DOWNLOAD PDF CAT Feeder Breaker 54-2188 Operation & Maintenance Manual BI629492

Operation and Maintenance Manual Bucyrus - Feeder Breaker Model GH-MFBHM-48CDH Serial Number 54-2188 Doc. No.:

A6474X389

Bucyrus____________________________________________________ 4041 Wurno Road Pulaski, VA 24301

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

Internet: www.bucyrus.com

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

This machine was manufactured under the guidelines, procedures, and requirements the appropriate regulatory agencies. At the completion of the manufacturing process, the machine 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 and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus’s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all local and national 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 Bucyrus 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 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 nontransferable. 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 2011 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 ................................................................1.4

2. Your safety Your safety ..........................................................................................2.3 Personnel .......................................................................................2.4 Operation...................................................................................2.4 Installation and repair ................................................................2.4 Operating conditions ......................................................................2.5 Intended use..............................................................................2.5 Unauthorized use ......................................................................2.5 Safety instructions ..........................................................................2.6 General rules: ............................................................................2.6 Storage and transport................................................................2.7 Installation and start-up .............................................................2.7 Operation...................................................................................2.8 Maintenance and repair.............................................................2.8

3. Storage and transport Storage and transport .........................................................................3.3 Storage...........................................................................................3.3 Storage of the machine and spare parts ...................................3.3 Transport ........................................................................................3.5 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 Removing and installing the hopper...............................................4.9 Towing the feeder breaker .............................................................4.13

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Table of contents _________________________________________________ 5. Operation Operation ..............................................................................................5.3 Controls and indicators .........................................................................5.4 Operating procedures ...........................................................................5.15 Electrical system ...................................................................................5.23 Hydraulic system...................................................................................5.33 Mechanical assemblies.........................................................................5.37 Instructions on the maintenance of the feeder ....................................5.45 Specific lubrication and maintenance procedures ........................5.50 Every shift ................................................................................5.50 Weekly ....................................................................................5.54 Monthly ...................................................................................5.53 Every 200 hours of tram operation ..........................................5.56 Every 1000 hours.....................................................................5.57 Every 6 months .......................................................................5.60 Inspection of the feeder .................................................................5.62 Inspection of wear parts on the feeder ..........................................5.63 Inspection of the fire suppression system ......................................5.64 Recharge of the fire suppression system.......................................5.66 Replace of parts....................................................................................5.75 Head shaft ......................................................................................5.75 Head shaft sprockets......................................................................5.82 Tail shaft .........................................................................................5.86 Conveyor chain ..............................................................................5.92 Crawler track ..................................................................................5.95 Crawler assembly...........................................................................5.98 Power unit ......................................................................................5.106 Gear pump .....................................................................................5.118 Breaker assembly...........................................................................5.120 Breaker drive chain ........................................................................5.124 Breaker bit ......................................................................................5.127 Shear pin ........................................................................................5.128 Tilt cylinder .....................................................................................5.130 Lift cylinder .....................................................................................5.132 Conveyor motor distributor cap ......................................................5.135 Tach mount and speed sensor.......................................................5.143 Instructions on the adjustment procedures ..........................................5.145 Conveyor chain adjustment ...........................................................5.145 Crawler track adjustment ...............................................................5.147 Breaker drive chain ........................................................................5.149 Under speed sensor calibration .....................................................5.152 Main pump, margin pressure .........................................................5.155 Main pump, pressure compensator................................................5.155 Main relief pressure........................................................................5.157 Pressure limiter ..............................................................................5.159

________________________________________________________________ Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

________________________________________________ Table of contents Troubleshooting ....................................................................................5.161 Open loop pump.............................................................................5.163 Excessive noise..............................................................................5.165 Excessive heat ...............................................................................5.166 Incorrect flow ..................................................................................5.167 Incorrect pressure ..........................................................................5.168 Hydraulic system, general ..............................................................5.169 Hydraulic cylinders .........................................................................5.171 Hydraulic pump ..............................................................................5.172 Valves.............................................................................................5.174 Bearings .........................................................................................5.176 Torque hub .....................................................................................5.177

6. Technical data Technical data.......................................................................................6.3 Tightening torques ................................................................................6.5 Permissible data ...................................................................................6.6

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

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Table of contents _________________________________________________

________________________________________________________________ Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________________

About this manual

________________________________________________________________

_______________________________________________________________

________________________________________________________________

__________________________________________ Before starting to work

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

Before starting to work Ensure that the operating manual available is applicable for the machine.

This operating manual is intended for: Bucyrus Model GH-MFBHM-48CDH Feeder Breaker Serial No. 54-2188 and is only permitted to be used for equipment of this type.

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

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, in the intersection between face and entry, or in the entry must read this operating manual.

This includes persons who: ■

are in charge of transport

■

perform assembly/disassembly work

■

operate the machine

■

eliminate faults

■

perform daily routine work on the face or in the entry

■

perform maintenance work

■

perform repair work

and supervisory personnel who: ■

initiate and/or

■

supervise the activities just indicated.

______________________________________________________________ A6474X389 REV 0 1.3

Before starting to work ____________________________________________ What is the purpose of this operating manual?

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 your Bucyrus service representative. Service addresses are listed in Chapter 7.

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

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

Try to memorize the symbols and their meanings.

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

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

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

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

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

________________________________________________________________ 1.4 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

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Your safety

________________________________________________________________

_______________________________________________________________

________________________________________________________________

__________________________________________________ Personnel

Your safety Pay special attention to this chapter as it provides vital safety information. The safety instructions and rules of procedure help to avoid hazardous situations and to perform necessary work as safely as possible.

The machine has been manufactured in accordance with state of the art and generally recognized safety standards and regulations. Nevertheless, dangerous situations can exist as a result of environmental influences, machine damage, or operator error.

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

Use only original spare parts from Bucyrus. 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 of the country in which the machine is in used.

Observe the safety and accident prevention regulations of ■

the mine,

■

the mine inspector, and

■

the mining supervisory authorities.

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

______________________________________________________________ A6474X389 REV 0 2.3

Personnel _______________________________________________________ Personnel Operation The machine may only be operated by qualified, trained personnel who can provide proof of having been trained on this unit. Reading of the operation manual shall constitute a part of this training.

The operator must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

________________________________________________________________ 2.4 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________ Safety instructions Operating conditions Intended use The feeder breaker has been designed and manufactured for breaking (crushing) mined material and transporting the material to the main conveying system.

Intended uses include: 

The breaking and transport of mined material to the main conveying system.

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

© BUCYRUS AMERICA, INC.

Unauthorized uses include: 

the transport of persons



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



crushing (breaking) of material not specified

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

______________________________________________________________ A6474X389 REV 0 2.5

Safety instructions _______________________________________________ Safety instructions General rules 

Always work with full concentration.



Familiarize yourself with the working environment.



Always wear the required personal protective equipment.



Inform your colleagues of 

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 audible and/or optical start-up warnings, if equipped, of the machine.



Observe the symbol plates on the machine.



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



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

maintenance work



inspection work



repair work



Cordon off your working area widely for the machine.



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

conveyor chains



flights



pivot points



crawler assemblies

________________________________________________________________ 2.6 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________ Safety instructions

© BUCYRUS AMERICA, INC.

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 the working area.



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



Ensure that the transport safety devices are correctly fitted.



Fix all moving parts with transport locks.



Never stand under unsupported parts or suspended loads.



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.



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

Installation and start-up 

When the machine is on an incline, secure all component parts by chains.



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.



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.

______________________________________________________________ A6474X389 REV 0 2.7

Safety instructions _______________________________________________ Operation The feeder breaker operator must have a profound knowledge of the control elements and their functions and must be 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 accidents.

Maintenance and repair 

Observe the prescribed maintenance and inspection intervals.



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



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 or unintentional restarting.



Protect the work area against falling rocks.



Send defective components for servicing without delay in order to prevent these parts from being unintentionally reinstalled elsewhere.



Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Bucyrus 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

________________________________________________________________ 2.8 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________ Safety instructions

© BUCYRUS AMERICA, INC.

Hydraulics 

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.



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



Do not alter the 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 to prevent electrical shock.



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



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



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



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

the hoses are not pinched or trapped



the hoses have no bubbles or blisters



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



the outer sheaths of the hoses are not damaged



the connectors are securely inserted into the sockets



the connections are leak-tight



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

Flush out the hydraulic lines thoroughly before connecting.



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

______________________________________________________________ A6474X389 REV 0 2.9

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.



Use only hydraulic hoses approved for the prevailing pressures.



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



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



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



Never try to repair damaged hydraulic hoses.



Replace hydraulic hoses at the first suspicion of damage.

Laying hydraulic hoses Lay the hydraulic hoses properly behind the brackets and clamps provided for them. Always lay hydraulic hoses so they: 

always have a little slack (Fig. 1)

Fig. 1: Laying hydraulic hoses, slack Right



Wrong

are not twisted (Fig. 2)

Fig. 2: Laying hydraulic hoses, twisting Right

Wrong

________________________________________________________________ 2.10 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________ Safety instructions 

are not bent directly behind the connections (distance min. 1.5 x nominal diameter) (Fig. 3)

Fig. 3: Laying hydraulic hoses, bending Right

© BUCYRUS AMERICA, INC.



Wrong

are crossed correctly (Fig. 4)

Fig. 4: Laying hydraulic hoses, crossing Right



are not kinked



always have a little slack



do not have to withstand tensile strains



are protected against thermal radiation



are accessible at all times

Wrong

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

______________________________________________________________ A6474X389 REV 0 2.11

Safety instructions _______________________________________________ When installing the hydraulic hoses, ensure that they cannot be: 

torn out,



kinked,



crushed,



driven over, or



twisted by movement of the machine.

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

Wrong

________________________________________________________________ 2.12 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________________

Storage and transport

________________________________________________________________

_______________________________________________________________

________________________________________________________________

____________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the feeder breaker. Observance of the instructions and tips will increase the service life and availability of the machine. Careful attention to the points in this chapter can simplify day-to-day work.

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

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

Storage of the machine and spare parts 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

long-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.

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.



Coat exposed valve bank valve spools with rust inhibitor.

______________________________________________________________ A6474X389 REV 0 3.3

Storage and transport _____________________________________________ 

Completely drain the water system, if equipped, 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)

inspection

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

natural aging

Even with proper storage, seals and hoses are subject to natural aging. Do not use these parts if they have been stored for more than two years.

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

other components

motors plastic deformation

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.

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).

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 GH-MFBHM-48CDH Feeder Breaker

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

dimensions,

■

weights,

■

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

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

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.

It may be necessary to remove the hopper from the machine before transport.

See the separation and connection procedure in the Towing section of Chapter 4.

Fig. 6: Lifting points on the feeder breaker

Lifting point (typical both sides)

Lifting points

Note: Approximate machine weight is 38,555 kg (85,000 lbs), as

______________________________________________________________ A6474X389 REV 0 3.5

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

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

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

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

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

________________________________________________________________ 3.6 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________________

Installation

________________________________________________________________

_______________________________________________________________

________________________________________________________________

______________________________________________________ Installation

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

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

Work on 

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



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



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

should only be carried out by Bucyrus service engineers or by specially trained personnel.

Which tools are required for installation?

General tools are required to put the feeder breaker into service.

Various items of auxiliary equipment and machines may be required at the point of installation, including 

hoists with adequate lifting capacity



means of attachment with adequate lifting capacity



unloading dock



jacks with adequate lifting capacity



impact wrenches, including accessories

______________________________________________________________ A6474X389 REV 0 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.

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 GH-MFBHM-48CDH Feeder Breaker

______________________________________________________ Installation Pre-installation check list NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components. However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: 

perform daily maintenance



visually inspect all hydraulic hoses and electrical cables for damage



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



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



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



check tension of conveyor chain



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



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



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



jog the breaker motor to check for correct rotation of breaker



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



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



check the operation of the remote start pushbuttons (if equipped)



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



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



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

______________________________________________________________ A6474X389 REV 0 4.5

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

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

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

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

You could be seriously injured.

“SYSTEM STOP” (starter enclosure)

Depressing the “SYSTEM STOP” button, located on the starter enclosure cover, will shutdown the electric motor immediately.

“E-STOP” (starter enclosure)

This emergency stop switch is located on the starter enclosure cover. Depressing the “E-STOP” button will shutdown the electric motor, stopping all machine functions. Power is still active on the machine and the machine can be restarted using normal start up procedures.

panic strip

The machine is equipped with two panic strips: one on each side of the machine. The panic strip is actuated by striking it with a small amount of force.

The panic strip is used to break the control circuit in emergency situations.

When the panic strip is struck, the electric motor is shut down, stopping all machine functions. Power is still active on the machine and the machine can be restarted using normal start up procedures.

neutral start mechanism

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

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators; one on each 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 GH-MFBHM-48CDH Feeder Breaker

______________________________________________________ Installation Fig. 7: Safety features

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Panic strip Fire suppression actuator location Neutral start mechanism “SYSTEM STOP” button “E-STOP”

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______________________________________________________________ A6474X389 REV 0 4.7

Installation ______________________________________________________ Fig. 8: Overview 11 10 9 8

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Head shaft Conveyor drive reducer and motor Air/oil heat exchanger Electric starter enclosure Hydraulic operator’s station Hydraulic oil tank

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7. Crawler 8. Power unit assembly 9. Breaker shaft 10. Conveyor chain (not shown) 11. Tail shaft (located under cover)

________________________________________________________________ 4.8 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

______________________________________________________ Installation Removing and installing the receiving hopper Before moving the machine, it may be necessary to disconnect the hopper from the machine. While removing or installing the hopper, follow all safety procedures and precautions and be aware of the following: WARNING! You can be seriously injured or killed by falling loads. Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads.

WARNING! Failure to follow all applicable energy lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

To remove the hopper (reference Fig. 9): 1. Verify that it is safe to start the machine.

2. Start the machine in manual, “MAN”, mode (see Start up procedure in Chapter 5).

3. Raise the machine using the lift and tilt hydraulic cylinders.

4. Block the receiving hopper by placing appropriate blocking under all four corners of the hopper.

5. Lock and tag out the feeder breaker power source.

6. Remove the breaker shaft drive chain (see Drive chain removal procedure in Chapter 5).

7. Remove the tail shaft and conveyor chain covers on the receiving hopper.

8. Separate and completely remove the conveyor chain (see Conveyor chain removal procedure in Chapter 5).

9. Tag, remove, and cap all grease hoses for the tail shaft and conveyor chain take-up cylinders.

10. Remove and store all shims.

11. Remove the twenty-four (24) 1-1/2 inch hex head bolts, nuts, and lock washers that secure the receiving hopper to the main body of the machine.

12. Anchor the receiving hopper using the two D-rings located on the front of the hopper.

13. Restore electrical power to the machine.

14. Start the machine in manual, “MAN”, mode (see Start up procedure in Chapter 5).

15. Slowly tram the machine about two inches (50 mm) away from the receiving hopper and stop tramming.

______________________________________________________________ A6474X389 REV 0 4.9

Installation ______________________________________________________ 16. Ensure that the tail shaft push rods will remain in place inside of the receiving hopper.

Note: The main body of the machine is equipped with tapered dowels that engage the receiving hopper. At this point, the dowels should still be engaged in the hopper.

17. Verify the stability and balance of the main body of the machine and determine if it will need support at the discharge end before proceeding.

18. After verifying the stability of the machine, continue to tram the machine away from the hopper, completely disengaging the tapered dowels from the receiving hopper.

________________________________________________________________ 4.10 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

______________________________________________________ Installation Fig. 9: Hopper removal and installation

D-ring anchor (2)

Tapered dowel (2)

Nut (24)

Bolts and lock washers (24)

Alignment dowel holes (2)

Tail shaft push rod (2)

______________________________________________________________ A6474X389 REV 0 4.11

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

WARNING! Failure to follow all applicable energy lockout/tagout procedures may result in machine damage or serious injury or death of personnel.

To install the hopper (reference Fig. 9): 1. Position the receiving hopper so that the feeder breaker can be trammed into position.

2. Block the hopper at all four corners, ensuring that it is stable and level.

3. Start the feeder breaker in manual, “MAN”, mode (see Start up procedure in Chapter 5).

4. Slowly tram the machine toward the hopper, stopping the machine a short distance from the hopper.

5. Ensure that the tapered dowels on the machine align with the holes in the hopper. Using the lift and tilt cylinders, adjust the machine until proper alignment is achieved.

6. Ensure that the push rods line up correctly with the cylinders.

7. Slowly tram forward until the receiving hopper is butted tight to the feeder.

8. Shut down the machine (see Shut down procedure in Chapter 5) and remove power from the machine following all applicable lockout/tagout regulations.

9. Insert the twenty-four 1-1/2 inch hex head bolts, nuts, and lock washers.

Torque bolts to 4,286 N-m (3,161 ft-lbs) (dry).

10. Reconnect all grease hoses for the tailshaft and the conveyor chain take-up cylinders.

11. Install the conveyor chain (see Conveyor chain installation in Chapter 5).

12. Install the tail shaft and conveyor chain covers on the hopper.

13. Install the breaker shaft drive chain.

14. Restore power to the machine.

15. Start the machine in manual, “MAN”, mode (see Start up procedure in Chapter 5).

16. Using the lift and tilt cylinders, raise the machine so that the hopper is lifted off of the blocking.

________________________________________________________________ 4.12 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

______________________________________________________ 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 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 this warning could cause serious injury or death to you or other workers.

To tow the feeder breaker proceed as follows: 1. Couple the towing machine securely to the feeder breaker.

2. 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, resulting in serious injury or death to you or other workers.

3. Loosen both cover bolts and remove the bolts (Fig. 10).

4. Rotate the cover and pull the shaft out until the groove in the shaft and the edge of the hole in the cover are locked inplace (Fig. 11). Note: The force to disengage the shaft will depend upon whether the gear mesh is loaded.

The force required to engage the shaft with the plate will be enough to squeeze an o-ring. The o-ring prevents leakage when disengaged (the shaft is sealed when fully engaged or disnegaged although there will be leakage when going from one position to the other).

5. Reinstall the bolts to hold the plate in position.

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.

6. Remove chocks from crawler and begin towing.

______________________________________________________________ A6474X389 REV 0 4.13

Installation ______________________________________________________ Fig. 10: Cover bolt removal

Cover bolt (2)

Cover bolt removed

Fig. 11: Torque hub disengagement

________________________________________________________________ 4.14 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

______________________________________________________ Installation 7. Once the destination is reached, stop both machines and chock both feeder crawlers in both directions to prevent accidental movement.

8. Remove the two cover bolts and re-insert the shaft. Re-inserting the shaft requires two sets of splines to engage and may require the unit to be rotated.

9. Reinsert the two cover bolts and torque to 80 ft-lbs.

______________________________________________________________ A6474X389 REV 0 4.15

Installation ______________________________________________________

________________________________________________________________ 4.16 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________________

Operation

________________________________________________________________

_______________________________________________________________

________________________________________________________________

_______________________________________________________ Operation

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

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

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

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 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 operation 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.

______________________________________________________________ A6474X389 REV 0 5.3

Operation _______________________________________________________ Controls and indicators This section provides descriptions of the operational controls and indicators (gauges, display screens, etc.) used to operate the feeder breaker.

Starter enclosure The following controls are located on the front cover of the starter enclosure (Fig. 12): “AUTO/OFF/MAN”

The “AUTO/OFF/MAN” selector switch is used to select whether the outby conveyor needs to be operating while the feeder breaker is operating. When the switch is in the “OFF” position, the conveyor/breaker electric motor will not start.

Manual mode, “MAN”, is used to bypass the outby conveyor sequence switch (when in manual mode, the outby conveyor belt does not need to be running).

“AUTO” mode (outby conveyor belt running) is used for normal feeder breaker operations.

“CONV/OFF/TRAM”

The “CONV/OFF/TRAM” selector switch is used to select tram or conveyor mode of operation. When in the “OFF” position, tram and conveyor functions are not active. “TRAM” mode is used for tramming the machine (when in tram mode, conveyor functions are not active). Conveyor mode, “CONV”, is used for normal operations (when in conveyor mode, tramming functions are not active).

“FOR/OFF/REV”

The “FOR/OFF/REV” selector switch is used to select the conveyor direction.

When in “OFF” mode, the conveyor will not run. Reverse mode, “REV”, is a momentary function (conveyor runs in reverse as long as switch is held in “REV” position). Forward mode, “FOR”, is used for normal operations.

“SYSTEM START”

The “SYSTEM START” button is used to start the conveyor/breaker electric motor.

“SYSTEM STOP”

The “SYSTEM STOP” pushbutton is used to stop the conveyor/breaker motor during normal operations.

“ALARM RESET”

The “ALARM RESET” pushbutton is used to clear alarms from the PLC after the alarm situation has been resolved.

circuit breaker reset

The circuit breaker reset lever is used to reset the main circuit breaker when it has tripped. To reset the breaker, push the handle down, past “OFF”, to “RESET” and then back up to “ON”.

“EMERGENCY STOP”

Pushing the “EMERGENCY STOP” button shuts down the conveyor/breaker electric motor. Power is still active on the machine. To restart after pushing the “EMERGENCY STOP” button, follow normal start up procedures.

________________________________________________________________ 5.4 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________ Operation Fig. 12: Starter enclosure 1

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“MAN/OFF/AUTO” Panel view display “CONV/OFF/TRAM” “FOR/OFF/REV” “SYSTEM START” “E-STOP” “SYSTEM STOP” “ALARM RESET” Circuit breaker reset

______________________________________________________________ A6474X389 REV 0 5.5

Operation _______________________________________________________ PLC display

The display panel (Fig. 13) is located in the starter enclosure and is used to monitor machine performance during operation, to troubleshoot the machine, and to change operating parameters.

Fig. 13: PLC display panel location PLC display panel

Number pad

Function keys

“OVERVIEW SCREEN”

On screen navigation keys

The normal operation display screen is the “OVERVIEW SCREEN” (Fig. 14).

This screen displays active alarms, breaker motor amps, conveyor speed, and mode of operation (with or without belt sequence active). It also provides a login/logout access and is the only screen accessible without a password. After log in, four additional screens are available: speed “PRESETS”, operating “STATUS”, operational “OPERATIONAL TIMERS”, and material “JAM TIMERS” .

Fig. 14: “OVERVIEW SCREEN”

________________________________________________________________ 5.6 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________ Operation “STATUS SCREEN”

The operating “STATUS SCREEN” (Fig. 15) displays the conveyor speed, hydraulic system oil pressure, vacuum pressure, electric motor three phase amperage, and line voltage. To return to the “OVERVIEW SCREEN” from the “STATUS SCREEN”, press “F1”.

Fig. 15: “STATUS SCREEN”

“PRESET SCREEN”

The “PRESET SCREEN” (Fig. 16) allows access to the preset breaker shaft speed designations for low, medium and high speeds. To return to the “STATUS SCREEN” from the “PRESET SCREEN”, press “F1”. The timer screens can be accessed from the “PRESET SCREEN”.

Fig. 16: “PRESET SCREEN”

______________________________________________________________ A6474X389 REV 0 5.7

Operation _______________________________________________________ “OPERATION TIMERS SETUP SCREEN”

The “OPERATION TIMERS SETUP SCREEN” (Fig. 17) provides access to the breaker idle shutdown, the start-up warning horn, and conveyor run timers.

The “OVERVIEW SCREEN”, “SPEED PRESET” and “MATERIAL JAM TIMER” screens can be accessed from the “OPERATION TIMERS” screen.

Fig. 17: “OPERATION TIMERS SETUP SCREEN”

“JAM TIMERS SETUP SCREEN”

The “JAM TIMERS SETUP SCREEN” (Fig. 18) provides access to the breaker overload preset amps, beaker overload delay, conveyor slow backup, and conveyor slow forward timers. The “OVERVIEW SCREEN”, “PRESET SCREEN” and “OPERATION TIMERS SETUP SCREEN” can be accessed from this screen.

Fig. 18: “JAM TIMERS SETUP SCREEN”

________________________________________________________________ 5.8 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________ Operation panic strip

The panic strip (Fig. 19) is used to break the control circuit in emergency situations. Striking with a small amount of force will actuate the panic strip. All machine functions immediately shut down. There are two panic strips located on the machine; one each on the left and right sides.

fire suppression actuator

The machine fire suppression (remote) actuator (Fig. 19) is used to active the fire suppression system on the machine. The system is pneumatically actuated and extinguished with dry chemicals. To activate, pull the safety pin and strike the plunger, labeled “PUSH”. Immediately after being struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellant after it has been actuated. There are two actuators located on the machine; one each on the right and left sides.

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

Fig. 19: Fire suppression actuators and panic strips

Fire suppression actuator location Panic strip

Panic strip

Fire suppression actuator location

______________________________________________________________ A6474X389 REV 0 5.9

Operation _______________________________________________________ Valve bank The hydraulic functions on the machine are controlled via a valve bank (Fig. 20). The valve bank is equipped with a neutral start mechanism that prevents the machine from starting unless in the down position (the two halves of the magnetic switch are in full contact). The valve bank handles are now centered and locked in the neutral position.

NOTICE! Once a hydraulic control valve handle other than “TANK FILL” is released by the operator, the lever will automatically return to the centered (neutral) position. The “TANK FILL” lever must be manually returned to the centered (neutral) position.

“LEFT TRAM”

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

“RIGHT TRAM”

The second lever from the operator’s left controls the right side tram 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 forward in a straight direction (towards the receiving end), push both tram control levers forward.



To tram the machine in a straight direction in reverse (towards the discharge end), pull back on both tram control levers.



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



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

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

________________________________________________________________ 5.10 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________ Operation “LH FRAME LIFT”

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

“RH FRAME LIFT”

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

“FRAME TILT”

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

“TANK FILL”

The sixth lever from the operator’s left, “TANK FILL”, controls the machine’s hydraulic oil power jet fill function.

WARNING! The “TANK FILL” lever is the only lever on the valve bank that does not spring return to neutral when released. When not in use, the valve should be manually returned to the neutral position.

“PRIMARY SYSTEM PRESSURE”

The “PRIMARY SYSTEM PRESSURE” gauge (Fig. 13) provides a pressure reading for each active function on the machine.

______________________________________________________________ A6474X389 REV 0 5.11

Operation _______________________________________________________ Fig. 20: Hydraulic valve bank 9

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1. Conveyor sections (solenoid controlled) 2. “LEFT TRAM” section 3. “RIGH TRAM” section 4. “LH FRAME LIFT” section 5. “RH FRAME LIFT” section 6. FRAME TILT” section 7. TANK FILL/AUX V.B” section 8. “PRIMARY SYSTEM PRESSURE” 9. Neutral start mechanism 10. Magnetic switch

________________________________________________________________ 5.12 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________ Operation To operate the hydraulic oil “TANK FILL”: 1. Clean suction hose attached to the hydraulic power fill motor, located below the hydraulic oil tank (Fig. 21).

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

3. Position the “TANK FILL” lever in the “TANK FILL” position.

4. Turn the handle of the ball valve to the open position. The handle should now be inline with the hydraulic hose to which it is attached. Oil from the valve bank will now drive the power fill motor and a suction force will be created in the suction line. Oil from the new oil supply will be drawn through the power fill motor to the hydraulic oil tank.

5. Once the tank is filled to the desired level, close the ball valve and pull the power fill lever on the valve bank to the neutral (center) position.

