Cat BUCYRUS FB110 Feeder Breaker Operation and Maintenance Manual BI016382 (1) by www.heydownloads.com

Technical Manual

BI016382

BUCYRUS

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Operationand Maintenance Manual

SerialNumber54-2185

FB110FeederBreaker SAFETY.CAT.COM

BI016382 A6474X338 December2012

54-2193 BI016382

ThismanualisintendedtoprovideGENERALproductinformation.The illustrations,descriptions,andprocedurescontainedinthispublication applyonlytoTHISmachine.Caterpillarreservestherighttorevise modelsanddesignswithoutpriornotice.

Thismachinewasmanufacturedundertheguidelines,procedures,and requirementsoftheappropriategovernmentregulatoryagencies.

Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofCaterpillarand theseregulatoryagencies,oranyrepairorreplacementofpartscontrarytoCaterpillar’sinstructions,mayinvalidatetheseapprovalsand renderthisunitunsafetooperate.

StrictcompliancewithallFederalandStateMininglaws,regulations, andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.

Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourServiceRepresentative immediately

Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distribution,orunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.

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© Caterpillar2012 ALLRIGHTSRESERVED

_________________________________________________ Tableofcontents A6474X338 REV3 BI016382 Tableofcontents

Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual?....................1.4 Charactersandsymbols 1.5

Yoursafety Yoursafety 2.3 Personnel 2.4 Operation 2.4 Installationandrepair......................................................2.4 Operatingconditions 2.5 Intendeduse 2.5 Unauthorizeduse 2.5 Safetyinstructions 2.7 Generalrules: 2.7 Storageandtransport 2.9 Installationandstart-up 2.9 Operation 2.10 Maintenanceandrepair 2.10

Storageandtransport Storageandtransport 3.3 Storage 3.3 Storageofthemachineandspareparts 3.3 Transport 3.4 Beforetransport 3.6

Installation Installation 4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation? 4.3 Whichtoolsarerequiredforinstallation? 4.3 Notesoninstallation 4.4 Pre-installationchecklist 4.5 Safetyfeatures 4.6 Towingthefeederbreaker 4.10 BI016382

5. Operation

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Operation..................................................................................5.3 Howtooperatethefeederbreaker 5.3 Whoisallowedtooperatethefeederbreaker ................5.3 Whencanconveyingbestarted? 5.3 Controlsandindicators 5.4 Operatingprocedures 5.19 “AUTO”startingprocedure............................................5.19 “MANUAL”startingprocedure 5.20 Shutdownprocedure 5.21 Tramming 5.22 Conveyor 5.23 Electricalsystem 5.27 Hydraulicsystem 5.39 Mechanicalassemblies 5.45 Crawlerassembly(s) 5.45 Conveyorchain .............................................................5.46 Headshaft 5.47 Conveyorpowerunit 5.48 Tailshaft 5.48 Breakerandbreakerpowerunitassembly....................5.49 Tailpieceassembly 5.52 Instructionsonthemaintenanceofthefeeder ..................5.53 Importantnotes 5.53 Beforemaintenance .....................................................5.53 Lubricationandinspection 5.55 Specificlubricationandmaintenanceprocedures .............5.59 Every8hoursofoperation 5.59 Weekly ..........................................................................5.67 Monthly 5.71 Every1000hours ..........................................................5.74 Every6months 5.77 Inspection 5.79 Inspectionofwearparts 5.80 Inspectionofthefiresuppressionsystem 5.81 Rechargeofthefiresuppressionsystem 5.83 Instructionsontheadjustmentprocedures 5.85 Conveyorchainadjustment 5.85 Crawlertrackadjustment 5.87 Underspeedsensorcalibration 5.89 Mainpump 5.91 Marginpressure 5.91 Pressurecompensator 5.91 Mainrelief 5.93 Pressurelimiter 5.94 BI016382

