PDF DOWNLOAD Cat Bucyrus 7MFBH-48A Feeder Breaker Operation Manual A6474X248

Operation Manual BUCYRUS - Feeder Breaker Model - 7MFBH-48A Doc. No.:

A6474X248

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

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

Internet: www.bucyrus.com

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

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

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

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

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

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

© BUCYRUS AMERICA, INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

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

2. Your safety

© BUCYRUS AMERICA, INC.

Your safety .............................................................................. 2.3 Personnel............................................................................. 2.4 Operation ........................................................................ 2.4 Installation and repair...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use ................................................................... 2.5 Unauthorized use............................................................ 2.5 Safety instructions................................................................ 2.7 General rules: ................................................................. 2.7 Storage and transport ..................................................... 2.9 Installation and start-up................................................... 2.9 Operation .......................................................................2.10 Maintenance and repair .................................................2.10 Overview of the safety instructions .....................................2.15 Chapter 3: Storage and transport ..................................2.15 Chapter 4: Installation ....................................................2.15 Chapter 5: Operation .....................................................2.16 Chapter 6: Technical data..............................................2.19

3. Storage and transport Storage and transport ............................................................ 3.3 Storage ................................................................................ 3.3 Storage of the machine and spare parts......................... 3.3 Transport.............................................................................. 3.4 Before transport .............................................................. 3.5

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

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Table of contents _________________________________________________

Operation ................................................................................. 5.3 How to operate the feeder breaker ..................................... 5.3 Who is allowed to operate the feeder breaker ............... 5.3 When can conveying be started?.................................... 5.3 Controls and indicators ........................................................ 5.4 Operator’s station............................................................ 5.4 Primary valve bank ......................................................... 5.5 Starter enclosure............................................................. 5.8 Conveyor........................................................................5.10 Daily starting procedure .................................................5.11 Shutdown procedure......................................................5.13 Electrical system ............................................................5.15 Starter enclosure.......................................................5.17 Electrical components ...............................................5.18 Hydraulic system............................................................5.19 Major hydraulic components ....................................5.20 Mechanical assemblies..................................................5.23 Crawler assembly (s) ...............................................5.23 Conveyor chain ........................................................5.24 Grease take-up ........................................................5.24 Head shaft ................................................................5.25 Power unit ................................................................5.26 Tail shaft ...................................................................5.26 Breaker assembly .....................................................5.27 Instructions on the maintenance of the feeder breaker 5.29 Important notes ........................................................5.29 Before maintenance .................................................5.29 Lubrication and inspection .......................................5.31 Specific lubrication and maintenance procedures ........5.34 Every 8 hours of operation .......................................5.34 Weekly ......................................................................5.36 Every 2 weeks ..........................................................5.39 Monthly .....................................................................5.40 Every 3 months ........................................................5.41 Every 2500 hours ......................................................5.42 Every 6 months ........................................................5.43 Inspection of the feeder breaker ...................................5.45 Inspection of wear parts on the feeder breaker ............5.46 Instructions on the adjustment procedures ...................5.47 Conveyor chain adjustment .....................................5.47 Crawler track adjustment .........................................5.49 Breaker drive chain ...................................................5.51 Instructions on the replacement of wear parts ..............5.54 Head shaft ................................................................5.54 Head shaft sprockets ...............................................5.56 Tail shaft ...................................................................5.58 Conveyor chain ........................................................5.63 Crawler track ............................................................5.66 Crawler assembly .....................................................5.69 Power unit ................................................................5.76 Conveyor drive motor ...............................................5.84 Breaker assembly .....................................................5.87 Breaker bits ...............................................................5.90

_________________________________________________________________ BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

5. Operation

________________________________________________ Table of contents 6. Technical data Technical data ......................................................................... 6.3 Components of the feeder breaker breaker ......................... 6.3 Tightening torques................................................................ 6.7 Permissible data ................................................................. 6.13 Lubrication fluids and greases....................................... 6.13

7. For your information

© BUCYRUS AMERICA, INC.

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

________________________________________________________________ A6474X248

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© BUCYRUS AMERICA, INC.

Table of contents _________________________________________________

_________________________________________________________________ BUCYRUS – Model 7MFBH-48A Feeder Breaker

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1

About this manual

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_______________________________________ Before starting to work

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

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: BUCYRUS – Model 7MFBH-48A Feeder Breaker Serial No.: 54-2143 / 54-2144 and is only permitted to be used for equipment of this type.

© BUCYRUS AMERICA, INC.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine.

It should, if possible, always be available at the place of operation.

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

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine.

Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who: ■ ■ ■ ■ ■ ■ ■ ■

are in charge of transport prepare the rise heading perform assembly / disassembly work operate the machine eliminate faults perform daily routine work on the face or in the entry perform maintenance work perform repair work

supervisory personnel who: ■ ■

initiate and/or supervise the activities just indicated.

______________________________________________________________ A6474X248 SSVI/03 1.3

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

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

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

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

safety

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

© BUCYRUS AMERICA, INC.

service

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

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

Try to memorize the symbols and their meanings.

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

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

© BUCYRUS AMERICA, INC.

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

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

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

■

Items in lists are marked with bullets.

–

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

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

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

______________________________________________________________ A6474X248 SSVI/03 1.5

© BUCYRUS AMERICA, INC.

Before starting to work ________________________________________

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

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2

Your safety

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__________________________________________________ Personnel

Your safety This chapter provides vital information for your safety.

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine.

■

of the Mines Inspector and

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of the mining supervisory authorities

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

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Personnel ___________________________________________________ Personnel Operation training

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

The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit.

Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the ■

mechanics,

■

hydraulics and

■

control engineering

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

Installation and repair work on: ■

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

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

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

© BUCYRUS AMERICA, INC.

and must be able to prove this knowledge.

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

Intended uses include: ■

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

Unauthorized use

© BUCYRUS AMERICA, INC.

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

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the transport of persons

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

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

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© BUCYRUS AMERICA, INC.

Operating conditions __________________________________________

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

___________________________________________ Safety instructions Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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

© BUCYRUS AMERICA, INC.

Inform your colleagues of:

safety equipment

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your exact location.

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the work you are performing.

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the time that you will probably require.

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

Observe the acoustic and optical start-up warnings of the machine.

symbol plates emergency stop (panic strip)

lock-out

cordon off working area

Observe the symbol plates on the machine.

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

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

maintenance work

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inspection work

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repair work

Cordon off your working area widely for the machine.

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

conveyor chains

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flights

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pivot points

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boom assemblies

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crawler assemblies

© BUCYRUS AMERICA, INC.

moving parts

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

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

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

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

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

© BUCYRUS AMERICA, INC.

means of attachment

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

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

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

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

mobile handling equipment

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

Installation and start-up inclined face

environmental acceptability

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

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

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

inspection maintenance instruction and safety tags

operator’s area

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

Verify that all maintenance has been performed.

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

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

Clean any foreign material from the operator’s area.

______________________________________________________________ A6474X248 SSVI/03 2.9

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

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

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

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

Maintenance and repair

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

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

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

Protect your work area against falling rocks.

replacing components

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

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

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

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

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

For raising the feeder breaker use only: ■

crib blocks with adequate load-holding capacity

■

hoists, jacks or cranes with adequate load-carrying capacity

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© BUCYRUS AMERICA, INC.

Be sure to observe the prescribed maintenance and inspection intervals.

___________________________________________ Safety instructions handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

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

maintenance, repair

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

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

Always replace damaged or lost decals and metal instruction plates.

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

© BUCYRUS AMERICA, INC.

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

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

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

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

the hoses are not pinched or trapped

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the hoses have no bubbles or blisters

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

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the outer sheath of the hoses is not damaged

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the connectors are securely inserted into the sockets

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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.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

© BUCYRUS AMERICA, INC.

Fig. 1: Example: 4SP hydraulic hose, designation

1. manufacturer 2. hose type 3. date of manufacture 1st quarter 2000

4. nominal diameter 5. flame-resistant and antistatic

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.

_________________________________________________________________ 2.12 BUCYRUS – Model 7MFBH-48A Feeder Breaker

___________________________________________ Safety instructions 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. 2: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

© BUCYRUS AMERICA, INC.

Fig. 3: Laying hydraulic hoses, twisting Right

■

Wrong

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

Fig. 4: Laying hydraulic hoses, bending Right

Wrong

______________________________________________________________ A6474X248 SSVI/03 2.13

Safety instructions ____________________________________________ ■

always have a little slack.

Fig. 5: 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.

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

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

Fig. 6: Laying hydraulic hoses, connections on moving parts Right

Wrong

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

© BUCYRUS AMERICA, INC.

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.

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

Use only suitable load handling devices.

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

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

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

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

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

Chapter 5: Operation DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

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

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

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

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

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

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

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

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© BUCYRUS AMERICA, INC.

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

_________________________________________________________________ 2.18 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

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

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

© BUCYRUS AMERICA, INC.

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

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

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

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

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

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

______________________________________________________________ A6474X248 SSVI/03 2.19

© BUCYRUS AMERICA, INC.

Overview of safety instructions _________________________________

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

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3

Storage and transport

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________________________________________________________________

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________________________________________ Storage and transport

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

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

Storage corrosion protection

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

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

© BUCYRUS AMERICA, INC.

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

dirt and moisture

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

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

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

short-term storage

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

long-term storage

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

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

■

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

■

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

■

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

■

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

______________________________________________________________ A6474X248 SSVI/03 3.3

■

Coat exposed valve bank valve spools with rust inhibitor.

