ContinuousHaulageSystem SAFETY.CAT.COM BI016242
Operationand Maintenance Manual
A6474X251 April2012
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ThismanualisintendedtoprovideGENERALproductinformation.The illustrations,descriptionsandprocedurescontainedinthispublication applyonlytoTHISmachine.Caterpillarreservestherighttorevise modelsanddesignswithoutpriornotice.
Thismachinewasmanufacturedundertheguidelines,proceduresand requirementsoftheappropriategovernmentregulatoryagencies.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofCaterpillarand theseregulatoryagencies,oranyrepairorreplacementofpartscontrarytotheinstructions,mayinvalidatetheseapprovalsandrenderthis unitunsafetooperate.
Strictcompliancewithalllaws,regulationsandpracticesregardingthe safeoperationandmaintenanceofundergroundminingequipmentand strictadherencetotheinstructionsinthismanualisnecessaryforthe personalsafetyofthoseworkingonoraroundthisunit.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourservicerepresentative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
© CATERPILLAR2012 ALLRIGHTSRESERVED
__________________________________________________________ BI016242
_________________________________________________ Tableofcontents A6474X251 REV07 BI016242 Tableofcontents
Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual?....................1.4 Charactersandsymbols 1.5
1.
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 2.8 Pre-startinspection 2.9 Installationandstart-up 2.9 Operation 2.9 Maintenanceandrepair 2.10 Overviewofthesafetyinstructions 2.15 Chapter3:Storageandtransport 2.15 Chapter4:Installation ................................................... 2.15 Chapter5:Operation 2.16 Chapter6:Technicaldata............................................. 2.23
Storageandtransport Storageandtransport 3.3 Storage 3.3 Storageoftheequipment 3.3 Transport 3.4 Dimensionsandweights .................................................3.4 Beforetransport 3.5
2.
3.
Installation Installation ...............................................................................4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation 4.3 Whichtoolsarerequiredforinstallation..........................4.3 Notesoninstallation 4.4 Pre-installationchecklist 4.5 Safetyfeatures 4.6 Overviewofthecontinuoushaulagesystem .......................4.8
4.
5. Operation
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Operation .................................................................................5.3 Howtooperatethecontinuoushaulagesystem 5.3 Controlsandindicators.........................................................5.4 CSTandradioremote 5.4 IRremote 5.9 Displays 5.11 Operatingprocedure .......................................................... 5.20 Checklist 5.20 Operatingprocedures 5.22 DesignatingMBCidentifications 5.22 Radioremoteuniqueidentification 5.23 Startingthepumpmotor 5.24 Startingtheconveyors(automaticmode) 5.25 Startingtheconveyors(individualmode) 5.26 Joggingtheconveyors 5.27 Tramming ................................................................. 5.28 Stoppingthepump 5.29 Pumpmotorreset 5.30 Continuoushaulagesystemmaintenanceinstructions 5.31 Importantnotes ............................................................. 5.31 Beforemaintenance 5.31 Lubricants...................................................................... 5.33 MBClubricationinstructions 5.34 Centrallubricationsystem........................................ 5.34 Specificlubricationprocedures 5.37 Every8hours ........................................................... 5.37 Daily 5.39 Everyweek............................................................... 5.40 Afterfirst50hoursofservice 5.42 Every2weeks.......................................................... 5.43 Everymonth 5.46 Every3months 5.49 Every6months 5.50 Asrequired 5.51 PIGlubricationinstructions 5.52 Specificlubricationprocedures(PIG) 5.53 Daily 5.53 Everyweek 5.54 Every30hours 5.55 Every3to6months 5.56 Every6months 5.57 RFMtaildollylubricationinstructions 5.58 Specificlubricationprocedures(RFMtaildolly) 5.59 Every8hours 5.59 Every24hours ......................................................... 5.59
_________________________________________________ Tableofcontents A6474X251 REV07 BI016242 RFMpulleysupportsectionlubricationinstructions 5.60 Specificlubricationprocedures 5.61 Every8hours 5.61 Every6months 5.61 IntermediateRFMsectionlubricationinstructions 5.62 Specificlubricationprocedures............................. 5.63 Every6months 5.63 MBCinspection 5.64 MBCwearpartinspections 5.65 MBCFiresuppressioninspection ................................. 5.65 MBCFiresuppressionrecharge 5.67 PIGinspection............................................................... 5.70 PIGwearpartinspections 5.70 RFMinspection ............................................................. 5.71 Adjustmentprocedures 5.73 Mobilebridgecarrier...................................................... 5.73 Conveyorchain 5.73 Crawlertrack......................................................... 5.75 Piggybackbridgeconveyor - conveyorchain 5.77 Replacementofparts......................................................... Mobilebridgecarrier(MBC) 5.79 Conveyordrive 5.79 Driveshaft 5.80 Removal.......................................................... 5.81 Installation 5.84 Driveshaftsprocket 5.88 Removal 5.89 Installation 5.89 Fieldreplacement 5.90 Conveyordrivemodule 5.92 Removal 5.93 Installation 5.94 Disassembly 5.95 Assembly 5.96 Tailshaft................................................................ 5.98 Removal 5.99 Installation....................................................... 5.99 Disassembly 5.101 Assembly.......................................................5.102 Conveyorchain 5.103 Conveyorchainsectionassembly.................5.104 Removal 5.105 Installation......................................................5.106 Crawlertrack 5.108 Removal.........................................................5.109 Assembly 5.109 Installation......................................................5.110 Crawlerdrivemodule 5.111 Disassembly .................................................5.112 Assembly 5.113 Crawlertake-upandidler 5.114 Removal 5.115 Installation 5.116
_________________________________________________ ContinuousHaulageSystem BI016242 Piggybackbridgeconveyor(PIG) 5.117 Conveyordrive 5.117 Driveshaft 5.118 Removal 5.119 Installation 5.121 Driveshaftsprockets........................................... 5.124 Removal 5.125 Installation 5.125 Fieldreplacement 5.126 Conveyordrivemodule........................................ 5.127 Removal 5.128 Installation..................................................... 5.129 Disassembly 5.131 Assembly....................................................... 5.131 Tailshaft 5.133 Removal........................................................ 5.134 Installation 5.134 Disassembly.................................................. 5.135 Assembly 5.136 Conveyorchain.................................................... 5.138 Assembly 5.139 Removal 5.140 Installation 5.141 Mobilebridgecarrier(MBC)......................................... 5.143 Hydrauliccomponents(MBC) 5.143 Tramhydrostaticpump 5.145 Disassembly 5.146 Assembly 5.147 Trammotor 5.148 Removal 5.148 Installation 5.148 Conveyorliftcylinders(inbyandoutby) 5.149 Removal 5.149 Installation 5.150 Canopycylinder................................................... 5.151 Removal 5.151 Installation...................................................... 5.151 Troubleshootingprocedures 5.153 Hydraulicsystem(general).................................. 5.154 Hydrauliccylinders 5.156 Hydraulicpump.................................................... 5.157 Valves 5.160 Errorcodes .......................................................... 5.161 Communicationfaults 5.162 Faultlogcodes.............................................. 5.162 Realtimecodes 5.165
Tableofcontents
_________________________________________________ Tableofcontents A6474X251 REV07 BI016242
Technicaldata Technicaldata .........................................................................6.3 Componentsofthecontinuoushaulagesystem 6.3 MobileBridgeCarrier(MBC)...........................................6.3 PiggybackBridgeConveyor(PBC) 6.4 PiggybackBridgeConveyor(PBC liquidcooled) 6.5 MBCdolly 6.5 RFMpulleysection..........................................................6.5 RFMintermediatesection 6.5 Taildolly 6.5 Tighteningtorques 6.7 Permissiblemedia 6.13 Lubricationfluidsandgreases 6.13 7. Foryourinformation Foryourinformation 7.3 Ourservice 7.3 Serviceaddress 7.3 Rebuildfacilityaddress 7.4
6.
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_______________________________________________________________ 1 Aboutthismanual BI016242
_______________________________________________________________ BI016242
applicableoperatingmanual machinetype