_________________________________________________ Tableofcontents A6474X338 REV3 BI016382 Instructionsonthereplacementofwearparts 5.95 Headshaft 5.95 Headshaftsprockets 5.99 Tailshaft 5.102 Conveyorchain 5.108 Crawlertrack ............................................................... 5.111 Crawlerassembly 5.114 Breakershaftandbreakerpowerunit 5.123 Conveyorpowerunit 5.148 Breakerbitremoval...................................................... 5.156 Tailpieceinstallation 5.157 Roofcylinder................................................................ 5.161 Footcylinder 5.163 Tiltcylinder................................................................... 5.165 Liftcylinder 5.167 Tailpiecetiltcylinder..................................................... 5.169 Tailpiecesteeringcylinder 5.171 Troubleshooting................................................................ 5.173 6. Technicaldata Technicaldata..........................................................................6.3 Componentsofthefeederbreaker 6.3 Tighteningtorques................................................................6.7 Permissibledata 6.9 Lubricationfluidsandgreases.........................................6.9 7. Foryourinformation Foryourinformation ...............................................................7.3 Ourservice 7.3 Serviceaddress ...............................................................7.3 Rebuildfacilityaddress 7.4 BI016382

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_______________________________________________________________ 1 Aboutthismanual BI016382 BI016382

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applicableoperatingmanual machinetype

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.

Beforestartingtowork

Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.

Thisoperatingmanualisintendedfor:

ModelFB110FeederBreaker

SerialNo.54-2185,54-2193

andisonlypermittedtobeusedforequipmentofthistype.

newoperationmanual

Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.

Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.

Whoisthisoperatingmanualintendedfor?

Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.

Thisincludespersonswho:

■ areinchargeoftransport

■ performassembly/disassemblywork

■ operatethemachine

■ eliminatefaults

■ performdailyroutineworkonthefaceorintheentry

■ performmaintenancework

■ performrepairwork

andsupervisorypersonnelwho:

■ initiateand/or

■ supervisetheactivitiesjustindicated.

__________________________________________ Beforestartingtowork A6474X338 REV3 1.3 BI016382

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cost-effectiveness service safety

Whatisthepurposeofthisoperatingmanual?

Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.

Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.

Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.

Readthechapter“Yoursafety”withspecialattention.Thechaptercontainsimportantinformationindicatingpossiblehazards.Observethe informationgivenandfollowtheproceduralinstructions.

Beforestartingtowork____________________________________________ 1.4 FB110FeederBreaker BI016382

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Charactersandsymbolsused

Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.

Trytomemorizethesymbolsandtheirmeanings.

DANGER!

Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.

WARNING!

Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.

CAUTION!

Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.

NOTICE!

Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.

IMPORTANT!

Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.

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Beforestartingtowork____________________________________________ 1.6 FB110FeederBreaker BI016382 BI016382

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2 Yoursafety

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stateoftheart

Yoursafety

Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.

Themachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. Youandotherscanneverthelessbeexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.

Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.AllmodificationsandchangesmustbeapprovedbytheOEM.

Useonlyoriginalspareparts.Notethattheuseofpartsfromother manufacturerswillvoidtheguarantee.

Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.

Observethesafetyandaccidentpreventionregulationsof

■ themine,

■ themineinspector,and

■ theminingsupervisoryauthorities.

furtheroperatingmanuals

Pleasereadalsotheoperatingmanualsofthecomponentsrequiredfor operation,e.g.ofgearboxes,electricmotors,etc.,carefullyandthoroughly.Clarifyanyquestions before startingwork.

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Personnel

Operation

Themachinemayonlybeoperatedbyqualified,trainedpersonnel.

Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit.Readingofthe operationmanual,especiallythechapteronsafety,shallconstitutea partofthistraining.

Youmusthaveadequateknowledgeofthe

■ mechanics,

■ hydraulics,and

■ controlengineering andmustbeabletoprovethisknowledge.

Installationandrepair

Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.

Installationandrepairworkon:

■ safetycomponents(pressurereliefvalves,extinguishers,etc.)

■ theelectrics(motors,controllers,etc.)

■ thehydraulics(controls,cylinders,etc.)

mayonlybecarriedoutbyserviceengineersorbyspeciallyqualified personnelofthemine.

Personnel _______________________________________________________ 2.4 FB110FeederBreaker BI016382

training BI016382

Operatingconditions

Intendeduse

Thefeederbreakerhasbeendesignedandmanufacturedpurelyfor transportingminedandcrushedmaterialfromacontinuousminerto themainconveyingsystemfortransportingoutside.

Intendedusesinclude:

■ Thetransportofminedandcrushedmaterialbetweencontinuous minerandmainconveyingsystem.

Unauthorizeduse

Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.

Unauthorizedusesinclude:

■ thetransportofpersons

■ thetransportofobjectsofanykindsuchassingleprops,boards, spareparts,etc.

TheOEMacceptsnoliabilityforanydamageresultingfromanysuch unauthorizeduse.

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A6474X338 REV3 2.5 BI016382

Safetyinstructions

BI016382

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL