PDF DOWNLOAD Cat Bucyrus 7MFBH-48A Feeder Breaker Operation Manual A6474X269

Operation Manual BUC Model

Feeder Breaker 7MFBH-48A

Doc. No.:

A6474X269

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

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

Internet: www.bucyrus.com

__________________________________________________________

This manual is intended to provide GENERAL product information for the Model 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..............................................2.22

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

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

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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 Secondary valve bank....................................................5.10 Starter enclosure............................................................5.11 Control features .............................................................5.13 Conveyor (s)...................................................................5.14 Daily starting procedure .................................................5.15 Shutdown procedure......................................................5.17 Electrical system ............................................................5.19 Starter enclosure.......................................................5.21 Electrical components ...............................................5.22 Hydraulic system............................................................5.23 Major hydraulic components ....................................5.24 Mechanical assemblies..................................................5.27 Crawler assembly (s) ...............................................5.27 Conveyor chain ........................................................5.28 Grease take-up ........................................................5.28 Head shaft ................................................................5.29 Power unit ................................................................5.30 Tail shaft ...................................................................5.30 Breaker assembly .....................................................5.31 Instructions on the maintenance of the feeder ..............5.33 Important notes ........................................................5.33 Before maintenance .................................................5.33 Lubrication and inspection .......................................5.35 Specific lubrication and maintenance procedures ........5.39 Every 8 hours of operation .......................................5.39 Weekly ......................................................................5.41 Every 2 weeks ..........................................................5.46 Monthly .....................................................................5.47 Every 3 months ........................................................5.48 Every 2500 hours ......................................................5.50 Every 6 months ........................................................5.51 Inspection of the feeder ................................................5.53 Inspection of wear parts on the feeder .........................5.54 Inspection of the fire suppression system......................5.55 Recharge of the fire suppression system ......................5.57 Instructions on the adjustment procedures ...................5.59 Conveyor chain adjustment .....................................5.59 Crawler track adjustment .........................................5.61 Breaker drive chain adjustment ................................5.63 Hydrostatic pump relief valve adjustment .................5.65 Hydrostatic pump charge pressure adjustment ........5.67 Primary valve bank pressure setting.........................5.68 Secondary valve bank pressure setting ....................5.69

_________________________________________________________________ BUC – Model 7MFBH-48A Feeder Breaker

Bucyrus America, Inc.

5. Operation

________________________________________________ Table of contents Instructions on the replacement of wear parts ............. 5.73 Head shaft ............................................................... 5.73 Head shaft sprockets ............................................... 5.76 Tail shaft .................................................................. 5.79 Conveyor chain ........................................................ 5.84 Crawler track ............................................................ 5.87 Crawler assembly .................................................... 5.90 Power unit ................................................................ 5.97 Conveyor drive motor…………………………………5.105 Breaker assembly ....................................................5.109

6. Technical data Technical data ......................................................................... 6.3 Components of the feeder breaker ...................................... 6.3 Tightening torques................................................................ 6.9 Permissible data ................................................................. 6.15 Lubrication fluids and greases....................................... 6.15

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

________________________________________________________________ A6474X269

VSVI / 01

Bucyrus America, Inc.

Table of contents _________________________________________________

_________________________________________________________________ BUC – Model 7MFBH-48A Feeder Breaker

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1

About this manual

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________ 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: BUC Serial No.

Model 7MFBH-48A Feeder 54-2172

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.

______________________________________________________________ A6474X269 VSVI / 01 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 BUC – Model 7MFBH-48A Feeder

_______________________________________ 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.

______________________________________________________________ A6474X269 VSVI / 01 1.5

© Bucyrus America, Inc.

Before starting to work ________________________________________

_________________________________________________________________ 1.6 BUC – Model 7MFBH-48A Feeder

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2

Your safety

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________________________________________________________________

_________________________________________________________________

__________________________________________________ Personnel

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

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

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

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by Bucyrus America, Inc. Use only original spare parts from Bucyrus America, Inc. Note that the use of parts from other manufacturers will void the guarantee.

© Bucyrus America, Inc.

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

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine,

■

of the Mine Inspector, and

■

of the mining supervisory authorities.

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

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Personnel ___________________________________________________ Personnel Operation training

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

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

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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

Installation and repair work on ■

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

■

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

■

the hydraulics (controls, cylinders, etc.)

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

_________________________________________________________________ 2.4 BUC – Model 7MFBH-48A Feeder

© Bucyrus America, Inc.

Installation and repair

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

Intended uses include: ■

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

Unauthorized use

© Bucyrus America, Inc.

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

■

the transport of persons

■

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

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

______________________________________________________________ A6474X269 VSVI / 01 2.5

© Bucyrus America, Inc.

Operating conditions __________________________________________

_________________________________________________________________ 2.6 BUC – 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).

Inform your colleagues of:

© Bucyrus America, Inc.

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

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

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

symbol plates emergency stop (panic strip)

lock-out

cordon off working area

Observe the symbol plates on the machine.

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

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

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

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

conveyor chains

■

flights

■

pivot points

■

boom assemblies

■

crawler assemblies

■

breaker shaft assemblies

© Bucyrus America, Inc.

moving parts

_________________________________________________________________ 2.8 BUC – 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.

means of attachment

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

© Bucyrus America, Inc.

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

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

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

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

Installation and start-up inclined face

environmental acceptability

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

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

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

inspection

maintenance instruction and safety tags operator’s area

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

Verify that all maintenance has been performed.

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

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

Clean any foreign material from the operator’s area.

______________________________________________________________ A6474X269 VSVI / 01 2.9

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

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

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

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

Maintenance and repair

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

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

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

Protect your work area against falling rocks.

replacing components

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

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

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

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

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

For raising the feeder breaker use only: ■

crib blocks with adequate load-holding capacity

■

hoists, jacks, or cranes with adequate load-carrying capacity

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

© Bucyrus America, Inc.

Be sure to observe the prescribed maintenance and inspection intervals.

___________________________________________ Safety instructions handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

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

maintenance, repair

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

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

Always replace damaged or lost decals and metal instruction plates.

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

© Bucyrus America, Inc.

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

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

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

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

the hoses are not pinched or trapped,

■

the hoses have no bubbles or blisters,

■

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

■

the outer sheaths of the hoses are not damaged,

■

the connectors are securely inserted into the sockets, and

■

the connections are leak-tight.

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

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

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

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

Use only hydraulic hoses approved for the prevailing pressures.

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

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

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

Never try to repair damaged hydraulic hoses.

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

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting Right

Wrong

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

© Bucyrus America, Inc.

Replace hydraulic hoses at the first suspicion of damage.

___________________________________________ Safety instructions ■

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

Fig. 3: Laying hydraulic hoses, bending Right

■

Wrong

cannot chafe.

Fig. 4: Laying hydraulic hoses, crossing

© Bucyrus America, Inc.

Right

■ ■ ■ ■

Wrong

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

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

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

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

______________________________________________________________ A6474X269 VSVI / 01 2.13

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

© Bucyrus America, Inc.

Right

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

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

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

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

© Bucyrus America, Inc.

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

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

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

Use only suitable load handling devices.

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

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

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

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

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

______________________________________________________________ A6474X269 VSVI / 01 2.15

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

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

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

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

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

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

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

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

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

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

Should anything be unclear, please contact your immediate supervisor.

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

© Bucyrus America, Inc.

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

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

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

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

© Bucyrus America, Inc.

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

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.

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

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

WARNING! 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.

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.

______________________________________________________________ A6474X269 VSVI / 01 2.17

Overview of safety instructions _________________________________ WARNING! When tramming the machine from the operator’s station, the operator should stand beside the machine facing he 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.

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

WARNING! 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! The Hydraulic system section of Chapter 5 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.

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! The Mechanical assemblies section of Chapter 5 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.

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

© Bucyrus America, Inc.

WARNING! The Electrical system section of Chapter 5 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.

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

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.

© Bucyrus America, Inc.

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.

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

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

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

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

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

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

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.

______________________________________________________________ A6474X269 VSVI / 01 2.19

Overview of safety instructions _________________________________ 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.

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

WARNING! The hose plug and the fitting cap must be properly torqued before proceeding as the system pressure will reach 5,000 psi. Failure to do so may result in serious injury or death.

WARNING! Two people are required to adjust the pressure settings. One person must move the conveyor direction valve handle to the forward direction and remain at the conveyor controls and Start/Stop push button station at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

CAUTION! Do not turn the adjustment screw in any further once it is felt that the screw has bottomed out as this may damage the needle valve and seat. Likewise, do not turn the adjustment screw out all the way as this may present difficulties in reassembly and may introduce contamination into the hydraulic pump.

NOTICE! While adjusting the relief pressure, if the system pressure gauge reading is not changing, it must be determined that the conveyor direction valve handle is in the correct position and that the corresponding pump pressure port hose was disconnected and plugged. To resolve this issue, place the conveyor direction valve handle in the opposite direction.

WARNING! The hose fitting must be properly torqued before proceeding as the system pressure will reach 5,000 psi. Failure to do so may result in serious injury or death.

WARNING! The feeder will move during this step and it must be ensured that all standard safety procedures are adhered to in order to avoid personnel injury and equipment damage. Do not operate the tram function to perform this adjustment as it is unsafe. Failure to adhere to this warning may result in serious injury or death. _________________________________________________________________

2.20

BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

IMPORTANT! Do not run the pump for a long period of time while setting the reliefs as all of the flow will be going over the relief. Excessive pump operation with the lines plugged will result in overheating and the eventual failure of the pump.

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

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

© Bucyrus America, Inc.

IMPORTANT! Adhere to all the welding specifications shown on Fig. 55. Failure to do so may result in sprocket failure and machine damage.

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

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

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

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

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

CAUTION! The grease line may have to be purged of air before the first use.

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

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

______________________________________________________________ A6474X269 VSVI / 01 2.21

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

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

CAUTION! Do not damage motor shaft seal during installation.

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

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

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

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

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

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

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

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

_________________________________________________________________ 2.22 BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

Chapter 6: Technical data

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3

Storage and transport

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________________________________________________________________

_________________________________________________________________

________________________________________ Storage and transport

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

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

Storage corrosion protection

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

Before delivery, the hydraulically operated equipment is operated and all axles, gear boxes, hydraulic oil tank, etc. are filled to their maximum fill point.

© 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. 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).

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

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. 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 hydraulic components must be completely filled with a corrosion inhibiting/frostproofing fluid such e.g. CV 50.

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.

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

______________________________________________________________ A6474X269 VSVI / 01 3.3

Storage and transport _________________________________________ plastic deformation

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

random sample inspection

After a storage period of approximately two years, a random sample inspection 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 America, Inc..

natural aging

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

HFA fluids

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

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. (See Fig. 6 for lifting point locations)

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

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

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

Use only suitable load handling devices.

_________________________________________________________________ 3.4 BUC – Model 7MFBH-48A Feeder

© Bucyrus America, Inc.

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.

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

© Bucyrus America, Inc.

Lifting point (typical 2 places): Insert hook into slot and route the chain under the frame and into the conveyor discharge area.

Horizontal (lengthwise) center of gravity

Note: Approximate machine weight is 100,000 lbs (45,360 kg) as shown.

Lift point (typical 2 places): Lift hook is to be attached directly under the arrow, hooking into the pocket under the edge of the frame.

______________________________________________________________ A6474X269 VSVI / 01 3.5

Storage and transport _________________________________________ Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid (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 are taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

electronic components

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

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

_________________________________________________________________ 3.6 BUC – Model 7MFBH-48A Feeder

© Bucyrus America, Inc.

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

_______________________________________________________________

4

Installation

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________________________________________________________________

_________________________________________________________________

__________________________________________________Installation

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

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

© Bucyrus America, Inc.

Work on: ■

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

■

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

■

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

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

Which tools are required for installation? tool box

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

Various items of auxiliary equipment and machines may be required at the point of installation.

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

______________________________________________________________ A6474X269 VSVI / 01 4.3

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

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

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

© Bucyrus America, Inc.

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

_________________________________________________________________ 4.4 BUC – Model 7MFBH-48A Feeder

__________________________________________________Installation Pre-installation check list

© Bucyrus America, Inc.

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

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

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

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

■

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

■

check tension of conveyor chain

■

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

■

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

■

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

■

jog the breaker motor to check for correct rotation of breaker

■

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

■

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

■

check the operation of the remote start pushbuttons

■

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

______________________________________________________________ A6474X269 VSVI / 01 4.5

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

emergency stop pull cord switch (2)

There are two (2) emergency stop pull cord switches located on the receiving end of the machine. To actuate the switch (s), pull the cord (s) located across the conveyor. When the cord (s) 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 with any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts.

