

7.9 (.31)

43.7 (1.72)

ø14.27 (.562 Dia)

Coupling may not protrude beyond this surface

47.6 (1.88)

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

(-.002)

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

120.4 (4.74) Port L2 152.4 (6.0)

View "Y"

0

"Z"

82.6 (3.25)

14.2 (.56)

Approx center of gravity

CW

65 (2.56)

"X"

CCW

ø127 -0.05 (5 Dia) (+.000)

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

90.4 (3.56) Port A

Rotation

12.45 ±0.25 (.49) (±.01)

Null position

"W"

length of full spline

27.9 (1.10)

ø24.9 (.98 Dia)

B

110.7 (4.36)

93.7 (3.69)

Coupling may not protrude beyond this surface

149.9 (5.90)

"Y"

136.35 (5.37)

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

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

mm (in.)

Endcap Twin Ports, Option 8 "Y"

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

Control MDC, Option MA

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

27.76 (1.093)

57.9 (2.28)

57.9 (2.28)

B

A

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

57.15 (2.25)

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

85.1 (3.35) Port S

88.9 (3.54)

View "Y"

P001 386E

37

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

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

View "X"

"X"

106.375 (4.188)

ø82.6 (3.252 Dia)

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

SAE A, Option A

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

15.13 (.59)

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

316.6 (12.46)

106.375 (4.188)

330.4 (13.01)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

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

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

17.66 (.70)

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

311.5 (12.26)

146 (5.75)

329 (12.95)

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

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

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

30.73 (1.21)

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

314 (12.36) 331 (13.03)

114.5 (4.51) 181 (7.13) P001 387E

38

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

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

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

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

20.75 (.82)

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

311.5 (12.26)

146 (5.75)

329 (12.95) P001 387E/1

39

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 075 mm (in.)

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

99.3 (3.91)

9.4 (.37)

139.7 (5.50)

126 (4.96) Port B

Splined Shaft Option S1

Rotation

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

View "Y"

306.1 (12.05)

41.6 (1.64)

27.76 (1.093)

A Max. Displacement

248.2 (9.77)

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

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

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

Tapered Shaft Option T2

View "X" Charge Pressure Relief Valve

Multifunction Valve

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

104 (4.09)

View "W"

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

66.9 (2.63) 8.65 (.34)

ø38.1 (1.5 Dia)

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

40

(2x)

Multifunction Valve

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

28° min.

28° min.

B Null position

81.3 (3.20) 172.2 (6.78)

R 50.8 (R 2.0)

Max. Displacement

114.5 (4.50)

A

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

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

Approx center of gravity

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

(2x)

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

ø31.8 (1.25 Dia)

Manual Displacement Control Handle Dimensions

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

(-.002)

Splined Shaft Option C7

57.15(2.25)

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

57.25 (2.25)

length of full spline

34.8 (1.37)

ø37.59 (1.48 Dia)

7.9 (.31)

40.6 (1.60)

ø14.27 (.562 Dia)

Coupling may not protrude beyond this surface

47.6 (1.88)

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

0

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

84 (3.31)

262.6 (10.34) Port S

141.7 (5.58) Port L2 155.7 (6.13)

"Z"

12.45 ±0.25 (.49) (±.01)

71 (2.79)

Approx center of gravity

14.2 (.56)

ø127 -0.05 (5 Dia) (+.000)

3.8

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

CW

M4

94.5 (3.72) Port A

ø24.9 (.98 Dia)

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

CCW

B

124.2 (4.89) Port L1

length of full spline

27.9 (1.10)

M5

"X"

"W"

Coupling may not protrude beyond this surface

47.6 (1.88) 7.9 (.31)

110.7 (4.36)

155.7 (6.13)

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

View "Z"

"Y"

47.8 (1.88) 62.02 (2.44)

141.1 (5.55)

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

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

mm (in.)