■

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

■

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

machine electrics

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

random sample inspection

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

natural aging

HFA fluids

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

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

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

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

Long-term storage of spare components hydraulic components

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

miscellaneous components

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

motors

plastic deformation

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

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

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

© BUCYRUS AMERICA, INC.

Storage and transport _________________________________________

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

Dimensions

■

Weight

■

lifting points, etc.

© BUCYRUS AMERICA, INC.

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

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

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

Use only suitable load handling devices.

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 (e.g. CV 50).

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.

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© BUCYRUS AMERICA, INC.

Storage and transport _________________________________________

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

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4

Installation

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__________________________________________________Installation

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

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

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

© BUCYRUS AMERICA, INC.

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

Which tools are required for installation? tool box

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

In addition, various items of auxiliary equipment and machines may be required at the point of installation.

These include i.e.: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

______________________________________________________________ A6474X248 SSVI/03 4.3

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

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

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

© BUCYRUS AMERICA, INC.

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

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

__________________________________________________Installation Pre-installation check list

© BUCYRUS AMERICA, INC.

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

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

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

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

■

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

■

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

■

check the operation of the remote start pushbuttons

■

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

■

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

■

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

■

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

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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.

emergency stop pull cord switch

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

guards and covers

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

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

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

valve handle retainer

The machine is equipped with a valve handle retainer to reduce the possibility of accidental movement of the control handles. The retainer should be put in the down position during conveying operations to prevent the possibility of accidental movement of control handles.

stop switch (starter enclosure)

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

stop switch (remote)

The machine is equipped with two (2) remote start/stop switches. Depressing either of the stop switch buttons will shutdown all machine functions immediately.

stop switch (power center)

The machine is equipped with two (2) start/stop switches located on the left and right sides of the machine. Depressing either of the stop switch buttons will de-energize the machine from the main power center.

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

© BUCYRUS AMERICA, INC.

Safety features include: (Reference Fig. 7)

__________________________________________________Installation Fig. 7: Safety features on the feeder breaker Stop switch (power center)

Stop switch (power center)

Emergency stop pull cord switch Valve handle retainer

© BUCYRUS AMERICA, INC.

Stop switch (starter enclosure)

Stop switch (2) (remote)

______________________________________________________________ A6474X248 SSVI/03 4.7

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

Power unit

Discharge section Starter enclosure

Hydraulic oil tank

Breaker assembly

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

Torque hub

Ratio chains

Conveyor chain

Emergency pull cord stop

Receiving section

Tail shaft take-ups Tail shaft

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

© BUCYRUS AMERICA, INC.

Operator’s area

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

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

 Couple the towing machine securely to the feeder breaker.  Chock front and rear of both crawler drives.

WARNING! Failure to chock the front and rear of both crawlers could allow uncontrolled movement of the feeder breaker. Failure to follow this warning could cause serious injury or death to you or other workers.  Rotate the torque hubs on both right and left sides of the feeder breaker to the free position as follows (Fig. 8).  Remove the two (2) bolts that secure the cover to the center of the torque hub.  Rotate cover and reinstall with the two (2) bolts to disengage driveshaft.

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

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

_________________________________________________________________ 4.9 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

To tow the feeder breaker proceed as follows:

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

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

© BUCYRUS AMERICA, INC.

 Rotate the torque hub covers on both right and left sides of the feeder breaker to the drive position.

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

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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. It also includes instructions on the replacement of wear parts.

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

How to operate the feeder breaker

© BUCYRUS AMERICA, INC.

DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the feeder breaker?

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

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

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 Operator’s station The primary controls for the machine are located on the left hand side.

The operator’s station (Fig. 9) consists of the following controls and indicators: primary valve bank, auxiliary function pressure gauges, conveyor speed pressure gauge, conveyor speed control valve, conveyor direction control valve, starter enclosure, oil level sight gauge and remote push button start/stop switch.

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

Starter enclosure

Oil Level sight gauge

Primary valve bank

Auxiliary function pressure gauges

Conveyor speed and direction control valves Conveyor speed pressure gauge

Start/stop switch (power center)

_______________________________________________________________________ 5.4 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Fig. 9: Operator’s station

___________________________________________________Operation Primary valve bank The primary valve bank (Fig. 10) consists of the following hydraulic controls: “POWER FILL”

The first lever from the operator’s right controls the “POWER FILL”. To operate the power fill, energize the control lever and turn ball valve handle located on the left side of the discharge section to the open position. To de-energize power fill pump, turn ball valve handle to closed position and move control lever to the centered position.

© BUCYRUS AMERICA, INC.

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

“RIGHT FRAME LIFT”

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

“RIGHT TRAM”

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

“LEFT TRAM”

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

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

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

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

______________________________________________________________ A6474X248 SSVI/03 5.5

Operation____________________________________________________ “LEFT FRAME LIFT”

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

“FRAME TILT”

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

Fig. 10: Primary valve bank “LEFT LIFT”

“LEFT TRAM”

“RIGHT TRAM”

“RIGHT LIFT”

“POWER FILL”

Power fill ball valve location

auxiliary function pressure gauges

The auxiliary function pressure gauge (Fig. 11) is a high pressure gauge (6,000 psi) located to the left of the tram control levers. This gauge gives the operator a constant reading of the auxiliary system pressure.

conveyor speed pressure gauge

The conveyor speed pressure gauge (Fig. 11) is a low pressure gauge (600 psi) located to the right of the conveyor direction control lever.

This gauge gives the operator a constant reading of the conveyor speed pressure.

_______________________________________________________________________ 5.6 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

“TILT”

___________________________________________________Operation two position conveyor direction control valve

The two position conveyor direction control valve (Fig. 11) controls the conveyor direction. Push the control lever down to run the conveyor in the direction of the discharge end and pull the control lever up to run the conveyor in the direction of the receiving end.

conveyor speed control valve

The conveyor speed control valve (Fig. 11) allows the operator to adjust the speed of the conveyor. To increase conveyor speed, turn the adjustment knob clockwise (CW). To decrease conveyor speed, turn the adjustment knob counter-clockwise (CCW).

© BUCYRUS AMERICA, INC.

Located on the right side of the discharge end of the machine is two (2) pressure gauges that gives the operator a constant pressure reading for system and charge pressures. See below for a brief description of each gauge. tram circuit system pressure gauge

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

tram circuit charge pressure gauge

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

oil level sight gauge

The oil level sight gauge (Fig. 11) is located on the side of the oil tank.

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

Start/stop switch (power center)

The machine is equipped with two (2) start/stop switches (Fig. 11) located on the left and right sides of the machine. The machine can be energized or de-energized from the main power center with either of the switches.

Fig. 11: Controls and indicators

Oil Level sight gauge Auxiliary function pressure gauges Conveyor speed and direction control valves Conveyor speed pressure gauge

Start/stop switch (power center)

______________________________________________________________ A6474X248 SSVI/03 5.7

Operation____________________________________________________ Starter enclosure The starter enclosure (Fig. 12) is located on the left hand side of the machine and consists of the following machine’s electrical functions: “START” (conveyor)

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

“STOP” (conveyor)

This pushbutton switch (when depressed) stops the electric motor on the machine.

“MANUAL/OFF/AUTOMATIC” selector switch

The “MANUAL/OFF/AUTOMATIC” switch is a three (3) position rotary switch that is used TO:

circuit breaker lever

–

“MANUAL” - is used to bypass the belt sequence switch.

–

“AUTOMATIC” - is used with the belt sequence switch to stop the conveyor when the outby belt stops.

–

“OFF” - shuts down the machine.

This lever is used to reset the circuit breaker when it has tripped. If the breaker has tripped, the reset lever must be moved to the “RESET” position first and then to the “ON” position.

Fig. 12: Starter enclosure cover “START” conveyor

“STOP” conveyor

Not used

“AUTOMATIC” “MANUAL” “OFF”

Circuit breaker reset lever

_______________________________________________________________________ 5.8 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

___________________________________________________Operation start/stop switch (remote)

The machine is equipped with two (2) remote start/stop switches (Fig. 13). These remote start/stop switches allows the operator to start or stop the machine from a remote location.

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

Fig. 13: Start/stop switch (remote)

© BUCYRUS AMERICA, INC.

“START”

“STOP”

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Operation____________________________________________________ Conveyor Perform daily start-up procedure (see Start-up procedure in this chapter). The conveyor may be started utilizing the conveyor direction and speed control valves located on the left side of the machine (Fig. 14).

The running speed of the conveyor is controlled by a pressure reducing valve located below the conveyor direction control valve. To increase conveyor speed, turn the adjustment knob clockwise (CW). To decrease conveyor speed, turn the adjustment knob counter-clockwise (CCW).

IMPORTANT! If it is necessary to reverse the conveyor, it should be jogged only. Running the conveyor in the reverse direction for a period of time with material in the hopper, will jam the conveyor and it will be necessary to empty the machine hopper before the conveyor will restart.

Fig. 14: Conveyor control levers

Conveyor speed pressure gauge

Conveyor speed and direction control valves

_______________________________________________________________________ 5.10 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

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

___________________________________________________Operation Daily starting procedure (Reference Fig. 15) After reading the previous descriptions and locating each control, the operator is ready to operate the feeder breaker . An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

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

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

© BUCYRUS AMERICA, INC.

 Operate all valve control levers to ensure that they are free and in neutral position.  Check conveyor for any foreign material or objects.  Check that all other personnel are within a safe distance of the machine.

WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the machine.  Apply power to the machine. (Line side of the main circuit breaker)  Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET” position and then to the “ON” position.

Regular mode (conveying)  Turn the “MAN - OFF - AUTO” selector switch located on the door of the starter enclosure to either “MAN” or “AUTO”.

–

“AUTO” when the outby belt is running.

–

“MAN” when the outby belt is not running (for testing).