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.

fire suppression

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

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

_________________________________________________________________ 4.6 BUC – Model 7MFBH-48A Feeder

© Bucyrus America, Inc.

Safety features include: (Reference Fig. 7)

__________________________________________________Installation Fig. 7: Safety features on the feeder breaker

Stop switch (starter enclosure)

© Bucyrus America, Inc.

Fire suppression actuator location

Emergency stop pull cord switch

Stop switch (power center)

Fire suppression actuator location

Stop switch (power center)

Emergency stop pull cord switch

Stop switch (2) (remote)

______________________________________________________________ A6474X269 VSVI / 01 4.7

Installation___________________________________________________ Fig. 8: Overview of the feeder breaker

Belt tailpiece Head shaft

Power unit

Discharge section Starter enclosure

Hydraulic oil tank Torque hub

Operator’s area R.H. crawler assembly

Ratio chains

Emergency pull cord stop Roof anchor cylinders

Conveyor chain Emergency pull cord stop

Receiving section

Crawler assembly

Tail shaft shim storage area (typical both sides) Tail shaft take-ups Tail shaft retainers (typical both sides)

Tail shaft

_________________________________________________________________ 4.8 BUC – Model 7MFBH-48A Feeder

© Bucyrus America, Inc.

Breaker assembly

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

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

To tow the feeder breaker proceed as follows:

© Bucyrus America, Inc.

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

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

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

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

______________________________________________________________ A6474X269 VSVI / 01 4.9

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

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

© Bucyrus America, Inc.

Fig. 9: Torque hub disengagement

Retaining bolts (2)

Normal tram position

End cap button pointing outward

Retaining bolts (2)

End cap button pointing inward Freewheel position

_________________________________________________________________ 4.10 BUC – Model 7MFBH-48A Feeder

__________________________________________________Installation Installing the tailpiece To install the tailpiece on the feeder breaker (Reference Fig. 10: Tailpiece installation): WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Install spacer blocks (Item 14) into the underside of the tailpiece weldment (Item 6).  Make sure that bolts (Item 37) will pass through the bearing spacers and the tailpiece weldment.  Tack weld bearing spacer blocks (Item 14) to tailpiece weldment (Item 6).

© Bucyrus America, Inc.

 Install belt pulley assembly (Item 15) using hex bolts, flat washers, hex nuts, and lock washers (Items 37, 36, 35, and 22).  Bolt impact bed assembly (Item 13) to tailpiece weldment (Item 6) using flat washers, lock washers, hex nuts, and bolts (Items 31, 32, 33, and 34).  Install slider assembly (Item 18) using flat washers, lock washers, hex nuts, and bolts (Items 27, 28, 29, and 30).  Install knuckle piece (Item 4) to tailpiece weldment (Item 6) using tailpiece swivel pin, flat washer, hex nut, keeper pin, and cotter pin (Items 7, 38, 39, 40, 43).  Tighten the hex nut (Item 39) onto the tailpiece swivel pin (Item 7) then weld the pin keeper (Item 40) across the flat of the tailpiece swivel pin (Item 7) on three sides.  Position the assembled knuckle joint and the tailpiece frames to the main frame. (Reference Figure 10 for placement). Install pins (Item 5).  Install the tailpiece hopper weldments (Items 8 and 9) on the main frame using flat washers, lock washers, hex nuts and bolts (Items 23, 24, 25, and 26) and flat washers, lock washers, hex nuts, and bolts (Items 27, 28, 29, and 30).  Install tailpiece tilt cylinders (Item 12) into the tailpiece hopper weldments (Items 8 and 9) and the tailpiece weldment (Item 6) using the swivel clevis weldments, pins, and cotter pins (Items 11, 16, and 41).  Install the steering cylinders (Item 10) between the tailpiece frame (Item 6) and the knuckle joint weldment using pins and cotter pins (Items 16 and 41).

______________________________________________________________ A6474X269 VSVI / 01 4.11

Installation___________________________________________________  Refer to the hydraulic schematic (Fig. 11) for hydraulic installation of the cylinders. Route all hoses, avoiding pinch points, so that hose damage does not occur.

© Bucyrus America, Inc.

Fig. 10: Tailpiece installation

4. knuckle piece 5. pin 6. tailpiece weldment 7. tailpiece swivel pin 8. tailpiece hopper weldment 9. tailpiece hopper weldment 10. steering cylinder 11. swivel clevis weldment 12. tailpiece tilt cylinder 13. impact bed assembly 1.

14. spacer block 15. belt pulley assembly 16. pin 18. slider assembly 22. lock washer 23. flat washer 24. lock washer 25. hex nut 26. bolt 27. flat washer

28. lock washer 29. hex nut 30. bolt 31. flat washer 32. lock washer 33. hex nut 34. bolt 35. hex nut 36. flat washer 37. bolt

38. flat washer 39. hex nut 40. keeper pin 41. cotter pin 43. cotter pin

_________________________________________________________________ 4.12 BUC – Model 7MFBH-48A Feeder

__________________________________________________Installation Fig. 10: Tailpiece installation (continued)

See Detail A 1 14

© Bucyrus America, Inc.

4

2

3

43

39 38 41 16

5 7 40

41

Detail A

______________________________________________________________ A6474X269 VSVI / 01 4.13

Installation___________________________________________________

© Bucyrus America, Inc.

Fig. 11: Hydraulic schematic

_________________________________________________________________ 4.14 BUC – Model 7MFBH-48A Feeder

_______________________________________________________________

5

Operation

________________________________________________________________

________________________________________________________________

_________________________________________________________________

___________________________________________________Operation

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

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

How to operate the feeder breaker DANGER! Incorrect operation endangers yourself and others!

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

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

Should anything be unclear, please contact your immediate supervisor.

© Bucyrus America, Inc.

Who is allowed to operate the feeder breaker?

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

This also includes: ■

what safety devices are installed on the machine,

■

where these safety devices are located, and

■

how these safety devices are to be operated.

When can conveying be started?

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

______________________________________________________________ A6474X269 VSVI / 01 5.3

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. 12) 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, auxiliary valve bank, fire suppression actuator, and remote push button start/stop switch.

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

Oil level sight gauge

Starter enclosure

Fire suppression actuator

Primary valve bank

Secondary valve bank

Auxiliary system pressure gauges Conveyor speed pressure gauge (not shown - located behind fire suppression actuator)

Start/stop switch (power center)

Conveyor speed and direction control valves

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

© Bucyrus America, Inc.

Fig. 12: Operator’s station

___________________________________________________Operation Primary valve bank The primary valve bank (Fig. 13) consists of the following hydraulic controls: “POWER FILL” and “SECONDARY VALVE BANK”

The first lever from the operator’s right has two (2) functions, it controls oil flow for “POWER FILL” and “SECONDARY VALVE BANK”. To operate the power fill, turn ball valve handle located on the left side of the discharge section to the open position and push the control lever. To de-energize power fill pump, move control lever to the centered position and turn ball valve handle to closed position. Pull the control lever towards the operator to energize the secondary valve bank.

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

© Bucyrus America, Inc.

power fill procedure

To operate the power fill:  Clean suction hose attached to the hydraulic power fill motor, located on top of the oil tank.  Remove the suction hose plug and submerge the suction hose in the new oil supply.  Turn the handle of the ball valve that is attached to the power fill motor to the open position. The handle should now be inline with the hydraulic hose to which it is attached.  Oil from the valve bank will now drive the power fill motor and a suction force will be created in the suction line.  Oil from the new oil supply will be sucked thru the power fill motor and fill the hydraulic system oil tank.  Once the tank is filled to desired level, pull power fill lever on valve bank to neutral (center) position. Turn the ball valve handle 90° to close the ball valve.  Remove the suction hose from the new oil supply.  Clean and install hose plug into suction hose and store suction hose on top of the oil tank.

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

______________________________________________________________ A6474X269 VSVI / 01 5.5

Operation____________________________________________________ “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.

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.

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

© Bucyrus America, Inc.

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

___________________________________________________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 of the hopper and end of the crawlers, which adjust the discharge height of the machine. To raise the height, slowly push the control lever away from the operator and to lower the height, slowly pull the control lever towards the operator.

© Bucyrus America, Inc.

Fig. 13: Primary valve bank

“POWER FILL” and “SECONDARY VALVE BANK”

“TILT”

“LEFT LIFT” “LEFT TRAM”

“RIGHT TRAM”

“RIGHT LIFT”

auxiliary system pressure gauges

The auxiliary function pressure gauges (Fig. 14) are high pressure gauge (6,000 psi) located to the right of the tram control levers. These gauges give the operator a constant reading of the auxiliary system pressures.

conveyor speed pressure gauge

The conveyor speed pressure gauge (Fig. 14) is a low pressure gauge (400 psi) located to the right of the conveyor direction control lever.

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

two position conveyor direction control valve

The two position conveyor direction control valve (Fig. 14) controls the feeder breaker and discharge 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.

______________________________________________________________ A6474X269 VSVI / 01 5.7

Operation____________________________________________________ conveyor speed control valve

The conveyor speed control valve (Fig. 14) allows the operator to adjust the speed of the feeder breaker conveyor and discharge conveyor.

To increase conveyor speed, turn the adjustment knob clockwise (CW).

To decrease conveyor speed, turn the adjustment knob counterclockwise (CCW).

conveyor circuit system pressure gauge

The conveyor 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 conveyor circuit system pressure.

conveyor circuit charge pressure gauge

The conveyor 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 conveyor circuit charge pressure.

oil level sight gauge

The oil level sight gauge (Fig. 14) 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. 14) 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.

power fill ball valve

The power fill ball valve (Fig. 14) is located on the left hand side of the discharge section of the machine on top of the oil tank and is used to control the flow of hydraulic fluid from the power fill pump.

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators (Fig. 14). One is located adjacent to the operator’s station on the left side of the machine. The other is located adjacent to the crawler on the right side of the machine. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated. All eight (8) fire nozzle sprays must have blow off caps installed.

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

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

© Bucyrus America, Inc.

Located on the right side of the discharge end of the machine, on top of the hydrostatic pump, are 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.

___________________________________________________Operation Fig. 14: Controls and indicators

Conveyor and charge pressure gauges

Fire suppression actuator

© Bucyrus America, Inc.

Oil Level sight gauge

Power fill ball valve

Conveyor speed pressure gauge (not shown)

Auxiliary system pressure gauges

Main valve bank

Secondary valve bank Fire suppression actuator

Start/stop switch (power center)

Conveyor speed control valve

Conveyor direction control valve

______________________________________________________________ A6474X269 VSVI / 01 5.9

Operation____________________________________________________ Secondary valve bank The secondary valve bank (Fig. 15) consists of the following hydraulic controls: “TAILPIECE BOOM TILT”

The first lever from the operator’s left controls the tailpiece boom lift cylinders. Push the lever down to lower the tailpiece boom and push the lever up to raise the tailpiece boom.

“TAILPIECE STEER”

The second lever on the operator’s left side controls the tailpiece steering cylinders. Push the lever down to steer left and push the lever up to steer right.

“ROOF ANCHOR CYLINDER” left hand

The third lever from the operator’s left controls the roof anchor cylinder on the off side of the machine. Push the lever up to extend the cylinder and push the lever down to retract the cylinder.

“ROOF ANCHOR CYLINDER” right hand

The fourth lever from the operator’s left controls the roof anchor cylinder on the operator’s side of the machine. Push the lever up to extend the cylinder and push the lever down to retract the cylinder.

© Bucyrus America, Inc.

Fig. 15: Secondary valve bank

“ROOF ANCHOR CYLINDER” right hand “TAILPIECE TILT” “TAILPIECE STEER”

“ROOF ANCHOR CYLINDER” left hand

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

___________________________________________________Operation Starter enclosure The starter enclosure (Fig. 16) is located on the left hand side of the machine and consists of the following machine’s electrical functions: “START” (conveyor/breaker)

The “START” pushbutton, when pressed in, is used to start the machine’s electric motor.

© Bucyrus America, Inc.

WARNING! If the “START” conveyor/breaker 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 (s) before depressing the “START “ conveyor/breaker pushbutton to prevent serious injury or death to you or other workers.

“STOP” (conveyor/breaker)

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: –

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

–

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

–

“OFF” - shuts down the machine

circuit breaker lever

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.

“HIGH TEMPERATURE”

The “HIGH TEMPERATURE” light will be illuminated when it detects a high temperature at the hydraulic oil tank. There is a high temperature switch located at the oil tank that will shut down the motor and cause the light to be illuminated if a high temperature is detected.

“LOW OIL”

The “LOW OIL” light will be illuminated when it detects low oil issue at the hydraulic oil tank. If the low oil switch located at the hydraulic oil tank detects a low oil, the motor will shut down and the light will be illuminated.

