DOWNLOAD PDF CAT Feeder Breaker 54-2192 Operation & Maintenance Manual BI629495

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A6474X391 September 2012

Operation and Maintenance Manual Model FB140 (7MFBHM-56DDH) Feeder Breaker S/N 54-2192 54-2197

SAFETY.CAT.COM

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This manual is intended to provide GENERAL product information for the Model FB140 (7MFBHM-48DD) Feeder Breaker . The illustrations, descriptions, and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

This feeder breaker was manufactured under the guidelines, procedures, and requirements of the appropriate government regulatory agencies.

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

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

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

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

© Caterpillar 2012 ALL RIGHTS RESERVED

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_________________________________________________Table of contents

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

2. Your safety Your safety............................................................................... 2.3 Personnel ............................................................................. 2.4 Operation......................................................................... 2.4 Installation and repair ...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use.................................................................... 2.5 Unauthorized use ............................................................ 2.5 Safety instructions ................................................................ 2.7 General rules:.................................................................. 2.7 Storage and transport...................................................... 2.9 Installation and start-up ................................................... 2.9 Operation....................................................................... 2.10 Maintenance and repair................................................. 2.10

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............................................................... 3.5

4. Installation Installation ............................................................................... 4.3 Points to observe prior to installation ................................... 4.3 Who is allowed to carry out installation? ......................... 4.3 Which tools are required for installation? ........................ 4.3 Notes on installation ........................................................ 4.4 Pre-installation check list................................................. 4.5 Safety features ................................................................ 4.6 Removing and installing the receiving hopper ................... 4.10 Towing the feeder breaker ................................................. 4.14

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Table of contents _________________________________________________ 5. Operation Operation..................................................................................5.3 How to operate the feeder breaker ......................................5.3 Who is allowed to operate the feeder breaker ................5.3 When can conveying be started? ....................................5.3 Controls and indicators.........................................................5.4 Primary operator’ s station................................................5.4 Function pressure gauge.................................................5.8 Power fill and hydraulic oil sight glass .............................5.9 Auxiliary valve bank (if equipped).................................. 5.10 Starter enclosure ........................................................... 5.11 Dust suppression system .............................................. 5.16 Infrared pump motor controls ........................................ 5.17 Radio remote ................................................................. 5.18 “AUTO”mode starting procedure ....................................... 5.20 “MANUAL”mode starting procedure .................................. 5.21 Shutdown procedure .......................................................... 5.22 Tramming the machine....................................................... 5.23 Conveyor ............................................................................ 5.24 Control system operating parameters ................................ 5.26 Electrical system................................................................. 5.29 Starter enclosure ........................................................... 5.32 Hydraulic system ................................................................ 5.36 Major hydraulic components.......................................... 5.38 Primary hydraulic circuit ................................................ 5.40 Mechanical assemblies ...................................................... 5.43 Crawler assembly (s) .................................................... 5.43 Conveyor chain ............................................................. 5.44 Grease take-up ............................................................. 5.45 Head shaft .................................................................... 5.46 Conveyor power unit ..................................................... 5.47 Tail shaft ....................................................................... 5.48 Breaker and breaker power unit assembly.................... 5.49 Breaker assembly.................................................. 5.50 Breaker power unit assembly ................................ 5.51 Instructions on the maintenance of the feeder .................. 5.53 Important notes ............................................................. 5.53 Before maintenance ..................................................... 5.53 Lubrication and inspection ............................................ 5.55 Specific lubrication and maintenance procedures ............. 5.59 Every 8 hours of operation ........................................... 5.59 Weekly .......................................................................... 5.64 Monthly ......................................................................... 5.69 Every 3 months ............................................................. 5.72 Every 1000 hours .......................................................... 5.73 Every 6 months ............................................................. 5.75 Inspection of the feeder ..................................................... 5.78 Inspection of wear parts ..................................................... 5.79 Inspection of the fire suppression system .......................... 5.80 Recharge of the fire suppression system ........................... 5.82 Instructions on the adjustment procedures ....................... 5.85 Conveyor chain adjustment .......................................... 5.85 Crawler track adjustment .............................................. 5.87

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_________________________________________________Table of contents Under speed sensor calibration .....................................5.89 Main pump adjustments .................................................5.91 Main relief pressure........................................................5.93 Pressure limiter adjustment ...........................................5.94 Instructions on the replacement of wear parts ...................5.95 Head shaft .....................................................................5.95 Head shaft sprockets ....................................................5.99 Tail shaft ...................................................................... 5.102 Conveyor chain ........................................................... 5.108 Crawler track ............................................................... 5.111 Crawler assembly ........................................................ 5.114 Breaker shaft and breaker power unit ......................... 5.123 Breaker power unit only ............................................... 5.129 Breaker shaft only ........................................................ 5.132 Conveyor drive unit ...................................................... 5.141 Breaker bit removal ...................................................... 5.144 Tailpiece installation..................................................... 5.145 Roof cylinder ................................................................ 5.149 Foot cylinder................................................................. 5.152 Tilt cylinder ................................................................... 5.154 Lift cylinder ................................................................... 5.156 Tailpiece tilt cylinder..................................................... 5.159 Tailpiece steering cylinder ........................................... 5.161 Troubleshooting ................................................................ 5.163

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

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

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1

About this manual

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__________________________________________ Before starting to work

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

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: Cat® FB140 (7MFBHM-56DDH) Feeder Breaker Serial No. 54-2192, 54-2197, and 54-2198 and is only permitted to be used for equipment of this type.

new operation manual

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

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

Who is this operating manual intended for?

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

This includes persons who: ■

are in charge of transport

■

perform assembly/disassembly work

■

operate the machine

■

eliminate faults

■

perform daily routine work on the face or in the entry

■

perform maintenance work

■

perform repair work

and supervisory personnel who: ■

initiate and/or

■

supervise the activities just indicated.

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

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

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

service

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

safety

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

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

Try to memorize the symbols and their meanings.

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

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

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

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

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

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Before starting to work ____________________________________________

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2

Your safety

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___________________________________________________Personnel

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

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

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

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

Use only original Cat® spare parts. Note that the use of parts from other manufacturers will void the guarantee.

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

Observe the safety and accident prevention regulations of

further operating manuals

■

the mine,

■

the mine inspector, and

■

the mining supervisory authorities.

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

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Personnel _______________________________________________________ Personnel Operation training

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

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

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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 Cat® service engineers from or by specially qualified personnel of the mine.

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

Intended uses include: ■

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

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

Unauthorized uses include: ■

the transport of persons

■

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

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

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Safety instructions _______________________________________________

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_______________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

Inform your colleagues of

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

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

Observe the optical start-up warnings of the machine.

symbol plates panic strip

lock-out

cordon off working area

Observe the symbol plates on the machine.

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

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

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

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Safety instructions _______________________________________________ moving parts

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

conveyor chains

■

flights

■

pivot points

■

crawler assemblies

■

breaker shaft assemblies

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

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

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

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

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

mobile handling equipment

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

Installation and start-up inclined face

environmental acceptability

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

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

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

inspection maintenance instruction and safety tags

operator’s area

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

Verify that all maintenance has been performed.

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

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

Clean any foreign material from the operator’ s area.

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

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

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

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

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

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

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

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

Protect your work area against falling rocks.

replacing components

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

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

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Cat® spare parts.

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

For raising the feeder breaker use only: ■

crib blocks with adequate load-holding capacity

■

hoists, jacks or cranes with adequate load-carrying capacity

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_______________________________________________ Safety instructions handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

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

maintenance, repair

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

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

Always replace damaged or lost decals and metal instruction plates.

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

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.

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

laying hydraulic hoses

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

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting

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_______________________________________________ Safety instructions ■

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

Fig. 3: Laying hydraulic hoses, bending Right

■

Wrong

always have a little slack.

Fig. 4: Laying hydraulic hoses, crossing Right

■ ■ ■ ■

Wrong

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

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

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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

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3

Storage and transport

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____________________________________________ Storage and transport

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

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

Storage corrosion protection

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

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

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

dirt and moisture

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

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

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

short-term storage

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

long-term storage

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

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

■

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

■

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

■

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

■

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

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Storage and transport _____________________________________________ ■

Coat exposed valve bank valve spools with rust inhibitor.

■

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

■

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

machine electrics

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

random sample inspection

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

natural aging

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

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

HFA fluids

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

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

Long-term storage of spare components hydraulic components

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

miscellaneous components

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

motors

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

plastic deformation

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.

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____________________________________________ Storage and transport Transport Before transport temperatures below freezing

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

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

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

electronic components

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

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

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.

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

Lifting Points

Lifting Points

Lifting Points

Note: Approximate machine weight (w/out tailpiece and anchoring accessories) = 82,000 lbs Approximate machine weight, as shown, with tailpiece and anchoring accessories = 86,000 lbs

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4

Installation

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______________________________________________________ Installation

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

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

Work on the safety components (pressure relief valves, fire extinguishing equipment, etc.), the electrical equipment (control units, signaling devices, etc.), and the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by Cat® service engineers or by specially trained personnel.

Which tools are required for installation? tool box

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

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

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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 Cat® specialists. installation plan

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

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

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______________________________________________________ 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

■

check for correct position and/or operation of all stop switches (including pull cord, if equipped)

■

check the operation of the remote conveyor start system

■

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

■

check the breaker shaft for frozen or missing bits

■

check breaker shaft drive chain tension, if equipped

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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 any of the guards or covers removed.

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

“PICK BRK/CONV STOP”switch (starter enclosure)

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

“E-STOP”switch (starter enclosure)

This stop switch is located on the right hand side of the machine, on the starter enclosure cover. Depressing the “E-STOP”button will shutdown all machine functions immediately. All power is removed from the machine and the circuit breaker must be reset at the power center before the machine can be restarted.

panic strip

The machine is equipped with three panic strips: one centrally located on each side of the machine and one located at the auxiliary operators station. Striking with a small amount of force will actuate either of the panic strips. The panic strip is used to break the control circuit in emergency situations. When the panic strip is struck, all machine functions are shutdown immediately.

emergency pull cord

The emergency pull cord is located over the hopper. Pulling the cord from either side of the machine will shutdown the feeder by tripping the master control relay. Power is still on the machine and the machine can be restarted using normal start-up procedures after the latch at the pull cord is flipped and the chord positioned back in the center, neutral, position.

siren/warning light

The machine is equipped with a siren that will sound upon initial startup and each time the conveyor is restarted after timing out. The warning light will operate the entire time the machine is energized. The siren/ warning light is on a 20 ft. cable and is equipped with a magnetic base so that optimal placement can be determined by mine personnel.

neutral start guard

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.

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______________________________________________________ Installation fire suppression

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

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

convey/tram enable

The machine is equipped with a convey/tram enable solenoid located directly behind the primary valve bank. The CONV/OFF/TRAM mode switch controls the solenoid, making it impossible for the conveyor sections of the valve bank to operate while in TRAM mode and the remaining six valve bank sections inoperable while in CONV mode.

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Installation ______________________________________________________ Fig. 7: Safety features on the feeder breaker (typical)

Emergency pull cord

Fire suppression actuator Panic strip Neutral start guard

“PICK BK STOP”

Panic strip

“E-STOP”

CONVEY/TRAM ENABLE (behind valve bank)

Fire suppression actuator

Panic strip

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______________________________________________________ Installation Fig. 8: Overview of the feeder breaker (covers removed for clarity)

1

2

3 4, 5

6

7

18 17 16 15

8 14

13

12 11

10 9

1. Tail shaft 2. Emergency pull chord 3. Photo eye sensors 4. Breaker shaft 5. Breaker shaft cleaner 6. Power unit 7. Fire suppression bottles 8. Head shaft 9. Conveyor drive unit 10. Water/oil heat exchanger

11. Dust suppression system 12. Electrical starter enclosure 13. Breaker underspeed sensor (behind oil tank) 14. Hydraulic oil tank 15. Power fill 16. Torque hub (both crawlers) 17. Operator’ s station 18. Centralized grease manifold (both sides) 19. Head shaft tachometer (located on right hand end of head shaft)

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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: To remove the hopper (reference Fig. 9): 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.

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 PT Tech clutch from between the gear reducer and the electric motor to prevent the breaking shaft from moving during transport.

WARNING! If the breaker shaft is allowed to turn during transport, do not place any material on the conveyor. This material could get caught by the rotating breaker shaft. Damage to the material or injury to surrounding personnel could occur.

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 twelve (12) 1-1/2 inch hex head bolts, nuts, and lock washers that secure the receiving hopper to the main body of the machine.

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______________________________________________________ Installation 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.

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. A suitable means of support would be a utility scoop.

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.

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Installation ______________________________________________________ Fig. 9: Hopper removal and installation

Bolt (12)

Nut (12)

Alignment dowel (2)

Washer (12)

D-ring anchor (2)

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______________________________________________________ Installation To install the hopper (reference Fig. 9): 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.

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. Support the discharge end of the feeder breaker with a utility scoop.

5. Slowly tram the feeder breaker and scoop (supporting the discharge end of the feeder breaker) toward the hopper.

6. 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.

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

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

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

10. Insert the twelve (12) 1-1/2 inch hex head bolts, nuts, and lock washers. Torque bolts to 3,161 ft-lbs (dry).

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

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

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

14. Install the PT Tech clutch between the reducer and the electric motor.

15. Restore power to the machine.

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

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

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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 all personnel from injury. The primary towing device being used (cables, bars, etc.) and the towing machine must have sufficient load limits to maintain control through all conditions that may be encountered at any time during towing. 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 this warning could result in 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! Both the front and rear of the crawler drives must be chocked to prevent uncontrolled movement of the feeder breaker. Failure to follow this warning could result in serious injury or death to you or other workers.

3. Rotate the torque hub end cap on both right and left sides of the feeder to the free position as follows (Fig. 10).

4. Remove the two (2) bolts that retains the end cover to the center of the torque hub.

5. Rotate cover and reinstall with the two (2) bolts to disengage torque hub. Torque bolts to 120 in lb.

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

WARNING! Do not exceed 5 mph during towing. Failure to follow this warning could result in serious injury or death to you or other workers or damage to machine.

6. Remove chocks from crawler and begin towing.

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

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

8. Rotate the torque hub end cap on both right and left sides of the feeder breaker to the drive position.

9. Remove the two (2) bolts that retains the end cap to the center of the torque hub.

10. Rotate end cap and reinstall with the two (2) bolts to engage torque hubs to the drive position. Torque bolts to 120 in lb.

Fig. 10: Torque hub disengagement

Retaining bolts (2)

End cap button pointing outward

Normal tram position

Retaining bolts (2)

End cap button pointing inward

Freewheel position

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Installation ______________________________________________________

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_______________________________________________________________

5

Operation

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_______________________________________________________________

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_______________________________________________________ Operation

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

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

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

Who is allowed to operate the feeder breaker?

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

This also includes: ■

what safety devices are installed on the machine,

■

where these safety devices are located, and

■

how these safety devices are to be operated.

When can conveying be started?

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

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Operation _______________________________________________________ Controls and indicators Manual operational controls The machine may be operated manually via hydraulic and electrical controls mounted on the machine (Fig. 11).

Fig. 11: Manual operational controls 3

1

2

3

4

5

6

7

8

9

10

1

1. Fire suppression actuator 2. Neutral start guard 3. Panic strip 4. Primary valve bank 5. Function pressure gauge 6. Power fill ball valve 7. Oil level sight glass 8. Electrical starter enclosure 9. Dust suppression system 10. Auxiliary valve bank (if equipped)

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_______________________________________________________ Operation fire suppression

There are two (2) fire suppression (remote) actuators (Fig. 12) used to activate the fire suppression system on the feeder breaker; one located centrally on each side of the machine. The fire suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system, pull the safety pin and strike downward on the plunger.

Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

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

neutral start guard

The machine is equipped with a guard (Fig. 12) 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.

panic strip

There are three panic strips located on the feeder breaker; one centrally located on each side of the machine and one located at the auxiliary operator’ s station (if equipped). The panic strip (Fig. 12) is used to break the control circuit in emergency situations. Striking the panic strip with a small amount of force will actuate the panic strip: all machine functions are shutdown immediately.

Fig. 12: Fire suppression actuators, neutral start guard, and panic strips 1. Fire suppression actuator location 2. Panic strip 3. Neutral start guard

2

1

2

3

1

2

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Operation _______________________________________________________ Primary valve bank The primary valve bank (Fig. 13) is used to manually operate the machine when radio remote operation is not possible. The valve section handles are stored in a storage tube beside the valve bank. To manually operate the machine, the “MAN/OFF/AUTO”switch must be in the “MAN”position.

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

The first two sections on the operator’ s left are conveyor forward and reverse. The two sections can be used independently or together to control conveyor direction and speed. To run the conveyor in the forward direction (towards the discharge end), push either valve handle up. If the conveyor is sluggish, use both valve sections. To run the conveyor in reverse (towards the receiving hopper), push either valve handle down. If the conveyor is sluggish, use both valve sections.

Note: The two conveyor valve sections are tied to a common circuit.

Using both valve sections will increase flow to the conveyor motors, increasing speed.

“LEFT TRAM”

The third section from the operator’ s left controls the left tram functions.

“RIGHT TRAM”

The fourth section from the operator’ s left controls the right side tram functions.

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

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

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

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_______________________________________________________ Operation “LH FRAME LIFT”

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

“TANK FILL” and “AUX VB”

The sixth lever from the operator’ s left has two (2) functions, it controls the “TANK FILL”and auxiliary valve bank, “AUX VB”oil flow for the machine. To operate the power fill, turn ball valve handle (Fig. 13) to the open position and push the control lever. To de-energize power fill pump, move control lever to the centered position and turn ball valve handle to closed position. Pull the control lever towards the operator to energize the auxiliary valve bank (if equipped).

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 unexpected machine movement if the secondary valve bank is energized and a lever on the secondary valve bank is inadvertently moved or machine overheating if the power fill pump is left energized. Unexpected machine movement could result in serious injury to personnel or damaged equipment.

To operate the power fill (Fig. 14): 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 and hydraulic oil return filter to the hydraulic oil tank.

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Operation _______________________________________________________ 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 the ball valve.

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. function pressure gauge

The function pressure gauge (Fig. 13) is located below the primary valve bank. This gauge provides a pressure reading for each active function on the machine.

Fig. 13: Primary valve bank and function pressure gauge

Valve bank

Function pressure gauge

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_______________________________________________________ Operation Fig. 14: Power fill system and hydraulic oil sight glass

Power fill Sight glass

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Operation _______________________________________________________ Auxiliary valve bank (if equipped) The auxiliary valve bank (if equipped) consists of the following controls: “TAIL TILT”

The first lever from the operators left is the “TAIL TILT”control lever which is used to position the tailpiece vertically (up and down). To tilt the tailpiece up, slowly pull the control lever towards the operator. To tilt the tailpiece down, push the control lever away from the operator.

“TAIL STEER”

The second lever from the operator’ s left is the “TAIL STEER”control lever which is used to position the tailpiece horizontally (left and right).

To move the tailpiece away from the operator, push the control lever forward. To move the tailpiece toward the operator, pull the control lever back.

“LEFT FLOOR”

“RIGHT FLOOR”

The third lever from the operator’ s left is the “LEFT FLOOR”control lever which controls the left floor (foot) stabilizer cylinder. To lower the foot, slowly push the control lever away from the operator. To raise the foot, slowly pull the control lever towards the operator.

The fourth lever from the operator’ s left is the “RIGHT FLOOR”control lever which controls the right floor (foot) stabilizer cylinder. To lower the foot, slowly push the control lever away from the operator. To raise the foot, slowly pull the control lever towards the operator.

“LEFT ROOF”

The fifth lever from the operator’ s left is the “LEFT ROOF”control lever which controls the left roof stabilizer cylinder. To raise the arm, slowly push the control lever away from the operator. To lower the arm, slowly pull the control lever towards the operator.

“RIGHT ROOF”

The sixth lever from the operator’ s left is the “RIGHT FLOOR”control lever which controls the left roof stabilizer cylinder. To raise the arm, slowly push the control lever away from the operator. To lower the arm, slowly pull the control lever towards the operator.

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_______________________________________________________ Operation Electrical starter enclosure The starter enclosure (Fig. 15) houses the primary electrical control components of the machine. The following switches and controls are located on the front of the enclosure: “MAN/OFF/AUTO”

The “MAN/OFF/AUTO”selector switch is used to set the mode of operation. 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 is used for normal operations.

“TRAM/OFF/CONV”

The “TRAM/OFF/CONV”selector switch is used to select tram or conveyor mode of operation. When in “OFF”mode, tram and conveyor functions are not active. “TRAM”mode is used when 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.

“FWD CONV/OFF/REV CONV”

The “FWD CONV/OFF/REV CONV”selector switch is used to select the conveyor direction. If the switch is in “OFF”mode while the “MAN/ OFF/AUTO”switch is in “AUTO”mode, the conveyor will not run. Forward mode, “FWD CONV”, is used for normal operations.

“15A CB RESET”

The “15A CB RESET”pushbutton is used to reset the control circuit breaker.

“PICK BK STOP”

The “PICK BK STOP”pushbutton is used to stop the pick breaker motor.

“E-STOP”

The “E-STOP”button is used to trip the master control relay, thereby shutting down the machine. Power is still on the machine.

“ACKNOWLEDGE ALARMS”

The “ACKNOWLEDGE ALARMS”pushbutton is used to clear an alarm from the display panel after the condition that generated the alarm is corrected. This pushbutton is also used to engage the master control relay when starting the machine for the first time or after the panic switch/e-stop has been pressed.

“CONV START”

The “CONV START”pushbutton will initiate an automatic conveyor run cycle. The conveyor will run for the time duration preset. Note: The conveyor will not run until the breaker motor and hydraulic pump are running.

“START BREAKER”

The “START BREAKER”pushbutton is used to start the breaker motor.

When the button is pushed, an alarm sounds for a preset amount of time. After the alarm sound, the breaker motor will start.

circuit breaker reset lever

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”.

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Operation _______________________________________________________ Fig. 15: Starter enclosure cover 1

5

6

7

2

8

3

9

4

10 11

1. “MAN/OFF/AUTO”selector switch 2. “TRAM/OFF/CONV”selector switch 3. “FWD CONV/OFF/REV CONV”selector switch 4. PLC display 5. “15A CB RESET”pushbutton 6. “PICK BK STOP”pushbutton 7. “E-STOP”pushbutton 8. “ACKNOWLEDGE ALARMS”pushbutton 9. “CONV START”pushbutton 10. “START BREAKER”pushbutton 11. Main circuit breaker reset lever

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_______________________________________________________ Operation PLC display

The display panel (Fig. 16) is located in the starter enclosure. The display is used to monitor machine performance during operation, to troubleshoot the machine, and to change operating parameters.

Fig. 16: PLC display (touch screen feature) PLC display

Number pad

Function keys

“MAIN SCREEN”

On screen navigation keys

The normal operation display screen is the “MAIN SCREEN”(Fig. 17).

This screen displays any active alarm, breaker motor amps, conveyor speed, breaker and motor hours, and mode of operation (with or without belt sequence active). It also provides a login/logout access. The “MAIN SCREEN”and “STATUS SCREEN”are the only screens available without a password. After log in, access to three additional screens is displayed. For alarm information, see the troubleshooting section in this chapter.

Fig. 17: “MAIN SCREEN”

Operating status Conveyor speed

Alarm banner Motor hours

Login access Logout

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Operation _______________________________________________________ “STATUS SCREEN”

The “STATUS SCREEN”(Fig. 18) is accessed by pushing function key “F1”. This screen displays the conveyor speed, hydraulic oil pressure, vacuum pressure, and the current in each phase of the breaker motor.

To return to the “MAIN SCREEN”from the “STATUS SCREEN”, press “F1”.

Fig. 18: “STATUS SCREEN”

After logging in, the functions keys “F2”through “F4”(Fig. 16) are used to access four additional screens: “PRESETS”, “OPERATION TIMERS”, and “JAM TIMERS”. Currently, function keys “F5”through “F8” are not used.

“PRESETS SCREEN”

The “PRESETS SCREEN”(Fig. 19) is accessed from the “MAIN SCREEN”by pushing function key “F2”. This screen allows access to the preset breaker shaft speed designations for low, medium and high speeds. To return to the “MAIN SCREEN”from the “PRESET SCREEN”, press “F1”. The timer screens can be accessed from the “PRESET SCREEN”by pressing “F3”or “F4”.

Fig. 19: “PRESET SCREEN”

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_______________________________________________________ Operation “OPERATION TIMERS SETUP SCREEN”(“TIMERS 1”)

The “TIMERS 1 SCREEN”(Fig. 20) is accessed from the “MAIN SCREEN”by pushing function key “F3”. This screen allows access to the “OPERATION TIMERS SETUP SCREEN”where the timers for the breaker idle shutdown, the start-up warning horn, and conveyor run timers can be set. To return to the “MAIN SCREEN”from the “TIMERS 1 SCREEN”, press “F1”. The “PRESETS”and “TIMER 2”screens can be accessed from the “TIMERS 1 SCREEN”by pressing “F2”or “F4”.

Fig. 20: “OPERATION TIMERS SETUP SCREEN”(“TIMERS 1”)

“JAM TIMERS SETUP SCREEN”(“TIMERS 2”)

The “TIMERS 2 SCREEN”(Fig. 21) is accessed from the “MAIN SCREEN”by pushing function key “F4”. This screen allows access to the “JAM TIMERS SETUP SCREEN”where the timers for the breaker overload preset amps, beaker overload delay, conveyor slow backup, and conveyor slow forward timers can be set. To return to the “MAIN SCREEN”from the “TIMERS 2 SCREEN”, press “F1”. The “PRESETS” and “TIMER 1”screens can be accessed from the “TIMERS 1 SCREEN” by pressing “F2”or “F3”.

Fig. 21: “JAM TIMERS SETUP SCREEN”(“TIMERS 2”)

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Operation _______________________________________________________ WARNING! The pressure regulator should never be adjusted above 125 psi. dust suppression system regulator

The dust suppression system regulator (Fig. 22) is located below the breaker power unit on the right side of the machine and is used to control the water pressure to the six spray nozzles located in the hose crossover tray over the breaker shaft. The water pressure to the nozzles is monitored by the dust suppression system pressure gauge (Fig. 18). To increase pressure, turn the regulator handle in (cw). To decrease pressure, turn the regulator handle out (ccw).

dust suppression system pressure gauge

The dust suppression system pressure gauge (Fig. 22) is used to monitor the water pressure to the spray nozzles. The gauge should read between 5 and 125 psi.

dust suppression system strainer

The dust suppression system strainer (Fig. 22) is located below the breaker power unit on the right side of the machine and is used to filter particles from the mine water supply. The strainer should periodically be flushed to avoid becoming clogged. To flush the strainer, turn the ball valve handle, located on the branch of the strainer body, 90° in-line with the outlet. Allow to flush for approximately thirty seconds to one minute and then close the ball valve handle.

water solenoid

The water solenoid is located beside the regulator/strainer assembly and is used to control flow of water to the six spray nozzles located in the hosed crossover tray over the breaker shaft. The solenoid is controlled by a pressure transducer located in the hydraulic pressure gauge manifold beside the primary valve bank. When the “MAN/OFF/ AUTO”switch on the starter enclosure is set to “AUTO”, the “TRAM/ OFF/CONV”switch is set to “CONV”, and the hydraulic system pressure reaches 1,000 psi, the solenoid will open and allow water to flow through the water/oil cooler and then to the spray bars. The solenoid activation pressure is adjustable through the PLC.

Fig. 22: Dust suppression system regulator and pressure gauge Water solenoid

Gauge

Regulator

Strainer

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_______________________________________________________ Operation photo eye pump motor controls and remote start/stop stations

The photo eye sensors (Fig. 23) and remote start/stop pushbutton stations are used to control conveyor operation. When the conveyor is started, an adjustable timer with a default value of 2-1/2 minutes is initiated through the PLC. If, during this 2-1/2 minutes, a light is shone on either photo eye sensor for 4 continuous seconds or either remote start button is pushed, the conveyor timer is reset and the conveyor will continue running. If neither action is take, the conveyor will shut down.

When the conveyor shuts down, an adjustable timer with a default value of 15 minutes is activated. If, during this 15 minute period, neither photo eye sensor or remote start button is activated, the pump motor will shut down. If either action is taken, the timers will reset and the conveyor will restart.

In addition, the remote pushbutton station is equipped with a “STOP” button. This button can be used to shut down the pump motor at any time.

Note: A siren will sound upon initial start up and every time the conveyor is restarted after timing out. There will be a start up delay while the siren sounds.

Fig. 23: Photo eye sensors

Photo eye sensors

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Operation _______________________________________________________ radio remote

The machine is equipped with a wireless remote (Fig. 24) that can be used to control tramming and to operate the lift and tilt cylinders. The radio remote is active when the “CONV/OFF/TRAM”selector switch is in the “TRAM”position and the neutral start guard is in place (valve levers in neutral, guard covering handles, magnetic switch engaged).

Fig. 24: Radio remote

1. Push to operate bar (deadman switch) 2. Battery good indicator 3. Battery low indicator 4. Left tram 5. Right tram 6. Left lift cylinder 7. Right lift cylinder 8. Tilt cylinder 9. Pump (breaker motor) start/stop 10. Radio remote power on/off 11. Emergency stop 12. Reset

2 1 3

4

5

6

7

9 8 11

10

12

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_______________________________________________________ Operation The remote is equipped with the following performance and safety features: Power on self diagnostics: When the radio remote is powered on (“POWER”toggle switch is in the “ON”position), a self-test is initiated. when the self-test is complete, the radio remote will beep two times.

Transmit/battery charge indicator: When the battery is good, the green LED will flash with each transmission. When the battery level drops below a preset level, the radio remote will beep every ten seconds and the red LED will flash during data transmission. At this point, there is approximately one hour of battery life remaining. The radio remote will shut itself off before the battery drops low enough to result in erratic operation.

Battery saver: The radio remote will enter sleep mode if there is no input for fifteen minutes. To reset the remote, toggle the “POWER” switch to the “OFF”position and then to “ON”.

The operational controls on the remote are: push to operate bar (deadman switch)

The push to operate bar (deadman switch) is a spring-return switch located on top of the radio remote that is used as a safety device that electrically disconnects all functions when released. This bar must be held in while operating any function on the radio remote.

left and right “TRAM”

The left and right “TRAM”switches are used to tram the machine.

Each crawler can be trammed independently in either the forward or reverse direction.

left and right “LIFT”

The left and right “LIFT”switches are used to operate the lift cylinders.

The left and right cylinders can be raised and lowered independently.

“TILT”

The “TILT”switch is used to operate the left and right tilt cylinders.

These cylinders are not independent and operate on a common hydraulic circuit.

“PUMP”

The “PUMP”start/stop switch is used to start the breaker electric motor.

“POWER”

The “POWER”on/off switch is used to power on and off the radio remote.

“STOP”

The “STOP”pushbutton is an emergency stop button used to shutdown the radio remote.

“RESET”

The “RESET”button is used to reset the system and must be pressed after turning the “POWER”switch to the “ON”position. Each time the radio remote is powered “OFF”and then back to “ON”the “RESET” pushbutton must be pressed initially before any command will work.

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Operation _______________________________________________________ remote control batteries

Battery Options The remote control is battery powered. There are two different battery pack options: 

Disposable Alkaline Battery Pack (standard— machine ships with this battery pack) - provides approximately 75 hours of life (based on continuous transmission).



Rechargeable Ni-Cad Battery Pack (optional) - provides approximately 23 hours of life (based on continuous transmission).

Battery Replacement When the “TRANSMIT/LOW BATTERY”LED begins to flash red, there is approximately one hour of continuous operation remaining.

To replace the battery pack: 1. Set the remote control power switch to “OFF”.

2. Unlatch and open the battery door and remove the battery pack from the tray.

3. Insert a fully charged battery pack into the remote control. Ensure that the contacts on the underside of the battery pack align with the corresponding contacts on the battery tray.

4. closs and latch the battery door.

5. Move the remote control power switch to the “ON”position. The “TRANSMIT/LOW BATTERY”LED should flash yellow and two quick beeps will be heard.

6. Operate a non-motion function such as the lights. The “TRANSMIT LOW/BATTERY”LED should flash green, indicating the remote control is fully operational.

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_______________________________________________________ Operation Battery Charging (optional) The Ni-Cad battery pack is rechargeable using the appropriate charging station. Contact your Cat Service Representative for battery and battery charging options.

To recharge: 1. Remove the Ni-Cad battery pack from the radio remote.

2. Connect the charger to a standard 120VAC outlet.

3. Insert the battery pack into the charger. The battery charger red “CHARGING”LED will be lit until the end of the charging process.

When fully charged, the green “FULLY CHARGED”LED will illuminate.

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Operation _______________________________________________________ “AUTO”mode 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 to run).

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. 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 primary and secondary valve bank (if equipped) control levers to ensure that they are free and in neutral position.

2. Position the primary 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 clear of the machine.

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

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

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

7. Push the “ACKNOWLEDGE ALARMS”button once to engage the MCR. Press the button a second time to clear any faults.

8. Engage the “START BREAKER”pushbutton located on the cover of the starter enclosure. An alarm will sound for a preset amount of time and then the breaker motor will start.

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_______________________________________________________ Operation “MANUAL”mode starting procedure If the machine needs to be operated while the outby belt is off (belt sequence switch by-passed), start the machine in “MANUAL”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. 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 primary and secondary valve bank (if equipped) control levers to ensure that they are free and in neutral position.

2. Position the primary 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 clear of the machine.

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

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

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

7. Push the “ACKNOWLEDGE ALARMS”button once to engage the MCR. Press the button a second time to clear any faults.

8. Engage the “START BREAKER”pushbutton located on the cover of the starter enclosure. An alarm will sound for a preset amount of time and then the pick break motor will start.

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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 from the starter enclosure: 2. Engage the “PICK BKR STOP”pushbutton located on the starter enclosure to stop the breaker motor.

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

4. Move the “TRAM/OFF/CONV”switch to the “OFF”position.

5. Move the “MAN/OFF/AUTO”switch to the “OFF”position.

To shutdown the feeder breaker from the radio remote: 2. Move the “PUMP”start/stop toggle switch to the “STOP”position to stop the breaker motor.

3. Move the radio remote “ON/OFF”toggle switch to “OFF”.

4. Move the circuit breaker reset switch, located on the starter enclosure, to the “OFF”position.

5. Move the “TRAM/OFF/CONV”switch located on the starter enclosure to the “OFF”position.

6. Move the “MAN/OFF/AUTO”switch located on the starter enclosure to the “OFF”position.

Emergency stop procedures: The machine can also be shutdown in emergency situations using: 1. Either panic strip, 2. The “EMERGENCY STOP”button on the starter enclosure, 3. The pull cord, 4. The “EMERGENCY STOP”button on either remote start station., or Activating any one of the emergency stop devices will open the master control relay, “MCR”. Power will still be on the machine and the machine can be restarted using normal starting procedures.

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_______________________________________________________ Operation Tramming using the hydraulic control levers 1. Turn the “FWD/OFF/REV”selector switch located on the cover of the starter enclosure to the “OFF”position.

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

3. Turn the “MAN/OFF/AUTO”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. Push the “ACKNOWLEDGE ALARMS”button once to engage the MCR. Press the button a second time to clear any faults.

6. Engage the “START BREAKER”pushbutton located on the cover of the starter enclosure to start the pump motor.

7. Lift up the neutral start valve handle guard all the way back so that the guard will not fall on the operator’ s hands.

The machine can now be trammed.

Tramming using the radio remote 1. Turn the “FWD/OFF/REV”selector switch located on the cover of the starter enclosure to the “OFF”position.