 Engage either the start pushbutton located on the cover of the starter enclosure or one of the two remote pushbuttons. The motor should start.  Push the two position conveyor direction control lever to the desired direction of travel.  Adjust the conveyor speed control valve to the desired speed.

______________________________________________________________ A6474X248 SSVI/03 5.11

Operation____________________________________________________ Tram only mode  Turn the “MAN - OFF - AUTO” selector switch located on the door of the starter enclosure to “MAN”.  Engage either the start pushbutton cover of the starter enclosure or one of the two remote pushbuttons. The motor should start.  Operate tram control levers to the desired direction of travel.

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

© BUCYRUS AMERICA, INC.

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

Fig. 15: Conveyor and tram control levers

Tram control levers

Conveyor speed pressure gauge

Conveyor speed and direction control valves

_______________________________________________________________________ 5.12 BUCYRUS – Model 7MFBH-48A Feeder Breaker

___________________________________________________Operation Shutdown procedure (Reference Fig. 16)  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.  Stop the machine by depressing the “STOP” push-button located on the starter enclosure or either of the two remote pushbuttons.  Turn the “MAN / OFF / AUTO” switch to the “OFF” position.

© BUCYRUS AMERICA, INC.

 Move the conveyor directional control handle to the centered “NEUTRAL” position.  Turn the conveyor speed control knob counter clockwise (CCW) to the lowest speed.

Fig. 16: Shutdown control (s) locator “STOP” conveyor “START” conveyor

“OFF”

Starter enclosure cover Conveyor speed pressure gauge

Conveyor speed and direction control valves

“STOP” Remote pushbutton

______________________________________________________________ A6474X248 SSVI/03 5.13

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

_______________________________________________________________________ 5.14 BUCYRUS – Model 7MFBH-48A Feeder Breaker

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

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

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

© BUCYRUS AMERICA, INC.

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

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

Fig. 17: Electrical component loca-

Remote pushbutton (2)

Electric motor 200 hp

Start/Stop switch

Starter enclosure Emergency stop pull cord switch

Start/Stop switch

_____________________________________________________________ A6474X248 SSVI/03 5.15

Electrical system _____________________________________________

© BUCYRUS AMERICA, INC.

200

Fig. 18: Electrical layout

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

____________________________________________ Electrical system Starter enclosure The starter enclosure (Fig. 19) located on the left hand side of the discharge end of the machine houses the primary electrical control components.

On the cover of the starter box are the electrical switches . These are labeled and control the start and stop functions for the electric motor.

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

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

© BUCYRUS AMERICA, INC.

Fig. 19: Starter enclosure components

Circuit breaker Timer (3)

Rectifier

Relay (4)

Control transformer

Terminal blocks

Fuse block (2)

Interlock

Overload relay

Ground fault circuit breaker

_____________________________________________________________ A6474X248 SSVI/03 5.17

Electrical system _____________________________________________ Electrical components (Reference Fig. 17) The machine has one (200 hp) electric drive motor that drives the hydraulic pumps.

emergency stop pull cord switch

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

remote start/stop switch (2)

The machine is equipped with two (2) remote start/stop switches.

These remote start/stop switches allows the operator to start or stop the machine from a remote location.

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

sequence switch

The machine is equipped with a sequence switch that will automatically shutdown the machine in the event that the belt system stops for any reason.

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

© BUCYRUS AMERICA, INC.

electric motor

____________________________________________ 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.

© BUCYRUS AMERICA, INC.

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

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

Fig. 20: Hydraulic component locator

1. oil tank 2. hydrostatic pump 3. tandem gear pump 4. valve bank 5. tilt and lift cylinders 6. tram motors 7. conveyor motor 8. flow divider (power fill) 9. ball valve 10. manifold block

11. pressure gauge (6,000 psi) 12. pressure gauge (600 psi) 13. shuttle valve 14. loop flush valve 15. heat exchanger 16. charge filter 17. pressure filters 18. return filter 19. pressure filter (hydrostatic) 20. return line filter

21. flow control valve 22. 4-way manual valve 23. pressure reducing valve 24. o-ring manifold 25. manifold block

_____________________________________________________________ A6474X248 SSVI/03 5.19

Hydraulic system _____________________________________________ Major hydraulic components

hydraulic oil tank

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

hydrostatic pump

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

tandem gear pump

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

primary valve bank

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

power fill pump

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

tilt hydraulic cylinders

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

lift hydraulic cylinders

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

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

tram motors

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

conveyor motor

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

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

© BUCYRUS AMERICA, INC.

(Reference Fig. 20)

____________________________________________ Hydraulic system loop flush valve

The machine is equipped with a loop flush valve located within the conveyor circuit. The valve is used to dump approximately 30% of the charge oil to the low pressure side of the circuit.

heat exchanger

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

two position conveyor direction control valve

The two (2) position conveyor control valve is used to control the conveyor direction of travel.

charge filter

The charge filter are located within the machines hydraulic circuit is used to filter the charge fluid. The filter removes hot oil from the circuit, allowing the charge pump to replenish the circuit with cooler oil.

pressure filter (s)

Two (2) pressure filter (s) are located within the machines hydraulic circuit. These are used to filter fluid on the pressure side of the circuit.

return filter

The return filter is used to filter fluid from the case drains of the hydraulic pump and motors.

© BUCYRUS AMERICA, INC.

power fill filter

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

pressure filter (hydrostatic)

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

ball valve

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

pressure reducing valve

The pressure reducing valve located on the left side of the machine is used to control the speed of the conveyor.

_____________________________________________________________ A6474X248 SSVI/03 5.21

Hydraulic system _____________________________________________

© BUCYRUS AMERICA, INC.

Fig. 21: Hydraulic schematic

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

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

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

Crawler assembly (s)

© BUCYRUS AMERICA, INC.

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

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

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

_____________________________________________________________ A6474X248 SSVI/03 5.23

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

Fig. 23: Conveyor chain components

Roll pin

© BUCYRUS AMERICA, INC.

Chain link section

Flight bar

Grease take-up The machine is equipped with a conveyor chain grease take-up assembly (Fig. 24) that provides ease of adjustment for the conveyor chain.

The take-up assembly provides constant tension on the tail shaft around which the conveyor chain rides at the receiving end of the machine. (See Conveyor chain adjustment in this chapter) Fig. 24: Grease take-up main components Stop valve (2)

Grease manifold

Grease fitting (2)

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

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

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

Head shaft

© BUCYRUS AMERICA, INC.

Key (2)

Bearing (2)

Fig. 26: Conveyor torque arm and hydraulic motor

Torque arm

Coupling

Hydraulic motor

_____________________________________________________________ A6474X248 SSVI/03 5.25

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

Fig. 27: Power unit main components Sprocket Reducer

Coupling Motor (200 HP) Connecting tube

Hydrostatic pump Mounting base Gear pump

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

Fig. 28: Tail shaft components Roller (2)

Key (2) Set screw (2)

Tail shaft

Slide plate

Roller bearing (2) Piston rod adapter (2)

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

© BUCYRUS AMERICA, INC.

Coupling

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

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

Fig. 29: Breaker assembly main components Bearing (2)

Shear hub

© BUCYRUS AMERICA, INC.

Grease inlet

Shear pin

Retainer cap (2)

Shear hub grease fitting (3) Grease outlet

Bearing housing (2)

Pick (25) (each pick is retained by retainer rings)

Breaker side plate (2)

Chain sprocket

_____________________________________________________________ A6474X248 SSVI/03 5.27

© BUCYRUS AMERICA, INC.

Mechanical assemblies ________________________________________

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

________________________________________________ Maintenance Instructions on the maintenance of the feeder breaker Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine.

In particular, observe the safety instructions in chapter 2 “Your safety”.

Important notes

© BUCYRUS AMERICA, INC.

Please observe the following: ■

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

■

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

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus spare parts when replacing components.

■

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

■

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

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

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

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

■

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

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

______________________________________________________________ A6474X248 SSVI/03 5.29

Maintenance _________________________________________________ ■

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

■

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

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

■

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

■

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

■

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

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

© BUCYRUS AMERICA, INC.

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

________________________________________________ Maintenance Lubrication and inspection Maintenance of the feeder breaker includes: ■

Lubrication of the machine in accordance with the lubrication schedule.

■

Inspection of the machine for faults and proper function.

■

Inspection for wear parts.

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

© BUCYRUS AMERICA, INC.

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

Fig. 30: Central lubrication Outboard bearing

Tail shaft

Breaker

Note: Outboard bearing and breaker shaft ports used only if applicable on machine.

Head shaft

Central lubrication manifold

______________________________________________________________ A6474X248 SSVI/03 5.31

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

Table 1: Lubrication and maintenance schedule Description Every 8 hours of operation

Places

Lubricant

Specification

1

Head shaft bearings

2

Century Replex 2

Spec. 100-3

2

Breaker bearings

2

Century Replex 2

Spec. 100-3

3

Tail shaft and slide tube bearings

4

Century Replex 2

Spec. 100-3

4

Hydraulic oil level (check)

1

Century Hydraulic AW 68

Spec. 100-1

5

Charge filter (check)

1

6

Pressure filter (auxiliary circuit) (check)

2

7

Return filter (check)

1

8

Pressure filter (hydrostatic) (check)

9

Breaker bits

Century Replex 2

Spec. 100-3

1 Inspect

Weekly 10

Crawler track take-up bearings

2

11

Conveyor chain tension

1

12

Fasteners (nuts, bolts and screws)

Inspect

13

Electrical cables, conduits and glands

Inspect

14

Hydraulic hoses and connections

Inspect

15

Hydraulic system pressures

Check

16

Tram reducer (s) (check oil level)

2

17

Breaker drive chain

1

18

Breaker reducer (check)

1

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

Every 2 weeks 19

Charge filter (change)

1

20

Pressure filter (auxiliary circuit) (change)

2

21

Return filter (change)

1

22

Pressure filter (hydrostatic) (change)

1

Monthly 23

Power fill filter (change)

1

24

Conveyor tilt and lift cylinders

4

Century Replex 2

Spec. 100-3

25

Crawler anchor pin (s)

2

Century Replex 2

Spec. 100-3

Every 3 months 26

Electric motor

2

Exxon Unirex N-2

Spec. 100-14

27

Breaker reducer

2

Century Replex 2

Spec. 100-3

28

Breaker reducer (change)

After 1st 500 hours, Every 2500 hours thereafter 1

Spec. 100-6

Every 6 months 29

Hydraulic oil tank (change)

1

30

Tram reducer (change oil)

2

Century Hydraulic AW 68

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

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

© BUCYRUS AMERICA, INC.