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

7. Remove the suction hose from the new oil supply.

8. Clean and install hose plug into suction hose. Store the suction hose on top of the oil tank. power fill ball valve

The power fill ball valve (Fig. 21) is located below the hydraulic oil tank is used to open the hydraulic flow to the power fill pump. To operate the power fill, the ball valve must be opened, handle in line with the hydraulic line. Then the control handle on the primary valve bank (6th handle from the operator’s left is moved to the “POWER FILL” position (handle pushed forward). To de-energize the power fill pump, move the control lever to the centered position and turn ball valve handle to closed position.

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

______________________________________________________________ A6474X389 REV 0 5.13

Operation _______________________________________________________ Fig. 21: Power fill

Power fill ball valve

hydraulic oil level sight glass/thermometer

Power fill pump (flow divider)

The hydraulic oil level sight glass (Fig. 22) is located on the hydraulic oil tank.

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

The sight glass also is a thermometer that measures the temperature of the hydraulic oil in the tank.

Fig. 22: Hydraulic oil level sight glass/thermometer

Sight glass/thermometer

________________________________________________________________ 5.14 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________ Operation “AUTO” (conveyor auto) starting procedure The feeder breaker is normally operated in “AUTO” mode. While in “AUTO” mode, the belt sequence switch is active: the outby belt must be running for the feeder breaker’s conveyor chain to operate.

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° F (1° C). 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.

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

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

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

3. Check conveyor for any foreign material or objects.

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

5. Set main circuit breaker (located at the starter enclosure) by first moving the circuit breaker lever down past “OFF” to the “RESET” position and then all the way up to the “ON” position.

6. Turn the “AUTO/OFF/MAN” selector switch located on the cover of starter enclosure to the “AUTO” position.

7. Engage the “SYSTEM START” pushbutton located on the cover of the starter enclosure to start the conveyor/breaker motor.

______________________________________________________________ A6474X389 REV 0 5.15

Operation _______________________________________________________ Conveyor manual, “MAN”, starting procedure If the machine needs to be operated while the outby belt is off (belt sequence switch by-passed), start the machine in “MAN” mode.

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° F (1° C). 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.

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

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

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

3. Check conveyor for any foreign material or objects.

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

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

6. Turn the “AUTO/OFF/MAN” selector switch located on the cover of starter enclosure to the “MAN” position.

7. Engage the “SYSTEM START” pushbutton located on the cover of the starter enclosure to start the conveyor/breaker motor.

________________________________________________________________ 5.16 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________ Operation Shutdown procedures 1. Allow the machine to run until the hopper is empty. Continue to run the machine until all material that has been carried back into the return line has been cleaned out.

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

To shutdown the feeder breaker in “AUTO” OR “MANUAL” mode: 2. Engage the “SYSTEM STOP” pushbutton located on the starter enclosure.

This will stop the conveyor/breaker motor.

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

The machine can also be shutdown in emergency situations using either panic strip or the “E-STOP” button on the starter enclosure. Activating any of these shutdown devices will open the safety control relays, “SR1” and “SR2”. Power will still be on the machine and the machine can be restarted using normal starting procedures.

To shutdown the feeder breaker using a panic strip: There are two (2) panic strips located on feeder breaker: one on the left side and one on the right side of the machine. Striking either panic strip with a small amount of force will shutdown the electric motor, stopping all machine fucntions.

To shutdown the feeder breaker using the “E-STOP” button: There is an emergency stop, “E-STOP”, button located on the cover of the starter enclosure. Pushing the “E-STOP” button will shutdown the electric motor, stopping all machine functions.

______________________________________________________________ A6474X389 REV 0 5.17

Operation _______________________________________________________ Start up and tramming with hydraulic control levers 1. Turn the “FOR/OFF/REV” selector switch located on the cover of the starter enclosure to the “OFF” position.

2. Turn the “CONV/OFF/TRAM” selector switch located on the cover of the starter enclosure to the “TRAM” position.

3. Turn the “AUTO/OFF/MAN” selector switch located on the cover of starter enclosure to the “MAN” position.

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

5. Engage the “SYSTEM START” switch on the front of the starter enclosure.

6. If the valve handles are installed, lift the neutral start valve handle guard.

Make sure to lift the guard all the way back so that the guard will not fall on the operator’s hands.

7. Hydraulic functions can now be engaged from the remote control (if equipped) or the valve bank.

The machine can now be trammed.

________________________________________________________________ 5.18 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________ Operation Conveyor operation - forward 1. Start the machine in either “AUTO” or “MAN” mode (see Starting procedures in this chapter).

2. Turn the “CONV/OFF/TRAM” selector switch located on the cover of the starter enclosure to the “CONV” position.

3. Push the “SYSTEM START” button to start the convyeor/breaker motor.

4. Turn the “FOR/OFF/REV” selector switch located on the cover of the starter enclosure to the forward (“FOR”) position.

Conveyor operation - reverse 1. Turn the “FOR/OFF/REV” selector switch located on the cover of the starter enclosure to the reverse (“REV”) position. The conveyor chain will run in reverse as long as the switch is in the reverse, “REV”, position. To avoid jamming the conveyor, however, the coveyor should only be jogged in reverse.

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.

Conveyor jam - clear The PLC constantly monitors the amperage of the electric motor. If the amperage exceeds 125% of full motor torque breakdown, the PLC will stop the conveyor, run it in reverse for three seconds, and then run it forward at 20% speed.

If the motor continues to run at a maintained high amperage condition, the PLC will repeat the stop/reverse/20% forward cycle three times. If, at any time during the cycle, the amperage drops to normal amperage, the PLC will return to normal conveyor operation. If, after the third attempt, the high amperage condition still exists, the machine will shut down and a “BIG JAM SHUTDOWN ALARM” will be displayed on the panel view. The operator must then start the machine and manually reverse the conveyor to clear the large obstruction.

______________________________________________________________ A6474X389 REV 0 5.19

Operation _______________________________________________________ Control system operation The following parameters affect the operation of the machine as indicated: Breaker underspeed If the pick break sensor does not pick up within ten seconds of the breaker motor starting, the control system will shutdown the breaker motor and a “BREAKER UNDERSPEED ALARM” will be displayed.

Breaker motor overload If the breaker motor current exceeds a preset value, the control system will shutdown the machine and the “MOTOR OVERLOAD ALARM” will be displayed.

High oil temperature There is a temperature sensor located in the hydraulic oil tank. If the hydraulic oil temperature exceeds 165° F (74° C), the control system will shutdown the machine and the “OIL TEMPERATURE ALARM” will be displayed.

Low oil level There is an oil level float switch located in the hydraulic oil tank. If the hydraulic oil level falls below a preset level for more than three seconds, the control system will shutdown the machine and the “OIL LEVEL ALARM” will be displayed.

High oil pressure There is a pressure transducer located in the valve bank inlet line. If the hydraulic oil pressure exceeds 4,800 psi (330 bar) for more than three seconds, the control system will shutdown the machine and the “HI OIL PRESS ALARM” will be displayed.

Low pump suction There is a vacuum transducer located in the suction line fitting of the pump suction port. If the vacuum suction in the main suction line in the hydraulic oil tank is less than a preset value for five seconds, the control system will shutdown the machine and the “LOW VACUUM PRESS ALARM” will be displayed.

Emergency stop If a panic strip, an emergency stop push button, or the emergency stop at the starter enclosure is activated, the machine will shutdown and the “E-STOP ALARM” will be displayed.

Conveyor jam shutdown The control system recognizes that the conveyor is jammed based upon the electric motor amp reading. There is a clearing sequence in the PLC (see Conveyor operation). If the machine fails to clear a jam after three attempts (see Conveyor operation in this section), the control system will shutdown the machine and a “MATERIAL JAM ALARM” will be displayed.

________________________________________________________________ 5.20 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________ Operation Electric motor contactor If the auxiliary switch on the electric motor contactor fails to close within one second of the main contactor closing, the control system will shutdown the machine and the “MOTOR CONTACTOR ALARM” will be displayed.

Return line hydraulic oil filter If the dirt indicator on the end of the hydraulic oil return line filter closes for more than five second, indicating high pressure across the filter, the “RETURN OIL FILTER ALARM” will display. The return line hydraulic oil filter element needs to be changed.

Pressure line hydraulic oil filter If the dirt indicator on the end of the hydraulic oil pressure line filter closes for more than five second, indicating high pressure across the filter, the “SUPPLY OIL FILTER ALARM” will display. The pressure line hydraulic oil filter element needs to be changed.

Tram control magnet switch If the neutral start guard is not in place on the primary valve bank when a motor is start is attempted, the control system will not allow the motor to start and the “VALVE GUARD OPEN ALARM” will be displayed.

Breaker shaft idle shutdown timer If, when the conveyor is running, a tilt switch is not engaged within a 2-1/2 minute time period, the control system will shutdown the conveyor. If tilt switch is not engaged within the next fifteen (15) minute time period, the control system will shut down the electric motor. Note: both timers are adjustable within the PLC Conveyor control There is a mag pulse sensor located on the head shaft that counts how many revolutions per minute the head shaft turns. This information is fed to the PLC where it is converted to speed (meters per minute (mpm and feet per minute (fpm)) and is displayed as conveyor speed.

The conveyor chain speed is controlled by the PLC based upon input to the PCL from the belt scales. The PLC will process the input signal and send an output signal to the electrical solenoids on the conveyor sections of the primary valve bank. The electrical solenoids will operate a spool within the hydraulic valve sections that will regulate flow to the hydraulic motor on the conveyor drive system. The goal of conveyor speed regulation is to maintain an even and steady flow of material into the central bunker of the mine.

The machine is equipped with two timers that will partially and then completely shutdown the machine. The purpose of these timers is to reduce component wear and to save electrical energy consumption during idle time (feeder breaker is not being loaded).

______________________________________________________________ A6474X389 REV 0 5.21

Operation _______________________________________________________ The first conveyor timer is reset every time the remote tilt switch is displaced 15° past vertical. The timer operates a set of contactors that will open and remove power from the solenoids on the conveyor sections of the primary valve bank. The electric motor and the breaker shaft are still powered on. This timer is adjustable in the PLC and has a default value of 2-1/2 minutes. The conveyor can be restarted by activating the tilt switch. The PLC will send current to the conveyor solenoids in such a manner as to allow the pump to ramp back up to full flow.

The second time will shutdown the electric motor if the remote tilt switch s not activated within a preset amount of time. The default value is 15 minutes and is adjustable in the PLC. If this timer expires and the electric motor is shut down, the machine must be restarted from the starter enclosure.

The PLC is constantly monitoring the amperage of the electrical motor. If the amperage exceeds 125% of full motor amps, the PLC assumes there is a jam and initiates a jam clearing reverse/forward conveyor cycle (see Conveyor jam clear in the conveyor operation procedure section of this manual).

________________________________________________________________ 5.22 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

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

The machine receives electrical power through a heavy-duty trailing cable. Be sure that the box connector is correctly identified and is securely connected; also check that the cable entrance is in good mechanical condition. Walk along the trailing cable from the power center to the feeder breaker and check the condition of the trailing cable. Give special attention to points most apt to cause damage, such as corners, intersections, and where cable may be run over by moving equipment. Never use trailing cable with exposed wires or splices as it may heat up or spark under load.

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

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

______________________________________________________________ A6474X389 REV 0 5.23

Electrical system _________________________________________________ Fig. 23: Major electrical component locator

3

5 8 6

2

4 8

1

1.

2.

3.

4.

Head shaft tachometer Electric motor Breaker shaft underspeed sensor Starter enclosure

5. Low oil switch 6. High temperature switch 7. Tilt switch (2) (not shown - attached to 50 feet (15 meters) of cable and hung in mine entry) 8. Panic strip (2)

________________________________________________________________ 5.24 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

Electrical system _________________________________________________ head shaft tachometer

The head shaft tachometer is mounted on the left hand hydraulic conveyor motor and monitors the speed of the head shaft. The PLC converts the rpm reading to feet per minute and displays the chain speed on the PLC display.

electric motor

The electric motor is a 150 kW, 690 VAC, 3 phase, 50 Hz, 1550 rpm, totally enclosed, fan cooled non-explosion proof electric motor.

breaker shaft underspeed sensor

The breaker shaft underspeed sensor is mounted on the breaker shaft assembly and monitors the speed of the breaker shaft. If the breaker shaft speed falls below a preset value, the electric motor will shut off.

starter enclosure

low oil switch high temperature switch

The starter enclosure houses the machines electrical controls.

The low oil switch is mounted inside the oil tank. The electric motor will shut off if the oil level in the tank falls below a preset value.

The high temperature switch is mounted on the wall behind the oil tank on the left side of the machine and will shut down the machine if the hydraulic oil temperature exceeds 165° F (74° C). The temperature probe is located in the oil tank.

tilt switches

There is a tilt switch located on each side of the machine. The switches are equipped with 50 feet (15 meters) of cable and are placed in the mine entry for the load vehicle operator to activate upon approach to the feeder breaker.

When the switch is tilted past 15° vertical, the conveyor will start. If the switch is not tilted within 2-1/2 minutes, the conveyor will shut down. If the switches are not tilted within 15 minutes, the electric motor will shut down and the machine will have to be restarted from the starter enclosure.

panic strips

There is a panic strip located on each side of the machine. Activating the panic strip will open a control relay, shutting down the machine.

________________________________________________________________ 5.25 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

Electrical system _________________________________________________ Starter enclosure The starter enclosure houses the primary electrical control components.

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

There are operational controls located on the front of the starter enclosure (Fig. 24). For control descriptions, see the Controls and Indicators section in this chapter.

Fig. 24: Starter enclosure 1

2

5 1.

2.

3.

4.

5.

6.

7.

8.

9.

“MAN/OFF/AUTO” Panel view display “CONV/OFF/TRAM” “FOR/OFF/REV” “SYSTEM START” “E-STOP” “SYSTEM STOP” “ALARM RESET” Circuit breaker reset handle

6

3

7

4

8

9

________________________________________________________________ 5.26 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

________________________________________________ Electrical system Back panel The back panel (Fig. 25) is accessed by removing the swing panel retaining bolt located in the upper left hand corner of the swing panel and swinging the panel out.

Note that component locations are typical. Always consult the parts book for your machine to verify locations.

Fig. 25: Back panel 1

4

1.

2.

3.

4.

5.

6.

7.

2

5

3

6

7

Transformer, “T1” Fuses, 6A, “FU-1” and “FU-2” Vacuum contactor, “M1” Voltage transducer, “TDCR2” Overload relay, “OL1” Current transducer, “TDCR1” Current transformer (3)

______________________________________________________________ A6474X389 REV 0 5.27

Electrical system _________________________________________________ “T1” control transformer

The “T1” control transformer reduces the incoming voltage from 690V to 120V.

“FU1” and “FU2”

“FU1” and “FU2” are 6A fuses located on each leg of the power to transformer “T1”

“M1” vacuum contactor

“M1” is the motor vacuum contactor. When power is on the machine and the “SYSTEM START” button is pressed, “M1” is closed and the motor starts.

current transformers

The three current transformers read the current in each leg of the motor power supply and send a reduced current (40:1) to the current transducer, “TCDR1”.

“TDCR1” current transducer

The motor current transducer, “TCDR1”, receives current signals from the current transformers. It reduces the current to a 4-20 mA signal to send to the motor overload relay, “OL1”.

“OL1”

“OL1” is the overload relay for the motor. If the current signal received by “OL1” from “TDCR1” exceeds the full load amp rating of the motor, “OL1” will open and the motor will shut down.

“TDCR2” voltage transducer

The line voltage transducer, “TDCR2”, monitors the 120V control circuit voltage and sends a reduced signal (4-20 mA) to the controller.

________________________________________________________________ 5.28 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

________________________________________________ Electrical system Swing panel The swing panel (Fig. 26) is accessed by opening the cover on the enclosure.

Immediately adjacent to the swing panel is the main circuit breaker, “MCB. Note that component locations are typical. Always consult the parts book for your machine to verify locations.

Fig. 26: Back panel, typical 12

11

13

1.

2.

3.

4.

5.

6.

7.

8.

9.

Ethernet processor Power supply, 24VDC Digital input module Digital input module Digital output module Analog input module Analog output module Ethernet switch Power supply, “PS2”

10

14

9

15

8

16

17

18

7

6

19

20

10. Power supply, “PS1” 11. Amplifier card, “AMP-2” 12. Amplifier card, “AMP-1” 13. Tape switch relay, “TSR” 14. Safety relay, “SR” 15. Safety relay, “SR1” 16. Safety relay, “SR2” 17. Control relay, “CR1” 18. Control relay, “CR2”

5

21

4

3

22

2

23

1

24

25

19. Control relay, “CR3” 20. Control relay, “CR4” 21. Control relay, “CR5” 22. Fuse, 2amp, “FU3” 23. Fuse, 2amp, “FU4” 24. Circuit breaker, “CB” 25. Main circuit breaker, MCB”

______________________________________________________________ A6474X389 REV 0 5.29

Electrical system _________________________________________________ Ethernet processor power supply digital input modules

The Ethernet processor is the machine control system.

The 24VDC power supply is the power supply for the control system.

There are two 16 point, 24VDC digital input modules that receive the inputs from the following: Module 1: Safety relay status, motor overload status, outby belt sequence switch, vacuum contactor switch, high oil temperature switch, low oil level switch, neutral start guard, pick breaker rpm proximity sensor, conveyor sprocket rpm proximity sensor, and the conveyor re-start tilt switch Module 2: Manual/auto switch, tram/conveyor switch, conveyor forward/reverse switch, and the fault reset button.

digital output module

The 8 point, 24VDC digital output module sends output to the breaker contactor control relay, the tram selection solenoid control relay, the conveyor selection control relay, the conveyor reverse solenoids, the warning siren control relay, and the fault reset pushbutton indicator.

analog input module

The 8 channel, 24VDC analog input module receives input from the motor transducer, “TDCR1”, the hydraulic oil pump pressure transducer, the hydraulic oil pump suction line vacuum transducer, and “TDCR2” (line voltage transducer).

analog output module

The analog output module sends output to the electronic amplifier cards, “AMP1” and “AMP-2”.

Ethernet switch, “ENET”

The Ethernet switch, “ENET”, is the “traffic control center”. It manages the transmission of data packets from the various control system components.

power supply, “PS1”

“PS1” is the 24VDC power supply for the tram and conveyor solenoids, the conveyor forward and reverse solenoids, and the amplifier cards.

power supply, “PS2”

“PS2” is the 24VDC power supply for the input and output modules, the warning siren, and the tape switch and safety relays.

amplifier cards, “AMP1”/“AMP2”

The amplifier cards, “AMP1” and “AMP2” drive the conveyor speed solenoids.

tape switch interface relay, “TSR”

The tape switch interface relay, “TSR”, reads input from the tape switches and sends a signal to the safety relay.

safety relay, “SR”

Relay “SR” is the safety relay for the tape switch panic strips.

safety relays, “SR1” and “SR2”

Relays “SR1” and “SR2” are the safety relays for the conveyor and tram solenoids.

________________________________________________________________ 5.30 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

________________________________________________ Electrical system control relay, “CR1”

“CR1” is the pick breaker contactor control relay.

control relay, “CR2”

“CR2” is the tram selection solenoid control relay.

control relay, “CR3”

“CR3” is the conveyor selection solenoid control relay.

control relay, “CR4”

“CR4” is the conveyor reverse solenoids control relay.

control relay, “CR5”

“CR5” is the warning siren control relay.

fuse, “FU3”

“FU3” is a 2 amp fuse on the 24VDC power supply, “PS1”.

fuse, “FU4”

“FU4” is a 2 amp fuse on the 24VDC power supply, “PS2”.

circuit breaker, “CB1”

“CB1” is a 13 amp circuit breaker on the 24VDC side of transformer “T1” that protects the control system from over current.

circuit breaker, “MCB”

“MCB” is the 200 amp main circuit breaker. There is no power on the machine until “MCB” is closed.

______________________________________________________________ A6474X389 REV 0 5.31

Electrical system _________________________________________________

________________________________________________________________ 5.32 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

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

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

WARNING! This section is intended only to familiarize the user with the hydraulic components of the feeder breaker. All hydraulic maintenance should only be performed 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.

______________________________________________________________ A6474X389 REV 0 5.33

Hydraulic system_________________________________________________ Major hydraulic components valve bank

The valve bank is used to control the machine’s conveyor 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.

enabler valve

The conveyor/tram enabler valve is located behind the valve bank. The valve is used to disable the conveyor sections of the valve bank when the “CONV/OFF/ TRAM” switch is in the “TRAM” position or to disable the tram, tilt and lift cylinder, and jet fill sections of the valve bank when the “CONV/OFF/TRAM” switch is in the “CONV” position by blocking the load sense signal from the valve section intended to be non-functional.

system pressure gauge

The system pressure gauge will display the system pressure for the active function.

open loop load sense

The open loop load sense pump is a part of the power unit and supplies hydraulic fluid to all hydraulic functions on the machine.

piggyback gear pump

The piggyback gear pump is bolted to the rear of the open loop load sense pump. This pump supplies hydraulic fluid to the main pump and the conveyor motor for cooling purposes. This pump also supplies hydraulic fluid to drive the fan motor on the hydraulic oil/air heat exchanger, if equipped.

return filter pressure filter

power fill, hydraulic oil

air/oil heat exchanger

The return filter is used to filter fluid on the return side of the hydraulic circuit and as the power fill filter.

The pressure filter is used to filter fluid on the pressure side of the hydraulic circuit.

The hydraulic oil power fill system consists of a ball valve and fill pump. This power fill function on the valve bank must be engaged before opening the ball valve. The tank fill pump is a flow divider that is hosed to run backwards from normal flow divider operation and is used to replenish oil supply. It is capable of delivering approximately 5 gallons of fluid per 30 seconds.

The air/oil heat exchanger is used to cool the hydraulic fluid during tramming and conveying. It is equipped with a hydraulic motor driven fan.

hydraulic oil tank

The hydraulic oil tank has a 135 gallon capacity. The hydraulic oil temperature and level is monitored by a temperature probe and float switch. The tank is equipped with a sight glass and thermometer.

frame lift cylinders

The frame 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.

frame tilt cylinders

The frame 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. The cylinders are controlled by one section of the primary valve bank.

________________________________________________________________ 5.34 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

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

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

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

conveyor drive motors

The conveyor motors drive the conveyor reducers, which in turn drive the conveyor chain.

Fig. 27: Major hydraulic component locator Hydraulic oil tank

Air/oil heat exchanger

Conveyor drive motor

Lift cylinder Tilt cylinder

Pressure filter

Valve bank Enabler valve

Torque hub Tram motor

Return filter

Open loop load sense pump

Gear pump

______________________________________________________________ A6474X389 REV 0 5.35

Hydraulic system_________________________________________________ Fig. 28: Hydraulic schematic The hydraulic schematic shown if Fig. 31 is for reference only. Always consult the schematic in the Bucyrus parts book that shipped with your machine.

________________________________________________________________ 5.36 Bucyrus – Model GH-MFBHM-48CDH 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 assemblies The feeder breaker is trammed by two (2) hydraulically driven crawlers (Fig. 29) 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 (idler) assembly located on the opposite end of the crawler assembly. The take-up roller 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.)

______________________________________________________________ A6474X389 REV 0 5.37

Mechanical assemblies____________________________________________ Fig. 29: Crawler assembly main components 2 1

3

4

11

10 9

5

8 7

6

1.

2.

3.

4.

5.

6.

Crawler frame Tram motor Torque hub Crawler drive sprocket Crawler pad assembly Removable side plate

7. Take-up access cover 8. Shims, chain take-up 9. Grease take-up cylinder 10. Shim retainer plate 11. Crawler take-up assembly

________________________________________________________________ 5.38 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

___________________________________________ Mechanical assemblies Conveyor chain The feeder breaker is equipped with a conveyor chain assembly (Fig. 30) 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. 30: Conveyor chain components

1 3

2

1.Roll pin 2.Flight bar 3.Chain link section

______________________________________________________________ A6474X389 REV 0 5.39

Mechanical assemblies____________________________________________ Conveyor chain grease take-up The feeder breaker is equipped with two (2) conveyor chain grease take-up assemblies (Fig. 31) that provide ease of adjustment for the conveyor chain. The take-up assemblies provide constant tension on the tail shaft around which the conveyor chain rides at the receiving end of the machine. (See Conveyor chain adjustment procedure in the Adjustment Procedure section of this chapter) Fig. 31: Grease take-up main components (typical) 1 2

3 4

3

1.

2.

3.

4.

Right side of machine

Stop valve (2) Grease fitting (2) Shim storage (2) Take-up cylinder (2)

Left side of machine

________________________________________________________________ 5.40 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

___________________________________________ Mechanical assemblies Head shaft assembly The feeder breaker is equipped with a head shaft (Fig. 32) located on the discharge end of the conveyor. The head shaft is driven by two hydraulic motors mounted to the head shaft through gear boxes.

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

Fig. 32: Head shaft assembly main components

8 7

9

2

1

3 11

10 4 5 6

7

8 1.

2.

3.

4.

5.

Bearing (2) Sprocket (2) Head shaft Splined adapter (2) Retainer (2)

6. Bolt (2) 7. Gear box (2) 8. Hydraulic motor (2) 9. Reaction pin (2) 10. Clevis (2) 11. Reaction clevis (2) ______________________________________________________________

A6474X389

REV 0

5.41

Mechanical assemblies____________________________________________ Power unit The power unit (Fig. 33) consists of a 200 HP, 690VAC, 50 hz electric motor coupled to a load sense pump. The power unit has been assembled as a unit and can be removed as a unit or as individual components (see Replacement of wear parts section of this chapter).

Fig. 33: Power unit components 2 1

3

4 5

6

7 8 9 10 11

12

1.

2.

3.

4.

5.

6.

Sprocket Gear reducer Fan shroud Taperlock bushing Coupling Taperlock bushing

7. Coupling cover 8. Electric motor, 200 hp 9. Connecting tube 10. Rotex coupling 11. Load sense pump assembly 12. Mounting tray

________________________________________________________________ 5.42 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

___________________________________________ Mechanical assemblies Tail shaft The feeder breaker is equipped with a tail shaft (Fig. 34) 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. 34: Tail shaft components 1

2

3

4

8 9

10

1.

2.

3.

4.

5.

Key (2) Set screw (2) Slide plate Adapter (2) Bearing (2)

7

6

5

6. Head shaft 7. Sprocket or roller (2) 8. Bearing grease exit port 9. Slide plate grease entry port 10. Bearing grease entry port

______________________________________________________________ A6474X389 REV 0 5.43

Mechanical assemblies____________________________________________ Breaker assembly The breaker assembly (Fig. 35) on the machine has a 19 inch (483 mm) or 25 inch (635 mm) pick circle with a five point star arrangement. It has a 8 inch (203 mm) shaft diameter turned down to 6.1875 inches (157 mm) through the bearings.

Fig. 35: Breaker assembly main components

24 19 20

16

25

27

29

31

22

15 13 9

14

10

26

6 5

17

18

21

28

30

23

11 12 8 7 1

2

3

4

1. Retainer cap 2. Shear hub 3. Seal housing 4. Seal 5. Spiral retaining ring 6. O-ring 7. Side plate 8. Bearing housing 9. Sealing ring 10. Bearing

11. O-ring 12. Bearing retaining ring 13. Seal 14. Bearing backing ring 15. Bit 16. Breaker shaft 17. Bearing backing ring 18. Seal 19. Bearing retaining ring 20. O-ring

21. Bearing 22. Sealing ring 23. Bearing housing 24. Side plate 25. O-ring 26. Spiral retaining ring 27. Seal housing 28. Breaker end cap 29. Underspeed sensor mount 30. U-bolt

________________________________________________________________ 5.44 Bucyrus – Model GH-MFBHM-48CDH 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 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 manual.