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

3. Turn the “MAN/OFF/AUTO”selector switch located on the cover of starter enclosure to the “OFF”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. Remove the tram valve handles from the primary valve bank.

6. Position the neutral start guard over the primary valve bank.

7. Push the “ACKNOWLEDGE ALARMS”button once to engage the MCR. Press the button a second time to clear any faults.

8. Move the radio remote “POWER”button to the “ON”position.

Listen for 2 beeps.

9. Press the “RESET”button on the radio remote. Listen for 2 beeps.

10. Press and hold the push to operate (deadman) switch on the top of the radio remote.

11. Move the “PUMP START”button on the radio remote to the “START”position.

12. While holding the push to operate switch in, tram the machine using

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

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

3. Push the “START BREAKER”button to start the breaker motor.

4. Turn the “FWD/OFF/REV”selector switch located on the cover of the starter enclosure to the “FWD”position.

It is important to note the following concerning the operation of the conveyor in the forward direction: –

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

–

If the current increases above 125% FLA and stays at that level for three seconds, the PLC will assume there is a conveyor jam. The PLC will try to clear the jam by stopping the conveyor, running it in reverse for three seconds at 10% speed, and then running it forward for ten seconds at 25% speed.

–

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

–

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

–

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

–

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

5. Press the “START CONVEYOR”button on the front of the starter enclosure or the “START”button on either one of the remote pushbutton stations. A siren will sound warning that the conveyor is starting. The siren will sound any time the conveyor has timed out and is restarted.

Notes: 1. The PLC controls the speed of the conveyor based upon the amperage monitoring of the breaker motor. There are three preset forward conveyor speeds that are, by default, 20%, 50%, and 100%. These speeds are adjustable and can be reset to suit the operating conditions.

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_______________________________________________________ Operation 2. The conveyor operating time is controlled by a timer that is reset by pushing a start button on the starter enclosure or either remote pushbutton station or shining a light on the photo eye sensor mounted above the hopper. If the timer is not reset within the allotted time, the conveyor will stop.

3. There is a second adjustable timer that will shut down the electric motor if, within a preset amount of time, there is no conveyor activity. If, within this amount of time, the conveyor is idle and a conveyor start button is pushed, the PLC will allow the pump to ramp back up to full flow.

Conveyor reverse IMPORTANT! If it is necessary to reverse the conveyor, it should be jogged only. Running the conveyor in the reverse direction for even a short period of time with material in the hopper may cause the conveyor to jam. It will then be necessary to empty the machine hopper before the conveyor can be restarted.

Operating the conveyor in reverse 1. Turn the “FWD/OFF/REV”selector switch located on the cover of the starter enclosure to the “REV”position. The conveyor chain will now run in reverse at 25% full speed as long as the switch is in the “REV”position. Note: the conveyor should not be run in reverse for extended periods; only jog the conveyor when in reverse.

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Operation _______________________________________________________ Control system operating parameters The following parameters affect the operation of the machine as indicated: Breaker underspeed If the breaker underspeed 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 “BREAKER MOTOR OVERLOAD ALARM”will be displayed.

Breaker idle shutdown timer If the conveyor is running and no cars dump on the conveyor within a 21/2 minute time period (adjustable within the PLC), the control system will shutdown the conveyor motor.

If no conveyor function is engaged on a running machine within a 15 minute time period (adjustable within the PLC), the control system will shutdown the breaker motor.

High oil temperature If the hydraulic oil temperature exceeds a preset value of 165° F, the control system will shutdown the machine and the “HIGH OIL TEMPERATURE ALARM”will be displayed.

Low oil level If the hydraulic oil level falls below a preset level for more than three seconds, the control system will shutdown the machine and the “LOW OIL LEVEL ALARM”will be displayed.

High oil pressure If the hydraulic oil pressure exceeds 4,800 psi for more than three second, the control system will shutdown the machine and the “HIGH OIL PRESSURE ALARM”will be displayed.

Low pump suction If the vacuum 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 PUMP SUCTION ALARM”will be displayed.

The vacuum transducer is located in the suction line fitting of the pump suction port.

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_______________________________________________________ Operation Pressure transducer If the hydraulic system pressure transducer reads greater than 1,000 psi (adjustable within the PLC), the water solenoid is turned on and the water sprays are activated. This transducer also activates the high oil pressure alarm and is located in the gauge manifold at the main operator’ s station.

Tram control magnet switch If the neutral start switch (see Controls and Indicators section of this chapter) is not in place when the pump motor is started, the control system will not allow the motor to start and the “TRAM CONTROL MAGNET SWITCH ALARM”will be displayed.

Emergency stop If the master control relay is opened by activating an emergency stop device, the machine will shutdown and the “EMERGENCY STOP ALARM”will be displayed.

Big jam shutdown 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 the “BIG JAM SHUTDOWN ALARM”will be displayed.

Conveyor speed 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 sent to the PLC where it is converted to feet per minute (fpm) and displayed as conveyor speed.

Tilt switch There is a tilt switch located on the discharge of the feeder breaker to sense spillage. When activated (held at a 45° angle) for three seconds, the system will display a “TILT SWITCH ACTIVATED”alarm. These feature is disabled in tram mode.

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Operation _______________________________________________________

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

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

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

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.

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Electrical system _________________________________________________ Fig. 25: Major electrical component locator

7 8 1 5

4

3 2 9

11

7

7 6

6

1. Breaker shaft motor 2. Breaker shaft underspeed sensor 3. Starter enclosure

4.

5.

6.

7.

High temp switch Water solenoid Photo cell (2) Panic strips

10

8. Conveyor motor 9. Radio control box 10. Photo eye control box 11. Low oil switch

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________________________________________________ Electrical system

breaker motor

The breaker motor is a 200 HP, 575 VAC, 3 phase, 60 Hz, 1750 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 motors will shut off.

starter enclosure

The starter enclosure is located on the left side of the machine and houses the machines electrical controls.

low oil switch

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.

high temperature switch

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. The temperature probe is located in the oil tank.

water solenoid

The water solenoid enclosure is located on the wall behind the conveyor drive reducer. When the conveyor motor forward pressure is greater than 1,000 psi, the pressure transducer signals the PLC to open the electric water valve, activating the dust sprays and the oil cooler (water over oil heat exchanger).

photo eye sensors

The photo eye sensors are used to remotely start the conveyor/pump motor and are mounted on top of the machine on both sides of the hopper. The conveyor/pump motor will start when a light shines on the sensor for approximately four seconds.

panic strips

There is one panic strip located near the valve bank on the left side of the machine and one panic strip located near the main grease manifold on the right side of machine. The third panic strip is located above the auxiliary valve bank on the left hand side of machine. Activating either panic strip will open both master control relays, “MCR”and “MCRA”, thereby shutting down the machine.

remote pushbutton station

The remote pushbutton stations (2) are attached with 50 ft. cables and are mounted in the entry to allow the shuttle operator to remotely start and stop the conveyor.

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Electrical system _________________________________________________ Starter enclosure The starter enclosure, located on the left side of the machine, houses the primary electrical control components.

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

There are operational controls located on the front of the starter enclosure (Fig. 26). For control descriptions, see the Controls and Indicators section in this chapter.

Fig. 26: Starter enclosure 1

1.

2.

3.

4.

5.

6.

2

3

5

6

4

7

8

9

10

“MAN/OFF/AUTO” “TRAM/OFF/CONV” “FWD CONV/OFF/REV CONV” PLC display “15A CB RESET” “PICK BRK STOP”

11

7. “E-STOP” 8. “ACKNOWLEDGE ALARMS” 9. “CONV START” 10. “START BREAKER” 11. Circuit breaker reset lever

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________________________________________________ Electrical system Swing panel - front side The swing panel (Fig. 27) is accessed by opening the cover on the enclosure. Immediately adjacent to the swing panel is the main circuit breaker, CB1, for the feeder breaker.

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

Fig. 27: Swing panel, front side

1

10

1.

2.

3.

4.

5.

6.

7.

8.

11

12

Power Supply Analog input module Analog output module Input module #1 Input module #2 Output module Amplifier card 1 Amplifier card 2

2

13

3

4

5

6

14 15 16 17 18 19 20 21

9. IS Relay 10. AC/DC converter #1 11. AC/DC converter #2 12. AC/DC converter #3 13. AC/DC converter #4 14. SR 15. MCR 16. CRWS

7

8

22

9

23

17. CR1 18. CR2 19. CRR 20. SSR 21. R1A 22. Ethernet switch 23. TAC monitor

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Electrical system _________________________________________________ power supply

The power unit houses the system processor for the machine control system.

analog input module

The analog input module receives inputs from the current transducer.

analog output module

The analog output module sends a signal to the amplifier boards.

input module #1

Input module #1 is for the 120V inputs (selector switches, push buttons, etc.).

input module #2

Input module #2 is an analog input module for the current transducer, pressure transducer, vacuum transducer, and TAC monitor.

output module

The analog output module sends a signal to the amplifier boards.

amplifier boards

The electronic amplifier boards drive the conveyor speed solenoids.

IS relay

The IS relay is the intrinsically safe relay for the panic bars.

AC/DC converter #1

AC/DC converter #1 is the 120VAC/24VDC power supply for the panel view display.

AC/DC converter #2

AC/DC converter #2 is the 120VAC/24VDC power supply for the conveyor and tram forward solenoids, two pressure transducers, and the vacuum transducer.

AC/DC converter #3

AC/DC converter #3 is the 120VAC/24VDC power supply for the reverse tram solenoids.

AC/DC converter #4

AC/DC converter #4 is the 120VAC/24VDC power supply for the

MCR

SR CRWS CR1 and CR2

MCR is the master control relay. This relay receives input from the emergency stop button located on the starter enclosure, and the remote control.

SR is the safety relay for the panic bar.

CRWS is the water solenoid relay.

CR1 and CR2 are conveyor forward relays.

CRR

CRR is the conveyor reverse relay.

SSR

SSR is the strobe/siren relay.

R1A

R1A is the radio remote relay.

Ethernet switch TAC monitor

The Ethernet switch provides access for programming.

The TAC monitor picks up the conveyor shaft and pick break speeds and sends a signal to the PLC.

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________________________________________________ Electrical system Back panel The back panel (Fig. 28) is accessed by removing the swing panel retaining bolt located in the upper left hand corner of the swing panel and swinging the panel out. Note that component locations are typical.

Always consult the parts book for your machine to verify locations.

Fig. 28: Back panel, typical

1

2

4 1. “T1”, control transformer 2. “OL1”, overload 3. “M1”, vacuum contactor

3

5

6

4. Fuse 5. Current transducer 6. Current transformer (3)

“T1”

“T1”is the control transformer that reduces the voltage to the control circuit from 575V to 120V.

“OL1”

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

“M1”

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

fuse

The 5A fuse is for the power supply for the display panel.

current transducer

The current transducer converts the current to a 4 - 20 mA signal that is relayed to the analog input module and is then displayed as full motor current on the PLC display.

current transformer

300:5 current transformers used to step down the current.

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

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

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

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

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

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________________________________________________ Hydraulic system Fig. 29: Hydraulic component locator

2

17 16

1

3

19 11

9

18 12

8 6

6

15 13 20

5 7

14 4

10

1.

2.

3.

4.

5.

6.

7.

Conveyor motor Piggyback gear pump Open loop load sense pump Pressure filter Valve bank Tram motor (2) System pressure gauge

8.

Hydraulic oil level/temperature gauge 9. Hydraulic oil tank 10. Frame tilt cylinder (2) 11. Hydraulic oil fill hand pump 12. Hydraulic power fill ball valve 13. Return filter

14. Conveyor/tram engage valve 15. Frame lift cylinder (2) 16. Tailpiece steering cylinders (2) 17. Tailpiece lift cylinders (2) 18. Roof cylinders (2) 19. Stab cylinders (2) 20. Schroeder test mate port

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Hydraulic system_________________________________________________ Major hydraulic components (Reference Fig. 29) conveyor motor

The conveyor motor is located on the left hand side of the machine, and is mounted directly to the conveyor reducer. This radial piston motor receives hydraulic fluid from the main valve bank’ s first and second sections.

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.

open loop load sense pump

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

pressure filter

The pressure filter is located on the left hand side of the machine near the operator’ s station. This filter is used to filter fluid on the pressure side of the hydraulic circuit.

primary valve bank

The primary valve bank, located on the left hand side of the machine directly above the crawler, 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.

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.

system pressure gauge

The system pressure gauge is located at the primary operator’ s station on the left side of the machine. This single gauge will display the system pressure for the active function.

hydraulic oil tank with sight glass and thermometer

The hydraulic oil tank is located on the left hand side of the machine and has a 110 gallon capacity. The hydraulic oil temperature and level is monitored by the PLC via a temperature probe and float switch. The tank is equipped with a sight glass and thermometer.

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.

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.

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________________________________________________ Hydraulic system power fill ball valve

The hydraulic power fill ball valve is located on the left hand of the machine. This valve must be opened before activating the power fill function on the valve bank.

tank fill pump

The tank fill pump is a flow divider that is hosed to run backwards from normal flow divider operation. The pump is located on top of the hydraulic oil tank on the left side of the machine and is used to replenish oil supply. It is capable of delivering approximately 5 gallons of fluid per 30 seconds.

return filter

The return filter is located on the left hand side of the machine near the primary operator’ s station. This filter is used to filter fluid on the return side of the hydraulic circuit and as the power fill filter.

conveyor/tram engage valve

The conveyor/tram engage valve is located behind the valve bank on the left side of the machine. The valve is used to disable the conveyor sections of the valve bank when the “TRAM/OFF/CONVEYOR”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 “TRAM/OFF/CONVEYOR” switch is in the “CONVEYOR”position. This is accomplished by dumping the hydraulic load sense signal from either the conveyor sections (tram only) or the other sections (conveyor only). Without the load sense signal, a valve bank section is disabled.

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.

auxiliary valve bank

The auxiliary valve bank, if equipped, is used to control the tailpiece tilt and steer cylinders and the roof and floor cylinders.

Schroeder test mate port

The Schroeder test mate port is used to connect a Schroeder test mate device to troubleshoot the hydraulic system.

tailpiece lift and steering cylinders

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

roof and stab cylinders

The roof and stab cylinders are used support and stabilize the feeder breaker while conveying of material.

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.

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Hydraulic system_________________________________________________ Primary hydraulic circuit The primary hydraulic circuit is powered by an open loop load sense pump rated at 165cc/75 gpm at 1750 rpm electric motor speed. This pump supplies oil flow to the main valve bank. The main valve bank operates the conveyor motor, tram motors, lift cylinders, tilt cylinders, and power fill function.

There is a suction transducer located between the oil tank and the pump. If the suction pressure drops below a preset value, meaning that the line is pulling in air from either a low oil condition or a leaking suction line, an alarm will be issued by the PLC. If the condition lasts longer than three seconds, the PLC will shutdown the machine to avoid pump damage. From the pump, oil enters a 5 micron by-passing pressure filter and continues to the main valve bank, whose relief is set at 5,000 psi.

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________________________________________________ Hydraulic system Fig. 30: Primary hydraulic schematic

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Hydraulic system_________________________________________________

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___________________________________________ 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. 31); one is located on each side of the machine. The complete drive assemblies are housed in crawler frames which enclose, guide and support the tram components. Each tram drive is independently controlled by the operator for moving the machine forward, backward and for making turns.

The crawlers on the machine are hydraulic driven through torque hub gear reducers. Attached to the torque hub is a single sprocket that engages the crawler tracks directly. The crawler track loops around the take-up roller (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.)

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Mechanical assemblies____________________________________________ Fig. 31: Crawler assembly main components

1

6 (access) 5 (access) 4

3 2 4

1

5

6

1.

2.

3.

4.

5.

6.

Cat pad assembly Hydraulic motor Sprocket Torque hub Take-up cylinder and shims Take-up roller assembly

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___________________________________________ Mechanical assemblies Conveyor chain The feeder breaker is equipped with a conveyor chain assembly (Fig. 32) 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. 32: Conveyor chain components

1 3

2

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

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Mechanical assemblies____________________________________________ Grease take-up The feeder breaker is equipped with two (2) conveyor chain grease take-up assemblies (Fig. 33) 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. 33: Grease take-up main components

Stop valve (2)

Grease fitting (2)

Shim storage (2)

1.

2.

3.

4.

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

Take-up cylinder

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___________________________________________ Mechanical assemblies Head shaft assembly The feeder breaker is equipped with a head shaft (Fig. 34) located on the discharge end of the conveyor. The head shaft is driven from the left hand side via a hydraulic motor directly mounted to the head shaft.

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

Fig. 34: Head shaft main components 10

9 11

7

8

1 6 5 3

4

2

1. Hydraulic motor 2. Gear box 3. Retaining bolt 4. Retainer 5. Adapter 6. Bearing (2) 7. Head shaft 8. Key (2) 9. Sprocket (2) 10. Sensor unit 11. Gear box support bracket

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Mechanical assemblies____________________________________________ Conveyor power unit The conveyor power unit drives the hydraulic pump (s) and pick breaker reducer (Fig. 35). It consists of a 125 HP 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. 35: Conveyor power unit main components

7 5 6 4

2

3

8

1

1.

2.

3.

4.

5.

6.

7.

8.

9.

9

Hex head bolt, Lockwasher, Flat washer, Hydraulic motor Gearbox Headshaft retainer Headshaft splined adapter Hex head bolt End cap

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___________________________________________ Mechanical assemblies Tail shaft The feeder breaker is equipped with a tail shaft (Fig. 36) 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. 36: Tail shaft components

2

3

4

1

8 9

10

1.

2.

3.

4.

5.

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

7

6 5

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

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Mechanical assemblies____________________________________________ Breaker and breaker power unit assembly The breaker and breaker power unit (Fig. 37) are assembled with a bolt flange coupling so that they can be installed as individual assemblies.

The power unit can be removed as a separate, complete assembly. To remove the breaker shaft, bolt flange coupling hardware must be removed..

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

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

Fig. 37: Breaker and breaker power unit assembly

4

3

2

1.

2.

3.

4.

Under speed sensor Breaker power unit Bolt flange coupling Breaker shaft

1

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___________________________________________ Mechanical assemblies Breaker assembly The breaker assembly (Fig. 38) on the machine has a 32”(813 mm) pick circle with a 5 point star arrangement. It has a 10”(254 mm) shaft diameter turned down to 8”(203 mm) thru the bearings.

Fig. 38: Breaker assembly main components

18 17

13

14

12 21 8

10

20 19

5 15

3 1

16

11

9

6 7 2

4

1. Bolt flange 2. End cap 3. Seal housing 4. Side plate 5. Bearing housing 6. Seal ring 7. Bearing 8. Bearing retainer 9. Seal 10. Bearing backing ring 11. Breaker shaft

12. Bit (requires 2 snap rings, supplied with bit) 13. Bearing backing ring 14. Bearing retainer 15. Seal 16. Bearing 17. Bearing housing 18. Seal hosing 19. Side plate 20. End cap 21. Underspeed sensor mount

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Mechanical assemblies____________________________________________ Breaker power unit The breaker power unit (Fig. 39) drives the pick breaker. It consists of a 200 HP electric motor coupled to a reducer. The power unit has been assembled as a unit and can be removed as a unit or as individual components (see Replacement of wear parts section of this chapter).

Fig. 39: Breaker power unit 9 6

8 7

5 4

1

1.

2.

3.

4.

5.

6.

7.

8.

9.

3 2

Pump Connecting tube Rotex coupling Electric motor, 200 hp Flexible coupling Torque limiter Companion flange Connecting tube Gear reducer

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____________________________________________________ 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, it is recommend that a general maintenance plan be implemented. For example, develop 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 Cat® 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 Cat® 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.

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Maintenance_____________________________________________________ ■

If either tram drive is to be operated during maintenance or servicing, securely block the crawler clear of the ground. 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 cylinder. If maintenance must be performed while the circuit is under load, securely block the load. 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 as it increase the risk of injury to personnel.

■

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.

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

Table 2: Lubrication and maintenance schedule Item

8 9 10

Description Every 8 hours of operation Head shaft bearing Head shaft bearing seal Breaker bearing Tail shaft and slide tube bearing Tailpiece pulley bearing (if equipped) Hydraulic oil level (check) Breaker bits Weekly Pressure filter (alarm check) Return filter (alarm check) Breaker shaft underspeed sensor

11 12 13 14 15 16

Crawler track take-up bearing Conveyor chain tension Fasteners (nuts, bolts and screws) Electrical cables, conduits and glands Hydraulic hoses and connections Torque hub (check oil level)

17 18 19

1 1 1

20 21

Conveyor reducer (check oil level) Breaker reducer (check oil level) Dust system strainer (check) Monthly Crawler anchor pin (s) Breaker electric motor

22

Crawler chain tension

2

23 24

Breaker reducer (grease) Hydraulic oil tank breather vent Every 3 months Torque limiter Every 1000 hours Breaker reducer oil analysis/change as required * Conveyor reducer oil analysis/change as required * Every 6 months Hydraulic oil tank (change) Torque hub (change oil)

1 2 3 4 5 6 7

25 26 27

28 29

Places 2 2 2 4 2 1 Inspect

Lubricant

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

1 1 Inspect 2 Inspect Inspect Inspect Inspect 2

2 2

2 Inspect

Spec. 100-3

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

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

Inspect

1 2

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

* Initial oil change to be done after first 500 hours of operation. ______________________________________________________________ A6474X391

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Maintenance_____________________________________________________ Table 3: Lubricants: Fluids and capacities Location Hydraulic oil tank Breaker reducer Conveyor reducer Torque hub

Grease points (except electric motors) Grease points (electric motors)

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

Approximate capacity 175 gal (663 L) 15 gal (57 L) 6.7 gal (25 L) 2.5 gal per side (10 L per side)

Spec. 100-14 or Spec. 100-16

Two pumps per month (hand pump only)

As required

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____________________________________________________ Maintenance Fig. 40: Lubrication chart

5 (tail piece bearing location)

5 (tail piece bearing location)

1,2 (bearing and seal location)

1,2 (bearing and seal location)

12 (chain tension check location) 7 3 (bearing location)

3 (bearing location)

23 (seal location)

10

20

20

12 (take-up cylinder location)

4 (tail shaft and slide tube bearing location)

12 (take-up cylinder location)

4 (tail shaft and slide tube bearing location)

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Maintenance_____________________________________________________ Fig. 40 (continued): Lubrication chart

5 (grease fitting location)

5 (grease fitting location)

17, 27 21, 23 (grease fitting location) 21 (bearing location) 23 (seal location)

19 25

18, 26

28 24

6

16, 29

16, 29

9 22

1, 2 (grease fitting location)

11

3 (grease fitting location)

8 22 11

4 (grease fitting location)

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____________________________________________________ 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 8 hours of operation head shaft bearings

Lubricate the feeder breaker head shaft bearings with Spec. 100-3 through the grease fittings located lubrication panel (Fig. 41) located on the right side of the machine at the secondary operator’ s station.

Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

breaker bearings

Lubricate the feeder breaker head shaft bearings with Spec. 100-3 through the grease fittings located lubrication panel (Fig. 41) located on the right side of the machine at the secondary operator’ s station.

Pump grease into the two (2) fittings until new grease can be observed coming out of the return ports.

tail shaft and slide tube bearings

Lubricate the feeder breaker tail shaft and slide tube bearings with Spec. 100-3 through the grease fittings located on right side of the machine at the primary operator’ s station (Fig. 41). Pump grease into the four (4) fittings until new grease can be observed coming out of the return ports.

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Maintenance_____________________________________________________ Fig. 41: Head shaft, breaker, and tail shaft bearing lubrication

Tail shaft bearings

Breaker bearings

Head shaft bearing

Breaker return ports

Tail shaft return ports (if equipped)

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____________________________________________________ Maintenance hydraulic oil tank

Check the hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 42). 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 unexpected machine movement if the secondary valve bank is energized and a lever on the secondary valve bank is inadvertently moved or machine overheating if the power fill pump is left energized. Unexpected machine movement could result in serious injury to personnel or damage equipment.

To operate the power fill: 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 the ball valve.

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.

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Maintenance_____________________________________________________ Fig. 42: Hydraulic oil level check Power fill ball valve

Sight glass pressure filter

The pressure filter is located on the left side of the machine (Fig. 43).

Check the dirt alarm located on the filter and change as required.

return filter

The return filter is located on the left side of the machine (Fig. 43).

Check the dirt alarm located on the filter and change as required.

Fig. 43: Pressure and return filter locations

Pressure filter

Return filter

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____________________________________________________ Maintenance breaker bits

Check the breaker bits (Fig. 44) before every shift 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 44: Breaker bits

Breaker bits

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Maintenance_____________________________________________________ Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 45) 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. 45: Crawler track take-up lubrication

Crawler take-up grease fitting location 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. 46). 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. 46: Conveyor chain tension measurement

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____________________________________________________ Maintenance fasteners

electrical cables, conduits and glands hydraulic hoses and fittings

tram reducers

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

head shaft bearing bolts

■

breaker shaft side plate bolts

■

conveyor drive motor mounting bolts

■

tail shaft retainer hold down bolts

■

all cover and guard retaining bolts

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

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

Check the oil level in both tram reducer torque hubs (Fig. 47):  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 .  Remove the oil level check and fill plugs. When correctly filled, oil should just begin to flow from the check oil level check hole.  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.  Replace the fill and check plugs.

Fig. 47: Tram reducer oil level Fill plug

Check plug

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Maintenance_____________________________________________________ breaker reducer

Check oil level in the breaker drive reducer (Fig. 48). To access the dipstick, remove the cover from on top of the reducer. If oil is needed, add oil (Spec. 100-6) through the dipstick hole or the fill port until the correct level is reached on the dipstick. .

Fig. 48: Breaker reducer oil level

Fill port, breather, and dip stick

Drain plug (located on bottom of gearcase)

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____________________________________________________ Maintenance dust system strainer

Clean the strainer mounted inside the dust suppression system located under the breaker power unit on the right side of the machine. Turn the ball valve handle (Fig. 49) to open the water line. Allow to flush for approximately thirty seconds to one minute. Close ball valve.

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

Fig. 49: Dust system strainer Pressure gauge

Ball valve

Regulator handle

Regulator

Strainer

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Maintenance_____________________________________________________ tailpiece bearing (belt pulley)

Grease the tailpiece bearing (2 places) through the grease manifold (Fig. 50) located on the right hand side of the machine with Spec. 1003. Pump new grease into the fitting until old grease can be observed coming out of the bearing.

Fig. 50: Tailpiece bearing (belt pulley)

Grease manifold

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____________________________________________________ Maintenance Monthly crawler anchor pins

Lubricate grease fittings on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 51). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 51: Crawler anchor pin lubrication

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

Lubricate the breaker power unit electric motor with Spec. 100-14 or Spec. 100.16 high temperature grease through the two (2) grease fittings located on the lubrication manifold (Fig. 52) on the right side of the machine. Pump only one or two pumps of grease into each fitting.

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

breaker reducer

Lubricate the breaker reducer with Spec. 100-3 through the two (2) grease fittings located on the below the breaker electric motor (Fig. 52) located on the right side of the machine. Pump only one or two pumps of grease into each fitting using a hand grease gun.

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

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Maintenance_____________________________________________________ Fig. 52: Breaker reducer lubrication

Electric motor grease fitting (2)

conveyor motor/gearbox

Breaker reducer grease fitting (2)

Check the gearbox oil level through the oil level sight glass. If low add oil thought the breather/fill port.

Fig. 53: Conveyor motor/gearbox

Breather/fill port

Sight glass

Drain plug

________________________________________________________________ 5.72 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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____________________________________________________ Maintenance hydraulic oil tank breather vent

Check the breather vent element on the hydraulic oil tank (Fig. 54) and change as required.

Fig. 54: Hydraulic oil tank breather vent

Breather vent

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Maintenance_____________________________________________________ Every three months breaker reducer cooling fan

Remove the connecting tube cover (Fig. 55) and inspect the breaker reducer fan. Clean all accumulated debris from the fan, guard, and deflector.

Fig. 55: Breaker reducer cooling fan

Cooling fan

________________________________________________________________ 5.74 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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____________________________________________________ Maintenance Every 1000 hours breaker reducer oil analysis

Every 1000 hours of operation, analyze a breaker 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 reducer oil change

Change the oil in the breaker drive reducer (Fig. 56) 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.  Remove the drain plug and allow the oil to completely drain.  Clean and reinstall drain plug.  Remove the cover.  Remove the fill port plug 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.  Install fill port plug.  Install inspection cover.

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Maintenance_____________________________________________________ Fig. 56: Breaker reducer Oil fill, breather, and dip stick location

Drain plug (located under cooling fan)

________________________________________________________________ 5.76 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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____________________________________________________ Maintenance Every 6 months hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank (Fig. 57).  Clean all dirt and debris from around the fill cap and drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and reinstall drain plug.  Remove the fill cap and pour 20 gallons (76 L) of oil (Spec. 100-1) through the fill cap strainer to avoid cavitating the pumps with the power fill unit.

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

Fig. 57: Hydraulic tank oil level

Power fill ball valve

Breather vent

Sight glass

Drain plug (under tank)

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Maintenance_____________________________________________________ tram reducer

Change oil in the tram reducer (Fig. 58).  Clean all dirt and debris from and around the level and fill plugs.  Rotate reducer until drain plug is at the 6 o’ clock position and remove drain plug and allow the oil to completely drain.  Clean and reinstall drain plug.  Rotate reducer until plugs are at the 12 o’ clock and 3 o’ clock positions.  Add oil (80W-90) through the fill hole until fluid begins to flow from the check plug.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Install level and fill plugs.  Do not overfill reducer.

Fig. 58: Tram reducer oil change Fill plug

Check plug

________________________________________________________________ 5.78 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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____________________________________________________ Maintenance breaker power unit torque limiter

Inspect the breaker power unit torque limiter clutch for wear. The measurement shown in Fig. 59 should be 3.55 inches for a new torque limiter. When the measurement reaches 3.46 inches, rebuild using kit part number 622432 or replace the entire torque limiter (see the Cat® parts book for your machine for torque limiter part number).

Fig. 59: Torque limiter wear check

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

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

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

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

5. 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.

6. Check oil level in the crawler reducers.

7. Inspect the condition of all electrical and hydraulic components.

8. Check for proper conveyor chain tensioning.

9. Check for proper crawler chain tensioning.

10. Lubricate per the lubrication schedule.

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

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

13. Check that all covers are installed and secure.

14. Check the tightness of all connecting elements.

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

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____________________________________________________ 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: 1. conveyor chain 2. conveyor chain flights 3. conveyor drive sprockets 4. conveyor tail shaft 5. conveyor wear plates 6. crawler pads 7. crawler drive sprockets 8. crawler idler rollers

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Maintenance_____________________________________________________ Inspection of fire suppression system To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 60).

1.

Note general appearance for mechanical damage or corrosion.

2.

Check nameplate for readability, corrosion or looseness.

3.

Remove fill cap assembly.

4.

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

5.

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

6.

Check pressure relief vent in fill opening threads for obstruction.

7.

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

8.

Unscrew cartridge and weigh (replace if weight is ½ oz. less than stamped on cartridge).

9.

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

10. Check pressure vents in receiver/actuator for obstruction.

11. 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.

12. 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).

13. Reposition extinguisher, engage bursting disc union (wrench tighten) and close bracket clamp.

14. Check hoses, fittings and nozzles for mechanical damage.

15. Check nozzle openings; slot should be closed (capped) with silicone grease.

16. Check remote actuator (dashboard type).

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

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____________________________________________________ Maintenance 18. Inspect threads on cartridge and in actuator for nicks, burrs, cross threading, rough or feathered edges.

19. Check pressure safety vent in actuator body for obstruction.

20. Examine actuator cartridge gasket for elasticity, clean and lightly coat with a good grade of high heat resistant grease.

21. Pull ring pin and operate actuator button several times to check for free movement.

22. Seal ring pin to puncture lever with lead and wire seal. Return cartridge to remote actuator, hand tighten.

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

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Maintenance_____________________________________________________ Recharge of fire suppression system To return your fire suppression system to service after use (Fig. 60).

1.

Pull ring on safety valve to relieve actuator system pressure.

2.

Disconnect actuation system hose at cartridge receiver/actuator assembly.

3.

Open bursting disc union assembly.

4.

Remove extinguisher from bracket.

5.

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

6.

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

7.

Clean fill opening threads and gasket seating surface.

8.

Secure fill cap, hand tighten.

9.

Remove cartridge guard assembly.

10. Remove empty cartridge.

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

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

13. Replace cartridge guard.

14. Secure extinguisher in bracket.

15. Assemble bursting disc union, wrench tighten.

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

17. 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.

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

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____________________________________________________ Maintenance Fig. 60: Fire suppression system

Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Breaker coupling Nozzle

Operator’ s station

Nozzle Nozzle Breaker motor Nozzle

Nozzle

Oil tank LP canister

LP expellant

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Maintenance_____________________________________________________

________________________________________________________________ 5.86 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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___________________________________________ 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. 61): 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 retainers.

6. Release pressure on the take-up cylinders by opening the top valve

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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. 61: Conveyor chain adjustment

Needle valve (2)

Grease fitting (2)

Shim storage (2)

Grease take-up cylinder (2)

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___________________________________________ 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. 62): 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 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 1 3/4”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 sag.

9. 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. Install shim retainer plate.

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.

12. Store and secure any unused shims on back of crawler cover plate.

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Adjustment procedures ___________________________________________ Fig. 62: Crawler track adjustment

When properly tensioned, chain sag should be 2”at center of crawler.

Access cover

Cylinder retainer bar/shim retainer plate mount

Retainer plate

Grease fitting

Needle valve

Take-up cylinder

Shims (located behind retainer plate)

________________________________________________________________ 5.90 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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___________________________________________ Adjustment procedures Underspeed sensor calibration To calibrate the underspeed sensor (Fig. 63): 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. Confirm red LED lights up when intended target passes in front of sensor 4. Press calibration switch to set the unit to desired targets. The green LED will confirm calibration state.

Fig. 63: Under speed senor calibration

Test switch

Calibrate switch

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Adjustment procedures ___________________________________________ Fig. 63: Under speed senor calibration

Test/set switch, SW1 Speed 1 control switch

Test/set switch, SW1

________________________________________________________________ 5.92 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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___________________________________________ 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. 64). 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, 30 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. 64) 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).

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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. 64: Pump

Pressure compensator adjustment

Margin pressure adjustment

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___________________________________________ Adjustment procedures Main relief pressure To adjust the main relief (Fig. 65): 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).

Fig. 65: Main relief Main relief adjustment (on end of block)

Pressure limiter “A”adjustment

System pressure

Pressure limiter “B”adjustment

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Adjustment procedures ___________________________________________ Pressure limiter adjustment To adjust the pressure limiter (Fig. 65).

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). The system pressure gauge will read the function pressure.

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.

________________________________________________________________ 5.96 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts

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

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

Head shaft The head shaft (Fig. 66) transmits the torque of the hydraulic motor to the conveyor chain assembly and is part of a complete assembly. As soon as any component is worn, the component or complete head shaft must be replaced. Due to high abrasion forces, the chain sprockets are subject to a very high level of wear.

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

head shaft

■

sprockets (2)

■

bearings (2)

Fig. 66: Head shaft main components Sprocket (2)

Head shaft Key (2)

Bearing (2)

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Replacement of wear parts_________________________________________ How to remove the headshaft To remove the headshaft assembly from the feeder breaker proceed as follows (Fig. 67): 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.

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”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 last cover on the left hand side of the machine.