Endcap Twin Ports, Option 8 "Y"

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

Control MDC, Option MA

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

27.76 (1.093)

61 (2.40)

93.77 (3.69)

61 (2.40)

B

A

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

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

92 (3.62)

View "Y"

P001 381E

41

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

View "X" SAE A, Option A

B

M4

106.375 (4.188)

ø82.6 (3.252 Dia)

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

M5

"X"

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

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

15.13 (.59) 333.93 (13.14)

106.375 (4.188)

347.8 (13.69)

M4

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

146 (5.75)

(- .000)

B

+ 0.13

View "X" SAE B, Option B M5

"X"

ø101.65 0 (4.002 Dia) (+.005)

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

A

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

17.66 (.70) 328.9 (12.95)

146 (5.75)

346.5 (13.64)

114.5 (4.51)

(- .000)

M4

+ 0.13

B

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

View "X" SAE C, Option C M5

"X"

ø127.03 0 (5.001 Dia) (+.005)

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

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

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

A 114.5 (4.51) 181 (7.13)

P001 384E

42

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

146 (5.75)

(- .000)

M4

+ 0.13

B

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

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

"X"

ø101.65 0 (4.002 Dia) (+.005)

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

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

22.75 (.896) 328.9 (12.95)

A 146 (5.75)

346.5 (13.64) P001 384E/1

43

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 100 mm (in.)

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

View "Z"

"Y"

Control MDC, Option MA

108.4 (4.27)

9.4 (.37)

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

length of full spline

49.5 (1.95)

Splined Shaft Option F1

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

288 (11.34) Port S

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

161 (6.34) Port L2

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

180.3 (7.10)

339 (13.35)

View "Y"

47.6 (1.88)

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

38.9 (1.53)

27.76 (1.093)

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

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

"A" Max. Displacement

30° min.

Woodruff key 9.525 x 38.1 (.375 x 1.50)

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Tapered Shaft Option T2

114.6 (4.51)

View "W"

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

66.9 (2.63) 9.54 (.38)

SAE J744c

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

44

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

ø38,1 (1.5 Dia)

Null position

Coupling may not protrude beyond this surface

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

Multifunction Valve

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

30° min.

Max. Displacement

Charge Pressure Relief Valve

Multifunction Valve

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

87.3 (3.44)

View "X"

Splined Shaft Option C7

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

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

57.25 (2.25)

length of full spline

33 (1.30)

57.15(2.25)

Approx center of gravity

Coupling may not protrude beyond this surface

ø37.59 (1.48 Dia)

7.9 (.31)

42 (1.65)

ø14.27 (.562 Dia)

89.7 (3.53)

Approx center of gravity

76 (2.99)

"X"

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

"Z"

12.45 ±0.25 (.49) (±.01) 14.2 (.56)

CW

(-.002)

0

CCW

ø127 -0.05 (5 Dia) (+.000)

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

99.0 (3.89) Port A

Rotation

ø34.5 (1.36 Dia)

"B"

"W"

Coupling may not protrude beyond this surface

66.7 (2.625) 7.9 (.31)

119.7 (4.71)

164.7 (6.48)

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

47.8 (1.88) 62.02 (2.44)

164.34 (6.47)

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

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

mm (in.)

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

"Y"

Control MDC, Option MA

47.6 (1.88)

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

7.9 (.31)

30.5 (1.20)

Coupling may not protrude beyond this surface length of full spline

Splined Shaft Option S1

ø24.9 (.98 Dia)

A

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

57.15 (2.25)

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

ø31.14 (1.226Dia)

27.76 (1.093)

66.8 (2.63)

66.8 (2.63)

B

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

99.8 (3.93) Port S

107.95 (4.25)

View "Y"

P001 378E

45

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

mm (in.)

View "X"

106.375 (4.188)

"X"

ø82.6 (3.252 Dia)

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

SAE A, Option A

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

15.13 (.60)

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

366.02 (14.41)

106.375 (4.188)

379.69 (14.95)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

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

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

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

17.66 (.70) 360.9 (14.21)

146 (5.75)

378.3 (14.89)

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

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

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

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

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

A 114.5 (4.51) 181 (7.13)

P001 379E

46

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

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

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

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

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

mm (in.)

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

22.75 (.896) 360.9 (14.21)

146 (5.75)

378.3 (14.89) P001 379E/1

47

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 130 mm (in.)

