Cat FB140 Feeder Breaker Operation & Maintenance Manual SN FBS02200 - PDF DOWNLOAD

EM003784 BI632977 Dec. 2015

Operation and Maintenance Manual FB140 Serial Number: FBS02200

SAFETY.CAT.COM

BI632977

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This manual is intended to provide GENERAL product information for the FB140 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 U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U.S. regulatory agency standards.

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, Inc., and these regulatory agencies, or any repair or replacement of parts contrary to the 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.

© CATERPILLAR 2015 ALL RIGHTS RESERVED

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________________________________________________ Table of contents

Table of contents 1. About this manual 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

2. Your safety 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 Overview of the safety instructions .................................... 2.15 Chapter 3: Storage and transport .................................. 2.15 Chapter 4: Installation ................................................... 2.15 Chapter 5: Operation ..................................................... 2.16 Chapter 6: Technical data ............................................. 2.20

3. Storage and transport Storage and transport ............................................................. 3.3 Storage ................................................................................. 3.3 Storage of the machine and spare parts ......................... 3.3 Transport .............................................................................. 3.4 Before transport ............................................................... 3.6

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 Towing the feeder breaker ................................................... 4.9

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Table of contents _________________________________________________ 5. Operation 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 Operator’s station ............................................................ 5.4 Primary valve bank .......................................................... 5.5 Starter enclosure ............................................................. 5.9 Control features ............................................................. 5.15 Conveyor ....................................................................... 5.16 Daily starting procedure................................................. 5.17 Receiver/Decoder components ................................ 5.19 Shutdown procedure ..................................................... 5.24 Electrical system............................................................ 5.31 Starter enclosure ...................................................... 5.34 Major electrical components ..................................... 5.36 Hydraulic system ...................................................... 5.37 Major hydraulic components .................................... 5.37 Mechanical assemblies ................................................. 5.41 Crawler assembly (s) ............................................... 5.41 Conveyor chain ........................................................ 5.42 Grease take-up ........................................................ 5.42 Head shaft ............................................................... 5.43 Power unit ................................................................ 5.44 Tail shaft .................................................................. 5.44 Breaker assembly ..................................................... 5.45 Instructions on the maintenance of the feeder ............. 5.47 Important notes ........................................................ 5.47 Before maintenance ................................................ 5.47 Lubrication and inspection ....................................... 5.49 Specific lubrication and maintenance procedures ........ 5.52 Every 8 hours of operation ...................................... 5.52 Weekly ..................................................................... 5.54 Every 2 weeks ......................................................... 5.57 Monthly .................................................................... 5.58 Every 3 months ........................................................ 5.59 Every 2500 hours...................................................... 5.60 Every 6 months ........................................................ 5.61 Inspection of the feeder ................................................ 5.63 Inspection of wear parts on the feeder ......................... 5.64 Inspection of the fire suppression system ..................... 5.65 Recharge of the fire suppression system ...................... 5.67 Procedure to set Amplifier Card .................................... 5.69 Instructions on the adjustment procedures .................. 5.71 Conveyor chain adjustment ..................................... 5.71 Crawler track adjustment ......................................... 5.73 Instructions on the replacement of wear parts ............. 5.75 Head shaft ............................................................... 5.75 Head shaft sprockets ............................................... 5.78 Tail shaft .................................................................. 5.81 Conveyor chain ........................................................ 5.86 Crawler track ............................................................ 5.89

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________________________________________________ Table of contents Crawler assembly ..................................................... 5.92 Power unit ................................................................ 5.99 Conveyor drive motor ............................................... 5.107 Breaker assembly ..................................................... 5.110 Tightening torques…………………………………………….5.122

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About this manual

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____________________________________________Before starting to work

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 applicable operating manual machine type

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: FB140 Feeder Breaker Serial No.: FBS02200 and is only permitted to be used for equipment of this type.

new operation manual

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 prepare the rise heading 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

supervisory personnel who: ■ ■

initiate and/or supervise the activities just indicated.