Before maintenance Please observe the following: 

Shutdown the machine on level ground.



Disconnect the electrical power. The circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source.

Follow all Federal and mine safety regulations for lockout/tagout procedures.

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

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

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

______________________________________________________________ A6474X389 REV 0 5.45

Maintenance_____________________________________________________ ■

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

■

Do not perform maintenance on a hydraulic cylinder while there is a load resting on the hydraulic cylinder. Loads must be securely blocked if maintenance is to be performed with a load on the hydraulic cylinder.

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

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

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

■

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

■

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

■

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

________________________________________________________________ 5.46 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ 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 1: Lubrication and maintenance schedule Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

20 21

22 23

Description Every shift Head shaft bearings Breaker bearings Tail shaft and slide tube bearings Hydraulic oil level (check) Breaker bits Weekly Pressure filter Return filter Breaker shaft underspeed sensor Crawler track take-up bearings Conveyor chain tension Breaker shaft drive chain tension Breaker shaft drive reducer (oil level) Conveyor drive reducer (oil level) Shear hub (grease) Fasteners (nuts, bolts and screws) Electrical cables, conduits and glands Hydraulic hoses and connections Monthly Crawler anchor pin (s) Electric motor shaft bearing (grease)

Breaker shaft drive reducer shaft seals (grease) Torque hub (check oil level)

24

Hydraulic oil tank breather vent Crawler chain tension Every 200 hours of tram operation Torque hub (change oil)

25

Every 1000 hours *Breaker shaft drive reducer

26

*Conveyor reducer oil

27

Every 6 months Hydraulic oil tank (change)

Places 2 2 4 1 Inspect 1 1 Inspect 2 Inspect Inspect Check Check 1 Inspect Inspect Inspect 2 2

2 2

Lubricant

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

Spec. 100-3

Spec. 100-6 Spec. 100-6 Spec. 100-3

Spec. 100-3 Spec. 100-14 or Spec. 100-16 Spec. 100-3 Spec. 100-2 or Spec. 100-13

Inspect Check 2

Spec. 100-2 or Spec. 100-13

Analyze/ change Analyze/ change 1

Spec. 100-1

* Initial oil change to be done after first 500 hours of operation.

______________________________________________________________ A6474X389 REV 0 5.47

Maintenance_____________________________________________________ Table 2: Lubricants: Fluids and capacities Location Hydraulic oil tank Breaker drive reducer Grease points (except electric motor) Grease points (electric motor)

Specification Spec. 100-1 Spec. 100-6 Spec. 100-3

Approximate capacity 135 gal (511 L) 15 gal (57 L) As required

Spec. 100-14 or Spec. 100-16

Two pumps per month (hand pump only)

________________________________________________________________ 5.48 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance Fig. 36: Lubrication chart 3 (bearing)

3 (bearing)

10 ( manifold)

10 ( shims & cylinder)

5 2 (bearing)

9 8

12, 25 20 (seal)

3

2 (bearing)

2

14 4, 27

1

11 20 (seal)

23

22

6 21, 24

19 (bearing) 20 (manifold)

7

19 (manifold)

18 19 (bearing)

13, 26

1 (bearings) ______________________________________________________________ A6474X389 REV 0 5.49

Maintenance_____________________________________________________ Specific lubrication and maintenance procedures WARNING! The feeder breaker is equipped with lubrication manifolds to allow the remote greasing of bearings. It is important to check the bearing to ensure it is receiving adequate lubrications. Running the machine with inadequately lubricated bearings may result in premature bearing failure and/or machine damage.

Every shift head shaft bearings

Lubricate the feeder breaker head shaft bearings with Spec. 100-3 through the grease fittings located on the lubrication panel (Fig. 37). Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

breaker bearings

Lubricate the breaker bearings with Spec. 100-3 through the grease fittings located on the lubrication panel (Fig. 37). Pump grease into the fittings until new grease can be observed coming out of the bearing return lines. It is recommended that a weekly inspection of the bearings and grease hoses be carried out to ensure bearings are actually receiving grease.

tail shaft and slide tube bearings

Lubricate the feeder breaker tail shaft and slide tube bearings with Spec. 100-3 through the lubrication panel (Fig. 37). Pump grease into the four (4) fittings until new grease can be observed coming out of the tail shaft return lines.

Fig. 37: Lubrication manifold

1

1.

2.

3.

4.

5.

2

3

4

5

Tailshaft and slide tube bearing grease fittings Breaker bearing grease fittings Head shaft bearing grease fittings Tailshaft grease return lines Breaker bearing grease return lines

________________________________________________________________ 5.50 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance hydraulic oil tank

Check the hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 38). The oil level should not be allowed to drop below the bottom of the sight glass. If the hydraulic oil level is low, add hydraulic oil (Spec.

100-1). To add oil via the power fill, reference the following procedure.

WARNING! The “TANK FILL/AUX VB” lever is the only lever on the valve bank that does not spring return to neutral when released. When not in use, the valve should be manually returned to the neutral position. Failure to do so could result in machine overheating if the power fill pump is left energized.

To operate the power fill (Fig. 39): 1. Clean suction hose attached to the hydraulic power fill motor, located on top of the oil tank.

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

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

4. Position the “TANK FILL/AUX VB” lever in the “TANK FILL” position. Oil from the valve bank will now drive the power fill motor and a suction force will be created in the suction line. Oil from the new oil supply will be drawn through the power fill motor to the hydraulic oil tank.

5. Once the tank is filled to the desired level, pull the power fill lever on the valve bank to the neutral (center) position.

6. Turn the ball valve handle 90° to close.

7. Remove the suction hose from the new oil supply.

8. Clean and install hose plug into suction hose. Store the suction hose on top of the oil tank.

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

______________________________________________________________ A6474X389 REV 0 5.51

Maintenance_____________________________________________________ Fig. 38: Hydraulic oil level check

Sight glass

Fig. 39: Power fill controls

Power fill ball valve

Power fill pump (flow divider)

Power fill valve section

________________________________________________________________ 5.52 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance breaker bits

Check the breaker bits (Fig. 40) to see if they will rotate in their holders and for damaged or missing bits. The bits may be inspected by looking into the receiving end of the machine. If bits need to be replaced, see Bit replacement in the Replacement of wear parts section of this chapter.

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

Fig 40: Breaker bits

Breaker bit

______________________________________________________________ A6474X389 REV 0 5.53

Maintenance_____________________________________________________ Weekly pressure filter return filter

The PLC monitors the dirt alarm on each filter element and will display an alarm when the filter needs to be changed. Additionally, the procedure listed below can be sued to check the dirt alarm located on the each filter (Fig. 41). Change filter element as required.

1. Start the machine.

2. Reset the filter alarm by pressing the button on the alarm.

3. Operate any hydraulic function except conveyor reverse.

4. Visually check the filter alarm. If the red indicator ring is exposed, the element must be changed.

Fig. 41: Pressure and return filter locations

Pressure filter breaker shaft underspeed sensor

Return filter

Inspect the breaker shaft underspeed sensor (Fig. 42). Remove all build-up, grease, and debris from around the sensor. The gap between the targets and the sensor end should be 1/8 to 1/4 inch.

Fig. 42: Breaker shaft underspeed sensor and targets Target (8)

Sensor

________________________________________________________________ 5.54 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 43) with Spec. 100-3. The fittings (one per side) may be reached through the slot in the end of the crawler frame on the outside of each crawler. Pump grease into the fitting until new grease can be observed coming out of the bearings.

Fig. 43: Crawler track take-up lubrication

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

conveyor chain tension

Check the conveyor chain tension. As the conveyor chain comes around the head shaft sprocket, measure the amount of swag the conveyor chain has from the bottom of the sprocket (Fig. 44). If the swag is greater than 2 inches, adjust the chain tension (see Conveyor chain adjustment procedure in this chapter).

With the machine running, visually inspect tail shaft to ensure shaft is turning and conveyor chain is not sliding across tail shaft.

Fig. 44: Conveyor chain tension measurement

______________________________________________________________ A6474X389 REV 0 5.55

Maintenance_____________________________________________________ breaker shaft drive chain

With the machine off, check the breaker shaft drive chain tension. There should be approximately 1 inch of swag in the bottom of the chain (Fig. 45). If the swag is greater or less than 1 inch, adjust the drive chain tension (see Breaker shaft drive chain adjustment procedure in this chapter).

Fig. 45: Breaker shaft drive chain tension

Drive chain (located behind guard) break shaft drive reducer oil level

With the machine setting as level as possible, check the oil level in the gear reducer using the dip stick located on the reducer (Fig. 46). If needed, add oil (Spec. 100-6).

Fig. 46: Gear reducer oil level Dip stick

________________________________________________________________ 5.56 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance shear hub

Lubricate the shear hub with Spec. 100-3 through one of the three grease fittings located on the back of the hub (Fig. 47).

Fig. 47: Shear hub lubrication

Grease fittings on back of shear hub behind the guard

conveyor reducer oil level

With the machine setting as level as possible, check the oil level in the conveyor reducer using the sight glass located on the reducer (Fig. 48). Oil should be visible in the middle of the sight glass. If needed, add oil (Spec. 100-6).

Fig. 48: Conveyor reducer oil level Sight glass

______________________________________________________________ A6474X389 REV 0 5.57

Maintenance_____________________________________________________ fasteners

The feeder breaker is continually subjected to shock loading and vibration, therefore, 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 and glands

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

Replace as required.

hydraulic hoses and fittings

With the machine running, visually inspect all hydraulic hoses and fittings for signs of wear, damage or leakage. Repair or replace as required.

________________________________________________________________ 5.58 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance Monthly crawler anchor pins

Lubricate grease fittings (located in the middle of the mounting tube) on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 49). Pump grease into the fittings until new grease can be observed exiting the ends of the mounting tube.

Fig. 49: Crawler anchor pin

Anchor pin

Grease fitting

Anchor pin

______________________________________________________________ A6474X389 REV 0 5.59

Maintenance_____________________________________________________ electric motor

Lubricate the power unit electric motor with Spec. 100-14 or Spec. 100-16 through the two (2) grease fittings located on the lubrication manifold (Fig. 50).

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.

breaker shaft drive reducer

Lubricate the reducer with Spec. 100-3 through the two (2) grease fittings located on the lubrication manifold (Fig. 50). Pump only one or two pumps of grease into each fitting using a hand grease gun.

IMPORTANT! Rapid greasing or greasing with a power grease gun can force grease inward past the seals, causing seal leaks.

Fig. 50: Electric motor and reducer grease manifold (typical) Reducer shaft seals grease fittings (2)

Motor shaft bearings grease fittings (2) Reducer shaft seal (located at back of reducer)

Motor shaft bearing

Motor shaft bearing

Reducer shaft seal

________________________________________________________________ 5.60 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance tram reducers

Check the oil level in both tram reducer torque hubs (Fig. 51): 1. Position the oil level check and fill plugs at the 3 o’clock and 12 o’clock positions so that they are accessible through the cutouts in the cover.

2. Remove the oil level check and fill plugs. When correctly filled, oil should just begin to flow from the check oil level check hole.

3. If it is necessary to add oil, add Spec.100-2 or 100-13 through the fill hole until it begins to flow out of the check hole. Do not overfill the reducer.

4. Replace the fill and check plugs.

Fig. 51: Tram reducer oil level

Fill hole

Drain hole hydraulic oil tank breather vent

Check hole

Check the breather vent element on the hydraulic oil tank (Fig. 52) and change as required.

Fig. 52: Hydraulic oil tank breather vent Breather

______________________________________________________________ A6474X389 REV 0 5.61

Maintenance_____________________________________________________ crawler chain tension

The crawler chain (track) should be checked for wear and correct tension at regular intervals. See the Crawler track adjustment procedure in the Adjustment section of this manual for instructions.

________________________________________________________________ 5.62 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance Every 200 hours of tram operation tram reducer oil change

After every 200 hours of tram operation, change the oil in the tram reducer.

1. Position the reducer so that the drain hole (Fig. 53) is at the lowest position.

2. Remove the fill and drain plugs and drain the oil from the reducer.

3. Replace the drain plug.

4. Add oil (Spec. 100-2 or 100-13) through the fill plug until oil flows from the check plug.

Fig. 53: Tram reducer oil change

Fill hole

Drain hole

Check hole

______________________________________________________________ A6474X389 REV 0 5.63

Maintenance_____________________________________________________ Every 1000 hours reducer oil analysis (breaker shaft and conveyor)

Every 1000 hours of operation, analyze a reducer oil sample. Follow mine analysis oil change guidelines to determine whether oil needs changed. If no mine standards are established, the following guidelines may be used: 

Water content is greater than 500 ppm (0.05%)



Iron content exceeds 150 ppm



Silicon (dust/dirt) is more than 25 ppm greater than silicon concentration in sample from new oil container



Copper content exceeds 75 ppm



TAN (Total Acid Number) is 50% greater than that in sample from new oil container



Viscosity changes more than ±15%

At a minimum, oil should be changed in both reducers every six months/2500 hours of operation. breaker shaft drive reducer oil change

Change the oil in the reducer (Fig. 54) as indicated by the oil analysis or every six months/2500 hours of operation.

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

1. Make sure that the machine is level.

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

3. Clean and reinstall drain plug.

4. Remove the dipstick and add lubricant, Spec. 100-6, until fluid reaches the correct level on the dipstick. When filling the reducer, allow enough time for all cavities inside the reducer to fill but take care to not overfill the reducer.

5. Install fill port plug.

________________________________________________________________ 5.64 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance Fig. 54: Reducer Dipstick location (located on top of reducer)

______________________________________________________________ A6474X389 REV 0 5.65

Maintenance_____________________________________________________ conveyor drive reducer oil change

Change the oil in the reducer (Fig. 55) as indicated by the oil analysis or every six months/2500 hours of operation.

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

1. Make sure that the machine is sitting level.

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

3. Clean and reinstall drain plug.

4. Remove the breather vent and add lubricant, Spec. 100-6, until fluid reaches the correct level in the sight glass. When filling the reducer, allow enough time for all cavities inside the reducer to fill but take care to not overfill.

5. Install the breather vent.

Fig. 55: Conveyor drive reducer Breather vent

Sight glass

Drain plug

________________________________________________________________ 5.66 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance Every 6 months hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank.

1. Clean all dirt and debris from around the fill cap, suction strainer, inspection cover, and drain plug.

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

3. Remove the suction strainer inspection cover. Clean the cover and the mating surface.

4. Remove the suction strainer, clean, and reinstall.

5. Clean and reinstall drain plug.

6. Remove the fill cap and add oil (Spec. 100-1) through the fill cap strainer until suction strainers are covered with new oil to avoid cavitating the pump with the power fill unit.

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

7. Apply RTV silicon or Loctite Gasket maker to suction cover and install cover.

8. Add oil Spec 100-1 as required via the power fill system until fluid is visible in sight glass.

To operate the power fill (Fig. 56): a. Clean suction hose attached to the hydraulic power fill motor, located on top of the oil tank. b. Remove the suction hose plug and submerge the suction hose in the new oil supply. c.

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

d. Position the “TANK FILL/AUX VB” lever in the “TANK FILL” position.

Oil from the valve bank will now drive the power fill motor and a suction force will be created in the suction line. Oil from the new oil supply will be drawn through the power fill motor to the hydraulic oil tank. e. Once the tank is filled to the desired level, pull the power fill lever on the valve bank to the neutral (center) position. f.

Turn the ball valve handle 90° to close.

______________________________________________________________ A6474X389 REV 0 5.67

Maintenance_____________________________________________________ g. Remove the suction hose from the new oil supply. h. Clean and install hose plug into suction hose. Store the suction hose on top of the oil tank.

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

9. Install fill cap.

10. Start the machine and allow the hydraulic pump to run in order to purge air from the system.

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

Fig. 56: Hydraulic oil level check

Power fill valve section

Ball valve

Suction hose

________________________________________________________________ 5.68 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

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

Prior to each shift the following points should be inspected: 

Clean and remove any foreign material from the operator’s station.



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



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



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



Check the hydraulic oil level in the feeder breaker by looking at the sight glass. The oil level should be kept at the level of the top sight glass.



Check oil level in the crawler reducers.



Inspect the condition of all electrical and hydraulic components.



Check for proper conveyor chain tensioning.



Check for proper crawler chain tensioning.



Lubricate per the lubrication schedule.



Check power input cable to power source, insuring that the voltage and breaker settings are correct.



Check that the cable handling device is intact and oriented correctly.



Check that all covers are installed and secure.



Check the tightness of all connecting elements.



Check that the neutral start mechanism is installed on the primary valve bank.

______________________________________________________________ A6474X389 REV 0 5.69

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

conveyor chain



conveyor chain flights



conveyor head shaft drive sprockets



conveyor tail shaft rollers or sprockets



conveyor wear plates



crawler pads



crawler drive sprockets



crawler idler rollers



breaker bits



breaker drive chain



breaker drive sprocket and shear hub sprocket

________________________________________________________________ 5.70 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ 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. 

Note general appearance for mechanical damage or corrosion.



Check nameplate for readability, corrosion or looseness.



Remove fill cap assembly.



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



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



Check pressure relief vent in fill opening threads for obstruction.



Make certain extinguisher is filled with free flowing Ansul dry chemical to a level of not more than 3” from bottom of fill opening.



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.



Inspect threads on cartridge and in actuator for nicks, burrs, cross threading, rough or feathered edges.

______________________________________________________________ A6474X389 REV 0 5.71

Maintenance_____________________________________________________ 

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.



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

________________________________________________________________ 5.72 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

____________________________________________________ Maintenance Recharge of fire suppression system To return your fire suppression system to service after use. 

Pull ring on safety valve to relieve actuator system pressure.



Disconnect actuation system hose at cartridge receiver/actuator assembly.



Open bursting disc union assembly.



Remove extinguisher from bracket.



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



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



Clean fill opening threads and gasket seating surface.



Secure fill cap, hand tighten.



Remove cartridge guard assembly.



Remove empty cartridge.



Make certain that receiver/actuator puncture pin is fully retracted.



Screw full charged cartridge into receiver/actuator assembly, hand tighten.



Replace cartridge guard.



Secure extinguisher in bracket.



Assemble bursting disc union, wrench tighten.



Connect actuation system hose at cartridge receiver/actuator assembly, wrench tighten.



Replace cartridge in remote actuator (dashboard type). Pull out button, insert ring pin and remove empty cartridge. Screw fully charged cartridge into actuator, hand tighten. Seal ring pin to actuator button stem with lead and wire seal.



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

______________________________________________________________ A6474X389 REV 0 5.73

Maintenance_____________________________________________________

________________________________________________________________ 5.74 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts

Instructions on the replacement of parts This section provides instructions on the removal and installation of machine components. If a component is a wear item, it is essential that it is replaced before reaching the lowest wear limit. Failure to replace wear items as noted may cause damage to other components of the machine. Inspect the wear parts at regular intervals.

Note: All drawings are for reference only. Always consult the drawing in the parts book for your machine.

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

Headshaft The headshaft transmits the torque of the hydraulic motors to the conveyor chain assembly and is part of a complete assembly. As soon as any component is worn, the component or complete headshaft must be replaced. Due to high abrasion forces, the chain sprockets are subject to a very high level of wear.

The head shaft assembly (Fig. 69) consists of the following main components: 

drive shaft



bearing (2)



sprocket (2)



hydraulic motor (2)



gear reducer (2)

______________________________________________________________ A6474X389 REV 0 5.75

Replacement of parts _____________________________________________ How to remove the head shaft When removing or installing the head shaft, follow all applicable safety rules and regulations and be aware of the following: WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

IMPORTANT! While the head shaft assembly can be removed with the hydraulic motors and gear reducers attached, it is not recommended. When the assembly is being pulled from the machines, the gear reducers and motors will swing on the end of the shaft.

To remove the headshaft (Fig. 57): 1. Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).

2. Remove the two (2) sprocket guards located over the head shaft sprockets by removing the five (5) 3/4 inch bolts that secure each guard to the mounting plate.

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

4. Remove the hydraulic motors: a. Disconnect, tag, and cap all hydraulic hoses to the motor. b. Attach an appropriate lifting device to the motor and take up all slack so that the weight of the motor is resting on the lifting device. c.

Remove the five (5) 1/2 inch bolts, lock washers, and flat washers (items 20, 21, and 22) from the end of the motor.

d. Repeat steps (a) through (c) for the second motor.

5. Remove the conveyor gear reducers: a. Insert a lifting lug into the threaded hole on top of the gear reducer and attach an appropriate lifting device to the lug. Take up all slack so that the weight of the gear reducer is resting on the lifting device. b. Remove the four (4) bolts (item 23) from the end cap on the output stage of the reducer. c.

Insert two (2) of the bolts in the threaded pusher holes to remove the cover.

d. Remove the retaining bolt (item 6). e. Remove the retainer end cap (item 5).

________________________________________________________________ 5.76 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts f.

Remove the cotter pin (item 19) and retainer pin (item 9) from the clevis on the front of the reducer.

g. Using the lifting device, slide the gear reducer off of the head shaft. h. Remove the splined adapter from the head shaft. i.

Repeat steps (a) through (h) for the second reducer.

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

7. Remove the four (4) 7/8 inch bolts, flat washers, lock washers, and nuts (items 13, 14, 15, and 16) from each of the headshaft bearings (item 1).

Note that there may be bearing shims under the bearing. If shims are present, make note of their thickness, quantity and location.

8. Attach an appropriate lifting device to the headshaft and slide out towards the rear of the frame.

______________________________________________________________ A6474X389 REV 0 5.77

Replacement of parts _____________________________________________ How to install the headshaft assembly To install the headshaft assembly proceed as follows (Fig. 57): 1. Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the feeder breaker.

2. Reinstall bearing shims, if applicable, into the same location from which they were removed. Make sure to install the shims of the same thickness and quantity.

3. Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) 7/8 inch bolts, nuts, flat washers, and lock washers (items 13, 14, 15, and 16). Torque bolts to 645 ft-lbs.

NOTICE! After tightening the four (4) 17/8 inch bolts and nuts and before installing the gear reducer, ensure that the headshaft can turn freeely by hand. If it cannot, loosen the nuts and bolts and add or remove shims between the frame and the pillow block base as required. The headshaft must turn freely by hand or the bearings will fail prematurely.

4. Install the left and right sprocket guards.

5. Connect the central lubrication hoses on both head shaft bearings.

6. Install the hydraulic motor onto the input shaft of the gear reducer: a. Attach an appropriate lifting device to the motor and position the motor on the gear reducer. b. Install the five (5) 1/2 inch mouting bolts, lock washers, and flat washers (items 20, 21, and 22) and torque to 400 ft-lbs. c.

Reconnect hydraulic hoses.

d. Repeat steps (a) through (c) for the second motor.

8. Install the conveyor gear reducers: a. Attach an appropriate lifting device to the lifting lug located on top of the reducer and position the reducer on the head shaft. b. Insert the retainer end cap (item 5) and secure with the M20X2.5X100 Grade 10.9 retaining bolt (item 6). Torque the bolt to 450 ft-lbs. c.

Insert the reaction pins (item 9) and secure with 1/4 inch cotter pins (item 19).

d. Place the end cap on the output stage of the reducer and secure with four (4) bolts.

9. Clean and lubricate splined end of headshaft and splined adapater with ISO 68 hydraulic fluid or coat with Never Seez.

________________________________________________________________ 5.78 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts 10. Connect conveyor chain. (See Conveyor chain replacement in this chapter).

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

______________________________________________________________ A6474X389 REV 0 5.79

Replacement of parts _____________________________________________ Fig. 57: Headshaft removal and installation 8 7

17

16

9

18

15

2

1

3 11

Threaded hole for lifting lug

19

10

22

4

21

14

13

5 6

20

Pusher hole (2)

8

2

7 24

23

3

12

1

________________________________________________________________ 5.80 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 57, continued: Head shaft removal and installation 1. Bearing (2) 2. Sprocket (2) 3. Head shaft 4. Splined adapter (2) 5. Retainer (2) 6. Hex head bolt, M20X2.5X100 G 10.9 (2) 7. Gear box (2) 8. Hydraulic motor (2) 9. Reaction pin (2) 10. Clevis (2) 11. Reaction clevis (2) 12. Key (2) 13. Hex head bolt, 7/8 (8) 14. Flat washer, 7/8 (8) 15. Lock washer, 7/8 (8) 16. Hex nut, 7/8 (8) 17. Hex head bolt, 5/8 (8) 18. Lock washer, 5/8 (8) 19. Cotter pin, 1/4 20. Hex head bolt, 1/2 (10) 21. Lock washer, 1/2 (10) 22. Flat washer, 1/2 (10) 23. Bolts (8) 24. End cap

______________________________________________________________ A6474X389 REV 0 5.81

Replacement of parts _____________________________________________ Headshaft sprockets The headshaft sprockets transmit the torque of the hydraulic motor to the conveyor chain assembly and are part of the headshaft 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 headshaft sprockets Note: If replacing one piece sprockets with split sprockets, torch the old sprockets off of the shaft and then follow Split sprocket installation procedure.

To remove the sprockets from the headshaft assembly (Fig. 58): 1. Remove the headshaft assembly from the feeder (see Headshaft removal in this chapter).

2. Remove the two (2) bearings from the headshaft by loosening the set screw in the locking collar.

3. Remove the two (2) set screws from each sprocket (it may be necessary to apply heat to loosen Loctite).

4. Slide both sprockets from the drive shaft.

5. Remove old keys.

6. Inspect all components of the drive shaft for wear and damage. See the Bucyrus parts manual for your machine for a replacement parts list.

How to install the headshaft sprockets To install the sprockets on the headshaft (Fig. 58): 1. Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.

2. Insert one of the keys into the shaft keyway and slide first sprocket onto shaft (see Fig. 80 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 79 for weld specifications and dimensions. Verify position with conveyor chain before tightening set screws or welding. Apply Loctite 242 (blue) to screws and torque to 100 ftlbs.

3. Insert the other key into the shaft keyway and slide second sprocket onto shaft (see Fig. 79 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 80 for weld spcifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.

4. Install bearings on shaft (see Bearing installation procedure in this chapter).

Note that the bearing housing must be installed on shaft so that the Taconite seal is facing the middle of the shaft, if so equipped. Only one of the bearings must have the internal spacer removed to allow the shaft to float and not be in a bind (if the bearing is a sealed style, this does not apply). a. If the bearing is a split housing style, then one of the bearings must have the internal spacer removed to allow the shaft to float and prevent the shaft from binding.

________________________________________________________________ 5.82 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts b. If the bearing is a solid housing with an external lock ring and set screw, one of the bearings must have the set screw left loose to prevent the shaft from binding.

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

How to install the head shaft split sprockets To install the split sprockets on the head shaft proceed as follows (Fig. 58): IMPORTANT! Adhere to all weld specifications shown on Fig. 58. Failure to do so may result in sprocket failure and machine damage.

1. Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).