Item

________________________________________________ Maintenance Fig. 31: Lubrication chart 8, 22 7, 22 15 5, 20

26

18, 27, 28

23

17

© BUCYRUS AMERICA, INC.

4, 29

24

25

16, 30

9

15

6, 20 15

10

6, 20

1, 2, 3

24

11

______________________________________________________________ A6474X248 SSVI/03 5.33

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

Lubricate the head shaft bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 32) located on the left side of the receiving section. Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

tail shaft and slide tube bearings

Lubricate the tail shaft and slide tube bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 32) located on the left side of the receiving section. Pump grease into the three (3) fittings until new grease can be observed coming out of the tail shaft and bearings.

breaker bearings

Lubricate the breaker bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 32) located on the left side of the receiving section. Pump grease into the fittings until new grease can be observed coming out of the bearing return lines. © BUCYRUS AMERICA, INC.

Fig. 32: Central lubrication panel

Central lubrication panel

hydraulic oil tank

Check the hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 33). The oil level should not be allowed to drop below the bottom of the sight glass. If the hydraulic oil level is low, add oil Spec. 100-1 via the power fill system.

Fig. 33: Hydraulic tank oil level

Oil level sight glass

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

________________________________________________ Maintenance charge filter

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

pressure filter (auxiliary circuit)

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

return filter

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

pressure filter (hydrostatic)

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

Fig. 34: Filter location

© BUCYRUS AMERICA, INC.

Pressure filter (hydrostatic) Charge filter

Return filter

Pressure filter (auxiliary circuit)

______________________________________________________________ A6474X248 SSVI/03 5.35

Maintenance _________________________________________________ Weekly crawler track take-up bearings

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

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

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

conveyor chain tension

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

fasteners

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

electrical cables, conduits and glands hydraulic hoses and fittings

■

head shaft bearing 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.

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

© BUCYRUS AMERICA, INC.

Fig. 35: Crawler track take-up lubrication

________________________________________________ Maintenance hydraulic system pressure (s)

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

Fig. 36: Hydraulic system pressure gauges (s) location Conveyor circuit charge pressure gauge

Conveyor system circuit pressure gauge

Tram system circuit pressure gauge

© BUCYRUS AMERICA, INC.

Tram system circuit pressure gauge Conveyor speed pressure gauge

tram reducer (s)

Check the oil level in both tram reducer torque hubs (Fig. 37):  Oil level/fill plug should be at the 3 o’clock and 12 o’clock position.  Remove the oil level/fill plugs.  The oil level should be kept at the level of the level/fill plug.  Should it be necessary to add oil, add Spec. 100-2 or 100-13 oil through the fill plug hole until it begins to flow out of the check hole.  Do not overfill the reducer.

Fig. 37: Tram reducer oil level Fill plug location

Check plug location

Drain plug location

______________________________________________________________ A6474X248 SSVI/03 5.37

Maintenance _________________________________________________ breaker drive chain breaker reducer

Lubricate the breaker drive chain with a good quality chain lube Check oil level in the breaker drive reducer (Fig. 38). Oil level should be maintained inside the sight glass on the side of the reducer when it is in operation. The oil should be changed after the first 500 hours of operation. Use Spec. 100-6 lubricant.

Fig. 38: Breaker reducer Inspection cover

Breather

Sight glass

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

© BUCYRUS AMERICA, INC.

Drain plug

________________________________________________ Maintenance Every 2 weeks charge filter

Change the charge filter element (Fig. 39). If the element is extremely dirty, a more frequent interval may be required.

pressure filter (auxiliary circuit)

Change the two (2) pressure filter’s element (Fig. 39). If the element is extremely dirty, a more frequent interval may be required.

return filter

Change the return filter’s element (Fig. 39). If the element is extremely dirty, a more frequent interval may be required.

pressure filter (hydrostatic)

Change the hydrostatic pressure filter’s element (Fig. 39). If the element is extremely dirty, a more frequent interval may be required.

Fig. 39: Filter location Pressure filter (hydrostatic)

© BUCYRUS AMERICA, INC.

Charge filter

Return filter

Pressure filter (auxiliary circuit)

______________________________________________________________ A6474X248 SSVI/03 5.39

Maintenance _________________________________________________ Monthly filter (power fill)

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

Fig. 40: Power fill filter location

conveyor lift and tilt cylinders

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

crawler anchor pins

Lubricate grease fittings on both left and right side crawler anchor pins with Spec. 100-3 (Fig. 41). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 41: Conveyor cylinder (s) and crawler anchor pin lubrication Lift cylinder (s) (grease fitting located on rod and base end)

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

Crawler anchor pin grease fitting located inside crawler frame

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

© BUCYRUS AMERICA, INC.

Power fill filter

________________________________________________ Maintenance Every 3 months electric motor

Lubricate the electric motor with Spec. 100-14 (Fig. 42):  Clean dirt and debris from around the two plugs, one is located on each end of motor.  Remove the plugs.  Install grease fittings and grease sparingly.  Remove grease fittings, clean and reinstall plugs.

NOTICE! The plugs must always be reinstalled in the electric motors.

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

© BUCYRUS AMERICA, INC.

breaker reducer

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

Fig. 42: Electric motor and breaker reducer lubrication Reducer central lubrication panel

Electric motor central lubrication panel

______________________________________________________________ A6474X248 SSVI/03 5.41

Maintenance _________________________________________________ Every 2500 hours reducer

Change the oil in the breaker drive reducer (Fig. 43). The reducer oil should be changed after the first 500 hours of operation and every 2500 hours afterwards. Remove the drain plug and allow the oil to completely drain. Clean and reinstall drain plug.  Add Spec. 100-6 lubricant as required until fluid is visible in sight glass.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Install level/fill plug.

Fig. 43: Breaker reducer Inspection cover

Breather

Drain plug

Sight glass

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

© BUCYRUS AMERICA, INC.

Do not overfill reducer.

________________________________________________ Maintenance Every 6 months hydraulic oil tank

Change the hydraulic fluid in the oil tank (Fig. 44).  Clean all dirt and debris from and around the fill cap and drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and reinstall drain plug.  Add oil 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.

© BUCYRUS AMERICA, INC.

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

Fig. 44: Hydraulic oil tank

Sight glass

Drain plug (located under bottom)

______________________________________________________________ A6474X248 SSVI/03 5.43

Maintenance _________________________________________________ tram reducer

Change oil in the tram reducer (Fig. 45).  Clean all dirt and debris from and around the level and fill plugs.  Rotate reducer until drain plug is at the 6 o’clock position and remove drain plug and allow the oil to completely drain.  Clean and reinstall drain plug.  Rotate reducer until plugs are at the 12 o’clock and 3 o’clock positions.  Add oil Spec 100-2 or 100-14 through the fill hole until fluid begins to flow from the check plug.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.

 Do not overfill reducer.

Fig. 45: Tram reducer oil change Fill plug location

Check plug location

Drain plug location

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

© BUCYRUS AMERICA, INC.

 Install level and fill plugs.

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

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

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X248 SSVI/03 5.45

Maintenance _________________________________________________ Inspection of wear parts on the feeder breaker

■

the conveyor chain

■

the conveyor chain flights

■

the conveyor drive sprockets

■

the conveyor tail shaft rollers/sprockets

■

the crawler pads

■

the crawler drive sprockets

■

the crawler idler rollers

■

the breaker drive shaft sprockets

■

the breaker drive chain

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

© BUCYRUS AMERICA, INC.

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

Inspect:

_______________________________________ Adjustment procedures Instructions on the adjustment procedures 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.

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

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

© BUCYRUS AMERICA, INC.

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 46):  Close the stop valve on manifold assembly securely.  Attach a grease gun to the grease fitting located on the manifold and apply grease until the conveyor chain is tight.  After tensioning chain, remove the allen head bolts from the tail shaft retainers and lift out retainers.  Insert shims over cylinder rod to maintain gap between bearing and end plate of box.  Store any unused shims under cover plate.

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.  Allow tail shaft pressure to rest completely on shims. Release pressure on the take-up cylinders by opening the top valve to vent grease. After grease has vented, close valve.

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

______________________________________________________________ A6474X248 SSVI/03 5.47

Adjustment procedures ________________________________________ Fig. 46: Conveyor chain adjustment

Stop valve

Grease fitting

© BUCYRUS AMERICA, INC.

Tail shaft retainer

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

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

To adjust tension on the crawler track with the take-up cylinders proceed as follows (Fig. 47):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Chain sag should be 1 3/4” at the center of the crawler.

© BUCYRUS AMERICA, INC.