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Before starting to work ____________________________________________ What is the purpose of this operating manual? cost-effectiveness

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

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For 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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____________________________________________Before starting to work 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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Items in lists are marked with bullets.

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Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

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2

Your safety

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______________________________________________________ Personnel

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. state of the art

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.

Use only original 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:

further operating manuals

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of the mine.

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of the Mines Inspector and

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of 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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Personnel _______________________________________________________ Personnel Operation training

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,

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hydraulics and

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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.)

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the electrics (motors, controllers, etc.)

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the hydraulics (controls, cylinders, etc.)

may only be carried out by service engineers or by specially qualified personnel of the mine.

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_____________________________________________ Operating conditions 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.

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the transport of persons

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the transport of objects of any kind such as e.g. single props, boards, spare parts, etc.

The manufacturer accepts no liability for any damage resulting from any such unauthorized use.

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Operating conditions _____________________________________________

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_______________________________________________ Safety instructions Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 db(A).

Inform your colleagues of:

safety equipment

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your exact location.

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the work you are performing.

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the time that you will probably require.

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the machine.

symbol plates emergency stop (panic strip)

lock-out

cordon off working area

Observe the symbol plates on the machine.

Press the STOP switch immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Lock-out and disconnect the power system while performing: ■

maintenance work

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inspection work

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repair work

Cordon off your working area widely for the machine.

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Safety instructions _______________________________________________ moving parts

Never allow parts of your body to come between parts which could move, such as e.g.: ■

conveyor chains

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flights

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pivot points

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boom assemblies

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crawler assemblies

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breaker shaft assemblies

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_______________________________________________ Safety instructions Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.

mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

Installation and start-up inclined face

environmental acceptability

On inclined faces secure all component parts by chains, e.g. to the support.

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

inspection maintenance instruction and safety tags

operator’s area

Inspect the machine and have any malfunctioning, broken or missing parts corrected or replaced before use.

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

These are as important as any other equipment on the machine.

Clean any foreign material from the operator’s area.

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Safety instructions _______________________________________________ Operation Operate the feeder breaker only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective feeder breaker.

Before start-up, ensure that there are no persons around the machine.

Check that all protective devices are installed on the machine and function properly.

Clean the control panel and operator’s area at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration. securing

Secure your working area over a wide range, in order to avoid endangering other persons.

Lock-out and disconnect power from the machine to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

replacing components

Stop, lock-out and disconnect power from machine to prevent from restarting before replacing any defective components.

Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original spare parts.

Please refer to the spare parts lists for the order numbers.

For raising the feeder breaker use only: ■

crib blocks with adequate load-holding capacity

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hoists, jacks or cranes with adequate load-carrying capacity

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_______________________________________________ Safety instructions handling of hydraulic fluids

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

Never use hydraulic fluid for rinsing or cleaning. Hydraulic fluid represents a very serious danger to health.

maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work on the hydraulic system.

Do not alter the electrical or hydraulic settings from that indicated in this manual or as set at the factory.

Always replace damaged or lost decals and metal instruction plates.

Disconnect power at the main power source on the unit to prevent electrical shock.

Always follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: ■

the hoses are not pinched or trapped

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the hoses have no bubbles or blisters

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the hose or outer sheathes of the hose are not abnormally rigid or hard

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the outer sheath of the hoses is not damaged

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the connectors are securely inserted into the sockets

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the connections are leak-tight

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage in the whole system! Flush out the hydraulic lines thoroughly before connecting.

If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

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Safety instructions _______________________________________________ Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn orings.

Replace hydraulic hoses only with hoses of the same or a higher quality.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

Fig. 1: Example: 4SP hydraulic hose, designation

1. manufacturer 2. hose type 3. date of manufacture 1st quarter 2000

4. nominal diameter 5. flame-resistant and antistatic

Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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_______________________________________________ Safety instructions laying hydraulic hoses

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 2: Laying hydraulic hoses, slack Right

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Wrong

are not twisted.