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

3. Remove the two (2) sprocket guards located on the end of the feeder breaker.

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

5. Thoroughly clean and degrease the drive shaft.

6. Insert key into shaft keyway.

7. Install both sprocket halves onto shaft and tack weld in place (see Fig. 58 for location). Ensure sprocket alignment and proper spacing with conveyor chain.

8. Preheat sprocket weld joint to 600°F .

9. Weld sprocket halves together and do not exceed 800°F maximum interpass temperature. Ensure that the weld is smooth in the tooth area to prevent damage to the conveyor chanin bushings during chain operation.

10. If possible, cover sprocket with insulating blanket and allow weld to coolt to a maximum of 100°F before uncovering. If this is not possible, then post weld heat to 800°F. 11. Connect conveyor chain. (See Conveyor chain replacement in this chapter).

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

______________________________________________________________ A6474X389 REV 0 5.83

Replacement of parts _____________________________________________ Fig. 58: Head shaft sprocket removal and installation 2

1

1.

2.

3.

4.

5.

5

3

4

Bearing (2) Head shaft Sprocket guard Sprocket (2) and key (2) Conveyor chain (not shown)

________________________________________________________________ 5.84 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 58, continued: Head shaft sprocket removal and installation

General notes: 1.

2.

3.

4.

Do not mix and match halves with other sprockets.

Install sprocket and keys on head shaft.

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

Blend and smooth welds to avoid chain roller damage.

3/8 X 45° weld chamfer

3/8 X 45° weld chamfer

Weld notes: 1.

2.

3.

4.

5.

6.

7.

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

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

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

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

Split sprocket (typical)

______________________________________________________________ A6474X389 REV 0 5.85

Replacement of parts _____________________________________________ Tailshaft The tailshaft (Fig. 59) allows for even adjustments and friction free transition to the conveyor chain assembly. As soon as any component of the tailshaft is worn the component or complete tail shaft assembly must be replaced. Due to the high abrasion forces the tailshaft is subject to a very high level of wear.

Fig. 59: Tail shaft main components

2

3

4

1

7 6

1.

2.

3.

4.

5.

6.

7.

5

Key (2) Set screw (2) Slide plate Adapter (2) Bearing (2) Head shaft Sprocket or roller (2)

________________________________________________________________ 5.86 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts How to remove the tailshaft WARNING! You could be seriously injured or even killed by falling loads. Whenever instructed to lift or block, observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

To remove the tailshaft assembly (Fig. 60): 1. Remove the RTV silicone from twelve (12) bolt heads and remove the bolts from each end of the tailshaft retainers and lift out the retainers.

2. Make sure the grease take-up release valves are closed and pump up the grease cylinders until the grease shims are loose.

3. Release tension on the conveyor chain by removing the tail shaft shims.

Open the valves on the grease cylinder take-up manifold located on the left hand side of the machine, directly above the tilt cylinder. Pry the tailshaft toward the discharge end of the machine to fully collapse the grease takeup cylinders.

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

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

6. It may be necessary to remove the take-up cylinders from the feeder frame and disengage the take-up pushrod from the take-up bearing.

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

How to install the tail shaft To install the tailshaft assembly (Fig. 60): 1. Apply a coat of grease to the bearing guide bars.

2. With an appropriate lifting device, insert tail shaft into the receiving end of the feeder breaker. Center the tail shaft in the feeder breaker frame, ensuring that the slots of the take-up bearing are aligned witht the guide bars and that the bearings are fully seated on the guide bars. It may be necessary to loosen the set screws of the bearing retainer collars and reposition the bearings so that the bearing slots are aligned with the frame guide bars. Apply Loctite 242 and torque set screws to 100 ft-lbs if loosened.

3. Install the take-up pushrod into the take-up bearing.

4. Fold the conveyor chain over tailshaft.

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

______________________________________________________________ A6474X389 REV 0 5.87

Replacement of parts _____________________________________________ 6. Connect central lubrication hoses and lubricate the tailshaft slide plate and take-up bearings with Spec. 100-3 grease until grease is seen coming out of the return port of the central grease manifold (marked tailshaft bearing grease return) and from the tailshaft slide plate tube.

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

8. Coat the twelve (12) 3/4-10X1-1/2” countersunk bolts with Never Seez and install the tailshaft retainers. Fill the bolt heads with blue RTV silicone.

9. Open the grease valves on the conveyor chanin take-up manifold to allow shims to carry the conveyor chain load.

10. With machine running, visually inspect tailshaft to ensure that the chain is smoothly engaging the rollers or sprockets.

________________________________________________________________ 5.88 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 60: Tailshaft removal and installation 5 1

10

2

3

6

7

4

9

8

1. Countersunk bolt, 3/4-10X1-1/2” (12) 2. Tail shaft retainer, right hand 3. Tail shaft cover 4. Push rod 5. Grease take-up cylinder 6. Shims 7. Grease manifold 8. Tail shaft retainer, left hand 9. Adapter (2) 10. Tail shaft

______________________________________________________________ A6474X389 REV 0 5.89

Replacement of parts _____________________________________________ How to disassemble the tailshaft To disassemble the tailshaft assembly (Fig. 61): 1. Remove the tailshaft assembly from the feeder breaker. (see Tailshaft removal procedure in this chapter).

2. Loosen the set screws (2 per bearing assembly) and slide both take-up bearings and piston rod adapters from the tailshaft.

3. Loosen the set screw from the tailshaft roller/sprocket and slide roller/ sprocket from the shaft. Note that heat may be required to loosen set screw as Loctite was used during installation.

4. Remove the tailshaft from the slide plate.

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

How to assemble the tailshaft To assemble the tailshaft assembly (Fig. 61): 1. Thoroughly clean all parts that will be installed.

2. Grease tailshaft with Spec. 100-3 grease.

3. Slide tailshaft into the slide plate.

4. Insert key into keyway on tailshaft.

5. Apply Loctite 242 (blue) on set screw and install set screw into the roller/ sprocket with the key, ensuring that the roller/sprocket and tail shaft slide plate are centered on tail shaft (see Fig. 73 for dimensions).

6. Tighten set screw and torque to 100 ft-lb.

7. Install both take-up bearings onto the tail shaft, flush with the ends of the shaft.

8. Apply Loctite 242 (blue) to the set screw and install. Tighten and torque to 100 ft-lb.

9. Install swivel grease fittings in the ends of the shaft and the 90° grease hose elbows into the take-up bearings.

10. Install tailshaft into machine. (see Tailshaft installation procedure in this chapter).

________________________________________________________________ 5.90 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 61: Tail shaft disassembly and assembly 2

1

1.

2.

3.

4.

5.

6.

7.

3

7

4

6

5

Bearing (2) Set screw (2) Tail shaft Key (2) Piston rod adapter (2) Roller (2) Slide plate

______________________________________________________________ A6474X389 REV 0 5.91

Replacement of parts _____________________________________________ Conveyor chain The conveyor chain (Fig. 62) 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

Fig. 62: Conveyor chain main components

6 link chain section

Spiral pin

Flight bar

________________________________________________________________ 5.92 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 63): 1. Lay conveyor chain sections on a clean flat surface.

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

3. Insert spiral pin.

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

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

Fig: 63: Conveyor chain assembly

Extended pin connecting link Spiral pin (4)

Flight bar

Side bar Block link assembly 6 link chain section

How to remove the conveyor chain assembly To remove the conveyor chain assembly proceed as follows: 1. Release tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

2. At the chain disassembly/assembly point, raise the chain a minimum of 3” high and block it under the flight.

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

______________________________________________________________ A6474X389 REV 0 5.93

Replacement of parts _____________________________________________ 3. Separate conveyor chain by removing spiral pins and connecting links in one section of the chain.

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

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

How to install the conveyor chain assembly To install the conveyor chain assembly proceed as follows: 1. Check to ensure that the conveyor tail shaft is completely retracted. If not retracted, see Conveyor chain adjustment in this chapter.

2. If the old conveyor chain was not used to install the new conveyor chain, then run a cable or pull rope with an adequate load limit through the bottom conveyor pan and connect to the conveyor chain.

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

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

4. 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.

5. Ensure that the chain is properly meshed with the sprockets on the head and rollers on the tailshaft.

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

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

8. With machine running, visually inspect tail shaft to ensure that the conveyor chain is properly engaged with the tailshaft rollers/sprockets.

________________________________________________________________ 5.94 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Crawler track The crawler track (Fig. 64) 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: 1. Crawler pad block link 2. Crawler pad pin link 3. T-head cotter pin Fig. 64: Crawler track main components

2 1

3

______________________________________________________________ A6474X389 REV 0 5.95

Replacement of parts _____________________________________________ How to assemble the crawler track pads (Fig. 64) To assemble the crawler track pads proceed as follows: 1. Lay crawler track pads on a flat surface.

2. The crawler chain consists of a block link and a connecting link. Alternate each link during assembly (block, connecting, block, connecting, etc.)

3. Insert connector into center of crawler pad connecting holes.

4. Drive roll pin through connecting pin and bend end to secure.

5. Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly (Fig. 64) To remove the crawler track pad assembly proceed as follows: 1. 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.

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

3. Separate the crawler pads.

IMPORTANT! Heating or cutting connections with a torch or chisel may be required to ease the removal of T- pins. a. Drive out or cut roll pin from crawler pad connection using hammer and punch or chisel. b. Separate crawler track assembly. c.

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.

WARNING! When using an additional pulling device 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.

4. Inspect the crawler drive sprocket and idler rollers for wear or damage.

Replace if necessary.

________________________________________________________________ 5.96 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts How to install the crawler track pad assembly To install the crawler track pad assembly proceed as follows (Fig. 64): 1. Remove old crawler track pad assembly (see previous section, How to remove crawler track pad assembly).

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

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

3. Slide crawler track pad assembly under crawler assembly.

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

5. Connect crawler track pad assembly (see How to assemble crawler track pad assembly in this chapter for proper connection).

6. Adjust tension on the crawler track pad assembly (see Crawler track pad adjustment procedure in this chapter for proper adjustment).

______________________________________________________________ A6474X389 REV 0 5.97

Replacement of parts _____________________________________________ Crawler assembly The crawler assembly (Fig. 65) 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.

Fig. 65: Crawler assembly main components

2

1

3

5

1.

2.

3.

4.

5.

4

Crawler track Hydraulic motor (not shown) Torque hub Grease take-up (located behind cover) Take-up roller assembly

________________________________________________________________ 5.98 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 66): 1. 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.

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

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

4. Securely block under the crawler frame.

5. 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 6. Remove the eight (8) bolts from the tilt cylinder mounting bracket.

7. Swing the tilt cylinder and mounting bracket free of the crawler frame.

8. 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.

9. Inspect all components for wear or damage.

______________________________________________________________ A6474X389 REV 0 5.99

Replacement of parts _____________________________________________ How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 66): 1. 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.

2. Inspect all components for wear or damage prior to assembly.

3. Clean all dirt and debris from inside crawler frame.

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

5. Install and connect crawler and track pad assembly, see How to install the crawler track pad assembly in this chapter.

6. Swing the tilt cylinder and mounting bracket into crawler frame and secure with the eight (8) bolts, washers and nuts.

7. Connect hydraulic hoses to tilt cylinder.

8. Purge hydraulic system of air.

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

________________________________________________________________ 5.100 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 66: Crawler take-up removal and installation 1

2

3

1. Tilt cylinder 2. Tilt cylinder mounting bracket 3. Crawler take-up

______________________________________________________________ A6474X389 REV 0 5.101

Replacement of parts _____________________________________________ How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 67): 1. Raise complete crawler assembly off ground and securely block under the machine, leaving 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.

2. Release crawler track tension (see Crawler track adjustment in this chapter).

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

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

5. Remove slotted nut, roll pin and washer from lift cylinder anchor pin.

6. Remove anchor pin from crawler frame and crawler guide weldment.

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

8. Remove the seventeen (17) bolts and lock washers (items 3 and 4) that secure the torque hub (item 2) to the crawler frame.

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

CAUTION! Do not bump hydraulic motor or hydraulic motor fittings when removing the motor from the machine.

10. Remove the two (2) bolts and lock washers (items 2 and 9) that secure the hydraulic motor (item 11) and adapter plate (item 8) to the torque hub and remove the adapter plate and motor from the torque hub as an assembly.

11. If not replacing the hydraulic motor, it is not necessary to separate the adapter plate from the hydraulic motor. If replacing the hydraulic motor, remove the four (4) nuts, lock washers, and flat washers (items 13, 14, and 16) that secure the hydraulic motor to the adapter plate and remove the adapter plate.

12. Thoroughly clean and degrease the adapter plate mating face.

13. Remove the splined coupling insert and retaining ring (items 12 and 34) as an assembly.

14. Remove the the ten (10) nuts and lock washers (items 6 and 7) that secure the sprocket to the torque hub and remove the torque hub.

15. Inspect all components for wear or damage.

________________________________________________________________ 5.102 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 67): 1. Place sprocket onto torque hub and apply Loctite 242 (blue) to the threaded studs of the torque hub. Intall the ten (10) M22X1.5 nuts and lock washers (items 6 and 7) and torque incrementally and evenly in a crossing pattern as follows.   

Step 1: 300 N-m Step 2: 600 N-m Step 3: 912 N-m

Thoroughly clean and degrease the adapter plate (item 8) and mating faces of the torque hub (item 2) and hydraulic tram motor (item 11).

Apply Loctite 518 gasket eliminator or equivalent to the adaptor plate. Be sure to apply the sealant completely around all bolt holes to prevent leakage.

4. Place hydraulic motor gasket (item 10) onto motor adapter plate.

5. Apply Loctite 518 to the second side of the motor gasket.

6. Install adapter plate onto hydraulic motor. Apply Loctite 242 (blue) to the four (4) nuts and secure the adapter plate with the four (4) nuts, flat washers, and lock washers (items 13, 14, and 16).

7. Ensure that the retainer ring is installed in the groove of the splined adapter coupling and install the splined adapter.

8. Install the o-ring into the adapter plate and apply a light film of oil to the oring.

9. 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

10. If using a motor adapter plate that does not have the keepers already installed, weld four (4) keepers against the motor flanges to prevent motor movement.

11. Clean all dirt and debris from mounting area of crawler frame.

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

______________________________________________________________ A6474X389 REV 0 5.103

Replacement of parts _____________________________________________ 13. Secure torque hub assembly to frame with the twelve (12) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.    

Step 1: 50 ft-lb Step 2: 140 ft-lb Step 3: 280 ft-lb Step 4: 420 ft-lb

14. Connect hydraulic hoses to drive motor.

15. Install and connect crawler and track pad assembly (see How to install the crawler track pad assembly in this chapter).

16. 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

17. Apply grease to anchor pin and slide anchor pin through crawler frame and tilt cylinder. Secure pin with slotted nut, washer and roll pin.

18. Purge hydraulic system of air.

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

Fig. 67: Crawler drive disassembly and assembly 1. Crawler frame 2. Torque hub 3. Washer (spring), M16 hi-collar (19) 4. Socket head bolt, M16X45 (17) 5. Sprocket 6. Lock washer, M22 (10) 7. Hex nut, M22X1.5 (10) 8. Adapter Plate, torque hub 9. Socket head bolt, M16X40 (2) 10. Motor gasket 11. Motor 12. Adapter shaft 13. Flat washer, 1/2 inch (4) 14. Lock washer (4) 15. Hex head bolt, 1/2X1-1/2 (4) 16. Motor keeper (4) 17. Grease cylinder

18. Take-up access cover 19. Shim set, roller take-up 20. Crawler take-up 21. Retainer 22. Take-up shim retainer bar 23. Lock washer, hi-collar 1/2 inch 94) 24. Socket head bolt, 1/2-13X1-1/4 (4) 25. Removable side plate 26. Lock washer, 1 inch (6) 27. hex head bolt, 1X3/1/2 (6) 28. Bushing 29. Bushing 30. Lock washer, 3/4 inch (4) 31. Hex head bolt, 3/4X2 (4) 32. Crawler pad assembly 33. O-ring 34. External snap ring

________________________________________________________________ 5.104 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 67, continued: Crawler drive disassembly and assembly

1 2 23

20

5 24

21

6

22

7

17 19 18 30

25 31 29 32

26 27

28 3 34 33

4

2 12 10 8 13

9

15 16

11 14

______________________________________________________________ A6474X389 REV 0 5.105

Replacement of parts _____________________________________________ Power unit The breaker power unit (Fig. 68) can be removed or installed as a single assembly or individual components of the unit can be removed separately.

Fig. 68: Power unit

1

2 3 4

1.

2.

3.

4.

5.

5

Reducer Connecting tube Electric motor, 200 hp Power unit tray Load sense pump assembly

________________________________________________________________ 5.106 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts How to remove the power unit assembly When removing and installing the power unit assembly, follow all safety rules and regulations, including the following: 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 following all applicable lockout/tagout rules and regulations. Electrical shock or accidental machine movement can cause serious injuries or death to you or other personnel.

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

To remove the power unit as a complete assembly (Fig. 69): 1. Remove power unit covers from the machine.

2. Disconnect and tag all electrical wiring to the drive motor.

3. Disconnect, cap, and tag all hydraulic hoses to the hydraulic pumps and grease lines to the electric motor and gearbox.

4. Remove the eight (8) Super nuts, flat washers, and bolts as follows: a. Loosen each jackbolt on the nut 1/8 turn following a star pattern around the nut (one round only). As you move around and get back to the first jackbolt, it will be tight again. b. Repeat a second round as in step a, loosening each jackbolt 1/4 turn in a start pattern. c.

Continue loosening 1/4 turn for third and following rounds until all jackbolts are loose. Note: Usually after the third or fourth round, the jack bolts can be completely removed.

d. Remove, clean, and lubricate the jackbolts with Never Seeze prior to installation. e. Repeat fro the remaining Super nuts.

5. Separate and remove the breaker drive chain (see Breaker drive chain adjustment procedure).

6. Attach an appropriate lifting devie to the electric motor and gear reducer and slowly lift the entire unit from the machine.

Note: The electric motor is machine to accept a lifting eye. The lifting eye is attached to the electric motor via a zip tie when not in use. The gear reducer is also machine to accet lifting eyes, however, the actual eyes are customer supplied.

______________________________________________________________ A6474X389 REV 0 5.107

Replacement of parts _____________________________________________ How to install the power unit assembly To install the power unit proceed as follows (Fig. 69): 1. Ensure all dirt and debris is cleaned from the area so that the power unit will sit flat in the machine.

2. Attach an appropriate lifting device to the electric motor and the gear reducer and slowly lift the complete unit onto the machine.

3. Align the mounting base holes in the frame and in between the guide bars that are welded to the feeder frame.

4. Install and adjust breaker drive chain (see Breaker drive chain installation procedure in this chapter).

5. Secure the mounting base to the frame with eight super nuts, flat washers, and bolts as follows: a. Spin the tensioner (nut) onto the main thread (bolt) until it seats against the washer. b. In a star pattern, torque all jackbolts to 7 ft-lbs using a torque wrench. c.

Stabilize the jackbolt torque to 14 ft-lbs by repeating the tightening process in a start pattern an additional two to four passes.

d. Repeat for each Super nut.

6. Connect all hydraulic hoses to the hydraulic.

7. Connect all electrical wiring to the electric motor.

8. Connect all grease lines to the electric motor and gear box.

________________________________________________________________ 5.108 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 69: Power unit removal and installation

4 3

5

1.

2.

3.

4.

5.

1

2

Power unit assembly Power unit take-up assembly Flat washer, heavy, 1 inch (8) Super nut, MT-100-8 (8) Bolt, Hex head, 1X4-1/2 (8)

______________________________________________________________ A6474X389 REV 0 5.109

Replacement of parts _____________________________________________ How to disassemble the power unit When disassembling and assembling the power unit, observe all safety rules and regulations and be aware of the following: 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.

To disassemble the power unit proceed as follows (Fig. 71): 1. Remove complete unit from machine. (See How to remove the power unit assembly in this chapter) 2. Remove the two (2) 3/4 inch bolts and lockwashers (items 29, 30, and 31) from the gear pump (mounted on item 28) and remove pump.

3. Open the access cover on connecting tube (item 24) and loosen the two (2) bolts on the pump end and set screw on the motor end of the coupling.

4. Remove the four (4) bolts and lockwashers from the open loop load sense pump (item 28). With the aid of a lifting device, slowly pull pump from coupling (item 27) and connecting tube (item 24).

5. Remove the eight (8) 5/8 inch bolts and lockwashers (items 25 and 26) from the connecting tube (item 24) and remove connecting tube from motor (item 23).

6. Remove the coupling guard (item 36) by removing the two (2) lynch pins (item 32) and flat washers (item 20).

7. Remove coupling (item 17) and key from motor shaft.

8. Remove the four (4) 3/4 inch bolts, lock washers, and nuts (items 21, 22, and 34) from motor base and the eight (8) 5/8 inch bolts, lockwashers, and nuts (items 1, 2, and 3) from the reducer base. With the aid of a lifting device, slowly lift motor and reducer from mounting base (item 35).

9. Remove the sprocket retainer bolt, lock washer, and retainer plate (items 4, 5, and 6).

10. Loosen the sprocket set screws (Note: Application heat to the sprocket hub may be necessary to loosen the set screws as Loctite 242 (blue) was used during assembly.) and remove the sprocket.

11. Separate motor and reducer coupling halfs by removing the twelve (12) bolts from around the center of coupling (item 17).

12. With the aid of a lifting device, slowly separate motor (item 23) and reducer (item 13).

13. Remove the M16 bolt, lockwasher, and end cap (item 16, 39, and 40) the end of the reducer shaft.

14. Remove the three (3) bolts that secures the taper lock (item 2) to the reducer shaft.

________________________________________________________________ 5.110 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts 15. 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. 70). Tighten both bolts equally until the taper lock is free from reducer shaft.

16. Remove the 1/2 inch bolt, lockwasher and end cap (item 18, 37, and 38) the end of the motor shaft.

17. Remove the three (3) bolts that secure the taper lock (item 19) to the motor shaft.

18. 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. 70). Tighten bolts equally until the taper lock is free from the motor shaft.

19. visually inspect all componets for wear or damage and replace as necessary.

Fig. 70: Taper lock removal and installation

Jack screw holes (2) for bushing removal

Bolt holes (3) for bushing installation

______________________________________________________________ A6474X389 REV 0 5.111

Replacement of parts _____________________________________________ How to assemble the power unit When disassembling and assembling the power unit, observe all safety rules and regulations and be aware of the following: 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.

To assemble the power unit proceed as follows (reference Fig. 71): 1. With the aid of a lifting device, slowly lift reducer (item 13) onto mounting base (item 35)) and align mounting holes. Loosely secure reducer with the eight (8) 5/8 inch bolts, lockwashers and nuts (items 1, 2, and 3) to mounting base but do not tighten.

2. Install 1 inch set screw, lock washer, and hex nut (items 8, 9, and 10) but do not tighten.

3. Install the fan shroud kit (item 14).

4. Install the set screws and jam nuts (items 2 and 3) on the side of the reducer but do not tighten.

5. Install the reducer taper lock (item 15) and shaft key onto reducer shaft.

Locate reducer coupling element so that taper lock is flush with the end of the reducer shaft (see Fig. 63). Secure taper lock with the three (3) bolts supplied with taper lock and torque bolts to 85 ft-lb.

6. Install end cap (item 40) onto reducer shaft and secure with bolt and lockwasher (items 16 and 39). Torque bolt to 80 ft-lb.

7. Slide reducer coupling hub (item 17) onto reducer shaft.

8. Install motor taper lock (item 19) and shaft key onto motor shaft. Do not tighten bolts at this time.

9. Install end cap (item 37) onto motor shaft and secure with bolt and lockwasher (items 18 and 38). Torque bolt to 80 ft-lb.

10. Slide motor coupling hub (item 17) onto motor shaft.

11. With the aid of a lifting device, slowly lift motor onto mounting base (item 35) and align mounting holes. Secure motor with the four (4) 3/4 inch bolts, lockwashers and nuts (items 21, 22, and 34) to the mounting base but do not tighten.

12. Align the reducer and the motor using shims. Refer to Fig. 72 for factory recommended combination of parallel and angular misalignment for the Size 70 coupling. Note: It is recommended that the shimming be done under the electric motor and that the reducer be installed directly on the base plate. However, in some instances, it may be necessary to shim under the reducer, as well.

________________________________________________________________ 5.112 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts 13. Tighten all mounting hardware as follows: a. Reducer mounting bolts (5/8 inch - qty 8) - torque to 225 ft-lb. b. Reducer set screws (1 inch - qty 2) - torque to 900 ft-lb. c.

Motor mounting bolts (3/4 inch - qty 4) - torque to 400 ft-lb.

14. Install the coupling element halves (item 17).

15. Determine the final position of the taper lock hub by aligning the coupling element bolt holes with the taper lock hub bolt holes on the gear redecure.

Secure the taper lock with the three (3) supplied bolts. Torque to 85 ft-lbs.

16. Install end cap (item 37) onto reducer shaft and secure with bolt and lockwasher (items 18 and 38). Torque bolt to 80 ft-lb.

17. Connect the coupling (item 17) with the twelve (12) bolts supplied with coupling. Apply Loctite 242 (blue) to the twelve (12) bolts before installation.

18. Insert key into keyway of motor shaft and slide motor coupling half (item 27) onto motor shaft until shaft and coupling face are flush (see Fig. 63).

19. Apply Loctite 242 (blue) to set screw and install and tighten in motor half of coupling.

20. Insert coupling element into motor half of coupling.

21. Align the eight (8) holes of connecting tube (item 24) with motor (item 23) and secure with the eight (8) 5/8 bolts and lockwashers (items 25 and 26).

Torque to 225 ft-lbs.

22. Slide pump half of coupling (item 27) onto open loop load sense pump shaft. Do not tighten coupling half bolts at this time.

23. With the aid of a lifting device, slowly lift the pump (item 28) and carefully alight the jaws of the pump half and motor half of the coupling (item 27).

24. Secure the pump to the connecting tube with four (4) 5/8 bolts and lock washers (items 25 and 26). Torque the bolts to 225 ft-lbs. The coupling spacing should be 0.18 inches (4.5 mm) after the pump mounting bolts are tightened (see Fig. 71).

25. Tighten the two (2) retaining bolts of the pump coupling half.

26. Apply a light film of hydraulic oil to the o-ring on the gear pump.

27. Align the mounting holes and splined shaft of the gear pump with the open loop load sense pump (item 28) mounting holes and splined coupling and secure with two (2) bolts and lock washers.

28. Install the sprocket (item 7) onto the output shaft of the gear reducer and secure with M24X60-10.9 bolt, one inch lock washer, and retainer plate (items 4, 5, and 6).

______________________________________________________________ A6474X389 REV 0 5.113

Replacement of parts _____________________________________________ 29. Install the coupling guard (item 36) and secure with flat washers 1/2 inch (item 20) and lynch pins (item 32).

30. Install completed power unit onto machine (see How to install power unit assembly in this chapter).

31. Fill the open loop load sense pump (item 28) with hydraulic oil (Spec. 1001) through the case drain port before running pump.

32. Fill the gear pump with hydraulic oil (Spec. 100-1) through all pressure ports before running pump.

CAUTION! Failure to fill the hydraulic pumps with oil prior to operation will result in catastrophic damage to the pumps.