Figure 43: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

View "Z"

"Y"

Control MDC, Option MA

110.5 (4.35)

9.4 (.37)

length of full spline

42.5 (1.67)

7.9 (.31)

Splined Shaft Option F1 (-.002)

0

"X" 14.6 (.57)

66.68 (2.63)

185 (7.28) 290 (11.42) 300 (11.81)

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

View "Y"

66.68 (2.63)

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

42.5 (1.67)

48 (1.89) 209.3 (8.24) 370 (14.58)

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

"A" Max. Displacement

30° min.

Woodruff key 10.074 x 50.67 (.397 x 1.995)

R 25.4 (R 1.0)

Tapered Shaft Option T4

75.95 (2.99) 12.27 (.48)

SAE J744c

ø6.73 2x (.265 Dia)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

48

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

View "W" 121.2 (4.8)

ø44.45 (1.75Dia)

Null position

Coupling may not protrude beyond this surface

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

M3

"B"

Charge Pressure Relief Valve

Multifunction Valve

Castle nut, 1-1/4-18UNEF Wrench size: 46 (1.811) Torque nut to 370-430 Nm (270-317 lbf-ft)

30° min.

Max. Displacement

View "X"

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 42.8625 (1.6875) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

101.5 (3.99)

Port L2 (2x) Case drain 1-5/16-12UN-2B 161.6 (2x) (6.36)

Splined Shaft Option C8

111 (4.37)

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

80.8 (3.18)

length of full spline

ø37 (1.46 Dia)

Port L1 Case drain use highest port as outlet 1-5/16-12UN-2B

Approx center of gravity

Coupling may not protrude beyond this surface

ø44.35 (1.75 Dia)

7.9 (.31)

48.8 (1.92)

ø20.6 (.81 Dia)

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

166 (6.54) Port L2 Approx center of gravity

"Z"

12.45 ±0.25 (.49) (±.01)

CW

91 (3.58)

Ports A and B 1- 1/4 -6000 psi Split Flange Boss per SAE J518 (Code 62) 1/2-13UNC-2B 23 (.906) min. Full Thread

CCW

111.6 (4.39) 109,81 (4.32) Port L2

ø34.04 (1.34 Dia) A

15 (.59) ø43.89 (1.73Dia) ø114 max. (max. 4.49 Dia)

Rotation

31.75 (1.25)

77 (3.03)

B

ø152.4 -0.05 (6 Dia) (+.000)

147.1 (5.79) Port L1 77 (3.03)

168.5 (6.63)

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

"W"

Coupling may not protrude beyond this surface

66.68 (2.63)

184.5 (7.26)

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

53.85 (2.12) 71.35 (2.81)

178.6 (7.03)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 373E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 130 (Continued) Continued Figure 43: Auxiliary Mounting Pad - Options A, B, C, D, V

mm (in.)

View "X"

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 22.4 (.88)

"X"

106.375 (4.188)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

(- .000)

SAE A, Option A

4 Threads 3/8-16UNC-2B 8 (.31) deep

15.6 (.61)

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

400.89 (15.78)

106.375 (4.188)

414.56 (16.32)

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

146 (5.75)

"X"

View "X" SAE B, Option B

(- .000)

+ 0.13

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 28.77 (1.1)

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

18.2 (.72) 408 (16.06)

146 (5.75)

425.65 (16.76)

View "X"

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.97 (1.18) (- .000)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

114.5 (4.51)

+ 0.13

ø127.03 0 (5.001 Dia) (+.005)

"X"

SAE C, Option C

6 Threads 1/2-13UNC-2B 22 (.87) deep

31.4 (1.24) 411.05 (16.18) 427.75 (16.84)

114.5 (4.51) 181 (7.13)

P001 374E

49

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 130 (Continued) mm (in.)

