PDF Operation Manual CAT Bucyrus 7MFBH-48A Feeder Breaker - 1 MB
This operation manual is the essential guide for the CAT Bucyrus 7MFBH-48A Feeder Breaker.
It provides critical information on safety procedures, machine controls, and daily operational checks.
Proper understanding and application of the contents are vital for maximizing productivity and ensuring the safety of personnel in a mining environment.
This document should be readily available to all operators and maintenance staff.
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BI000863
Operation Manual
BUCYRUS - Feeder Breaker
Model - 7MFBH-48A
Doc. No.: A6474X248
Bucyrus America, Inc. ________________________________________
4041 Wurno Road Telephone: 540-980-4530
Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.bucyrus.com
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BI000863
_______________________________________ 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. Possi-
ble consequences are: very serious injury or even death.
CAUTION!
This symbol draws attention to dangerous situations. Possible
consequences are: light to moderately serious injuries and ma-
chine damage.
© BUCYRUS AMERICA, INC.
NOTICE!
Points in the text marked with this symbol draw attention to harm-
ful situations. Possible consequences are: damage to the ma-
chine or damage in the immediate vicinity.
IMPORTANT!
Points in the text marked with this symbol contain useful tips and
information intended to facilitate work for you. They do not warn
about harmful or dangerous situations.
■ Items in lists are marked with bullets.
– Points in sub-lists are marked with a long dash at the start of
the line.
Points in text marked in this way describe individual operations.
Follow these instructions step by step. They will help you carry out
your work faster and more importantly, safer.
______________________________________________________________
A6474X248 SSVI/03 1.5
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BI000863
___________________________________________ 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 sur-
faces, 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 On inclined faces secure all component parts by chains, e.g. to the
support.
environmental acceptability When working with oils, greases and other chemical substances, ob-
serve 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 Inspect the machine and have any malfunctioning, broken or missing
parts corrected or replaced before use.
maintenance Verify that all maintenance has been performed.
instruction and safety tags Verify that all instruction and safety tags are in place and readable.
These are as important as any other equipment on the machine.
operator’s area Clean any foreign material from the operator’s area.
______________________________________________________________
A6474X248 SSVI/03 2.9
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BI000863
________________________________ Overview of safety instructions
Chapter 6: Technical data
IMPORTANT!
Due to the application of fasteners being subject to great stresses
and heavy or extreme vibration, it is imperative that all bolts be
applied with an adequate amount of torque. For this reason this
list of recommended torque settings for different types and sizes
of fasteners used has been compiled.
The tightening torques stated in the spare parts lists have to be
observed, as well, for installation and maintenance.
NOTICE!
Use only lubrication fluids and greases approved by Bucyrus
America, Inc. These fluids and greases have been tested at Bu-
cyrus America, Inc. and guarantee reliable operation of the me-
chanical 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 guar-
antee that they are equivalent.
© BUCYRUS AMERICA, INC.
Differently composed fluids and greases must not be mixed as
this may change the consistency, i.e. the mixture can become thin-
ner 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 me-
chanical and hydraulic systems. The responsibility for the con-
stituents used in the hydraulic concentrates lies solely with the
respective manufacturer.
NOTICE!
When performing maintenance on the machine, all used oil and
lubricants should be disposed of per your local EPA standards.
______________________________________________________________
A6474X248 SSVI/03 2.19
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BI000863
__________________________________________________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 re-
ceived adequate training to perform this task.
Work on:
the safety components (pressure relief valves, fire extinguishing equip-
ment etc.)
the electrical equipment (control units, signaling devices, etc.)
and
the hydraulic equipment (cylinders, directional control valves, hoses
© BUCYRUS AMERICA, INC.
etc.)
should only be carried out by Bucyrus America, Inc. service engineers
or by specially trained personnel.
Which tools are required for installation?
tool box No special tools are required to put the feeder breaker into service.
In addition, various items of auxiliary equipment and machines may be
required at the point of installation.
These include i.e.:
■ hoists with adequate lifting capacity
■ means of attachment with adequate lifting capacity
■ unloading dock
■ jacks with adequate lifting capacity
■ impact wrenches, including accessories
______________________________________________________________
A6474X248 SSVI/03 4.3
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BI000863
___________________________________________________Operation
Operation
This chapter contains important information on the operation and main-
tenance of the machine. It also includes instructions on the replace-
ment 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 seri-
ous 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 super-
visor.
© BUCYRUS AMERICA, INC.
Who is allowed to operate the feeder breaker?
The feeder breaker is only allowed to be operated by persons with ade-
quate knowledge of the complete machine.
This also includes:
■ what safety devices are installed on the machine.
■ where these safety devices are located.
■ how these safety devices are to be operated.
When can conveying be started?
Operation must not be started until the safe condition and proper func-
tion of the complete machine has been checked and the daily mainte-
nance operations have been carried out.
______________________________________________________________
A6474X248 SSVI/03 5.3
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BI000863
___________________________________________________Operation
Shutdown procedure
(Reference Fig. 16)
Allow the machine to run until the hopper is empty. Continue to run
the machine until all material that has been carried back into the
return line has been cleaned out.
IMPORTANT!
If material is very wet or sticky, it is recommended that the return
line be flushed with water and the conveyor be allowed to run and
clean out the return line before shutting the machine down.
Stop the machine by depressing the “STOP” push-button located
on the starter enclosure or either of the two remote pushbuttons.
Turn the “MAN / OFF / AUTO” switch to the “OFF” position.
Move the conveyor directional control handle to the centered
“NEUTRAL” position.
© BUCYRUS AMERICA, INC.