Fig. 3: Laying hydraulic hoses, twisting Right

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Wrong

are not bent directly behind the connections. (distance min. 1.5 x nominal diameter).

Fig. 4: Laying hydraulic hoses, bending Right

Wrong

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Safety instructions _______________________________________________ ■

always have a little slack.

Fig. 5: Laying hydraulic hoses, crossing Right

■ ■ ■ ■

Wrong

are not kinked. do not have to withstand tensile strains. are protected against thermal radiation. are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

When installing the hydraulic hoses, ensure that they cannot be: ■ ■ ■ ■ ■

torn out, kinked, crushed, driven over or twisted by movement of the machine.

Fig. 6: Laying hydraulic hoses, connections on moving parts Right

Wrong

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_____________________________________Overview of safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and transport Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

IMPORTANT! Take care to insure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

Chapter 4: Installation CAUTION! Serious damage can be caused to the feeder breaker as a result of incorrect installation.

The unit should therefore only be installed under the instruction of specialists from the manufacturer.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the prestartup checks should be performed: NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

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Overview of safety instructions _____________________________________ DANGER! Do not operate the machine any of the guards or covers removed.

You or other personnel could be seriously injured from moving or rotating parts.

WARNING! It is not possible, within the scope of this guide, to anticipate all possible arrangements for towing the feeder breaker. Before attempting to tow the machine, you must take all possible precautions to protect the operators and anyone around the feeder breaker and the towing machine from being injured by either the towing machine or the feeder breaker. The primary towing device being used (cables, bars, etc.) and the towing machine must have load limits strong enough and heavy enough to maintain control through all conditions that may be encountered at any time. Safety chains or other safety devices must be used in case of failure of the primary towing device. All operators must be alert at all times to prevent either machine from running out of control during towing. Failure to follow the above warning could cause serious injury or death to you or other workers.

WARNING! Failure to chock the front and rear of both crawlers could allow uncontrolled movement of the feeder breaker. Failure to follow this warning could cause serious injury or death to you or other workers.

WARNING! At no time during towing should anyone ride in or on the machine being towed or stand in between the towing machine and the machine being towed. Failure to follow the above warning could cause serious injury or death to you or other workers.

WARNING! Do not exceed 5 mph during towing. Exceeding 5 mph could cause serious injury or death to you or other workers or damage to machine.

WARNING! Failure to chock the front and rear of both crawlers could allow uncontrolled movement of the feeder breaker. Failure to follow this warning could cause serious injury or death to you or other workers.

Chapter 5: Operation DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

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_____________________________________Overview of safety instructions NOTICE! Once either of the hydraulic control valve handles is released by the operator, the lever will automatically return to the centered (neutral) position.

NOTICE! After oil filling operation is completed, return “POWER FILL” lever to the neutral position or overheating of the machine will occur.

WARNING! When tramming the machine from the operator’s station, the operator should stand beside the machine facing the conveyor with the tram control levers at arms length. Care should be taken to ensure that the operator’s feet do not get under the crawler tracks while the machine is moving.

NOTICE! The feeder breaker has skid type steering; it is capable of turning within its own limits.

IMPORTANT! If it is necessary to reverse the conveyor (s), it should be jogged only. Running the conveyor (s) in the reverse direction for a period of time with material in the hopper will jam the conveyor (s) and it will be necessary to empty the machine hopper before the conveyor (s) will restart.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.

WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the machine.

WARNING! If the “START” conveyor pushbutton is depressed while the conveyor direction control valve is in either forward or reverse position the conveyor will start running. Ensure that you and other workers are clear of the conveyor before depressing the “START “ conveyor pushbutton to prevent serious injury or death to you or other workers.

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Overview of safety instructions _____________________________________ WARNING! The machine should not be started if it’s core temperature is below 30° Fahrenheit. If the machine is started at extremely low temperatures pump and pump motor failure could occur.

NOTICE! The feeder has skid type steering; it is capable of turning within its own limits.