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

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

You could be seriously injured or even killed by falling loads.  Run crawler in forward direction for 3 minutes at slow speed.  Run crawler in reverse direction for 3 minutes at slow speed.  Shutdown machine.  If necessary, re-adjust chain sag.  Add or remove required amount of shims to maintain correct tension.  Store and secure any unused shims on back of crawler cover plate.  Release grease pressure in the cylinder with the needle by loosening the grease fittings and turning the knob counterclockwise (CCW), allowing the shims to maintain the correct tension.  Tighten grease fitting.

WARNING! Due to grease cylinder being under high pressure, do not visually inspect to see if grease is released. You could be seriously injured from high pressure grease. ______________________________________________________________ A6474X248

SSVI/03

5.49

Adjustment procedures ________________________________________ Fig. 47: Crawler track adjustment

Idler assembly Take-up cylinder

Access cover

Needle valve © BUCYRUS AMERICA, INC.

Grease fitting

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

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

________________________________________________ Maintenance Breaker drive chain The breaker drive chain should be checked for correct tension at regular intervals.

To adjust tension on the breaker drive chain with the take-up cylinder proceed as follows (Fig. 48):  Remove the covers from the power unit.  Loosen the seven power unit adjustment bolts located on the side of the mounting base, bolts do not have to be removed.  Close the needle valve securely.  Attach a grease gun to the grease fitting and apply grease. Pump grease into the grease fitting until the correct tension is attained.

© BUCYRUS AMERICA, INC.

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

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

Fig. 48: Breaker drive chain adjustment

Adjustment bolts (7) located in bottom of mounting base

Shim location Take-up cylinder

Needle valve Shim storage

Grease fitting

Bleeder valve

______________________________________________________________ A6474X248 SSVI/03 5.51

© BUCYRUS AMERICA, INC.

Maintenance _________________________________________________

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

____________________________________ Replacement of wear parts

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

Head shaft The head shaft (Fig. 49) transmits the torque of the hydraulic motor to the conveyor chain assembly. It is part of a complete assembly. As soon as any component is worn, the component or complete head shaft must be replaced. Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

© BUCYRUS AMERICA, INC.

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

drive shaft

■

sprockets

■

bearings

■

hydraulic motor

Fig. 49: Head shaft main components Sprocket (2)

Head shaft Key (2)

Bearing (2)

______________________________________________________________ A6474X248 SSVI/03 5.53

Replacement of wear parts _____________________________________ How to remove the head shaft To remove the head shaft assembly from the discharge boom proceed as follows (Fig. 50):  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the two (2) sprocket guards located on the end of the discharge boom.  Remove the hydraulic motor. (See Hydraulic motor removal in this chapter).

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

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

How to install the head shaft To install the head shaft assembly proceed as follows (Fig. 50):  Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the discharge boom.  Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) nuts, bolts, and lock washers. Torque bolts to 645 ft-lbs.  Install the left and right covers to the end of the boom frame.  Connect the central lubrication hoses on both head shaft bearings.  Install the hydraulic motor. (See Hydraulic motor installation in this chapter).

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

© BUCYRUS AMERICA, INC.

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

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

Fig. 50: Head shaft removal and installation

© BUCYRUS AMERICA, INC.

Conveyor chain (not shown)

Covers

See hydraulic motor removal in this chapter

Head shaft Sprocket guard (s)

______________________________________________________________ A6474X248 SSVI/03 5.55

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

How to remove the head shaft sprockets To remove the sprockets from the head shaft assembly proceed as follows (Fig. 51):  Remove the drive shaft assembly from the discharge boom (see Drive shaft removal in this chapter).  Remove the two (2) bearings from the head shaft.

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

See parts manual for replacement parts list.

How to install the head shaft sprockets To install the sprockets on the head shaft proceed as follows (Fig. 51):  Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.  Insert one of the keys into the shaft keyway and slide first sprocket onto shaft.  Insert the other key into the shaft keyway and slide second sprocket onto shaft.  Slide both bearings onto shaft.  Install the drive shaft assembly in the discharge boom. (See drive shaft installation in this chapter.

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

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts How to install the head shaft split sprockets To install the split sprockets on the head shaft proceed as follows (Fig. 51): IMPORTANT! Adhere to all weld specifications shown on Fig. 51. Failure to do so may result in sprocket failure and machine damage.  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the two (2) sprocket guards located on the end of the feeder breaker.

© BUCYRUS AMERICA, INC.

 Remove damaged sprockets and keys from head shaft. Old sprockets may require cutting to remove.  Thoroughly clean and degrease the drive shaft.  Insert key into shaft keyway.  Install both sprocket halves onto shaft and tack weld in place.

Ensure sprocket alignment and proper spacing with conveyor chain.  Preheat sprocket weld joint to 600°F .  Weld sprocket halves together and do not exceed 800°F maximum interpass temperature. Ensure that the weld is smooth in the tooth area to prevent damage to the conveyor chanin bushings during chain operation.  If possible, cover sprocket with insulating blanket and allow weld to cool to a maximum of 100°F before uncovering. If this is not possible, then post weld heat to 800°F.  Connect conveyor chain. (See Conveyor chain replacement in this chapter).  Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

______________________________________________________________ A6474X248 SSVI/03 5.57

Replacement of wear parts _____________________________________ Fig. 51: Head shaft sprocket removal and installation 3/8 X 45° weld chamfer Head shaft

Bearing (2)

Sprocket guard 3/8 X 45° weld chamfer

Split sprocket Hydraulic motor

Conveyor chain

Sprocket (2) & key (2)

1.

2.

3.

4.

Do not mix and match halves with other sprockets.

Install sprocket and keys on head shaft.

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

Blend and smooth welds to avoid chain roller damage.

Weld notes: 1.

2.

3.

4.

5.

6.

7.

20.34

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

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

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

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

58.50 HOLD

3.97

41.88 HOLD

26.50

10.19

82.81 _________________________________________________________________ 5.58 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

General notes:

____________________________________ Replacement of wear parts Tail shaft The tail shaft (Fig. 52) allows for even adjustments friction free transition to the conveyor chain assembly. As soon as any component of the tail shaft is worn the component or complete tail shaft assembly must be replaced. Due to the high abrasion forces the tail shaft is subject to a very high level of wear.

© BUCYRUS AMERICA, INC.

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

shaft

■

roller (2)

■

slide plate

■

key (2)

■

set screw (2)

■

roller bearing (2)

■

piston rod adapter (2)

■

grease fitting (2)

Fig. 52: Tail shaft main components Tail shaft Roller (2)

Key (2) Set screw (2)

Grease fitting (2)

Slide plate

Roller bearing (2) Piston rod adapter (2)

______________________________________________________________ A6474X248 SSVI/03 5.59

Replacement of wear parts _____________________________________ How to remove the tail shaft To remove the tail shaft assembly from the receiving boom proceed as follows (Fig. 53):  Release tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).  Remove the five (5) bolts and lock washers from each of the tail shaft retainers and lift out the retainers.  Disconnect, tag and cap the central lubrication hoses to the tail shaft.  Remove the tail shaft shims.  Separate conveyor chain and fold back to clear tail shaft. (See Conveyor chain replacement in this chapter).

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

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 53):  With an appropriate lifting device, insert tail shaft into receiving boom.  Fold the conveyor chain over tail shaft.  Connect conveyor chain (see Conveyor chain replacement in this chapter.  Connect central lubrication hoses and lubricate tail shaft and slide plate bearings with Spec. 100-3 grease.  Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).  Install the tail shaft retainers with the five (5) bolts and lock washers in each side.  With machine running, visually inspect tail shaft to ensure that the shaft is turning and conveyor chain is not sliding across tail shaft.

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

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Fig. 53: Tail shaft removal and installation

Cover Tail shaft retainer plates (2)

Shims

© BUCYRUS AMERICA, INC.

Take-up cylinder

Tail shaft

______________________________________________________________ A6474X248 SSVI/03 5.61

Replacement of wear parts _____________________________________ How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 54):  Remove the tail shaft assembly from the receiving boom. (See How to remove the tail shaft in this chapter).  Slide both roller bearings and piston rod adapters from the tail shaft.  Remove the set screws from both tail shaft rollers and slid rollers from the shaft.  Remove the tail shaft from the slide plate.  Visually inspect all components for damage or wear and replace as necessary.

To assemble the tail shaft assembly proceed as follows (Fig. 54):  Thoroughly clean all parts that will be installed.  Grease tail shaft with Spec. 100-3 grease.  Slide tail shaft into the slide plate.  Insert keys into keyways on tail shaft.  Slide both rollers onto tail shaft, one on each end.  Install set screws into both rollers, ensuring that rollers and tail shaft slide plate are centered on tail shaft.  Tighten set screws.  Install both roller bearings and adapter plates on tail shaft, one on each end.  Install grease fittings, if required.  Install assembled tail shaft into machine. (See How to install the tail shaft in this chapter).

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

© BUCYRUS AMERICA, INC.

How to assemble the tail shaft

____________________________________ Replacement of wear parts Fig. 54: Tail shaft disassembly and assembly Tail shaft Roller (2)

Slide plate

Roller bearing (2) Piston rod adapter (2)

© BUCYRUS AMERICA, INC.

Key (2) Set screw (2)

Grease fitting (2)

______________________________________________________________ A6474X248 SSVI/03 5.63

Replacement of wear parts _____________________________________ Conveyor chain The conveyor chain (Fig. 55) 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

6 link chain section Spiral pin Flight bar

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

© BUCYRUS AMERICA, INC.

Fig. 55: Conveyor chain main components

____________________________________ Replacement of wear parts How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 56):  Lay conveyor chain sections on a clean flat surface.  Insert connector pins through flight end and align holes in spiral pin with holes in flight bar.  Insert spiral pin.  Drive spiral pin in with a hammer and punch. Ensure that spiral pin is recessed on both sides of flight bar.  Repeat the previous assembly instructions until the complete chain has been assembled.