Turn the conveyor speed control knob counter clockwise (CCW) to
the lowest speed.
Fig. 16: Shutdown control (s) locator
“STOP”
conveyor
“START”
conveyor
“OFF”
Starter enclosure cover
Conveyor speed Conveyor speed
pressure gauge and direction
control valves
“STOP”
Remote pushbutton
______________________________________________________________
A6474X248 SSVI/03 5.13
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BI000863
_______________________________________ 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)
The feeder breaker is trammed by two (2) hydraulically driven crawlers
(Fig. 22); one is located on each side of the machine. The complete
drive assemblies are housed in crawler frames which enclose, guide
and support the tram components. Each tram drive is independently
controlled by the operator for moving the machine forward, backward
and for making turns.
© BUCYRUS AMERICA, INC.
The crawlers on the machine are hydraulic driven through torque hub
gear reducers. Attached to the torque hub is a single sprocket that en-
gages the crawler tracks directly. The crawler track loops around the
take-up roller assembly located on the opposite end of the crawler as-
sembly. The idler assembly, along with a grease take-up is used to
adjust the tension on the crawler tracks. (See Maintenance section in
this chapter for Crawler track adjustment procedure)
Fig. 22: Crawler assembly main components
Sprocket
Hydraulic motor
(not shown)
Cat pad assembly
Torque hub
Take-up cylinder
& shims
Take-up roller
assembly
_____________________________________________________________
A6474X248 SSVI/03 5.23
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BI000863
________________________________________________ Maintenance
Fig. 31: Lubrication chart
8, 22
7, 22
15
5, 20
26
18, 27, 28 23
17
4, 29 24
25
16, 30
© BUCYRUS AMERICA, INC.
15
9
6, 20
15 10
6, 20
1, 2, 3
24 11
______________________________________________________________
A6474X248 SSVI/03 5.33
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BI000863
________________________________________________ Maintenance
Every 6 months
hydraulic oil tank Change the hydraulic fluid in the oil tank (Fig. 44).
Clean all dirt and debris from and around the fill cap and drain plug.
Remove the drain plug and allow the oil tank to completely drain.
Clean and reinstall drain plug.
Add oil Spec 100-1 as required via the power fill system until fluid is
visible in sight glass.
Install fill cap.
Start the machine and allow the hydraulic pump to run in order to
purge air from the system.
Shut down the machine and recheck the oil level. Add oil if
necessary.
© BUCYRUS AMERICA, INC.
Fig. 44: Hydraulic oil tank
Sight glass
Drain plug
(located under bottom)
______________________________________________________________
A6474X248 SSVI/03 5.43
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BI000863
____________________________________ Replacement of wear parts
Instructions on the replacement of wear parts on the
feeder breaker
It is essential that wear parts are replaced before they reach the lowest
wear limit, as otherwise damage can be caused to other parts of the
machine. Inspect the wear parts at regular intervals.
Head shaft
The head shaft (Fig. 49) transmits the torque of the hydraulic motor to
the conveyor chain assembly. It is part of a complete assembly. As
soon as any component is worn, the component or complete head
shaft must be replaced. Due to the high abrasion forces the chain
sprockets are subject to a very high level of wear.
The head shaft assembly consists of the following main components:
■ drive shaft
■ sprockets
© BUCYRUS AMERICA, INC.
■ bearings
■ hydraulic motor
Fig. 49: Head shaft main components
Sprocket (2)
Head shaft
Key (2)
Bearing (2)
______________________________________________________________
A6474X248 SSVI/03 5.53
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BI000863
____________________________________ Replacement of wear parts
Fig. 54: Tail shaft disassembly and assembly
Tail shaft
Roller (2) Grease
fitting (2)
Key (2) Roller bearing (2)
Set screw (2) Slide plate Piston rod adapter (2)
© BUCYRUS AMERICA, INC.
______________________________________________________________
A6474X248 SSVI/03 5.63
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BI000863
____________________________________ Replacement of wear parts
How to install the crawler take-up assembly
To install the crawler take-up assembly proceed as follows (Fig. 59):
Remove old take-up assembly (see previous section, How to
remove crawler take-up assembly).
WARNING!
You could be seriously injured or even killed by falling loads. Ob-
serve the safe working load of the lifting devices and keep a safe
distance away from suspended loads.
Inspect all components for wear or damage prior to assembly.
Clean all dirt and debris from inside crawler frame.
Attach appropriate lifting device to take-up assembly and slide
assembly completely into the end of crawler frame.
Install and connect crawler and track pad assembly, see How to
install the crawler track pad assembly in this chapter.
© BUCYRUS AMERICA, INC.
Swing the tilt cylinder and mounting bracket into crawler frame and
secure with the eight (8) bolts, washers and nuts.
Connect hydraulic hoses to tilt cylinder.
Purge hydraulic system of air.
Adjust crawler track pad tension, see How to adjust crawler track
pad tension in this chapter.
______________________________________________________________
A6474X248 SSVI/03 5.73
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BI000863
____________________________________ Replacement of wear parts
Install end cap (item 21) onto motor shaft and secure with bolt and
lockwasher. Torque bolt to 80 ft-lb.
With the aid of a lifting device, slowly lift motor onto mounting base
(item 1) and align mounting holes and coupling halfs. Secure
reducer with the eight (8) bolts, lockwashers and nuts to mounting
base. Torque bolts to 280 ft-lb.
Connect coupling (item 3) with the twelve (12) bolts supplied with
coupling.
Insert key into slot of motor shaft and slide motor coupling half
(item 7) onto motor shaft until shaft and coupling face are flush.
Tighten set screw in motor half of coupling.
Insert coupling element into motor half of coupling.
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