5. Remove the last cover’ s support post.

6. Block and secure tailpiece.

7. Unpin and fold down tailpiece tilt cylinders (if equipped). It is not necessary to remove hydraulic hoses.

8. Remove the tailpiece hoppers (2) (if equipped) and head shaft filler plates (2) using appropriate lifting equipment.

9. Remove the hydraulic motor. The motor can remain on the gearbox if desired. a. Disconnect, tag, and cap all hydraulic hoses. b. Remove the five (5) 1/2”bolts, lock washers, and flat washers from the end of the motor.

10. Remove the conveyor gear reducer (see Conveyor gear reducer removal/installation procedure in this chapter). The conveyor gear reducer may remain on the shaft if desired.

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

12. Remove the four (4) 1”bolts, flat washers, lock washers, and nuts from each of the headshaft bearings. Note that there may be bearing shims under the bearing. If shims are present, make note of their thickness, quantity and location.

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________________________________________ Replacement of wear parts 13. Attach an appropriate lifting device to the headshaft and slide out towards the rear of the frame.

How to install the headshaft To install the headshaft assembly proceed as follows (Fig. 67): 1. Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the feeder breaker. The gear reducer may be installed on shaft if desired.

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

3. Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) 1”bolts, nuts, and lock washers.

Torque bolts to 645 ft-lbs.

NOTICE! After tightening the four (4) 1”bolts and nuts and before installing the gear reducer, ensure that the headshaft can turn freely 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.

WARNING! The headshaft must turn freely by hand or the bearings will fail prematurely.

4. Install the left and right sprocket guards and head shaft filler plates.

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. Install the five (5) 1/2”mouting bolts, lock washers, and flat washers and torque to 100 ft-lbs. b. Reconnect hydraulic hoses.

7. Install the conveyor gear reducer (see Conveyor gear reducer removal/installation procedure in this chapter). The gear reducer may have been installed.

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

9. Install cover support post and cover.

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).

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Replacement of wear parts_________________________________________ 12. Using an appropriate lifting device install the tailpiece hoppers (2) and head shaft filler plates (2) (if equipped) using appropriate lifting equipment (see installing the tailpiece in this chapter).

13. If equipped, attach the tailpiece lift cylinders (2) into the tailpiece hopper weldments using pins and cotter pins (see installing the tailpiece in this chapter).

Fig. 67: Headshaft removal and installation

10

9 11

7

8

1 6 5 3

4

2

1. Hydraulic motor 2. Gear box 3. Retaining bolt 4. Retainer 5. Adapter 6. Bearing (2) 7. Head shaft 8. Key (2) 9. Sprocket (2) 10. Sensor unit 11. Gear box support bracket

________________________________________________________________ 5.100 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear 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. 68): 1. Remove the headshaft assembly from the feeder (see Headshaft removal in this chapter).

2. Remove the two (2) bearings from the headshaft.

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 Cat® parts manual for your machine for a replacement parts list.

How to install the headshaft sprockets To install the sprockets on the headshaft (Fig. 68): 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. 68 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 79 for weld specifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.

3. Insert the other key into the shaft keyway and slide second sprocket onto shaft (see Fig. 68 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 68 for weld spcifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.

4. Install bearings on shaft (ss Bearing installation procedure in this chapter). Note that the bearing housing must be installed on shaft so that the Taconite seal is facing the middle of the shaft. Only one of the bearings must have the internal spacer removed to allow the shaft to float and not be in a bind.

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

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Replacement of wear parts_________________________________________ How to install the head shaft split sprockets To install the split sprockets on the head shaft proceed as follows (Fig. 68): IMPORTANT! Adhere to all weld specifications shown on Fig. 68. 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. 68 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).

________________________________________________________________ 5.102 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Fig. 68: Head shaft sprocket removal and installation 1

3/8 X 45° weld chamfer

3

2

3/8 X 45° weld chamfer

Split sprocket (typical) 5

1.

2.

3.

4.

5.

4

General notes: 1.

2.

3.

Bearing (2) Head shaft Sprocket guard Sprocket (2) and key (2) Conveyor chain

4.

Do not mix and match halves with other sprockets.

Install sprocket and keys on head shaft.

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

Blend and smooth welds to avoid chain roller damage.

Weld notes: 1.

2.

3.

4.

5.

6.

7.

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

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

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

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

Taconite seal (optional) Taconite seal (optional)

(optional for one piece sprockets)

(optional for one piece sprockets)

______________________________________________________________ A6474X391 REV 2 5.103

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Replacement of wear parts_________________________________________ Tailshaft The tailshaft (Fig. 69) 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. 69: Tail shaft main components 2

4

3

1

7 6 5 1.

2.

3.

4.

5.

6.

7.

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

________________________________________________________________ 5.104 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear 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. 70): 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 take-up 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. 70): 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.

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Replacement of wear parts_________________________________________ 5. Connect conveyor chain (see Conveyor chain replacement in this chapter.

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 chain 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.

________________________________________________________________ 5.106 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Fig. 70: Tailshaft removal and installation 3

2

5 4

1

6

10 9

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. High speed swivel 10. Tail shaft

8

7

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Replacement of wear parts_________________________________________ How to disassemble the tailshaft To disassemble the tailshaft assembly (Fig. 71): 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 and slide sprockets 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. 71): 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. If equipped with sprockets, apply Loctite 242 (blue) on set screw and install set screw into the sprocket with the key, ensuring that the sprockets and tail shaft slide plate are centered on tail shaft.

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).

________________________________________________________________ 5.108 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Fig. 71: Tail shaft disassembly and assembly Set screw (2)

Key (2) Tail shaft

Roller (2)

Bearing (2) Slide plate

Piston rod adapter (2)

______________________________________________________________ A6474X391 REV 2 5.109

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Replacement of wear parts_________________________________________ Conveyor chain The conveyor chain (Fig. 72) 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. 72: Conveyor chain main components

Spiral pin

6 link chain section

Flight bar

________________________________________________________________ 5.110 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Measure Chain for Elongation One of the most important areas in the evaluation of chain wear is the elongation of the chain. This is obtainable in the field and does not require chain disassembly or return to manufacturer for analysis.

To measure a chain for elongation: The selected strand must be under some load to pull out internal clearances and must be supported, if necessary, to insure the chain lies in a straight line.

The selected strand should include as many pitches as possible, with a minimum of four pitches. Always use an even number of pitches for straight sidebar chain.

Use any reasonably accurate measuring device (steel ruler, calipers, tape measure, etc.).

Determine the distance from a spot on the first pitch to the same spot on the last pitch. The edge of the pin head is usually a good spot to measure (see Fig. 73).

Fig. 73: Chain elongation measurement

MEASURE LENGTH

OFFSET SIDEBAR (WORN)

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Replacement of wear parts_________________________________________ The percent elongation is defined as: % elongation = measured strand length –(nominal pitch x number of pitches measured) x 100 (nominal pitch x number of pitches measured)

Example 1: 20 pitches of 3.500 inch pitch chain were measured as 71 13/16inches, therefore % elongation = 71 13/16 –(3.5 x 20) x 100 = 2.57% (3.5 x 20) Example 2: 20 pitches of 3.750 inch pitch chain were measured as 76 15/16 inches, therefore % elongation = 76 15/16 –(3.75 x 20) x 100 = 2.67% (3.75 x 20) Replacement chain should be order at approximately 2.6% elongation and replaced at approximately 3% elongation. It is highly recommended that the headshaft sprockets be changed at the same time as a new chain is installed to obtain maximum chain life.

Table 4 lists chain order and replacement values.

Table 4: Chain elongation values Chain Pitch

Baseline Length (20 pitches) 70 inches

Order Length (approximately 2.6%) (20 pitches) 71 13/16 inches

Replacement Length (approximately 3%) (20 pitches) 72 1/8 inches

3.500 3.750

75 inches

76 15/16 inches

77 1/4 inches

________________________________________________________________ 5.112 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 74): 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: 74: Conveyor chain assembly 6 link chain section

Extended pin connecting link

Spiral pin (4)

Flight bar Block link assembly Side bar

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.

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Replacement of wear 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.

________________________________________________________________ 5.114 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts TAC monitor for conveyor speed sensor To replace the conveyor speed sensor TAC monitor: Note: The machine shipped from the factory with TAC monitor model 22-8100. This model is obsolete and has been replaced with model 220 -8100. All instructions are for the installation of 220-8100.

1. Disconnect power from the machine following all applicable lockout/tagout regulations.

2. Open the control panel enclosure and locate the existing TAC monitor, mounted on the front side of the swing panel (Fig. 75).

Fig. 75: TAC monitor location (typical)

TAC monitor

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Replacement of wear parts_________________________________________ 3. Disconnect the existing monitor and remove.

4. Mount the new monitor on the swing panel. Connect the wires as shown in Table 4. Note: the connections on the model 22-8100 TAC monitor do not match the connections on the new monitor.

Table 4 is for the 220-8100 model only.

Table 4: Terminal connections (220-8100 model) Terminal

Connection Front

1

No connection

2

No connection

3

4-20mA Output - Positive (+)

4

4-20mA Output - Common (1)

5

No connection

6

No connection

7

Sensor Input (+)

8

Sensor Input Common (-) Back

9

No connection

10

No connection

11

No connection

12

No connection

13

No connection

14

No connection

15

AC Input (N)

16

AC Input (H)

5. Restore power to the machine.

________________________________________________________________ 5.116 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Setup and display indicators When power is applied to the TAC monitor, the display will should show the following: 000 RPM - displays the actual value from the remote speed sensor. If “Line Open”is displayed, check the 4-20mA line. The maximum line resistance is 0-500 ohm.

10-XXXX RPM - displays the current speed range of the TAC monitor (10 to XXXX RPM). The display should read 10-100 RPM. If the correct range is not selected, chose the correct range as follows: 1. Press and hold the “SET”button for approximately 4 seconds.

The display should now show models from 100 RPM top range to 6000 RPM top range.

2. Using the arrow key, highlight the 100 RPM top range model from the list.

3. With the 100 RPM top range model selected, press and hold the “SET”button for approximately 4 seconds. The display will now change back to normal operation with eh new RPM range shown on the bottom of the screen.

Note: If a selection is not made with approximately 10 seconds, the display will return to normal operation and will keep the existing model speed range.

______________________________________________________________ A6474X391 REV 2 5.117

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Replacement of wear parts_________________________________________ Crawler track The crawler track (Fig. 76) assembly (left and right) carries the machine via torque received from the tram drive reducer. The crawler track is made up of two crawler pad links, one block link and one pin link, which alternatingly repeat 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. 76: Crawler track main components

2 1

3

________________________________________________________________ 5.118 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts How to assemble the crawler track pads (Fig. 76) To assemble the crawler track pads proceed as follows: 1. Lay crawler track pads on a flat surface.

2. Align pads with chain connecting holes centered.

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

4. Drive rool 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. 76) 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 (Fig. 76).

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

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Replacement of wear parts_________________________________________ How to install the crawler track pad assembly To install the crawler track pad assembly proceed as follows (Fig. 75): 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).

________________________________________________________________ 5.120 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Crawler assembly The crawler assembly (Fig. 77) 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. 77: Crawler assembly main components

1

2

5

4

3

1.

2.

3.

4.

5.

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

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Replacement of wear parts_________________________________________ How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 78): 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.

________________________________________________________________ 5.122 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 78): 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).

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Replacement of wear parts_________________________________________ Fig. 78: Crawler take-up removal and installation

1

3

2

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

________________________________________________________________ 5.124 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 79): 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 (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 twelve (12) bolts and lock washers that secure the torque hub to the crawler frame.

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

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

11. 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.

12. Remove the adapter plate and motor from the torque hub as an assembly.

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Replacement of wear parts_________________________________________ 13. If not replacing the hydraulic motor, it is not necessary to separate the adapter plate from the hydraulic motor. If replacing the hydraulic motor, remove the four (4) nuts and lock washers that secure the hydraulic motor to the adapter plate. And remove adapter plate.

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

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

16. Inspect all components for wear or damage.

________________________________________________________________ 5.126 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 79): 1. Remove old crawler drive assembly (see previous section, How to remove crawler drive assembly).

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

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

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

■ ■ ■

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

4. Thoroughly clean and degrease the adapter plate and mating faces of the torque hub and hydraulic tram motor.

5. 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.

6. Place hydraulic motor gasket onto motor adapter plate.

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

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

9. Apply Loctite 518 to the adapter plate gasket.

10. Place adapter plate gasket onto the adapter plate.

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

12. 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

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Replacement of wear parts_________________________________________ 13. 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.

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

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

16. 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

17. Connect hydraulic hoses to drive motor.

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

19. 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

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

21. Purge hydraulic system of air.

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

________________________________________________________________ 5.128 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Fig. 79: Crawler drive disassembly and assembly

25 1

16, 17

21

24

18

8

10, 13, 14 9

12

15

10, 11

3, 4

23

6, 7

22 5 19

20

2

1.

2.

3.

4.

5.

6.

7.

8.

9.

crawler frame torque hub washer (high collar lock) (12) cap screw (socket head) (12) sprocket washer (high collar lock) (20) cap screw (socket head) (20) gasket (adaptor plate) plate (adaptor)

10.

11.

12.

13.

14.

15.

16.

17.

18.

washer (lock) (8) cap screw (hex head) (4) gasket washer (flat) (4) nut (hex) (4) keeper washer (lock) (6) bolt (hex head) (6) crawler pad

19.

20.

21.

22.

23.

24.

25.

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

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Replacement of wear parts_________________________________________ Breaker shaft and breaker power unit The breaker power unit (Fig. 80) and the breaker shaft assembly (Fig. 81) can be removed or installed as a single assembly (Fig. 82) or as two separate assemblies.

Fig. 80: Breaker power unit main components

7

8

9

10

6 4 5 2

3

1

1.

2.

3.

4.

5.

Pump assembly Connecting tube Pump coupling Electric motor, 200 hp Flexible coupling

6. Torque limiter clutch 7. Taperloc bushing 8. Companion flange 9. Connecting tube 10. Gear reducer

It is important to check the torque limiter clutch (item 3) for wear.

See the Maintenance section of this chapter for the wear check procedure.

________________________________________________________________ 5.130 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts Fig. 81: Breaker shaft assembly

Fig. 82: Breaker shaft and power unit assembly

1

2

1. Breaker shaft assembly 2. Breaker power unit assembly

______________________________________________________________ A6474X391 REV 2 5.131

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Replacement of wear parts_________________________________________ How to remove the breaker shaft and breaker power unit Whenever performing maintenance procedures, follow all safety regulations and be aware of 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. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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

To remove the breaker shaft and breaker power unit as a single assembly (Fig. 83).

1. Turn the machine main circuit breaker (CB1) to the “OFF”position.

2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

3. Remove all power unit and breaker shaft covers.

4. Remove the junction box access panel of the electric motor. Tag and disconnect the cable leads from the motor leads.

5. Remove and cap all grease lines from the breaker shaft, gear reducer, and electric motor.

6. Remove the power unit support structure.

7. Remove the under speed sensor by loosening the nuts on the ubolt and sliding the sensor out.

8. Attach an appropriate lifting device to the breaker shaft and power unit assembly in such a manner to keep breaker shaft and power unit level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting hardward is removed.

9. Remove the hardware from the breaker side plates and the power unit reaction pin.

10. Lift the breaker shaft and power unit out of the machine as an assembly.

________________________________________________________________ 5.132 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts How to install the breaker shaft and breaker power unit Whenever performing maintenance procedures, follow all safety 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 install the breaker shaft and breaker power unit as a single assembly (Fig. 83).

1. Attach an appropriate lifting device in such a manner as to keep the breaker shaft and power unit level during the lift and slowly lift the unit onto the machine.

2. Install the power unit reaction pin and the hardware into the breaker side plates.

3. Install the under speed sensor on the left hand side of the breaker shaft. The distance from the sensor end to end cap target is approximately 1/8 to 1/4 inch.

4. Remove caps and install all grease lines to the breaker shaft, gear box, and electric motor.

5. Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.

6. Install the power unit cover support structure.

7. Install all power unit covers.

8. Turn the machine circuit breaker on.

9. Unlock and remove tags from electric power at the power center.

10. Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.

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Replacement of wear parts_________________________________________ Fig. 83: Breaker shaft and power unit removal and installation

18 17 15 9

1

10 8

11

12 3

16 19 4 6

2

5

7

1.

2.

3.

4.

5.

6.

7.

8.

9.

Breaker assembly Stub shaft Breaker power unit assembly Socket head shoulder bolt, 1X3 (12) Lock washer, 3/4 (12) Hex nut, 3/4 (12) Hex head bolt, M24x65-10.9 Pivot lug Power unit reaction pin

11. Lock washer, 1”(4) 12. Hex head bolt, 1X2 (4) 13. Underspeed sensor mount (shown on next page) 14. U-bolt, 2X3-3/4X3/8-16 (shown on next page) 15. Hex head bolt, 1-1/4X5 (4) 16. Hex head bolt, 1-1/4X4 (20) 17. Lock washer, 1-1/4 (24) 18. Hex nut, 1-1/4 (24) 19. Reducer end cover (reference only)

________________________________________________________________ 5.134 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Fig. 83, continued: Breaker shaft and power unit removal and installation

14

13

______________________________________________________________ A6474X391 REV 2 5.135

BI001467

Replacement of wear parts_________________________________________ How to remove the breaker power unit assembly Whenever performing maintenance procedures, follow all safety regulations and be aware of 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. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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

To remove the breaker power unit proceed as follows (Fig. 83).

1. Turn the machine main circuit breaker (CB1) to the “OFF”position.

2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

3. Remove all power unit covers.

4. Remove the junction box access panel of the electric motor. Tag and disconnect the cable leads from the motor leads.

5. Remove and cap all grease lines from the gear reducer and electric motor.

6. Remove the under speed sensor.

7. Attach an appropriate lifting device to the power unit assembly in such a manner as to keep the power unit level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting power unit reaction pin and bolts from breakershaft bolt flange and stub shaft are removed.

8. Remove the twelve (12) one inch socket head sholder bolts, twelve (12) 3/4 inch lock washers, and twelve (12) 3/4 inch hex nuts that connect the breaker shaft bolt flange to the stub shaft.

9. Remove cotter pins from the power unit reaction pin and remove the pin.

10. Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.

11. Lift the power unit out of the machine.

________________________________________________________________ 5.136 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts How to install the breaker power unit assembly To install the breaker power unit proceed as follows (Fig. 83).

Whenever performing maintenance procedures, follow all safety 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.

1. Attach an appropriate lifting device to the power unit in such a manner that the power unit is level during the lift and slowly lift the unit onto the machine.

2. Install the power unit reaction pin and secure with cotter pins.

3. Bolt the breaker shaft bolt flange to the stub shaft.

4. Remove the lifting device.

5. Install the under speed sensor on the breaker shaft. Distance

from sensor end to end cap target is approximately 1/8”to 1/4”. Note (Reference Fig. 84): The end cap is gear shaped with eight “teeth”. The teeth are targets for the underspeed sensor.

Fig. 84: Sensor target

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Replacement of wear parts_________________________________________ 6. Remove caps and install all grease lines to the gear box and electric motor.

7. Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.

8. Install all power unit covers.

9. Unlock and remove tags from electric power at the power center.

10. Turn the machine circuit breaker on.

11. Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.

________________________________________________________________ 5.138 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts How to remove the breaker shaft assembly only Whenever performing maintenance procedures, follow all safety regulations and be aware of 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. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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

To remove the breaker shaft assembly (Fig. 83).

1. Turn the machine main circuit breaker (CB1) to the “OFF”position.

2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.

3. Remove all breaker shaft and gear reducer covers.

4. Remove and cap all grease lines from the breaker shaft.

5. Remove the underspeed sensor from the breaker shaft by loosening the nuts on the u-bolt just enough to allow the senosr to slide out.

6. Properly support the breaker shaft gear reducer so that it does not fall during breaker shaft removal. Ensure that the power unit reaction pin is in place and not removed during this procedured.

7. Attach an appropriate lifting device to the breaker shaft. in such a manner that the breaker shaft is level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting hardware is removed.

8. Remove the hardware from the breaker side plates and from between the two halves of the bolt flange and the stub shaft flange.

9. Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.

10. Lift the breaker shaft out of the machine.

______________________________________________________________ A6474X391 REV 2 5.139

BI001467

Replacement of wear parts_________________________________________ How to install the breaker shaft assembly Whenever performing maintenance procedures, follow all safety 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 install the breaker shaft assembly (Fig. 83).

1. Attach an appropriate lifting device to the breaker shaft in such a manner that the breaker shaft is level during the lift and slowly lift the unit onto the machine.

2. Install the one inch hex bolts, hex nuts, and lockwashers into the breaker side plates. Torque to 545 ft-lbs.

3. Install the one inch socket head shoulder bolts, 3/4 inch lock washers, and 3/4 inch hex nuts to attach breaker shaft bolt flange to stub shaft in gear reducer. Torque to 240 ft-lbs.

4. Remove support from under gear reducer.

5. Remove lifting device from breaker shaft.

6. Remove caps and install all grease lines to the breaker shaft.

7. Install all breaker shaft and power unit covers.

8. Turn the machine circuit breaker on.

9. Unlock and remove tags from electric power at the power center.

________________________________________________________________ 5.140 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts How to disassemble the breaker power unit To disassemble the breaker power unit proceed as follows (Fig. 85): WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

WARNING! Follow all applicable rules and regulations regarding lockout/ tagout procedures.

IMPORTANT! Caterpillar does not recommend field disassembly or repair of the breaker shaft. If the breaker shaft requires repair, please consult your service representative.

1. Remove complete unit from machine. (See Breaker shaft and breaker power unit removal/installation procedure in this section.)

2. Remove the reducer end cover, bolts, and lock washers.

3. Remove the stub shaft retaining bolt and lock washer.

4. Remove the stub shaft and key from the gear reducer. Note: A jacking screw may be needed to push the stub shaft out of the reducer.

5. Open the access door on the small connecting tube.

6. Loosen the two socket head cap screws that retain the pump coupling half.

7. Attach a lifting device to the pump assembly and take up any slack so that the weight of the pump assembly is resting on the lift device.

8. Remove the four 5/8X2 hex head bolts, 5/8 lock washers, and 5/8 flat washers that retain the pump assembly and remove the pump assembly and the pump coupling half.

9. Attach a lifting device to the small connecting tube.

10. Remove the eight 5/8X2-1/4 hex bolts, 5/8lock washers, and 5/8 flat washers that retain the small connecting tube.

11. Loosen the socket set screw on the motor coupling half and remove from the motor shaft.

12. Attach a lifting eye and lifting device to the electric motor. Take up any slack in the lifting device.

13. Open the access door on the large connecting tube.

14. Remove the eight M12X1.75X35 socket head cap screws and lock washers that attach the flexible coupling to the torque limiter.

______________________________________________________________ A6474X391 REV 2 5.141

BI001467

Replacement of wear parts_________________________________________ 15. Remove the eight 3/4X2-1/4 hex bolts, lock washers, and flat washers that retain the electric motor to the connecting tube.

16. Remove the electric motor and flexible coupling sub-assembly.

17. Loosen the three 1/2-13X1-1/2 socket head cap screws on the motor taper loc bushing and remove the flexible coupling and the taper loc bushing using a dead blow hammer.

18. Remove the 1/2X-1/2 hex head cap screw, 1/2 lock washer, and end cap from the electric motor shaft and remove the electric motor key, if necessary.

19. Block under the torque limiter and remove the twelve 7/16-20 socket head cap screws and twelve 7/16 lock washers that retain the torque limiter to the companion flange.

20. Remove the eight M12X1.75X35 socket head cap screws and M12 lock washers that secure the torque limiter to the flex coupling and remove the torque limiter.

21. Loosen the three 1/2-13X1-1/2 socket head cap screws on the reducer taper loc bushing and remove the companion flange and the taper lock bushing sub-assembly from the reducer input shaft using a dead blow hammer.

22. Remove the reducer fan by loosening the set screw in the fan hub.

23. Remove the reducer input shaft seal grease line from the input shaft and the grease manifold.

24. Remove the M16 hex head cap screw, M16 lock washer, and end cap from the gear reducer input shaft.

25. Remove the key from the gear reducer input shaft.

26. Attach a lifting device to the large connecting tube.

27. Remove the four 1X5 hex head bolts and 1 inch lock washers that retain the large connecting tube to the reducer.

________________________________________________________________ 5.142 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts Fig. 85: Breaker power unit assembly

3

2

1

1. End cover 2. Stub shaft retaining bolt, M24X65 3. Stub shaft

______________________________________________________________ A6474X391 REV 2 5.143

BI001467

Replacement of wear parts_________________________________________ Fig. 85, continued: Breaker power unit assembly 33

21,22 9,10,11 19 8

20

25

28,29

24

15

35 34 27

7 5

1

23

6

30,31,32

26

16,17,18

12,13

14

4

2

3

1. Pump 2. Hex head bolt, 5/8X2 (4) 3. Lock washer, 5/8 (4) 4. Connecting tube, small 5. Hex head bolt, 5/8X2-1/4 (8) 6. Lock washer, 5/8 (8) 7. Coupling 8. Motor 9. End cap 10. Lock washer 11. Hex head bolt, 1/2X1-1/2 12. Hex head bolt, 3/4X2-1/4 (8) 13. Lock spring washer, 3/4 (8) 14. Cover, connecting tube 15. Connecting tube, large 16. Flat washer, 1/2 (2) 17. Lock washer, 1/2 (2) 18. Hex head bolt, 1/2X1 (2)

19. Socket head bolt, 1/2-13X1-1/2 (3) 20. Bushing 21. Socket head bolt, M12X1.75X35 (8) 22. Lock washer, M12 (8) 23. Flexible coupling 24. Torque limiter 25. Socket head bolt, 1/2-13X1-1/2 (3) 26. Bushing 27. Companion flange 28. Lock washer, 7/16 (12) 29. Socket head cap screw, 7/16-20X1-1/4 (12) 30. Hex head bolt, M16X2X40 31. Lock washer, M16 32. End cap 33. Gear reducer 34. Lock washer, 1”(4) 35. Hex head cap screw, 1X5 (4)

________________________________________________________________ 5.144 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts Fig. 85, continued: Breaker power unit assembly

______________________________________________________________ A6474X391 REV 2 5.145

BI001467

Replacement of wear parts_________________________________________ How to assemble the breaker power unit To assemble the breaker power unit proceed as follows (Fig. 85): 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.

1. Attach a lifting device to the large connecting tube and position on the gear reducer.

2. Attach the large connecting tube to the gear reducer with four 1X5 hex head cap screws and four one inch lock washers. Torque to 900 ft-lb.

3. Attach input shaft seal grease hard line to the input shaft seal housing and the grease manifold.

4. Install the key in the keyway of the gear reducer input shaft.

5. Install the end cap, M16 lock washer, and M16X2X40 hex head bolt to retain the key.

6. Install the reducer fan and secure by tightening the set screw.

7. Install the taper loc bushing and companion flange onto the input shaft of the gear reducer (see Fig. 84 for correct position). Apply Loctite 242 to the three 1/2-13X1-1/2 socket head cap screws and install to secure the bushing. Torque to 90 ft-lb.

8. Install the torque limiter on the companion flange. Apply Loctite 242 to the 7/16-20 socket head cap screws and tighten to secure the torque limiter.

9. Install the key in the keyway of the electric motor shaft.

10. Install end cap, 1/2 lock washer, and 1/2X1-1/2 hex head bolt into the electric motor shaft to retain the motor shaft key.

11. Install the taper loc bushing and flex coupling on to the electric motor shaft. Do not tighten cap screws.

12. Attach an appropriate lifting device to the electric motor and slowly position the electric motor shaft (with flex coupling and taper loc bushing installed) inside the large connecting tube. Secure with eight 3/4 lock spring washer and eight 3/4X2-1/4 hex head bolts.

Torque to 379 ft-lb.

13. Align the flex coupling with the torque limiter. Apply Loctite 242 to the eight M12X1.75X35 socket head bolts and install the bolts and eight M12 lock washers. Torque to 90 ft-lb.

14. Adjust the electric motor side of the flex coupling assembly and taper loc bushing until proper clearance between the flex coupling jaws is achieved.

________________________________________________________________ 5.146 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts 15. Remove the three 1/2-13X1-1/2 socket head cap screws, apply Loctite 242, and reinstall. Torque to 90 ft-lbs.

16. Replace the large connecting tube access cover and secure.

17. Verify that the electric motor shaft key is installed and is retained, if applicable, with end cap and bolt. Install the pump coupling onto the electric motor shaft (see Fig. 85 for correct coupling position).

Apply Loctite 242 to the set screw and tighten to secure the coupling.

18. Install the small connecting tube onto the electric motor and secure with eight 5/8 lock washer and eight 5/8X2-1/4 hex head cap screws. Torque to 210 ft-lb.

19. Remove the bolt from and open the door of the small connecting tube.

20. Attach a lifting device to the pump and orient as shown in Fig. 84.

21. Guide the pump shaft inside the small connecting tube and align the splined shaft with the pump coupling. Secure with four 5/8 lock washers and four 5/8X2 hex head cap screws. Torque to 210 ft-lb.

22. Verify the jaw spacing of the pump coupling (see Fig. 84). Adjust as required by loosening the set screw on the electric motor shaft side and reposition. Once correct position is achieved, tighten set screw.

23. Apply Loctite 242 to the threads of the pump coupling socket head cap screws on the pump side hub. Install cap screws and tighten.

24. Install the key into the keyway of the stub shaft.

25. Apply Never Seeze to the outside diameter of the stub shaft and the key and install into the hollow bore of the gear reducer.

26. Install the stub shaft M24X65 retaining bolt and M24 lock washer and torque bolt to 1,000 ft-lb.

27. Install reducer output shaft end cap and retaining hardware.

______________________________________________________________ A6474X391 REV 2 5.147

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Replacement of wear parts_________________________________________ Conveyor drive unit The conveyor drive unit (Fig. 86) has been assembled as a unit and can be removed and installed as a unit.

Fig. 86: Conveyor drive unit 7 5 6 4

2

3

8

1

1.

2.

3.

4.

5.

6.

7.

8.

9.

9

Hex head bolt, Lockwasher, Flat washer, Hydraulic motor Gearbox Headshaft retainer Headshaft splined adapter Hex head bolt End cap

________________________________________________________________ 5.148 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts How to remove the conveyor drive unit (Fig. 86) Whenever performing maintenance procedures, follow all safety regulations and be aware of 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. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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

1. Remove the last cover on the left hand side of the machine.

2. Remove the last cover’ s support post.

3. Remove the hydraulic motor: 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 from the end of the motor.

4. 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 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. e. Remove the retainer end cap. f.

Remove the cotter pin and retainer pin 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.

______________________________________________________________ A6474X391 REV 2 5.149

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Replacement of wear parts_________________________________________ How to install the conveyor drive unit (Fig. 86) 1. 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 and torque to 400 ft-lbs. c.

Reconnect hydraulic hoses.

2. Install the conveyor gear reducer: 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 and secure with the M20X2.5X100 Grade 10.9 retaining bolt. Torque the bolt to 450 ft-lbs. c.

Insert the reaction pin and secure with 1/4 inch cotter pin.

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

3. Install the last cover’ s support post.

4. Install the last cover on the left hand side of the machine.

________________________________________________________________ 5.150 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts How to remove the breaker bit To remove the breaker bit from the breaker shaft bit holder proceed as follows (Fig. 87): 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. 87): 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. 87: Breaker bit removal and installation

Retaining rings

Bit holder

Breaker bit

______________________________________________________________ A6474X391 REV 2 5.151

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Replacement of wear parts_________________________________________ Installing the tailpiece To install the tailpiece on the feeder breaker (Reference Fig. 88: Tailpiece installation): WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

1.

Install spacer blocks into the underside of the tailpiece weldment. a.

Make sure that bolts will pass through the bearing spacers and the tailpiece weldment.

b. Tack weld bearing spacer blocks to tailpiece weldment.

2.

Install belt pulley assembly using hex bolts, flat washers, hex nuts, and lock washers.

3.

Bolt impact bed assembly to tailpiece weldment using flat washers, lock washers, hex nuts, and bolts.

4.

Install slider assembly using flat washers, lock washers, hex nuts, and bolts.

5. Install knuckle piece to tailpiece weldment using tailpiece swivel pin, flat washer, hex nut, keeper pin, and cotter pin.

6. Tighten the hex nut onto the tailpiece swivel pin then weld the pin keeper across the flat of the tailpiece swivel pin on three sides.

7. Position the assembled knuckle joint and the tailpiece frames to the main frame. (Reference figure 86 for placement). Install pins.

8. Install the tailpiece hopper weldments on the main frame using flat washers, lock washers, hex nuts and bolts and flat washers, lock washers, hex nuts, and bolts.

9. Install tailpiece tilt cylinders into the tailpiece hopper weldments and the tailpiece weldment using the swivel clevis weldments, pins, and cotter pins.

10. Install the steering cylinders between the tailpiece frame and the knuckle joint weldment using pins and cotter pins.

________________________________________________________________ 5.152 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts 11. Refer to the hydraulic schematic (Fig. 89) for hydraulic installation of the cylinders. Route all hoses, avoiding pinch points, so that hose damage does not occur.

Fig. 88: Tailpiece installation

Tailpiece hopper (2)

Tailpiece skirt

Rubber skirt

Impact bed assembly Valve bank

Tilt cylinder

Steering cylinder

Belt pulley assembly

______________________________________________________________ A6474X391 REV 2 5.153

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Replacement of wear parts_________________________________________ Fig. 88: Tailpiece installation (continued)

Knuckle clevis

Slider saddle assembly

Swivel pin

Tailpiece mount clevis

________________________________________________________________ 5.154 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

________________________________________ Replacement of wear parts Fig. 89: Tailpiece and Roof Support hydraulic schematic

______________________________________________________________ A6474X391 REV 2 5.155

BI001467

Replacement of wear parts_________________________________________ Roof cylinder and roof anchor arm removal and Installation (typical both sides) To remove the roof cylinder (reference Fig. 90): 1. Extend the roof anchor arm pullout far enough to rest on adjacent cover.

2. Retract the roof cylinder until the anchor arm pullout rests on cover.

3. Shutdown the feeder breaker (see Shutdown procedure in this manual).

4. 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.

5. For the left hand roof anchor remove the eight (8) hex bolts located towards the hopper end of the hinged cover above main valve bank. Flip up cover to access roof anchor cylinder and arm. a. If no room to flip cover, pull pins on opposite side of cover and completely remove cover.

6. There are no covers to remove to access the right hand roof anchor, skip step 5.

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.

7. Attach an appropriate lifting device to the roof cylinder and take in any slack in chain.

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.

8. 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.

9. Pull the upper cotter pin and upper roof cylinder pin. Pull the lower cotter pin and lower cylinder pin.

10. Lift the roof cylinder free from the machine.

________________________________________________________________ 5.156 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts 11. If necessary, remove the roof anchor arm: a. Attach an appropriate lifting device to the roof anchor arm and take up any slack in chain. b. Remove the cotter pin from the anchor arm clevis and pull pin. c. Lift anchor arm free from machine.

To install the roof cylinder (reference Fig. 90): 1. If necessary, install the roof anchor arm: a. Extend anchor arm pullout far enough to rest on cover when lifted into position. b.

Attach an appropriate lifting device to the roof anchor arm, lift into place and rest anchor arm pullout on adjacent cover.

c.

Lower anchor arm into clevis, insert the anchor arm pin and secure with cotter pin.

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. Lower the roof cylinder into place with an appropriate lifting device.

3. Place the lower cylinder eye into clevis and install the lower cylinder pin and cotter pin.

4. Place the upper cylinder eye into clevis and install the upper cylinder pin and cotter pin. Remove lifting device.

5. Install the hydraulic hoses to the roof cylinder.

6. Install the cover over the main valve bank on the left hand side of machine. Note: For right hand roof anchor arm it is not necessary to install any covers.