______________________________________________________________ A6474X269 VSVI / 01 5.11

Operation____________________________________________________ Fig. 16: Starter enclosure cover “HIGH TEMPERATURE”

“LOW OIL”

“OFF” “ON” “TRIPPED” “AUTOMATIC”

“OFF” Circuit breaker reset lever

start/stop switch (remote)

“START” conveyor/breaker

“STOP” conveyor/breaker

The machine is equipped with four (4) (remote) start/stop switches (Fig. 17). Two (2) are located on each side of the machine and two (2) are remote. These remote start/stop switches allows the operator to start or stop the machine and power unit from a remote location.

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

Fig. 17: Start/stop switch (remote)

“START”

“STOP”

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

© Bucyrus America, Inc.

“MANUAL”

___________________________________________________Operation Control features

© Bucyrus America, Inc.

The following is a list of control features that could affect the running of the feeder breaker. high temperature switch

There is a high temperature located onboard the machine at the oil tank. If a high temperature at the oil tank both is detected, the motor will be turned off and a light (high temperature) will be illuminated. This light is located on the cover of the electrical enclosure (Fig. 16).

low oil cut off switch

There is a low oil cut off switches for the feeder breaker located onboard the machine at the oil tank. If a low oil issue is detected at the oil tank, the motor will be turned off and a light (low oil) will be illuminated.

This light is located on the cover of the electrical enclosure (Fig. 16).

belt sequence sensor and pick breaker sensor

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

motor overload (OL)

There is an overload on the electric motor. If the overload detects an over current condition, it will trip and the motor will stop. The overload will also detect a phase unbalance (10%) and will trip and stop the motor.

______________________________________________________________ A6474X269 VSVI / 01 5.13

Operation____________________________________________________ Conveyor Perform daily start-up procedure (see Start-up procedure in this chapter). The conveyor is controlled hydraulically by a 200 hp crusher motor. The conveyor may be started utilizing the conveyor direction and speed control valves located on the left side of the machine (Fig. 18).

“CONVEYOR SPEED”

The running speed of the conveyor is controlled by a pressure reducing valve located beside the conveyor direction control valve (Fig. 18). To increase conveyor speed, turn the adjustment knob clockwise (CW).

To decrease conveyor speed, turn the adjustment knob counterclockwise (CCW).

There is a timer on the circuit which in “AUTO” mode only allows the conveyor to run for a preset time (3 minutes) then times out. If during this time a start button is engaged the timer is reset back to zero and the timer starts timing again.

“CONVEYOR DIRECTION”

The conveyor chain direction in controlled by a three (3) position valve.

To run the conveyor chain forward (toward the discharge end), pull the handle down. To run the conveyor chain backwards (toward the hopper end), push the handle up. If the handle is in the middle position, the conveyor is in neutral (no movement).

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

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

Fig. 18: Conveyor control levers Conveyor speed pressure gauge (not shown)

Conveyor speed control valve

Conveyor direction control valves

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

© Bucyrus America, Inc.

The speed of the conveyor chain is monitored by a pressure gauge (Fig. 18). Normal operating pressure is between 0 and 400 psi. At pressure readings between 0 and 100 psi, there will be no chain movement. Pressure readings between 100 and 400 psi correspond to conveyor chain speeds of 1 to 135 feet per minute (fpm).

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

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

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

© Bucyrus America, Inc.

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

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

Regular mode (conveying)  Turn the “MANUAL/OFF/AUTOMATIC” selector switch located on the cover of the starter enclosure to either “MAN” or “AUTO”: “AUTOMATIC” position if using the belt sensor or “MANUAL” position to bypass the belt sensor.  Engage either the start pushbutton located on the cover of the starter enclosure (this button must be held in until the pick breaker comes up to speed) or one of the four (4) 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.

______________________________________________________________ A6474X269 VSVI / 01 5.15

Operation____________________________________________________ Tram only mode  Turn the “MANUAL/OFF/AUTOMATIC” selector switch located on the door of the starter enclosure to “MANUAL”.  Engage either the start pushbutton on the cover of the starter enclosure or one of the four (4) 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 has skid type steering: it is capable of turning within its own limits.

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

___________________________________________________Operation Shutdown procedure There are several methods of shutting down the feeder breaker. Some methods will remove the main incoming power and other methods will only stop the motor.  Allow the machine to run until the hopper is empty. Continue to run the machine until all material that has been carried back into the return line has been cleaned out.

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

To shutdown the feeder breaker proceed as follows:  Depress either of the onboard pushbutton stations “STOP” buttons.

This will remove the main incoming power.

© Bucyrus America, Inc.

 Engage the pull cord switch located across the receiving end.

This will remove the main incoming power.  Depress either of the remote pushbutton stations “STOP” buttons.

This will stop the crusher motor.  Turn the “MANUAL/OFF/AUTOMATIC” selector switch located on the cover of the starter enclosure to the “OFF” position. This will stop the crusher motor.  Depress the “STOP” button located on the cover of the starter enclosure. This will stop the crusher motor.  Move the conveyor directional control handle to the centered “NEUTRAL” position.  Turn the conveyor speed control knob counter clockwise (CCW) to the lowest speed.

______________________________________________________________ A6474X269 VSVI / 01 5.17

© Bucyrus America, Inc.

Operation____________________________________________________

_________________________________________________________________ 5.18 BUC – 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. 19: Electrical component locator

Remote pushbutton (2) (located on 50 ft cords) Start/Stop switch

Emergency stop pull cord switch

Emergency stop pull cord switch

Start/Stop switch

Electric motor 200 hp

Starter enclosure

_____________________________________________________________ A6474X269 VSVI / 01 5.19

Electrical system _____________________________________________

© Bucyrus America, Inc.

Fig. 20: Electrical layout

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

____________________________________________ Electrical system Starter enclosure The starter enclosure (Fig. 21) 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 enclosure is the electrical switches . These are labeled and control the start and stop functions for the electric motor (s). 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.

Fig. 21: Starter enclosure components

© Bucyrus America, Inc.

Circuit breaker Control transformer

Vacuum contactor

Overload relay

Terminal blocks

Panel board

Isolator relay

Pick break timer

Horn delay timer

Rectifier Ground fault circuit breaker

Neon bulb (2)

Conveyor run timer Relay 120 VAC (3)

Fuse 2 amp

Relay 24 VAC (4)

Fuse 10 amp Terminal blocks Swing panel

_____________________________________________________________ A6474X269 VSVI / 01 5.21

Electrical system _____________________________________________ Electrical components (Reference Fig. 18 and 19) The machine has a (200 hp) electric drive motor that drives the pick breaker and hydraulic pump for the feeder breaker.

emergency stop pull cord switch (2)

The machine is equipped with two (2) emergency stop pull switches located on the receiving end of the machine. To actuate the switch (s), pull the cord (s) that is across the conveyor. When the cord (s) is pulled, all machine functions are shutdown immediately.

start/stop switch (4)

The machine is equipped with four (4) start/stop switches. Two (2) are remote and two (2) are onboard, located on each side of the machine.

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

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

belt sequence sensor and pick breaker sensor

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

high temperature switch

The high temperature switch for the feeder breaker is located onboard the machine at the oil tank. If a high temperature at the oil tank is detected, the motor will shut off and a light (high temperature) will be illuminated. This light is located on the cover of the electrical enclosure.

low oil cut off switch

The low oil cut off switch for the feeder breaker is located onboard the machine at the oil tank. If a low oil issue is detected, the motor will be turned off and a light (low oil) will be illuminated. This light is located on the cover of the electrical enclosure.

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

© Bucyrus America, Inc.

electric motor (feeder breaker)

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

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

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

Fig. 22: Hydraulic component locator 20

9

14,15

18 8 7

23

21

3

16

19

11, 12,13

6

21

2

4

10

22

23 1

17

1

© Bucyrus America, Inc.

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

1.

2.

3.

4.

5.

6.

7.

8.

primary valve bank auxiliary pressure gauges auxiliary pressure filters conveyor speed valve conveyor direction valve conveyor pressure gauge charge filter hydrostatic filter

9. loop flushing valve 10. return filter 11. tank fill filter 12. power fill pump 13. ball valve 14. pressure gauge (6,000 psi) 15. pressure gauge (600 psi) 16. tram motors

5

17. heat exchanger 18. tandem gear pump 19. hydraulic oil tank 20. hydrostatic pump 21. tilt and lift cylinders 22. conveyor motor 23. roof anchor cylinders

_____________________________________________________________ A6474X269 VSVI / 01 5.23

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.

tandem gear pump

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

primary valve bank

The primary valve bank located on the left hand side of the machine is used to control the machine’s 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 on top of the oil tank and is used to replenish fluid to the hydraulic tank from an external source. The pump is capable of delivering approximately 5 gallons 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.

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

© Bucyrus America, Inc.

(Reference Fig. 22)

© Bucyrus America, Inc.

____________________________________________ Hydraulic system loop flush valve

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

heat exchanger

The heat exchanger located on the left 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 located above the left hand crawler is used to control the conveyor direction of travel.

charge filter

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

pressure filter (s)

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

return filter

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

tank fill filter

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

pressure filter (hydrostatic)

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

ball valve

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

Conveyor speed pressure reducing valve

The pressure reducing valve, located above the left hand crawler of the machine, is used to control the speed of the conveyor.

auxiliary valve bank

The auxiliary valve bank, located on the left hand side of the machine, is used to control the tailpiece steering and lift functions and the roof anchor cylinders. All sections of the valve bank are spring return (self centering).

roof anchor cylinders

The roof anchor cylinders are located on each side of the machine and are used to stabilize the feeder breaker against the roof of the mine.

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

_____________________________________________________________ A6474X269 VSVI / 01 5.25

Hydraulic system _____________________________________________

© Bucyrus America, Inc.

Fig. 23: Hydraulic schematic feeder breaker

_________________________________________________________________ 5.26 BUC – 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. 24) 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. 24: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

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

_____________________________________________________________ A6474X269 VSVI / 01 5.27

Mechanical assemblies ________________________________________ Conveyor chain The feeder breaker is equipped with a conveyor chain assembly (Fig. 25) that carries mined material along the conveyor trough from the receiving section and out through the discharge end. The conveyor chain is made up of one basic chain assembly, which repeats sequentially along the entire chain loop. (See Maintenance section in this chapter for Conveyor chain maintenance) Fig. 25: Conveyor chain components

Roll pin

© Bucyrus America, Inc.

Chain link section

Flight bar

Grease take-up The feeder breaker is equipped with a conveyor chain grease take-up assembly (Fig. 26) 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. 26: Grease take-up main components Stop valve (2)

Grease manifold

Grease fitting (2)

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

_______________________________________ Mechanical assemblies Head shaft The feeder breaker is equipped with a head shaft (Fig. 27 and 28) 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. 27: Head shaft main components Sprocket (2)

Head shaft Key (2)

© Bucyrus America, Inc.

Bearing (2)

Fig. 28: Conveyor torque arm and hydraulic motor

Torque arm

Coupling

Hydraulic motor

_____________________________________________________________ A6474X269 VSVI / 01 5.29

Mechanical assemblies ________________________________________ Power unit The power unit drives the hydraulic pumps and pick breaker reducer (Fig. 29). It consists of a 200 HP electric motor, coupled to a reducer, hydrostatic pump, and piggyback gear pump. The power unit has been assembled as a unit and can be removed as a unit or as individual components.

Fig. 29: Power unit main components Sprocket Reducer

Coupling Motor (200 HP) Connecting tube Coupling Hydrostatic pump

Mounting base © Bucyrus America, Inc.

Gear pump

Tail shaft The feeder breaker is equipped with a tail shaft (Fig. 30) 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. 30: Tail shaft components Sprocket (2)

Key (2) Set screw (2)

Tail shaft

Slide plate

Roller bearing (2) Piston rod adapter (2)

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

_______________________________________ Mechanical assemblies Breaker assembly The breaker assembly (Fig. 31) 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. 31: Breaker assembly main components Underspeed sensor mount

Grease inlet

Bearing (2)

Shear hub

Shear pin

© Bucyrus America, Inc.

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

_____________________________________________________________ A6474X269 VSVI / 01 5.31

© Bucyrus America, Inc.

Mechanical assemblies ________________________________________

_________________________________________________________________ 5.32 BUC – 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 America, Inc. spare parts when replacing components.

■

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

■

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

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

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

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

■

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

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

______________________________________________________________ A6474X269 VSVI / 01 5.33

Maintenance _________________________________________________ ■

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

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

■

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

■

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

■

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

_________________________________________________________________ 5.34 BUC – 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 of 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 manifold (Fig. 32) is located on the left hand side of the receiving end of the feeder breaker. It allows the following to be easily lubricated from a central point: head shaft, breaker shaft and tail shaft.