33. Check the gear box oil level using the dip stick located on top of the gear box. Add oil (Spec. 100-6) as required.

________________________________________________________________ 5.114 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 71: Power unit 12

11

13 14 15

9 10

8

16 17

20

21 22

18

23

19

24

25 26

27

28

7 6 4

40

5

3

39

38

29

37

2 1

33

36

30 31

32 35 34 1.Hex head bolt, 5/8X4-1/2 (8) 2.Hex nut, 1” (4) 3.Set screw, 1-8X3 (4) 4.Hex head bolt, M24X60-10.9 5.Lock washer, 1” 6.Flat washer, 5X1X.25 7.Sprocket 8.Socket set screw, 1-8X5-1/2 (2) 9.Lock washer, 1” (2) 10.Hex nut, 1” (2) 11.Hex nut, 5/8 (8) 12.Lock washer (5/8) 13.Gear box 14.Fan shroud 15.Tapered bushing 16.Hex head bolt, M16-2X40 Gr 8.8 17.Coupling 18.Lock washer, 1/2 19.Tapered bushing 20.Flat washer, 1/2 (2)

21.Hex nut, 3/4 (4) 22.Lock washer, 3/4 (4) 23.Electric motor 24.connecting tube 25.Flat washer, 5/8 (8) 26.Hex head bolt, 5/8X2-1/4 (8) 27.Rotex coupling 28.Pump 29.Flat washer, 3/4 (2) 30.Lock washer, 3/4 (2) 31.Hex head bolt, 3/4X2 (2) 32.Lynch pin, 1/4X1-9/16 (2) 33.Retainer 34.Hex head bolt, 3/4X3-3/4 (4) 35.Power unit tray 36.Coupling cover 37.End cap 38.Hex head bolt, 1/2X1-1/2 39.Lock washer, M16 40.End cap

______________________________________________________________ A6474X389 REV 0 5.115

Replacement of parts _____________________________________________ Fig. 71, continued: Power unit

Detail A

Detail b

________________________________________________________________ 5.116 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 72: Recommended parallel and angular misalignment

______________________________________________________________ A6474X389 REV 0 5.117

Replacement of parts _____________________________________________ Gear pump removal and installation Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: WARNING! Before removing each pump and the connecting tube be sure to properly support the component. Failure to properly support the component may result in damage to the component or injury to personnel.

WARNING! Remove all fittings from the pumps and plug the ports before removal.

Failure to remove fittings and plug ports could result in damage to the pumps.

To remove the gear pump from the open loop pump (reference Fig. 73): 1. Remove two M10 bolts and spring washers (items 5 and 6) and remove priority gear pump (item 4).

2. Save the o-ring (item 1) from the gear pump and the splined pump insert (item 2) from the rear of the open loop pump for use in reassembly. a. Inspect the o-ring for damage (nicks, brittleness, etc.) and replace if necessary. b. Inspect the splined adapter for wear or damage and replace if necessary.

To install the gear pump on the open loop pump (reference Fig. 73): 1. Clean the mounting faces of both pumps.

2. Install the o-ring (item 1) in the gear pump (item 4) and apply a thin film of hydraulic oil.

3. Install the splined adapter (item 2) in the load sense pump (item 3).

4. Insert the gear pump shaft into the splined insert until the gear pump is fully seated against the load sense pump. Take care to not damage the o-ring during installation.

5. Insert the two (2) M10 bolts and spring washers (items 5 and 6) and torque the bolts to 37 ft-lb.

________________________________________________________________ 5.118 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 73: Open loop pump assembly

1

2 5

3

4

6

1.

2.

3.

4.

5.

6.

O-ring Splined insert Open loop pump Gear pump (typical) Spring washer, M10 (2) Bolt, M10X1.5X25 G. 8.8 (2)

______________________________________________________________ A6474X389 REV 0 5.119

Replacement of parts _____________________________________________ Breaker assembly The breaker assembly (Fig. 74) is assembled as a complete unit and should be removed as a unit for repairs except for the replacement of the shear hub assembly, bits, and magnetic cutoff assembly. As soon as any component of the breaker assembly is worn or damaged, the component or complete assembly must be replaced.

The breaker assembly consists of the following main components: ■

breaker shaft

■

shear hub assembly

■

bearing housing (2)

■

bearing (2)

■

bits (25)

■

bearing retainer (2)

■

under speed sensor

■

breaker side plate (2)

■

retaining cap (2)

■

dust cover

Fig. 74: Breaker assembly main components Under speed sensor mount

Breaker side plate (2)

Bearing (2)

Bearing housing (2)

Breaker

Shear hub

Retainer cap (2)

Pick (25)

________________________________________________________________ 5.120 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Breaker shaft assembly When removing and installing the breaker shaft assembly, follow all safety rules and regulations, including the following: 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 following all applicable lockout/tagout rules and regulations. Electrical shock or accidental machine movement can cause serious injuries or death to you or other personnel.

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

To remove the breaker shaft assembly (Fig. 75): 1. Remove covers and guards as required to gain access to the breaker assembly.

2. Release tension on the breaker drive chain and remove chain (see Breaker drive chain removal in this chapter).

3. Disconnect, tag, and cap the bearing central lubrication hoses.

4. Attach an appropriate lifting device around the breaker shaft assembly and apply just enough lift to remove the twenty (24) 1 inch bolts, nuts, and washers (12 per side) (items 2, 3, and 4) that secure the breaker assembly to the frame.

5. With the aid of the lifting device, slowly lift the complete assembly out of the frame.

To install the breaker shaft assembly (Fig. 75): 1. With the aid of the lifting device, slowly lift the breaker assembly into the frame and align mounting holes.

2. Secure the breaker with the twenty (24) 1 inch bolts, nuts, and washers (12 per side) (items 2, 3, and 4) and securely tighten. Torque bolts to 900 ft-lb.

3. Install breaker drive chain and adjust tension. (See Breaker drive chain adjustment in this chapter).

4. Connect the bearing central lubrication hoses.

5. Install covers and guards.

______________________________________________________________ A6474X389 REV 0 5.121

Replacement of parts _____________________________________________ Fig. 75: Breaker shaft assembly

4

1

4

2

3

2 3

2 3

1.

2.

3.

4.

Breaker shaft assembly Washer, 1 inch (24) Hex nut, 1 inch (24) Hex head bolt, 1X4 (24)

________________________________________________________________ 5.122 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Breaker shaft and power unit height adjustment procedure To adjust the height of the breaker shaft and power unit: 1. Remove covers to gain access to both ends of the breaker shaft, above the breaker shaft, and the power unit.

2. Loosen the breaker shaft drive chain, removing the chain if necessary.

3. Attach a lifting device to the power unit and breaker shaft so that both pieces will remain level during the adjustment procedure.

4. Take up all slack in the lifting device.

5. Remove all breaker shaft side plate hardware.

6. Using the lifting device, raise or lower the power unit and breaker shaft assembly.

7. The breaker shaft height is adjustable in two inch (50 mm) increments.

8. Reinstall the breaker shaft side plate hardware and remove the lifting device.

9. Tighten or reinstall the breaker shaft drive chain (see Breaker drive chain installation procedure in this section), it was removed. Note: It may be necessary to add or remove chain links to the drive chain (see Breaker drive chain link removal and installation procedure in this chapter).

10. Adjust breaker shaft drive chain tension (see Breaker drive chain adjustment procedure in the Adjustment section of this manual).

______________________________________________________________ A6474X389 REV 0 5.123

Replacement of parts _____________________________________________ How to remove the breaker drive chain 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 following all applicable lockout/tagout rules and regulations. Electrical shock or accidental machine movement can cause serious injuries or death to you or other personnel.

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

To remove the breaker drive chain (reference Fig. 76): 1. Remove the covers from the power unit and remove the chain guard.

2. Release the tension from the chain (see Breaker drive chain adjustment procedure in the Adjustment section of this chapter).

3. Locate the master link. If necessary, rotate the breaker shaft so that the master link is in the 6 o’clock position on the breaker shaft drive sprocket.

The breaker shaft can be rotated by manually turning the coupling between the motor and the gear box or by jogging the motor.

WARNING! If the breaker shaft must be jogged, power must be restored to the machine. Ensure that all tools and all personnel are clear of the machine.

Ensure that all personnel are aware that power is being restored and the breaker shaft will be jogged. Use extreme caution around rotating parts when looking for the master link while jogging the breaker shaft. After the master link is rotated to an accessible location, move the circuit breaker to the “OFF” position and disconnect power to the machine following all lock out/tag out rules and regulations.

4. Remove the cotter pins from the master link.

5. Separate the master link connecting pins from the chain.

6. Attach a lifting device to the chain and lift off of the machine.

________________________________________________________________ 5.124 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts How to install the breaker drive chain To install the breaker drive chain (reference Fig. 76): 1. Using an appropriate lifting device, drape the drive chain over the gear reducer sprocket in such a manner that the cotter pins securing the connecting pins are facing the machine.

2. To aid in identification of the master link, install the master line backwards from the other links (cotter pins are facing out, away from the machine).

Secure with connecting pins and cotter pins.

3. Adjust the tension on the drive chain (see Breaker drive chain adjustment procedure in the adjustment section of this chapter).

4. Replace the chain guard.

5. Replace the power unit covers.

______________________________________________________________ A6474X389 REV 0 5.125

Replacement of parts _____________________________________________ Fig. 76: Breaker drive chain removal and installation Note: Electric motors and chain guards removed for clarity.

Gear reducer sprocket

Breaker shaft sprocket

Master link

________________________________________________________________ 5.126 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts How to remove a breaker bit To remove the breaker bit from the breaker shaft bit holder proceed as follows (Fig. 77): 1. Remove the external retaining rings from the shank end of the bit with a pair of external retaining ring pliers.

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

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

How to install the breaker bit To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 77): 1. Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.

2. Install the external retaining rings (two per bit) on the shank end of the bit with a pair of external retaining ring pliers. Ensure that the retaining ring is completely seated inside grooved area of the bit.

Fig. 77: Breaker bit removal and installation

Retaining rings

Bit holder

Breaker bit

______________________________________________________________ A6474X389 REV 0 5.127

Replacement of parts _____________________________________________ Shear pin removal 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 following all applicable lockout/tagout rules and regulations. Electrical shock or accidental machine movement can cause serious injuries or death to you or other personnel.

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

To remove a broken shear pin (reference Fig. 78): 1. Remove the power unit covers.

2. Remove the Omega coupling guard.

3. Remove the bolts from the coupling element on the electric motor shaft.

4. Turn the reducer input shaft via the Omega coupling element and align the oversized “knock out” hole (hole without any steel bushing inserts) on the breaker shaft shear hub with the broken shear pin.

5. Using a hammer and punch, remove the broken shear pin pieces. Make sure to retrieve all pieces of the broken shear pin. If pieces fall into the chain and the breaker shaft is operated, the pieces will damage the chain and the sprockets.

To install a broken shear pin (reference Fig. 78): 1. Using the Omega coupling element, turn the input shaft of the gear reducer to align the holes of the shear hub. The correct holes for alignment are identified by the presence of hardened steel bushing inserts. Note: there are multiple shear pin holes but only one set of holes will align at a time to prevent the installation of multiple shear pins. If a set of bushings is damaged and unsuitable for use, rotate to the next set of holes.

2. Install the shear pin, wire retaining hook end first, into the shear pin hole.

3. Using a hammer, tap the shear pin into the shear hub until the “e” retaining clip is shouldered against the face of the shear hub.

4. Install the bolts into the coupling element on the electric motor shaft.

5. Install the Omega coupling guard.

6. Install the power unit covers.

________________________________________________________________ 5.128 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Fig. 78: Shear pin removal and installation Shear pin

______________________________________________________________ A6474X389 REV 0 5.129

Replacement of parts _____________________________________________ Tilt cylinder removal and installation To remove a tilt cylinder (reference Fig. 79): 1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

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

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

4. Attach an appropriate lifting device to the tilt cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

5. Pull a cotter pin out of the pin through the cylinder eye and remove the pin.

6. Pull a cotter pin out of the pin through the rod eye and remove the pin.

________________________________________________________________ 5.130 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts To install a tilt cylinder (reference Fig. 79): 1. Attach an appropriate lifting device to the tilt cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

2. Align the cylinder in the mounting clevises on the machine.

3. Install the pin through the cylinder eye and secure with a cotter pin.

4. Install the pin through the rod eye and secure with a cotter pin.

5. Reconnect the hydraulic hoses to the cylinder.

6. Reconnect power to the machine.

7. Purge the hydraulic system of air.

Fig. 79: Tilt cylinder removal and installation

1

2

3

1.

2.

3.

4.

Pin (2) Cotter pin (2 per pin) Tilt cylinder Mounting clevis

4

______________________________________________________________ A6474X389 REV 0 5.131

Replacement of parts _____________________________________________ Lift cylinder removal and installation To remove a lift cylinder (reference Fig. 80): Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

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

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

1. Shutdown the feeder breaker (see Shutdown procedure in this chapter).

2. Turn the circuit breaker to the “OFF” position and disconnect and lock and tag out the main power source. Follow all standard Federal and mine practices for locking/tagging out power sources.

3

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

4. Attach an appropriate lifting device to the lift cylinder.

5. Pull a cotter pin out of the pin through the cylinder eye and remove the pin.

6. Pull a cotter pin out of the pin through the rod eye and remove the pin.

________________________________________________________________ 5.132 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts To install a lift cylinder (reference Fig. 80): Whenever performing maintenance procedures, follow all safety regulations and be aware of the following: WARNING! Before performing maintenance on the machine, the circuit breaker should be in the “OFF” position and power should be locked and tagged out at the main power source. Electrical shock or accidental machine movement can cause serious injury or death to personnel.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

1. Attach an appropriate lifting device to the lift cylinder.

2. Align the cylinder in the mounting clevises on the machine.

3. Install the pin through the cylinder eye and secure with a cotter pin.

4. Install the pin through the rod eye and secure with a cotter pin.

5. Reconnect the hydraulic hoses to the cylinder.

6. Reconnect power to the machine.

7. Purge the hydraulic system of air.

______________________________________________________________ A6474X389 REV 0 5.133

Replacement of parts _____________________________________________ Fig. 80: Lift cylinder removal and installation

Cotter pin (2 per pin) (typical both ends)

Pin (typical both

Lift cylinder

________________________________________________________________ 5.134 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Conveyor motor distributor cap removal and installation When replacing the conveyor motor equipped with a tachometer sensor (right side of the machine), check to ensure that the replacement motor has a distributor cap with a “K” port (Fig. 81). If it does not, it will be necessary to remove the distributor cap from the old motor and install it on the replacement motor.

Fig. 81: Distributor cap and “K” port Incorrect distributor cap (no “K” port)

Correct distributor

“K” port

______________________________________________________________ A6474X389 REV 0 5.135

Replacement of parts _____________________________________________ To remove the distributor First remove the distributor with the “K” port from the existing motor: 1. Drain the motor casing of oil.

2. Mark the alignment of the distributor ports with respect to the drain-line holes. Make sure to mark both the distributor and the motor.

3. Remove the five (5) closing bolts of the distributor. Lift off the distributor cover and the distributor rotary (Fig. 82).

4. Take out the distributor drive pin and the distributor centering bush (Fig. 83).

5. If the distributor has a bronze bearing disc, remove the two locating pins.

6. Repeat steps 1 through 5 to remove the distributor from the replacement motor.

Fig. 82: Distributor cover and rotary removal

Fig. 83: Distributor drive pin and centering bush removal

________________________________________________________________ 5.136 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts To install the distributor 1. To avoid seriously damaging the motor, do not try to place a pre-assembled distributor cover with rotary valve and disc directly on the motor cover. The internal components of the distributor must be assembled separately from the distributor cover.

IMPORTANT! Make sure that no parts fall into the cylinder feed holes in the motor cover during assembly. If they do, the motor must be dismantled and the parts retrieved before continuing.

2. Rotary valve sub-assembly: Insert the o-ring (Fig. 84) and the plastic slipper (concave side on the o-ring side) (Fig. 85) in the seat in the top side of the distributor rotary. The plastic seal should be assembled by first placing the positioning lug in its seat (Fig. 86). for versions with the steel ring, first place the o-ring, then the plastic seal (without lug) and then the steel ring.

Fig. 84: O-ring installation

Fig. 85: Plastic slipper installation

Fig. 86: Plastic seal installation

______________________________________________________________ A6474X389 REV 0 5.137

Replacement of parts _____________________________________________ 3. Distributor cover sub-assembly: Insert the distributor/motor cover o-ring in the seat in the bottom of the distributor cover (Fig. 87). For distributors with the bronze disc, insert the o-ring (Fig. 88) and the plastic slipper (Fig. 89) with the chamfer on the side of the bottom of the distributor.

Fig. 87: O-ring installation

Fig. 88: O-ring installation

Fig. 89: Plastic slipper installation

________________________________________________________________ 5.138 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts 4. Rotary group assembly: Insert the distributor drive pin the shaft through the central hole in the motor cover (Fig. 90). Ensure that no parts fall in the cover. If they do, it will be necessary to dismantle the motor to retrieve the objects before continuing.

Fig. 90: Drive pin installation

5. Insert the locating pins in their holes in the motor cover (Fig. 91).

Fig. 91: Locating pin installation

______________________________________________________________ A6474X389 REV 0 5.139

Replacement of parts _____________________________________________ 6. Place the disc on cover, positioning it with the locating pins (Fig. 92).

Note: Motors produced before 7/87 used 0.236 inch pins. Motors produced after 7/87 use 0.196 inch pins. Some discs have holes for both size pins and it is important to position the disc using the correct holes. The disc must sit flush the motor cover. It does not need to be pressed on and the five oil feed holes must line up with the holes in the motor cover. Once positioned, it must not be able to rotate or to move laterally.

Fig. 92: Disc installation

7. Insert the centering bush in the disc (Fig. 93).

Fig. 93: Centering bush installation

________________________________________________________________ 5.140 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts 8. Position the distributor rotary on the disc with the side containing the seals on top and with the three radial holes to the left of the reference cylinder and the three axial holes to the right (Fig. 94).

Fig. 94: Distributor rotary installation

9. Place the distributor cover over the rotary, aligning the bolt holes in the distributor cover and the motor cover (Fig. 95). The distributor can be placed in any one of the five positions. Secure the cover with the five bolts.

Fig. 95: Distributor cap installation

______________________________________________________________ A6474X389 REV 0 5.141

Replacement of parts _____________________________________________ Fig. 96: Distributor assembly

2

3

4

5

6

7

8

9

10

11

12

13 14

1

1. Plastic plug 2. Bolt, M12X80 3. Distributor cover 4. O-ring 5. O-ring 6. Plastic seal 7. Anti-extrusion ring 8. Plastic seal 9. O-ring 10. Rotary distributor 11. Bushing 12. Bronze disc 13. Locating pins 14. Distributor drive pin

________________________________________________________________ 5.142 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_____________________________________________ Replacement of parts Tach mount and speed sensor installation (Fig. 97) 1. Remove the 1/2 inch BSP plug from the rear of the motor distributor cover.

2. Remove the gear cover by removing the four 1/8 inch screws.

3. Rotate the gear so that the male shaft tang aligns with the slot in the distributor housing.

4. Thread the tach mount assembly into the rear port of the motor distributor and snug tight.

5. Align gear so that a tip is directly under the M12 tapped hole by rotating the motor shaft.

6. Thread the HTM sensor into the M12 tapped hole.

7. Using a feeler gage, adjust the sensor so that the tip is between 1.0 and 1.5mm from the tip of the gear. Tighten lock nuts.

8. Reinstall the rear cover.

9. Attach M12 cable to end of the sensor.

______________________________________________________________ A6474X389 REV 0 5.143

Replacement of parts _____________________________________________ Fig. 97: Tach mount and sensor installation

________________________________________________________________ 5.144 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

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

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

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

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

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

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 98): 1. Close the needle valve on manifold assembly securely.

2. Attach a grease gun to the grease fitting located on the manifold and apply grease until the required chain tension is obtained. Sight across the bottom of the head shaft sprocket. The chain should sag approximately two inches below the bottom of the head shaft sprocket.

3. After tensioning the conveyor chain, locate the tailshaft take-up grease cylinders to the inside of the crawler tilt cylinders and remove the hardware that secures the shim pack onto the grease cylinder rod.

4. Insert shims over cylinder rod to fill the gap between the cylinder and the take-up push rod. Note the thickness and number of shims so that the other side is shimmed to the same length.

NOTICE! Make certain that the same amounts of shims are used on both sides of the conveyor to prevent chain from stretching unevenly. Incorrect tension or adjustment can cause premature wear of sprockets and chain.

Measure the exposed rod length on the grease take-up cylinders and make sure they are within 1/4” of each other.

5. Replace shim retainers.

6. Release pressure on the take-up cylinders by opening the top needle valve to vent grease. After grease has vented, close valve.

______________________________________________________________ A6474X389 REV 0 5.145

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

7. Store any unused shims inside the shim storage boxes.

Fig. 98: Conveyor chain adjustment (typical)

Shims

Shim storage

Grease take-up cylinder

Needle valve Shim retainer bar

________________________________________________________________ 5.146 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

___________________________________________ 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 crawler track tension with the take-up cylinders (Fig. 99): 1. 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.

2. Chain sag should be approximately two to three inches at the center of the crawler.

3. 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 two to three inches at the center of the crawler.

4. Turn needle valve knob clockwise (CW) to close.

WARNING! If only one side of the machine is raised, be careful and only move the control lever for that particular side. Moving the wrong control lever could cause the machine to move and fall off its supports. You could be seriously injured or even killed by falling loads.

5. Run crawler in forward direction for 30 seconds at slow speed.

6. Run crawler in reverse direction for 30 seconds at slow speed.

7. Shutdown machine.

8. If necessary, re-adjust chain tension.

9. Remove shim retainer bar and add or remove shims to maintain correct tension.

10. Release grease pressure in the cylinder by loosening the grease fitting and then turning the needle valve knob counter clockwise (CCW), allowing the shims to maintain the correct tension.

11. Cloase need valve and tighten grease fitting.

12. Install shim retainer bar.

WARNING! The grease cylinder is under high pressure. Do not visually inspect to see if grease is released. You could be seriously injured from high pressure grease.

13. Store and secure any unused shims on back of crawler cover plate.

______________________________________________________________ A6474X389 REV 0 5.147

Adjustment procedures ___________________________________________ Fig. 99: Crawler track adjustment

Access cover

When properly tensioned, chain sag should be 2” at center of crawler

Cylinder retainer bar/ shim retainer plate

Retainer bar location (not shown for shim viewing) Grease fitting

Needle valve

Take-up cylinder

Shims (located behind retainer plate)

________________________________________________________________ 5.148 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

___________________________________________ Adjustment procedures Breaker drive chain The breaker drive chain should be checked for correct tension at regular intervals. If the chain is too loose or too tight, the power unit tray position can be moved to adjust the chain tension. Correct tension of the chain is achieved when the non-driving side of the chain has approximately one inch (25 mm) of slack or droop.

To adjust the breaker drive chain tension (Fig. 100): 1. Open the covers to access the power unit.

2. Loosen the Super nuts (jack bolts) that secure the power unit tray in position as follows: a. Loosen each jackbolt on the nut 1/8 turn following a star pattern around the nut (1 round only). As you move around and get back to the first jackbolt, it will be tight again. b. Repeat a 2nd round as in Step a, loosening each jackbolt 1/4 turn in a star pattern. c.

Continue loosening 1/4 turn for 3rd and following rounds until all jackbolts are loose. Note: Usually after the 3rd or 4th round, can be completely remove.

d. Remove, clean and lubricate with Never Seeze the jackbolts prior to installation. e. Repeat this process for all nine (9) Super nuts.

3. Open both grease valves.

To tighten the chain (move the power unit tray towards the tail shaft): 4. Loosen the grease fitting on the left take-up cylinder so that it can collapse as the chain is loosened.

5. Pump grease into the grease fitting on the right take-up cylinder until the correct chain tension is achieved.

To loosen the chain (move the power unit tray towards the head shaft): 4. Loosen the grease fitting on the right take-up cylinder so that it can collapse as the chain is loosened.

5. Pump grease into the grease fitting on the right take-up cylinder until the correct chain tension is achieved.

6. Close the open grease fitting.

7. Close both grease valves.

8. Install the take-up shims to fill the gap between the power tray and the grease cylinder mount.

______________________________________________________________ A6474X389 REV 0 5.149

Adjustment procedures ___________________________________________ 9. Install the Super nuts (jackbolts) as follows: a. Spin the tensioner (nut) onto the main thread until it seats against the washer. b. In a star pattern, torque all jackbolts to 7 ft-lbs using a torque wrench. c.

Tighten in a star pattern all nine (9) jackbolts to 14 ft-lbs using a torque wrench.

d. Stabilize the jackbolt torque to 14 ft-lb by repeating the tightening process in a star pattern an additional two to four passes. e. Repeat steps a through d for each Super nut on the power tray unit.

Fig. 100: Breaker drive chain tensioning

Jackbolt

Tensioner

Power unit tray

________________________________________________________________ 5.150 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

___________________________________________ Adjustment procedures Fig. 100, continued: Breaker drive chain tensioning

Loosen chain (move towards head shaft )

1

1.

2.

3.

4.

5.

6.

2

Tighten chain (move towards tail shaft )

3

4

5

6

Left take-up cylinder Left grease fitting Left grease valve Right grease valve Right grease fitting Right take-up cylinder

______________________________________________________________ A6474X389 REV 0 5.151

Adjustment procedures ___________________________________________ Underspeed sensor calibration To calibrate the underspeed sensor (Fig. 101): 1. Start the feeder breaker (see Startup procedure in this chapter).

2. Start the conveyor belt and run at the slowest normal operating speed expected.

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

3. Turn Speed 1 control switch left (ccw) until it stops (approximately 7 o’clock).

4. Hold test/set switch (SW1) in the set position to engage relay (RY1).

5. Turn Speed 1 control switch right (cw) slowly until critical speed LED (LED 3) stays lit continuously.

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

6. Continue turning Speed 1 control right (cw) until margin LED (LED 4) begins to blink. a. The control relay will drop out with the above at a 15% slow down. b. For a 20% margin, adjust the Speed 1 control so that the margin light (LED 4) is continuously on. c.

For a 10% margin, turn the Speed 1 control left (ccw) until the margin light (LED 4) turns off.

7. After the relay status LED is illuminated, return the test/set switch to the run position.

8. A momentary test position is provided to simulate the loss of sensor signal, which releases the relay.

9. Clean any accumulated dirt and grease from around the sensor (Fig. 53) to avoid sensor interference.

________________________________________________________________ 5.152 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

___________________________________________ Adjustment procedures Fig. 101: Under speed senor calibration

Test/set switch, SW1

Speed 1 control switch

Test/set switch, SW1

______________________________________________________________ A6474X389 REV 0 5.153

Adjustment procedures ___________________________________________ Fig. 102: Underspeed sensor and target

Target

Sensor

________________________________________________________________ 5.154 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

___________________________________________ Adjustment procedures There are two pumps on the machine: an open loop, load sense pump and a piggyback fixed displacement gear pump. The open loop, load sense pump powers all hydraulic functions while the piggyback fixed displacement gear pump supplies cooling flow to the cases of the main pump and the conveyor drive motor and drives the heat exchanger fan motor, if equipped. There are no adjustments on the gear pump.

Main pump adjustments Margin pressure To adjust the margin pressure on the main pump: 1. Tee a multi-gauge into the system pressure line.