Continued Figure 43: Auxiliary Mounting Pad - Options A, B, C, D, V View "X"

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.22 (.993)

"X"

161.6 (6.36)

+ 0.13

ø152.45 0 (6.002 Dia) (+.005)

(- .000)

SAE D, Option D

4 Threads 3/4-10UNC-2B 41 (1.6) deep

50.84 (2.00)

for O-Ring ø153 x 3.0 (6.02 Dia x 0.118)

415.62 (16.36)

161.6 (6.36)

439.22 (17,29)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.59 (.96)

4 Threads 1/2-13UNC-2B 22 (.87) deep

23.3 (.92) 408 (16.06)

146 (5.75)

425.65 (16.76) P001 375E

50

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Notes

51

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 Figure 44: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

View "Z"

"Y"

Control MDC, Option MA

Splined Shaft Option F1

B

201.5 (7.93)

length of full spline

42.5 (1.67)

Rotation

66.68 (2.63) Approx center of gravity

20 (.79)

186 (7.32) Port L2

200 (7.87) 321 (12.64) 326 (12.83)

Gauge port M1 System pressure A 9/16-18UNF-2B

Gauge port M4 Servo pressure 9/16-18UNF-2B

7.9 (.31)

42.5 (1.67)

0

(-.002)

View "X"

Charge Pressure Relief Valve

Splined Shaft Option C8 Multifunction Valve

56 (2.20)

138 (5.43)

108 Gauge port M5 (4.25) Servo pressure 9/16-18UNF-2B 228 (8.97)

Approx center of gravity

56 (2.20) Port L2 112.25 (2x) Case drain (4.42) 1-5/8-12UN-2B 224.5 (2x) (8.84)

length of full spline

Gauge port M3 Charge pressure 9/16-18UNF-2B

ø39 (1.54 Dia) Port L1 Case drain use highest port as outlet 1-5/8-12UN-2B

ø20.6 (.81 Dia)

Coupling may not protrude beyond this surface

ø44.35 (1.75 Dia)

View "Y"

"Z"

SHAFT SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

66.68 (2.63)

CW

143 (5.63) 142 (5.59) Port L2

15.5 ±0.25 (.61) (±.01)

ø165.1 -0.05 (6.5 Dia) (+.000)

31.75 (1.25)

93 (3.66)

Ports A and B 1- 1/4 -6000 psi Split Flange Boss per SAE J518 (Code 62) 1/2-13UNC-2B 23 (.906) min. Full Thread

ø34.04 (1.34 Dia)

A

12 (.47) ø43.89 (1.73Dia) ø114 max. (max. 4.49 Dia)

195 (7.68)

CCW

93 (3.66)

204 (8.03)

7.9 (.31)

181 (7.13) Port L1

"X"

"W"

Coupling may not protrude beyond this surface

66.68 (2.63) Port S: Charge pump inlet 1-5/8-12UN-2B

177 (6.97)

160 (6.30)

9.4 (.37)

Gauge port M2 System pressure B 9/16-18UNF-2B

mm (in.)

Multifunction Valve

SHAFT SPLINE DATA: Pitch Dia = 42.8625 (1.6875) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

View "W"

398 (15.67)

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

Null position

"A" Max. Displacement

30° min.

"B"

30° min.

Max. Displacement

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

52

191 (7.52)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 376E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 (Continued) mm (in.)

Continued Figure 44: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

106.375 (4.188)

"X"

View "X" SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 17.8 (.70)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

4 Threads 3/8-16UNC-2B 17.8 (.70) deep

15 (.59) 429.3 (16.90)

106.375 (4.188)

442.9 (17.44)

View "X" SAE B, Option B

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.5 (1.16)

4 Threads 1/2-13UNC-2B 22 (.87) deep

17.5 (.69) 436.4 (17.18)

146 (5.75)

454.1 (17.88)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 22.1 (.87)

6 Threads 1/2-13UNC-2B 22 (.87) deep

30.5 (1.20) 439.4 (17.30) 456.1 (17.96)

114.5 (4.51) 181 (7.13)

P001 388E

53

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 (Continued) mm (in.)

