Maintenance Manual FB110FeederBreaker SAFETY.CAT.COM BI001899 A6474X258 October2012
Operationand
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ThismanualisintendedtoprovideGENERALproductinformationfor theModelFB110FeederBreaker.Theillustrations,descriptionsand procedurescontainedinthispublicationapplyonlytoTHISmachine. Caterpillarreservestherighttorevisemodelsanddesignswithoutprior notice.
Thisfeederbreakerwasmanufacturedundertheguidelines,proceduresandrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart0, Part75forundergroundcoalmines,andotherapplicablenon-U.S. regulatoryagencystandards.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofCaterpillarand theseregulatoryagencies,oranyrepairorreplacementofpartscontrarytotheinstructions,mayinvalidatetheseapprovalsandrenderthis unitunsafetooperate.
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,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
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© CATERPILLAR2012 ALLRIGHTSRESERVED
_________________________________________________ Tableofcontents A6474X258 Rev3 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 Overviewofthesafetyinstructions 2.15 Chapter3:Storageandtransport 2.15 Chapter4:Installation 2.15 Chapter5:Operation..................................................... 2.16 Chapter6:Technicaldata 2.20
Storageandtransport Storageandtransport.............................................................3.3 Storage 3.3 Storageofthemachineandspareparts 3.3 Transport 3.4 Beforetransport 3.6 4. 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
2.
3.
5. Operation
Tableofcontents _________________________________________________ ModelFB110FeederBreaker
Operation .................................................................................5.3 Howtooperatethefeederbreaker 5.3 Whoisallowedtooperatethefeederbreaker ...............5.3 Whencanconveyingbestarted? 5.3 Controlsandindicators 5.4 Operator’sstation 5.4 Starterenclosure.............................................................5.9 Dailystartingprocedure 5.12 Shutdownprocedure 5.15 Electricalsystem 5.17 Hydraulicsystem 5.31 Mechanicalassemblies 5.35 Instructionsonthemaintenanceofthefeederbreaker 5.41 Importantnotes 5.41 Beforemaintenance 5.41 Lubricationandinspection ....................................... 5.43 Specificlubricationandmaintenanceprocedures 5.44 Every8hoursofoperation 5.46 Weekly 5.48 Every2weeks ......................................................... 5.51 Monthly 5.52 Every3months ........................................................ 5.53 Every2500hours 5.54 Every6months ........................................................ 5.55 Inspectionofthefeeder 5.57 Inspectionofwearpartsonthefeederbreaker ............ 5.58 Inspectionofthefiresuppressionsystem 5.59 Rechargeofthefiresuppressionsystem...................... 5.61 Instructionsontheadjustmentprocedures 5.63 Instructionsonthereplacementofwearparts ............. 5.77 Troubleshooting 5.115 6. Technicaldata Technicaldata .........................................................................6.3 Componentsofthefeederbreaker ......................................6.3 Tighteningtorques 6.5 Permissibledata...................................................................6.7 Lubricationfluidsandgreases 6.7 7. Foryourinformation Foryourinformation...............................................................7.3 Ourservice...........................................................................7.3 Serviceaddress 7.3 Rebuildfacilityaddress ...................................................7.4
_______________________________________________________________ 1 Aboutthismanual
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applicableoperatingmanual
machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
ModelFB110FeederBreaker SerialNo.:54-2168and54-2184
andisonlypermittedtobeusedforthisequipment.
newoperationmanual
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.
Thisincludespersonswho:
■ areinchargeoftransport
■ performassembly/disassemblywork
■ operatethemachine
■ eliminatefaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/or
■ supervisetheactivitiesjustindicated.
________________________________________Beforestartingtowork A6474X258 Rev3 1.3
cost-effectiveness
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
service safety
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Beforestartingtowork ________________________________________ 1.4 ModelFB110FeederBreaker
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.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
tsintextmarkedinthiswaydescribeindividualoperations.Follow theseinstructionsstepbystep.Theywillhelpyoucarryoutyour workfasterandmoreimportantly,safer.
________________________________________Beforestartingtowork A6474X258 Rev3 1.5
Beforestartingtowork ________________________________________ 1.6
ModelFB110FeederBreaker
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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.Allmodificationsandchangesmustbeapproved.
Useonlyoriginalspareparts.Notethattheuseofpartsfromother manufacturerswillvoidtheguarantee.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations:
■ ofthemine,
■ ofthemineinspector,and
■ oftheminingsupervisoryauthorities.
furtheroperatingmanuals
Pleasereadalsotheoperatingmanualsofthecomponentsrequiredfor operation,e.g.ofgearboxes,electricmotors,etc.,carefullyandthoroughly.Clarifyanyquestions before startingwork.
___________________________________________________ Personnel A6474X258 Rev3 2.3
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
ModelFB110FeederBreaker
training
Operatingconditions
Intendeduse
Thefeederbreakerhasbeendesignedandmanufacturedpurelyfor transportingminedandcrushedmaterialfromacontinuousminerto themainconveyingsystemfortransportingoutside.
Intendedusesinclude:
■ thetransportofminedandcrushedmaterialbetweencontinuous minerandmainconveyingsystem.
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
■ thetransportofobjectsofanykindsuchase.g.singleprops, boards,spareparts,etc.
Themanufactureracceptsnoliabilityforanydamageresultingfrom anysuchunauthorizeduse.
_________________________________________ Operatingconditions A6474X258 Rev3 2.5
Operatingconditions __________________________________________ 2.6 ModelFB110FeederBreaker
general
Safetyinstructions
Generalrules:
Alwaysworkwithfullconcentration.
noiseemissions
Familiarizeyourselfwithyourworkingenvironment. Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).
Informyourcolleaguesof:
■ yourexactlocation,
■ theworkyouareperforming,and
■ thetimethatyouwillprobablyrequire.
safetyequipment symbolplates emergencystop(panicstrip) lock-out
Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.STOPdevices,coverplates,etc.are correctlyinstalled.
Observetheacousticandopticalstart-upwarningsofthemachine.
Observethesymbolplatesonthemachine.
Pressanemergencystopswitchimmediatelyintheeventoffaultor irregularitiesinoperation.Reportanypeculiaritytoyoursuperiorso thatnecessarymeasurescanbetakenimmediately.
Lock-outanddisconnectthepowersystemwhileperforming:
■ maintenancework
■ inspectionwork
■ repairwork
cordonoffworkingarea
Cordonoffyourworkingareawidelyforthemachine.
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A6474X258 Rev3 2.7
Safetyinstructions