7. Re-energize machine and start the feeder breaker (see “AUTO”or “MANUAL”starting procedures in this manual).

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.

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Replacement of wear parts_________________________________________ Fig. 90: Roof cylinder removal and installation (typical both sides) Roof anchor arm pullout (2)

Roof anchor arm (2)

Cotter pin (2)

Anchor arm pin (2)

Cylinder pin (4) Roof cylinder (2)

Cotter pin (4)

Left hand side (with cover)

Hinged cover Anchor arm pullout resting on adjacent cover

Right hand side (no cover)

Anchor arm pullout resting on cover. Right and left side shown individually.

________________________________________________________________ 5.158 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Foot cylinder removal and installation To remove a foot cylinder (reference Fig. 91): Note: If room permits, lower the foot for this procedure.

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. Block the cylinder and foot as necessary.

4. 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.

5. Remove the cotter pin from the outrigger arm pin, remove the castle nut, and washer and pull the outrigger arm pin.

6. Remove the two cotter pins from the cylinder eye pin and pull the cylinder eye pin.

To install a foot cylinder (reference Fig. 91): 1. Mount the cylinder eye to the outrigger mount plate. a. Position the cylinder eye in the outrigger mount plate clevis. b. Insert the cylinder eye pin through the cylinder eye and outrigger mount plate clevis. c.

Install the two cotter pins through the cylinder eye pin.

2. Position the foot clevis on the rod eye and align the rod eye in the outrigger arm weldment.

3. Install the outrigger arm pin through the outrigger arm weldment, foot, and rod eye. Install the washer and castle nut on the end of the pin. Secure with new cotter pins.

4. Reconnect the hydraulic hoses to the cylinder.

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Replacement of wear parts_________________________________________ 5. Reconnect power to the machine.

6. Purge the hydraulic system of air.

Fig. 91: Foot cylinder removal and installation

See detail A

Castle nut

Outrigger foot Washer Foot cylinder

Outrigger mount plate

Cylinder pin

Outrigger arm pin

Outrigger arms Detail A

________________________________________________________________ 5.160 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Tilt cylinder removal and installation To remove a tilt cylinder (reference Fig. 92): 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.

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Replacement of wear parts_________________________________________ To install a tilt cylinder (reference Fig. 92): 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. 92: Tilt cylinder removal and installation

1

2

3

4

1.

2.

3.

4.

Pin (2) Cotter pin (2 per pin) Tilt cylinder Mounting clevis

________________________________________________________________ 5.162 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Lift cylinder removal and installation To remove a lift cylinder (reference Fig. 93): 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.

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Replacement of wear parts_________________________________________ To install a lift cylinder (reference Fig. 93): 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.

________________________________________________________________ 5.164 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts Fig. 93: Lift cylinder removal and installation Cotter pin (2 per pin) (typical both ends)

Pin (typical both ends)

Lift cylinder

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Replacement of wear parts_________________________________________ Tailpiece tilt cylinder removal and installation To remove a tailpiece tilt cylinder (reference Fig. 94): 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. Install spacer blocks into the underside of the tailpiece.

4. 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.

5. Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

6. Pull cotter pin out of the pin through the cylinder eye. Remove pin.

7. Pull cotter pin out of the pin through the rod eye. Remove pin.

To install a tailpiece tilt cylinder (reference Fig. 94): 1. Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

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.

________________________________________________________________ 5.166 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts 5. Reconnect the hydraulic hoses to the cylinder.

6. Reconnect power to the machine.

7. Purge the hydraulic system of air.

Fig. 94: Tailpiece tilt cylinder removal and installation

Cotter pin (4) (2 per eye)

Tailpiece tilt cylinder

Pin (2)

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Replacement of wear parts_________________________________________ Tailpiece steering cylinder removal and installation To remove a tailpiece steering cylinder (reference Fig. 95): 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 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 cotter pin out of the pin through the cylinder eye.

6. Pull cotter pin out of the pin through the rod eye.

To install a tailpiece steering cylinder (reference Fig. 95): 1. Attach an appropriate lifting device to the cylinder.

WARNING! Serious injury or death can result from falling loads. Observe the safe working load limits of lifting devices and keep a safe distance from suspended loads.

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.

________________________________________________________________ 5.168 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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________________________________________ Replacement of wear parts 5. Reconnect the hydraulic hoses to the cylinder.

6. Reconnect power to the machine.

7. Purge the hydraulic system of air.

Fig. 95: Tailpiece steering cylinder removal and installation

Pin (2)

Cotter pin (4) (2 per eye)

Tailpiece steering cylinder

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Replacement of wear parts_________________________________________

________________________________________________________________ 5.170 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_________________________________________________ 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

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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.

________________________________________________________________ 5.172 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_________________________________________________ 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 destroke 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.

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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.

________________________________________________________________ 5.174 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_________________________________________________ Troubleshooting Table 5: 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

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Troubleshooting _________________________________________________ Table 6: Troubleshooting excessive heat Pump Heated

Motor Heated Cause

Remedy

Relief Valve Heated

Fluid Heated

Cause

Remedy

Cause

Remedy

See Fluid Heated

System pressure too high

D

Cause

Remedy

Fluid heated

See Fluid Heated

Fluid heated

See Fluid Heated

Cavitation

A

Excessive load

C

Valve setting incorrect

D

Fluid dirty or low supply

F

Air in fluid

B

Worn or damaged motor

E

Worn or damaged valve

E

Incorrect fluid viscosity

F

Excessive load

C

Faulty fluid cooling system

G

Worn or damaged pump

E

Worn pump, valve, motor, cylinder, or other component

E

Fluid heated

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.  change filters  check system fluid viscosity; change if necessary  fill reservoir to proper level G.  clean cooler and/or strainer  repair or replace cooler

B. Any or all of the following:  tighten leaky inlet connections  fill reservoir to proper levels: with few exceptions, all return lines should be below fluid level in the reservoir  bleed air from system  replace pump shaft seal; also replace shaft if worn at seal journal C. All of the following:  align unit  check condition of seals, bearings, and coupling  locate and correct mechanical binding  check for workload in excess of circuit design D.  adjust setting on valve E.  overhaul or replace defective parts

________________________________________________________________ 5.176 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_________________________________________________ Troubleshooting Table 7: Troubleshooting incorrect flow No Flow Cause

Low Flow Remedy

Excessive Flow

Cause

Remedy

Cause

Remedy

Pump not receiving fluid

A

Flow control set too low

D

Flow control set too high

D

Pump drive motor not operating

E

Relief or unloading valve set too low

D

RPM of pump drive motor incorrect

H

Pump to drive coupling sheared

C

Flow by-passing thru partially open valve

E of F

Improper size pump used for replacement

H

Pump drive motor turning in wrong direction

G

External leak in system

B

Directional control set in wrong position

F

RPM of pump drive motor incorrect

H

Entire flow passing over relief valve

D

Worn pump, valve, motor, cylinder, or other component

E

Damaged pump

C

Pilot filter clogged

A

Improperly assembled pump

E

Pilot filter clogged

A

Remedies A. Any or all of the following:    

replace dirty filters clean clogged inlet line clean reservoir breather vent fill reservoir to proper level

F. Any or all of the following  check position of manually operated controls G.  reverse rotation H.  replace with correct unit

B. Any or all of the following:  tighten leaky inlet connections  bleed air from system C. All of the following:  check for damaged pump or pump drive  replace and align coupling D.  adjust setting on valve E.  overhaul or replace part

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Troubleshooting _________________________________________________ Table 8: Troubleshooting incorrect pressure No Pressure

Low Pressure

Cause

Remedy

Cause

Remedy

No flow

See Table 5

Pressure relief path exists

See Table 5

Damaged pump, motor, or cylinder

E

Erratic Pressure Cause

Remedy

Air in fluid

B

Worn relief valve

E

Contamination in fluid

A

Worn pump, motor, or cylinder

E

Remedies A.  replace dirty filters and system fluid B.  tighten leaky connections  fill reservoir to proper level and bleed air from system C.  gas valve for leakage  charge to correct pressure  overhaul if defective D.  adjust valve E.  overhaul or replace part

________________________________________________________________ 5.178 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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

Probable cause

dirty oil 

Test, check and/or remedy

Components not properly cleaned during servicing.



Disassemble components and reclean parts.



Air breather left off.



Add breather.



Hose lines not properly covered when servicing machine.



Keep hose ends protected from contamination while disconnected.

Clean hose lines before reconnecting.



Filter elements not replaced at proper intervals or when indicated.



Replace elements at proper intervals.

Tank return lines not below fluid level.



Check oil level.



Oil contaminated with incompatible foreign matter.



Drain out oil and replace with clean oil and change filter.



Suction leak to pump aerating oil.



Replace or tighten fittings and lines.

moisture in oil 

Soluble oil solution splashing into poorly sealed tank gasket or fill holes left open.



Drain out and refill with clean oil.

Check fill pipes to see if they are properly closed.

foaming oil 



Moisture in cans of replacement oil. 



Extreme temperature differential in certain geographical locations.



Store oil in an area that protects against exposure to frequent extreme temperature changes.

Fluid viscosity too high.



Check fluid specifications.

overheating of system 

Replace with new cans of oil.



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



Oil level too low.



Check/add oil.



Improper air circulation around reservoir.



Check to see if the area around the reservoir is clear.



System relief valve set too high or too low.



Reset the relief valve to specifications.

Sticking selector or other control valve.



Isolate circuits/components and identify fault.

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

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

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

Probable cause

Test, check and/or remedy

foreign matter sources  in the circuit

Sealing compound (pipe dope, Teflon tape).



Clean or replace seals. Drain and replace oil as necessary.



Tank or component ports left open to atmosphere.



Cap or plug properly. Replace filter elements and monitor oil cleanliness. Drain and replace oil as necessary.



Lines left unprotected or dirty repaired components.



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



Repair parts not properly protected while stored.



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

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_________________________________________________ Troubleshooting Hydraulic cylinders Table 10: Hydraulic cylinder troubleshooting Trouble or symptom

Probable cause

cylinder drifts 

Piston seal leak.

Test, check and/or remedy 

Repair seals or replace cylinder.



Replace cartridge or cylinder as required.



Correct leaks.



Control cartridge by-passing.



Other circuit leaks.

cylinder fails to move  the load when actuated

Pressure too low.



Check pressure of circuit controls and cylinder to insure designed system pressure is attained.



Piston seal leak.



Repair seals or replace cylinder.



Piston rod broken internally.



Repair as required or replace cylinder.



Contamination in hydraulic system resulting in scored cylinder bore.



Replace cylinder. Check oil cleanliness and change as required.

Excessive friction due to misalignment and/or side loading.



Inspect cylinder installation for proper operation and/or for foreign objects that inhibit the normal operation of the cylinder.

Air in circuit.



Cycle cylinder to full stop positions to purge air.

excessive or rapid piston  seal wear

Excessive system pressure due to over adjustment.



Check and correct pressure adjustment to rated limits.



Excessive friction due to misalignment and/or side loading.



Inspect cylinder installation for proper operation and/or for foreign objects that inhibit the normal operation of the cylinder.

Excessive pressure.



Check and correct pressure adjustment to rated limits.



Seal is pinched or extruded.



Replace seal and/or cylinder as required.



Seal deterioration (soft or gummy). 

erratic or chatter in operation 



cylinder body seal leak 

piston is leaking 

Check for contamination of fluids (incompatibility). Flush system and refill with correct fluid. Replace seal and/or cylinder as required.

Dirt has scored the piston or the rod.



Replace cylinder.

piston freezes to the tube 

Scoring in the piston.



Replace cylinder.

packing and gasket leaks  develop

Excessive heat/wear.



Replace seal and/or cylinder as required.

______________________________________________________________ A6474X391 REV 2 5.181

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Troubleshooting _________________________________________________ Hydraulic pump Table 11: Hydraulic pump troubleshooting Trouble or symptom

Probable cause

pump makes excessive noise 

Test, check and/or remedy

Vacuum leaks in suction line.



Check for leaks in fittings or damaged suction lines.



Vacuum leaks in the pump shaft seal.



Check pump shaft seal for signs of brittleness or damage due to excessive heat. Replace seal as required.



Poor alignment with drive mechanism.



Check pump shaft and motor shaft insert, as well as pilot engagement, for interference.



Incorrect fluid in system.



Check fluid specifications - change fluid if necessary.



System relief settings.



Pressure adjustment too low or cartridge fouled with foreign material. Readjust to correct setting and/ or clean foreign material from cartridge.



Pump cavitation.



Check fluid level for proper level.

Check for aeration of fluid reservoir.

Check for vacuum leaks in suction lines. Repair all faults as required and/or replace pump as required.



Worn or damaged gears/ housing.



Replace pump.



Worn or faulty bearing.



Replace pump.



Reversed rotation.



Check pump motor wiring.



Plugged or restricted suction line or  suction strainer.

Clean by removing the foreign material blocking oil flow.



Plugged reservoir filter breather.



Clean or replace filter breather as required.

seal leak 

Torn or worn seals.



Replace seal.



Gland bearing worn.



Excessive gland bearing wear will likely require pump replacement.



Seal deterioration (soft or gummy).



Check oil for fluid compatibility.

Drain oil tank and replace oil as required or if questionable. Replace seals.



Seal deterioration (hardened or loss  of elasticity).



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



Replace seal.

Check pump shaft for possible bearing wear. Replace seal.

 Loose or worn pump parts.  Replace worn pump parts. ________________________________________________________________ 5.182 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_________________________________________________ Troubleshooting Table 11 (continued): Hydraulic pump troubleshooting Trouble or symptom

Probable cause

pump fails to deliver oil 

Test, check and/or remedy

Low oil level in reservoir.



Fill to proper level.



Oil intake hose suction strainer plugged.



Clean or replace strainer.



Air leak in suction line preventing priming.



Tighten or replace suction lines.

 

Pump shaft turning too slowly.

Check pump motor and controls to insure proper pump speed is attained.



Oil viscosity too high.



Replace with recommended oil.



Wrong shaft rotation.



Check pump motor wiring.



Pump shaft or parts broken.



Replace shaft or broken parts.



Pump damaged due to contamination.



Change pump, drain and replace oil in the reservoir and replace filter elements.

Shaft seal worn.



Replace seals.



Hose connections leaking.



Tighten flange bolts or adapters and hose connections as required. Replace hose, adapters, and/or seals as required.



Pump housing bolts loose or improperly torqued.



Tighten bolts to correct torque and/or replace pump if correct performance cannot be attained.

excessive pump wear 

Contaminated hydraulic oil being circulated through the system.



Drain oil from the reservoir and replace it with clean hydraulic oil. Replace filter elements and implement frequent element changes until the desired cleanliness of the system is attained.



Oil viscosity too low.



Replace with recommended oil and change filter elements.



Excessive pump loads.



Check relief valve adjustment.

Reset to correct setting.

oil leakage around pump 

______________________________________________________________ A6474X391 REV 2 5.183

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Troubleshooting _________________________________________________ Table 11 (continued): Hydraulic pump troubleshooting Trouble or symptom

Probable cause

pump parts inside  the housing are broken 

Test, check and/or remedy

Seizure due to lack of oil.



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

Excessive system pressure above maximum pump rating.



Replace pump and filter elements.

Minimize the relief pressure adjustment before starting the new pump.

Replace relief valve if correct adjustment cannot be obtained.



Replace pump and filter elements.



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



Excessive torque to housing bolts.



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

________________________________________________________________ 5.184 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_________________________________________________ Troubleshooting Valves Table 12: Valve troubleshooting Trouble or symptom

Probable cause

operating pressure  cannot be changed

Test, check and/or remedy

Valve spring broken.



Replace the spring, valve cartridge, or valve assembly as required.

Open valve in the system.



Locate and repair the open valve condition.

valve piston sticks 

Dirt in the system.



Remove the valve and clean it thoroughly; flush the system as necessary. Replace valve as required and replace filter elements.

certain passages are blocked or  pressure fluctuates

Dirt in the system.



Remove the valve and clean it thoroughly; flush the system as necessary. Replace valve as required and replace filter elements.

the pressure fluctuates and there is  extreme noise in the valve

Air in the system.



Check for leaks and other points that may allow air into the system.

Repair as required.



Pressure or volume too high.



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

valve leaks internally 

Valve piston and body worn.



Replace the valve.



Check and replace filter elements as required.



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



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

Dirt in the system.



Drain and replace the oil in the reservoir. Check and replace all filter elements.

Pinched, blown or missing section seal.



Replace section seal.



Stud fasteners not correctly torqued.



Replace section seals and retorque.



Mounting plate not level.



Loosen mounting bolts and shim as required.



Contamination/butts on seal.



Clean seal groove and replace section seal.



excessive leakage or  sticking pistons occurs



oil leaks  between sections

Valve excessively hot.

______________________________________________________________ A6474X391 REV 2 5.185

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

Probable cause

oil leaks at either  end of spool

Test, check and/or remedy

Over-pressurized tank core.



Correct high back pressure condition.

Worn or damaged spool seals.



Replace seals and seal retainers.

Broken centering spring.



Replace centering spring.

Misalignment of operating linkage.



Check linkage for mechanical binding.

Foreign particles in system.



Clean valve and system.

Cylinder leaking or worn.



Check cylinder, repair as needed.



Port relief valve not holding.



Remove and clean or replace.



Spool or housing scored or worn excessively.



Replace section.

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

load drops when spool  moved from neutral

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

Disassemble, clean, and reassemble.



Scored or sticking check valve pop-  pet.

Replace poppet.

no motion, slow, or erratic  system operation 

Worn pump.



Check flow and pressure.

Defective cylinder or motor.



Repair or replace.



Low reservoir oil level.



Add oil to specifications.



Clogged suction strainer.



Clean or replace.



Suction line restricted.



Check lines.



Relief valve not properly set.



Check pressure setting.



Relief valve poppet or seat scored and sticking open.



Replace relief valve.



Valve spool not shifted full stroke.



Check spool linkage travel.

________________________________________________________________ 5.186 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_________________________________________________ Troubleshooting Bearings Table 13: Bearing troubleshooting Trouble, symptom or cause

Probable cause

overheating bearing 

Test, check and/or remedy

Wrong type of grease or oil.



Consult the lubrication chart for the proper lubricant.



Low oil level; loss of lubricant through seal; excessive grease.



Oil level should normally be at the center of lowest ball or roller in bearing; check seals for signs of leaking.



Insufficient clearance in bearing.



Replacement bearing should be identical to original equipment to ensure proper internal clearance.



Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.



Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.



Shaft out of line.



Correct alignment and be sure shafts are coupled in a straight line.

Insufficient clearance in bearing.



Replacement bearing should be identical to original equipment to ensure proper internal clearance.



Foreign matter acting as abrasive.



Clean bearing housing and replace worn seals.



Housing bore out of round; housing warped; excessive distortion of housing; undersized housing bore.



Check and scrape housing bore to relieve pinching of bearing; be sure pedestal surface is flat and shims cover entire area of pillow block base when applicable.



Shaft and other parts of bearing assembly distorted.



Replace bearing, shaft and other parts as needed.

vibrating bearing 

Enlarged housing bore causing spinning of outer ring in housing.



Re-bore housing and press steel bushing in bore, then machine bore to correct size.



Foreign matter acting as abrasive.



Clean bearing housing and replace worn seals.



Unbalanced loading.



Check balance of rotating parts and rebalance as needed.

Chip in bearing housing; insufficient clearance in bearing; Ball or roller dented from extreme loading.



Replace with OEM bearing; do not hammer on any part of bearing; clean housing and use fresh lube.

noisy bearing 

unsatisfactory performance 

______________________________________________________________ A6474X391 REV 2 5.187

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Troubleshooting _________________________________________________

________________________________________________________________ 5.188 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_______________________________________________________________

6

Technical data

________________________________________________________________

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_______________________________________________________________

________________________________________________________________

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__________________________________________________ Technical data

Technical data This chapter contains the most important technical data on the Model 7MFBHM-48DD Feeder Breaker, serial number 54-2197 & 54-2198.

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 542197 & 54-2198 only. Other machines with the same model number may vary.

Technical data sheet general

Overall length: with tailpiece ..................................................approx. 38’8-7/8” Overall width:........................................................approx. 130-7/16” Tramming height (without sideboards): Minimum ........................................................approx. 57-5/8” Maximum .......................................................approx. 75-7/16” Ground clearance (max. w/ tail piece)..................approx. 17-1/2” Receiving width ....................................................approx. 129” Receiving height (min.):........................................approx. 11” Discharge height of belt (typical dump position) ..approx. 24-11/16” Operating height (max. - typical dump position): with tailpiece ..................................................approx. 72” without tailpiece .............................................approx. 61-7/16” Heaped hopper capacity: .....................................approx. 1,090 ft³

performance

Weight: less tailpiece and anchoring accessories ......approx: 82,000 lbs with tailpiece and anchoring accessories ......approx. 86,000 lbs Material input size (max.): .......................approx. 2’x 3’x 4’ Maximum material strength:....................approx. 30,000 psi Nominal output size:................................approx. 8”(one dimension) Discharge rate (max.): 1”pick to flight clearance ..................approx. 930 TPH @ 102 fpm 3”pick to flight clearance ..................approx. 1,073 TPH @ 102 fpm 5”pick to flight clearance ..................approx. 1,215 TPH @ 102 fpm Material to be broken:..............................Coal & Rock @ 60 lb/ft³

______________________________________________________________ A6474X391 REV 2 6.3

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Technical data ___________________________________________________

________________________________________________________________ 6.4 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_______________________________________________ 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 14: 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 15: Hex and sockethead 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

______________________________________________________________ A6474X391 REV 2 6.5

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Tightening torques _______________________________________________ Table 16: 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 16: 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 16: 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 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_______________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Use only lubrication fluids and greases approved by Caterpillar.

These fluids and greases have been tested at Caterpillar 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! Caterpillar expressly points 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.

______________________________________________________________ A6474X391 REV 2 6.7

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Permissible media________________________________________________ Table 17: 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 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_______________________________________________ Permissible media Table 18: Anti-wear hydraulic oil (Spec 100-1) approved suppliers Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation Chevron U.S.A.

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

14 15 16 17 18

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 Hydraulic 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

______________________________________________________________ A6474X391 REV 2 6.9

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Permissible media________________________________________________ Table 19: 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 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

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_______________________________________________ Permissible media Table 20: 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

______________________________________________________________ A6474X391 REV 2 6.11

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Permissible media________________________________________________ Table 21: 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 22: 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 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

_______________________________________________ Permissible media Table 23: 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 24: 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

______________________________________________________________ A6474X391 REV 2 6.13

BI001467

Permissible media________________________________________________ Table 25: 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 26: Synthetic EP gear lubricants (Spec. 100-13) approved suppliers

1

Supplier Fuchs

Brand name Powergear H680

________________________________________________________________ 6.14 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

BI001467

_______________________________________________ Permissible media Table 27: 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 28: 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

______________________________________________________________ A6474X391 REV 2 6.15

BI001467

_______________________________________________ Permissible media

______________________________________________________________ A6474X391 REV 2 6.16

BI001467

_______________________________________________________________

7

For your information

________________________________________________________________

BI001467

_______________________________________________________________

________________________________________________________________

BI001467

_____________________________________________________ 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

______________________________________________________________ A6474X391 REV 2 7.3

BI001467

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 Cat® FB140 (7MFBHM-48DD) Feeder Breaker

AT and ATS 816 SERIES PORTABLE REMOTE CONTROL SYSTEMS INSTALLATION, OPERATION & MAINTENANCE MANUAL Models AT4, AT8, AT12, and AT16

CUSTOMER: MODEL NUMBER: SERIAL NUMBER: FREQUENCY ASSIGNMENT: ADDRESS ASSIGNMENT: MANUAL P/N:

68C-816AT Rev. 008, 04/2006

AT and ATS 816 Series INSTALLATION, OPERATION & MAINTENANCE

IMPORTANT NOTICES This manual covers both the CATTRON-THEIMEG™ Advanced Technology (AT) and Advanced Technology Standard (ATS) 816 Series Portable Remote Control (PRC) systems, including auxiliary function kits and accessories. System installation information is included. In cases where more than one system is provided, it is advisable to mark the controlled equipment number on the manual cover to avoid confusion.

Your new PRC system has been pre-configured to operate on a specific address and frequency before leaving our factory. Thus, the address and frequency of the system controller is factory set to operate its corresponding 816 Series receiver/decoder.

Upon installation, CATTRON-THEIMEG™ strongly advises you to check that our pre-configured address and frequency is not duplicated in other CATTRON-THEIMEG™ remote control equipment located at, or around, your operating facility.

This equipment is firmware based, including encoder, decoder, transmitter and receiver. Any duplication of operating firmware without written consent of CATTRON-THEIMEG™ is prohibited.

All firmware, product listings, assembly files, and this manual are protected by U.S. Copyright Laws.

ã04/2006, CATTRON-THEIMEG™

Page i

List of Technical Abbreviations The following abbreviations (acronyms) are frequently used in CATTRON-THEIMEG™ Portable Remote Control Technology and may be used in this manual: AC AT ATS

MK ML NEMA

CS DC DP

Alternating Current Advanced Technology Advanced Technology Standard Automatic Safety Override Bose-ChaudhuriHocquenghem (data error detection routines) Complimentary Metal Oxide Semiconductor Crane Specific Direct Current Dual Pressure

EDP

Electronic Data Processing

RSSI

EEPROM

Electrically Erasable Programmable Read Only Memory Electro-Magnetic Interference Erasable Programmable Read Only Memory Federal Communications Commission Ground Input/Output Liquid Crystal Display Light Emitting Diode

ASO BCH

CMOS

EMI EPROM FCC GND I/O LCD LED

Page ii

Ni-Cad OPR

Metal Keypad Mainline National Electrical Manufacturer’s Association Nickel Cadmium Operate

PRC

Portable Remote Control

PTO RF RFI

RST

Push-to-Operate Radio Frequency Radio Frequency Interference Receive Signal Strength Indication Reset Relay

SP

Single Pressure

SYNC

Synchronization

TP

Test Point

TS VAC VDC VFD

Transfer Switch Volts Alternating Current Volts Direct Current Variable Frequency Drive

ã04/2006, CATTRON-THEIMEG™

Safety Summary WARNING and CAUTION statements have been strategically placed throughout all text prio r to operating or maintenance procedures, practices or conditions considered essential to the protection of personnel (WARNING), or equipment and property (CAUTION). A WARNING and CAUTION will apply each time the related step is repeated. Before starting any task, the WARNINGS or CAUTIONS included in the text for the task shall be reviewed and understood. All WARNINGS and CAUTIONS appearing in this manual are included below.

WARNINGS. WARNINGS: CATTRON-THEIMEG™ MAKES EVERY EFFORT TO ENSURE THE ADDRESS AND FREQUENCY ASSIGNED TO YOUR NEW PRC SYSTEM IS NOT DUPLICATED BASED UPON RECORDS WHICH ONLY INDICATE THE ADDRESS AND FREQUENCY OF ALL PAST PRC SYSTEMS AS SHIPPED FROM OUR FACILITY TO YOURS. THEREFORE, IT SHOULD BE FULLY UNDERSTOOD THAT; (1) WHEN A PRC SYSTEM HAS LEFT OUR FACTORY, CATTRON-THEIMEG™ HAS NO CONTROL OF ANY ADDRESSES AND FREQUENCIES SUBSEQUENTLY ASSIGNED AND PROGRAMMED BY YOURSELVES, OR OTHERS, EITHER NOW OR IN THE FUTURE AND, (2) CATTRON-THEIMEG™ HAS NO CONTROL OF THE ADDRESS AND FREQUENCY ASSIGNMENTS OF ANY OTHER PRC SYSTEMS(S) THAT MAY BE IN OPER ATION IN CLOSE PROXIMITY TO YOUR FACILITY. CONSEQUENTLY, AND PURSUANT TO STATEMENTS (1) AND (2) ABOVE, CATTRON-THEIMEG™ WILL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE ARISING FROM DUPLICATED ADDRESSES AND FREQUENCIES OF CONTROL SYSTEMS.

ã04/2006, CATTRON-THEIMEG™

Page iii

Safety Summary, continued WARNINGS, continued.

WARNINGS: CATTRON-THEIMEG™ ATS 816 SERIES PORTABLE REMOTE CONTROL (PRC) SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS (i.e., electromagnet circuits, vacuum circuits, grab, pump motors, fire suppression etc.).

WE SPECIFICALLY REFER YOU TO SECTION 2 PAGE 2 OF THIS MANUAL WHICH PROVIDES INFORMATION REGARDING PROPER INTERFACE TO SAFETY CRITICAL MAINTAINED FUNCTIONS USING A CATTRON-THEIMEG™ RELAY INTERFACE UNIT PART # RI004NE. ALTERNATIVELY, WE INCLUDE TYPICAL CIRCUIT DIAGRAMS IN SECTION 2 THAT ILLUS TRATE HOW TO PROPERLY INTERFACE YOUR CATTRON-THEIMEG™ ATS SERIES PRC SYSTEM TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS BEFORE OPERATIONAL USE. SHOULD CATTRON-THEIMEG™ ATS SERIES PRC SYSTEMS BE INADVERTENTLY CONFIGURED TO INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY RESULT. IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM. WARNINGS: ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED EQUIPMENT (I.E. CRANES) HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE CONTACTOR AND SET THE EQUIPMENT BRAKE. FAILURE TO COMPLY WI TH THESE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

Page iv

ã04/2006, CATTRON-THEIMEG™

Safety Summary, continued WARNINGS, continued.

WARNING: MORE THAN ONE REMOTE CONTROL SYSTEM MAY BE USED AT, AROUND, OR NEARBY YOUR OPERATING FACILITY. THEREFORE, IF THE WRONG ADDRESS AND OPERATING FREQUENCY IS PROGRAMMED INTO A REMOTE CONTROLLER, OTHER EQUIPMENT LOCATED AT, AROUND, OR NEARBY YOUR FACILITY MAY BECOME OPERATIONAL. FAILURE TO COMPLY WI TH THIS WARNING MAY RESULT IN OPERATION OF UNDESIRED EQUIPMENT WHICH IN TURN COULD RESULT IN PERSONAL INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPM ENT. WARNING: ATS PORTABLE REMOTE CONTROL SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS, (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors, fire suppression, etc.). THE USE OF AN APPROPRIATE RELAY INTERFACE UNIT WILL BE REQUIRED FOR THESE APPLICATIONS. FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNING: ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED. IN ADDITION, ALL EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS. FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. WARNING: FAILURE TO PROPERLY SELECT FREQUENCY AND ADDRESS MAY RESULT IN THE UNINTENTIONAL OPERATION OF OTHER MACHINERY. DO NOT DUPLICATE ADDRESS ASSIGNMENT. FAILUR E TO OBSERVE THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

ã04/2006, CATTRON-THEIMEG™

Page v

Safety Summary, continued WARNINGS, continued.

WARNING: DE-ENERGIZE AND TAG OUT ALL SOURCES OF ELECTRICAL POWER BEFORE CARRYING OUT TOUCH TESTS ON EQUIPMENT. FAILURE TO PROPERLY DE-ENERGIZE EQUIPMENT MAY RESULT IN DEATH OR SERIOUS INJURY FROM ELECTRIC SHOCK. WARNING: HIGH VOLTAGE MAY BE PRESENT ON RELAY OUTPUT TERMINALS. EXERCISE CAUTION WHEN WORKING NEAR THE RELAY OUTPUT BOARDS. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN DEATH OR SERIOUS INJURY FROM ELECTRIC SHOCK. WARNING: REMOVE POWER FROM THE CRANE OR MACHINE MOTORS BEFORE PERFORMING ASO TESTS. THESE TES TS REQUIRE THE ENERGIZING OF THE OUTPUT RELAYS USING JUMPERS. ENERGIZING THE RELAYS WHILE POWER IS APPLIED TO THE SYSTEM MOTORS MAY RESULT IN UNDESIRED MOVEMENT OF THE CRANE OR MACHINE. IN ADDITION, DAMAGE TO THE CIRCUIT BOARDS MAY RESULT IF THE TEST JUMPER CONTACTS THE WRONG COMPONENT. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

Page vi

ã04/2006, CATTRON-THEIMEG™

Safety Summary, continued CAUTIONS. CAUTIONS: On 12 VDC applications, incoming power must have a 1 Amp slow blow fuse in line with the positive lead near the battery or power source.

Insure the proper DC voltage is connected to the receiver/decoder.

Observe proper polarity when making all connections.

Failure to comply with these cautions will result in vehicle and equipment damage.

CAUTION: Electrostatic sensitive devices such as EPROMs are present on circuit boards. Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving circuit boards and electrostatic sensitive devices. Failure to comply with this caution may result in equipment damage and will void our warranty.

CAUTION: EPROMs are electrostatic sensitive devices. Use an anti-static mat and personal grounding strap (wrist) when replacing or installing EPROMs. Failure to comply with this caution may result in equipment damage and will void our warranty.

ã04/2006, CATTRON-THEIMEG™

Page vii

Safety Summary, continued GENERAL. The following are general safety precautions that are not related to any specific procedure and therefore do not appear elsewhere in this manual. These are general safety precautions and instructions that people must understand and apply during many phases of operation and maintenanc e to ensure personal safety and health and the protection of your company property.

KEEP AWAY FROM LIVE CIRCUITS. Maintenance personnel must observe all safety requirements at all times. Do not replace components or make adjustments inside the equipment with the electrical supply turned on. Under certain conditions, danger may exist even when the power control is in the off position due to charges retained by capacitors. To avoid injuries, always remove power, discharge and ground a circuit before touc hing it. Adhere to all lock out/tag out requirements.

DO NOT SERVICE OR ADJUST ALONE. Whenever possible, do not attempt internal service or adjustment of equipment unless another person capable of rendering aid and resuscitation is present.

FINGER RINGS/JEWELRY. Finger rings have caused many serious injuries. Remove rings, watches and other metallic objects which may cause shock or burn hazards.

SOLDERING/DE-SOLDERING. Avoid breathing fumes generated by soldering/de-soldering.

Perform all operations in a ventilated area. Eye protection is required.

CLEANING SOLVENTS. Some cleaners and solvents have adverse effects on skin, eyes, respiratory tract and internal organs. These adverse effects range from discomfort to serious injury and death, depending on the material and degree of exposure. Observe manufacturers’ warning labels and contact your immediate supervisor if in any doubt.

Remember…. the person now reading these instructions is primarily responsible for his or her own health and safety.