© BUCYRUS AMERICA, INC.

Fig 56: Conveyor chain assembly

Extended pin connecting link Spiral pin (4)

Block link assembly

Flight bar

Side bar

6 link chain section

______________________________________________________________ A6474X248 SSVI/03 5.65

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

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

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

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

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

© BUCYRUS AMERICA, INC.

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

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

____________________________________ Replacement of wear parts Crawler track The crawler track (Fig. 57) assembly (left and right) carries the machine via torque received from the tram drive reducer. The crawler track is made up of one basic crawler pad assembly, which repeats sequentially along the entire pad loop. As soon as any component of the crawler track is worn the component or complete crawler track assembly must be replaced.

Each crawler track consists of the following main components: ■

crawler pad

■

connector pin

■

t-pin

Fig. 57: Crawler track main components

© BUCYRUS AMERICA, INC.

Crawler pad

Connector pin and T-pin

______________________________________________________________ A6474X248 SSVI/03 5.67

© BUCYRUS AMERICA, INC.

Replacement of wear parts _____________________________________

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

_______________________________________ Adjustment procedures How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 57):  Lay crawler track pads on a clean flat surface.  Align pads with chain connecting holes centered.  Insert connector into center of crawler pad connecting holes.  Drive T-pin through connecting pin and bend end to secure.  Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly

© BUCYRUS AMERICA, INC.

To remove the crawler track pad assembly proceed as follows (Fig. 57):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

To separate the crawler pads proceed as follows (Fig. 57) IMPORTANT! Heating or cutting connections with a torch or chisel may be required to ease the removal of T- pins.  Drive or cut T-pin from crawler pad connection using hammer and punch.  Separate crawler track assembly.  Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the crawler track assembly and slowly pull the crawler track completely out from under the machine.

______________________________________________________________ A6474X248 SSVI/03 5.69

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

Use only approved lifting equipment for connecting pulling devices to the crawler track.  Inspect the crawler drive sprocket and idler rollers for wear or damage. Replace if necessary.

How to install the crawler track pad assembly To install the crawler track pad assembly proceed as follows (Fig. 57):

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

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

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts Crawler assembly The crawler assembly (Fig. 58) consists of a take-up assembly and drive assembly that transmits torque to the crawler track via a hydraulic drive motor coupled to the tram drive torque hub. As soon as any component of the drive assembly is worn or damaged, the component must be replaced.

© BUCYRUS AMERICA, INC.

The crawler assembly consists of the following main components: ■

hydraulic drive motor

■

tram drive torque hub

■

cat pad assembly

■

take-up roller assembly

■

grease take-up assembly

■

drive sprocket

Fig. 58: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

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

______________________________________________________________ A6474X248 SSVI/03 5.71

Replacement of wear parts _____________________________________ How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 59):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

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

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

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

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

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

© BUCYRUS AMERICA, INC.

 Securely block under the crawler frame.

____________________________________ Replacement of wear parts How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 59):  Remove old take-up assembly (see previous section, How to remove crawler take-up assembly).

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

© BUCYRUS AMERICA, INC.

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

______________________________________________________________ A6474X248 SSVI/03 5.73

Replacement of wear parts _____________________________________ Fig. 59: Crawler take-up removal and installation

Tilt cylinder

Tilt cylinder mounting bracket

© BUCYRUS AMERICA, INC.

Crawler frame

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

____________________________________ Replacement of wear parts How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 60):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

© BUCYRUS AMERICA, INC.

 Disconnect, cap and tag all hydraulic hoses to hydraulic motor.  Remove slotted nut, roll pin and washer from lift cylinder anchor pin.  Slide anchor pin out of crawler frame and swing tilt cylinder free of the crawler frame.  Remove the six (6) bolts and lock washers that secure the removable side plate to crawler frame and remove side plate.  Remove the twelve (12) bolts and lock washers that secure the torque hub to the crawler frame.  Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.  Remove the four (4) bolts and lock washers that secure the hydraulic motor and adapter plate to the torque hub.  Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.  Slide adapter plate and motor off of torque hub.  Remove adapter plate gasket.  Remove the four (4) nuts and lock washers that secure the hydraulic motor to the adapter plate. And remove adapter plate.  Remove the twenty (20) bolts and lock washers that secure the sprocket to the torque hub and separate hub and sprocket.  Inspect all components for wear or damage.

______________________________________________________________ A6474X248 SSVI/03 5.75

Replacement of wear parts _____________________________________ How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 60):  Remove old crawler drive assembly (see previous section, How to remove crawler drive assembly).

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

■

step 1 – 70 ft-lb

■

step 2 – 140 ft-lb

■

step 3 – 210 ft-lb

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

■

step 1 – 25 ft-lb

■

step 2 – 50 ft-lb

■

step 3 – 70 ft-lb

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

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

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts ■

step 1 – 50 ft-lb

■

step 2 – 140 ft-lb

■

step 3 – 280 ft-lb

■

step 4 – 420 ft-lb

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

© BUCYRUS AMERICA, INC.

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

■

step 1 – 300 ft-lb

■

step 2 – 600 ft-lb

■

step 3 – 905 ft-lb

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

Fig. 60: Crawler drive disassembly and assembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

10.

11.

12.

13.

14.

15.

16.

17.

18.

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

19.

20.

21.

22.

23.

24.

25.

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

______________________________________________________________ A6474X248 SSVI/03 5.77

Replacement of wear parts _____________________________________ Power unit The power unit (Fig. 61) has been assembled as a unit and can be removed as a unit or as individual components. As soon as any component of the power unit is worn or damaged, the component must be replaced.

The power unit consists of the following main components: ■

gear pump

■

hydrostatic pump

■

pump coupling

■

motor (200 hp)

■

reducer

■

sprocket

■

connecting tube

Fig. 61: Power unit main components Sprocket reducer Coupling Motor (200 HP)

Connecting tube Coupling Hydrostatic pump Gear pump

Mounting base

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

© BUCYRUS AMERICA, INC.

■ reducer/motor coupling

____________________________________ Replacement of wear parts How to remove the power unit To remove the power unit as a complete assembly proceed as follows (Fig. 62).  Remove power unit covers from the machine.  Disconnect and tag all electrical wiring to the drive motor.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.  Disconnect, cap and tag all hydraulic hoses to the hydraulic pumps.  Remove the seven (7) mounting base bolts.

© BUCYRUS AMERICA, INC.

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

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

How to install the power unit To install the power unit as a complete assembly proceed as follows (Fig. 62).  Attach an appropriate lifting device to the complete unit and slowly lift the unit onto the machine and align mounting base holes with holes in the frame.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Secure mounting base to frame with the seven (7) base bolts, lockwashers, flatwashers and nuts previously removed.  Connect all hydraulic hoses to the hydraulic pumps.  Connect all electrical wiring to the drive motor.  Connect the drive chain. (See Breaker drive chain installation and adjustment in this chapter).  Install breaker drive covers.

______________________________________________________________ A6474X248 SSVI/03 5.79

Replacement of wear parts _____________________________________ Fig. 62: Power unit removal and installation

Power unit

© BUCYRUS AMERICA, INC.

Mounting bolts

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

____________________________________ Replacement of wear parts How to disassemble the breaker power unit To disassemble the power unit proceed as follows (Fig. 64):  Remove complete unit from machine. (See How to remove the drive unit in this chapter)  Remove the four (4) bolts and lockwashers from gear pump (item 26) and remove pump.  Open access cover on connecting tube (item 8) and loosen the two (2) bolts on the pump end and set screw on the motor end of the coupling.

© BUCYRUS AMERICA, INC.

 Remove the four (4) bolts and lockwashers from hydrostatic pump (item 25). With the aid of a lifting device, slowly pull pump from coupling (item 7) and connecting tube (item 8).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Remove the eight (8) bolts and lockwashers from connecting tube (item 8) and remove connecting tube from motor (item 5).  Remove coupling (item 7) and key from motor shaft.  Remove the four (4) bolts and nuts from motor base and the eight (8) bolts, lockwashers and nuts from the reducer base. With the aid of a lifting device, slowly lift motor and reducer from mounting base (item 11).  Remove sprocket (item 6) and key from reducer shaft.  Separe motor and reducer coupling halfs by removing the twelve (12) bolts from around the center of coupling (item 3).  With the aid of a lifting device, slowly separate motor (item 5) and reducer (item 1).  Remove the bolt, lockwasher and end cap (item 21) the end of the reducer shaft.  Remove the three (3) bolts that secures the taper lock (item 2) to the reducer shaft.  Insert two (2) of the bolts removed from the taper lock into the jack screw threaded holes located in the end of the taper lock (Fig. 79).

Tighten both bolts equally until the taper lock is free from reducer shaft.  Remove the bolt, lockwasher and end cap (item 21) the end of the motor shaft.

______________________________________________________________ A6474X248 SSVI/03 5.81

Replacement of wear parts _____________________________________  Remove the three (3) bolts that secures the taper lock (item 4) to the motor shaft.  Insert two (2) of the bolts removed from the taper lock into the jack screw threaded holes located in the end of the taper lock (Fig. 79).