Fig. 32: Central lubrication

Breaker

Tail shaft

Plugged port

Head shaft

Breaker bearing return lines.

Do not plug

______________________________________________________________ A6474X269 VSVI / 01 5.35

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 (feeder breaker) Item

Description

Places

Lubricant

Specification

Every 8 hours of operation 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)

1

9

Bits (breaker)

Century Replex 2

Spec. 100-3

Weekly 10

Crawler track take-up bearings

2

11

Conveyor chain tension

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

EP-90

17

Breaker drive chain

1

Chain lube

18

Breaker reducer (Check)

1

Century 220

19

Dust system strainer (Check)

1

20

Charge filter (change)

1

1

Every 2 weeks 21

Pressure filter (auxiliary circuit) (change)

2

22

Return filter (change)

1

23

Pressure filter (hydrostatic) (change)

1

Monthly 24

Power fill filter (change)

1

25

Conveyor tilt and lift cylinders

8

Century Replex 2

Spec. 100-3

26

Crawler anchor pin (s)

2

Century Replex 2

Spec. 100-3

27

Shear hub

3

Century Replex 2

Spec. 100-3

Every 3 months 28

Electric motor

2

Exxon Unirex N-2

Spec. 100-2

29

Breaker reducer

2

Century Replex 2

Spec. 100-3

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

© Bucyrus America, Inc.

Inspect

________________________________________________ Maintenance Table 1 Continued: Lubrication and maintenance schedule (feeder breaker) Item

Description

Places

Lubricant

Specification

Every 2500 hours 30

** Breaker reducer (Change)

1

Century 220

Every 6 months 31

Hydraulic oil tank (change)

1

Century Hydraulic AW 68

32

Tram reducer (change oil)

2

80W-90

Spec. 100-1

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

Fig. 33: Lubrication chart (feeder breaker)

8,23

5,20

15 7,22

© Bucyrus America, Inc.

28

19

29

18,30 25 17, 27

4,31

15

26 16,32

9

6,21

1,2,3

10

25

9

______________________________________________________________ A6474X269 VSVI / 01 5.37

Maintenance _________________________________________________ Table 2: Lubrication and maintenance schedule (tailpiece) Item

Description

Places

Lubricant

Specification

Century Replex 2

Spec. 100-3

Every 8 hours of operation 1

Bearings

2

Fig. 33: Lubrication chart (tailpiece)

1 (2 places)

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

© Bucyrus America, Inc.

1 (2 places) (Hose whip not shown)

________________________________________________ Maintenance Specific lubrication and maintenance procedures Every 8 hours of operation: Lubricate the tailpiece bearings with Spec. 100-3 through the hose whips located on each side of the tailpiece (Fig. 34). Pump grease into the two (2) hose whips until new grease can be observed coming out of the bearings.

head shaft bearings

Lubricate the feeder breaker head shaft bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 35) located on the left side of the receiving section. Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

tail shaft and slide tube bearings

Lubricate the feeder breaker tail shaft and slide tube bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 35) located on the left side of the receiving section.

Pump grease into the four (4) fittings until new grease can be observed coming out of the tail shaft and bearings.

breaker bearings

Lubricate the breaker bearings with Spec. 100-3 through the grease fittings located on the central lubrication panel (Fig. 35) 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.

tailpiece bearings

Fig. 35: Central lubrication panel

Central lubrication panel

hydraulic oil tank

Check the feeder breaker hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 36). 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. 36: Hydraulic tank oil level

Oil level sight glass

______________________________________________________________ A6474X269 VSVI / 01 5.39

Maintenance _________________________________________________ Check the feeder breaker charge filter’s pop-up style dirt alarm ( Fig. 37) 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. 37) 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. 37) 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. 37) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

breaker bits

Check the breaker bits to see if they will rotate in their holders and for damaged or missing bits (Fig. 37). The bits may be inspected by looking into the receiving end of the machine. If bits need to be replaced, see Bit replacement in this chapter.

Fig. 37: Filter and breaker bit location Breaker bits

Pressure filter (s) (auxiliary circuit)

Charge filter

Pressure filter (hydrostatic)

Return filter

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

© Bucyrus America, Inc.

charge filter

________________________________________________ Maintenance Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 38) with Spec. 100-3. The fittings (one per side) may be reached through the slot in the end of the crawler frame on the outside of each crawler.

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

© Bucyrus America, Inc.

Fig. 38: Crawler track take-up lubrication

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

conveyor chain tension

With the machine off, check the conveyor chain tension at the head shaft end. (Fig. 39). When the conveyor chain is properly tensioned, there will be approximately 2 inches (50 mm) of droop on the bottom side of the head shaft sprockets. With the machine running, visually inspect tail shaft to ensure shaft is turning and conveyor chain is engaging the tail shaft sprockets properly. If adjustment is necessary, see Conveyor chain adjustment procedure in this chapter.

Fig. 39: Conveyor chain tension

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

______________________________________________________________ A6474X269 VSVI / 01 5.41

Maintenance _________________________________________________

electrical cables, conduits and glands hydraulic hoses and fittings

charge filter

hydraulic system pressure

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

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

head shaft bearing bolts

■

power unit tray mounting bolts

■

breaker shaft side plate bolts

■

crawler side plate bolts

■

conveyor drive motor mounting bolts

■

tilt cylinder crawler mount bracket bolts

■

tail shaft retainer hold down bolts

■

pump coupling set screws and retainer bolts

■

crawler motor mount nuts

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.

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

Check the hydraulic system pressure by visually looking at the pressure gauges (Fig. 40). Refer to the hydraulic schematic in your parts manual for correct pressure (s).

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

© Bucyrus America, Inc.

fasteners

________________________________________________ Maintenance Fig. 40: Hydraulic charge filter and system pressure gauges (s) location

Conveyor circuit charge pressure gauge

Charge filter (located beside hydrostatic filter)

© Bucyrus America, Inc.

Hydrostatic filter

Conveyor system circuit pressure gauge

Auxiliary system circuit pressure gauge, left hand

Conveyor speed pressure gauge (located directly behind fire suppression actuator)

Auxiliary system circuit pressure gauge, right hand

Fire suppression

______________________________________________________________ A6474X269 VSVI / 01 5.43

Maintenance _________________________________________________ tram reducer (s)

Check the oil level in both tram reducer torque hubs (Fig. 41):  Oil level/fill plug should be at the 3 o’clock position and the drain plug at the 6 o’clock position.  Remove the oil level/fill plug. The oil level should be kept at the level of the level/fill plug.  Should it be necessary to add oil, add EP-90 oil through the fill plug hole until it begins to flow out of the check hole. Do not overfill the reducer.  Replace the oil level/fill plug.

Fig. 41: Tram reducer oil level

Drain plug location

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. 42). Oil level should be maintained inside the sight glass on the side of the reducer when it is in operation. If the reducer does not have a sight glass, a pipe plug will be installed in the side of the reducer slightly below the input shaft center line. This is the level that the fluid should be maintained at. The oil should be changed after the first 500 hours of operation. Use CenFig. 42: Breaker reducer Inspection cover Breather

Sight glass (fill to this level) Drain plug

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

© Bucyrus America, Inc.

Fill/check plug location

________________________________________________ Maintenance dust system strainer

Clean the strainer mounted inside the dust suppression system. Open ball valve (Fig. 43) and allow water to flow from the short attached hose. The flowing water will flush out the filter strainer.

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

Fig. 43: Dust system Strainer

Ball valve

© Bucyrus America, Inc.

Short drain hose

Strainer

______________________________________________________________ A6474X269 VSVI / 01 5.45

Maintenance _________________________________________________ Every 2 weeks pressure filter (auxiliary circuit)

Change the two (2) pressure filter’s element (Fig. 44). If the element is extremely dirty, a more frequent interval may be required.

return filter

Change the return filter’s element (Fig. 44). If the element is extremely dirty, a more frequent interval may be required.

pressure filter (hydrostatic)

Change the hydrostatic pressure filter’s element (Fig. 44). If the element is extremely dirty, a more frequent interval may be required.

Fig. 44: Filter location

Charge filter (not shown)

Return filter

Pressure filter (s) (auxiliary circuit)

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

© Bucyrus America, Inc.

Pressure filter (hydrostatic)

________________________________________________ Maintenance Monthly power fill filter

Change the power fill filter element (Fig. 45). If the element is extremely dirty, a more frequent interval may be required.

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. 45). 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. 45). Pump grease into the fittings until new grease can be observed coming out of the pins.

shear hub

Lubricate grease fittings (3) on the breaker shaft shear hub with Spec.

100-3 (Fig. 45). Pump grease into the fittings until new grease is observed coming out of the spare shear pin holes and around the outer diameter of the hub collar.

Fig. 45: Power fill filter and lubrication point location

© Bucyrus America, Inc.

Shear hub grease fitting (3)

Power fill filter

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

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

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

______________________________________________________________ A6474X269 VSVI / 01 5.47

Maintenance _________________________________________________ Every 3 months electric motor

Lubricate the feeder breaker’s electric motor with Spec. 100-2 through the two (2) button head grease fittings located on the central lubrication panel (Fig. 46) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

CAUTION! The grease line may have to be purged of air before the first use.

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

reducer

Lubricate the reducer with Spec. 100-3 through the two (2) button head grease fittings located on the central lubrication panel (Fig. 46) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

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

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

© Bucyrus America, Inc.

CAUTION! The grease line may have to be purged of air before the first use.

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

________________________________________________ Maintenance Fig. 46: Electric motor and reducer lubrication Reducer central lubrication panel

© Bucyrus America, Inc.

Electric motor central lubrication panel

______________________________________________________________ A6474X269 VSVI / 01 5.49

Maintenance _________________________________________________ Every 2500 hours reducer

Change the oil in the breaker drive reducer (Fig. 47). 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 Century 220 lubricant as required until fluid is visible in sight glass or begins to flow from the check plug that is slightly below the center line of the input shaft.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Install level/fill plug. Do not overfill reducer.

Inspection cover Breather

Sight glass (fill to this level) Drain plug

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

© Bucyrus America, Inc.

Fig. 47: Breaker reducer

________________________________________________ Maintenance Every 6 months hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank (Fig. 48).  Clean all dirt and debris from and around the fill cap and drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and reinstall drain plug.  Remove the fill cap and pour 20 gallons (76 L) through the fill cap strainer to avoid cavitating the pumps with the power fill unit.

© Bucyrus America, Inc.

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

CAUTION! Do not cut holes in or remove the fill cap strainer. If the strainer is missing or damaged, the hydraulic component warranty will be voided.  Add oil Spec 100-1 as required via the power fill system until fluid is visible in sight glass (see procedure in Operation section of this chapter).  Install fill cap.  Start the machine and allow the hydraulic pump to run in order to purge air from the system.  Shut down the machine and recheck the oil level. Add oil if necessary.

Fig. 48: Hydraulic oil tank

Sight glass

Drain plug (located underneath)

______________________________________________________________ A6474X269 VSVI / 01 5.51

Maintenance _________________________________________________ tram reducer

Change oil in the tram reducer (Fig. 49).  Rotate the reducer until the fill/check plug is located in the 3 o’clock or 9 o’clock position and the drain plug is located at the 6 o’clock position.   Clean all dirt and debris from and around the level and fill plugs.  Remove both the fill/check plug and the drain plug. Allow the oil to completely drain from the unit.  Clean and reinstall drain plug.  Add oil (EP 90) through the fill hole until fluid begins to flow from the fill/check plug hole.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Clean and install fill/check plug..

Fig. 49: Tram reducer oil change

Fill/check plug location

Drain plug location

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

© Bucyrus America, Inc.

 Do not overfill reducer.

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

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

© Bucyrus America, Inc.

 Check the hydraulic oil resevoir level in the feeder breaker by looking at the sight glass. The oil level should be kept at the level of the top sight glass.  Check oil level in the crawler reducers.  Check oil level in the breaker shaft gear reducer using the bottom sight glass.  Inspect all electrical and hydraulic components for condition.  Check for proper conveyor chain tensioning.  Check for proper breaker shaft drive chain tensioning.  Check for proper crawler chain tensioning.  Lubricate per the lubrication schedule.  Check power input cable to power source insuring that the voltage and breaker settings are correct.  Check that the cable handling device is intact and oriented correctly.  Check that all covers are installed and secure.  Check the tightness of all connecting elements.  Clean and remove any foreign materials from around the head shaft bearings.  Check the breaker shaft for missing or damaged bits.

______________________________________________________________ A6474X269 VSVI / 01 5.53

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

Inspect: the conveyor chain

■

the conveyor chain flights

■

the conveyor drive sprockets

■

the conveyor tail shaft

■

the conveyor wear plates

■

the crawler pads

■

the crawler drive sprockets

■

the crawler idler rollers © Bucyrus America, Inc.

■

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

________________________________________________ Maintenance Inspection of fire suppression system on the feeder breaker To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 50).  Note general appearance for mechanical damage or corrosion.  Check nameplate for readability, corrosion or looseness.  Remove fill cap assembly.  Examine gaskets for elasticity, clean and coat lightly with a good grade of high heat resistant grease.  Inspect threads on fill cap and in fill opening for nicks, burrs, cross threading, rough or feathered edges.

© Bucyrus America, Inc.

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

______________________________________________________________ A6474X269 VSVI / 01 5.55

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

© Bucyrus America, Inc.

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

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

________________________________________________ Maintenance Recharge of fire suppression system on the feeder breaker To return your fire suppression system to service after use (Fig. 50).  Pull ring on safety valve to relieve actuator system pressure.  Disconnect actuation system hose at cartridge receiver/actuator assembly.  Open bursting disc union assembly.  Remove extinguisher from bracket.  Replace ruptured bursting disc with new disc. (Full disc side must face extinguisher).  Fill extinguisher to rated capacity with Ansul dry chemical specified on nameplate.

© Bucyrus America, Inc.

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

______________________________________________________________ A6474X269 VSVI / 01 5.57

Maintenance _________________________________________________ Fig. 50: Fire suppression system

Conveyor motor

Conveyor coupling

Nozzle

Nozzle

Starter box

Hopper end Remote actuator

Nozzle

LP canister

Remote actuator

LP expellant

Pump

Breaker coupling Nozzle

Operator’s station

Nozzle Nozzle Breaker motor Nozzle

Nozzle

Oil tank LP expellant © Bucyrus America, Inc.

LP canister

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

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

Inspect the adjustments at regular intervals.

Conveyor chain adjustment The conveyor chain is a complete assembly and should be checked for correct tension at regular intervals (see Weekly Maintenance section in this chapter, Fig. 39).

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. 51):  Close the stop valves on manifold assembly securely by turning clockwise.  Attach a grease gun to the grease fittings located on the manifold and apply grease until the required pressure is attained.  After tensioning chain, remove the allen head bolts from the tail shaft retainers and lift out retainers.  Insert shims over cylinder rod to maintain gap between bearing and end of grease cylinder.

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

Incorrect tension or adjustment can cause premature wear of sprockets and chain.  Replace retainers.  Release pressure on the take-up cylinders by opening the valves (turn counter clockwise) to vent grease, allowing tail shaft pressure to rest completely on shims. Do not close valve.

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

______________________________________________________________ A6474X269 VSVI / 01 5.59

Adjustment procedures ________________________________________ Fig. 51: Conveyor chain adjustment

Stop valve, left hand grease cylinder Stop valve, right hand grease cylinder

Grease fitting, left hand grease cylinder

Cover plate (shim storage)

Grease fitting, right hand grease cylinder

Cover plate (shim storage)

Tail shaft retainer plate

Tail shaft retainer plate

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

© Bucyrus America, Inc.

Valve manifold, typical both sides of machine

_______________________________________ 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. 52):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

© Bucyrus America, Inc.

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

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

You could be seriously injured or even killed by falling loads.  Run crawler in forward direction for 3 minutes at slow speed.  Run crawler in reverse direction for 3 minutes at slow speed.  Shutdown machine.  If necessary, re-adjust chain sag.  Add or remove required amount of shims to maintain correct tension.  Release grease pressure in the cylinder by loosening the grease fitting and turning the valve knob counter clockwise, allowing the shims to maintain the correct tension. Tighten the grease fitting once grease has stopped coming out around the grease fitting.

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

______________________________________________________________ A6474X269 VSVI / 01 5.61

Adjustment procedures ________________________________________ Fig. 52: Crawler track adjustment

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

Idler assembly

© Bucyrus America, Inc.

Access cover

Take-up cylinder

Grease fitting

Needle valve

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

_______________________________________ Adjustment procedures Breaker drive chain The breaker drive chain should be checked for correct tension at regular intervals. The required tension is approximately one inch (1”) of vertical movement in the chain at the midpoint between sprockets.

To adjust tension on the breaker drive chain with the take-up cylinder proceed as follows (Fig. 53):  Remove the covers from the power unit side of the machine as necessary to expose the four (4) 1-1/2” bolts behind the electric motor and gearbox.  Loosen the nine (9) power unit adjustment bolts located along both sides of the base tray of the power unit.  Open the needle valve by turning the handle counter clockwise..

© Bucyrus America, Inc.

 Attach a grease gun to the grease fitting and pump grease into the grease cylinder to tension the chain. The chain is properly tensioned when there is one inch (1”) of vertical movement at the midpoint of the chain between sprockets.  After correct tension is obtained, insert or remove the required amount of shims between the mounting base and machine frame to maintain correct tension.  With the valve still open, slowly loosen the grease fitting to relieve pressure in the grease cylinder. When the grease stops coming out of the grease fitting, tighten the fitting backup and close the needle valve by turning the handle clockwise.

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 the five adjustment bolts along the outside of the machine first. Next, tighten the four remaining bolts on the inside of the machine. Torque bolts to 800 ft-lbs.

Note: There are bolt access holes in the frame for the four bolts located inside of the machine.  Store and secure any unused shims on the mounting stud located directly behind the grease cylinder.  Lubricate drive chain with proper chain lubrication oil.  Install power unit covers.

______________________________________________________________ A6474X269 VSVI / 01 5.63

Adjustment procedures ________________________________________ Fig. 53: Breaker drive chain adjustment

Shim storage Shim location

Bolt hole not used on this model

Adjustment bolts (9)

Grease fitting

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

© Bucyrus America, Inc.

Needle valve

_______________________________________ Adjustment procedures Hydrostatic pump relief valve adjustment The hydrostatic pump used to drive the conveyor chain on the feeder breaker has two main pressure relief valves and one charge relief valve (Fig. 54). The main relief valves are preset at 5,000 psi and the charge relief valve at 350 psi.

To adjust the main relief: WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.  1. Locate the forward direction pressure port on the hydrostatic pump (Fig. 54) and remove the forward pressure hose from the pump. Plug the hose end and cap the pump fitting.

© Bucyrus America, Inc.

WARNING! The hose plug and the fitting cap must be properly torqued before proceeding as the system pressure will reach 5,000 psi. Failure to do so may result in serious injury or death.  2. Turn the machine on (refer to Start up section in this chapter).

IMPORTANT! Do not run the pump for a long period of time while setting the reliefs as all of the flow will be going over the relief. Excessive pump operation with the lines plugged will result in overheating and the eventual failure of the pump.  3. Two people are required to adjust the pressure settings. One person must move the conveyor direction valve handle to the forward direction and must remain at the conveyor controls and Start/Stop push button station (Fig. 55) at all times during the adjustment procedure. The second person will monitor the system pressure gauge and perform the actual pressure relief adjustment at the hydrostatic pump (Fig. 56).

WARNING! Two people are required to adjust the pressure settings. One person must move the conveyor direction valve handle to the forward direction and remain at the conveyor controls and Start/Stop push button station at all times during the adjustment procedure. Failure to do so may result in serious injury or death.

The conveyor forward pressure must be adjusted if the system pressure gauge does not read 5,000 psi when the conveyor direction valve is placed in the forward direction.

If the system pressure gauge does read 5,000 psi during the conveyor forward relief pressure test, then proceed to Step 8.  4. Locate the corresponding relief pressure adjustment valve for the forward pressure port (Fig. 54).

______________________________________________________________ A6474X269 VSVI / 01 5.65

Adjustment procedures ________________________________________  5. Loosen the hex jam nut be turning counterclockwise.   6. Insert an internal hex key into the pressure adjustment screw and turn the internal hex key clockwise to increase the conveyor relief pressure setting and counterclockwise to decrease the conveyor relief pressure setting.

CAUTION! Do not turn the adjustment screw in any further once it is felt that the screw has bottomed out as this may damage the needle valve and seat. Likewise, do not turn the adjustment screw out all the way as this may present difficulties in reassembly and may introduce contamination into the hydraulic pump.

 7. Monitor the system pressure gauge until the desired 5,000 psi pressure relief setting is obtained for the conveyor pressure.  8. Lock the pressure adjustment screw in place by turning the hex jam nut clockwise while still holding the pressure adjustment screw with the internal hex key so as not to alter the desired pressure setting. Once the hex jam nut is snugged down, observe the system pressure gauge to ensure the relief pressure setting was not accidentally changed during the tightening of the hex jamb nut. If the relief pressure setting has changed, loosen the hex jamb nut and readjust the pressure to 5,000 psi with the adjustment screw.  9. Return the conveyor direction valve handle to the neutral position and turn the machine off.  10. Cautiously remove the hose plug and fitting cap from the conveyor pressure hose and the pump pressure port. Adhere to all safety procedures when performing this step. Install the pressure hose to the pressure port on the pump.

WARNING! The hose fitting must be properly torqued before proceeding as the system pressure will reach 5,000 psi. Failure to do so may result in serious injury or death.  11. Return to Step 1 and repeat the adjustment procedure for the conveyor reverse pressure relief setting.  12. Restart the machine and check for leaks at the pressure ports of the hydrostatic pump by positioning the conveyor direction control valve in both forward and reverse direction.

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

© Bucyrus America, Inc.

NOTICE! While adjusting the relief pressure, if the system pressure gauge reading is not changing, it must be determined that the conveyor direction valve handle is in the correct position and that the corresponding pump pressure port hose was disconnected and plugged. To resolve this issue, place the conveyor direction valve handle in the opposite direction.

_______________________________________ Adjustment procedures Hydrostatic pump charge pressure adjustment WARNING! Follow all standard safety procedures before beginning this adjustment process. Failure to do so may result in serious injury or death.  1. Start the machine (see Start-up procedure in this chapter).  2. The charge pressure gauge (Fig. 56) should read 350 psi while the machine is at idle, the conveyor direction valve handle is in neutral, and the oil temperature is between 90°F and 110°F. Locate the charge pressure adjustment screw (Fig. 54).

© Bucyrus America, Inc.

Note: The charge pressure will drop slightly (as low as 290 psi) while the conveyor is running. This is normal and does not require further adjustment after initial setting.

Note: The charge pressure will vary depending on oil temperature (the hotter the oil, the lower the pressure and the cooler the oil, the higher the pressure). This is normal and does not require further adjustment after initial setting.  3. Insert an internal hex key into the pressure adjustment screw and turn the internal hex key clockwise to increase the charge pressure setting and counterclockwise to decrease the charge pressure setting.

CAUTION! Do not turn the adjustment screw in any further once it is felt that the screw has bottomed out as this may damage the needle valve and seat. Likewise, do not turn the adjustment screw out all the way as this may present difficulties in reassembly and may introduce contamination into the hydraulic pump.  4. Monitor the charge pressure gauge until the desired 350 psi pressure setting is obtained for the charge pressure.  5. Lock the pressure adjustment screw in place by turning the hex jam nut clockwise while still holding the pressure adjustment screw with the internal hex key so as not to alter the desired pressure setting. Once the hex jam nut is snugged down, observe the charge pressure gauge to ensure the relief pressure setting was not accidentally changed during the tightening of the hex jamb nut. If the charge pressure setting has changed, loosen the hex jamb nut and readjust the pressure adjustment screw.  6. Turn off the machine.

______________________________________________________________ A6474X269 VSVI / 01 5.67

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

Note: The primary valve bank (Fig. 55) has two relief adjustment screws located at the inlet section and the mid-inlet section. The required auxiliary system pressure is 2,250 psi.  1. Start the machine (see Start-up procedure in this chapter).

WARNING! The feeder will move during this step and it must be ensured that all standard safety procedures are adhered to in order to avoid personnel injury and equipment damage. Do not operate the tram function to perform this adjustment as it is unsafe. Failure to adhere to this warning may result in serious injury or death.  3. Refer to the corresponding auxiliary system pressure gauge (Fig. 55) for that half of the valve bank and observe the pressure value while holding the valve bank handle in the operating position chosen to bottom out the hydraulic cylinder. If the pressure reading is not 2,250 psi, adjustment is required.  4. Release the valve bank handle to allow it to return to the neutral position.  5. Loosen the locking hex collar of the corresponding pressure relief valve for the inlet valve bank section.  6. Insert a large flat blade screwdriver into the pressure adjustment screw slot and turn the screwdriver clockwise to increase the relief pressure setting and counterclockwise to decrease the relief pressure setting. Repeat Step 3 until 2,250 psi is indicated on the corresponding inlet pressure gauge.

CAUTION! Do not turn the adjustment screw in any further once it is felt that the screw has bottomed out as this may damage the needle valve and seat. Likewise, do not turn the adjustment screw out all the way as this may present difficulties in reassembly and may introduce contamination into the hydraulic pump.

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

© Bucyrus America, Inc.

 2. Operate a hydraulic cylinder function (Fig. 55) from the inlet section of the valve bank until the cylinder is completely bottomed out and no further movement of the cylinder is observed.

_______________________________________ Adjustment procedures NOTICE! While adjusting the relief pressure, if the system pressure gauge reading is not changing, it must be determined that the valve handle from the same half of the valve bank as the pressure relief valve is being operated. To resolve this issue, ensure that the valve bank function is from the same half of the valve bank as the relief pressure adjustment screw.  7. Maintain the position of the adjustment screw by holding with the screwdriver while turning the hex lock collar clockwise to increase the relief pressure setting and counterclockwise to decrease the relief pressure setting. Repeat Step 3 until 2,250 psi is indicated on the corresponding pressure gauge.  8. Return to Step 2 and repeat the same adjustments for the midinlet section of the primary valve bank.

© Bucyrus America, Inc.

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

Note: The hydraulic source of the secondary valve bank is from the far right hand valve bank section of the primary valve bank. The primary valve bank relief adjustment must be performed first before the relief adjustment of the secondary valve bank can be preformed. The required auxiliary system relief pressure is 2,250 psi for both the primary and secondary valve banks.  1. Turn the machine on. Refer to the corresponding section of this manual for start up procedures if necessary.  2. Pull the far right hand handle of primary valve bank towards the operator to send hydraulic fluid to the secondary valve bank.

The far right hand section of the primary valve bank has a detent action handle and will remain in an operating position until it is manually placed back into neutral.  3. Operate a hydraulic cylinder function from the secondary valve bank until the cylinder is completely bottomed out and no further movement of the cylinder is observed.

CAUTION! The feeder tailpiece or a roof anchor cylinder will move during this step and it must be ensured that all standard safety procedures are adhered to avoid personnel injury and equipment damage.  4. Refer to the corresponding auxiliary system pressure gage for that half of the primary valve bank from which the secondary valve bank is fed and observe the pressure value while holding the valve bank handle in the operating position chosen to bottom the hydraulic cylinder. Adjustment will be required if the pressure gage does not read 2,250 psi.

______________________________________________________________ A6474X269 VSVI / 01 5.69

Adjustment procedures ________________________________________  5. Release the valve bank handle to allow it to return to the neutral position.  6. Loosen the locking hex collar of the pressure relief valve.  7. Insert a large flat blade screwdriver into the pressure adjustment screw slot and turn the screwdriver clockwise to increase the relief pressure setting and counterclockwise to decrease the relief pressure setting. Repeat Step 3 until 2,250 psi is indicated on the corresponding pressure gage used to set the relief pressure on the mid inlet of the primary valve bank.

 8. Lock the pressure adjustment screw in place by turning the hex collar clockwise while still holding the pressure adjustment screw with the screwdriver so as not to alter the desired pressure setting. Once the hex collar is snugged down, Repeat Step 3 to ensure the relief pressure setting was not accidentally changed during the tightening of the hex collar. If the relief pressure setting has changed, loosen the hex collar and readjust the pressure adjustment screw.  9. Turn off the machine.

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

© Bucyrus America, Inc.

CAUTION! Do not turn the adjustment screw in any further once it is felt that the screw has bottomed out as this may damage the needle valve and seat. Likewise, do not turn the adjustment screw out all the way as this may present difficulties in reassembly and may introduce contamination into the hydraulic system.

_______________________________________ Adjustment procedures Fig. 54: Pump relief valves Charge pressure relief adjustment System pressure relief adjustment, forward: located directly across from forward system pressure port

© Bucyrus America, Inc.

System pressure relief adjustment, reverse: located directly across from reverse system pressure port

System pressure port, forward

System pressure port, reverse

______________________________________________________________ A6474X269 VSVI / 01 5.71

Adjustment procedures ________________________________________ Fig. 55: Valve banks

Hydraulic cylinder function - left lift

Tram, left

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

Tram, right

Hydraulic cylinder function - right lift

Auxiliary system pressure gauges

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

Start/Stop push button station

Secondary valve bank inlet relief

© Bucyrus America, Inc.

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

Conveyor direction control valve

Fig. 56: System and charge pressure gauges

Charge pressure gauge

System pressure gauge

_________________________________________________________________ 5.72 BUC – 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. 57) 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. 57: Head shaft main components Sprocket (2)

Head shaft Key (2)

Bearing (2)

______________________________________________________________ A6474X269 VSVI / 01 5.73

Replacement of wear parts _____________________________________ How to remove the head shaft To remove the head shaft assembly from the feeder breaker proceed as follows (Fig. 57):  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Remove the two (2) sprocket guards located over the head shaft sprockets.  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove head shaft safety guard located on the left hand side of the feeder, behind the conveyor motor.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads. Un pin and fold down tailpiece tilt cylinders. It is not necessary to remove hydraulic hoses. Remove the tailpiece hoppers (2) and head shaft filler plates (2) using appropriate lifting equipment.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.   Remove the hydraulic motor. (See Hydraulic motor removal in this chapter).  Disconnect, tag and cap the central lubrication hoses on both head shaft bearings.  Remove the four (4) nuts, bolts, and lock washers from each of the head shaft bearings.  Attach an appropriate lifting device to the head shaft and slide out towards the rear of the frame.

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

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

© Bucyrus America, Inc.

 Block and secure tailpiece.

____________________________________ Replacement of wear parts How to install the head shaft To install the head shaft assembly proceed as follows (Fig. 57):  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 sprocket guards, head shaft filler plates, tailpiece hoppers, amd tailpiece tilt cylinders.  Connect the central lubrication hoses on both head shaft bearings.  Install the hydraulic motor. (See Hydraulic motor installation in this chapter).  Clean and lubricate spined end of head shaft with ISO 68 hydraulic fluid. © Bucyrus America, Inc.

CAUTION! Do not damage motor shaft seal during installation.   Install head shaft safety guard.  Connect conveyor chain. (See Conveyor chain replacement in this chapter).  Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

Fig. 57: Head shaft removal and installation Conveyor chain (not shown)

Head shaft filler plates

See hydraulic motor removal in this chapter

Head shaft safety cover (not shown) Head shaft Sprocket guard (s)

______________________________________________________________ A6474X269 VSVI / 01 5.75

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

How to remove the head shaft sprockets To remove the sprockets from the head shaft assembly proceed as follows (Fig. 58):  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.  Remove the two (2) set screws from each sprocket.

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

See parts manual for replacement parts list.

How to install the head shaft sprockets To install the sprockets on the head shaft proceed as follows (Fig. 58):  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.)

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

© Bucyrus America, Inc.

 Slide both sprockets from the drive shaft.

____________________________________ Replacement of wear parts How to install the head shaft split sprockets To install the split sprockets on the head shaft proceed as follows (Fig. 58): IMPORTANT! Adhere to all weld specifications shown on Fig. 58. 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 discharge boom.

© 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 coolt 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).

______________________________________________________________ A6474X269 VSVI / 01 5.77

Replacement of wear parts _____________________________________ Fig. 58: 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 _________________________________________________________________ 5.78 BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

General notes:

____________________________________ Replacement of wear parts Tail shaft The tail shaft (Fig. 59) tail shaft function is to provide a means for adjusting the conveyor chain and to redirect conveyor chain direction.

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

© Bucyrus America, Inc.

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

shaft

■

sprocket (2)

■

slide plate

■

key (2)

■

set screw (2)

■

roller bearing (2)

■

piston rod adapter (2)

■

grease fitting (2)

Fig. 59: Tail shaft main components Sprocket (2)

Key (2) Set screw (2)

Tail shaft

Slide plate

Grease fitting (2)

Roller bearing (2) Piston rod adapter (2)

______________________________________________________________ A6474X269 VSVI / 01 5.79

Replacement of wear parts _____________________________________ How to remove the tail shaft To remove the tail shaft assembly from the feeder proceed as follows (Fig. 60):  Release tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).  Clean the silicone from the five (5) socket head bolts and remove the bolts from each of the tail shaft retainers and lift out the retainers.  Disconnect, tag, and cap the central lubrication hoses to the tail shaft.  Remove the tail shaft shims and swivel grease fittings.  Separate conveyor chain and fold back to clear tail shaft. (See Conveyor chain replacement in this chapter).

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

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 60):  With an appropriate lifting device, insert tail shaft into receiving boom.  Fold the conveyor chain over tail shaft.  Connect conveyor chain (see Conveyor chain replacement in this chapter.  Install swivel grease fittings.  Connect central lubrication hoses and lubricate tail shaft and slide plate bearings with Spec. 100-3 grease.  Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).  Install the tail shaft retainers with the five (5) bolts in each side.  With machine running, inspect tail shaft to ensure that the shaft is turning and conveyor chain is engaging the tail shaft sprockets properly.  Fill the socket head bolts with silicone. _________________________________________________________________ 5.80 BUC – 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. 60: Tail shaft removal and installation

Cover

Tail shaft retainer plates (2)

Shims

© Bucyrus America, Inc.

Take-up cylinder

Shim storage (typical both sides)

Tail shaft

Sprocket (2) Swivel grease fitting (2)

______________________________________________________________ A6474X269 VSVI / 01 5.81

Replacement of wear parts _____________________________________ How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 61):  Remove the tail shaft assembly from the feeder. (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 sprockets and slide rollers from the shaft.  Remove the tail shaft from the slide plate weldment.  Visually inspect all components for damage or wear and replace as necessary.

How to assemble the tail shaft

 Thoroughly clean all parts that will be installed.  Grease tail shaft with Spec. 100-3 grease.  Slide tail shaft into the slide plate.  Insert keys into keyways on tail shaft.  Slide both sprockets onto tail shaft, one on each end.  Apply Loctite 242 (blue) and install set screws into both sprockets, ensuring that rollers and tail shaft slide plate are centered on tail shaft.  Tighten set screws (torque to 100 ft-lb).  Install both roller bearings and adapter plates on tail shaft, one on each end.  Install swivel grease fittings into each end of shaft.  Install assembled tail shaft into machine. (See How to install the tail shaft in this chapter).

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

© Bucyrus America, Inc.

To assemble the tail shaft assembly proceed as follows (Fig. 61):

____________________________________ Replacement of wear parts Fig. 61: Tail shaft disassembly and assembly

Key (2) Set screw (2)

Sprocket (2) Tail shaft

Swivel grease fitting (2)

© Bucyrus America, Inc.

Roller bearing (2) Piston rod adapter (2)

Slide plate

______________________________________________________________ A6474X269 VSVI / 01 5.83

Replacement of wear parts _____________________________________ Conveyor chain The conveyor chain (Fig. 62) is made up of one basic chain assembly which repeats sequentially along the entire chain loop. As soon as any component of the conveyor chain is worn the component or complete conveyor chain assembly must be replaced.

Each conveyor chain section consists of the following main components: ■

6 link chain section

■

flight bar

■

spiral pin

6 link chain section Spiral pin Flight bar

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

© Bucyrus America, Inc.

Fig. 62: 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. 63):  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 63: Conveyor chain assembly

Extended pin connecting link Spiral pin (4)

Block link assembly

Flight bar

Side bar

6 link chain section

______________________________________________________________ A6474X269 VSVI / 01 5.85

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

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

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

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

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

IMPORTANT! If old conveyor chain is still on machine, installation can be facilitated by connecting the new conveyor chain to the old conveyor chain via the chain connectors and pulling it through the bottom conveyor pan.  Fold conveyor chain back over the tail shaft and drive shaft and slowly pull the chain along the conveyor ensuring that the chain is under the chain hold downs.  Ensure that the chain is properly meshed with the drive sprockets and aligned with the tail shaft sprockets.  Connect conveyor chain (see How to assemble the conveyor chain sections in this chapter for proper connection).  Adjust tension on the conveyor chain (see Conveyor chain adjustment procedure in this chapter.  With machine running, visually inspect tail shaft to ensure that that the shaft is turning and conveyor chain is engaging tail shaft sprockets properly. _________________________________________________________________

5.86

BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

How to install the conveyor chain assembly

____________________________________ Replacement of wear parts Crawler track The crawler track (Fig. 64) assembly (left and right) carries the machine via torque received from the tram drive reducer. The crawler track is made up of one basic crawler pad assembly, which repeats sequentially along the entire pad loop. As soon as any component of the crawler track is worn the component or complete crawler track assembly must be replaced.

Each crawler track consists of the following main components: ■

crawler pad

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connector pin

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t-pin

Fig. 64: Crawler track main components

© Bucyrus America, Inc.

Crawler pad

Connector pin and T-pin

______________________________________________________________ A6474X269 VSVI / 01 5.87

Replacement of wear parts _____________________________________ How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 64):  Lay crawler track pads on a clean flat surface.  Align pads with chain connecting holes centered.  Insert connector into center of crawler pad connecting holes.  Drive T-pin through connecting pin and bend end to secure.  Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly

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

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Crawler track tension must be released (see Crawler track adjustment in this chapter).  Lift and block th the crawler pad to expose a connecting pin at the drive sprocket area (Fig. 65).  Separate the crawler pads.

To separate the crawler pads proceed as follows (Fig. 64) 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.

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

© Bucyrus America, Inc.

To remove the crawler track pad assembly proceed as follows (Fig. 65):

____________________________________ 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. 65):

© Bucyrus America, Inc.

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

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Check to ensure that crawler track tension cylinder is completely retracted (see Crawler track adjustment in this chapter).  Slide crawler track pad assembly under crawler assembly.  Fold pad assembly over both ends of crawler assembly. Ensure that pad assembly meshes with drive sprocket and idler roller.  Connect crawler track pad assembly at the drive sprocket location (Fig. 65) (see How to assemble crawler track pad assembly in this chapter for proper connection).  Adjust tension on the crawler track pad assembly (see Crawler track pad adjustment procedure in this chapter for proper adjustment).

______________________________________________________________ A6474X269 VSVI / 01 5.89

Replacement of wear parts _____________________________________ Crawler assembly The crawler assembly (Fig. 65) consists of a take-up assembly and drive assembly that transmits torque to the crawler track via a hydraulic drive motor coupled to the tram drive torque hub. As soon as any component of the drive assembly is worn or damaged, the component must be replaced.

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hydraulic drive motor

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tram drive torque hub

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cat pad assembly

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take-up roller assembly

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grease take-up assembly

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drive sprocket © Bucyrus America, Inc.

The crawler assembly consists of the following main components:

Fig. 65: Crawler assembly main components

Cat pad assembly

Recommended crawler chain separation point

Drive sprocket

Hydraulic motor (not shown)

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

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

____________________________________ Replacement of wear parts How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 66):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

© Bucyrus America, Inc.

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

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

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

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

______________________________________________________________ A6474X269 VSVI / 01 5.91

Replacement of wear parts _____________________________________ How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 66):  Remove old take-up assembly (see previous section, How to remove crawler take-up assembly).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Inspect all components for wear or damage prior to assembly.  Grease the take-up assembly thru the grease fitting located in the end of the roller pin. Ensure that there is a grease fitting in each end of the roller pin and that grease completely fills the bearing housing and appears between the roller wheels and the bearing housing.

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

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

© Bucyrus America, Inc.

 Clean all dirt and debris from inside crawler frame.

____________________________________ Replacement of wear parts Fig. 66: Crawler take-up removal and installation

Crawler take-up assembly

Tilt cylinder Tilt cylinder mounting bracket

© Bucyrus America, Inc.

Crawler frame

______________________________________________________________ A6474X269 VSVI / 01 5.93

Replacement of wear parts _____________________________________ How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 67):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

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

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

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

© Bucyrus America, Inc.

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

____________________________________ Replacement of wear parts How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 67):  Remove old crawler drive assembly (see previous section, How to remove crawler drive assembly).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Inspect all components for wear or damage prior to installation.  Place sprocket onto torque hub and secure with the twenty (20) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows:

© Bucyrus America, Inc.

■ ■ ■

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

 Apply Loctite 518 gasket eleiminator or equivalent to the adaptor plate. Be sure to apply the sealant completely around all bolt hoest to prevent leakage.   Place hydraulic motor gasket onto motor adapter plate.  Install adapter plate and gasket onto hydraulic motor and secure with the four (4) nuts and lock washers. Apply Loctite 242 (blue) to nuts.  Place adapter plate gasket onto torque hub.  Apply Loctite 518 gasket eleiminator or equivalent to the adaptor plate. Be sure to apply the sealant completely around all bolt hoest to prevent leakage.  Install motor and adapter plate assembly onto torque hub, being careful not to damage motor shaft or gasket. Secure with the (4) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows: ■ ■ ■

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

 If using a motor adaptor plate that does not have the keepers already installed, then weld four (4) keepers at each corner of the motor flanges to prevent motor movement  Clean all dirt and debris from mounting area of crawler frame.  Attach an appropriate lifting device to the torque hub and slide complete assembly into crawler frame.

______________________________________________________________ A6474X269 VSVI / 01 5.95

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

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

 Connect hydraulic hoses to drive motor.  Install and connect crawler and track pad assembly (see How to install the crawler track pad assembly in this chapter).  Install the removable side plate and secure with the six (6) bolts and lock washers. Torque incrementally as follows.

Step 1: 300 ft-lb Step 2: 600 ft-lb Step 3: 905 ft-lb

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

Fig. 67: Crawler drive disassembly and assembly

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

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

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

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

© Bucyrus America, Inc.

■ ■ ■

____________________________________ Replacement of wear parts Power unit The power unit (Fig. 68) 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

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pump coupling

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motor (200 hp)

© Bucyrus America, Inc.

■ reducer/motor coupling ■

reducer

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sprocket

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connecting tube

Fig. 68: Power unit main components Sprocket Reducer Coupling Motor (150 HP)

Connecting tube Coupling Hydrostatic pump Gear pump

Mounting base

______________________________________________________________ A6474X269 VSVI / 01 5.97

Replacement of wear parts _____________________________________ How to remove the power unit To remove the power unit as a complete assembly proceed as follows (Fig. 69):  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 and grease lines to the electric motor and gearbox.  Remove the nine (9) mounting base bolts.

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

To install the power unit as a complete assembly proceed as follows (Fig. 69):  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 nine (9) 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 all grease lines to the drive motor and gearbox.

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

© Bucyrus America, Inc.

 Separate and remove breaker drive chain.

____________________________________ Replacement of wear parts  Connect the drive chain. (See Breaker drive chain installation and adjustment in this chapter).  Apply an adequate amount of hydraulic oil on the drive chain, if necessary.  Check oil level in gearbox. Oil should be visible in the lower sight glass only.  Install breaker drive covers.

Fig. 69: Power unit removal and installation

© Bucyrus America, Inc.

Power unit

Mounting bolts

This bolt not used in this model only.

______________________________________________________________ A6474X269 VSVI / 01 5.99

Replacement of wear parts _____________________________________ How to disassemble the breaker power unit To disassemble the power unit proceed as follows (Fig. 71):  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.  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).

 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.  Separate 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. 64).

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.

_________________________________________________________________ 5.100 BUC – 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.

____________________________________ 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. 70).

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. 70: Taper lock removal and installation

Jack screw holes (2) for bushing removal

© Bucyrus America, Inc.

Bolt holes (3) for bushing installation

______________________________________________________________ A6474X269 VSVI / 01 5.101

Replacement of wear parts _____________________________________ How to assemble the power unit To assemble the power unit proceed as follows (Fig. 71):  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.

 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.  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.  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.

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

© Bucyrus America, Inc.

 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.

____________________________________ Replacement of wear parts  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.  Check gearbox oil level. Oil shoud be visible in the lower sight glass only.

© Bucyrus America, Inc.

CAUTION! Failure to fill the hydraulic motor thru the case drain port to prime the motor will result in catastrophic damage to the motor.

Fig. 71: Power unit disassembly and assembly

______________________________________________________________ A6474X269 VSVI / 01 5.103

Replacement of wear parts _____________________________________

© Bucyrus America, Inc.

Fig. 71: Power unit disassembly and assembly (continued)

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

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

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

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

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

____________________________________ 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. 72): 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 conveyor motor.

© Bucyrus America, Inc.

 Remove the top pin and cotter key from the torque arm and fold the torque arm connecting link back out of the way.  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.

______________________________________________________________ A6474X269 VSVI / 01 5.105

Replacement of wear parts _____________________________________ How to install the conveyor drive motor To install the conveyor drive motor proceed as follows (Fig. 72): 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.

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

CAUTION! Do not damage motor shaft seal during this step.

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 pin and cotter key.  Fill hydraulic motor thru case drain port to prime the motor.

CAUTION! Failure to fill the hydraulic motor thru the case drain port to prime the motor will result in catastrophic damage to the motor.  Connect all hydraulic hoses to the conveyor motor.  Purge hydraulic system of air.

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

© Bucyrus America, Inc.

Note index torque arm on motor so that when installed on machine the motor case drain is located between 10 o’clock and 2 o’clock.

____________________________________ Replacement of wear parts Fig. 72: 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)

© Bucyrus America, Inc.

Coupling

Mounting bolt (torque to 280 ft-lb)

Case drain will be located between 10 and 2 o’clock

Mounting bolts (torque to 400 ft-lb)

______________________________________________________________ A6474X269 VSVI / 01 5.107

Replacement of wear parts _____________________________________ Breaker assembly The breaker assembly (Fig. 73) 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.

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breaker shaft

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shear hub assembly

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bearing housing (2)

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bearing (2)

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bits (25)

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bearing retainer (2)

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underspeed sensor

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breaker side plate (2)

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retaining cap (2)

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dust cover

© Bucyrus America, Inc.

The breaker assembly consists of the following main components:

Fig. 73: Breaker assembly main components Underspeed sensor mount

Breaker side plate (2)

Bearing (2)

Bearing housing (2)

Breaker

Shear hub

Retainer cap (2)

Pick (25)

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

____________________________________ Replacement of wear parts How to remove the breaker assembly To remove the breaker assembly from the machine proceed as follows (Fig. 74):  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.  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.

© 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.  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. 74):  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.

______________________________________________________________ A6474X269 VSVI / 01 5.109

Replacement of wear parts _____________________________________

© Bucyrus America, Inc.

Fig. 74: Breaker assembly removal and installation

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4.

5.

breaker shaft assembly lock washer flat washer bolt nut

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

____________________________________ Replacement of wear parts How to disassemble the breaker assembly (drive side) To disassemble the breaker assembly (drive side) proceed as follows (Fig. 75): IMPORTANT! Use tool P/N 356549 to disassemble breaker shaft assembly.  Remove the breaker assembly from the machine (see How to remove the breaker assembly in this chapter).  Remove the three (3) bolts and lockwashers (items 24 and 25) from shaft and remove end cap (item 23).  Remove the shear hub assembly (item 21) from shaft.  Remove the side plate (item 13).

© Bucyrus America, Inc.

 Remove the eight (8) bolts and lockwashers (items 18 and 20) from seal housing (item 14).  Remove seal housing (item 14), seal (item 15), retaining ring (item 16) and o-ring (item 11) as an assembly from shaft.  Remove o-ring (item 11) from seal housing (item 14).  Remove retaining ring (item 16) and seal (item 15) from seal housing (item 14).  Remove sealing ring (item 7) from shaft.  Remove eight (8) bolts and lockwashers (items 9 and 10) from bearing retainer ring (item 4).  Remove bearing housing (item 8).  Remove bearing (item 6) from shaft.  Remove bearing retainer ring (item 4) from shaft.  Remove o-ring (item 5) from bearing retainer ring (item 4).  Remove seal half (item 3) from bearing backing ring (item 2).  Remove bearing backing ring(item 2) and seal half (item 3) from shaft.  Remove remaining seal half (item 3) and bearing backing ring (item 2).  Visually inspect all components for wear or damage and replace as necessary.

______________________________________________________________ A6474X269 VSVI / 01 5.111

Replacement of wear parts _____________________________________ How to disassemble the breaker assembly (underspeed sensor side) To disassemble the breaker assembly (underspeed sensor side) proceed as follows (Fig. 75): IMPORTANT! Use tool P/N 356549 to disassemble breaker shaft assembly.  Remove the breaker assembly from the machine (see How to remove the breaker assembly in this chapter).  Remove the eight (8) bolts and lockwashers (items 18 and 19) from underspeed sensor mount (item 17) and remove underspeed sensor and mount.  Remove the three (3) bolts and lockwashers (items 24 and 25) from shaft and remove end cap (item 22).

 Remove the eight (8) bolts and lockwashers (items 18 and 20) from seal housing (item 14).  Remove seal housing (item 14), seal (item 15), retaining ring (item 16) and o-ring (item 11) as an assembly from shaft.  Remove o-ring (item 11) from seal housing (item 14).  Remove retaining ring (item 16) and seal (item 15) from seal housing (item 14).  Remove sealing ring (item 7) from shaft.  Remove eight (8) bolts and lockwashers (items 9 and 10) from bearing retainer ring (item 4).  Remove bearing housing (item 8).  Remove bearing (item 6) from shaft.  Remove bearing retainer ring (item 4) from shaft.  Remove o-ring (item 5) from bearing retainer ring (item 4).  Remove seal half (item 3) from bearing backing ring (item 2).  Remove bearing backing ring(item 2) and seal half (item 3) from shaft.  Remove remaining seal half (item 3) and bearing backing ring (item 2).  Visually inspect all components for wear or damage and replace as necessary.