Page viii

ã04/2006, CATTRON-THEIMEG™

Table of Contents Front Matter Important Notices ............................................................................................................. i List of Technical Abbreviations ...................................................................................... ii Safety Summary ............................................................................................................. iii Warnings ............................................................................................................ iii Cautions ............................................................................................................ vii General ............................................................................................................. viii

Section 1 - Functional Description General ........................................................................................................................ 1-1 Operability .................................................................................................................. 1-1 Advanced Control Functions ...................................................................................... 1-1 AT & ATS 816 Series Receiver/Decoders – Functional description ......................... 1-2 Specifications .............................................................................................................. 1-3 System Features .......................................................................................................... 1-4 Safety Considerations ................................................................................................. 1-5 Standard Safety & Security Features .............................................................. 1-5 Principle of Operation ................................................................................................. 1-6 Radio Remote Control .................................................................................... 1-6 AT & ATS 816 Series PRC Systems - model summary chart .................................... 1-7

Section 2 - Installation Pre-installation checks ................................................................................................ 2-1 Interface connections ................................................................................................... 2-1 Introduction ..................................................................................................... 2-1 Safety Interface Unit (ATS 816 Series only) ................................................... 2-2 The controlled machine ................................................................................... 2-4 Control transformer ......................................................................................... 2-4 Disconnect and outlet ...................................................................................... 2-5

ã04/2006, CATTRON-THEIMEG™

Page ix

Section 2 – Installation, continued Transfer switch ................................................................................................ 2-5 Relay outputs ................................................................................................... 2-6 R/C snubbing ................................................................................................... 2-6 Mainline circuit (operate and reset relays) ...................................................... 2-6 Attenuator ........................................................................................................ 2-8 Installation ................................................................................................................... 2-9 Getting started ................................................................................................. 2-9 Choosing a mounting location ......................................................................... 2-9 Remote antenna location ............................................................................... 2-10 Triple diversity antenna ................................................................................. 2-11 Direct DC wiring option ................................................................................ 2-12 Pre-set frequency selections (ATS 816 Series only) ................................................. 2-13 Post installation checks .............................................................................................. 2-14 System status display and LED indicators .................................................... 2-14 Check-out procedures .................................................................................... 2-16 Power-up messages ........................................................................... 2-16 Run-time Messages ........................................................................... 2-17 ASO Hexadecimal Codes .................................................................. 2-19

Section 3 - Operating Instructions General ........................................................................................................................ 3-1

Section 4 - Maintenance General ........................................................................................................................ 4-1 Preventive maintenance ............................................................................................... 4-2 Typical additional checks ................................................................................ 4-2 Primary power supply .......................................................................... 4-2 Fuses .................................................................................................. 4-2 Fuse holders ......................................................................................... 4-3 Unit assemblies .................................................................................... 4-3 Antenna system ................................................................................... 4-3 Page x

ã04/2006, CATTRON-THEIMEG™

Section 4 – Maintenance, continued Netting ................................................................................................. 4-3 Adjustments ................................................................................................................ 4-4 Troubleshooting .......................................................................................................... 4-5 Automatic Safety Override (ASO) .............................................................................. 4-9 ASO Circuit test procedure ............................................................................. 4-9 Receiver/Decoder repair ........................................................................................... 4-11 Replacing the EMI/RFI shielded chassis (gold box) .................................... 4-11 Relay replacement ......................................................................................... 4-12 Receiver replacement .................................................................................... 4-13 Decoder replacement ..................................................................................... 4-15 Code Plug replacement ................................................................................. 4-17 EPROM replacement .................................................................................... 4-20

Section 5 - Parts List and Accessories Introduction ................................................................................................................. 5-1 AT & ATS 816 Series Receiver/Decoder ....................................................... 5-2 EMI/RFI Shielded Chassis .............................................................................. 5-4 Accessories .................................................................................................................. 5-6 Two-step electro-hydraulic brake package ..................................................... 5-6 Transfer Switch ............................................................................................... 5-7

Appendix ‘A’ – R1014T2 Receiver Introduction ................................................................................................................ A-1 Additional Safety Feature .......................................................................................... A-2 Close Start Setup ........................................................................................................ A-2 Range Limit Setup ..................................................................................................... A-7 Range Extender Setup .............................................................................................. A-10 Scanner Setup ........................................................................................................... A-12 Attenuator Setup ...................................................................................................... A-13 Factory Set & Field Programmable Frequencies ..................................................... A-14 ã04/2006, CATTRON-THEIMEG™

Page xi

Appendix ‘B – New R1HN and R2HN Receiver Boards Frequency Programming Procedure ........................................................................... B-1

Index Addendum RECOMMENDED SAFETY RULES FOR PORTABLE REMOTE CONTROLLED (PRC) CRANES.

Page xii

ã04/2006, CATTRON-THEIMEG™

Section 1 – Functional Description General.

CATTRON-THEIMEG™ AT and ATS 816 Series PRC systems offer the safety and dependability required for harsh industria l control applications. These systems incorporate a high-performance microcomputer with a minimum number of components in their design. A single board decoder is under the direct control of a variety of lightweight, hand-held style control transmitters. All AT systems are custom designed for each application. A variety of ATS (AT Standard) systems exist that have been pre-configured for standard applications.

Operability.

All functions of these systems can be operated simultaneously and independently. This creates a more efficient and flexible system, increasing productivity. There are no confusing do's and do not’s to remember when selecting functions.

Systems can be provided which allow multiple operators to control one crane on a first-come, firstserved basis, two to four operators working one piece of equipment using ‘Pitch and Catch’, two operators simultaneously controlling a single decoder, or one operator with a Supervisory control overriding the second operator.

With the CATTRON-THEIMEG™ AT and ATS 816 Series systems, all speed steps are under direct operator control. This allows the operator to select the appropriate speed for his or her load and operating conditions with care.

Advanced Control Functions.

An optional Model R1014T2 Receiver Board is available which enables several advanced control functions such as ‘Close Start’, ‘Range Limit’, and ‘Range Extend’ to be programmed into the receiver/decoder when used in conjunction with a Triple Diversity Antenna System. In addition, this optional Model R1014T2 Receiver Board has a built- in attenuator, a field programmable frequency select function, and a frequency scanning option. Refer to APPENDIX ‘A’ of this manual for details of this board and its enhanced functions.

ã04/2006, CATTRON-THEIMEG™

Section 1, Page 1

AT and ATS 816 Series Receiver/decoder – functional description.

The receiving and decoding hardware, along with relay interface, is housed within a NEMA 12 or other optional enclosure. The decoder has a two digit display to show system status and act as central test point. The output interface is handled by plug- in relays rated for heavy duty resistive and inductive industrial loads. Each output function relay has 2 screw terminals, an output fuse, and an LED indicator. The decoder uses a secondary contact on each relay to sense and verify each of the outputs.

Upon detection of a fault condition, the Operate (OPR) relay and all outputs are disabled. This is the Automatic Safety Override function, a safety feature found on all CATTRON-THEIMEG™ Portable Remote Control systems.

Refer to Figure 1-1 and Table 1-1 below for a description of the AT and ATS 816 Series components.

Figure 1-1. Receiver/decoder components

Section 1, Page 2

ã04/2006, CATTRON-THEIMEG™

AT and ATS 816 Series Receiver/decoders – functional description, continued.

Table 1-1. Receiver/decoder components

Component EMI/RFI shielded chassis (Gold Box)

Description The enclosure, commonly known as the ‘gold box’ due to its gold anodized coating, contains the receiver and decoder circuit boards along with the power supply for the entire receiver/decoder. For ease of repair, the entire gold box can be quickly swapped out with a spare and returned to CATTRONTHEIMEG™ for repair.

Relay output boards

The relay output boards provide a common connection point for all user connections to the output relays. The AT/ATS system will contain one or two relay output boards depending on the number of outputs in the system.

Receiver

The receiver contains the electronic circuits that perform the radio reception functions. Several LEDs mounted on the receiver circuit board indicate the status of the radio communications link with the controller.

Decoder

The decoder contains the electronic circuits that control system functions. This includes checking the address of incoming signals, interpreting the controller’s commands, and controlling the status of the output relays.

Antenna

The antenna provides radio reception for the receiver/decoder. If the mounting location of the receiver/decoder does not provide good radio reception, optional remote mount antennas are available.

Power supply

The power supply inside the gold box provides all required power for the receiver/decoder. The power supply requires 115 VAC at 50-60 Hz. The receiver/decoder can also be supplied directly with 12 VDC nominal (13.5 VDC).

Other AC & DC supply voltages are available upon request. Contact CATTRON-THEIMEG™ for options.

Specifications.

AT and ATS Receiver/decoders: Interface type: Mechanical relays, NO contacts, 5 A @ 250 VAC or 30 VDC. Output termination: 2 screw terminals per relay contact allowing mixed control voltages and transformers.

Number of outputs: 4, 8, 12, or 16 independent and simultaneous, plus one ON/OFF OPR on 4 & 8 systems and two ON/OFF OPRs on 12 & 16 output systems.

ã04/2006, CATTRON-THEIMEG™

Section 1, Page 3

Specifications, continued.

Enclosure: NEMA 12 (IP65) steel, NEMA 4 (IP66) steel, or NEMA 4X (IP66) stainless steel.

Control voltage range: 30 VDC or 120-250 VAC ±20%, fused at 5 A. Power requirements: 115 VAC 50-60 Hz, or 13.8 VDC @ less than 1 Amp. Optional 10-36 or 24-78 power regulators.

Receiver freque ncy: Synthesized 16 channel capability; whip antenna, Non- licensed Canadian, European, and US; 447-473 MHz High band, mid band receiver. Licensed Canadian and US 447473 MHz, High Band, wide band and narrow band receiver. European: 425-447 MHz mid band receiver.

Sensitivity: 0.5 mV (20 dB quieting).

Frequency stability: ±0.0005 of frequency range.

Environmental: Outdoors, -22°F to 140°F (-30°C to 60°C), RH 0 to 95% non-condensing.

Dimensions: Approximately 12"H x 10"W x 4.5"D (305 mm x 254 mm x 100 mm).

System Features.

CATTRON-THEIMEG™ AT and ATS 816 Series PRC systems offer the following features: · High message security. · Four, eight, twelve, or sixteen output functions, plus ON/OFF operate(s). · Synthesized controller and receiver frequency control. · Average response time of less than 60mS. · Power-on self diagnostics. · Multiple watchdog timers. · Automatic Safety Override (ASO) for output verification of all outputs. · Operate different control voltages from a single receiver/decoder. · EMI/RFI shielded sub-chassis contains the receiver/decoder electronics. · Custom engineered for each application (AT series only). · Proven CATTRON-THEIMEG™ reliability.

Section 1, Page 4

ã04/2006, CATTRON-THEIMEG™

Safety considerations.

CATTRON-THEIMEG™ believes that to safely operate any remotely controlled equipment, the overall system needs to be configured so that movement or operation of the equipment will take place only when the device is commanded to move or operate. For example; overhead cranes must be equipped with a braking system which can only be released when an electrical signal is sent to the motor.

Removal of electrical power or loss of the radio transmitted signal results in application of the brakes.

One way to accomplish this is with a CATTRON-THEIMEG™ Electro-Hydraulic brake package – contact the factory for details.

In keeping with this philosophy - NO COMMAND, NO MOVEMENT - CATTRON-THEIMEG™ has designed your Portable Remote Control system with the following safety and security features.

Standard Safety & Security Features.

Unique address code : Each CATTRON-THEIMEG™ controller and receiver/decoder pair is configured with a unique address code so that the equipment will respond only to the controller whose address code matches that of the decoder.

Ope rate relay (OPR): The operate (OPR) output relay is wired to control a user-provided Electro- magnetic power contactor. The Electro- magnetic contactor opens and closes the main electrical supply circuit(s) to the controlled device.

ON/OFF power switch: A controller is provided with an ON/OFF switch that must be set to ‘ON’ in order to send commands to the receiver/decoder. If the power switch is set to ‘OFF’, the decoder will remove all commands from the controlled machinery, stopping all movement.

However, the mainline control relay (OPR) may be maintained for 10 minutes, depending on system configuration.

System STOP Switch: A controller is provided with a system STOP switch. Operating this switch while the controller is turned on will repeatedly send a burst of stop commands to all outputs including the mainline Operate (OPR) relay or, for AT12 & AT16 systems, two OPR relays. For continuous transmit systems, turning off the controller immediately de-energizes all outputs.

Automatic Safety Override : The Automatic Safety Override (ASO) function continually monitors all relays. If any relay closes without command from the controller, the Operate (OPR) Relay(s) immediately de-energizes. This prevents any movement of the controlled machine without command from the controller.

Close Start : The optional Close Start feature requires the operator to be within a specified distance of the controlled machine prior to the system activating.

Range Limit: The optional Range Limit feature ensures that the operator stays within a preset distance of the controlled machine. This keeps the operator within a safe distance of the machine.

Push To Operate: Some controllers have a Push To Operate (PTO) feature. This feature requires the operator to press and hold a large switch while operating the system. Releasing the PTO switch immediately stops all movement of the controlled system. ã04/2006, CATTRON-THEIMEG™

Section 1, Page 5

Standard Safety & Security Features, continued.

Intelligent digital message protocol: CATTRON-THEIMEG™ remote control systems utilize a unique message protocol for industrial control applications rather than the customary Electronic Data Processing (EDP) type of message format.

Data Error Checking: All communications from the controller to the receiver/decoder contain error-checking information (BCH data error detection routines). The entire data command packet must pass error detection tests before being processed.

Principle of Operation.

Radio Remote Control. Referring to Figure 1-2 below, the target receiver/decoder is controlled by a remote controller. Provided the correct address and frequency is programmed into the controller, the receiver/decoder receives signals from the controller using a UHF radio link. The signal is picked up by the antenna and passed on to the receiver. If the signal is the correct frequency and passes all required data tests, the signal is passed on to the decoder.

The decoder compares the address code of the signal to its own address code. If the signal’s address code does not match its address code, it is ignored and a message is displayed on a system status display located in the receiver/decoder unit. If the address code is correct, the decoder processes the message and energizes and de-energizes the appropriate relays mounted on the relay output board(s).

Figure 1-2. Simplified block diagram, RF PRC System 12 VDC

Tx

Rx

CONTROLLER

FREQ

ADDRESS

RECEIVER

DECODER

POWER SUPPLY

MAINS INPUT 50-60 HZ

WATCHDOG TIMER

ADDRESS FREQ

C W U I S R T I O N M G E R

OPR RELAY

RELAY 15

RELAY 1

C W U I S R T I O N M G E R

ASO

LH RELAY OUTPUT BOARD

Section 1, Page 6

RELAY 16

RELAY 14

RELAY 2

RELAY 13

RELAY 3

RELAY 12

RELAY 4

RELAY 11

RELAY 5

RELAY 10

RELAY 6

RELAY 9

RELAY 7

OPR RELAY

RELAY 8

RH RELAY OUTPUT BOARD

ã04/2006, CATTRON-THEIMEG™

Principle of Operation, continued.

An Automatic Safety Override (ASO) function continually monitors the state of all relay outputs. If a relay electrically fails closed without a command from the controller, the ASO circuit logic deenergizes the Operate (OPR) output relay(s). This prevents any movement of the controlled machine without command from the controller.

The relay output board(s) provides a mounting location for all the relays in the system. The relays control the high current loads required by the controlled machine. Mounted next to each relay is a fuse to provide overcurrent protection. All customer wiring for the output relays takes place at the relay output board(s).

During operation, the microprocessor on the decoder board resets multiple watchdog timer circuits whenever valid messages are received and decoded. If the microprocessor fails to reset the watchdog timers, the timer circuits shut down and de-activate all relay outputs. The decoder microprocessor requires continuously valid transmitted signals to be received and decoded or all relay output functions will be de-activated unless programmed otherwise. It should be noted that the mainline control relay (OPR) may be maintained for 10 minutes, depending on system configuration.

ã04/2006, CATTRON-THEIMEG™

Section 1, Page 7

AT and ATS 816 Series PRC System - model summary chart.

LEGEND =

AT12

AT16

NOT AVAILABLE NUMBER OF ITEMS SUPPLIED ACCESSORY ACCORDING TO FREQUENCY BAND, SPECIFY FREQUENCY BAND (WIDE, MEDIUM OR NARROW) AND CHANNEL SPACING

AT8

= = =

AT4

1,2 + #

1

1

1

1

+

+

+

+

+

+

+

+

+

+

+

+

1

1

1

1

#

#

#

#

R1014T1HN

Receiver, Synthesized, UHF, 450-470 Megahertz, 12.5kHz spacing

+

+

+

+

R1014T2HW

Receiver, Synthesized, UHF, 450-470 Megahertz, 25kHz spacing

1

1

1

1

D32GII

Decoder Circuit Board, Less EEPROM

+

+

+

+

51S-0832-ATX

EPROM, Decoder Board

-

-

1

1

CPA-0225

Cable, Ribbon with Connector, 2 Output Boards

1

1

-

-

CPA-0226

Cable, Ribbon with Connector, 1 Output Board

1

1

1

1

CPA-0342

Adapter, D32 to PB9R Board Cables, 50-pin

1

1

1

1

85C-0035

Antenna, Flex Whip UHF **

1

1

2

2

01C-PB9R

Rack, Relay Output, 9 Position, With Relays

+

+

+

+

10C-0096

Remote Antenna Mounting Kit, with 20 foot coax cable, PL259 connector (Optional for NEMA 12 enclosures)

+

+

+

+

10C-0096-BNC

Remote Antenna Mounting Kit, with 20 foot coax cable, BNC connector (Standard for NEMA 4 and 4X enclosures)

+

+

+

+

TS-XX

Transfer Switch Kit, 3-Position, XX denotes number of circuits

+

+

+

+

80C-0375

Relay, 1 N.O. Contact (Usable)

+

+

+

+

AT-SPARE-KIT

One 120VAC Power Supply, Two Relays, Miscellaneous Fuses

2

2

2

2

68C-816AT

Instruction Manual, AT 816 Series Systems

PART NUMBER CPA-0228-12STL

ITEM DESCRIPTION Enclosure, Painted Steel, NEMA 12 (IP65), 12 x 10 x 5 inches, Pre-Wired W/Back Panel *

CPA-0228-4STL

Enclosure, Painted Steel, NEMA 4 (IP66), 12 x 10 x 5 inches, Pre-Wired W/Back Panel *

CPA-0228-4XSS

Enclosure, Stainless Steel, NEMA 4X (IP66), 12 x 10 x 6 inches, Pre-Wired W/Back Panel *

CPA-0228-4XFIB

Enclosure, Fiberglass, NEMA 4X (IP66), 12 x 10 x 5 inches, Pre-Wired W/Back Panel *

CPA-0216

EMI/RFI Chassis, Pre-Wired, less Decoder, with Lid (‘Gold Box’), and 120 VAC Power Supply

*NEMA 7 enclosures are available, **Optional antennas are available - consult CATTRON-THEIMEG™ for details.

END OF SECTION

Section 1, Page 8

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Section 2 - Installation Pre-installation check Before installing the receiver/decoder, the equipment must be checked to ensure that it is working properly. The pre- installation check is a test to ensure that all switches, relays, the display, and status indicators operate properly. To accomplish this check, the receiver/decoder should be positioned on a test bench with the appropriate input supply voltage connected to the Input Terminal Block located at the bottom right hand side of the Relay Output Board.

Refer to the drawings provided with your system for information on which relays correspond to which controller functions. Power up and cycle all the switches on the appropriate controller(s), observing the relay status LEDs next to each relay as a controller function is activated. The LED should illuminate, indicating that the relay is energized. Check each relay output with an ohm meter to ensure that the relay is closing properly, and that the fuse for the output is good. If any of the relays do not operate properly, contact CATTRON-THEIMEG™ immediately.

Interface connections.

Introduction.

Due to the wide variety of existing control systems and the many options available, CATTRONTHEIMEG™ provides customized schematic drawings for each installation. Study these drawings carefully before installing any wiring.

If there are any questions concerning the drawings or installation requirements, contact CATTRON-THEIMEG™ before proceeding. If any additions or corrections are made during the installation, note the changes on the drawings in red ink. Return the marked-up drawings to CATTRON-THEIMEG™ after the installation so final prints may be prepared and issued.

Each relay on the relay output board(s) is completely independent of all other relays. There are no common connections between any output contacts. This allows the connection of different power sources, AC and DC, to each of the separate relays. The contacts are rated at 5 Amps, 250 VAC or 5 Amps, 30 VDC. All contacts are individually fused with 250 Volt, 5 Amp fuses.

All relays have a single normally open contact. This contact is connected to Terminal Block #1 (TB-1) on the appropriate Relay Output Board. All connections to the relays are made at this terminal block.

Refer to the drawings provided with your system for information on which relays correspond to which controller functions.

Before installing the remote control system, we advise you to first read the following topics of discussion (pages 1 thru 8 of this section).

NOTE.

If you have an ATS 816 Series PRC system, start reading at ‘Safety Interface Unit’, below. If you have an AT 816 Series PRC system, skip ‘Safety Interface Unit’ and proceed to ‘The Controlled Machine’.

ã04/2006, CATTRON-THEIMEG™

Section 2, Page 1

Safety Interface Unit – ATS 816 Series systems only.

WARNINGS: CATTRON-THEIMEG™ ATS 816 SERIES PORTABLE REMOTE CONTROL SYSTEMS ARE NOT DESIGNED TO INTERFACE DIRECTLY TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS (i.e., electro-magnet circuits, vacuum circuits, grab, pump motors, fire suppression etc).

A PROPER INTERFACE TO SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS SHALL BE INSTALLED, IDEALLY USING A CATTRON-THEIMEG™ RELAY INTERFACE UNIT, PART # RI004NE. ALTERNATIVELY, EXAMPLE CIRCUIT DIAGRAMS ARE PROVIDED BELOW TO ENABLE YOU TO PROPERLY INTERFACE YOUR CATTRON-THEIMEG™ ATS SYSTEM WITH SAFETY CRITICAL BISTABLE MAINTAINED FUNCTIONS BEFORE OPERATIONAL USE. SHOULD CATTRON-THEIMEG™ ATS SYSTEMS BE INADVERTENTLY CONFIGURED TO INTERFACE DIRECTLY WITH SAFETY CRITICAL BI-STABLE MAINTAINED FUNCTIONS AT YOUR OPERATING FACILITY, DAMAGE TO EQUIPMENT, SERIOUS INJURY, OR DEATH TO PERSONNEL MAY RES ULT. IT MUST BE FULLY UNDERSTOOD THAT CATTRON-THEIMEG™ WILL NOT BE HELD LIABLE FOR PERSONAL INJURY, DEATH, EQUIPMENT OR PROPERTY DAMAGE WHICH MAY ARISE FROM IMPROPER CONFIGURATION OF YOUR PORTABLE REMOTE CONTROL SYSTEM. When safety critical bi-stable maintained functions (i.e., electro- magnet circuits, vacuum circuits, grab, pump motors, fire suppression, etc.) are part of your controlled equipment, a proper interface must be installed between the CATTRON-THEIMEG™ ATS PRC and all such functions before operational use. We strongly recommend you use a CATTRON-THEIMEG™ Relay Interface Unit, Part # RI004NE. In addition, example circuit diagrams are provided below which illustrate how to properly interface your CATTRON-THEIMEG™ ATS PRC system with safety critical bi-stable maintained functions.

Section 2, Page 2

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Safety Critical Interfacing - example circuit diagrams (ATS 816 Series only).

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Section 2, Page 3

Safety Critical Interfacing - example circuit diagrams (ATS 816 Series only).

The Controlled Machine - all 816 Series systems.

The machine you are interfacing to may consist of single or multiple contactor panels, single or multiple manual controls, and single or multiple control transformers etc. Notice that there is no common connection between relay output contacts, allowing control of different power sources and combinations of AC and DC power. Application of the normally open relay contacts is similar to wiring that is required for any control switch, such as a pendant. Standard wiring practices should be observed. These can be found in the National Electrical Code and in local codes that may apply for your area.

Control Transformer - all 816 Series systems.

The power required to operate the remote control system is 115VAC, 50/60 Hertz, @ less than 1 Amp. The remote control system can be connected to an existing control transformer if the transformer’s size permits, otherwise, a control transformer must be supplied to provide the appropriate power for the remote control system.

Using a separate control transformer helps by reducing chances of a power slump if other electrical components connected to it fail. It can also be sized to allow installation of a utility outlet near the receiver/decoder for connection of a light or test equipment.

Section 2, Page 4

ã04/2006, CATTRON-THEIMEG™

Disconnect and Outlet - all 816 Series systems.

The receiver/decoder requires less than 1 Amp @ 115VAC to operate - refer to the drawings provided with your system for interconnection details. A larger 10 Amp circuit is recommended to allow installation of a utility outlet nearby for a light and test equipment. A fused disconnect switch provided by the installer should be installed as close to the power source as possible.

Transfer Switch - all 816 Series systems.

If the equipment is to be operated in the remote only mode and there are no manual controls, the Transfer Switch (TS) can be omitted. Otherwise, installation of a transfer switch is desirable to allow selection between remote or manual operation - refer to the drawings provided with your system fo r interconnection details. If a transfer switch is used, it should be connected so that power is removed from the remote control system when the transfer switch is in the ‘MANUAL’ position and vice versa.

The transfer switch provides an easy way to switch the controlled equipment from ‘MANUAL’ to ‘REMOTE’ control. Installing the transfer switch may require changes to the controlled equipment wiring. Prior to changing any existing wiring, create a wiring diagram of the planned changes. Use existing empty terminals on terminal boards as tie points.

When the transfer switch is in the ‘REMOTE’ position, the manual controls should be disconnected and vice versa. All power should be transferred to the radio control relays. When the transfer switch is placed in the ‘MANUAL’ position, manual control of the equipment should be restored. The equipment may now be controlled as it was prior to installation of the radio controls. Figure 2-1 below shows a typical transfer switch wiring setup. The transfer switch also contains an ‘OFF’ position. In this position all circuits are disconnected from both remote and manual controls.

Figure 2-1. Typical transfer switch wiring EXISTING CONTROL WIRING MANUAL CONTROLLER

CUT

ML

RECEIVER /DECODER OPR RELAY

M

C

TRANSFER SWITCH

R

NOTE: OPR RELAY CONNECTION SHOWN. OTHER RELAYS ARE SIMILAR

When switching the transfer switch between remote and manual control, observe the following precautions: · Do not transfer control of a crane with a load lifted. Always set down all loads prior to changing the position of the transfer switch. · If the crane is equipped with a magnet, it shall be set in the drop position prior to changing the position of the transfer switch. · When provided, set the STOP switch on the Portable Remote Controller to ‘STOP’ and the ON/OFF switch on the Portable Remote Controller to ‘OFF’. ã04/2006, CATTRON-THEIMEG™

Section 2, Page 5

Relay Outputs - all 816 Series systems.

Each output relay has a single Normally Open (NO) contact which is available for wiring at the relay board’s Terminal Block (TB). These contacts are rated at 5.0 Amps @ 120 – 250 VAC or 30 VDC. Each contact is individually fused at 5.0 Amps. Each relay has an internal secondary contact that is used by the decoder’s ASO circuitry to sense the relay’s status (energized or de-energized).

Each relay on the relay output boards is completely independent of all other relays. There are no common connections between any output contacts. This allows the connection of different power sources, AC and DC, to each of the separate relays.

R/C Snubbing - all 816 Series systems.

R/C snubbing circuits are provided on all relay outputs. These snubbing circuits provide protection for each relay contact when it is connected to an inductive load.

NOTE:

On some high-impedance loads, such as PLCs or VFDs, small leakage current (approximately 200 µA at 115 VAC), may present a problem. If this is the case, the snubbing circuit may be removed by cutting out either the resistor and/or capacitor located next to the affected relay.

Mainline Circuit (operate and reset relays) - all 816 Series systems.

WARNINGS: ALL EQUIPMENT MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED EQUIPMENT (I.E. CRANES) HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO) CIRCUITRY WILL DE-ENERGIZE THE MAINLINE CONTACTOR AND SET THE EQUIPMENT BRAKE. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN PERSONAL INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. NOTE:

The remote control Operate (OPR) Relay is relay 0.

Referring to Figure 2-2 opposite, the Operate (OPR) relay output(s) is special. It should always be connected to the mainline (ML) contactor. If a fault were to occur with any one of the other output relays, the ‘OPR’ relay(s), which control the mainline contactor, would be the device that would safely bring the equipment to a stop. This makes the use of a mainline contactor mandatory for safe operation of this equipment.

Section 2, Page 6

ã04/2006, CATTRON-THEIMEG™

Mainline Circuit (operate and reset relays) - all 816 Series systems, continued.

Figure 2-2. Operate (OPR) contact wiring

MANUAL DISCONNECT

ML

L1

TB R

OPR

C 5.0A

RECEIVER/DECODER

L2

LL1 LL2

L3

LL3

TO MOTOR

120V ML

EXISTING CONTROLS

The Operate (OPR) relay(s) is energized for the first time when the receiver/decoder has power applied, the controller is turned on, and a matching address code is sent from the controller to the decoder. The OPR relay(s) is wired to the mainline (ML) contactor. Once the mainline is energized, a continuously repeated valid signal must be received for function outputs to engage. If this signal is interrupted for any reason, all function outputs will turn off. The mainline control in non- licensed systems is an exception. Because FCC rules state that RF transmitters in non- licensed controllers must switch off within five seconds after the operator releases the function button, the OPR output is programmed to stay on for ten minutes after the last valid message is received. During this time all other outputs must stay off unless programmed otherwise or the ASO sensing in the decoder will interrupt this hold up time, de-energizing OPR. In Figure 2-2 above, the Operate (OPR) contact is wired directly to the mainline (ML) contactor.

Switching the remote controller on energizes the mainline contactor.

Referring to Figure 2-3 below, an auxiliary function may be used as a Reset (RST) output that will only be effective when the Operate (OPR) relay has been closed.

Momentary closure of the Reset (RST) relay picks up the mainline (ML) contactor, which is maintained under control of the OPR. Thus, power is supplied to the controlled device. If OPR opens, the mainline contactor releases, removing power from the controlled device and stopping all motion.

Figure 2-3 shows the Operate (OPR) relay and optional Reset (RST) relay wired to control a mainline contactor. This configuration requires the operator to activate the reset function on the controller after he or she has turned the unit on. Once reset, the ML contactor stays energized until OPR de-energizes.

Refer to the drawings provided with your system for OPR contact wiring details.

ã04/2006, CATTRON-THEIMEG™

Section 2, Page 7

Mainline Circuit (operate and reset relays), continued.

Figure 2-3. Operate (OPR) contactor and Reset Relay (RST) wiring

MANUAL DISCONNECT TB R

OPR

C 5.0A

ML

L1

LL1

L2

LL2

L3

LL3

TO MOTOR

120V ML TB

ML

R

RST

C 5.0A

RECEIVER/DECODER

EXISTING CONTROLS

In addition to being energized by the presence of a signal from the controller, OPR is under supervision of the Automatic Safety Override (ASO) circuit. The ASO circuit disables the OPR (shutting down the controlled machinery) if an output relay is active when no corresponding command is being received from the controller. In this event, no action is required by the operator to stop the equipment. The ASO safety circuitry will stop motion automatically without any operator command when an output relay fault is detected.

Attenuator - all 816 Series systems.

An attenuator reduces the incoming signal levels from the controller. This has the effect of reducing the range at which the machine may be controlled. Using an attenuator also makes the receiver less susceptible to overloading and distortion caused by strong signals on other adjacent channels. All 816 Series receiver/decoders can use an external attenuator where varying levels of attenuation can be selected from a range of attenuators. To obtain an external attenuator for your receiver/decoder, contact CATTRON-THEIMEG™ .

NOTE: If your PRRC is provided with the Model R1014T2 receiver which has a built-in attenuator, refer to Appendix ‘A’ of this manual.

Section 2, Page 8

ã04/2006, CATTRON-THEIMEG™

Installation.

Getting Started.

As previously instructed, study the customized schematic drawings for your installation. If there are any questions concerning the drawings or installation requirements, contact CATTRON-THEIMEG™ before proceeding. If any additions or corrections are made during the installation, note the changes on the drawings in red ink. Return the marked- up drawings to CATTRON-THEIMEG™ after the installation so final prints may be prepared and issued.

Choosing a Mounting Location.

When selecting a location to install the receiver/decoder the re are a few items to consider. First, the receiver/decoder must be installed in a location that allows easy access for maintenance and service.

Adequate clearance must be allowed to open the door for access. The location must also provide adequate RF reception. Select a location to minimize any possible interference from RF sources such as motors. Ideally, the receiver/decoder should be installed as close as practical to the crane electrical cabinet and should be mounted so that the antenna is vertical. There should be a minimum of 48 inches clearance from obstructions in all directions of the antenna within the line of sight. If this clearance is not possible, the installation must be tested to ensure that interference does not impact the system’s performance. Contact CATTRON-THEIMEG™ for more information or for help in resolving any problems.

Figure 2-4 below shows the footprint drawing for the standard NEMA 12 receiver/decoder enclosure.

Mount the enclosure in the desired location using the four mounting holes provided - do not weld the enclosure in position.

Figure 2-4. Receiver/decoder enclosure mounting footprint

ã04/2006, CATTRON-THEIMEG™

Section 2, Page 9

Choosing a Mounting Location, continued.

Figure 2-5 below shows the recommended location for installing the wiring conduit. Do not install any wiring in the shaded areas indicated. The enclosure shall not be used as a junction box for other control equipment, (i.e., a pendant). All wiring entering the enclosure must be terminated inside the enclosure. Do not install any pass-through wiring.

The ¾" conduit hole is only provided in NEMA 12 enclosures. If the system uses a NEMA 4, 4X, or other enclosure, conduit penetrations must be made by the installer.

To prevent interference on signal lines, do not install high and low voltage cables in the same conduit.

If using the optional remote antenna, do not run the antenna coaxial cable in the same conduit as any signal lines. Keep the antenna wire separate from all other wiring, both inside and outside the receiver/decoder cabinet.

Figure 2-5. Wiring locations

Remote Antenna Location.

The standard antenna for a receiver/decoder with a NEMA 12 enclosure mounts on the bottom of the receiver/decoder enclosure. In situations where this mounting arrangement is not suitable, and for all receiver/decoders with a NEMA 4 and 4X enclosure, a remote mounting kit is used. The mounting kit contains a 20 ft. coaxial cable, an antenna mount, and a mounting bracket.

The remote antenna mounting bracket should be placed in a location away from any sources of RF interference. For overhead crane applications, the remote antenna should be mounted vertically to the underside of the crane. Ensure there is a minimum of 48 inches clearance from obstructions in all directions within the line of sight. If this clearance is not possible, the installation must be tested to ensure the interference does not impact the system’s performance. Contact CATTRON-THEIMEG™ for more information or for help in resolving any problems.

Section 2, Page 10

ã04/2006, CATTRON-THEIMEG™

Remote antenna location, continued.

For NEMA 12 installations, connect one PL259 connector on the coaxial cable to the connector on the receiver/decoder enclosure and the other end to the remote antenna mounting bracket. For NEMA 4 and 4X applications, connect the BNC end of the coaxial cable to the BNC connector on the bottom of the gold box, and the PL259 connector to the remote antenna mounting bracket. For NEMA 4 and 4X applications, a hole must be cut in the bottom of the receiver/decoder enclosure for passage of the antenna cable.

If the 20 ft. cable supplied with the remote antenna mounting kit is too long, simply coil the excess cable and hang it securely out of the way of any moving equipment. If the 20 ft. cable is not long enough, contact CATTRON-THEIMEG™ to obtain a longer cable.

Refer to Figure 2-6 below for a drawing of the remote antenna mounting bracket.

Figure 2-6. Remote antenna mounting bracket

0.28 (7,11) HOLE DIA 2-PLACES

2.25 (57,15)

1.13 (28,70) NOTE: DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESIS BNC CONNECTOR SHOWN PL259 USED FOR NEMA 12 APPLICATIONS

Triple Diversity Antenna.

The triple diversity antenna consists of three flex whip antennas mounted at different locations around the controlled machine. This is useful in applications where a single antenna cannot provide the coverage area required. The triple diversity antenna is also required for some of the advanced features of the Model R1014T2 receiver. For information on the Model R1014T2 receiver, see Appendix ‘A’ of this manual.

Each remote antenna mounting bracket should be placed in a location away from any sources of RF interference. Mount the antennas on the controlled machine or crane in such a way that the operator can keep one antenna in the line of sight at all times. For example, mount one antenna on each of three corners of the controlled machine. If this is not possible, then mount the antennas so as to keep one in line of sight from as much of the work area as possible. In addition, we recommend you physically tag each antenna and its associated line kit with a number (1, 2, and 3) and permanently record its individual location on the controlled machine or crane. Test the controlled machine thoroughly from the entire work area to verify adequate performance of the system. If satisfactory performance cannot be obtained, contact CATTRON-THEIMEG™ for assistance. ã04/2006, CATTRON-THEIMEG™

Section 2, Page 11

Direct DC Wiring Option.