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

Fig. 63: Taper lock removal and installation

Jack screw holes (2) for bushing removal

How to assemble the power unit To assemble the power unit proceed as follows (Fig. 64):  With the aid of a lifting device, slowly lift reducer onto mounting base (item 1) and align mounting holes. Secure reducer with the eight (8) bolts, lockwashers and nuts to mounting base. Torque bolts to 460 ft-lb.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Slide reducer coupling element half (item 3) onto reducer shaft.  Slide taper lock (item 2) and shaft key onto reducer shaft. Locate reducer coupling element so that taper lock is flush with the end of the reducer shaft. Secure taper lock with the three (3) bolts supplied with taper lock. Torque bolts to 85 ft-lb.  Install end cap (item 21) onto reducer shaft and secure with bolt and lockwasher. Torque bolt to 80 ft-lb.  Slide motor coupling element half (item 3) onto motor shaft.  Slide taper lock (item 4) and shaft key onto motor shaft. Locate motor coupling element so that motor shaft has .5 inch (12.7 mm).

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

Torque bolts to 85 ft-lb.

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

© BUCYRUS AMERICA, INC.

Bolt holes (3) for bushing installation

____________________________________ Replacement of wear parts

  Install end cap (item 21) onto motor shaft and secure with bolt and lockwasher. Torque bolt to 80 ft-lb.  With the aid of a lifting device, slowly lift motor onto mounting base (item 1) and align mounting holes and coupling halfs. Secure reducer with the eight (8) bolts, lockwashers and nuts to mounting base. Torque bolts to 280 ft-lb.  Connect coupling (item 3) with the twelve (12) bolts supplied with coupling.  Insert key into slot of motor shaft and slide motor coupling half (item 7) onto motor shaft until shaft and coupling face are flush.  Tighten set screw in motor half of coupling.  Insert coupling element into motor half of coupling.

© BUCYRUS AMERICA, INC.

 Align the 8 holes of connecting tube (item 8) with motor (item 5)and secure with the eight (8) bolts and lockwashers.  Slide pump half of coupling (item 7) onto hydrostatic pump shaft (item 25) until a .67” (17 mm) shaft end gap is acquired. Tighten the two (2) coupling half bolts.  With the aid of a lifting device, slowly lift hydrostatic pump (item 25) and carefully align pump half and motor half of coupling. Secure pump to connecting tube with four (4) bolts and lockwashers.

Coupling spacing should be .18” (4.5 mm) after pump mounting bolts are tightened.  Align mounting holes and shaft of gear pump (item 26) with hydrostatic pump (item 25) and secure with four (4) bolts and lockwashers.  Install completed power unit onto machine. (See How to install the power unit in this chapter)  Fill hydrostatic pump thru case drain port with system oil before running pump.

______________________________________________________________ A6474X248 SSVI/03 5.83

Replacement of wear parts _____________________________________

© BUCYRUS AMERICA, INC.

Fig. 64: Power unit disassembly and assembly

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

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 64: Power unit disassembly and assembly (continued)

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

10.

11.

12.

13.

14.

15.

16.

17.

18.

bolt mounting base bolt washer (lock) nut (lock) bolt washer (lock) nut (lock) end cap

19.

20.

21.

22.

23.

24.

25.

26.

27.

washer (lock bolt end cap retainer bar retainer bar retainer bar hydrostatic pump gear pump washer (lock)

28.

29.

30.

35.

36.

37.

38.

39.

40.

bolt washer (flat) bolt key key element hub key key

______________________________________________________________ A6474X248 SSVI/03 5.85

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

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

How to remove the conveyor drive motor To remove the conveyor drive motor proceed as follows (Fig. 65): WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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

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

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

© BUCYRUS AMERICA, INC.

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

Replacement of wear parts _____________________________________ How to install the conveyor drive motor To install the conveyor drive motor proceed as follows (Fig. 65): WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.  Apply a coat of mineral oil to the splines of the headshaft, coupling and conveyor motor. Do not use never seez.  Slide coupling onto headshaft.  Install torque arm on conveyor motor with mounting bolts. Torque bolts to 400 ft-lb.

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

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

_________________________________________________________________ 5.87 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

 Remove conveyor motor cover bolts and remove cover.

Replacement of wear parts _____________________________________ Fig. 65: Conveyor drive motor removal and installation Pin and cotter key (2 places) Connecting link

Head shaft

Torque arm

cover bolts (torque to 59 ft-lb)

Mounting bolt (torque to 280 ft-lb)

Mounting bolts (torque to 400 ft-lb)

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

© BUCYRUS AMERICA, INC.

Coupling

____________________________________ Replacement of wear parts Breaker assembly The breaker assembly (Fig. 66) is assembled as a complete unit and should be removed as a unit for repairs except for the replacement of the shear hub assembly, bits, and magnetic cutoff assembly. As soon as any component of the breaker assembly is worn or damaged, the component or complete assembly must be replaced.

© BUCYRUS AMERICA, INC.

The breaker assembly consists of the following main components: ■

breaker shaft

■

shear hub assembly

■

bearing housing (2)

■

bearing (2)

■

bits (25)

■

bearing retainer (2)

■

breaker side plate (2)

■

retaining cap (2)

■

dust cover

Fig. 66: Breaker assembly main components Breaker

Breaker side plate (2)

Bearing housing (2)

Shear hub

Retainer cap (2)

Pick (25)

______________________________________________________________ A6474X248 SSVI/03 5.89

Replacement of wear parts _____________________________________ How to remove the breaker assembly To remove the breaker assembly from the machine proceed as follows (Fig. 67):  Remove covers and guards as required to gain access to the breaker assembly.  Release tension on the breaker drive chain and remove chain (see Breaker drive chain removal in this chapter).  Disconnect, tag, and cap the bearing central lubrication hoses.

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

How to install the breaker assembly To install the breaker assembly into the machine proceed as follows (Fig. 67):  With the aid of the lifting device, slowly lift the breaker assembly into the frame and align mounting holes.  Secure the breaker with the twenty (20) bolts, nuts, and washers (10 per side) and securely tighten. Torque bolts to 900 ft-lb.  Install breaker drive chain and adjust tension. (See Breaker drive chain adjustment in this chapter).  Connect the bearing central lubrication hoses.  Install covers and guards.

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

© BUCYRUS AMERICA, INC.

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

____________________________________ Replacement of wear parts

© BUCYRUS AMERICA, INC.

Fig. 67: Breaker assembly removal and installation

1.

2.

3.

4.

5.

breaker shaft assembly lock washer flat washer bolt nut

______________________________________________________________ A6474X248 SSVI/03 5.91

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. 68):  Remove the external retaining rings (2) from the shank end of the bit with a pair of external retaining ring pliers.  Remove the bit from its holder.

How to install the breaker bit To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 68):

 Install the external retaining rings (2) on the shank end of the bit with a pair of external retaining ring pliers. Ensure that the retaining ring is completely seated inside grooved area of the bit.

Fig. 68: Breaker bit removal and installation

Retaining rings Bit holder

Breaker bit

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

© BUCYRUS AMERICA, INC.

 Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.

_______________________________________________________________

6

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

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

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

Customer specials may not be listed.

Components of the feeder breaker Technical data sheet general

Overall length:

© BUCYRUS AMERICA, INC.

Overall width: Tramming height (min.): Ground clearance (min.): Ground clearance (max.): Receiving height (min.): Discharge height (max.)

Operating height (max.): Level hopper capacity: Capacity (w/ optional 12” sideboards): Receiving impact plate: Breaker impact plate: Coal line material: Return line material: Mainframe side plates: Weight:

approx. 34’ 61/2” 10,528 mm approx. 10’ 4” 3,149 mm approx. 44” 1,118 mm approx. 7” 178 mm approx. 24” 610 mm approx. 13” 330 mm approx. 53” 1,346 mm approx. 78” 1,981 mm approx. 440 ft³ 12.46 m³ approx. 530 ft³ 15 m³ HRS + CCO wear plate ASTM a514 + CCO wear plate HRS + CCO wear plate HRS + CCO wear plate HRS + CCO wear plate approx: 70,000 lbs 31,752 kg

performance Material input size (max.): Discharge rate (max.): Material to be broken:

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

______________________________________________________________ A6474X248 SSVI/03 6.3

Technical data ________________________________________________ Conveyor width: Number of strands:

Chain pitch: Chain pin diameter: Flights:

Conveyor speed: Flight attachment Flight spacing

head shaft

Shaft diameter: Bearing bore: Overload protection:

tail shaft

Shaft diameter: Bearing bore: Take-up:

conveyor drive

Drive motor: Mounting: Overload protection:

conveyor drive

Tram speed: Drive: Take-up: Overall length: Center to center distance: Pad width: Ground pressure:

approx. 48” 1,219 mm 2 @ 200,000 lb (90,720 kg) lb/strand ultimate approx. 3 1/2” 88.9 mm approx. 15/16” 23.81 mm 2 1/2” X 5” (63.5 mm x 140 mm) solid alloy steel approx. 35 - 135 fpm 11—41m/min solid flight pin w/roll pin approx. 21” 533 mm 5” 127 mm 4 15/16” 125.41 mm hydraulic relief 3 15/16” 100.01 mm 3 15/16” 100.01 mm grease cylinders w/locking shims radial piston hydraulic low speed high torque splined direct mount On head shaft hydraulic relief approx. 47 fpm 14.3 m/mm Fairfield W12 torque hub grease cylinder w/locking shims approx. 96.5” 2,451 mm approx. 79” 2,006 mm approx. 15” 381 mm approx. 25.3 psi .178 MPa

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

© BUCYRUS AMERICA, INC.

conveyor chain

_______________________________________________ Technical data hydraulic

Conveyor/tram pump:

axial piston variable displacement Cylinder circuit pump: gear pump Char Lynn 4000 series 19in³/rev (311 cc) Double acting 17” stroke (432 mm) Double acting 17” stroke (432 mm) (3) 12 micron pressure line w/low oil level switch ISO 68 Mineral Oil air to oil type JIC (standard)

Tram motors: Lift cylinders: Tilt cylinders: Filters:

Hydraulic fluid Heat exchanger: Hydraulic fittings:

© BUCYRUS AMERICA, INC.