Continued Figure 44: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

View "X"

A

161.6 (6.36)

(- .000)

+ 0.13

"X"

ø152.45 0 (6.002 Dia) (+.005)

B

SAE D, Option D

for O-Ring ø153 x 3.0 (6.02 Dia x 0.118)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

49.9 (1.96) 448.1 (17.64) 464.8 (18.30)

View "X" SAE E, Option E

224.5 (8.84)

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

"X"

46.5 (1.83)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

473.1 (18.63)

View "X" SAE H, Option H

224.5 (8.84) 46.5 (1.83)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

448.1 (17.64) 473.1 (18.63)

54

224.5 (8.84)

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

448.1 (17.64)

COUPLING SPLINE DATA: Pitch Dia = 42.862 (1.687) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 28.5 (1.12)

"X"

161.6 (6.36)

224.5 (8.84)

P001 469E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 180 (Continued) mm (in.)

Continued Figure 44: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

View "X" SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.49 (.96)

4 Threads 1/2-13UNC-2B 22 (.87) deep

22.6 (.89) 436.4 (17.18)

146 (5.75)

454.1 (17.88)

P001 469E/1

55

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 mm (in.)

Figure 45: Axial Piston Variable Displacement Pump with Manual Displacement Control (MDC) Endcap Twin Ports, Option 8

View "Z"

"Y" 9.4 (.37)

Control MDC, Option MA

length of full spline

42.5 (1.67)

Splined Shaft Option F1

B

201.5 (7.93)

212 max.

(8.35)

7.9 (.31)

Rotation

341 (13.43)

Ports A and B 1- 1/2 - 6000 psi Split Flange Boss per SAE J518 (Code 62) 5/8-11UNC-2B, 25 (.98) min.

Full Thread

331 (13)

210 (8.27)

(-.002)

0

"Z"

SHAFT SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

Gauge port M4 Servo pressure 9/16-18UNF-2B

7.9 (.31)

56 (2.20)

Coupling may not protrude beyond this surface

System pressure B 9/16-18UNF-2B

Multifunction Valve

56 (2.20) 108 Gauge port M5 (4.25) Servo pressure 9/16-18UNF-2B 228 (8.98)

Charge Pressure Relief Valve

Splined Shaft Option C8

136 (5.35)

M2

Approx center of gravity

56 (2.20) Port L2 112.25 (2x) Case drain (4.42) 1-5/8-12UN-2B 224.5 (2x) (8.84)

length of full spline

Gauge port M3 Charge pressure 9/16-18UNF-2B

ø39 (1.54 Dia)

Port L1 Case drain use highest port as outlet 1-5/8-12UN-2B

ø20.6 (.81 Dia)

View "X" Gauge port M2 66.68 (2.63)

ø44.35 (1.75 Dia)

View "Y"

20 (.79)

186 (7.32) Port L2

79.38 (3.13) Approx center of gravity

CW

143 (5.63) 142 (5.59) Port L2

15.5 ±0,25 (.61) (±.01)

ø165.1 -0.05 (6.5 Dia) (+.000)

ø34.04 (1.34 Dia)

12 (.47) ø43.89 (1.73Dia) ø114 max. (max. 4.49 Dia)

69.85 (2.75) A

36.5 (1.44)

Port S: Charge Pump Inlet 1- 1/2 3000 psi Split Flange Boss per SAE J518 (Code 61) 1/2-13UNC-2B 24 (.94) min.

Full Thread

185.5 (7.30)

35.71 (1.41)

98 (3.86)

CCW

98 (3.86)

181 (7.13) Port L1

"X"

"W"

Coupling may not protrude beyond this surface

66.68 (2.63)

SHAFT SPLINE DATA: Pitch Dia = 42.8625 (1.6875) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

419 (16.5)

Multifunction Valve

Gauge port M10 Charge Pump Inlet 9/16-18UNF-2B

Gauge port M1 System pressure A 9/16-18UNF-2B

View "W"

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in) R 50.8 (R 2.0)

Null position

"A" Max. Displacement

30° min.

"B"

30° min.

Max. Displacement

R 25.4 (R 1.0) ø6.73 2x (.265 Dia)

Contact SAUER-SUNDSTRAND Application Engineering for specific installation drawings.

56

191 (7.52)

Port N (optional), Speed pick-up 9/16-18UNF-2B P001 465E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 (Continued) mm (in.)