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

© Bucyrus America, Inc.

 Remove the side plate (item 13).

____________________________________ Replacement of wear parts How to assemble the breaker assembly (drive side) To assemble the breaker assembly proceed as follows (Fig. 75):  Thoroughly clean all components with a dry, lint free cloth prior to assembly.

IMPORTANT! Clean metal faces of the metal seal rings with a lint free cloth and apply a light coat of 30W oil to the metal faces only. Do not get grease or oil on the rubber rings or the seal bores in which the rubber rings seat.

Use degreaser to ensure that the seal bores are completely free of grease and oil before installing seal.

IMPORTANT! Install items 2, 6, and 7 with installation tool P/N 323334. Apply 60 tons (10,000 psi) of force to seat bearing. Do not apply heat to bearing.

© Bucyrus America, Inc.

 Apply Loctite gasket eleminator 518 to the 1 1/2” radius of the shaft before installing bearing backing ring (item 2).  Install seal half (item 3) into bearing backing ring (item 2) and carefully install both onto shaft.  Install seal half (item 3) into bearing retaining ring (item 4) and carefully install both onto shaft.  Install o-ring (item 5) onto bearing retaining ring (item 4). Apply a light coat of grease to aid installation.  Install bearing (item 6) and sealing ring (item 7) onto shaft.  Carefully seat installed items with installation tool P/N 323334.

Apply 60 tons (10,000 psi) of force. Do not heat bearing to install.  Apply a light coat of grease to bearing housing (item 8) slide over bearing (item 6).  Install three (3) 1/4” pipe plugs (item 12) flush with bearing housing face(item 8).  Secure bearing retainer ring (item 4) to bearing housing (item 8) with eight (8) bolts (item 10) and lockwashers (item 9). Torque bolts to 140 ft-lb.  Install side plate (item 13) onto bearing housing (item 8).  Install two (2) 3/4” pipe plugs (item 28) into outside of bearing housing (item 8).  Install seal (item 15) into seal housing (item 14). Use tool P/N 333685 to aid in installation.

______________________________________________________________ A6474X269 VSVI / 01 5.113

Replacement of wear parts _____________________________________  Install retaining ring (item 16) into seal housing (item 14).  Install o-ring (item 11) into seal housing (item 14). Apply a light coat of grease to aid installation.  Carefully install assembled items 11, 14, 15, and 16 onto shaft and secure with eight bolts (item 20) and lockwashers (item 18).

Torque bolts to 115 ft-lb.

IMPORTANT! Do not fold lip of seal (item 15) under during installation over sealing ring (item 7).

IMPORTANT! Apply never seize to breaker shaft splines before installing shear hub sprocket.  Install shear hub sprocket (item 21) onto breaker shaft.

© Bucyrus America, Inc.

 Install retainer cap (item 23) onto breaker shaft and secure with three bolts (item 25) and lockwashers (item 24). Torque bolts to 400 ft-lb and install retaining wire (item 26).

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

____________________________________ Replacement of wear parts How to assemble the breaker assembly (underspeed sensor side) To assemble the breaker assembly proceed as follows (Fig. 75):  Thoroughly clean all components with dry and lint free cloth prior to assembly.

IMPORTANT! Clean metal faces of the metal seal rings with a lint free cloth and apply a light coat of 30W oil to the metal faces only. Do not get grease or oil on the rubber rings or the seal bores in which the rubber rings seat.

Use degreaser to ensure that the seal bores are completely free of grease and oil before installing seal.

IMPORTANT! Install items 2, 6 and 7 with installation tool P/N 323334. Apply 60 tons (10,000 psi) of force to seat bearing. Do not apply heat to bearing.

© Bucyrus America, Inc.

 Apply Loctite gasket eleminator 518 to the 1 1/2” radius of the shaft before installing bearing backing ring (item 2).  Install seal half (item 3) into bearing backing ring (item 2) and carefully install both onto shaft.  Install seal half (item 3) into bearing retaining ring (item 4) and carefully install both onto shaft.  Install o-ring (item 5) onto bearing retaining ring (item 4). Apply a light coat of grease to aid installation.  Install bearing (item 6) and sealing ring (item 7) onto shaft.  Carefully seat installed items with installation tool P/N 323334.

Apply 60 tons (10,000 psi) of force. Do not heat bearing to install.  Apply a light coat of grease to bearing housing (item 8) slide over bearing (item 6).  Install three (3) 1/4” pipe plugs (item 12) flush with bearing housing face(item 8).  Secure bearing retainer ring (item 4) to bearing housing (item 8) with eight (8) bolts (item 10) and lockwashers (item 9). Torque bolts to 140 ft-lb.  Install side plate (item 13) onto bearing housing (item 8).  Install two (2) #12 pipe plugs (item 28) into outside of bearing housing (item 8).  Install seal (item 15) into seal housing (item 14). Use tool P/N 333685 to aid in installation.

______________________________________________________________ A6474X269 VSVI / 01 5.115

Replacement of wear parts _____________________________________  Install retaining ring (item 16) into seal housing (item 14).  Install o-ring (item 11) into seal housing (item 14). Apply a light coat of grease to aid installation.  Carefully install assembled items 11, 14, 15, and 16 onto shaft and secure with eight bolts (item 20) and lockwashers (item 18).

Torque bolts to 115 ft-lb.

IMPORTANT! Do not fold lip of seal (item 15) under during installation over sealing ring (item 7).

IMPORTANT! Apply never seize to breaker shaft splines before installing shear hub sprocket.

 Install underspeed sensor and mount (item 17) onto breaker shaft and secure with eight bolts (item 19) and lockwashers (item 18).

Torque bolts to 115 ft-lb.

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

© Bucyrus America, Inc.

 Install end cap (item 22) onto breaker shaft and secure with three bolts (item 25) and lockwashers (item 24). Torque bolts to 400 ft-lb and install retaining wire (item 26).

____________________________________ Replacement of wear parts

© Bucyrus America, Inc.

Fig. 75: Breaker shaft assembly and disassembly

1. breaker shaft 2. bearing backing ring 3. seal 4. bearing retainer ring 5. o-ring 6. bearing 7. sealing ring 8. bearing housing 9. lock washer 10. bolt 11. o-ring

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

pipe plug 1/4” side plate seal housing seal retainer ring underspeed sensor mount lock washer bolt bolt shear hub sprocket end cap

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

retainer cap lock washer bolt wire breaker bit pipe plug #12 u-bolt flat washer lock washer locknut

______________________________________________________________ A6474X269 VSVI / 01 5.117

Replacement of wear parts _____________________________________

© Bucyrus America, Inc.

Fig. 75: Breaker shaft assembly and disassembly (continued)

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

____________________________________ 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. 76):  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. 76):  Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.

© Bucyrus America, Inc.

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

Fig. 76: Breaker bit removal and installation

Retaining rings Bit holder

Breaker bit

______________________________________________________________ A6474X269 VSVI / 01 5.119

© Bucyrus America, Inc.

Replacement of wear parts _____________________________________

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

_______________________________________________________________

6

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

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

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

Customer specials may not be listed.

Components of the feeder breaker Technical data sheet general

Overall length (w/out tailpiece): Overall length (with tailpiece):

© Bucyrus America, Inc.

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

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

approx. 34’ 61/2” 10,528 mm approx. 38’ 2 5/8” 11,649 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. 79 1/2” 2,021 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: 80,000 lbs 36,288 kg 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

______________________________________________________________ A6474X269 VSVI / 01 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: Chain engagement:

conveyor drive

Drive motor: Mounting: Overload protection:

crawlers

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

approx. 48” 1,219 mm 2 @ 200,000 lb/strand ultimate (889,644 N) approx. 3 1/2” 88.9 mm approx. 15/16” 23.81 mm 2 1/2” X 5 1/2” (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 Sprocket 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 BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

conveyor chain

_______________________________________________ Technical data breaker

Shaft diameter: Bearing bore:: Pick circle diameter: Running pick force: Pick force maximum:: Overload protection: Under speed protection: Breaker speed: Height setting: Breaker bits and holders:

© Bucyrus America, Inc.

Breaker drive chain: hydraulic

Conveyor/tram pump: Tram motors: Lift cylinders: Tilt cylinders: Filters: Reservoir: Hydraulic fluid Heat exchanger: Hydraulic fittings:

electrical

Conveyor motor:

Starter:

Enclosure: Contactor: Circuit overload protection:

approx. 8” (203 mm) approx. 6 3/16” (157 mm) approx. 25” (635 mm) approx. 9,400 lbs (41,813 N) approx. 80,000 lbs (355,857 N) Shear pin Magnetic sensor 67 rpm Manually adjustable 2” (50.8mm) increments Heavy duty, rock type bits with carbide insert with hard surface weld.

Holder is improved design alloy steel with hard surface weld ASA-180-2 Axial piston variable displacement Char Lynn 4000 series 19in³/rev (311 cc) Double acting 17” stroke (432 mm) Double acting 17” stroke (432 mm) (6) 12 micron pressure line 175 gal (662 l) capacity w/oil level switch ISO 68 Mineral Oil Oil to air type JIC (standard) Reliance internal cooled 200 hp (150 kW)/ 1140v/AC/3ph/50Hz/ 1500rpm/TEFC Rated current: 56.59 amps Protection grade: IP54 Insulation class: F 200 hp/75 hp (150kW)/ single/1140v/AC 3ph/50Hz MSHA XP rated vacuum type Circuit breakers

______________________________________________________________ A6474X269 VSVI / 01 6.5

features

■

Head shaft is removable horizontally as a unit.

■

Tailshaft is removable vertically as a unit.

■

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 unit.

■

Extra heavy duty chain hold-downs at breaker transition.

■

Manual centralized lubrication system.

■

12” (304.8) high hinged sideboards (optional).

■

8 point Ansul dry chemical fire suppression system.

■

Shovel nose receiving.

■

Tailpiece swivels 5 degrees left to right and tilts from horizontal downward 15 degrees.

■

Roof anchor cylinders min 2.6 m (102 3/8”) to max 3.8 m (149 5/8”).

■

Mechanically activated dust sprays at the breakershaft.

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

© Bucyrus America, Inc.

Technical data ________________________________________________

___________________________________________ 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 3: 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 4: 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

______________________________________________________________ A6474X269 VSVI / 01 6.7

Tightening torques ____________________________________________ Table 5: 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 6: 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 BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

Nominal diameter

___________________________________________ Tightening torques Table 7: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Table 8: Untreated screw, black finish (Coarse thread, continued)

© Bucyrus America, Inc.

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 9: 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

______________________________________________________________ A6474X269 VSVI / 01 6.9

Tightening torques ____________________________________________ Table 10: 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

Table 11: Untreated screw, black finish (Fine thread, continued) 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 12: 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 BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

Property class

___________________________________________ Tightening torques Table 13: 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 14: 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 15: 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

______________________________________________________________ A6474X269 VSVI / 01 6.11

Tightening torques ____________________________________________ Table 16: 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 17: 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 18: 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 BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

Property class

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

© Bucyrus America, Inc.

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

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

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

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

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

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

______________________________________________________________ A6474X269 VSVI / 01 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.

Hydraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

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

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

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

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

© Bucyrus America, Inc.

Table 19: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© Bucyrus America, Inc.

Table 20: 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

______________________________________________________________ A6474X269 VSVI / 01 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 22: 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 BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

Table 21: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ Permissible media Table 23: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

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

5 6

Cincinnati – Vulcon Company Cities Service Oil company

7 8

10 11

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

12 13 14 15 16 17

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

18

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

© Bucyrus America, Inc.

9

19 20 21

22 23

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

24 25

Wynn Oil company Lubrication Engineers

26

Hydrotex

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

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

______________________________________________________________ A6474X269 VSVI / 01 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 BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

Table 24: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media

© Bucyrus America, Inc.

Table 25: 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

______________________________________________________________ A6474X269 VSVI / 01 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 27: 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 BUC – Model 7MFBH-48A Feeder Breaker

© Bucyrus America, Inc.

Table 26: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

___________________________________________ Permissible media

© Bucyrus America, Inc.

Table 28: 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 29: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 30: Multi-purpose tractor hydraulic fluid (Spec. 100-12)

1 2 3 4

Supplier Exxon / Mobil Century / Fuchs Shell Chevron

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid

5 6 7

BP Lubricants Quaker State Conoco

Tractran UTH Quaker State FCI HD Powertran Fluid

______________________________________________________________ A6474X269 VSVI / 01 6.21

© Bucyrus America, Inc.

Permissible media ____________________________________________

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

_______________________________________________________________

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

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

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

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

______________________________________________________________ A6474X269 VSVI / 01 7.3

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

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

© 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 BUC – Model 7MFBH-48A Feeder Breaker