Electrical

Conveyor motor:

Starter:

Enclosure: Contactor: Circuit overload protection: features

Reliance internal cooled 150 hp (112 kW)/ 1140v/AC/3ph/50Hz/ 1500rpm/TEFC Rated current: 56.59 amps Protection grade: IP54 150 hp (112kW)/ single/1140v/AC 3ph/50Hz MSHA XP rated vacuum type Circuit breakers

■

Head shaft is removable horizontally as a unit.

■

Tailshaft are removable vertically as a unit.

■

Emergency stop pull cord switch over hopper.

■

Locking shims included for tailshaft and crawler take-up cylinders.

■

Torque hubs can be free-wheeled for towing by reversing cap in center of hub.

■

Independently controlled frame lift cylinders.

■

Heavy duty guards at discharge end of machine.

■

Sectionalized covers over power units.

■

Extra heavy duty chain hold-downs at breaker transition.

■

Manual centralized lubrication system.

■

12” high hinged sideboards (optional).

■

Operator’s valve handle retainer with safety interlock to prevent accidental activation od hydraulic cylinder functions.

______________________________________________________________ A6474X248 SSVI/03 6.5

© BUCYRUS AMERICA, INC.

Technical data ________________________________________________

_________________________________________________________________ 6.6 BUCYRUS – Model 7MFBH-48A Feeder Breaker

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

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

Set screws

© BUCYRUS AMERICA, INC.

Table 2: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

Table 3: 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

______________________________________________________________ A6474X248 SSVI/03 6.7

Tightening torques ____________________________________________ Table 4: FSR hex bolts (SAE 5 and 325 steel) Recommended torque setting

¼”

9 ft-lbs

5/16”

18 ft-lbs

3/8”

31 ft-lbs

7/16”

50 ft-lbs

½”

75 ft-lbs

9/16”

110 ft-lbs

5/8”

150 ft-lbs

¾”

250 ft-lbs

7/8”

378 ft-lbs

1”

583 ft-lbs

1 1/8”

782 ft-lbs

1 ¼”

1,097 ft-lbs

1 3/8”

1,461 ft-lbs

1 ½”

1,748 ft-lbs

1 ¾”

3,114 ft-lbs

2”

4,504 ft-lbs

2 ¼”

6,497 ft-lbs

2 ½”

7,144 ft-lbs

2 ¾”

12,092 ft-lbs

3”

15,744 ft-lbs

Table 5: Socket, flat & button head cap screws (steel only) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting 26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs 30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

_________________________________________________________________ 6.8 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Nominal diameter

___________________________________________ Tightening torques Table 6: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

© BUCYRUS AMERICA, INC.

Table 7: 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 8: 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

______________________________________________________________ A6474X248 SSVI/03 6.9

Tightening torques ____________________________________________ Table 9: Untreated screw, black finish (Fine thread) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25

Nm

27

52

95

Ft-lbs

19

38

70

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5

Nm

150

225

325

Ft-lbs

110

165

239

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

Table 11: Untreated screw, black finish (Fine thread, continued)

Property class

Torque Ma

8.8

Nm

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399

Ft-lbs 10.9 12.9

610

780

449

575

Nm

640

860

1100

Ft-lbs

472

634

811

Nm

770

1050

1300

Ft-lbs

567

774

958

_________________________________________________________________ 6.10 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Table 10: Untreated screw, black finish (Fine thread, continued)

___________________________________________ Tightening torques Table 12: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M33 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

© BUCYRUS AMERICA, INC.

Table 13: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nm

36

Ft-lbs

26

42

Nm

83

132

Ft-lbs

61

97

58

Nominal diameter M18

M20

M22

121

171

230

54

89

126

169

200

275

390

530

147

202

287

390

88

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 14: Electrically zinc plated (Coarse thread, continued) Property class 5.6

8.8

10.9

12.9

Torque Ma

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

______________________________________________________________ A6474X248 SSVI/03 6.11

Tightening torques ____________________________________________ Table 15: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

Torque Ma Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

Recommended torque setting M8 X 1 25 18 35 25 42 30

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 16: Electrically zinc plated (Fine thread, continued)

8.8 10.9 12.9

Torque Ma

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 17: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

_________________________________________________________________ 6.12 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Property class

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© BUCYRUS AMERICA, INC.

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

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

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

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

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

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

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

______________________________________________________________ A6474X248 SSVI/03 6.13

Permissible media ____________________________________________ Approved suppliers:

Supplier

Brand name

1

Amoco Oil Company

Amoco AW oil No.68

2

Gulf oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hyldraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers

Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

_________________________________________________________________ 6.14 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Table 18: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 19: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460

6

Unocal 76

7

Shell Oil company

8

Century Lubricating Oils, Inc.

9

Texaco Lubricants Company

Hulbest EP-7 Powergear 460 Meropa 680

10

Exxon

Spartan EP 460

11

Pennzoil

Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

608 Almosal Vari-Purpose Gear Lubricant Gear oil 460

14

Hydrotex

933 Industrial Gear Lubricant

15

Phillips

16

Miners Oil

All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680

______________________________________________________________ A6474X248 SSVI/03 6.15

Permissible media ____________________________________________

Supplier

Brand name

1

Amoco Oil Company

2 3 4

Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil company Century Lubricating Oils, Inc.

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Amolith grease 2 EP Rykon Premium Grease 2 EP Gulfcrown grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Table 21: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century oils Limited Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

_________________________________________________________________ 6.16 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Table 20: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ Permissible media Table 22: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company

5 6

Cincinnati – Vulcon Company Cities Service Oil company

7 8

10 11

Century Oils limited Fiske Bros. Refining Company Getty Oil company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

12 13 14 15 16 17

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and chemical Co. Pennzoil Quaker Chemical Company

18

Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

© BUCYRUS AMERICA, INC.

9

19 20 21

22 23

Standard Oil Company of Ohio (Boron Sohio) Sun Oil company Tower Oil Company

24 25

Wynn Oil company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion fire resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR

Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant hydraulic Fluid HY-Guard

______________________________________________________________ A6474X248 SSVI/03 6.17

Permissible media ____________________________________________

Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

_________________________________________________________________ 6.18 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Table 23: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 24: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) Supplier Brand name 1

Amoco Oil Company

American Industrial Oil No. 68

2

Gulf oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy – Medium

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754

6

Unocal 76

7

Shell Oil Company

Unax RX68 or Turbine Oil 68 Turbo 68

8

Century Lubricating Oils, Inc.

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

______________________________________________________________ A6474X248 SSVI/03 6.19

Permissible media ____________________________________________

1

Amoco Oil Company

American Industrial oil No. 150

2

Gulf Oil

Harmony 150

3

Mobil Oil Corporation

DTE Oil EX. Heavy

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961

6

Unocal 76

7

Shell Oil company

Unax RX 700 or Turbine Oil 700 Turbo 150

8

Century Lubricating Oils, Inc.

Centraulic R&O 150

9

Atlantic Richfield Company

10

Texaco Lubricants Company

Duro 600 or S-700 Regal Oil R&O 150

11

Exxon

Teresstic 150

12

Pennzoil

Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15

Conoco Inc.

Dectol R&O 76

16

Hydrotex

System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Table 26: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier Brand name 1 Amoco Oil Company Cylinder oil No. 1000 2 Mobil Oil Corporation Extra Hecla Super Cylinder Oil 3 Chevron U.S.A. Chevron Cylinder Oil W ISO 1000 4 Sun Oil Company Sun Steam Cylinder Oil 5 Unocal 76 Worm gear Lube 250 or Stevalc 6 Century Lubricating Oils, Inc. Garwal 680 7 Atlantic Richfield Company Modoc 195 8 Texaco Lubricants Company 650 T Cylinder Oil 1000 9 Exxon Cylesstic TK-1000 10 Pennzoil Cylinder Oil #1000 11 Conoco Inc. Inca Oil 1000

_________________________________________________________________ 6.20 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

Table 25: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 27: Light gear oil, SAE 40 motor oil (Spec. 100-10)

1 2 3 4

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 28: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

______________________________________________________________ A6474X248 SSVI/03 6.21

Permissible media ____________________________________________ Table 29: High emulsibility extreme pressure gear oil (Spec. 100-13) 1

Supplier Fuchs

Brand name Powergear H680

Table 30: Synthetic lithium complex grease for electric motor bearings (Spec. 100-14) Supplier Mobil Conoco-Phillips Shell

Brand name Mobilith SHC 100 Triton 100 Albida EMS 2

Table 31: High demulsibility extreme pressure gear oil (Spec. 100-15) Supplier

Brand name

1

_________________________________________________________________ 6.22 BUCYRUS – Model 7MFBH-48A Feeder Breaker

© BUCYRUS AMERICA, INC.

1 2 3

_______________________________________________________________

7

For your information

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

© BUCYRUS AMERICA, INC.

Service address Beckley, WV 200 George Street, Suite 4 Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA (Corporate Headquarters) 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 Oak Hill, WV 25901

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Paonia, CO P.O. Box 566 Paonia, CO 81428

Price, UT 1814 North 1500 West P.O. Box 1016 Price, UT 84501 Phone: (435) 637-3930 Fax: (435) 637-9754

719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

______________________________________________________________ A6474X248 SSVI/03 7.3

Our service __________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

© BUCYRUS AMERICA, INC.

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

_________________________________________________________________ 7.4 BUCYRUS – Model 7MFBH-48A Feeder Breaker