IMPORTANT! If material is very wet or sticky, it is recommended that the return line be flushed with water and the conveyor be allowed to run and clean out the return line before shutting the machine down.

WARNING! Before removing the cover from the starter enclosure and attempting any maintenance or troubleshooting on the machine, the main power must be disconnected and locked out at the main power center.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

WARNING! The tilt and lift hydraulic cylinders have counterbalance cartridges which serve as load holding valves. Do not replace these cylinders with different style cylinders or the machine may fall. The machine could be damaged or you or other personnel could be seriously injured or killed by the falling machine.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

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_____________________________________Overview of safety instructions IMPORTANT! The feeder breaker is equipped with a central lubrication system that allows several lubrication points to be lubricated from one central point.

NOTICE! All hydraulic filter elements should be changed after one week of the initial start-up of machine or pre-mature wear of hydraulic components could occur.

CAUTION! During inspection, report any damage, missing parts or other faults to your immediate supervisor.

NOTICE! The adjustment procedure for conveyor chain take-up must be performed on both right and left hand sides of the conveyor.

NOTICE! Make certain that the same amounts of shims are used on both sides of the conveyor to prevent chain from stretching unevenly.

Incorrect tension or adjustment can cause premature wear of sprockets and chain.

WARNING! Due to grease cylinders being under high pressure, do not stand in direct line of grease fitting or bleeder valve when releasing pressure. You could be seriously injured from high pressure grease.

WARNING! If only one side of the machine is raised during maintenance, be careful and only move the control lever for that particular side.

Moving the wrong control lever could cause the machine to move and fall off its supports. You could be seriously injured or even killed by falling loads.

IMPORTANT! The head shaft split sprocket is designed for temporary use only and should be replaced during the first available maintenance shift.

WARNING! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the conveyor chain, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the conveyor chain.

IMPORTANT! If old conveyor chain is still on machine, installation can be facilitated by connecting the new conveyor chain to the old conveyor chain via the chain connectors and pulling it through the bottom conveyor pan.

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Overview of safety instructions _____________________________________ Chapter 6: Technical data IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

NOTICE! Use only lubrication fluids and greases approved by Caterpillar!

These fluids and greases have been tested at and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Caterpillar expressly point out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be disposed of per your local EPA standards.

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3

Storage and transport

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____________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the feeder breaker.

Observance of the instructions and tips will increase the service life and availability of the machine. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

Components coated with temporary corrosion inhibitor are protected for approximately six months.

Before delivery, the hydraulically operated equipment is operated and all axles, gear boxes, hydraulic oil tank, etc. are filled to their maximum fill point.

Storage of the machine and spare parts no direct exposure to sunlight

dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic – such as seals and hoses – and hydraulic fluids only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).

Protect the equipment and all spare parts stored outdoors against moisture and dirt, e.g. using tarpaulins.

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.

short-term storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

long-term storage

If the equipment is to be stored more than six months, the hydraulic components must be completely filled with a corrosion inhibiting/frostproofing fluid such e.g. CV 50.

Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow. Then seal the ports with plastic or steel plugs.

The equipment must be stored in a well ventilated, dry room. Do not store outdoors.

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Storage and transport _____________________________________________ plastic deformation

In order to prevent plastic deformation of the seal elements, cylinders must be stored in an upright position. Some cylinders must be removed so that they can be stored upright.

random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

On request, the inspection can be carried out.

natural aging

Even with proper storage, seals and hoses are subject to natural ageing. Do not use these parts if they have been stored for more than two years.

HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

IMPORTANT! Take care to insure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

Transport Load units; dimensions and weights Observe the transport sheets for the machine and spare parts. They contain information on: ■

Dimensions

■

Weight

■

lifting points, etc. (See Fig. 7 for lifting point locations)

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

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____________________________________________ Storage and transport Fig. 7: Lifting points on the feeder breaker Lift point

Lift point Lift point

Lift point

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Storage and transport _____________________________________________ Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid (e.g. CV 50).