2. With no functions active, the margin pressure should read 30 bar (435 psi).

If adjustment is necessary: a. Locate the margin pressure cartridge (Fig. 103). b. Loosen the hex nut that holds the adjustment stem in place. c.

Turn the stem clockwise (in) to increase pressure or counterclockwise (out) to decrease pressure.

d. Once the desired pressure, 40 bar (435 psi), is obtained, tighten the hex nut while holding the adjustment stem in place. e. After the hex nut is tight, recheck the pressure to ensure the adjustment stem did not move. If necessary, readjust.

Pressure compensator To adjust the pressure compensator setting: 1. Tee a multi-gauge into the system pressure line.

2. Adjust the main relief valve to 370 bar (5,365 psi) (see Main relief adjustment procedure in this section).

3. Zero out the margin pressure adjustment by turning the adjustment stem (Fig. 69) clockwise (in) all the way. This system will now be a pressure compensated system and will maintain system pressure at all times. The pressure should now read 350 bar (5,000 psi). If adjustment is necessary: a. Loosen the hex nut that holds the adjustment stem in place. b. Turn the stem clockwise (in) to increase pressure or counterclockwise (out) to decrease pressure. c.

While holding the adjustment stem in place, tighten the hex nut.

4. Adjust the main relief valve to 370 bar (5,365 psi).

______________________________________________________________ A6474X389 REV 0 5.155

Adjustment procedures ___________________________________________ 5. Once the pressure compensator is set, reset the margin pressure adjustment to 30 bar (435 psi) (see Margin pressure adjustment procedure in this section).

Fig. 103: Pump adjustments Pressure compensator adjustment

Margin pressure adjustment

________________________________________________________________ 5.156 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

___________________________________________ Adjustment procedures Main relief pressure To adjust the main relief (Fig. 104): 1. Maximize the main relief setting. a. Loosen the jam nut that holds the adjustment stem in place. b. Turn the adjustment stem fully clockwise.

2. Adjust the pressure compensator to 5,500 psi (see Pressure compensator adjustment procedure in this section).

3. Read the pressure on the system pressure gauge. If needed, adjust the main relief until the pressure reads 370 bar (5,365 psi). Turn the adjustment stem clockwise to increase pressure or counterclockwise to decrease pressure. The relief will be audible when dumping over.

4. Tighten the jam nut to secure the relief adjustment stem.

5. Adjust the pressure compensator to 350 bar (5,000 psi) (see Pressure compensator adjustment procedure in this section).

6. Once the pressure compensator is set, reset the margin pressure to 30 bar (435 psi) (see Margin pressure adjustment procedure in this section).

______________________________________________________________ A6474X389 REV 0 5.157

Adjustment procedures ___________________________________________ Fig. 104: Main relief and pressure limiter adjustments System pressure gauge

Main relief adjustment

Pressure limiter “A” adjustment

Pressure limiter “B” adjustment

________________________________________________________________ 5.158 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

___________________________________________ Adjustment procedures Pressure limiter adjustment To adjust the pressure limiter (Fig. 105).

1. Locate the pressure limiters on the bottom of the valve bank under the handle.

2. Refer to the hydraulic schematic to determine which pressure limiter, A or B, needs adjusted. To determine the pressure limiter setting, bottom out the cylinder (fully extend or retract) and read the function pressure on the system pressure gauge.

IMPORTANT! To determine the pressure limiter settings on the tram sections, the feeder breaker will have to be safely stalled out by deadheading into the rib in both directions or by plugging and capping both A and B ports.

3. If an adjustment is need, remove the cap over the adjustment stem.

4. Loosen the hex nut that holds the adjustment stem in place.

5. Turn the adjustment stem clockwise (in) to increase pressure or counterclockwise (out) to decrease pressure setting.

6. Once the desired pressure is obtained, tighten the hex nut while holding the adjustment stem in place.

7. Replace the cap over the adjustment stem.

8. Retest the function to ensure the pressure adjustment was not changed while tightening the hex nut. If necessary, repeat adjustment.

______________________________________________________________ A6474X389 REV 0 5.159

Adjustment procedures ___________________________________________ Torque hub brakes - PRV adjustment The pressure reducing valve (PRV) on the brakes on the torque hubs is set at the factory and should not need adjustment.

________________________________________________________________ 5.160 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_________________________________________________ Troubleshooting Troubleshooting procedures Typical hydraulic problems The most common causes for improper hydraulic functions are: 

contaminated or poor quality hydraulic oil



low or insufficient oil in the system



using the wrong type or viscosity grade of hydraulic oil



air in the hydraulic system



internal or external leakage of the hydraulic system



improper mechanical adjustments (such as reliefs)



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, or other critical components

The greatest aid to troubleshooting a hydraulic system is the confidence that comes with knowing the intended operation of the system, along with a fundamental understanding of basic hydraulic principles.

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 by scoring valves, clogging orifices, and wearing seals prematurely. It is not the intent of this manual to outline a contamination control program but some of the most effective steps that have been identified in successful programs are given below: 1. Ensure that bulk oils are at acceptable cleanliness levels.

–

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

–

utilize 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

______________________________________________________________ A6474X389 REV 0 5.161

Troubleshooting _________________________________________________ –

utilize filter carts to maintain oil cleanliness standards

–

properly train personnel on the importance of clean oil and best practices for storage and handling

–

monitor the 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 which are given below: –

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 machine

–

cap off all open hoses/fittings

–

never touch a filter with bare hands when installing it back onto the machine

–

pay close attention to the filler/breather cap and replace it when damaged or in the recommended time frame

Contact your Bucyrus representative for more information on implementing an effective program to ensure that your oil and maintenance practices are not contributing to your equipment failure.

________________________________________________________________ 5.162 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_________________________________________________ Troubleshooting Open loop pump troubleshooting The pump used on this machine is a axial piston pump with load sense and pressure compensation control. Maximum displacement is 165 cc/rev (10 cubic inches) and maximum service pressure is 400 bar (6,090 psi). There is a secondary gear pump mounted to the rear of the main pump that supplies cooling flow to the cases of the main pump and the conveyor drive motor. In an open loop configuration, there is no charge pump. The supply to the pump is a direct suction line to the hydraulic oil reservoir.

A pressure transducer is located at the pump inlet to monitor for a blocked suction line, however, it does not guard against aeration caused by a leaking suction line or low oil level in the reservoir. If either of these occur, the pump will make an erratic grinding noise and will run at elevated temperatures. The pump will fail quickly at these conditions and should be shutdown immediately.

Investigate oil level and suction hose integrity and identify and correct the issue before operating the pump.

At startup, the pump will be on full stroke to prime itself. Once the pump is at full speed, its control will de-stroke the displacement to a minimum and reduce system pressure to approximately 30 bar (435 psi). This mode is referred to as “standby” or “margin” and is typical of load sense controlled pumps. In standby, the system pressure gauge will read 30 bar (435 psi) and the load sense pressure gauge will read 0 bar. The actual output of the pump is at low pressure and only at a flow rate required to make up for internal system leakage. In this mode, the pump is waiting for a signal to provide higher pressure and flow to meet a specific task. That signal is in the load sense line which connects the pump control to the main valve bank. When valves are shifted to run a function of the machine. For example, the conveyor control valves will connect the load pressure of the conveyor motor circuit to the load sense line. The pump will quickly respond by increasing its displacement to create the pressure to meet that conveyor load. At this point, the load sense gauge will read the load of the conveyor function and the system pressure gauge will reflect that load pressure plus the margin pressure. If the conveyor requires 250 bar (3,625 psi) to operate, the system pressure will be 280 bar (250 bar +30 bar) (4,061 psi).

The adjustment of the load sense margin pressure is located on the control block at the top rear of the pump. It is the adjusting screw located at the front of the block.

The pump control includes a second stage for pressure compensation. This feature limits the maximum output pressure of the pump. When the pressure compensation setting is reached, the pump will quickly de-stroke to a minimum output. This condition is referred to as “dead head” or “stall” . The pump will continue to hold this pressure until the function is stopped. In the conveyor function, stall may arise from an obstruction in the breaker and this condition is monitored by a pressure transducer. The pump itself can operate in this mode indefinitely due to the operation of the pressure compensator.

______________________________________________________________ A6474X389 REV 0 5.163

Troubleshooting _________________________________________________ The pump itself can operate in this mode indefinitely due to the operation of the pressure compensator. There is no excess hydraulic heat generated because relief valves are not opening to control the pressure limitation. If there is significant heating during a stall or high pressure operation, check the setting of the system relief located in the inlet of the main valve bank. This relief valve is preset to 370 bar (5,365 psi). To verify its setting, the pump compensator must be raised to 380 bar (5,510 psi). Once the relief is correctly adjusted, reduce the pump compensator to 350 bar (5,075 psi). If the relief is set lower than the pressure compensator, the relief valve will open, causing system heating.

The adjustment of the pressure compensator setting is located on the control block at the top rear of the pump. It is the adjusting screw located at the rear of the block. The pressure compensator must be adjusted while the pump is “loaded”. This is best accomplished with the conveyor function engaged.

The main pump is an efficient device: displacement efficiency when new is approximately 98%. The pump will produce nominal 74.75 gpm at 1,750 rpm.

This means internal leakage is only 1.5 - 2.0 gpm. As a pump ages and wears, the efficiency will decrease, resulting in increased flow from the case drain port.

Because the flow from the main pump case is a combination of internal leakage and the cooling flow, the case drain flow from a new pump will average 6 gpm.

If case drain leakage exceeds 10 gpm, the main pump should be changed out. An acceptable method of measuring case drain leakage is to use a five gallon bucket and a stop watch. If the five gallon bucket is filled in 30 seconds, the pump needs changed.

When removing a used pump, use the plugs from the replacement pump and duct tape to seal off all ports on the used pump.

If a pump is replaced, 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.

The pump has two case drain ports - the highest on should be used for filling.

Upon installation, top up oil in pump case at the highest case drain port. Jog the pump motor at least five time before starting up. If the pump is properly filled and priming, it will run and sound smoothly on startup.

________________________________________________________________ 5.164 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_________________________________________________ Troubleshooting Table 3: Troubleshooting excessive noise

Pump Noisy Cause

Motor Noisy Remedy

Cause

Cavitation

A

Coupling misaligned

Air in fluid

B

Motor or coupling worn or damaged

Coupling misaligned

C

Pump worn or damaged

E

Relief/Counterbalance Valve Noisy Remedy

Cause

Remedy

C

Setting too low or too close to another valve setting

D

Worn poppet and seat

E

Remedies 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

______________________________________________________________ A6474X389 REV 0 5.165

Troubleshooting _________________________________________________ Table 4: Troubleshooting excessive heat Pump Heated

Motor Heated Cause

Relief Valve Heated

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

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

Remedies 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. Any or all of the following:   

change filters check system fluid viscosity; change if necessary fill reservoir to proper level

G. Any or all of the following: 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

 

clean cooler and/or strainer repair or replace cooler

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

________________________________________________________________ 5.166 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_________________________________________________ Troubleshooting Table 5: Troubleshooting incorrect flow No Flow 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

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 F. Check position of manually operated controls G. Reverse rotation H. Replace with correct unit

______________________________________________________________ A6474X389 REV 0 5.167

Troubleshooting _________________________________________________ Table 6: Troubleshooting incorrect pressure No Pressure Cause

Remedy

No flow

See Table 5

Low Pressure Cause

Erratic Pressure

Remedy

Pressure relief path exists

See Table 5

Damaged pump, motor, or cylinder

E

Cause

Remedy

Air in fluid

B

Worn relief valve

E

Contamination in fluid

A

Worn pump, motor, or cylinder

E

Remedies A. Replace dirty filters and system fluid B. Any or all of the following:  

tighten leaky connections fill reservoir to proper level and bleed air from system

C. Any or all of the following   

gas valve for leakage charge to correct pressure overhaul if defective

D. Adjust valve E. Overhaul or replace part

________________________________________________________________ 5.168 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_________________________________________________ Troubleshooting Hydraulic system (general) Table 7: Hydraulic system (general) troubleshooting Trouble or symptom

Probable cause

dirty oil  Components not properly cleaned during servicing.

Test, check and/or remedy  Disassemble components and re-clean parts.

 Air breather left off.

 Add breather.

 Hose lines not properly covered when servic-

 Keep hose ends protected from contamina-

ing machine.

tion while disconnected. Clean hose lines before reconnecting.

 Filter elements not replaced at proper intervals  Replace elements at proper intervals. or when indicated. foaming oil  Tank return lines not below fluid level.

 Oil contaminated with incompatible foreign matter.

 Suction leak to pump aerating oil. moisture in oil  Soluble oil solution splashing into poorly sealed tank gasket or fill holes left open.

 Check oil level.  Drain out oil and replace with clean oil and change filter.

 Replace or tighten fittings and lines.  Drain out and refill with clean oil. Check fill pipes to see if they are properly closed.

 Moisture in cans of replacement oil.

 Replace with new cans of oil.

 Extreme temperature differential in certain

 Store oil in an area that protects against

geographical locations. overheating of system  Fluid viscosity too high.

 Excessive slippage or internal leakage past pump or cylinders.

 Oil level too low.  Improper air circulation around reservoir.  System relief valve set too high or too low. prolonged operation of  Sticking selector or other control valve. a function at pressures above normal idle

exposure to frequent extreme temperature changes.

 Check fluid specifications.  Fluid viscosity too low. Test components for specified flow or by-pass conditions.

 Check/add oil.  Check to see if the area around the reservoir is clear.

 Reset the relief valve to specifications.  Isolate circuits/components and identify fault.

______________________________________________________________ A6474X389 REV 0 5.169

Troubleshooting _________________________________________________ Table 7 (continued): Hydraulic system (general) troubleshooting Trouble or symptom

Probable cause

foreign matter sources  Sealing compound (pipe dope, Teflon tape). in the circuit 

 Tank or component ports left open to atmosphere.

Test, check and/or remedy  Clean or replace seals. Drain and replace oil as necessary.

 Cap or plug properly. Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.

 Lines left unprotected or dirty repaired compo-  Replace filter elements and monitor oil nents.

 Repair parts not properly protected while stored.

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.

________________________________________________________________ 5.170 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_________________________________________________ Troubleshooting Hydraulic cylinders Table 8: Hydraulic cylinder troubleshooting Trouble or symptom

Probable cause

cylinder drifts  Piston seal leak.

Test, check and/or remedy  Repair seals or replace cylinder.

 Control cartridge by-passing.

 Replace cartridge or cylinder as required.

 Other circuit leaks.

 Correct leaks.

cylinder fails to move  Pressure too low. when actuated

 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

 Replace cylinder. Check oil cleanliness

scored cylinder bore. erratic or chatter in  Excessive friction due to misalignment and/or operation side loading.

 Air in circuit.

and change as required.

 Inspect cylinder installation for proper operation and/or for foreign objects that inhibit the normal operation of the cylinder.

 Cycle cylinder to full stop positions to purge air.

excessive or rapid  Excessive system pressure due to over adjust-  Check and correct pressure adjustment to piston seal wear ment. rated limits.

 Excessive friction due to misalignment and/or side loading. cylinder body seal leak  Excessive pressure.

 Inspect cylinder installation for proper operation and/or for foreign objects that inhibit the normal operation of the cylinder.

 Check and correct pressure adjustment to rated limits.

 Seal is pinched or extruded.

 Replace seal and/or cylinder as required.

 Seal deterioration (soft or gummy).

 Check for contamination of fluids (incompatibility). Flush system and refill with correct fluid. Replace seal and/or cylinder as required.

piston is leaking  Dirt has scored the piston or the rod. piston freezes  Scoring in the piston. to the tube packing and gasket  Excessive heat/wear. leaks develop

 Replace cylinder.  Replace cylinder.  Replace seal and/or cylinder as required.

______________________________________________________________ A6474X389 REV 0 5.171

Troubleshooting _________________________________________________ Hydraulic pump Table 9: Hydraulic pump troubleshooting Trouble or symptom

Probable cause

pump makes  Vacuum leaks in suction line. excessive noise

 Vacuum leaks in the pump shaft seal.

Test, check and/or remedy  Check for leaks in fittings or damaged suction lines.

 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

 Clean by removing the foreign material

strainer.

 Plugged reservoir filter breather.

blocking oil flow.

 Clean or replace filter breather as required.

seal leak  Torn or worn seals.

 Gland bearing worn.

 Replace seal.  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/ loss of elastic-

 Replace seal.

ity).

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

 Check pump shaft for possible bearing wear. Replace seal.

 Loose or worn pump parts.  Replace worn pump parts. ________________________________________________________________ 5.172 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_________________________________________________ Troubleshooting Table 9 (continued): Hydraulic pump troubleshooting Trouble or symptom

Probable cause

pump fails to deliver oil  Low oil level in reservoir.

Test, check and/or remedy  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.

oil leakage  Shaft seal worn. around pump

 Hose connections leaking.

 Replace seals.  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

 Oil viscosity too low.

 Replace with recommended oil and change

with clean hydraulic oil. Replace filter elements and implement frequent element changes until the desired cleanliness of the system is attained.

filter elements.

 Excessive pump loads.

 Check relief valve adjustment. Reset to correct setting.

pump parts inside  Seizure due to lack of oil. the housing are broken

 Excessive system pressure above maximum pump rating.

 Excessive torque to housing bolts.

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

 Replace pump and filter elements. Minimize the relief pressure adjustment before starting the new pump. Replace relief valve if correct adjustment cannot be obtained.

 Replace pump and filter elements.

 Solid matter being drawn in from reservoir and  Replace pump and filter elements, suction wedged in pump.

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

______________________________________________________________ A6474X389 REV 0 5.173

Troubleshooting _________________________________________________ Valves Table 10: Valve troubleshooting Trouble or symptom

Probable cause

operating pressure  Valve spring broken. cannot be changed

 Open valve in the system. valve piston sticks  Dirt in the system.

Test, check and/or remedy  Replace the spring, valve cartridge, or valve assembly as required.

 Locate and repair the open valve condition.  Remove the valve and clean it thoroughly; flush the system as necessary. Replace valve as required and replace filter elements.

certain passages are  Dirt in the system. blocked or pressure fluctuates

 Remove the valve and clean it thoroughly;

the pressure fluctuates  Air in the system. and there is extreme noise in the valve

 Check for leaks and other points that may

 Pressure or volume too high.

flush the system as necessary. Replace valve as required and replace filter elements. allow air into the system. Repair as required.

 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.

excessive leakage or  Valve excessively hot. sticking pistons occurs

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

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.

oil leaks  Pinched, blown or missing section seal. between sections

 Replace section seal.

 Stud fasteners not correctly torqued.

 Replace section seals and re-torque.

 Mounting plate not level.

 Loosen mounting bolts and shim as required.

 Contamination/butts on seal.

 Clean seal groove and replace section seal.

________________________________________________________________ 5.174 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

Mechanical assemblies____________________________________________ Table 10 (continued): Valve troubleshooting Trouble or symptom

Probable cause

oil leaks at either  Over-pressurized tank core. end of spool

 Worn or damaged spool seals. spring centered spools  Broken centering spring. do not return to neutral

Test, check and/or remedy  Correct high back pressure condition.  Replace seals and seal retainers.  Replace centering spring.

 Misalignment of operating linkage.

 Check linkage for mechanical binding.

 Foreign particles in system.

 Clean valve and system.

load will not hold  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.

load drops when spool  Dirt or foreign particles lodged between check moved from neutral valve poppet and seat.

 Scored or sticking check valve poppet. no motion, slow, or  Worn pump. erratic system operation  Defective cylinder or motor.

 Disassemble, clean, and reassemble.  Replace poppet.  Check flow and pressure.  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  Replace relief valve. open.

 Valve spool not shifted full stroke.

 Check spool linkage travel.

________________________________________________________________ 5.175 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

Troubleshooting _________________________________________________ Bearings Table 11: Bearing troubleshooting Trouble or symptom

Probable cause

overheating bearing  Wrong type of grease or oil.

Test, check and/or remedy  Consult the lubrication chart for the proper lubricant.

 Low oil level; loss of lubricant through seal; excessive grease.

 Insufficient clearance in bearing.

 Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.

 Replacement bearing should be identical to original equipment to ensure proper internal clearance.

 Housing bore out of round; housing warped;

 Check and scrape housing bore to relieve

excessive distortion of housing; undersized housing bore.

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.

noisy bearing  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;

 Check and scrape housing bore to relieve

excessive distortion of housing; undersized housing bore.

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

 Replace bearing, shaft and other parts as

distorted. vibrating bearing  Enlarged housing bore causing spinning of outer ring in housing.

 Foreign matter acting as abrasive.

needed.

 Re-bore housing and press steel bushing in bore, then machine bore to correct size.

 Clean bearing housing and replace worn seals.

 Unbalanced loading.

 Check balance of rotating parts and rebalance as needed.

unsatisfactory per- Chip in bearing housing; insufficient clearance in formance 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.

________________________________________________________________ 5.176 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_________________________________________________ Troubleshooting Torque hub troubleshooting Table 12: Torque hub troubleshooting Trouble or symptom

Probable cause

oil leaks  Damaged internal seals.

 Breathing plug clogged. excessive overhearing  Insufficient oil.

Test, check and/or remedy  Contact Bucyrus.  Change or clean the breather.  Check oil level and add as necessary.

 Internal problems.

 Call Bucyrus.

excessive noise  Internal problems.

 Call Bucyrus.

negative brake fails to  Loose hydraulic connection. disconnect

 Check hydraulic connections and repair as necessary.

 Internal problems.

 Call Bucyrus.

negative brake fails to  Internal problems. brake

 Call Bucyrus.

unit fails to turn when  Motor mounted incorrectly. motor is pressurized

 Check motor mounting and correct as nec-

 Internal breakage. gearbox rotates in  Incorrect hosing to the motor. wrong direction reduction gear cannot  Incorrect dimensioning. be assembled on the mounting face gearbox does not  Incorrect motor mounting. rotate

 Internal problems.

essary.

 Call Bucyrus.  Check hosing and correct as necessary.  Check dimensions. Contact Bucyrus.

 Check motor mounting and correct as necessary.

 Call Bucyrus.

______________________________________________________________ A6474X389 REV 0 5.177

Troubleshooting _________________________________________________

________________________________________________________________ 5.178 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

_______________________________________________________________

Technical data

________________________________________________________________

_______________________________________________________________

________________________________________________________________

__________________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Model GHMFBHM-48CDL Feeder Breaker, serial number 54-2183. 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 serial number 54-2186 only.

Other machines with the same model number may vary.

Technical data sheet general

Overall length ....................................................................... approx. 41’ 6-13/16” (12.67 m) Overall width......................................................................... approx. 11’ 5” (3.48 m) Tramming height minimum ........................................................................ approx. 79-11/16” (2.03 m) maximum ....................................................................... approx. 91-11/16” (2.33 m) Ground clearance minimum ........................................................................ approx. 0” (0 mm) maximum ....................................................................... approx. 12” (305 mm) Receiving height (min).......................................................... approx. 13” (330 mm) Discharge height (min) ......................................................... approx. 40” (1,014 mm) Heaped hopper capacity: ..................................................... approx. 431 ft³ (12.2 m3) Weight: ................................................................................. approx. 85,000 lbs (38,555 kg)

performance

Material input size (max) ...................................................... approx. 2’ x 3’ x 4’ (610mm x914 mm x1219mm) Maximum material strength: ................................................. approx. 30,000 psi (206.9 Mpa) Nominal output size:................................... approx. 8” (203 mm)(one dimension) Discharge rate minimum .......................... approx. 277 tph (251 mtph) @ 19 fpm (6 mpm) maximum ......................... approx. 554 tph (503 mtph) @ 37 fpm (11 mpm) Material to be broken:...........................................Oil shale & Limestone

______________________________________________________________ A6474X389 REV 0 6.3

Technical data ___________________________________________________

________________________________________________________________ 6.4 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

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

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

Set screws Table 13: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

Table 14: Hex and socket head cap screws, coarse thread (Grade 8) Nominal diameter ¼” 5/16” 3/8” 7/16” ½” 9/16” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting (lubed) 8 ft-lbs 16 ft-lbs 28 ft-lbs 45 ft-lbs 70 ft-lbs 99 ft-lbs 135 ft-lbs 240 ft-lbs 390 ft-lbs 545 ft-lbs 830 ft-lbs 1,160 ft-lbs 1,525 ft-lbs 2,030 ft-lbs

Recommended torque setting (dry) 13 ft-lbs 26 ft-lbs 47 ft-lbs 75 ft-lbs 115 ft-lbs 165 ft-lbs 225 ft-lbs 400 ft-lbs 645 ft-lbs 905 ft-lbs 1,380 ft-lbs 1,935 ft-lbs 2,540 ft-lbs 3,380 ft-lbs

______________________________________________________________ A6474X389 REV 0 6.5

Tightening torques _______________________________________________ Table 15: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15 10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Table 15: Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 15: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

________________________________________________________________ 6.6 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

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

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.

______________________________________________________________ A6474X389 REV 0 6.7

Permissible media________________________________________________ Table 16: Anti-wear hydraulic oil (Spec. 100-1) specification Limit

Type

ISO VG

61/75

68

ASTM Grade

380/345

315

Pour Point (ASTM D-97)

Max. 20° F (-7° C)

-20° F

Flash Point (ASTM D-92)

Min. 415° F (212° C)

400° F

Viscosity SUS @ 100° F 283-347

352

SUS @ 210° F 50-58

56

CST @ 40° C

61.2 - 74.8

CST @ 100° C

8.5 Typ.

Viscosity Index (ASTM D-2270)

Min. 90

96

Oxidation Test (ASTM D-943)

2.0 mg KOH max after 1000 hrs

Rust Prevention Test (ASTM D-665, A & B

Pass

Pass

Foam Test (ASTM D-892-46T)

Pass

Pass

Four Ball Wear Test (ASTM D-2266) (40 KG, 1800 RPM, 130° F, one hour)

Not more than 0.50 mm scar diameter

0.50 mm

400 mg max

294 mg

Copper

200 mg max

131 mg

Iron

100 mg max

3 mg

50 mg max

25 mg

Sludge & Metal Corrosion (ASTM D-943) (conducted at conclusion of 1000 hour oxidation test) Insoluble sludge in oil and water layers plut that adhering to the catalyst coils or the test tub.

Metals in combined oil, water, and sludge (ASTM D-810-59)

Pump Wear Test (ASTM D-2882) (Total Ring and Vane Weight Loss) Hydrolytic Stability Test (ASTM D-2619)

0.1

Copper Specimen Weight Loss

0.05 mg/CM2 max

Acidity of Water Layer

6.0 mg KOH max

0.5

________________________________________________________________ 6.8 Bucyrus – Model GH-MFBHM-48CDHFeeder Breaker

_______________________________________________ Permissible media Table 17: Anti-wear hydraulic oil (Spec 100-1) approved suppliers 1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18

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

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

______________________________________________________________ A6474X389 REV 0 6.9

Permissible media________________________________________________ Table 18: Extreme pressure gear oils (Spec. 100-2) specification Limit

Type

ISO VG

460

460

SAE Grade, Extreme Pressure Type

140

140

Pour Point (ASTM D-97)

Max. 20° F (-7° C)

20° F

Flash Point (ASTM D-92)

Min. 450° F (232° C)

440° F

SUS @ 100° F 283-347

1844/4345

22372609

SUS @ 210° F 50-58

120/200

149

CST @ 40° C

414/506

CST @ 100° C

30.3

Viscosity

Viscosity Index (ASTM D-2270)

Min. 85

96

Oxidation Test, Oil blown for 312 hours at 250° F 6% max (95° C). Ten liters of dry air per hour. Percent increase SSU viscosity at 210° F

2.2% increase

Four Ball Wear Test (ASTM D-2266) (20 KG, 1800 RPM, 130° F, one hour)

Max 0.8 mm scar diameter

0.27 mm

Four Ball EP Test (ASTM D-2783)

Load wear index not less than 45

47

Timken Test (ASTM D-2782)

Min. 60 lbs

65 lbs

Coefficient of Friction

Max. 0.1

Unknown

Water in Oil

1.5 mL max.

