EM009681 (BI001467) A6474X391 January 2016
Operation and Maintenance Manual
FB140
Serial Number: FBS02192 (54-2192)
FBS02197 (54-2197)
FBS02198 (54-2198)
SAFETY.CAT.COM
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This manual is intended to provide GENERAL product information for the Model FB140 (7MFBHM-48DD) Feeder Breaker . The illustrations, descriptions, and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.
This feeder breaker was manufactured under the guidelines, procedures, and requirements of the appropriate government regulatory agencies.
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 Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to Caterpillar 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 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.
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© Caterpillar 2016 ALL RIGHTS RESERVED
Table of contents
1. About this manual
2. Your safety
3. Storage and transport
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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
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
Storage and transport ............................................................. 3.3 Storage ................................................................................. 3.3 Storage of the machine and spare parts ......................... 3.3 Transport .............................................................................. 3.5 Before transport ............................................................... 3.5 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 Removing and installing the receiving hopper ................... 4.10 Towing the feeder breaker ................................................. 4.14
5. Operation
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Breaker BI001467
FB140 (7MFBHM-48DD) Feeder
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 Primary operator’s station................................................ 5.4 Function pressure gauge ................................................. 5.8 Power fill and hydraulic oil sight glass ............................. 5.9 Auxiliary valve bank (if equipped) .................................. 5.10 Starter enclosure ........................................................... 5.11 Dust suppression system .............................................. 5.16 Infrared pump motor controls ........................................ 5.17 Radio remote ................................................................. 5.18 “AUTO” mode starting procedure ....................................... 5.22 “MANUAL” mode starting procedure .................................. 5.23 Shutdown procedure .......................................................... 5.24 Tramming the machine ....................................................... 5.25 Conveyor ............................................................................ 5.26 Control system operating parameters ................................ 5.28 Electrical system................................................................. 5.31 Starter enclosure ........................................................... 5.34 Hydraulic system ................................................................ 5.38 Major hydraulic components .......................................... 5.40 Primary hydraulic circuit ................................................ 5.42 Mechanical assemblies ...................................................... 5.45 Crawler assembly (s) .................................................... 5.45 Conveyor chain ............................................................. 5.46 Grease take-up ............................................................. 5.47 Head shaft .................................................................... 5.48 Conveyor power unit ..................................................... 5.49 Tail shaft ....................................................................... 5.50 Breaker and breaker power unit assembly .................... 5.51 Breaker assembly .................................................. 5.52 Breaker power unit assembly ................................ 5.53 Instructions on the maintenance of the feeder .................. 5.55 Important notes ............................................................. 5.55 Before maintenance ..................................................... 5.55 Lubrication and inspection ............................................ 5.57 Specific lubrication and maintenance procedures ............. 5.61 Every 8 hours of operation ........................................... 5.61 Weekly .......................................................................... 5.66 Monthly ......................................................................... 5.71 Every 3 months ............................................................. 5.74 Every 1000 hours .......................................................... 5.75 Every 6 months ............................................................. 5.77 Inspection of the feeder ..................................................... 5.80 Inspection of wear parts ..................................................... 5.81 Inspection of the fire suppression system .......................... 5.82 Recharge of the fire suppression system ........................... 5.84 Procedure to set Amplifier Card ......................................... 5.86 Instructions on the adjustment procedures ....................... 5.88 Conveyor chain adjustment .......................................... 5.90 Crawler track adjustment .............................................. 5.92
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________________________________________________________________ A6474X391 REV 4 BI001467 Breaker shaft and power unit height adjustment ........... 5.94 Under speed sensor calibration .................................... 5.96 Main pump adjustments ................................................ 5.98 Main relief pressure………………………………………5.100 Pressure limiter adjustment .......................................... 5.101 Instructions on the replacement of wear parts ................. 5.102 Head shaft ................................................................... 5.102 Head shaft sprockets ................................................... 5.106 Tail shaft ...................................................................... 5.109 Conveyor chain ........................................................... 5.115 Crawler track ............................................................... 5.123 Crawler assembly ........................................................ 5.126 Breaker shaft and breaker power unit ......................... 5.135 Breaker power unit only................................................ 5.141 Breaker shaft only ........................................................ 5.144 Conveyor drive unit ...................................................... 5.153 Breaker bit removal ...................................................... 5.156 Tailpiece installation ..................................................... 5.157 Roof cylinder ................................................................ 5.161 Foot cylinder ................................................................. 5.164 Tilt cylinder ................................................................... 5.166 Lift cylinder ................................................................... 5.168 Tailpiece tilt cylinder ..................................................... 5.171 Tailpiece steering cylinder ............................................ 5.173 Troubleshooting ................................................................. 5.176 6. Technical data Technical data ......................................................................... 6.3 Components of the feeder breaker ...................................... 6.3 Tightening torques................................................................ 6.5 Permissible data ................................................................... 6.7 Lubrication fluids and greases ........................................ 6.7
Table of contents
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BI001467
FB140 (7MFBHM-48DD) Feeder Breaker
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BI001467
About this manual
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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
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:
Cat® FB140 (7MFBHM-56DDH) Feeder Breaker Serial No. 54-2192, 54-2197, and 54-2198
and is only permitted to be used for equipment of this type.
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
■ 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
and supervisory personnel who:
■ initiate and/or
■ supervise the activities just indicated.
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Before starting to work
applicable operating manual
machine type
new operation manual
cost-effectiveness
What is the purpose of this operating manual?
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.
service safety
If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.
Read the chapter “Your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.
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BI001467
Before starting to work
1.4
FB140 (7MFBHM-48DD) Feeder Breaker
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.
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.
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Before starting to work
1.6
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FB140 (7MFBHM-48DD) Feeder Breaker
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Your safety
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further operating manuals
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.
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 Cat®
Use only original Cat® spare parts. Note that the use of parts from other manufacturers will void the guarantee.
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 of
■ the mine,
■ the mine inspector, and
■ 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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state of the art
training
Personnel Operation
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.
Installation and repair
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.)
■ the hydraulics (controls, cylinders, etc.) may only be carried out by Cat® service engineers from or by specially qualified personnel of the mine.
Personnel _______________________________________________________ ________________________________________________________________
2.4
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FB140 (7MFBHM-48DD) Feeder Breaker
Safety instructions
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
Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.
Unauthorized uses include:
■ the transport of persons
■ the transport of objects of any kind such as single props, boards, spare parts, etc.
Caterpillar accepts no liability for any damage resulting from any such unauthorized use.
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Safety instructions _______________________________________________ ________________________________________________________________
2.6
BI001467
FB140 (7MFBHM-48DD) Feeder Breaker
• 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
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL