Technical Manual
© Bucyrus All Rights Reserved
R
BI001967
BUCYRUS
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FB140FeederBreaker SAFETY.CAT.COM BI001967 A6474X354 October2012 BI001967
Operationand Maintenance Manual
ThismanualisintendedtoprovideGENERALproductinformation.The illustrations,descriptions,andprocedurescontainedinthispublication applyonlytoTHISmachine.Caterpillarreservestherighttorevise modelsanddesignswithoutpriornotice.
Thismachinewasmanufacturedundertheguidelines,procedures,and requirementstheappropriateregulatoryagencies.Atthecompletionof themanufacturingprocess,themachinewasissuedtheappropriate approvalnumbersandnameplatesindicatingitmetthetechnicalrequirementsoftheseregulatoryagencies.Anychangetothedesignor structureofthisunit,withouttheconsentofCaterpillarandtheseregulatoryagencies,oranyrepairorreplacementofpartscontrarytoCaterpillar’sinstructions,mayinvalidatetheseapprovalsandrenderthisunit unsafetooperate.
Strictcompliancewithalllocalandnationallaws,regulations,andpracticesregardingthesafeoperationandmaintenanceofunderground miningequipmentandstrictadherencetotheinstructionsinthismanual isnecessaryforthepersonalsafetyofthoseworkingonoraroundthis unit.
WhileCaterpillarattemptstoanticipatethemostimportantoperations 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 A6474X354 REV3 BI001967 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 2.9 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
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 Towingthefeederbreaker 4.9 BI001967
4.
5. Operation
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Operation..................................................................................5.3 Howtooperatethefeederbreaker 5.3 Whoisallowedtooperatethefeederbreaker ................5.3 Whencanconveyingbestarted? 5.3 Controlsandindicators 5.4 Operatingprocedures 5.13 Electricalsystem.................................................................5.23 Hydraulicsystem 5.29 Mechanicalassemblies 5.33 Crawlerassembly(s) 5.33 Conveyorchain 5.35 Greasetake-up 5.36 Headshaft 5.37 Conveyorpowerunit 5.38 Tailshaft 5.39 Breakerassembly..........................................................5.40 Instructionsonthemaintenanceofthefeeder 5.41 Specificlubricationandmaintenanceprocedures 5.46 Everyshift 5.46 Weekly .....................................................................5.50 Monthly 5.55 Every200hoursoftramoperation ...........................5.58 Every1000hours 5.59 Every6months ........................................................5.62 Inspectionofthefeeder 5.64 Inspectionofwearpartsonthefeeder ..............................5.65 Inspectionofthefiresuppressionsystem 5.66 Rechargeofthefiresuppressionsystem...........................5.68 Instructionsontheadjustmentprocedures 5.69 Conveyorchainadjustment ..........................................5.69 Crawlertrackadjustment 5.71 Breakerdrivechain 5.73 Underspeedsensorcalibration 5.76 Mainpump,marginpressure 5.79 Mainpump,pressurecompensator 5.79 Mainreliefpressure 5.81 Pressurelimiter 5.83 Troubleshooting 5.85 Openlooppump 5.87 Excessivenoise 5.89 Excessiveheat 5.90 Incorrectflow 5.91 Incorrectpressure 5.92 Hydraulicsystem,general 5.93 Hydrauliccylinders ........................................................5.95 Hydraulicpump 5.96 Valves............................................................................5.99 Bearings 5.101 Torquehub ...................................................................5.102 BI001967
_________________________________________________ Tableofcontents A6474X354 REV3 BI001967 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 BI001967
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_______________________________________________________________ 1 Aboutthismanual BI001967 BI001967
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applicableoperatingmanual machinetype
newoperationmanual
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
ThisoperatingmanualisintendedforthemodelFB140feederbreaker andisonlypermittedtobeusedforequipmentofthistype.
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.
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cost-effectiveness
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
service safety
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Yoursafety”withspecialattention.Thechaptercontainsimportantinformationindicatingpossiblehazards.Observethe informationgivenandfollowtheproceduralinstructions.
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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 FB140FeederBreaker BI001967 BI001967
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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.
Useonlyoriginalparts;notethattheuseofpartsfromothermanufacturerswillvoidtheguarantee.
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 FB140FeederBreaker BI001967
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Operatingconditions
Intendeduse
Thefeederbreakerhasbeendesignedandmanufacturedpurelyfor transportingminedandcrushedmaterialfromacontinuousminerto themainconveyingsystemfortransportingoutside.
Intendedusesinclude:
■ Thetransportofminedandcrushedmaterialbetweencontinuous minerandmainconveyingsystem.
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
Unauthorizedusesinclude:
■ thetransportofpersons
■ thetransportofobjectsofanykindsuchassingleprops,boards, spareparts,etc.
TheOEMacceptsnoliabilityforanydamageresultingfromanysuch unauthorizeduse.
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Safetyinstructions
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• 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
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