The CATTRON-THEIMEG™ AT and ATS 816 Series PRC System receiver/decoders equipped for AC power may be powered directly from a proper1y filtered 13.8 VDC power source. This capability is normally used when the receiver/decoder is installed on a vehicle, such as a tow motor, truck, automated vehicle, or automobile. If this option is applicable, refer to the drawings provided with your system for actual wiring details.

CAUTIONS: On 12 VDC applications, incoming power must have a 1 Amp slow blow fuse in line with the positive lead near the battery or power source.

Insure that the proper DC voltage is connected to the receiver/decoder.

Observe proper polarity when making all connections.

Failure to comply with these cautions will result in vehicle and equipment damage.

The use of an external 13.8 VDC source requires the use of an external DC filter between the power supply and the receiver/decoder power terminals. When the receiver/decoder is supplied with DC voltage in this fashion, the circuit breaker on the gold box is non-functional. If an on/off switch is required, it must be provided in the power supply lines by the installer. The installer provides all wiring, switches, fuses, and terminals.

Referring to Figure 2-7 below, two screw terminals are provided for the 12 VDC wiring. These terminals are located on the side of the gold box. Connect the 12 VDC supply to the terminals marked Filtered DC Output. This bypasses the internal 115 VAC/12 VDC power supply. The AC/DC power supply may be left in place for use when bench testing the receiver/decoder. The Unfiltered DC Input terminals are not used when supplying power in this fashion.

Figure 2-7. 12 VDC wiring diagram

FILTERED + DC OUTPUT UNFILTERED + DC INPUT

RECEIVER/DECODER

Section 2, Page 12

INSTALLER SUPPLIED FILTER CATTR ON PN: CPA -0251 RED

NOT USED

BLK

18GA WIRE POWER SOURCE

OPTIONAL POWER ON/OFF SWITCH

1.0 AMP S.B.

18GA WIRE

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Pre-set Frequency Selections – ATS 816 Series only.

NOTE:

Each AT 816 Series PRC System has been custom designed by CATTRON-THEIMEG™ for a specific control application.

Consequently, the AT 816 series receiver frequency has been factory set and may not be changed by the customer.

In order for the receiver and the controller to communicate, they must be set to the same operating frequency and address. CATTRON-THEIMEG™ ATS 816 Series receivers offer several factory preconfigured frequency selections for maximum versatility. While the original factory setting should be adequate for most users, there may be conditions where it is necessary to change the operating frequency of an ATS 816 Series PRC system (installing a spare receiver circuit board, controller, or when other systems are emitting RF signals that interfere with safe operation). Before making any change to an ATS 816 Series frequency setting, remember that both the controller and the target receiver must be set to exactly the same operating frequency and address in order to communicate.

NOTES:

ATS 816 Series Receivers allow the customer to select any one of 16 factory pre -set frequencies. Refer to the radio frequency programming sheets supplied with the system for a list of the frequencies available on your ATS 816 Series receiver.

Frequencies for licensed systems must NOT be changed. If the frequency for a licensed system needs to be changed for any reason, including RF interference, contact CATTRON-THEIMEG™.

To change the frequency setting for the system controller, refer to the documentation provided with the controller. Follow the procedure below to change the ATS 816 Series receiver board frequency setting to one of the factory-preset frequencies: 1.

Open the cover of the receiver/decoder and remove power from the receiver/decoder by turning off the circuit breaker on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

2.

Remove the lid from the gold box and locate the rotary frequency selector switch on the receiver circuit board. The switch is shown in Figure 2-8.

Figure 2-8. Rotary frequency selector switch location

RECEIVER CIRCUIT BOARD

ROTARY FREQUENCY SELECTOR SWITCH

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Section 2, Page 13

Pre-set Frequency Selections – ATS 816 Series only, continued.

3.

Using a small screwdriver, rotate the selector switch to the desired position.

4.

Replace the lid on the gold box.

5.

Restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

6.

Close the cover of the receiver/decoder.

Post Installation Checks.

The system and status display indicators described below are provided to assist you in carrying out the post installation checks. Please familiarize yourself with each indicator function before starting the checks.

System Status Display and LED Indicators.

A two character LED display is mounted on the decoder circuit board. A clear plastic window in the cover of the gold box provides for viewing of the display without removing the cover. The location of the system status display is shown in Figure 2-9 below.

AS O T.P.

Figure 2-9. System status display and status LED locations

ASO T.P.

1

Q-SYNC LED

CARRIER DETECT LED

VCO LOCK LED

RECEIVER POWER LED

RECEIVER BOARD

P1

0

DATA LED

RELAY OUTPUT BOARD

RELAY STATUS LED OPERATE (OPR) RELAY LED OPERATE (OPR) RELAY

OPTIONAL SUB-ADDRESS SELECTOR SWITCHES

SYSTEM STATUS DISPLAY

GII DECODER BOARD

Section 2, Page 14

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System Status Display and LED Indicators, continued.

During operation, the system status display shows the current status of the receiver/decoder. This includes any general status messages, hardware errors, data reception errors, and ASO errors.

The most common messages during normal operation include the address of the controller sending messages to the receiver and the message Fd. The Fd message simply indicates that the receiver has timed out while waiting for a message to be received from the controller. Refer to page 16 of this section which provides a complete description of system status display codes (Power- up and Runtime messages).

In addition to the two digit code, the system status display contains a decimal point to the right of the second digit. This decimal point flashes in synchronization with the signal LED on the controller when the decoder receives a signal from the controller.

Additional LED indicators are located on the receiver board and relay output board(s). These LEDs also indicate system status and are particularly useful in troubleshooting and adjusting the receiver. Refer to Table 2-1 below for an explanation of the LED indicators and Figure 2-9 above for the location of the LEDs. Table 2-1. LED indicator status codes

LED Relay Status (relay output board)

Description The red relay status LEDs energize whenever the corresponding relay is energized.

Receiver Power

This red LED indicates the presence of DC power on the receiver circuit board.

Carrier Detect

The green Carrier Detect LED on the receiver circuit board indicates that the receiver is receiving a RF signal.

Data

This yellow LED on the receiver circuit board indicates that the message received contains data.

Q-Sync

This orange LED on the receiver circuit board indicates that the receiver has synchronized with the incoming message.

VCO Lock

This red LED is located on the receiver circuit board underneath the EMI/RFI shield. This LED lights when the receiver frequency synthesizer is unable to lock onto the required frequency.

During normal operation the Carrier Detect, Data, and Q-Sync LEDs will flash when a signal is received from the controller. The flashing will match the flashing of the green transmit LED on the controller.

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Section 2, Page 15

Check-out procedures.

After installing the receiver/decoder, it is necessary to perform the following checks. Completing these checks will perform a complete test of all system functions. If the receiver/decoder does not function properly at any step, stop the procedure and fix the error. Repeat that step and then continue on with the remaining steps.

NOTE: Verify the following before starting the check-out procedure. · Double check to ensure there are no other remote control systems assigned to the same address as the system being tested. Multiple systems may use the same frequency, but no two systems should share the same address even if they are on different frequencies. · The crane or controlled machine must be equipped with the proper braking devices. If a fault occurs in the remote control system, the Operate (OPR) relay will de-energize.

The machine must be capable of stopping if this happens or if a loss of power occurs. · Before applying power to the receiver/decoder, verify the correct supply voltage. If the system uses DC power, verify the correct polarity also.

1.

Remove power from the crane or machine motors. This may be done by opening the motor control power switches at the control panel for each motor.

2.

Connect control power and turn on the receiver/decoder. Observe the following sequence on the receiver/decoder display panel: · The display shows Fb momentarily during the hardware timer failure test. · The decoder then reads the address code switch and displays the address. · After approximately 5 seconds the decoder times out. The display changes to Fd. During this power- up self check, the receiver/decoder may display an error message if any of the self checks fail. Refer to ‘POWER-UP MESSAGES’ and ‘RUNTIME MESSAGES’ below which provides a complete listing of all display codes. Refer to the troubleshooting information in Section 4 to correct any problems.

POWER-UP MESSAGES .

DISPLAY CODE A- x

DESCRIPTION An ASO fault has occurred on the relay that is indicated by the number that follows this message. The user shall see the “A-” message followed by the relay number that produced this condition. x = the applicable relay number whose value shall be between 01 and 16.

L- x

A Loop-check fault has occurred on the relay that is indicated by the number that follows this message. The user shall see the “L- ” message followed by the relay number that produced this condition. x = the applicable relay number whose value shall be between 01 and 16.

Section 2, Page 16

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Check-out procedures, continued.

POWER-UP MESSAGES. DISPLAY CODE 01 through 16

DESCRIPTION Second part of the ASO fault message or the Loop-check fault message informing the user which output relay number has produced the condition.

Fb

A watchdog timer test failure has occurred.

FC

The main output relay (RLY 0) has Failed Closed.

Fo

The main output relay (RLY 0) has Failed Open.

88

A test of the LED segments of the display. This message may be seen briefly during decoder power- up.

F1

The OPR watchdog is being tested. This message may be seen during decoder power-up.

F2

The motor watchdog is being tested. This message may be seen during decoder power-up.

---------------------------------------------------------------------------------------------------------------------------xx * This message represents the decoder code plug address. It shall be displayed immediately after the F2 message.

-x *

This message displays the rotary switch positions. If the top horizontal bar is illuminated, the rotary switch being displayed is the HUNDREDS rotary switch.

If the middle horizontal bar is illuminated, the rotary switch being displayed is the TENS rotary switch. If the bottom horizontal bar is illuminated, the rotary switch being displayed is the UNITS rotary switch. The values for x are 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, b, C, d, E, and F.

* These symbols are ONLY displayed in Sub-Address Active Mode ---------------------------------------------------------------------------------------------------------------------------CC The reading of the EEPROM has failed.

SS

System Shutdown: The decoder firmware has detected an error that has caused the system to shutdown.

RUN-TIME MESSAGES. DISPLAY CODE A- x

DESCRIPTION An ASO fault has occurred on the relay that is indicated by the number that follows this message. The user shall see the “A-” message followed by the relay number that produced this condition. x = the applicable relay number whose value shall be between 01 and 16.

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Section 2, Page 17

Check-out procedures, continued.

RUN-TIME MESSAGES. DISPLAY CODE L- x

01 through 16 EA Eb nP

DESCRIPTION A Loop-check fault has occurred on the relay that is indicated by the number that follows this message. The user shall see the “L- ” message followed by the relay number that produced this condition. x = the applicable relay number whose value shall be between 01 and 16.

Second part of the ASO fault message or the Loop-check fault message informing the user which output relay number has produced the condition.

Error Address: A bad address has been received by the decoder.

Error bch: A bad BCH has been received by the decoder. no Power-up: No power- up message was received by the decoder.

nn

no neutral: No neutral message was received by the decoder. This message must follow the power- up message.

EE Error Estop: An E-stop has occurred. The controller address that sent the E-stop command shall be shown immediately after the EE message is seen.

FC The main output relay (RLY 0) has Failed Closed.

Fo The main output relay (RLY 0) has Failed Open.

FE The code-plug address is invalid or is missing.

EL Error Ladder: There is a problem with the ladder network.

---------------------------------------------------------------------------------------------------------------------------EF * This indicates the sub-address of the encoder does not match the sub-address of the decoder. This message shall be followed by the positions of the rotary switches that reside on the D32GIIA printed circuit board. The rotary switch which designates the hundreds position is SW1. Its value shall be shown first in the display of the decoder sub-address. The user shall always see a ‘0’ in the left digit of the LED display with the hundreds rotary switch position being displayed in the right digit. The rotary switch which designates the tens position is SW2, and the rotary switch which designates the units position is SW3. The LED display shall show the tens rotary switch position in the left digit and the units rotary switch position in the right digit. The ‘EF’ message shall be shown, then the hundreds switch position, followed by the ‘EF’ message again, and finally, the tens and units switch positions. This display cycle shall continue until the sub-addresses match. * These symbols are ONLY displayed in Sub-Address Active Mode ---------------------------------------------------------------------------------------------------------------------------SS System Shutdown: The decoder firmware has detected an error that has caused the system to shutdown. oL

Section 2, Page 18

onLine: The encoder that has been powered down is online with the D32GII decoder board until the address timeout has expired. ã04/2006, CATTRON-THEIMEG™

Check-out procedures, continued.

Figure 2-10 below lists the hexadecimal codes displayed when the ASO circuit detects a relay closed with no corresponding command signal from the controller. Relays 1 through 8 are the relays on the right hand relay output board, labeled 1 through 8 downwards after the OPR relay. Relays 9 through 16 are the relays on the left hand relay output board labeled 9 through 16 upwards after the OPR relay.

Note that the OPR relay on each of the two relay output boards is not counted in the relay numbering/ hexadecimal code sequence. Consequently, ‘FC’ is a system status display code which indicates the OPR relay(s) has failed shut.

Figure 2-10. ASO hexadecimal codes

DISPLAY CODE

A0

DISPLAY CODE RELAY 16

OPR RELAY

FC = OPR relay failed shut

AF

RELAY 15

RELAY 1

A1

AE

RELAY 14

RELAY 2

A2

Ad

RELAY 13

RELAY 3

A3

AC

RELAY 12

RELAY 4

A4

Ab

RELAY 11

RELAY 5

A5

AA

RELAY 10

RELAY 6

A6

A9

RELAY 9

RELAY 7

A7

FC = OPR relay

OPR RELAY

RELAY 8

A8

LEFT HAND SIDE RELAY OUTPUT BOARD

RIGHT HAND SIDE RELAY OUTPUT BOARD

failed shut

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Section 2, Page 19

Check-out procedures, continued.

1.

2.

3.

· ·

·

·

Check the controller and receiver/decoder for matching frequencies and address codes.

The controller and receiver/decoder must have identical frequencies and address codes.

Remove the lid from the gold box. With the receiver/decoder power still on, switch on power to the controller.

While observing the receiver/decoder, press an auxiliary control button on the controller, such as a light, horn, or siren. Refer to Figure 2-9 on page 14 and observe the following indications on the receiver/decoder: The red Receiver Power LED on the receiver board is lit steadily, indicating power is present at the receiver circuit board.

The green Carrier Detect LED on the receiver flashes in sync with the green transmit LED on the controller. This indicates that the receiver is receiving the RF signal from the controller.

The yellow Data and orange Q-Sync LEDs on the receiver flash in sync with the green transmit LED on the controller. This indicates that the DATA and SYNC signals are being received and processed.

The two digit code on the system status display indicates the address of the decoder.

· The dot to the right of the first digit of the system status display flashes in sync with the green transmit LED on the controller. · The Operate (OPR) relay(s) on the output relay board(s) is energized. The Operate (OPR) relay LED next to the relay will light, indicating that the relay is energized.

During operation, the two-digit code on the system status display may momentarily display the code EA. This indicates that the receiver is receiving a signal with an improper address code which may be caused by RF interference. This occurrence may be OK, provided the amount of EA errors are minimal. If the dot to the right of the first digit of the decoder system status display is continuously illuminated, contact CATTRON-THEIMEG™ .

4.

Check all system functions in accordance with the specific custom model drawings.

Observe the relay status LEDs next to each relay as the function on the controller is activated. The red LED should light, indicating that the relay is energized. Check each output with a volt/ohm meter to ensure that the relay is closing properly, and that the fuse for the output is good.

5.

Press and hold one function on the controller. While holding the function, turn off power to the controller using the ON/OFF switch. All function outputs must de-energize within one second. On non- licensed systems the OPR relay will remain energized for 10 minutes. This test simulates a loss of the controller signal.

Section 2, Page 20

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Check-out procedures, continued.

6.

7.

8.

9.

For non-licensed systems only, restore power to the controller. Activate and maintain a function switch on the controller. While holding the function switch, observe the relays on the relay output board and push down the red System STOP button on the controller. All relays on the relay output board including OPR should immediately deenergize, as indicated by all LEDs turning off. The display on the decoder will display EE. To restore operation of the system, set the STOP switch on the controller to the ‘RUN’ position and cycle power to the controller by setting the ON/OFF switch to ‘OFF’ and then ‘ON’.

Return the machine motor control switches to the ON position.

Check each controller function carefully. Observe the system for proper operation of all functions.

Check for proper range of control. Operate the various machine functions while moving around in the system’s operating area. Move to the extreme edges of the operating area and ensure that the system functions still operate properly. Control should be maintained at all times.

If all the above steps are completed successfully, your 816 Series PRC system is now fully operational.

END OF SECTION

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Section 2, Page 21

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Section 3 – Operating Instructions General.

During normal operation, the CATTRON-THEIMEG™ AT and ATS 816 series receiver/decoders require no operator action. The receiver/decoder is designed to operate completely unattended. All interfaces with the system are through the remote controller.

For controlling the system, CATTRON-THEIMEG™ offers several models of controllers. These models include single and dual pressure keypad controllers, toggle controllers, and paddle controllers.

For special installations, CATTRON-THEIMEG™ can custom-build a controller in any form to meet your exact specifications.

For information on operating the controller, refer to the instruction manual provided with the controller.

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Section 3, Page 2

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Section 4 – Maintenance General.

CAUTION: Electrostatic sensitive devices such as EPROMs are present on circuit boards. Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving circuit boards and electrostatic sensitive devices. Failure to comply with this caution may result in equipment damage and will void our warranty.

There are two basic types of maintenance: preventive and corrective. Preventive maintenance is a periodic check of the system to keep it functioning at peak performance. Preventive maintenance can also help prevent breakdowns and equipment outages by identifying potential problems before they become real problems. Corrective maintenance refers to fixing a problem once it has occurred. The goal of corrective maintenance is to get the system back on line as quickly as possible with a minimum impact on operations.

Any maintenance philosophy needs to encompass the entire system with the major components being the power supply, the receiver/decoder, the controller, and the antenna. A failure of any of these components prevents the entire system from functioning. As a result, the maintenance program needs to include all of these components.

When performing corrective maintenance, observe the following guidelines: · Tag all leads prior to de-soldering or removal from a terminal board. Use small wire tags or pieces of adhesive tape with handwritten numbers. Reconnect all wires to the same location from which they were removed.

NOTE:

Microprocessor devices, as used in CATTRON-THEIMEG™ PRC systems, use programmable EPROMs for program storage. Proper part numbers, version numbers and, in some cases, revision numbers must be used when installing spare circuit boards.

· Replace damaged or defective parts with identical parts. If it is necessary to use substitute parts, replace them with the correct part as soon as possible. The substitute part must have identical electrical properties. · Relocation of any part may result in a hum or other interference. Relocation of parts is not recommended.

©04/2006, CATTRON-THEIMEG™

Section 4, Page 1

General, continued. · Before soldering any connections, carefully scrape all parts that will be touched by solder until all rust, corrosion, paint, and/or varnish are removed. Dust the parts with a small, clean, brush. Tin all surfaces to be soldered. Wrap the wire around the lug for a good mechanical connection and support prior to soldering. Solder the connection using a minimum of solder with sufficient heat to make the solder flow evenly around the tinned surface. · Inoperative systems are normally repaired by circuit board substitution. If possible, the entire EMI/RFI shielded chassis, the ‘gold box’, should be returned to CATTRONTHEIMEG™ for testing and repair. Make sure all optional jumpers are properly configured and the proper address code and frequency are set prior to applying power.

Failed circuit boards should be tagged with a description of the fault and sent to CATTRON-THEIMEG™ for repairs. · Mount all replacement parts in the same location using the same mounting arrangement as the previous part. Fasten all mounting hardware firmly.

Preventive maintenance.

Every three months perform the ‘post installation checks’ outlined in Section 2. This procedure provides a thorough check of the entire remote control system.

Typical additional checks.

The following additional checks should be performed on a periodic basis. Simple visual checks of the equipment provide a good early warning of any potential problems and take very little time to perform.

Additional checks such as fuses and power supply tests can be performed every three months when carrying out ‘post installation checks’.

Primary power supply.

Primary power sources should be the first step in performing preventive maintenance as they are always suspect in problems dealing with AC circuits. The supply voltages can often be too high as well as too low. Loose connections on fuses can occur even on an AC system. With the system deenergized, check for ‘hot’ fuses and connections.

Fuses.

Fuses, sometimes even when new, may have too high a resistance. Check the fuse and replace if the voltage drop across the fuse exceeds 0.1 volt.

Section 4, Page 2

©04/2006, CATTRON-THEIMEG™

Preventive maintenance, continued.

Fuse holders.

Fuse holders may loosen or corrode. Accumulation of oil and dirt increases contact resistance. If this occurs, clean the contacts and tighten or replace the fuse holders.

Unit assemblies.

Unit assemblies include the receiver/decoder, controller, and relay output rack(s). To catch a maximum number of problems the technician must use his ears, eyes, sense of touch, and meter measurements, as well as past experience and good judgment.

Three types of basic observation are required: 1.

Visual inspection – Check for loose bolts, screws and clamps, arcing condition, and loose connections. A good visual inspection not only means quickly locating a source of potential problems, but also may prevent serious problems from developing later.

WARNING: DE-ENERGIZE AND TAG OUT ALL SOURCES OF ELECTRICAL POWER BEFORE CARRYING OUT TOUCH TESTS ON EQUIPMENT. FAILURE TO PROPERLY DE-ENERGIZE EQUIPMENT MAY RESULT IN DEATH OR SERIOUS INJURY FROM ELECTRIC SHOCK.

2.

Touch tests – Fuses, fuse holders, resistors, and transformers that are too hot indicate possible trouble spots. Such tests are quick and should be used often.

3.

Status display interpretation – Simulation of faults, such as ASO, while observing the display will re-enforce the understanding of normal operating characteristics. This allows quick troubleshooting of any faults which may occur.

Antenna system.

Periodically conduct inspections of the antenna(s), antenna mounting device(s), cables, and connectors.

Perform meter checks to find any open or shorted lines or any high standing wave ratios. Performance checks are important to ensure that the minute voltages picked up from the transmitter are transferred properly to the receiver.

Netting.

Netting means that the receiver and transmitter of the radio control system are aligned on the same frequency. It is very important that the receiver is exactly tuned to the frequency required. This check should be done once a year by a qualified radio technician.

©04/2006, CATTRON-THEIMEG™

Section 4, Page 3

Adjustments.

During normal system operation, there are no adjustments that need to be made to the receiver/decoder. Nearly all adjustments to the receiver/decoder are made during system installation.

The only setting that may require adjustment after installation is the squelch adjustment.

NOTE

The squelch control should not be adjusted except by trained personnel.

Tampering with the squelch could leave the receiver inoperable.

Referring to Figure 4-1 below, under normal operating conditions, when a carrier signal at a level just above the squelch limit of the receiver is detected, the receiver’s green Carrier Detect LED will turn on. If the carrier signal contains data and a Q-Sync pulse as would be the case if the signal had been transmitted from a CATTRON-THEIMEG™ controller, the receiver’s orange Data LED and yellow QSync LED would also turn on. In actual operation, these three LEDs will flash rhythmically with each transmission of the controller. This can be easily seen by observing the green transmit LED on the controller in conjunction with the receiver’s carrier detect, data, and Q-Sync LEDs. They will flash in unison.

In certain environments the squelch control may require adjustments. If the green Carrier Detect LED is on continuously, there may be an interfering signal on the selected operating frequency. The first option is to try to remove the interfering signal. If the signal cannot be removed, the squelch may need to be adjusted.

To adjust the squelch setting, turn on power to the receiver/decoder and turn off power to all controllers. Referring to Figure 4-1 opposite, while observing the green Carrier Detect LED, slowly rotate the squelch control potentiometer until the LED just turns off. This will set the receiver to a level where it will mask the interfering signals. Note that adjusting the squelch level will also reduce the receiver’s range. After adjusting the squelch, check the work area for range of control. Other options that may be affected by adjusting the squelch include the Range Limiter, Range Extender, and Close Start.

Adjustment of the squelch control is limited and may not be sufficient to solve the interference problem. A frequency change to another clearer channel, or the use of an attenuator to make the receiver less susceptible to overloading and distortion caused by strong signals on other adjacent channels may be required. Refer to Section 2 for attenuator details.

Section 4, Page 4

©04/2006, CATTRON-THEIMEG™

Adjustments, continued.

Figure 4-1. Squelch adjustment

Q-SYNC LED

SQUELCH CARRIER CONTROL DETECT LED

DATA LED

RECEIVER BOARD

816 Series Receiver/Decoder Troubleshooting.

Table 4-1 below, is arranged in a simple problem/cause/correction format. The possible faults are arranged in order from most likely to least. Perform all steps in the order listed when troubleshooting.

Table 4-1. Troubleshooting table

Problem

Cause

Correction

Receiver/Decoder ‘dead’. No status display light on decoder. No lights on receiver.

Loss of 110 VAC input power.

Check for 110 VAC power on input terminals in receiver/decoder.

Bad circuit breaker.

Check circuit breaker. Replace faulty circuit breaker.

Faulty power supply.

Check for 13.5 VDC output from power supply. If 13.5 VDC is not detected on power supply output terminals, replace power supply.

Faulty decoder.

Check for l3.5 VDC power to decoder. If 13.5 VDC is present, replace decoder.

Faulty wiring from power supply to decoder.

Measure DC voltage input to decoder at P6 from the red wire, V+, to the black wire, ground (see figure 4-6 on page 16 of this section for P6 location). If 13.5 VDC is present, replace decoder. Otherwise check and replace wiring from power supply to decoder as necessary.

Power on at receiver, but no power at decoder.

©04/2006, CATTRON-THEIMEG™

Section 4, Page 5

816 Series Receiver/Decoder Troubleshooting , continued.

Table 4-1. Troubleshooting table (continued)

Problem

Cause

Correction

Decoder completes power on test correctly, but will not accept commands from controller.

Receiver LEDs do not flash.

Wrong controller, or wrong controller frequency.

Ensure the correct controller is being used for this system. When installed, ensure the STOP switch on the controller is in the ‘RUN’ position and the ON/OFF switch on the controller is set to ‘ON’.

Ensure the controller is set to the same frequency as the receiver. Refer to the controller manual for information on checking and setting the controller frequency.

Controller not functioning.

Activate a safe, non- motion, function on the controller and observe the green Carrier Detect LED on the receiver. If the LED does not blink, check the green Transmit LED on the controller. If it is not blinking, check and replace/re-charge the controller batteries, or replace controller.

Decoder and controller address code not matched.

Check the system status display. If the display shows the code EA when a function is commanded, the addresses for the controller and decoder do not match.

Check the address code displayed during decoder power up sequence. If address is not correct, replace the code plug. Refer to the Code Plug Replacement procedure later in this section for information on setting the address and replacing the code plug. If the displayed address code is correct, the controller address code may be incorrect. Check the controller manual for instructions on changing the controller address code.

Faulty receiver, or excessive RF interference.

If Carrier Detect LED on receiver circuit board is on steadily, then there may be excessive RF interference on the selected channel, or the receiver may be faulty.

Check the system status display code. The codes E5, EA, Eb, EC, and EF may all indicate RF interference. Replace receiver with a spare. If indications remain unchanged, contact CATTRONTHEIMEG™ or perform a site spectrum analysis to locate and correct the interfering RF source.

Decoder completes power on test correctly, but will not accept commands from controller.

Receiver LEDs flash.

Section 4, Page 6

©04/2006, CATTRON-THEIMEG™

816 Series Receiver/Decoder Troubleshooting , continued.

Table 4-1. Troubleshooting table (continued)

Problem

Cause

Correction

Primary controller faulty but spare controller good.

Dead battery pack.

Replace/recharge battery packs.

Controller set to wrong address and/or frequency.

Check the system status display code. A code of EA indicates the controller and decoder are not set to the same address. Refer to controller manual and check/change address code and frequency.

Faulty controller.

If the above checks do not correct the problem, return the controller to CATTRON-THEIMEG™ for repair.

Antenna damaged or not installed properly.

Inspect antenna for any damage, including shorts, opens, and improper grounds. If a signal generator is available, test receiver sensitivity from the antenna location through the coaxial antenna cable to the receiver. Sensitivity should be 0.8 mV for 20dB quieting. Replace any antenna components found to be damaged.

Bad controller.

Substitute a spare controller.

Bad receiver.

Replace receiver. Refer to the Receiver Replacement procedure later in this section.

Decoder has registered an error.

Check decoder for any error messages. Refer to ‘POWER-UP MESSAGES’ and ‘RUNTIME MESSAGES’ in Section 2 for an explanation of system status display codes. Correct any faulty conditions resulting in error codes.

Decoder, relay, or interface wiring failure.

Check status LED for the Operate (OPR) relay. If LED is not lit when a function is activated, replace decoder per Decoder Replacement paragraph later in this section. If LED lights when the function is activated, inspect the wiring and associated fuse.

Replace relay per Relay Replacement procedure later in this section.

Unit works up close, but fails at longer ranges.

Controller, and receiver/decoder function properly, but mainline contactor will not pick up.

©04/2006, CATTRON-THEIMEG™

Section 4, Page 7

816 Series Receiver/Decoder Troubleshooting , continued.

Table 4-1. Troubleshooting table (continued)

Problem

Cause

Correction

Mainline contactor picks up, but certain output functions don’t work.

Controller is not sending a command.

If the controller is equipped with a PTO bar switch, it must be depressed along with the function switch to send certain commands.

Controller is defective.

Observe the green Carrier Detect LED on the receiver circuit board. It should blink rapidly whenever a function switch is activated on the controller. If the Carrier Detect LED does not blink, replace the controller.

Faulty relay, ribbon cable, or decoder board.

If the Carrier Detect LED blinks when the controller is activated but the Relay Status LED is not lighting, swap the relay out with another known functional relay. If that relay does not function, check the ribbon cable for damage and ensure all connector pins are within the header. If the ribbon cable is serviceable, the decoder is faulty. Replace the decoder circuit board per Decoder Replacement paragraph, later in this section.

Faulty wiring, no power to device being controlled.

Check the following items: power to the device being controlled, output relay operational in another position, associated fuse is in good condition, interface wiring to the driven device is in good condition, terminal screws tight, driven device functional. Repair all defective components.

Error code displayed on system status display.

The system status display shows an error code any time a malfunction occurs.

Refer to ‘POWER-UP MESSAGES’ and ‘RUNTIME MESSAGES’ in Section 2 for a complete description of all error codes. Correct any faulty conditions found.

Blown fuses on relay output board.

Overload condition in controlled machinery.

Check for shorted motor starters, contactors, or interface wiring. Ensure controlled device is in good functioning condition. Repair any defective equipment identified and replace fuse.

Section 4, Page 8

©04/2006, CATTRON-THEIMEG™

Automatic Safety Override (ASO).

The Automatic Safety Override (ASO) feature continually monitors the status of all relays. If any relay energizes when there is no corresponding signal from the controller, the ASO circuit will immediately de-energize the Operate (OPR) relay(s). This safety feature prevents uncommanded movement of any controlled equipment due to a shorted relay output by disconnecting power to the mainline contactor on the controlled equipment.

A simple test checks the functionality of the ASO circuit. Refer to Figure 4-2 below and the following procedure to test the ASO circuit.

WARNING: HIGH VOLTAGE MAY BE PRESENT ON THE RELAY OUTPUT TERMINALS. EXERCISE CAUTION WHEN WORKING NEAR THE RELAY OUTPUT BOARD(S). FAILURE TO OBSERVE THIS WARNING MAY RESULT IN DEATH OR SERIOUS INJURY FROM ELECTRIC SHOCK. WARNING: REMOVE POWER FROM THE CRANE OR MACHINE MOTORS BEFORE PERFORMING ASO TESTS. THESE TESTS REQUIRE THE ENERGIZING OF THE OUTPUT RELAYS USING JUMPERS. ENERGIZING THE RELAYS WHILE POWER IS APPLIED TO THE SYSTEM MOTORS MAY RESULT IN UNDESIRED MOVEMENT OF THE CRANE OR MACHINE. IN ADDITION, DAMAGE TO THE CIRCUIT BOARDS MAY RESULT IF THE TEST JUMPER CONTACTS THE WRONG COMPONENT. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.

ASO Circuit Test Procedure.

1.

When installed to the controller, set the system STOP switch to ‘STOP’ and the ON/OFF switch to ‘OFF’. This will completely isolate the controller.

2.

Remove power from the crane or machine motors. This is normally done by opening the circuit breakers for the motors at the motor control panels.

3.

Open the receiver/decoder door to access the relay output boards.

4.

Referring to Figure 4-2 below, touch one end of a test jumper to the GND (TEST) test point on the relay output board. Touch the other end of the jumper to the ASO TP test point next to relay #0, the Operate (OPR) relay.

©04/2006, CATTRON-THEIMEG™

Section 4, Page 9

ASO Circuit Test Procedure, continued.

Figure 4-2. ASO test points P2

P1

Relay 8

Relay 7

Relay 6

Relay 5

Relay 4

Relay 3

ASO T.P.

Relay 2

Relay 1

Relay 0 (OPR)

RELAY OUTPUT BOARD

GND (TEST) TEST POINT ASO T.P.

ASO T.P.

ASO T.P.

ASO T.P.

ASO T.P.

ASO T.P.

ASO T.P.

ASO T.P.

GND (TEST)

ASO TP TEST POINT

5.

Relay #0 will energize, simulating a fault in the OPR relay circuit. The system status display will show the fault as an error code FC. Set the controller to ‘ON’ and activate a non- motion function, such as a horn, siren, or light. The decoder should not operate, and the commanded action should not occur. Set the controller to ‘OFF’ and remove the jumper end from the ASO TP test point.

6.

Apply power to the controller (set the controller to ‘OFF’ and then to ‘ON’). Relay #0 should energize.

7.

Touch the free end of the jumper to the ASO TP test point for each of the remaining relays one at a time. The relay should energize. The ASO circuit will detect the relay energizing without a controller command and immediately de-energize relay #0, preventing any uncommanded movement of the machine. The system status display will show an error code indicating which relay activated the ASO circuit. For example, an error code of A4 indicates rela y #4 failed.

8.

If any relay fails the ASO test, replace the relay and repeat the test. If the relay fails again, replace the decoder board per the procedure later in this section.

9.

After testing all relays, remove the jumper from the ASO TP and GND (TEST) test points and close the cover of the receiver/decoder.

10.

Switch off and isolate the controller before restoring power to the crane or machine motors.

Section 4, Page 10

©04/2006, CATTRON-THEIMEG™

Receiver/Decoder Repair.

Replacing the EMI/RFI shielded chassis (gold box).

Replacing the EMI/RFI shielded chassis, or ‘gold box’, with a spare unit is the easiest and fastest way of correcting problems with the receiver/decoder. The gold box can then be returned to CATTRONTHEIMEG™ for repair. This is the recommended method of repair when the technician has not been trained on repairing CATTRON-THEIMEG™ receiver/decoders. Due to the interaction between the various electronic circuits, some errors may be difficult or impossible to track down without proper training or test equipment. This could result in sending the wrong part back to the factory for repair. In most cases it is simpler to just remove and replace the entire gold box.

Referring to Figure 4-3 below, replace the ‘gold box’ as follows: 1.

Open the cover of the receiver/decoder.

2.

Remove power from the gold box by turning off the circuit breaker on the bottom.

3.

Note the receiver frequency and decoder address printed on a label on the side of the gold box. The replacement gold box must be set to the same frequency and address.

Figure 4-3. EMI/RFI shielded chassis replacement

©04/2006, CATTRON-THEIMEG™

Section 4, Page 11

Replacing the EMI/RFI shielded chassis , continued.

4.

Disconnect the plug between the 110 VAC power input line and the gold box.

5.

Disconnect the antenna connector from the bottom of the gold box.

NOTE:

Take care not to bend the gold box connector pins in the following step.

When disconnecting the ribbon cable, carefully work the header slowly away from the connector pins.

6.

Disconnect the ribbon cable connecting the gold box to the relay output boards.

7.

Loosen the four nuts securing the gold box to the cover of the receiver/decoder and withdraw the gold box from the receiver/decoder.

8.

Place the new gold box on the door of the receiver/decoder and secure with the four nuts loosened in step 7.

NOTE:

When connecting the ribbon cable in the following step, the red strip on the ribbon cable header should align with the red spot on the gold box connector. Insure all gold box connector pins are located within the ribbon cable header.

9.

Make sure the ribbon cable adapter is connected in- line with the ribbon cable from the relay output board and the ribbon cable to the gold box.

10.

Connect the antenna cable to the connector on the bottom of the gold box.

11.

Connect the 110 VAC power cable to the plug from the input terminal block.

12.

Compare the frequency and address code for the new gold box to the frequency and address code from the old gold box. When applicable, set the frequency per Section 2 of this manual and replace the code plug using the procedure found later in this section.

13.

Restore power to the receiver/decoder. Close and secure the cover on the receiver/decoder.

14.

Perform a functional check of the PRC System (refer to Checkout Procedures in Section 2 of this manual).

Relay replacement.

Referring to Figure 4-4 below, replace an output relay as follows: 1.

Open the cover of the receiver/decoder.

2.

Remover power from the receiver/decoder by turning off the circuit breaker located on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

3.

Gently pull away the two retaining tabs on the sides of the relay being removed.

4.

Pull the relay from the relay output board.

5.

Verify that the replacement relay is the same type as the relay removed.

Section 4, Page 12

©04/2006, CATTRON-THEIMEG™

Relay replacement, continued.

6.

Install the new relay on the relay output board. Ensure that the relay orientation matches the orientation of the other relays installed. The relay is keyed to only fit in one direction. Do not force the relay onto the board. If it does not fit easily into the socket, remove the relay, check the orientation and pins, and try again.

7.

After installing the new relay, ensure the retaining tabs snap into place to hold the relay.

8.

If desired, restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

9.

Close and fasten the cover of the receiver/decoder.

Figure 4-4. Relay replacement RETAINING TABS

ASO T.P.

RELAY ASO T. P. GND (T EST)

Receiver replacement.

CAUTION: Electrostatic sensitive devices such as EPROMs are present on circuit boards.

Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving circuit boards and electrostatic sensitive devices. Failure to comply with this caution may result in equipment damage and will void our warranty.

When replacing the receiver circuit board, the new receiver must have the same frequency as the old receiver. Failure to match the frequencies will result in the receiver/decoder not receiving commands from the desired controller. Matching frequencies is accomplished by (1) verifying the EPROM part number (see next paragraph), and (2) setting the rotary frequency selector switch to the same position on the new receiver as the old receiver. Refer to the programming information provided with your customized documentation package.

As indicated above, the new receiver must have the same EPROM as the old receiver. The EPROM determines frequency and contains the program for the receiver. Check the part number on the label of the EPROM before replacing the receiver. If the EPROM does not match, contact CATTRON-THEIMEG™ . ©04/2006, CATTRON-THEIMEG™

Section 4, Page 13

Receiver replacement, continued.

Referring to Figure 4-5 below, replace the receiver circuit board as follows: Figure 4-5. Receiver replacement

RECEIVER CIRCUIT BOARD

GOLD BOX

ROTARY FREQUENCY SELECTOR SWITCH

MOUNTING SCREW

ANTENNA LEAD GOLD BOX LID

POWER AND SIGNAL WIRING CONNECTOR

1.

Open the cover of the receiver/decoder.

2.

Remove power from the EMI/RFI shielded chassis, or ‘gold box’, by turning off the circuit breaker on the bottom. Remove the lid from the gold box.

3.

Note the receiver frequency by checking the EPROM part number and noting the position of the rotary frequency selector switch. The new receiver circuit board must have the same EPROM part number and also be set to the same frequency.

4.

Disconnect the antenna lead from the receiver circuit board.

5.

Disconnect the power and signal wiring connector from the header on the receiver circuit board.

Section 4, Page 14

©04/2006, CATTRON-THEIMEG™

Receiver replacement, continued.

6.

Remove the four mounting screws securing the receiver.

7.

Remove the receiver circuit board from the gold box.

8.

Set the frequency of the new receiver to the same frequency as the old receiver. This is done by matching EPROM part numbers and the positions of the rotary frequency selector switches.

9.

Install the new receiver into the gold box and secure with the four mounting screws.

10.

Connect the power and signal wiring connector to the receiver terminal strip.

11.

Connect the antenna lead to the receiver.

12.

Install the lid on the gold box.

13.

If desired, restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

14.

Close the cover of the receiver/decoder.

15.

Perform a functional check of the PRC System (refer to Checkout Procedures in Section 2 of this manual).

Decoder replacement.

CAUTION: Electrostatic sensitive devices such as EPROMs are present on circuit boards.

Use an anti-static mat and personal grounding strap (wrist) for all maintenance procedures involving circuit boards and electrostatic sensitive devices. Failure to comply with this caution may result in equipment damage and will void our warranty.

When replacing the decoder circuit board, the new decoder must have the same address code as the old decoder. Failure to match the address code will result in the receiver/decoder not receiving commands from the desired controller. Matching the address code is accomplished by removing the code plug from the old decoder and installing it in the new decoder.

The code plug is secured in place by silicon sealant. This sealant prevents the code plug from vibrating free of its socket. Proper care must be taken to ensure that no components are damaged when removing the silicon sealant. After inserting the new code plug, it must be secured in place with a new application of silicon sealant. If the new decoder has the correct code plug installed, then the code plug will not need to be replaced. The address code of the decoder board may be checked by observing the address code displayed when the receiver/decoder is powered up.

The new decoder must also have the same EPROM as the old decoder. The EPROM contains the program for the decoder governing the behavior of the receiver/decoder. Check the part number on the label of the EPROM prior to replacing the decoder. If the EPROM does not match, contact CATTRON-THEIMEG™ .

When swapping out or installing an EPROM, refer to EPROM Replacement at the end of this Section. ©04/2006, CATTRON-THEIMEG™

Section 4, Page 15

Decoder replacement, continued.

Referring to Figure 4-6 below, replace the decoder circuit board as follows: 1.

Open the cover of the receiver/decoder.

2.

Remove power from the receiver/decoder by turning off the circuit breaker on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

3.

Remove the lid from the gold box.

4.

Disconnect the power and signal wiring connector from the header on the decoder circuit board.

5.

Observe and record the EPROM part number. The replacement decoder circuit board must have the same EPROM part number.

6.

Remove the four mounting screws securing the decoder circuit board.

7.

Carefully lift the left side of the decoder circuit board. Slide the board to the left to disengage the connector from the pins on the side of the gold box.

Figure 4-6. Decoder replacement

DECODER CIRCUIT BOARD POWER AND SIGNAL CONNECTOR

POWER AND SIGNAL HEADER (P6)

GOLD BOX

GOLD BOX CONNECTOR PINS CODE PLUG

GOLD BOX LID

EPROM

Section 4, Page 16

MOUNTING SCREW

©04/2006, CATTRON-THEIMEG™

Decoder replacement, continued.

NOTE:

When installing a new decoder circuit board in the following step, insure all gold box connector pins are aligned with and properly located within the circuit board header.

8.

Install the new decoder circuit board by carefully lining up the header on the right side of the circuit board with the connector pins on the side of the go ld box and sliding the circuit board firmly to the right.

9.

Install the four mounting screws securing the decoder circuit board to its mounting studs.

10.

Connect the power and signal wiring connector to the decoder header.

11.

Note the address codes of the new and old decoder circuit boards, as marked on their respective code plugs (the address of the old decoder is also printed on a label attached to the outside of the gold box). If the address of the new decoder does not match the address of the old decoder, the code plug installed in the new decoder circuit board may be replaced with the code plug from the old decoder circuit board.

12.

To replace the code plug, turn off the power to the receiver/decoder. Carefully cut away the silicon sealant holding the code plug. Remove the code plug by pulling straight up and away from the board. Remove the code plug from the old decoder circuit board in the same fashion. Install the code plug in the new circuit board and secure in place with a new application of silicon sealant.

13.

Install the lid on the gold box.

14.

If desired, restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

15.

Perform a functional check of the PRC System (refer to Checkout Procedures in Section 2 of this manual).

Code plug replacement.

Each CATTRON-THEIMEG™ receiver/decoder and controller is equipped with a code plug. This code plug contains the address of the receiver/decoder or controller. When a command is received by the receiver/decoder, the address of the controller sending the signal is checked against the address of the receiver/decoder. If the addresses do not match, the signal is ignored and an error message is displayed on the receiver/decoder. For safety reasons, it is important that no two receiver/decoders at a location use the same address and frequency settings. This could cause operation of undesired equipment resulting in damage to equipment and/or personal injury.

While the factory settings should be adequate for most users, there may be conditions where it is necessary to change the address code. This may be necessary when installing a spare receiver/decoder or controller. Prior to making any change in the address setting, check the address settings on both the receiver/decoder and the controller.

©04/2006, CATTRON-THEIMEG™

Section 4, Page 17

Code plug replacement, continued.

On some controllers, the factory assigned address code can be found by removing the battery cover and battery. For information on setting the code for your controller, refer to the documentation provided with the controller.

The code assigned to the receiver/decoder at the factory is found on a label placed on the side of the ‘gold box’. A code plug installed on the decoder circuit board sets the code. CATTRON-THEIMEG™ sets the code of all receiver/decoders before they leave the factory. If the code must be changed, a new code plug with the new code must be obtained from CATTRON-THEIMEG™ . In some circumstances CATTRON-THEIMEG™ may provide blank, or unset, code plugs. An unset code plug must have a code set prior to installing in the decoder. This is described in the procedure below. Installing an unset code plug will produce an error code and the receiver/decoder will not operate.

To replace the code plug for the receiver/decoder, follow the procedure below: 1.

Open the cover of the receiver/decoder.

2.

Remove power from the receiver/decoder by turning off the circuit breaker on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

3.

Remove the lid from the gold box.

4.

Find the code plug located on the decoder circuit board. The code plug location is shown in Figure 4-7.

5.

Carefully cut away the silicon sealant holding the code plug. Remove the old code plug by pulling straight up and away from the decoder board.

Figure 4-7. Code plug location DECODER BOARD

6.

CODE PLUG LOCATION

If the new code plug is blank, set the new code. To set the code, leads 2 through 8 must be cut in a specific pattern. Figure 4-8 opposite shows all possible codes for the code plug. For example, to set the code plug to code 26, leads 3, 4, and 7 must be cut.

Section 4, Page 18

©04/2006, CATTRON-THEIMEG™

Code plug replacement, continued.

Figure 4-8. Code plug settings

©04/2006, CATTRON-THEIMEG™

Section 4, Page 19

Code plug replacement, continued.

7.

8.

9.

10.

Install the new code plug and secure in place with a new application of silicon sealant.

Replace the lid on the gold box.

Close the cover of the receiver/decoder. If desired, restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

Perform a functional check of the PRC System (refer to Checkout Procedures in Section 2 of this manual).

EPROM replacement.

Replace an EPROM as follows: CAUTION: EPROMs are electrostatic sensitive devices. Use an anti-static mat and personal grounding strap (wrist) when replacing or installing EPROM’s.

Failure to comply with this caution may result in equipment damage and will void our warranty.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11

Open the cover of the receiver/decoder.

Remove power from the receiver/decoder by turning off the circuit breaker on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

Remove the lid from the gold box.

Find the EPROM located on the decoder circuit board. The EPROM location is shown in Figure 4-6.

Observe and record the exact orientation of the EPROM within its circuit board location.

Remove the EPROM. Carefully install the new EPROM in the vacated circuit board location, making sure its orientation is exactly the same as recorded in step 5 above.

Replace the lid on the gold box.

Close the cover of the receiver/decoder. If desired, restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the gold box.

Perform a functional check of the PRC System (refer to Checkout Procedures in Section 2 of this manual).

Return the EPROM to CATTRON-THEIMEG™ .

END OF SECTION

Section 4, Page 20

©04/2006, CATTRON-THEIMEG™

Section 5 – Parts List and Accessories Introduction.

The following two figures and tables provide an exploded view of the CATTRON-THEIMEG™ AT and ATS 816 Series receiver/decoder. Figure 5-1 shows the entire receiver/decoder. Figure 5-2 shows only the EMI/RFI shielded chassis (Gold Box) and its internal components. Cross refer to Table 5-1 or Table 5-2, respectively, for a complete part listing for that drawing.

The Accessories section, following the parts lists, provides information on some optional equipment to enhance the functionality of the receiver/decoder.

ã04/2006, CATTRON-THEIMEG™

Section 5, Page 1

Figure 5-1. AT & ATS 816 Series PRC Receiver/decoder - exploded view (illustrated parts breakdown)

Table 5-1. AT & ATS 816 Series PRC Receiver/decoder parts list

Index #

Part Number

Description

1

CPA-0228-12STL

Enclosure, painted steel, NEMA 12 (IP65), pre-wired with back panel *

16C-0087

Same as above, enclosure only

CPA-0228-4STL

Enclosure, painted steel, NEMA 4 (IP66), pre -wired with back panel *

16C-0220

Same as above, enclosure only

CPA-0228-4XSS

Enclosure, stainless steel, NEMA 4X (IP66), pre-wired with back panel *

16C-0247

Same as above, enclosure only

CPS-0228-4XFIB

Enclosure, fiberglass, NEMA 4X (IP66), pre-wired with back panel *

16C-0251

Same as above, enclosure only

Section 5, Page 2

ã04/2006, CATTRON-THEIMEG™

Table 5-1. AT & ATS 816 Series PRC Receiver/decoder parts list, continued

Index #

Part Number

Description

2

CPA-0217

Cable, antenna (includes items 3, 4, and 5 below)

3

Connector, antenna, PL259

4

Lock washer

5

Nut

6

85C-0035

Antenna, flex-whip, UHF

Not shown

CPA-0150

Antenna assembly, triple diversity, for Range Limit/Range Extender capabilities of R1014T2 receivers

7

Wing nut

8

Washer

9

Seal

10

32C-0021

Hole seal, conduit (Includes items 7, 8, and 9)

11

Back panel, chassis 816, DEC, aluminum

12

Screw, mounting

13

31C-0009

Barrier block, 141, 3 terminal, dual row

14

43C-0071

Spacer, threaded, male/female, 6-32

15

33C-0004

Nameplate, caution, 110 VAC, red/white

16

02C-0002

Nut, acorn, 6-32 x 0.315, brass, nickel

17

Screw, terminal

18

Ground wire

19

09C-0298

Socket, power harness, 3-prong, 110 VAC

20

01C-PB9R

Rack, relay output, 9 position, with relays, RC snubbing, includes items 21, 22, 23, and 24)

21

65C-0173

Fuse, 5 A

22

Screw, terminal, captive washer

23

Screw, mounting

24

80C-0375

Relay, 1 N.O. contact

25

CPA-0225

Cable, ribbon, with connector, 2 output boards

Not shown

CPA-0226

Cable, ribbon, with connector, 1 output board

Not shown

CPA-0342

Adapter, D32 to PB9R Board Cables, 50-pin

26

CPA-0216

EMI/RFI chassis, pre-wired, with lid, 120 VAC power supply

27

Nut, hex, 8-32 x 5/16, steel

28

Screw, machine, button head, 8-32 x 1/2, stainless

29

54C-0092

Label, CATTRON-THEIMEG™

Not shown

10C-0096-BNC

Remote antenna mount kit, 20 feet coax cable, BNC connector

Not shown

10C-0096

Remote antenna mount kit, 20 feet coax cable, PL259 connector

Not shown Not shown

Transfer switch kit, 3 position, 4 circuits AT-SPARE-KIT

One 120 VAC power supply, two relays, miscellaneous fuses

* Includes items 2 through 5, 7 through 19, and 27 through 29. Items 2 through 10 not included on NEMA 4 and 4X models. Items 15 through 19 not included on models equipped for DC power.

Parts with no part number listed are not available for individual sale. Contact CATTRON-THEIMEG™ for more information.

ã04/2006, CATTRON-THEIMEG™

Section 5, Page 3

Figure 5-2. EMI/RFI shielded chassis - exploded view (illustrated parts breakdown) 30 26 25

29 27

24 20

28

1

23 21 18

10

22

2 3

17

19 31

6

4

15 16 5

7 14

13

11

12

9 8

Section 5, Page 4

ã04/2006, CATTRON-THEIMEG™

Table 5-2. EMI/RFI shielded chassis parts list

Index #

Part Number

Description

1

Chassis, 816, decoder, aluminum

2

Barrier block, 4 termina l

3

Washer

4

Terminal screw

5

30C-0032

Cord, power, 3 conductor, 110 VAC

6

65C-0124

Circuit breaker, 1 Amp, SPST

7

Label plate, circuit breaker

8 9

Nut 01C-0089

Power supply, 120 VAC/12 VDC, 0.85A, 10W (AC powered systems only)

CPA-0251L

Convertor, 10-36 VDC/13.8 VDC @ 8A, 12W (DC powered synthesized systems only)

CPA-0251-13.8

12 VDC filter assembly (non synthesized, DC powered systems only)

10

Screw, mounting

11

Terminal block, bulkhead pass through

12 13

Nut R1014T1HW (see ƒ)

Receiver, 447-473 MHz, 25 kHz (High wide band) spacing, less EPROM

R1014T1HN (see ƒ)

Receiver, 447-473 MHz, 13.5 kHz (High narrow band) spacing, less EPROM

R1014T1MN (see ƒ)

Receiver, 425-447 MHz, 13.5 kHz (Mid narrow band) spacing, less EPROM

14

Screw, machine, pan, slot, 4-40 x 1/2, steel

15

51S-1014T-XXX

EPROM, basic synth. receiver, programmed

16

09C-0245

Connector, bulkhead BNC, right angle, soldered

17

Washer, lock

18

Nut

19

01C-0094SYN

Antenna cable, internal 816 chassis

20

D32GII

Decoder, less EPROM and code plug

21

Screw, machine, pan, slot, 6-32 x 5/8, steel

22

51S-0832-ATX

EPROM, decoder, programmed, AT system

23

06C-0335P

Code plug, high profile

24

Terminal block, bulkhead pass through

25

Washer

26

Nut

27

Harness, decoder power and signal

28

Harness, receiver power and signal

29

CPA-0220

30 31

Assembly, filter board, 50 pin Nut

01C-27C-0002L

Lid, chassis, 816 decoder, aluminum

ƒ = Other frequency bands/channel spacings available upon request, contact CATTRON-THEIMEG™ for details.

Item 5 through 8 not included on models equipped for DC power.

Parts with no part number listed are not available for individual sale. Contact CATTRON-THEIMEG™ for more information.

ã04/2006, CATTRON-THEIMEG™

Section 5, Page 5

Accessories.

A popular accessory that enhances the functio nality of CATTRON-THEIMEG™ AT 816 Series receiver/decoders is described below. In addition, we emphasize that a Transfer Switch will be necessary when the controlled equipment has both manual control and remote control (refer to page 7 for schematic diagram). Please contact the CATTRON-THEIMEG™ factory or your sales representative for further details.

1. Two-step electro-hydraulic brake package.

The CATTRON-THEIMEG™ Two-Step Electro-Hydraulic Brake Package allows a convenient and easy conversion of an electric overhead traveling (EOT) crane from cab control to remote or pendant control. The brake system is designed for installation in parallel to the existing foot brake. This eliminates the need to replace the current system. CATTRON-THEIMEG™ offers the brake package in several models for use with many different crane power sources, including 110, 220, 440 VAC and 250 VDC. Any model of CATTRON-THEIMEG™ PRC, as well as a pendant or other brand of remote control can control brake operation.

The standard brake package offers two steps of brake application and a brake release function. This allows precise control of crane brakes. Optional parking brake release and three step braking are available on some models.

Each braking step is individually adjustable. The PRC or pendant operator selects the amount of brake application pressure. Normally a soft brake is applied when the bridge control is in neutral. Hard brake pressure is selected through the controller and applied when a need for a faster stop arises.

The CATTRON-THEIMEG™ Two-Step Electro-Hydraulic Brake Package provides safety for the crane system. When properly installed, the brake package will not allow operation of the crane unless sufficient brake pressure exists to stop the crane in case of an emergency. Brake pressure is stored using a hydraulic accumulator. Any loss of power automatically results in application of the crane brake. This provides braking even when crane power is lost or turned off for a short period of time.

For more information on the CATTRON-THEIMEG™ Two-Step Electro-Hydraulic Brake Package, contact CATTRON-THEIMEG™ .

Section 5, Page 6

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2. Transfer Switch. Refer to Section 2, page 5 of this manual for description and typical wiring diagram.

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Section 5, Page 8

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Appendix A – R1014T2 Receiver Introduction.

The optional Model R1014T2 receiver contains several advanced functions that can be used to enhance the functionality of all CATTRON-THEIMEG™ Portable Radio Remote Control (PRRC) systems.

These functions are: · Close Start. ·

Range Limit.

·

Range Extend.

·

Scanner (optional) – may require ‘gold box’ modifications, contact CATTRONTHEIMEG™ .

·

Attenuator.

·

Field Programmable Frequency Selection.

Close Start, Range Limit, and Range Extend require the use of a Triple Diversity Antenna system.

When installing a triple diversity antenna system, we recommend you physically tag each antenna and its associated line kit with a number (1, 2, and 3) and permanently record its individual location on the controlled machine. Such identification will be required when setting up the advanced functions described on the following pages.

The Model R1014T2 receiver can be easily identified by its LCD display and two display control pushbuttons, shown in Figure A-1.

Figure A-1. R1014T2 receiver

ANTENNA #1 INPUT ANTENNA #2 INPUT ANTENNA #3 INPUT

NOTE: Pushbutton #1 increments the display Pushbutton #2 decrements the display

CARRIER DETECT LED

#2 #1

DISPLAY CONTROL PUSHBUTTONS

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LCD DISPLAY

ROTARY FREQUENCY SELECTOR SWITCH

Appendix A – Page 1

Additional Safety Feature.

As an additional safety measure, we have recently implemented a ‘Power- up/Neutral’ feature on all AT & ATS systems. To accomplish this, the R1014T2 Receiver has been factory programmed to clamp the data being sent to the decoder when the operator moves out of range with ‘Range Limiting’ enabled. Consequently, as the result of the decoder not receiving any valid messages, the OPR (Operate) Relay is de-energized, which in turn opens the Mainline Contactor of the controlled machine, preventing any machine movement.

When the operator moves back into range and the receiver again begins passing data to the decoder, the mainline contactor will not close because the OPR Relay remains de-energized until the decoder receives a new ‘Power- up/Neutral’ message from the controller.

Referring to the existing ‘Range Limiting’ and Close Start’ operating procedures in this Appendix: To resume remote control operations with ‘Range Limiting’ enabled, the operator must first move closer to the controlled machine to activate the Range Limit. In addition, the operator must now set the controller to ‘OFF’ and then back to ‘ON’ in order to regain full machine control.

If the ‘Close Start’ function is also enabled, and the operator stays out of range for longer than the programmed close start time, he or she must first walk forwards into the preset close start range of the machine. In addition, the operator must now set the controller to ‘OFF’ and then back to ‘ON’ in order to regain full machine control.

Close Start setup.

The Close Start option is a safety feature that prevents the controlled machine from operating until the operator is close enough to the machine to visually observe all machine control functions. Once the operator is within a preset, programmable operating range of the machine, he or she will be required to ‘unlock’ the Close Start function before being allowed to proceed with remote control operations.

There are three parameters you will be required to set: 1.

Time – determine the time the operator can be off the air before remote control operation is locked out and close start must be satisfied.

2.

Select Close Start Antenna – determine which antenna (1, 2, or 3) the operator will be closest to in order to capture (enable) the controlled machine.

3.

Signal level – determine the RF signal strength level of the controller that the receiver must select for the operator to unlock the Close Start function and perform remote control operation. This is a directly related function of the distance between the operator and machine.

Appendix A – Page 2

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Close Start setup, continued.

Close Start requires the use of the triple diversity antenna system. When setting the Close Start options, one of the three antennas must be selected (programmed) as the antenna used to unlock the Close Start function. Once operations have begun, the operator may be any distance from the machine up to the maximum operating range. This may be the maximum range of the controller, or it may be limited using the Range Limit option.

If a preset time limit passes without any operator commands (the programmable Close Start lockout time), the Close Start system will lock out all further operations until the operator moves back within the Close Start unlocking range.

Read and thoroughly understand this entire procedure prior to setting the Close Start options. It is recommended that two people work together to perform this procedure. For example: One person with the remote controller will need to assume the desired Close Start capture position when starting the controlled equipment on the ground. The second person will board the controlled equipment to (1) ensure the receiver/decoder is fully operational before setting the Close Start options, and (2) observe the RF signal strength indication on the LCD display while setting the desired close start parameters using the two control pushbuttons on the receiver.

Close Start utilizes RF signal strength to determine the close start distance and therefore is not a precision setting. Many factors may affect the RF signal strength, such as controller position, antenna position and direction, building environment, and background RF noise. After setting Close Start, check the system performance several times. You may have to repeat the setup procedure to optimize system performance.

Refer to Figure A-2 overleaf which shows the typical ranges for the Close Start option.

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Appendix A – Page 3

Close Start setup, continued.

Figure A-2. Close Start ranges

Close Start unlock circle.

Operator must be within this circle to unlock Close Start and allow data messages to the decoder. After Close Start unlock, operating range extends beyond this circle.

Receiver Close Start Antenna Location Unlock distance (Typical 10-20 ft) (3 - 6 m)

d

e na ng te n a R an g in an y t) t a f er o m 00 Op e f r l3 ) a c ic m ta n (Typ (9 0 is

To set Close Start, proceed as follows: 1.

Determine the length of time the operator can be off the air before he or she is required to satisfy the Close Start ‘unlock’ requirement. This time may be set from 0.1 minute to 15 minutes, depending on the application and user preference. It is factory set to 2 minutes.

2.

The person with the remote controller should assume a position on the ground at the desired distance to unlock Close Start. This distance is typically 10 to 20 feet from the controlled machine where he or she can visually observe all machine control functions.

Appendix A – Page 4

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Close Start setup, continued.

3.

Note which machine mounted antenna is closest to the person with the remote controller – this will be designated the Close Start Antenna. Record the number of this antenna – this may be 1, 2, or 3, as previously tagged and recorded when the triple diversity antenna system was installed.

4.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

5.

Board the controlled machine, open the receiver/decoder and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

6.

Set the gold box power to ‘ON’.

7.

Instruct the person with the remote controller on the ground to apply power to the controller. NOTE: (1) If FCC Part 90 requirements apply to your PRRC system the controller will transmit a continuous RF signal once power is applied. (2) If FCC Part 15 requirements apply to your PRRC system, you must also activate and maintain a controller function that will not cause any movement of the controlled machine. This function could be a horn, light, or other indicator and must be maintained until you are instructed otherwise. Observe the Transmit LED on the controller which should flash green when the controller is transmitting. Confirm that the green Carrier Detect LED on the receiver circuit board also flashes in sympathy. This indicates that the receiver is receiving a RF signal from the transmitter.

8.

Press and hold both display control pushbuttons on the receiver until the following message appears on the LCD display: PROGRAM OPTIONS *****MODE***** It should be noted that all remote control functions on the controlled machine are disabled any time the PROGRAM OPTIONS MODE is selected on the receiver.

Therefore, activating a controller function will not cause any machine movement.

Release both display control pushbuttons. The display now shows the first option to be set.

SET CLOSE START LOCK-OUT TIME 2.0 2.0 is the factory pre-set timeout value in minutes. This Close Start Lock Out Time represents the number of minutes that can elapse in which the receiver does not receive a message from the controller with the correct ‘unlock’ address. A new Close Start unlock requirement will be needed if this pre-set timeout expires.

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Appendix A – Page 5

Close Start setup, continued.

9.

Press either of the two display control pushbuttons on the receiver to set the required timeout value on the LCD display. This value may be set anywhere between 0.1 and 15 minutes in 0.1 minute increments. Note that (1) depressing Pushbutton #1 or Pushbutton #2 will increment or decrement their respective display values, and (2) it will take approximately two seconds for the receiver to register a key press.

10.

After setting the lock-out time, set the antenna which will be used for Close Start. To unlock the system, momentarily press and release both receiver buttons to show the following screen: SET CLOSE START ANTENNA: 1

11.

The number 1 indicates that antenna 1 is currently selected for use with Close Start.

Press either of the two buttons to select the designated Close Start Antenna noted in step 3, above. It will take approximately two seconds for the receiver to register a key press.

12.

The last parameter to be set is the Close Start RF signal level. This is directly related to the unlock distance. Momentarily press and release both receiver buttons to show the following screen: CLOSE START -dBm RSSI-65 SET-70 The example display above shows the controller’s Receive Signal Strength Indication (RSSI) value at -65dBm and the Close Start set value at -70dBm. The close start set signal level should be set slightly below the RSSI from the controller. This ensures repeatability while limiting the close start distance.

13.

14.

The RSSI level is the strength of the RF signal received from the controller which should be transmitting, or the background noise level if no signal is being broadcast.

The Set value is the signal strength limit for three consecutive controller transmissions with the same address for the receiver to unlock. In the above example, the signal strength must be at least -70dBm for three consecutive controller transmissions before Close Start will unlock and pass data to the decoder. Note that an RSSI of –65dBm is a stronger RF signal than –70dBm and, in this example, the receiver needs to see an RF signal greater than –70dBm to unlock.

The person with the controller should slowly turn around whilst transmitting, as well as moving within two or three feet of his or her normal operating position in all directions.

Observe the displayed RSSI from the controller while the operator is moving about the normal operating position, noting the weakest received signal.

Press either of the two buttons to select the desired Close Start signal level which should be set to a va lue between 3 and 5dBm less than the weakest RSSI from the controller noted in step 13 above. Remember that –65dBm is a stronger signal than –70dBm. It will take approximately two seconds for the receiver to register a key press.

Appendix A – Page 6

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Close Start setup, continued.

15.

Press and hold both buttons for approximately three seconds to exit the options menu.

The receiver will then cycle through its power-up self check.

16.

If applicable, de-activate the controller function previously maintained in step 7 above.

Set the controller power to ‘OFF’.

17.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

After making any changes to the Close Start options above, test the system for proper operation. Have an operator take the controller to the desired distance to unlock Close Start. Set the controller power to ‘ON’ and operate a switch/pushbutton function that will not cause any movement of the controlled machine, such as a horn, siren, or light. Ensure the selected control function activates. Referring to figure A-2 above, move out of the close start unlock circle into the normal operating area, ensuring the controller remains operational. Discontinue controller operation for longer than the timeout period selected above. Operate the controller to make sure close start has timed out (no control function should activate). Move back into the close start unlock circle and operate the controller, ensuring the selected control function activates. If not, repeat the Close Start Setup procedure as many times as required to optimize system performance.

Range Limit setup.

Range limit is a programmable option that restricts the maximum range between the remote control operator and the equipment he or she is controlling.

The Range Limit feature uses RF signal strength to determine the distance between the controller and receiver. This feature requires the use of the triple diversity antenna system. If the signal strength from all three antennas falls below a preset value, the controller is too far from the receiver and Range Limit becomes active. Once the Range Limit feature activates, the signal strength must increase to 3dB greater than the Range Limit set point before the receiver will return to normal operating mode.

This requires the operator to move closer to one of the antennas to reduce intermittent operation at the extremes of the range limit perimeter.

Range Limit is not a precision feature as many factors may affect the setting, such as controller position, antenna position & direction, building environment, floor obstructions, and background RF noise.

See Figure A-3 below for a pictorial representation of the Range Limit feature.

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Appendix A – Page 7

Range Limit setup, continued.

Figure A-3. Range Limit operation

+3dBm distance.

= Remote Control Operator Check signal strengths with remote control operator transmitting from various positions at the extremities of the Operating Range. Note that Signal strengths may vary due to materials and obstructions on the floor between the controller and antennas. Whenever possible, all such materials and obstructions are to be moved out of the operating area.

Range limit output becomes active beyond this point.

Remote control is disabled.

Once Range Limit becomes active, the operator must move closer to the antennas by a distance where the received signal is +3dBm stronger to de-activate range limit.

e ng Ra ft )

Triple Diversity Antenna.

ng 0 0 ati l 3

e r ic a m ) Op (Typ (90

Range Limit outer limit control circle.

It is recommended that two people work together to perform this procedure. For example: The person with the remote controller should be positioned on the ground at the required distance to activate the range limit. The second person is required to board the controlled equipment to (1) ensure the receiver and decoder are fully operational before setting the Range Limit option, and (2) observe the LCD display while setting the desired range limit using the two control pushbuttons on the receiver/decoder.

To set the Range Limit option, proceed as follows: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

Appendix A – Page 8

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Range Limit setup, continued.

3.

Set the gold box power to ‘ON’

4.

Position the person with the remote controller on the ground at the desired distance to activate the Range Limit.

5.

Instruct the person with the remote controller on the ground to apply power to the controller. NOTE: (1) If FCC Part 90 requirements apply to your PRRC system the controller will transmit a continuous RF signal once power is applied. (2) If FCC Part 15 requirements apply to your PRRC system, you must also activate and maintain a controller function that will not cause any movement of the controlled machine. This function could be a horn, light, or other indicator and must be maintained until you are instructed otherwise. Observe the Transmit LED on the controller which should flash green when the controller is transmitting. Confirm that the green Carrier Detect LED on the receiver circuit board also flashes in sympathy. This indicates that the receiver is receiving a RF signal from the transmitter.

6.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** It should be noted that all remote control functions on the controlled machine are disabled any time the PROGRAM OPTIONS MODE is selected on the receiver.

Therefore, activating a controller function will not cause any machine movement.

7.

Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

8.

Momentarily press and release both display control buttons until the following message appears on the display: RANGE LIMIT -dBm RSSI-120 SET OFF The example display above shows the controller’s Receive Signal Strength Indication (RSSI) value at -120dBm with the Range Limit option disabled

9.

The RSSI level is the strength of the RF signal received from the controller which should be transmitting, or the background noise level if no signal is being broadcast.

Referring to Figure A-3 above, check signal strengths with the remote control operator transmitting from various positions at the extremities of the operating range. Observe the displayed RSSI from the controller while the operator is transmitting from each of these positions, noting that received signal strengths will vary due to materials and obstructions on the ground between the controller and antennas. Whenever possible, remove all such obstructions out of the operating area to harmonize the received signal strengths from these operating positions.

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Appendix A – Page 9

Range Limit setup, continued.

10.

Press and release either button to change the Range Limit status. A display of a number enables the Range Limit option.

The setpoint can be set to any value between -50dBm and -126dBm. In this example, attempting to set a value below -120dBm will enable the Range Extend option and change the display to EXT. Setting a value higher than -50dBm disables the Range Limit and changes the display to OFF. - Remember that –117dBm is a stronger signal than –120dBm.

11.

Once the desired Range Limit status is set, press and hold both display control buttons for approximately three seconds. The status will be saved and the receiver will cycle through its power-up self check.

12.

If applicable, de-activate the controller function previously maintained in step 5 above.

Set the controller power to ‘OFF’

13.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

After making any changes to the Range Limit function, test the system for proper operation. Have an operator take the controller to the desired range and operate a control that will not cause any crane movement, such as a horn, siren, or light. Have the operator move closer to, and farther from, the controlled machine to activate and de-activate the Range Limit. If necessary, repeat the Range Limit Setup procedure to achieve the desired range limits.

Range Extend setup.

The Range Extend option is the opposite of Range Limit and requires the use of the triple diversity antenna system. When Range Limiting is not in use, the receiver can be put into Range Extend mode.

When a system with the Range Extend option enabled receives a signal, the signal strength is measured from each antenna. The signal from the antenna with the strongest signal strength is used to receive the remainder of the signal. This ensures that the best possible signal is used thereby optimizing the range of the system.

Note:

The Range Extend feature cannot be used in conjunction with the Range Limit feature.

Set the Range Extend option, as follows: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

3.

Set the gold box power to ‘ON’.

Appendix A – Page 10

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Range Extend setup, continued.

4.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** It should be noted that all remote control functions on the controlled machine are disabled any time the PROGRAM OPTIONS MODE is selected on the receiver.

Therefore, activating a controller function will not cause any machine movement.

Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

5.

Momentarily press and release both display control buttons until the following message appears on the display: RANGE LIMIT -dBm RSSI-120 SET OFF The example display above shows the controller’s Receive Signal Strength Indication (RSSI) value at -120dBm with the Range Limit option disabled The RSSI level is the strength of the RF signal received from the controller, or the background noise level if no signal is being broadcast.

6.

Press and release either button to change the Range Extend status. A display of ‘EXT’ enables the Range Extend option. A display of ‘OFF’ disables the Range Extend option.

A display of a number disables the Range Extend feature and enables the Range Limit feature described in the last topic.

7.

Once the desired Range Extend status is set, press and hold both display control buttons for approximately three seconds. The status will be saved and the receiver will cycle through its power-up self check.

8.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

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Appendix A – Page 11

Scanner setup.

The Optional Scanner function allows the receiver to scan up to 16 frequencies for signals from the controller. This feature can be used in multi-controller applications where the controllers operate on multiple frequencies.

NOTE The EMI/RFI shielded chassis, or ‘gold box’, must be modified to enable the scanner function to operate properly. Consult CATTRONTHEIMEG™ before enabling this feature.

Set the Scanner option as follows: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

3.

Set the gold box power to ‘ON’.

4.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

5.

Momentarily press and release both display control buttons until the following message appears on the display: SCANNER MODE IS TURNED………. OFF The display above shows the Scanner option disabled.

6.

Press and release either button to toggle the Scanner mode on and off.

7.

Once the desired Scanner status is set, press and hold both display control buttons for approximately three seconds. The status will be saved, and the receiver will cycle through its power-up self check.

8.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

The Scanner function starts scanning at the frequency indicated by the position of the rotary frequency selector switch. The receiver switches to the next sequential frequency every 0.5 second. The interval may be changed in 0.5 second increments.

Appendix A – Page 12

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Scanner setup, continued.

Note that the Scanner function will scan through all 16 frequencies when using factory programmed frequencies and all 14 frequencies when using field programmable frequencies. If scanning of all the frequenc ies is not desired, a field programmable frequency table must be created. Refer to Field Programmable Frequencies in this appendix for information on programming the frequency table. For example, to create a scan pattern that scans three separate frequencies in Field Programmable Frequency mode, set the following frequencies in the field programmable frequency table: Channel Channel 1

Frequency Frequency 1

Channel 2

Frequency 2

Channel 3

Frequency 3

Channel 4

Frequency 1

Channel 5

Frequency 2

Channel 6

Frequency 3

Etc…

Attenuator setup.

An attenuator reduces the incoming radio frequency signal level seen by the receiver from the controller or from other RF sources. The R1014T2 receiver’s attenuator is fixed and is 22dBm to 28dBm. Enabling the attenuator option has the effect of reducing the range at which the machine may be controlled and also makes the receiver less susceptible to interference caused by RF signals on, or adjacent to, the equipment operating frequency. An external attenuator can be used if a different amount of attenuation is necessary.

To obtain an external attenuator for your receiver/decoder, contact CATTRON-THEIMEG™ . To set the built- in attenuator on the Model R1014T2 receiver, perform the following procedure: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

3.

Set the gold box power to ‘ON’.

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Appendix A – Page 13

Attenuator setup, continued.

4.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

5.

Momentarily press and release both display control buttons until the following message appears on the display: ATTENUATOR STATUS OUT The display above shows the attenuator status as being disabled.

6.

Press and release either button to toggle the attenuator status from ‘OUT’ to ‘IN’, and vice versa.

7.

Once the desired attenuator status is set, press and hold both display control buttons for approximately three seconds. The attenuator status will be saved and the receiver will cycle through its power-up self check.

8.

Confirm the operating range of the controller, setting the attenuator to ‘OUT’ if the range is less than required

9.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

Factory Preset and Field Programmable Frequencies.

NOTE: Frequencies for licensed (FCC Part 90) systems must NOT be programmed to frequencies other than those you have been licensed for. If the frequency for a licensed system needs to be changed to a frequency that is not included in the factory preset table, refer to the radio frequency documentation supplied with the system for a list of the frequencies preset on your receiver.

In order for the receiver and the controller to communicate, they must be set to the same frequency.

CATTRON-THEIMEG™ receivers and controllers offer multiple frequency selections for maximum versatility. While the factory preset frequencies should be adequate for most users, there may be conditions where it is necessary to program a frequency. This may be necessary whe n installing a spare receiver/decoder or controller that operates on a frequency that has not been preset at the factory, or when other sources systems are emitting RF signals that interfere with safe operation. Prior to making any change in the frequency setting, check the frequency settings on both the receiver/decoder and the controller.

Appendix A – Page 14

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Factory Preset and Field Programmable Frequencies.

To change the frequency setting for the controller, refer to the documentation provided with the controller.

The receiver has the capability of selecting one of 16 factory preset frequencies using a rotary switch on the receiver circuit board. The Model R1014T2 receiver also allows for field programming of 14 additional frequencies to any frequency desired between 447MHz and 472MHz. When using field programmed frequencies, positions 0 and F of the rotary switch are not used. Selecting either of these positions will cause the receiver/decoder to stop functioning until the rotary switch is set to a valid position.

Factory Preset (default) Frequencies.

If more than one factory preset frequency has been set in your receiver, you may change to another factory preset frequency as follows: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

3.

Set the gold box power to ‘ON’.

4.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

5.

Momentarily press and release both display control buttons until the following message appears on the display: FREQUENCY TABLE: FACTORY PGM ROM This indicates that the receiver is currently using the factory programmed frequency table in Read only Memory (ROM).

6.

Locate the rotary frequency selector switch on the receiver circuit board. The switch is shown in Figure A-1 on Page 1.

7.

Using a small screwdriver, rotate the rotary selector switch to the desired position.

NOTE: The selected frequency will be displayed on the LCD display.

8.

Press and hold both display control buttons for approximately three seconds to exit the options menu. The receiver/decoder will then cycle through the power-up self check.

9.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

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Appendix A – Page 15

Field Programmable Frequencies.

Select and program the field programmable frequencies as follows: 1.

As a safety precaution, set the remote controller(s) power to ‘OFF’ and remove power to all controlled machine motors before boarding the controlled machine.

2.

Board the controlled machine, open the receiver/decoder door and remove the lid from the EMI/RFI shielded chassis, or ‘gold box’.

3.

Set the gold box power to ‘ON’.

4.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

5.

Momentarily press and release both display control buttons until the following message appears on the display: FREQUENCY TABLE: FACTORY PGM ROM This indicates that the receiver is currently using the factory programmed frequency table in ROM.

6.

Press and release one button. The display will change to the following: FREQUENCY TABLE: FIELD PGM EEPROM This indicates that the receiver is now using the field programmed frequency table stored in EEPROM.

7.

To select a frequency channel to program, press and release both display control buttons. The display will change to the following: CHANNEL NUMBER FOR FREQ ADJ.#1 This indicates that the frequency for channel one can now be programmed.

Press and release one button to select the channel number for the frequency to be changed.

8.

When the proper channel number is displayed, momentarily press and release both display control buttons. The display will change to the following: ADJ. CHANNEL # 1 FREQ: 448.2500 This indicates that channel 1 is currently set to 448.2500MHz.

Appendix A – Page 16

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Field Programmable Frequencies, continued.

9.

Press and hold either button to scroll the display to the desired frequency value from 447 MHz to 472MHz. After holding a button for approximately five seconds, the scrolling speed for the frequency will increase.

10.

When the desired frequency for the channel is displayed, momentarily press and release both display control buttons. This stores the frequency value in non-volatile EEPROM. The display will now change back to that shown in Step 7. Press and release one button to select the next channel number for the frequency to be changed, repeating steps 8 through 11 for each new frequency to be set.

11.

Press and hold both display control buttons for approximately three seconds to exit the options menu. The receiver/decoder will then cycle through the power-up self check..

12.

Press both display control pushbuttons on the receiver until the following message is shown on the LCD display: PROGRAM OPTIONS *****MODE***** Release both buttons. The display will now change to show one of the other options that may be set for this receiver.

13.

Press and release one button. The display will change to the following: FREQUENCY TABLE: FIELD PGM EEPROM

14.

Locate the rotary frequency selector switch on the receiver circuit board. The switch is shown in Figure A-1 on Page 1.

15.

Using a small screwdriver, select the desired frequency from the field programmed frequency table using the rotary frequency selector switch.

NOTE: Since there only 14 programmable frequencies and the rotary switch has 16 positions, positions 0 and F are not used with the field programmable frequency table. Selecting position 0 or F will cause the receiver/decoder to become non-functional until a valid frequency is selected on the rotary frequency selector switch.

16.

Press and hold both display control buttons for approximately three seconds to exit the options menu. The receiver/decoder will then cycle through the power-up self check.

17.

As required, set the gold box power to ‘OFF’, replace the lid, close the cover of the receiver/decoder enclosure, and apply power to the controlled machine motors.

END OF APPENDIX

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Appendix A – Page 17

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Appendix A – Page 18

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Appendix B – NEW R1HN and R2HN RECEIVER BOARDS FREQUENCY PROGRAMMING PROCEDURE – NEW R1HN and R2HN RECEIVER BOARDS. Programming Receiver Frequency.

NOTE:

R1HN and R2HN Receiver Boards allow the customer to select up to eight Frequency Banks, with individual Frequency Banks containing up to sixteen Frequencies. Refer to the radio frequency programming sheets supplied with your pre -engineered system for the Frequency Bank and corresponding Frequency allocations that apply to your installation.

To change the frequency setting for the system controller, refer to the documentation provided with the controller. Follow the procedure below to change the Receiver Board frequency: 1. Open the door of the receiver/decoder enclosure and remove power by turning off the circuit breaker on the bottom of the EMI/RFI shielded chassis, or ‘gold box’.

2. Remove the lid from the ‘gold box’ and locate the frequency bank selector binary SIP switches on the Receiver Circuit Board. (Refer to Figure B-1 below for location).

3. Using the radio frequency programming sheets supplied with your pre-engineered system, locate and set the allocated frequency bank on the binary SIP switches as shown in Figure B1.

4. Locate the rotary frequency selector switch on the Receiver Circuit Board. (Refer to Figure B-1 for location).

5. Using a small screwdriver, rotate the selector switch to the desired frequency position (refer to frequency programming sheets supplied with your pre-engineered system).

6. Replace the lid on the ‘gold box’.

7. Restore power to the receiver/decoder by turning on the circuit breaker on the bottom of the ‘gold box’.

8. Close the door of the receiver/decoder enclosure.

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Appendix B – Page 1

Programming Receiver Frequency, continued.

Figure B-1. Frequency Bank and rotary Frequency Selector Switch locations

OFF

FREQUENCY BANK SELECTOR BINARY SIP SWITCH

ROTARY FREQUENCY SELECTOR SWITCH

* Binary Weight shown - see NOTE 1

ON OFF

8

* 4 * 2 * 1*

OFF

(FREQUENCY BANK 0)

8

4

1

2

OFF

2

8

1

OFF

8

ON Left

4

4

OFF

1

(FREQUENCY BANK 6)

1

Right * * * * 1 2 3 4

ON

2

8

(FREQUENCY BANK 5)

ON

2

1

*

(FREQUENCY BANK 3)

(FREQUENCY BANK 4) 4

8

ON

4

ON

2

(FREQUENCY BANK 1)

(FREQUENCY BANK 2)

OFF

4

ON

2

OFF

8

4

OFF

2

1

ON

8

(FREQUENCY BANK 7)

END Appendix B – Page 2

ã04/2006, CATTRON-THEIMEG™

Index A

G

Accessories ............................................... 5-6

General

Two-step electro-hydraulic brake ...... 5-6

Functional description .........

1-1

Additional safety features ........................ A-2

Maintenance ................................. 4-1

Adjustments ............................................. 4-4

Operating instructions .................. 3-1

Antenna installation ................................. 2-10 Attenuator setup ...................................... A-13

I

Automatic safety override ....................... 4-9

Installation ..............................................

2-9

Interface Connections .............................

2-1

B Before installation checks .......................... 2-1

L LED indicators ........................................ 2-14

C

List of acronyms .......................................... ii

Checkout procedure following installation ............................................... 2-16

M

Choosing a mounting location .................. 2-9 Close start setup ...................................... A-3 Code plug replacement ............................ 4-17

Mainline Circuit ......................................... 2-6 Maintenance .............................................. 4-1 Mechanical installation for RF units ......... 2-9

D

Model summary chart ................................ 1-7

Decoder replacement ................................ 4-15

O

Direct DC wiring option ........................... 2-12

F

Operate and reset relays ..........................

2-6

Operating instructions ............................

3-1

Features .................................................... 1-4 Field programmable frequencies .............. A-14 Frequency selections (ATS only) ...............2-13 Functional description .............................. 1-1 ã04/2006, CATTRON-THEIMEG™

Index - 1

P

S

Parts list .............................................

5-1

Safety considerations ................................. 1-5

Pre-installation checks ............................ 2-1

Safety Interface Unit (ATS Systems only) 2-2

Preventive maintenance .......................... 4-2

Scanne r setup .......................................

A-12

Principle of Operation ............................. 1-6

Specifications ......................................

1-2

Power-up Messages ................................. 2-16

Standard Safety & Security features .......... 1-4 System status display ...........................

2-14

R R1014T2 receiver .................................... A-1

T

Range Extender setup .............................. A-10

Transfer switch .................................... 2-5, 5-7

Range Limit setup ................................... A-7

Triple diversity antenna .......................... 2-11

Relay outputs ........................................... 2-6

Troubleshooting ......................................

Receiver/decoder repair .......................... 4-11

Two-step electro-hydraulic brake package 5-6

Code plug replacement ...................... 4-17

Typical additional checks .......................... 4-2

4-5

Decoder replacement ......................... 4-15 EPROM replacement ........................ 4-20 Receiver replacement ........................ 4-13 Relay replacement ............................. 4-12 Replacing the EMI/RFI shielded chassis (gold box) ............... 4-11 Run-time Messages ................................. 2-17

Index - 2

ã04/2006, CATTRON-THEIMEG™

RECOMMENDED SAFETY RULES FOR PORTABLE REMOTE CONTROLLED (PRC) CRANES For the purpose of these rules, Portable Remote Control or PRC refers to Radio Frequency (RF) Controls. The information contained herein is based on data gathered from vario us users of portable remote control crane systems. We emphasize that the recommendations contained herein are not intended to supersede the rules or regulations of our customers, or the rules and regulations of any applicable local, state, or federal government organizations . It must be fully understood that the recommendations contained herein are provided solely for your consideration and possible adoption.

TABLE OF CONTENTS SECTION TITLE PAGE 1 Preface 1 2 Operator Safety Basics 2 2-1 Area Inspection 2 2-2 Crane Inspection (mechanical & structural) 2 2-3 Operational Safety Check 3 3 Persons Authorized to Operate Portable Remote Controlled cranes 3 4 Training Check List for Operation of Remote Controlled cranes 3 5 Operating Area for Remote Controlled Cranes 4 6 The Hand-held Portable Remote Controller 4 7 Operating the Remote Controlled Crane 5 8 Boarding the Remote Controlled Crane 6 9 On Board the Remote Controlled Crane 7 10 Remote Controlled Crane under Repair 7 11 The Condition of the Remote Controlled Crane 8 1.

PREFACE. 1-1. Electric Overhead Traveling (EOT) Cranes typically operate in three motions. They are large, bulky pieces of equipment that handle heavy loads efficiently at comparatively high speeds.

Frequently, they are operated in restricted areas where workmen are engaged in various tasks on the floor below. Under these conditions crane operators using Portable Remote Control must take great care, and workmen must be constantly on the alert if accidents are to be avoided.

1-2. The following guidelines have been carefully assembled and are promoted to indicate just how important your careful and thoughtful actions are in helping to protect you and your fellow workers from harm, and also to prevent equipment damage.

1-3. These guidelines cover cranes when they are operational in Portable Remote Control (PRC) mode. If a crane is operated from cab or pendant control, the PRC system’s controller(s) should be completely isolated by removing the battery and held under lock and key.

1-4. A routine pre-shift inspection of the crane takes a lot less time than repairing a crane suffering from a major problem. In addition, such pre-shift inspections are to be considered as ‘safety basics’ which are an important part of a crane operator’s duties. ã04/2006, CATTRON-THEIMEG™

Cranesafety - 1

2.

OPERATOR SAFETY BASICS. Before starting your shift as the crane operator, you should make sure the crane has a current inspection certificate and that qualified personnel have carried out the following inspections and checks. If any item below does not pass inspection, you should notify your supervisor immediately. In many cases, the problem will need to be fixed before you are allowed to operate the crane. In addition, did you realize that the person now reading these instructions is primarily responsible for his or her own health and safety?

2-1.

Area Inspection. · Take a good look around the work area for any obstructions. · Check that the rail sweeps are intact and not bent or damaged. · Make sure there are no oil or brake fluid leaks on the area below where the crane travels. · Make sure rail stops are present, physically secure, and free of damage at the end of all crane rails. · Check that walkways are sturdy and have handrails. Ladders are not to be loose and all rungs are to be in place.

2-2.

Crane Inspection (mechanical & structural). · Make sure all moving machinery has protective guards installed over moving parts. · Make sure all bridge and trolley rail stops are welded or bolted in position with no evidence of damage from bridge or trolley impact. · Check for proper fluid levels and make sure all grease fittings are lubricated to manufacturer recommendations. · Check for broken welds and cracks in the bridge structure. · Check for wheel damage, broken welds on the frame, and drum damage. · Check the wheels for flange wear, cracks, holes, or visible signs of bearing damage. · Make sure wire rope drums show proper wire rope lay; for example, each wire rope must lay in its own groove. This does not mean in the non-grooved area in the center of the drum. · Make sure wire rope size is correct for the sheaves. Look for either oversized or undersized rope that will not lay in the sheaves correctly. Make sure the sheaves show no evidence of rope corrugation and have the proper wall thickness. · Look for any type of bluing on the brake drums which indicates excessive heat. Make sure there are no protruding rivets from the brake shoes. Examine the shoes for glazing. · Look for carbon dust around the inspection covers of electric motors. Smell for any type of burning smells. Check for any type of burning on electrical covers. Make sure all protective covers are installed. · Check the festoon system for proper connections and inspect all hooks connecting the festoon to the holding wire. · Load bearing parts such as blocks and hooks shall have no signs of damage and be in perfect working order.

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2-3. Operational Safety Check. As a crane operator, you should satisfy yourself of the following.

If any item below does not meet the checklist criteria, you shall immediately notify your supervisor.

In many cases, the problem will need to be fixed before you are allowed to operate the crane.

Remember that the person now reading these instructions is primarily responsible for his or her own health and safety! · Horns, buzzers and all other warning devices shall be in working order. · All controls shall be in good working order. · Emergency Stop Buttons (when equipped) shall be in working order. · The load brakes shall hold the load safely at all times. The only way to ensure this is through a load test and inspection. · The ‘raise’ and ‘lower’ limit switches shall work correctly to help prevent two-blocking and accidental floor contact.

3.

PERSONS AUTHORIZED TO OPERATE PORTABLE REMOTE CONTROLLED CRANES. · Only properly trained employees who have been designated by management shall be permitted to operate the crane. · Both the operator and management shall insure the correct controller to operate the crane is selected and that any spare equipment capable of controlling the crane is completely isolated and held under lock and key. · The crane shall not be operated by personnel who cannot read and understand the signs, notices and operating instructions. · The crane shall not be operated by personnel with seriously defective eyesight or hearing, personnel under the influence of drugs or alcohol that will impair judgment, or personnel who may be suffering from a disease which may cause physical failure.

4.

TRAINING CHECKLIST FOR OPERATORS OF PORTABLE REMOTE CONTROLLED CRANES. As a minimum, Portable Remote Control Operators shall: · have knowledge of hazards inherent to crane operation. · have knowledge of safety guidelines for portable remote controlled cranes. · have the ability to judge distance to stationary objects. · have knowledge of the portable remote control system controller’s operation. · have performed limit switch test procedure before operating the crane. · have performed hoist, trolley and bridge brake test procedure before operating the crane. · have instructions as to plugging of crane motions when and where authorized. · observe signal lights on crane. · avoid striking any obstructions. · check for proper clearance of lifts or hooks before moving bridge or trolley. · properly store the portable remote controller when not in use. · know how to properly transfer the portable remote controller to another person.

ã04/2006, CATTRON-THEIMEG™

Cranesafety - 3

4.

TRAINING CHECKLIST FOR OPERATORS CONTROLLED CRANES, continued. · report unsafe or unusual operating conditions. · use caution in approaching bridge or trolley end-stops. · know the crane’s capacity. · keep body clear of lifts, avoiding ‘pinch’ points. · inspect cables and hooks.

5.

THE OPERATING AREA FOR THE PORTABLE REMOTE CONTROLLED CRANE. · Unobstructed aisles between equipment, stock, etc. shall be maintained for the Portable Remote-controlled crane operator's movement. These aisles should be a minimum of 3 feet wide (1m) or per local regulations. · Portable Remote-controlled crane operators shall always position themselves in a safe location with the best view of the crane they are controlling and never operate the crane blindly. They shall always keep the crane and load in sight, staying as close as practical to the crane load while maintaining a safe harms-way distance. Operators shall never position themselves or others underneath the load or in a ‘pinch’ point.

6.

THE HAND-HELD PORTABLE REMOTE CONTROLLER. · Typically, the portable remote controller incorporates a Push-To-Operate (PTO) bar or START button, and its motion switches are spring return to OFF. The PTO bar acts as a guard for these switches to prevent movement of the crane if one of the switches is accidentally bumped. These switches and the PTO bar must never be mechanically blocked in any ‘ON’ position. · Using the power ON/OFF switch(es), the portable remote controller shall be switched ‘OFF’ when not in use. When the controller is equipped with a STOP button, it shall be set to the ‘STOP’ position before switching off power to the controller. In addition, if equipped with a key, the key should be removed after use and kept in a secure location. · A prescribed, controlled, storage space shall be provided for portable remote controllers.

All controllers shall have their batteries removed and be placed there when not in use. This precaution is intended to prevent unauthorized personnel from operating the remote controlled crane. · When an operator is putting on or taking off the controller by means of its belt loop strap, carrying harness, or shoulder strap, the controller shall be switched OFF beforehand, using the appropriate ON/OFF switch(es). When the controller is equipped with a STOP button, it shall be set to the ‘STOP’ position before switching off power to the controller. · The portable remote controller shall always be switched ‘OFF’ when not in use and, when practical, held under lock and key.

Cranesafety - 4

OF

PORTABLE

REMOTE

ã04/2006, CATTRON-THEIMEG™

7.

OPERATING THE PORTABLE REMOTE CONTROLLED CRANE. · All crane limit switches shall be checked at the beginning of each turn or when a new operator takes control of the crane. While checking the limit switches, the hoist shall be centered over an area free of personnel and equipment so that if the limit switches fail, and the hook and block assembly falls, no one will be injured and no equipment will be damaged. · The limit switches shall never be used as a regular stopping devices. They are intended to be protective devices only. · The bridge and trolley brakes shall be tested at the beginning of each turn or when a new operator takes control of the crane. They should be tested with the bridge and trolley at low speed. · When lifting maximum or near maximum loads, the operator shall test the hoist brakes by raising the load a few inches from the floor. If hoist brakes do not hold, the load shall be immediately lowered to the floor and a report made to the supervisor. · Do not make lifts in excess of the rated capacity of the crane. · When making lifts, the bridge and trolley shall be centered directly over the load to prevent load swinging when the load is raised. · Side pulls shall be made only with the permission of, and under direct supervision of management. When such a lift is being made, operators shall not position themselves in the line or path of travel of the load, but shall operate the crane from a position to the side opposite to the path of travel. · When raising or lowering a lo ad, proceed slowly and make certain the load is under control. Tag lines shall be used for handling lengths or bulky loads. Take the slack out of the chains or slings gradually. Make sure all personnel are clear before making a lift. · Portable remote control crane operators shall keep all parts of their bodies away from the load and never position themselves under the load. · Do not make a lift or move the crane if anyone is in a position to be injured. · If a portable remote control crane operator is being helped, he or she shall not move the crane until he or she receives an ‘all clear’ signal from the helper(s). · Loads shall not be carried over workers' heads. · If anyone is in the path of travel, the portable remote control crane operator shall stop and clear the area before proceeding. · Bumping into runway stops or into other cranes on the same runway is prohibited. · When moving the crane, the portable remote control crane operator shall make sure the hook block, attachment and/or cables will not fall on nearby equipment. · The portable remote control crane operator shall not drag slings, chains, etc. along the floor. These could snag on something on the floor, causing the cables to break and strike the operator or a fellow worker.

ã04/2006, CATTRON-THEIMEG™

Cranesafety - 5

7.

OPERATING THE PORTABLE REMOTE CONTROLLED CRANE, continued. · If gloves are not required for safety reasons, they shall not be used when operating the portable remote controller. · All loose material or parts shall be removed from the load before starting the lift. Such material can fall and injure people below. · The portable remote control crane operator shall hoist lifts high enough to clear all apparatus and workers below the crane. · Plugging shall not be used as a regular means of stopping the crane and should be used for emergency stops only. If approved, plugging should only be performed as dictated by plant operating procedures. · If portable remote control crane operators are asked to do something they believe unsafe, they shall call their supervisors for advice. · Portable remote control crane operators shall never permit anyone to ride on the load or hook except when authorized by their supervisor. · When another crane on the same runway is stationary with or without a load, the portable remote control crane operator shall maintain a safe distance between the crane being operated and the stationary crane. In a power outage, the portable remote control crane operator shall set the ON/OFF switch(es) on the controller to ‘OFF’, keeping them in the OFF position until power is restored. · If the Portable Remote-controlled crane fails to respond correctly, the operator shall stop operation immediately by setting the ON/OFF switch(es) on the controller to ‘OFF’. When the controller is equipped with a STOP button, this shall be set to the ‘STOP’ position before switching off power to the controller. The fault condition shall be reported immediately to a supervisor. · Outside cranes subject to movement by winds, storms, etc. shall be securely anchored when left unattended. If the crane is equipped with a bridge parking brake, it shall also be set.

8.

BOARDING THE PORTABLE REMOTE CONTROLLED CRANE. · The Portable Remote-controlled crane shall not be boarded without permission of the supervisor in charge of crane operations in the area. · Using the power ON/OFF switch(es), the person boarding the Portable Remote-controlled crane shall switch the portable remote controller to ‘OFF’ and take it with him or her on to the crane. When the controller is equipped with a STOP button, this shall be set to the ‘STOP’ position before switching off power to the controller. · If the boarding party consists of more than one person, one person shall be designated as the leader of the boarding party. · The leader shall board the crane first, open and lock out the main switch (securing it with a padlock), and then signal the other members of the party that it is safe for them to board the crane.

Cranesafety - 6

ã04/2006, CATTRON-THEIMEG™

9.

ON BOARD THE PORTABLE REMOTE CONTROLLED CRANE. · Head room is at a minimum in some crane cabs and on some crane walkways. Caution shall be exercised by all people on board such cranes. Hard hats shall be worn at all times. · If the repair crew consists of more than one person, one person shall be designated as the crew leader. · Warning signs shall be placed on the floor beneath the crane or suspended from the crane indicating the crane is being serviced. · If any work to be done on the crane is carried out in locations unprotected by standard handrails, safety belts shall be worn by all crew members working in such unprotected locations. · All tools and equipment shall be moved onto the crane by the use of hand lines. All tools and equipment shall be securely attached to hand lines. · If it is necessary to have the control circuits on the crane energized, the repair crew leader shall open all power circuits to the motions before closing the main switch. · If, during the course of repairs, it becomes necessary to move the crane, it shall be the responsibility of the crew leader to insure that all personnel located on, and within the operational area of the crane are in a safe position out of harms-way. In addition the crew leader shall insure all tools and materials are stowed or tightly restrained before the crane is moved. · When the repair work is completed, the crew leader shall see that all crew members are off of the crane before he or she closes the main switch. · If more that one person is on board the remote controlled crane, one person shall be made responsible for seeing that all workers are off the crane before the portable remote controller is returned to operational use.

10.

PORTABLE REMOTE CONTROLLED CRANE UNDER REPAIR. · All persons operating other cranes on the same or adjacent runways shall be notified before anyone boards the subject crane. Such notification should include limitations of adjacent crane movement while others are on board. · Portable remote controlled cranes which have been pre-positioned for repairs and cannot be moved should be protected against being bumped by other cranes on the runway. Suitable bumpers adequate for the job should be installed on the exposed sides of the crane under repair and as far away from the crane as possible, with a minimum distance of 20 ft. (approximately. 6.1 m). The location of these bumpers shall be indicated by red lights so that they are clearly visible to other persons operating cranes traveling on the same runway.

When it is impossible to use bumpers for protection, red lights shall be placed in clear view of other persons operating cranes on the same runway to indicate the restricted travel zone.

It is desirable that such red lights be located a minimum of 20 ft. (approx. 6.1 m) from the crane under repair. · All operators of cranes on the same runway must be informed of the repair work, thoroughly instructed as to what their conduct should be for the duration of said repairs, and informed when repairs are completed.

ã04/2006, CATTRON-THEIMEG™

Cranesafety - 7

10.

PORTABLE REMOTE CONTROLLED CRANE UNDER REPAIR, continued. · When there is a runway adjacent to the runway on which the crane is being repaired, and if any hazard exis ts involving repairmen, red lights shall be placed in clear view of persons traveling on the adjacent runway to indicate the restricted travel zone. It is desirable that such red lights be located a minimum of 20 ft. (approx. 6.1 m) from the crane under repair.

When it is necessary to operate cranes on adjacent runways, such cranes shall come to a full stop before entering the restricted area. Cranes traveling on adjacent runways may only proceed through the restricted area when permission has been received from a signalman posted for this purpose. · Access of persons to and from the crane being repaired shall be under the control of the repair crew leader. · The floor area below the point where crane repairs are being made shall be roped off and posted with danger signs. · Handling of all small tools and materials, etc. from ground level to workers above shall be accomplished through the use of hand lines. Tools, materials, etc. shall not be tossed from the crane to the ground level and vice versa. · If crane repairs make it necessary for crew members to work on areas of the crane other than those protected by standard handrails, such crew members shall wear approved safety belts. · If it is necessary to move the crane to check the performance of operation, the crew leader shall designate who remains on the crane. The crew leader shall insure that all personnel located on, and within the operational area of the crane are physically located in a safe position out of harms-way. In addition the crew leader shall insure all tools and materials are stowed or tightly restrained before the main switch is closed and the crane is put into operation. · Upon completion of repairs, it is the crew leader's duty to personally insure that each person has left the crane and is clear before he or she removes the lock above the main switch and the crane is put back in operation.

11.

THE CONDITION OF THE PORTABLE REMOTE CONTROLLED CRANE. It is recommended that a written report be sent to your supervisor whenever you detect any conditio n that makes the crane unsafe. Many plants supply printed forms for this purpose. The Portable Remotecontrolled crane operator shall fill out these forms and turn them in at the end of each shift. Certain faults which the radio control crane operator may detect may be so critical that the crane shall be shut down at once and not operated until the fault is corrected. Typical check list items may include some or all of the following: · Condition of hoisting cable, drum, and hook blocks (broken strands, clipped sheave wheels, etc.). · Condition of brakes (hoist, trolley and bridge). · Oil or brake fluid leaks on the runway area. · Alignment of bridge (screeching or squealing wheels indicate that bridge is out of line). · Condition of bridge structure (broken welds, cracks and distortion).

Cranesafety - 8

ã04/2006, CATTRON-THEIMEG™

11.

THE CONDITION OF THE PORTABLE REMOTE CONTROLLED CRANE, continued. · Broken, cracked or chipped rails on bridge or runway. · Condition and security of trolley and bridge rail end-stops (missing or damaged from impact). · Condition of all limit switches. · Conditions of controls (electrical or mechanical defects that may lead to faulty operation). · Condition of electric motors (carbon dust around inspection covers indicate worn brushes). · Condition of gears (grinding or squealing may mean a lack of lubrication or foreign materials in gear teeth). · Frequent overload relay tripping of power circuits. · Mechanical parts loosened by vibration (loose rivets, covers, etc.). · Wheel condition (flange wear, cracks, holes, or visible signs of bearing damage). · Bumpy riding (worn wheels). · Worn collector shoes or bars. · Burned out, broken, or inoperable warning or signal lights. · Unintended stopping or starting of any crane motion, warning device, light or auxiliary function. · Condition of walkways and ladders (missing or loose handrails, ladder rungs, etc.)

Portable Remote-controlled Crane operators shall not attempt to make any repairs by themselves.

The condition shall be reported to a supervisor to enable repairs to be carried out by suitably qualified personnel.

END

Internet Address for All CATTRON-THEIMEG™ companies: www.cattron-theimeg.com

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ã04/2006, CATTRON-THEIMEG™

United States of America Cattron-Theimeg Inc. 58 West Shenango Street Sharpsville, PA 16150-1198 Phone: 1- 724- 962-3571 Fax: 1-724- 962-4310 e-mail: mail@cattron-theimeg.com Canada Cattron-Theimeg Canada Ltd. 150 Armstrong Avenue, Units 5 & 6 Georgetown, Ontario L7G 5G8 Phone: 1-905-873-9440 Fax: 1-905-873-9449 e-mail: salescdn@cattron-theimeg.com United Kingdom Cattron-Theimeg (UK) Ltd. Riverdene Industrial Estate, Molesey Road, Hersham Walton-on- Thames, Surrey KT12 4RY Phone: 44-1932-247511 Fax: 44-1932-220937 e-mail: sales@cattronuk.com

South Africa Cattron-Theimeg Africa (PTY.) Ltd. 24 O'Rielly Merry Road, Rynfield, Benoni P.O. Box 15444, Farrarmere, Benoni Gauteng 1518, South Africa Phone: 27-11-425-1123 Fax: 27-11-849-5717 e-mail: cattron@iafrica.com South America (Brazil) Cattron-Theimeg Américas Ltda.

Rua Antonio Rodrigues de Carvalho, 435 13033-220 - Campinas – SP Phone: 55-19-3243-7803 Fax: 55-19-3243-9258 e-mail: cattronamericas@cattron-theimeg.com Europe (Germany) Cattron-Theimeg Europe GmbH & Co. Krefelder Straße 423-425 41066 Mönchengladbach Phone: 49-2161-63630 Fax: 49-2161-6363100 e-mail: theimeg@theimeg.de

Internet Address for All CATTRON ® Group International Companies: www.cattron-theimeg.com

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.

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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.

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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.

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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.

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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

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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

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