Continued Figure 45: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

106.375 (4.188)

"X"

View "X" SAE A, Option A

(- .000)

+ 0.13

ø82.6 0 (3.252 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 14.288 (.5625) Pressure Angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 17.8 (.70)

for O-Ring ø82.27 x 1.78 (3.24 Dia x 0.07)

4 Threads 3/8-16UNC-2B 17.8 (.70) deep

15 (.59) 450.30 (17.73)

106.375 (4.188)

463.90 (18.26)

View "X" SAE B, Option B

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 20.6375 (.8125) Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29.5 (1.16)

17.5 (.69)

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

4 Threads 1/2-13UNC-2B 22 (.87) deep

457.4 (18.01)

146 (5.75)

475.1 (18.70)

for O-Ring ø126.72 x 1.78 (4.98 Dia x 0.07)

View "X" SAE C, Option C

114.5 (4.51)

(- .000)

+ 0.13

"X"

ø127.03 0 (5.001 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 29.6333 (1.167) Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 22.1 (.87)

6 Threads 1/2-13UNC-2B 22 (.87) deep

30.5 (1.20) 460.4 (18.13) 477.1 (18.78)

114.5 (4.51) 181 (7.13)

P001 466E

57

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 (Continued) Continued Figure 45: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V

161.6 (6.36)

"X"

View "X" SAE D, Option D

(- .000)

+ 0.13

ø152.45 0 (6.002 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

for O-Ring ø153 x 3.0 (6.02 Dia x 0.118)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

49.9 (1.96) 469.1 (18.47)

224.5 (8.84) 494.1 (19.45)

SAE H, Option H

224.5 (8.84) 46.5 (1.83)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

469.1 (18,47) 494.1 (19.45)

58

224.5 (8.84)

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

4 Threads 3/4-10UNC-2B 41 (1.61) deep

469.1 (18,47)

COUPLING SPLINE DATA: Pitch Dia = 42.862 (1.687) Pressure Angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 28.5 (1.12)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

View "X"

(- .000)

+ 0.13

ø165.15 0 (6.501 Dia) (+.005)

SAE E, Option E

46.5 (1.83)

for O-Ring ø164.77 x 2.62 (6.48 Dia x 0.10)

"X"

161.6 (6.36)

485.8 (19.13)

COUPLING SPLINE DATA: Pitch Dia = 41.275 (1.625) Pressure Angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 25.9 (1.02)

"X"

mm (in.)

224.5 (8.84)

P001 467E

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Frame Size 250 (Continued) Continued Figure 45: Auxiliary Mounting Pad - Options A, B, C, D, E, H, V View "X"

for O-Ring ø101.32 x 1.78 (3.99 Dia x 0.07)

SAE B-B, Option V

146 (5.75)

(- .000)

+ 0.13

"X"

ø101.65 0 (4.00 Dia) (+.005)

COUPLING SPLINE DATA: Pitch Dia = 23.8125 (.9375) Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24.49 (.96)

mm (in.)

4 Threads 1/2-13UNC-2B 22 (.87) deep

22.6 (.89) 457.4 (18.01)

146 (5.75)

475.1 (18.70) P001 467E/1

59

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Controls, Displacement Limiter Figure 46: Cover Plate

C2

Option CA

View "W"

C1

C4 max.

C3

C1

C4 max.

Port M4

Displacement Limiter Option 4 Limitation both sides

Ports: M4, M5 = Servo Pressure 9/16-18UNF-2B O-Ring Boss

Port M5

"W"

P001 363E

Table 22: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100

C1 63.5 (2.50) 67.9 (2.67) 69.2 (2.72) 74.2 (2.92) 83.3 (3.28)

C2 140.5 (5.53) 129.5 (5.10) 179.4 (7.06) 185.7 (7.31) 183.3 (7.22)

C3 95.5 (3.76) 99.5 (3.92) 103.6 (4.08) 109.4 (4.31) 118.3 (4.66)

C4 max. [Option 4] 106 (4.17) 108 (4.25) 114 (4.48) 118 (4.65) 136 (5.35)

130 180 250

86.6 (3.41) -

209.3 (8.24) -

137.2 (5.40) -

141 (5.55) 184 (7.24) 184 (7.24)

Figure 47: 3-Position (FNR) Electric Control

View "W"

C5.2

C5 max.