0.8 mL

Free Water

81 mL min.

83.0 mL

After Centrifuge

2 mL max.

0.7 mL

Total Water

84.85 mL min.

83.7 ml

Demulsibility Test (ASTM D-2711)

Demulsibility Test (USS 244 Requirement) Water in Oil

2.0 mL max.

Free Water

80 mL max.

After Centrifuge

2.0 mL max.

Total Water

30 mL min.

________________________________________________________________ 6.10 Bucyrus – Model GH-MFBHM-48CDHFeeder Breaker

_______________________________________________ Permissible media Table 19: Extreme pressure gear oils (Spec. 100-2) approved suppliers 1 2 3

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation

4

Chevron U.S.A.

5 6

Sun Oil Company Unocal 76

7 8

Shell Oil company Century Lubricating Oils, Inc.

9 10 11

Texaco Lubricants Company Exxon Pennzoil

12

Lubricating Engineers

13 14 15

Conoco Inc. Hydrotex Phillips

16

Miners Oil

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

______________________________________________________________ A6474X389 REV 0 6.11

Permissible media________________________________________________ Table 20: Extreme pressure motor bearing grease and hand grease (Spec. 100-3)specification Limit NLG1 Grade Number 2

Type 2

Worker Penetration (ASTM D-217)

265-295

280

Dropping Point (ASTM D-566) Bomb Oxidation (ASTM D-942)

Min. 350° F (177° C) Not more than 10 PSI DROP

373° F 2.5

Rust Inhibitors

Required

Yes

Wheel Bearing Test (ASTM D-1263) (6 Hours @ 235° F )

Not more than 5% loss

Water Washout (ASTM D-1264)

Loss not more than 5% @ 100° F Loss not more than 15% @ 175° F

Grease Mobility

Not less than 0.1 gram flow per Second @ 0° F

Timken OK Load (ASTM D-2509)

Not less than 50 lbs.

(50 lbs.)

Four Ball EP Test (ASTM D-2569)

Load wear index not less than 30.0 Weld point not less than 200 kg. Min.

31 200

4.25 4.00

Four Ball Wear Test (ASTM D-2266) Not more than 0.60 mm. SCAR diameter 0.44 (20KG., 1800 RPM, 130° F, One Hour) Table 21: Extreme pressure motor bearing and hand grease (Spec. 100-3) approved suppliers

1

Supplier Amoco Oil Company

2 3 4 5 6 7 8

Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century - Fuchs

9 10 11 12 13

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14

Hydrotex

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 Replex 2, 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

15 16

Phillips Atlantic Richfield Company

Philube EP Grease Litholine H EP-2 Grease

________________________________________________________________ 6.12 Bucyrus – Model GH-MFBHM-48CDHFeeder Breaker

_______________________________________________ Permissible media Table 22: Extreme pressure gear oil, SAE 90 (Spec. 100-6) specification Limit

Type

SAE Grade

90

90

ISO Viscosity Grade

320

320

Viscosity Index (ASTM D-2270)

95 min.

96

Flash Point (ASTM D-92)

420 min. (215° C)

440

Pour Point (ASTM D-97)

0° F (-18° C)

+10

Timken Load Test (ASTM D-2782)

60 lbs. weld

60 lbs.

Four Ball Wear Test (ASTM D-2266)

220 kg point min.

220 weld point

20kg, 1800 rpm, 130° F, 1 hour

0.5mm scar diameter

0.30 wear scar

SUS @ 100° F 283-347

720-1750 sec

1000 sec

SUS @ 210° F 50-58

100-120 sec

119

CST @ 40° C

288/352

CST @ 100° C

24

Viscosity

FZG Test

12

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

1 2 3 4

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

5 6 7 8 9 10 11 12

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

13 14 15

Conoco Inc. Hydrotex Phillips

16 17 18 19 20

Atlantic Richfield Cities Service Pennzoil Miner Oil Texaco, Lubricants Company

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

______________________________________________________________ A6474X389 REV 0 6.13

Permissible media________________________________________________ Table 24: Synthetic EP gear lubricants (Spec. 100-13) specification Limit ISO Viscosity Grade (ASTM D-2422)

680

AGMA Grade (AGMA 9005)

8 EP

API Gravity (ASTM D-1298)

25.0

Type

Viscosity SUS @ 100° F 283-347

236 calculated

SUS @ 210° F 50-58

3564 calculated

CST @ 40° C (ASTM D-445)

671 cst

CST @ 100° C (ASTM D-445)

48 cst

Viscosity Index (ASTM D-2270)

125

Flash Point (ASTM D-92)

450° F (232° C)

Pour Point (ASTM D-97)

15° F (-9° C)

Timken OK Load (ASTM D-2782)

80 lbs

Four Ball EP, Weld Point (ASTM D-2783)

315 kgf

Four Ball LWI (ASTM D-2783)

51 kgf

Falex (ASTM D-4172)

3000 lbs typ,

FZG Pass Stages (ASTM D-5182)

13

Copper Corrosion (ASTM D-130)

1 lb

Rust Protection, Dist. Water (ASTM D-665)

Pass

Rust Protection, Sea Water (ASTM D-665)

Pass

Emulsibility (ASTM D-1401M) Water-Millimeters

1 hour

Water-Millimeters

15 24 hours

Water-Millimeters

30 48 hours

Foam Suppression (ASTM D-892) 5 minutes

75 mls/max

10 mls/max Oxidation Stability (ASTM D-2893)

7% inc.

Table 25: Synthetic EP gear lubricants (Spec. 100-13) approved suppliers

1

Supplier Fuchs

Brand name Powergear H680

________________________________________________________________ 6.14 Bucyrus – Model GH-MFBHM-48CDHFeeder Breaker

_______________________________________________ Permissible media Table 26: Synthetic lithium complex grease for electric motor bearings (Spec. 100-14) specifications Limit

Type

NLG1 Grade

2

Thickener

Lithium soap complex

Base Oil Type

Synthetic polyalphaolefin base oils (POA)

Worked Penetration (60 strokes) (ASTM D-217)

265 - 295

280

Dropping Point (ASTM D-2265)

470° F (243° C) min

509° F (260° C)

Water Washout Resistance Weight 10% or less Loss @ 175° F (79° C) (ASTM D-1264)

6%

Grease Mobility (US Steel Test LT-37)

18 grams/min @ 0° F (-18° C) min

20 grams/min

Four Ball Wear (ASTM D-2266)

0.70 mm Max scar diameter

0.50 mm

Four Ball EP Weld Load (ASTM D2596)

530 lb (240 kg) min

550 lb (250 kg)

Timken OK Load (ASTM D-2509)

55 lb (25 kg) min

65 lb (30 kg)

Rust Corrosion Protection (ASTM D1743)

Pass

Pass

Base Oil Viscosity @ 104° F (40° C)

95 - 120

100

Table 27: Synthetic lithium complex grease for electric motor bearings (Spec. 100-14) approved suppliers 1

Supplier Mobil Oil Corp.

Brand name Mobility SHC 100

2 3

Conoco-Phillips Shell

Triton 100 Albida EMS 2

______________________________________________________________ A6474X389 REV 0 6.15

_______________________________________________ Permissible media

______________________________________________________________ A6474X389 REV 0 6.16

_______________________________________________________________

For your information

________________________________________________________________

_______________________________________________________________

________________________________________________________________

_____________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service address Beckley, WV 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 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

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

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

______________________________________________________________ A6474X389 REV 0 7.3

Our service______________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

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

________________________________________________________________ 7.4 Bucyrus – Model GH-MFBHM-48CDH Feeder Breaker

www.comerindustries.com

200

INSTALLATION, USE, MAINTENANCE AND SPARE PARTS MANUAL FOR

PGRF1002

Comer code : 5402.033.036

Release A09/07

INDEX

General information ......................................................................................................... page 3 Lubrication and ordinary maintnance ............................................................................... page 4 Preliminary checks and starting up .................................................................................. page 5 External drawing .............................................................................................................. page 6 Section drawing .............................................................................................................. page 7 Spare parts table............................................................................................................. page 8 Torque wrench setting ...................................................................................................... page 9

SYMBOLS USED ATTENTION Operation must be carried out with extreme care with special settings

PROTECTIVE CLOTHING Protective clothing must always be worn by personnel authorized to work with reduction gears.

RECOMMENDED KIT

PROTECTIVE GOGGLES Protective goggles must always be worn by personnel authorized to work with reduction gears.

DANGER Be careful of hanging loads

PROTECTIVE GLOVES Protective gloves must always be worn by personnel authorized to work with reduction gears.

PROHIBITION It is prohibited to lubrify moving components

PROTECTIVE FOOTWEAR Protective footwear must always be worn by personnel authorized to work with reduction gears.

Code: 5402033036

First issue 09/07

Release A09/07

2/9

GENERAL INFORMATION GEARBOX UNIT IDENTIFICATION

All the data which characterize the gear unit are reported on the name plate that can be seen herebelow.

1) Type of product 2) Comer code 3) Serial number 4) Series number 5) Ratio

1 2 3 5

4

RISKS AND PRECAUTION

Always take the necessary measures to guarantee the safety of the people authorised to work on the reduction gear, supplying them with the necessary IPG. There is oil in the reduction gear and during maintenance some of it may leak in the working area. For this reason slip-proof shoes should be worn.

Always handle the units with adequate lifting means never manually as there is an injury hazard.

STORAGE

The gear unit are best stored in closed and covered environments.

Do not store the unit ouside or directly onto the ground.

If the gear unit are stored for long periods (over 3 month), theese must be externally protected with antioxidising products and filled with oil to protect the internal components.

The unit are supplied unpainted.

Care should also be used to avoid violent impact.

General notes: Always make sure the system is clean before starting the machine.

HANDLING

The use of adequate means of transportation to lift and handle the gear unit is recommended.

Before moving the gear unit, check the stability of the element you must transport.

Lifting, transportation and allocation must be done by trained and qualified technical personnel.

Manual loads: If the gear unit must be handled manually, limit the load to 10 Kg. We recommend lifting the load by keeping it as close as possible to the body and bending the knees and not the back.

PRODUCT DISPOSAL

Dismantle the machine, separating the parts following the instructions given in this manual.

You must group the parts according to the materials they are made of: iron, aluminium, copper, plastic and rubber.

The parts must be disposed of by the relative centres in full compliance with the laws in force on the matter of dismantling and demolishing industrial waste. Waste oil: to dispose of waste oil abide by the laws for protecting the environment and the laws in force in the Country where the machine is used.

Code: 5402033036

First issue 09/07

Release A09/07

3/9

ORDINARY MAINTENANCE LUBRICATION

This gearbox is supplied without lubricant.

The type of recommended lubricant is mineral oil with ISO VG220 viscosity.

All fluids used, in any case, have to be compatible with all the components, elastomers, seals and filtering elements of the system.

OIL CHANGE OPERATIONS

To guarantee long life and excellent performance to the gear unit, oil change operations must be done on a regular basis.

After the first 100 hours of operation it is advisable to replace the oil contained in the reduction gear unit. The unit can be drained by the 3/8-24UNF or 9/16-18UNF drain hole into the lowest position (as illustrated) and, after having removed both plugs, draining the unit. Clean or substitution all plugs if necessary. Draining is always done when the lubricant is hot so as to help all the oil to drain, thus preventing sludge.

9/16-18UNF DRAINING HOLE

3/8-24UNF DRAINING HOLE

After the oil has been drained, refit the drain plug on place. Refill the unit adding lubricant to the upper hole until drain the oil from the level hole (until half of the gearbox internal volume is filled). When the filling oil procedure are finished, replace and tightening all plugs. Every 2000 working hours (or annually, whichever occurs first) replace the oil in the reduction gear unit by following the instructions given above. The oil should be checked every 250 working hours for not only oil level but also for any oil leaks.

3/8-24UNF FILLING HOLE DRAIN PLUGS

9/16-18UNF FILLING HOLE LEVEL

FUNCTIONING INTERRUPTION

Do not work with machines in movement.

Interrupt and disabled the functioning of the machine/vehicle during maintenance/revision procedures (e.g. lifting the wheels off the ground, turning off the work procedure...etc...) to avoid hurting operators and other people.

EXTRAORDINARY MAINTENANCE

In this case, prescribed intervals don’t exist since extraordinary maintenance is normally necessary because of bad functioning of components.

The instrucions for complete assembling and disassembling of the gear unit must be requested to Comer Industries S.p.A. specifying the product code.

Unauthorized disassembly or alteration of components of the gearbox can cause damage to people or to the unit. Comer Industries S.p.a. has no civil or penal responsibility in this case.

Code: 5402033036

First issue 09/07

Release A09/07

4/9

PRELIMINARY CHECKS AND STARTING UP STUD BOLT REPLACEMENT PROCEDURE

Chek and replace the stud bolts if damaged, by carrying out the following procedure:

Remove the damaged stud bolt using a hammer

Fully insert the stud bolt, pulling it by screwing on a nut

Position the new stud bolt with the flat side towards the inside

BRAKE FUNCTION

The PGRF1002 gear unit is equipped with hydraulics brakes with oil-bath disks, expressly designed for static or parking braking.

The integrated negative brake utilises the same oil as the gears hence, when changing the oil in the wheel drive, brake oil is also changed.

It is strictly forbidden to use it as a dynamic brake.

To ensure correct use of the brake, observe the values indicated at page 6.

If the brake fails to comply with the declared values, in the case of a malfunction or oil leak, consult Comer Technical-Commercial Service.

Always consult Comer Technical-Commercial Service before changing the disks or any other brake component.

HYDRAULIK MOTOR

To select the motor you must take into consideration the maximum performance of the reduction gear. Before mounting the motor on the reduction gear: - clean the centrings and the mounting faces, checking there are no dents.

- oil the centrings and spread grease over the motor/reduction gear O-ring.

- check that the motor shaft couples correctly with the reduction gear’s input joint.

Once you have seen that the motor is positioned correctly, fix it with the screws at the tightening torque given in the table on page 9.

PRELIMINARY CHECKS AND STARTING UP

Check oil level before starting up the unit.

In the negative case, please consult the “Oil change operations” at page 4.

Check that the reduction gear components are not damaged in any way and that the centrings and standing parts are not rusty.

Make sure there is no air inside the hydraulic circuit.

Make sure that the reduction gear screws and plugs have been tightened to the values given in table at page 9.

Check correct operation of the reduction gear, making sure that rotation direction is as wanted.

When parking brake is installed, make sure it is working properly (engaged/disengaged).

TROUBLESHOOTING

In case of different problems from this table contact a Comer TechnicalCommercial Service

Code: 5402033036

Problems

Possible cause

Rimedies

Oil leaks

1) The internal seals are damaged; 2) Breathing plug clogged;

1) Contact a Comer Assistance Centre; 2) Change or clean the breathing plug;

Excessive overheating

1) There is no oil; 2) Internal problem;

1) Restore correct oil level; 2) Contact a Comer Assistance Centre;

Excessive noise

Internal problem;

Contact a Comer Assistance Centre;

The negative brake fails to disconnect

1) Check the hydraulic connection; 2) Internal problem;

1) Remedy the hydraulic connection; 2) Contact a Comer Assistance Centre;

The negative brake fails to brake

Internal problem;

Contact a Comer Assistance Centre;

When pressure is sent to the motor the unit fail to turn

1) Motor mounted incorrectly; 2) Internal breakage;

1) Check correct motor fixing; 2) Contact a Comer Assistance Centre;

The gearbox rotates in the wrong direction

1) Uncorrect piping on the motor;

1) Verify the piping;

The reduction gear cannot be assembled on the mounting face

Incorrect dimensioning

Check correct fixing of the reduction gear or contact a Comer Assistance Centre;

The gearbox does not rotate

1) Uncorrect motor mounting; 2) Internal problem;

1) Verify the motor mounting; 2) Contact a Comer Industries Service Center;

First issue 09/07

Release A09/07

5/9

EXTERNAL DRAWING

Code: 5402033036

First issue 09/07

Release A09/07

6/9

SECTION DRAWING

Code: 5402033036

First issue 09/07

Release A09/07

7/9

SPARE PARTS LIST N° 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 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Code: 5402033036

Code

Description

Q.ty

BRAKE SPACER 64x103x6,15 END PLATE BRAKE DISK BRAKE PISTON ROTATING HOUSING SUN GEAR R.5,33 PLANETARY GEAR R.5,33 INPUT COUPLING 12/24DP TH=14 EXT. RETAINING RING BR50 HUB RING GEAR END PLATE FOR INPUT COUPLING RING NUT M190X3 SUN GEAR R.7 COVER SPRING STEEL DISK FRICTION DISK RETAINING DISK PAD D16X8 NEEDLE 6X12 INTERNAL SNAP RING 22 UNI 7437 EXT. RETAINING RING 40 UNI7435 INTERNAL SNAP RING 160 UNI7437 RING BACKUP RING BACKUP O RING (2X11,5) O RING O RING O RING 3950 (2,62X240,97) OIL SEAL NEEDLE BEARING TAPER ROLLER BEARING SHIM KIT 8,2X14 MAGNETIC PLUG 9/16-18UNF HEAD 3/8-24 PLUG PLASTIC PLUG 9/16UNF + O-RING PROTECTION COVER CONICAL HEAD BOLT M6X16 HEX. S.H.S. M10x130 UNI 5931 8G STUD M22X1,5X82 PLANETARY GEAR R.7 PLANET CARRIER 1=7 PIN THRUST WASHER THRUST WASHER W/TAGS SNAP RING 29X2mm UNI7436 PLUG 9/16-18UNF + O-Ring SHIM KIT 65X103 NAME PLATE

1 1 1 1 1 4 1 1 1 1 1 1 1 1 16 5 4 1 1 108 1 4 1 1 1 5 1 1 2 1 4 2 1 1 2 1 1 1 32 10 3 1 3 3 3 3 3 1 1

First issue 09/07

Release A09/07

8/9

TORQUES WRENCH SETTING (Nxm) Tab.1) screw torques (Nxm)

Tab. 3) screw torques ( Nxm)

screwed on cast iron or steel 4.8

dxp

6.8

8.8

(mm)

min

max

min

max

min

max

min

4x0,7

1,5

1,9

2,3

2,8

3,1

3,8

4,4

5,3

5x0,8

3,0

3,7

4,5

5,5

6,0

7,3

8,5

10,3

6x1

5,2

6,3

7,8

9,5

10,4

12,7

14,7

17,8

8x1,25

12,5

15,2

18,7

22,7

25,0

30,3

35,1

42,6

10x1,5

screwed on alluminum

10.9 max

70,2

85,2

12.9

4.8

dxp

6.8

8.8

10.9

12.9

max

(mm)

min

max

min

max

min

max

min

max

min

max

5,2

6,3

4x0,7

1,5

1,9

2,3

2,8

2,7

3,1

2,7

3,1

2,7

3,1

10,2

12,4

5x0,8

3,0

3,7

4,5

5,5

5,2

6,0

5,2

6,0

5,2

6,0

17,6

21,4

6x1

5,2

6,3

7,8

9,5

8,9

10,4

8,9

10,4

8,9

10,4

42,1

51,1

8x1,25

12,5

15,2

18,7

22,7

21,4

25,0

21,4

25,0

21,4

25,0

102,3

10x1,5

min

25,0

30,3

37,4

45,5

49,9

60,6

12x1,75 42,5

51,6

63,7

77,4

85,0

103,2 119,5 145,1 143,4 174,2

84,2

14x2

67,6

82,1

16x2

25,0

30,3

37,4

45,5

42,8

49,9

42,8

49,9

42,8

49,9

12x1,75 42,5

51,6

63,7

77,4

72,8

85,0

72,8

85,0

72,8

85,0

101,5 123,2 135,3 164,3 190,2 231,0 228,3 277,2

14x2

67,6

82,1

101,5 123,2 116,0 135,3 116,0 135,3 116,0 135,3

102,4 124,3 153,6 186,5 204,8 248,6 287,9 349,6 345,5 419,6

16x2

102,4 124,3 153,6 186,5 175,5 204,8 175,5 204,8 175,5 204,8

18x2,5 142,7 173,3 214,1 259,9 285,4 346,6 401,4 487,4 481,7 584,9

18x2,5 142,7 173,3 214,1 259,9 244,7 285,4 244,7 285,4 244,7 285,4

20x2,5

200

243

300

364

400

486

562

683

675

819

20x2,5

200

243

300

364

343

400

343

400

343

400

22x2,5

268

326

402

489

537

652

755

916

906

1.100

22x2,5

268

326

402

489

460

537

460

537

460

537

24x3

346

420

518

629

691

839

972

1.180 1.166 1.416

24x3

346

420

518

629

592

691

592

691

592

691

27x3

504

612

756

918

1.008 1.224 1.418 1.721 1.701 2.066

27x3

504

612

756

918

864

1.008

864

1.008

864

1.008

30x3,5

688

835

1.032 1.253 1.375 1.670 1.934 2.349 2.321 2.818

30x3,5

688

835

1.032 1.253 1.179 1.375 1.179 1.375 1.179 1.375

4.8

dxp

6.8

8.8

10.9

12.9

4.8

dxp

6.8

8.8

10.9

12.9

(mm)

min

max

min

max

min

max

min

max

min

max

(mm)

min

8x1

13,1

15,9

19,7

23,9

26,2

31,8

36,9

44,8

44,2

53,7

8x1

13,1

15,9

19,7

23,9

22,5

26,2

22,5

26,2

22,5

26,2

10x1,25 26,0

31,5

38,9

47,3

51,9

63,0

73,0

88,6

87,6

106,4

10x1,25 26,0

31,5

38,9

47,3

44,5

51,9

44,5

51,9

44,5

51,9

12x1,25 45,3

55,0

67,9

82,4

90,5

109,9 127,3 154,6 152,8 185,5

12x1,25 45,3

55,0

67,9

82,4

77,6

90,5

77,6

90,5

77,6

90,5

12x1,5

43,9

53,3

65,8

79,9

87,8

106,6 123,4 149,9 148,1 179,8

12x1,5

43,9

53,3

65,8

79,9

75,2

87,8

75,2

87,8

75,2

87,8

14x1,5

71,4

86,7

107,1 130,0 142,8 173,4 200,8 243,8 241,0 292,6

14x1,5

71,4

86,7

107,1 130,0 122,4 142,8 122,4 142,8 122,4 142,8

max

min

max

min

max

min

max

min

max

16x1,5 107,2 130,1 160,8 195,2 214,3 260,3 301,4 366,0 361,7 439,2

16x1,5 107,2 130,1 160,8 195,2 183,7 214,3 183,7 214,3 183,7 214,3

18x1,5 154,9 188,0 232,3 282,1 309,7 376,1 435,6 528,9 522,7 634,7

18x1,5 154,9 188,0 232,3 282,1 265,5 309,7 265,5 309,7 265,5 309,7

20x1,5

215

261

322

391

430

522

604

734

725

881

20x1,5

215

261

322

391

368

430

368

430

368

430

22x1,5

286

347

429

521

572

695

805

977

966

1.173

22x1,5

286

347

429

521

491

572

491

572

491

572

24x2

367

446

551

669

734

891

1.032 1.254 1.239 1.504

24x2

367

446

551

669

629

734

629

734

629

734

27x2

531

645

797

968

1.063 1.291 1.495 1.815 1.793 2.178

27x2

531

645

797

968

911

1.063

911

1.063

911

1.063

30x2

739

897

1.108 1.345 1.477 1.794 2.077 2.522 2.493 3.027

30x2

739

897

1.108 1.345 1.266 1.477 1.266 1.477 1.266 1.477

Tab. 2) plugs with copper washer torques Dimension

Ext. Diam.

Int. Diam.

Torque wrench setting

plug

plug

washer

min

max

mm

mm

N.m

N.m

1/8" GAS

14

10,5

13

16

1/4" GAS

18

13,5

28

36

3/8" GAS

22

17,2

46

59

1/2" GAS

26

21,5

65

83

3/4" GAS

32

27,0

111

141 306

1" GAS

40

33,0

240

3/8" 24UNF

14

10,0

14

18

9/16" 18UNF

19

14,5

32

41

3/4" 16UNF

25

19,5

69

88

M8x1

12

8,4

9

12

M10x1

14

10,5

13

17

M12x1.5

17

12,5

25

32

M14x1.5

19

14,5

32

41

M16x1.5

22

16,5

48

62

M18x1.5

23

18,5

50

63

M20x1.5

25

20,5

60

76

M22x1.5

27

22,5

71

90

Code: 5402033036

Tab. 4) resistance class coupling for screws and nuts When a screw is fastened with a nut, check that the minimum resistance class of the nut coupled is the following:

Screw class

First issue 09/07

3.6

5.6

4.6

5.8

6.8

8.8

4A

4D

5S

6S

4

5

6

8

10.9

12.9

10

12

4.8

Min nut class

Release A09/07

9/9

GM Crankshaft design radial piston motors

Motori idraulici ad albero eccentrico

The main characteristics of this type of design are high mechanical efficiency, especially at start up, and high volumetric efficiency.

A number of features distinguish SAI motors from other radial piston designs:

Le caratteristiche di questo tipo di motore sono il rendimento meccanico, in particolare allo spunto, ed i rendimenti volumetrici.

Le caratteristiche che distinguono i motori SAI rispetto ad altri motori di questo genere sono:

Swivelling cylinder: the cylinder (1) remaining aligned with the eccentric of the crank (3), eliminates side loading between the cylinder and piston (2). The articulation of the cylinder-piston assembly is achieved with large diameter trunnions (4) ensuring low specific loads.

Cilindro oscillante: il cilindro (1) rimane sempre allineato con l'eccentrico (3) dell'albero eliminando così sollecitazioni tra le pareti del pistone (2) e del cilindro. L'articolazione del cilindro avviene mediante codoli (4) a diametro largo che assicurano carichi specifici ridotti.

Double piston support bearing: the pistons transmit their load to the shaft via a hydrostatic bearing (5) and a central roller bearing (6). The roller bearing minimises the sliding velocity between the piston foot and the spherical piston support ring, reducing heat, friction, wearing and improving starting torque, low speed operation (reduced stick slip) and high speed operation. The hydrostatic bearing reduces metal-metal contact ensuring optimal lubrication and low friction.

Doppio cuscinetto porta-pistoni: i pistoni trasmettono il carico all'albero attraverso un cuscinetto idrostatico (5) ed un cuscinetto centrale a rulli (6). Il cuscinetto a rulli riduce la velocità di slittamento tra il piede del pistone e l'anello sferico di supporto, riducendo quindi calore, attrito ed usura e favorendo la coppia di spunto e funzionamento sia a velocità basse che elevate. Il cuscinetto idrostatico riduce il contatto metallo-metallo, ed assicura una lubrificazione ottimale con attriti ridotti.