C5.1

a

Option DC & DD

b

P001 399E

Table 23: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100 130 (Option DC only) 60

"W"

C5 max.

190.5 (7.50) 194.5 (7.66) 198.6 (7.82) 204.4 (8.05) 213.3 (8.40) 232.2 (9.14)

C5.1 110.2 (4.34) 110.2 (4.34) 110.2 (4.34) 110.2 (4.34) 101.6 (4.00) 116.6 (4.59)

C5.2 112.8 (4.44) 112.8 (4.44) 112.8 (4.44) 112.8 (4.44) 121.4 (4.78) 106.4 (4.19)

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Controls (Continued) Figure 48: Electric Displacement Control (EDC) with MS-Connector or Packard-Connector View "W"

C7

C6

C6

PackardConnector Option EP

Port X2

P001 403E

"W"

Frame Size 030 and 042 only

C7 (frame size 030 and 042 only)

Option KA & KP

Port X1

Ports: X1, X2 = 9/16-18UNF-2B O-Ring Boss

Table 24: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100

C6 95.3 (3.75) 95.3 (3.75) 95.3 (3.75) 105.2 (4.14) 114.0 (4.49)

C7 173.5 (6.83) 173.5 (6.83) 141.2 (5.56) 144.8 (5.70) 153.7 (6.05)

130 180 / 250

99.1 (3.90) 93.4 (3.68)

172.7 (6.80) 190.0 (7.48)

Figure 49: Hydraulic Displacement Control (HDC) C12

Port X1 Port X2

View "W"

Option HF

C8.1 (port X2)

C8.2 (port X1)

C10

C9

C11

Ports: X1, X2 = Control Pilot Pressure 9/16-18UNF-2B, O-Ring Boss

P001 372E

"W"

Table 25: Dimensions [mm (in.)]

Frame Size 030 042 055 075 100 130 180 / 250

C8.1 135.0 (5.31) 139.0 (5.47) 143.0 (5.63) 148.9 (5.86) 158.0 (6.22) 176.7 (6.95) 194.0 (7.63)

C8.2 131.0 (5.15) 135.0 (5.31) 139.0 (5.47) 139.9 (5.50) 149.0 (5.86) 167.7 (6.60) 185.0 (7.28)

C9 71.0 (2.79) 71.0 (2.79) 71.0 (2.79) 68.2 (2.68) 76.8 (3.02) 61.8 (2.43) 54.0 (2.12)

C10 75.7 (2.98) 75.7 (2.98) 75.7 (2.98) 67.0 (2.63) 67.0 (2.63) 67.0 (2.63) 67.0 (2.63)

C11 77.6 (3.05) 89.6 (3.52) 105.6 (4.15) 121.8 (4.79) 127.9 (5.03) 142.1 (5.59) 148.6 (5.85)

C12 87.2 (3.43) 99.2 (3.90) 115.2 (4.53) 125.3 (4.93) 131.4 (5.17) 145.6 (5.73) 152.1 (5.99) 61

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Controls (Continued) Figure 50: Manual Displacement Control (MDC) with Neutral Start Switch C13

View "W"

C14

Option MB

Neutral Start Switch

P001 364E

"W"

Table 26: Dimensions [mm (in.)]

Frame Size 042 055 075

~ C13 0.4 (.016) 18.0 (.71) 25.0 (.98)

C14 96.0 (3.78) 100.0 (3.94) 106.9 (4.21)

100

31.0 (1.22)

115.8 (4.56)

130

45.0 (1.77)

134.5 (5.29)

180 250

52.0 (2.04) 52.0 (2.04)

151.8 (5.97) 151.8 (5.97)

Figure 51: Non-Linear Manual Displacement Control (MDC) "V" Option NA

View "W"

View "V"

R 50.8 (R 2.0)

"A" P001 404E

"W"

Max. Displacement

31° min.

Null position

31° min.

Max. Displacement

"B"

C15

Torque applied to control handle shaft not to exceed 17 Nm (150 Lb•in)

R 26.4 (R 1.04) ø8.26 2x (.325 Dia)

Table 27: Dimensions [mm (in.)]

Frame Size 075 100 130

62

C15 178.9 (7.04) 187.8 (7.39) 206.7 (8.14)

CONTENTS

saue Axial Piston Variable Displacement Pumps

Series 90

Dimensions • Filtration Figure 52: Integral Pressure Filter View "X"

Option P & L

Gauge port M6 Charge pressure before filter 9/16-18UNF ø 94.2 max. (max. 3.71 Dia)

180°

"X"

180° Gauge port M3 Charge pressure after filter 9/16-18UNF

Required for removal

20.3 min. (.80 min.)

22.86 (.90)

F1 = short filter cartridge (Option P) F2 = long filter cartridge (Option L)

F4 max.

Frame Size030 - 130 = Option P Frame Size042 - 250 = Option L

F3

Figure 53: Remote Pressure - without filter View "X"

Option R & T

Port E from filter 7/8-14UNF (Option R) 1 1/16 -12UN (Option T)

5.6 (.22)

180°

5,6 (.22)

"X" 180°

Port D to filter 7/8-14UNF (Option R) 1 1/16 -12UN (Option T)

Gauge port M3 Charge pressure after filter 9/16-18UNF

F5 max.

F6 max.

Frame Size030 - 130 = Option R Frame Size180 + 250= Option T

F7 max.

28.5 (1.12) F3 P001 357E

Table 28: Dimensions [mm (in.)]

Frame Size

F1

F2

F3

F4 max.

F5 max.

F6 max.

F7 max.

030

174.5 (6.87)

-

176.8 (6.96)

203.0 (7.99)

107.7 (4.24)

147.7 (5.81)

163.0 (6.42)

042

174.5 (6.87) 262.6 (10.34) 201.4 (7.93)

208.0 (8.19)

112.7 (4.44)

152.7 (6.01)

168.0 (6.61)

055

174.5 (6.87) 262.6 (10.34) 240.9 (9.48)

209.6 (8.25)

114.3 (4.50)

154.3 (6.07)

169.6 (6.68)

075

174.5 (6.87) 262.6 (10.34) 270.5 (10.65) 214.4 (8.44)

119.1 (4.69)

159.1 (6.26)

174.4 (6.86)

100

174.5 (6.87) 262.6 (10.34) 280.7 (11.05) 223.0 (8.78)

127.7 (5.03)

167.7 (6.60)

183.0 (7.20)

130

174.5 (6.87) 262.6 (10.34) 299.9 (11.81) 233.0 (9.17)

137.7 (5.42)

177.7 (6.99)

193.0 (7.60)

180

-

-

327.8 (12.90)

-

182.0 (7.16)

236.8 (9.32)

259.2 (10.2)

250

-

-

342.8 (13.49)

-

182.0 (7.16)

236.8 (9.32)

259.2 (10.2) 63

CONTENTS

saue Hydraulic Power Systems SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide SAUER-SUNDSTRAND is a world leader in the design and manufacture of Hydraulic Power Systems. Research and development resources in both North America and Europe enable SAUER-SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology.

SAUER-SUNDSTRAND specializes in integrating a full range of system components to provide vehicle designers with the most advanced total-design system.

SAUER-SUNDSTRAND is Your World Source for Controlled Hydraulic Power Systems.

F000 691

F000 692

Heavy Duty Axial Piston Pumps and Motors

Heavy Duty Bent Axis Variable Motors F000 685 F000 688

Medium Duty Axial Piston Pumps and Motors

Cartridge Motors/ Compact Wheel Drives F000 690

Microcontrollers and Electrohydraulic Controls F000 689

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F000 686

F000 684

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F000 693

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Worldwide Service Support SAUER-SUNDSTRAND provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world.

Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.

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SAUER-SUNDSTRAND COMPANY 2800 East 13th Street Ames IA 50010 • U.S.A. Phone: (515) 239-6000 • FAX: (515) 239-6618

SAUER-SUNDSTRAND GMBH & CO. Postfach 2460 • D-24531 Neumünster Krokamp 35 • D-24539 Neumünster • Germany Phone: (04321) 871-0 • FAX: (04321) 871 122