Piston retaining rings (7) ensure the piston remains in contact with the shaft in all operating conditions, even during cavitation.

Anelli di ritegno pistone (7): assicurano il contatto del piede con l'albero in tutte le condizioni di funzionamento, anche in caso di cavitazione.

Rotary axial distributor (8) ensures optimal distribution with short, large section ducts for reduced power-loss with high flows, and very high volumetric efficiency; extensive clearance recovery capability of the seals ensures optimal functionality throughout the motor lifetime and in conditions of thermal shock.

Rotante a distribuzione assiale (8): assicura una distribuzione ottimale con passaggi corti a sezione larga per una minor perdita di potenza con portate elevate; elevato rendimento volumetrico - recupero tolleranze da parte delle tenute assicurano un ottimale funzionalità per l'intera vita del motore ed in condizioni di shock termico.

Interchangeable distributor (9): a wide range of distributors are available with various pressure and flow control valves.

Distributori intercambiabili (9): è disponibile un'ampia gamma di distributori con diverse valvole di controllo integrate nel coperchio distributore.

2

GM GM SERIES CHARACTERISTICS

CARATTERISTICHE DEI MOTORI GM

GM series motors are a result of the many years' of experience gained with the preceding M, L and P series motors, and incorporate a number of design variations with respect to these series intended to increase the strength of the motor casings and the load capacity of the internal dynamic components.

The result is a series of motors with high continuous power ratings, both because of the reduced internal specific loads and because of the high mechanical and volumetric efficiency that contribute in reducing the amount of heat produced and therefore also the negative effects associated with it.

I motori della serie GM sono frutto delle esperienze maturate con i motori delle serie M, L e P, riportando modifiche rispetto alle dette serie improntate all'incremento della robustezza del corpo del motore ed alla capacità di carico dei componenti dinamici interni.

Ne risulta una serie di motori capace di trasmettere potenze continue elevate, sia per i carichi specifici ridotti, che per rendimenti meccanici e volumetrici molto elevati che contribuiscono a mantenere a livelli ridotti la produzione di calore ed i relativi effetti negativi.

n Radial injection cylinder feed (1) eliminates direct hydraulic axial loading of the motor casing. n Larger cylinder feed channels (1) for reduced power loss with high flows. n Stronger castings (2) and internal reinforcement ribbing: increased casing strength and stiffness for higher internal and external load capacity. n High load capacity bearings (3) for applications requiring high lifetime, high power/pressure, high external loads. n Larger cylinder trunnions (4) for increased strength and stiffness and reduced specific loads. n Cylinder trunnions with hydraulic balancing (5) to reduce friction, wearing and heat generation, enabling operation with higher powers and improved efficiency. n Compatibility with shafts (6), adaptors, distributors of the motors of other preceding series. n Standardisation of components for increased modularity and flexibility as regards interchangeability of displacements, spare parts and options. n Reduced number of components for a more simple and reliable design. n Compatibility with non-polluting oils.

3

n Alimentazione cilindri con iniezione radiale (1): nessuna sollecitazione idraulica assiale diretta sul corpo motore n Canali di alimentazione (1) cilindri maggiorati per minor perdita di potenza con flussi elevati n Spessori di fusione incrementati (2), disegno interno con rinforzi: corpo motore irrobustito per sostenere meglio sollecitazioni meccaniche interne ed esterne n Cuscinetti ad elevata capacità di carico (3) per applicazioni richiedenti lunga durata, potenza/ pressioni elevate, elevati carichi esterni. n Codoli cilindri maggiorati (4) rispetto alle serie precedenti per maggior rigidità e resistenza, carichi specifici ridotti. n Codoli cilindri con bilanciamento idraulico (5): riduzione degli attriti, usura e minore generazione di calore consentono funzionamento con potenze più elevate e con rendimenti migliori n Compatibilità alberi (6), manicotti, distributori delle serie precedenti n Standardizzazione componenti per maggiore modularità e flessibilità per intercambiabilità delle cilindrate, ricambi e opzioni n Riduzione numero componenti per maggior semplicità costruttiva ed aumento affidabilità n Compatibilità con olii non inquinanti

GM PRESSURE RATINGS All the motors are rated at a nominal continuous pressure rating of 250 bar. The continuous and average operating pressure, however, should be chosen in function of the required bearing lifetime (see bearing lifetime graphs).

The peak operating pressures are given in the relative displacement tables. The motors may work at peak pressures for periods not exceeding 1% per minute, no more than 10 times per hour.

PRESSIONI D’ESERCIZIO Tutti i motori sono con pressione continua nominale di 250 bar. È consigliabile scegliere la pressione continua o media del motore in funzione della vita richiesta dei cuscinetti (vedi grafici di vita dei cuscinetti).

La pressione di picco dei motori è indicata nelle relative tabelle. I motori possono lavorare con pressione di picco per un periodo che non superi 1% per minuto, non più di 10 volte in un ora.

BACK-PRESSURE The motors are capable of operating with high backpressures with high efficiency, e.g. for series circuit applications.

The allowable pressures vary in function piston diameter and other factors. If the motors are required for an application with back pressure contact the tech. dept. for further details.

Typical allowable back-pressure Port A Port B Cont. 210 bar 150 bar Peak 350 bar 350 bar

CONTRO PRESSIONE I motori possono lavorare con contro pressioni elevate con buon rendimento, per esempio, in applicazioni con circuito in serie.

Le pressioni consentite variano da motore a motore.

Qualora i motori dovessero lavorare con contro pressioni elevate, si prega di consultare il Ns. ufficio tecnico.

Valori tipici di contro pressione consentiti.

Port A Port B Cont.

210 bar 150 bar Picco 350 bar 350 bar

CASE PRESSURE Continuous case pressure 1 bar, Peak case pressure 5 bar.

The case pressure is independent of the return line pressure.

For higher pressures (up to 15 bar) contact the tech. dept..

PRESSIONE IN CARCASSA Pressione continua 1 bar Pressione di picco 5 bar La pressione in carcassa è indipendente dalla pressione nel ramo di ritorno.

Su richiesta è possibile fornire motori adatti per pressioni in carcassa fino a 15 bar.

TORQUE To obtain the theoretical output torque of a motor, multiply the specific torque (Nm/bar) given in the displacement tables by the pressure (bar).

The graph below shows the output torque variation as the shaft rotates through 360°.

COPPIA La coppia teorica di un motore si ottiene moltiplicando la coppia specifica (Nm/bar) per la pressione di lavoro.

Il grafico indica la variazione della coppia in uscita durante la rotazione di 360° dell’albero.

STARTING TORQUE Typical starting torque efficiencies are given in the performance graphs of the motors. The starting torque, however, also depends on the starting position of the shaft (see graph above).

COPPIA DI SPUNTO I rendimenti tipici dei motori allo spunto sono indicati nei relativi grafici. La coppia di spunto, comunque, dipende anche dalla posizione di partenza dell’albero (vedi grafico sopra).

LOW SPEED OPERATION The motors are capable of operating at low speeds with a high degree of speed stability. The minimum stable speed depends on the displacement of the motor. In general the motors remain sensitive to flows of 0.1 lit/min + motor leakage rate. Best results are obtained with 5 - 10 bar back-pressure and after the circuit has been completely purged of air by running it at 2/3 max speed for 5-10 mins.

The output torque does not fall off at very low speeds or at standstill .

FUNZIONAMENTO A BASSA VELOCITÀ I motori funzionano a velocità molto ridotte con un elevato grado di stabilità di velocità. La minima velocità stabile dipende dalla cilindrata del motore. In generale, i motori rimangono sensibili a flussi di 0,1 lit/min + drenaggio. I risultati migliori si ottengono con 5-10 bar di contro pressione dopo che il circuito è stato completamente spurgato di aria facendo girare il motore a 2/3 della propria velocità max per 5-10 min.

La coppia erogata non diminuisce a velocità molto bassa o allo stallo.

4

GM 2-SPEED OPERATION For applications containing at least two drive units that require 2-speed operation, SAI can supply the flow control valves for a series-parallel circuit with speed differential also in series mode.

The valves enable dynamic switching of the circuit from series to parallel configuration to obtain the high-torque/low-speed or highspeed/low-torque operating modes.

A pressure reducing valve enables the differential effect of motors operating in parallel to be maintained also when operating in series.

FUNZIONAMENTO A 2 VELOCITÀ Per applicazioni con almeno 2 motori nelle quali sono richiesti il funzionamento a due velocità si consiglia il circuito serie-parallelo con velocità differenziabile anche in serie.

Una valvola direzionale consente il cambio dinamico dalla configurazione in parallelo (doppia coppia, metà velocità) a quella in serie (doppia velocità, metà coppia).

Una valvola proporzionale consente di ottenere il funzionamento con velocità differenziate anche con il circuito in serie.

NOISE LEVELS The motors operate with lowest noise levels with a back-pressure of 5-10 bar, such as in closed circuits.

Pressure lines and motor support structures can be efficient noise propagators or amplifiers. Pressure lines should preferably be made up of straight rigid lengths, flexible corners, firmly fixed to rigid supports at irregular intervals away from sheet panelling.

Motors must be rigidly fixed to solid supports.

RUMOROSITÀ I motori funzionano con rumorosità più bassa con 510 bar di contro pressione. Si noti che le tubazioni e le strutture portanti possono essere efficaci propagatori ed amplificatori di rumore. Pertanto le tubazioni sono preferibilmente dritte e rigide, con rinvii flessibili, fissati rigidamente a supporti rigidi con passi irregolari, lontano da pannelli estesi. I motori devono essere montati su supporti rigidi.

SILENT MOTORS Motors can be supplied with special distributor that run nearly silently in a wide operating range.

Please contact the technical department for further details.

MOTORI SILENZIOSI Sono disponibili, su richiesta, motori con distributore speciale dal funzionamento silenzioso entro ampie gamme di esercizio. Contattare il Ns. ufficio tecnico per informazioni.

VIBRATION The motors can be supplied with a counterbalanced shaft to reduce vibrations at high speeds.

Please contact the tech. dept. for further details.

VIBRAZIONI Su richiesta, è possibile fornire motori dotati di albero bilanciato per ridurre vibrazioni a velocità elevata. Contattare il Ns. ufficio tecnico.

CAVITATION The design of the motors ensures that they are not damaged if subjected to cavitation.

Cavitation, however, is to be avoided as there may be components in hydraulic systems that are very sensitive to and can be easily damaged by cavitation.

CAVITAZIONE I motori non vengono danneggiati se soggetti alla cavitazione.

La cavitazione, comunque, è una condizione da evitare in quanto vi possono essere altri componenti nel sistema idraulico i quali sono sensibili e possono essere danneggiati in cavitazione.

OPERATION IN FREEWHEELING AND AS HYDRAULIC BRAKE Transitions from normal motor operating mode to freewheeling and hydraulic braking mode can be carried out dynamically. For high speed freewheeling the inlet may need to be pressurised to prevent cavitation. See below for high speed freewheeling solutions.

FUNZIONAMENTO A RUOTA LIBERA E FRENO IDRAULICO Il cambio tra i modi di funzionamento motore - ruota libera - freno si può effettuare dinamicamente. Per funzionamento a ruota libera con velocità elevata potrà essere necessario pressurizzare la mandata per evitare la cavitazione. Vedi sotto per altre soluzioni a riguardo.

DISCONNECTION FROM HYDRAULIC CIRCUIT The motors can be disconnected from the hydraulic and driven externally (freewheeling, free fall, in case of breakdown, etc.) at speeds of up to the max. speeds given in the motor data tables.

SCOLLEGAMENTO DAL CIRCUITO IDRAULICO I motori possono essere scollegati dal circuito idraulico ed essere azionati esternamente (funz. a ruota libera, caduta libera pesi, movim. veicolo in avaria, ecc.) fino alla velocità max. indicata.

5

GM HIGH SPEED FREEWHEELING The diagram below show four possible circuit configurations for motor disconnection and/or for operation in freewheeling:

FUNZ. A RUOTA LIBERA AD ALTA VELOCITÀ I diagrammi indicano quattro configurazioni di circuito per lo scollegamento del motore e/o funzionamento a ruota libera:

A: Freewheeling with oil circulation; this condition is acceptable for low speeds only. At high speeds the motor inlet must be pressurised to prevent cavitation.

B: Freewheeling with air circulation; this condition is ideal for high speed freewheeling applications; transition from or to normal operation must be effected at low speed and pressure while the pistons are emptied or filled with oil.

C: "Short circuit" freewheeling: the motor runs with inlet and outlet ports connected. This circuit does not cause cavitation and is suitable for applications where speed control is required (e.g., with throttle); beware of heat build up in unfavourable conditions, esp. with throttle.

D: "Vacuum" freewheeling: this is the most suitable freewheeling condition, especially for very high speeds; the check valves allow oil to be expelled from the pistons which subsequently operate under vacuum conditions; the motors can operate in these conditions for several hours without being damaged or overheating; torque absorption is constant with speed and equivalent to 2-3 bar pressure. Transition from or to normal operation must be effected at low speed and pressure while the pistons are emptied or filled with oil. For further information please contact SAI.

A: Ruota libera con olio in circolazione: questa condizione è adatta solo per velocità ridotte. Con l'aumento della velocità sarà necessario pressurizzare la mandata per evitare la cavitazione.

B: Ruota libera con aria in circolazione: questa condizione risulta ideale per velocità elevate; la transizione da o in funzionamento normale deve essere effettuato a velocità ridotta mentre si svuotano o si riempono i pistoni.

C: Ruota libera in "corto circuito": il motore ruota con i canali di mandata e ritorno collegati. Questa condizione non provoca cavitazione ed è adatta ad applicazioni che richiedono controllo della velocità (tramite strozzatura); pericolo di surriscaldamento in condizioni sfavorevoli, specialmente con strozzature.

D: Ruota libera "sotto vuoto": questa è la condizione più indicata per funzionamento a ruota libera, specialmente per velocità molto elevate; le valvole consentono lo svuotamento dei pistoni che poi operano sotto vuoto; i motori sono in grado di operare in queste condizioni per diverse ore senza daneggiamento o surriscaldamento; la coppia assorbita è costante con la velocità ed equivale ad una pressione di 2-3 bar. La transizione da e in funzionamento normale va effettuata a velocità e pressione ridotta mentre i pistoni vengono svuotati o riempiti. Per ulteriori informazioni consultare SAI.

HYDRAULIC FLUIDS

FLUIDI IDRAULICI

MINERAL OILS SAI recommend the use of high quality mineralbased hydraulic oil, containing anti-wear, antifoaming, anti-oxidation and extreme pressure additives.

OLII MINERALI Si consiglia l’uso di un olio idraulico minerale di buona qualità, preferibilmente con additivi per pressioni alte, anti-corrosione, anti-usura e antischiuma.

Oil temperature:

ideal +30°C to +50°C allowable -20°C to + 80°C On request, motors can be supplied to operate with lower (to -40° C) or higher (to +120 °C) temperatures

Temperatura dell'olio: ottimale +30°C a +50°C ammissibile -20°C a +80°C Su richiesta si possono fornire motori per il funzionamento a temperature inferiori (fino -40°C) o superiori (fino 120°C).

Oil viscosity:

Viscosità dell’olio: ottimale ammissibile

ideal allowable

40 to 60 cSt 25 to 39 cSt

The choice of oil should be made so that the viscosity of the oil lies within the given range at its normal operating temperature.

40 cSt a 60 cSt 25 cSt a 39 cSt

Il fluido idraulico utilizzato va scelto in modo che la viscosità rientri nella gamma indicata alla temperatura normale di funzionamento.

6

GM ALTERNATIVE FLUIDS - Synthetic fluids: (Fosfate esters, polyesters, ...)

These fluids have similar properties to mineral oils and the same pressure, speed, temperature and viscosity ratings apply.

These fluids may require seals made of a different material (e.g. Viton), which are available on request.

- Water-based fluids: (Water-oil emulsions, water-glycol solutions, ...) with these fluids the following limits apply: max. continuous pressure 100 bar max. speed reduction 50% allowable temperature +10 to +60 °C - Vegetable oils The characteristics of these oils vary widely and manufacturers' recommendations should be followed. In general, whilst lubricating qualities are similar to those of mineral oils, temperature limits may apply and the oil may need to be changed frequently.

The guarantee on motors operating with fluids other than mineral oils for high pressure hydraulic applications is only valid if the application is first approved by SAI.

FLUIDI ALTERNATIVI - Fluidi sintetici: (Estero fosfati, poliesteri, ...)

Questi fluidi hanno cratteristiche simili a quelle degli olii minerali e sono applicabili gli stessi limiti di pressione, velocità, temperatura, e viscosità.

Possono essere necessarie tenute di materiale adatto (es. Viton), disponibili su richiesta.

- Fluidi a base di acqua: (Emulsioni acqua-olio, soluzioni acqua-glicole, ...) con questi fluidi sono applicabili i seguenti limiti: Massima pressione continua: 100 bar Riduzione di velocità massima: 50% Temperature ammissibili: +10°C a +60°C - Olii vegetali Le caratteristiche di questi olii variano da prodotto a prodotto e pertanto si consiglia di seguire le raccomandazioni del fabbricante. In generale, le qualità lubrificanti sono simili a quelle degli olii minerali, ma con limiti alla temperatura e con necessità di frequenti cambi dell'olio nel circuito.

La garanzia su motori che lavorano con fluidi diversi dagli olii minerali per applicazioni idrauliche, è valida solo se l’applicazione viene preventivamente approvata dalla SAI.

FILTRATION SAI recommend filters of 25 mm or better.

Allowable oil contamination according to ISO/DIS 5540/4 18/12, SAE 749 class 5, NAS 1638 class 8.

FILTRAZIONE Si consigliano filtri da 25 mm, o più fini.

Contaminazione dell'olio ammissibile secondo norme: ISO/DIS 5540/4 18/12, SAE 749 classe 5, NAS 1638 classe 8.

BRONZE COMPONENTS GM-series motors do not contain bronze components.

However, high speed distributors (including the standard D40 and D90 distributors) do contain bronze components.

If the hydraulic fluid used is not compatible with bronze, select an optional low speed (LS) distributor (no bronze components) or contact our tech. dept.

COMPONENTI IN BRONZO I motori della serie GM non contengono componenti in bronzo.

I distributori ad alta velocità (HS) (inclusi i distributori standard D40 e D90) invece contengono componenti in bronzo.

Se viene utilizzato un fluido idraulico non compatibile con il bronzo, specificare un distributore a bassa velocità (LS), oppure consultare il Ns. ufficio tecnico.

NON MAGNETIC MOTORS On request, it is possible to supply motors with up to 70% non magnetic content.

MOTORI NON MAGNETICI Su richiesta è possibile fornire motori aventi contenuto non magnetico fino a 70%.

DIRECTION OF SHAFT ROTATION All motors are bidirectional. The direction of shaft rotation is determined by the direction of oil flow.

Standard motors are supplied so that flow entering in port A causes the shaft to rotate clockwise (as seen from the shaft side of the motor).

Flow entering port B causes anticlockwise rotation. Motors can be supplied with the reverse configuration: see motor order codes.

SENSO DI ROTAZIONE DELL’ALBERO Tutti i motori sono bidirezionali. Il senso di rotazione è determinato dalla direzione di flusso. Per i motori standard, con il flusso in entrata in port A del distributore, l’albero gira in senso orario (visto dal lato albero).

Con il flusso in entrata in port B, l’albero gira in senso antiorario. I motori possono essere forniti in configurazione opposta: vedere codici d’ordinazione.

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GM DRAIN-LINE POSITIONING The drain-line must be positioned in such a way that there is always sufficient oil in the casing for the lubrication of the of the dynamic components in the motor.

If the motor is installed with the shaft in a horizontal position, the drain-line should be connected to the uppermost drain-line port.

If the motor is installed with the shaft pointing downwards the drain-line can be connected to either of the two drain-line ports.

If the motor is installed with the shaft pointing upwards, the motor casing has to be entirely filled with oil before being installed and the drain-line connected in such a way that no air can enter into the motor casing so causing the front bearing to run dry.

This is especially important if the motor operates at very low speeds or remains inactive for long periods, For alternative systems, contact your SAI representative.

The drain-line should be of a diameter corresponding to the size of the drain line port and flow must not be obstructed by sharp corners, restrictions, etc..

Standard motors are supplied with drain port Y closed (zinc plated HH plug) and drain port X open (with plastic plug).

Motors can be supplied with Y-open, Xclosed: see motor order codes.

POSIZIONAMENTO DEL TUBO DI DRENAGGIO Il tubo di drenaggio dovrà essere collegato in maniera che rimanga sempre sufficiente olio nella carcassa per la lubrificazione dei componenti dinamici del motore.

Se il motore viene installato con l’albero in posizione orizzontale il tubo di drenaggio va collegato al foro di drenaggio più in alto sul coperchio del motore. Se il motore viene installato con l’albero rivolto verso il basso il tubo di drenaggio va collegato ad uno qualunque dei due fori di drenaggio. Se il motore viene installato con l’albero rivolto verso l’alto il motore dovrà essere riempito completamente prima dell’installazione ed il tubo di drenaggio collegato in maniera che non possa entrare aria nella carcassa del motore, causando la mancata lubrificazione del cuscinetto anteriore. Questo è di particolare importanza se il motore lavora a velocità ridotte o rimane fermo per lunghi periodi. Per sistemi alternativi, contattate il vostro rappresentante SAI. Il tubo di drenaggio dovrà essere di diametro corrispondente alla filettatura del foro di drenaggio e non dovrà presentare curve strozzature, ecc..

Motori standard sono forniti con il foro di drenaggio Y chiuso (con tappo zincato) e foro X aperto (tappo in plastica). I motori possono essere forniti con Y-aperto, Xchiuso: vedi codici dI ordinazione.

DISTRIBUTOR COVER ORIENTATION Motors may be supplied with the distributor assembled with the arrow pointing towards any one of the five pistons. To order, use assembly code DM1, DM2, or DM3, etc.. (DM1 = standard).

ORIENTAMENTO COPERCHIO DISTRIBUTORE I motori possono essere assemblati con la freccia orientata verso uno qualsiasi dei cinque pistoni.

Indicare il codice di assemblaggio DM1, o DM2, o DM3, ecc.. (DM1 = standard).

START-UP Before connecting any tubes ensure that they are thoroughly clean, any excess material that could work loose should be removed and there should not be any oxidation of surfaces that come into contact with the oil.

Before starting work the motor casing must be filled with oil.

Before starting work the hydraulic circuit should be purged of air. This can be achieved by running the motor without load for 10-20 minutes, during which time checks should be made for leakages from connections.

During the first few hours of working under load checks should be made for leakages from connections and to ensure that all components remain firmly fixed to their supports.

All motors are factory tested and do not require to be run in.

MESSA IN FUNZIONE Prima del collegamento dei tubi assicurarsi che questi siano rigorosamente puliti, togliendo materiale che potrebbe staccarsi; evitare qualsiasi ossidazione delle superfici che verranno a contatto con l’olio.

Prima di iniziare il lavoro, la carcassa del motore deve essere riempita d’olio.

Prima di iniziare il lavoro, va eliminata l’aria dal circuito idraulico.

Questo si effettua mandando in velocità il motore a bassa pressione per 10-20 minuti, controllando che non vi siano perdite dai collegamenti.

Durante le prime ore di lavoro sotto sforzo si consiglia di ricontrollare se ci sono perdite e di assicurarsi che tutti i componenti rimangano ben fissati ai loro supporti.

Tutti i motori sono collaudati e non necessitano di un periodo di rodaggio.

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GM BEARING LIFETIME The bearing lifetimes given in this catalogue are B10 lifetimes. The B10 lifetime is the period of work after which 10% of the bearings can be expected to show signs of wearing. The average lifetime of the bearing, the B50 lifetime (where 50% of the bearings show signs of wearing), is approximately 5 times the B10 value.

VITA CUSCINETTI La durata dei cuscinetti calcolata con i grafici riportati rappresentano la vita B10 dei cuscinetti. Il valore B10 rappresenta il numero di ore di lavoro che raggiunge il 90% di un campione di cuscinetti identici sottoposti alle stesse condizioni di lavoro. La durata media di un cuscinetto, detta vita B50, è circa 5 volte superiore alla vita B10.

To determine the lifetime of the bearings in an application, constant or average pressures and speeds should be used, not peak or max values.

The continuous operating pressures of any motor should be chosen in function of the required motor lifetime.

Per calcolare la vita dei cuscinetti con i grafici riportati, si usano valori di pressione e velocità costanti o medi, e non valori massimi o di picco.

Si consiglia la scelta della pressione continua di lavoro in funzione della vita richiesta dall’applicazione.

The required bearing lifetime may be calculated using the following formula: Life (hours) = hours of work per day x days work per year x no. of years x correction factor.

La vita richiesta si può calcolare usando la formula seguente: Vita (ore) = ore di lavoro per giorno x giorni di lavoro per anno x anni di vita x fattore correttivo

Correction factor: the calculated lifetime of the bearings presumes favourable lubrication conditions with oil having values of temperature, viscosity and oil cleanliness that lie within the given ranges.

A correction factor should be applied for applications, for example including continuous duty over several hours, where high oil temperatures or other anomalous working conditions can occur.

The table below indicates the correction factor to be applied in function of the duration of the cycle of continuous work, for applications in which the working conditions of the oil are not regularly checked.

Fattore correttivo: la vita dei cuscinetti calcolata presume valori di viscosità, temperatura, pulizia dell’olio che rientrano nelle rispettive gamme prestabilite, e comunque condizioni di lubrificazione non anomale.

Un aspetto del ciclo di lavoro di un motore che può influire negativamente è il lavoro continuato per diverse ore, dove si possono verificare aumenti nella temperatura dell’olio od altre condizioni anomale.

La tabella sotto indica il valore del fattore correttivo da applicare in funzione della lunghezza del ciclo continuo, dove le condizioni dell’olio nel circuito non vengono regolarmente controllati.

non stop work cycle (hrs)

<3

6

12

18

24

ciclo di lavoro non stop (ore)

<3

6

12

18

24

correction factor

1

1.25

1.5

2

3

fattore di correzione 1

1.25

1.5

2

3

If the bearing lifetime for a desired working pressure is insufficient please contact the tech. dept.

Se la vita calcolata dovesse risultare insufficiente, contattare il Ns. ufficio tecnico.

Please note that a small variation in the pressure used to calculate the lifetime can produce a large difference in the calculated lifetime.

The relationship between the working pressure and the lifetime is not linear, but as shown in the graph below.

Si noti che da piccole differenze nella pressione usata per calcolare la vita dei cuscinetti risultano variazioni maggiori nella vita calcolata.

Il rapporto tra pressione di lavoro e la vita dei cuscinetti non è lineare, bensì come indicato nel grafico.

Lifetime factor - fattore vita

1

Example: If, with 100 bar (load factor = 1), the lifetime is 10'000 hours (lifetime factor = 1), then with 120 bar (load factor = 1.2) the lifetime becomes 5'500 hours (lifetime factor 0.55)

Esempio: Se con 100 bar (fattore pressione =1) la vita è 10'000 ore (fattore vita = 1), con 120 bar (fattore pressione = 1.2) la vita passa a 5'500 ore (fattore vita = 0.55).

0,8 0,6 0,4 0,2 0 1

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1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 Pressure factor - fattore pressione

2