Transport of equipment at temperatures between -6° F (-21° C) and 40° F (-40° C) is only permissible when certain measures were taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport.

electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

________________________________________________________________ FB140 Feeder Breaker 3.6

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4

Installation

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______________________________________________________ Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on: the safety components (pressure relief valves, fire extinguishing equipment, etc.) the electrical equipment (control units, signaling devices, etc.) and the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by service engineers or by specially trained personnel.

Which tools are required for installation? tool box

No special tools are required to put the feeder breaker into service.

In addition, various items of auxiliary equipment and machines may be required at the point of installation.

These include i.e.: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

■

impact wrenches, including accessories

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Installation ______________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the feeder breaker as a result of incorrect installation.

The unit should therefore only be installed under the instruction of specialists. installation plan

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established

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______________________________________________________ Installation Pre-installation check list NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: ■

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

operate all control valve handles to ensure that they are free and in the neutral position

■

check conveyor and breaker area for any foreign objects and clear any material that may cause a jam

■

check tension of conveyor chain

■

check safety provisions for operational condition on fire suppression system (if equipped)

■

check safety provisions for operational condition on tail shaft cover plate (if equipped)

■

check safety provisions for operational condition on power unit shrouds and guards

■

jog the breaker motor to check for correct rotation of breaker

■

jog the conveyor motor to check for correct rotation of conveyor chain

■

start up the machine and check for correct operation of all stop switches

■

check the operation of the remote start pushbuttons

■

check operation of the emergency pull cord stop switch located on the receiving end of the machine

■

start the machine and allow the hydraulic system to warm up for five (5) to ten (10) minutes

■

check hydraulic system pressures (see spare parts manual for proper hydraulic schematic)

■

check all control handles to ensure all machine functions are operating properly

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Installation ______________________________________________________ Safety features NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

Safety features include: (Reference Fig. 8) emergency stop pull cord switch

The emergency stop pull cord switch is located on the receiving end of the machine. To actuate the switch, pull the cord that is across the conveyor. When the cord is pulled, all machine functions are shutdown immediately.

guards and covers

The machine is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.

DANGER! Do not operate the machine any of the guards or covers removed.

You or other personnel could be seriously injured from moving or rotating parts.

“STOP” switch (starter enclosure)

This stop switch is located on the left hand side of the machine, on the starter enclosure cover. Depressing the stop switch button will shutdown all machine functions immediately.

“E-STOP” switch (starter enclosure)

This stop switch is located on the left hand side of the machine, on the starter enclosure cover. Depressing the stop switch button will shutdown all machine functions immediately.

panic strip (s)

One panic strip is located at the operator’s station on the left hand side of the machine and the other is located on the right side above the crawler assembly. Striking with a small amount of force will actuate either of the panic strips. The panic strip (s) is used to break the control circuit in emergency situations. When either of the panic strips are struck, all machine functions are shutdown immediately.

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators. One is located adjacent to the operator’s station on the left side of the machine. The other is located adjacent to the crawler on the right side of the machine. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

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______________________________________________________ Installation Fig. 8: Safety features on the feeder breaker Stop switch (starter)

E-Stop switch (starter)

Fire suppression actuator location

Panic strip

Emergency stop pull cord switch

Fire suppression actuator location Panic strip

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Installation ______________________________________________________ Fig. 9: Overview of the feeder breaker Head shaft

Power unit

Discharge section Starter enclosure

Hydraulic oil tank

Breaker assembly

R.H. crawler assembly

Operator’s area

L.H. crawler assembly Torque hub

Ratio chains

Conveyor chain

Emergency pull cord stop

Tail shaft take-ups Tail shaft

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______________________________________________________ Installation Towing the feeder breaker WARNING! It is not possible, within the scope of this guide, to anticipate all possible arrangements for towing the feeder breaker. Before attempting to tow the machine, you must take all possible precautions to protect the operators and anyone around the feeder breaker and the towing machine from being injured by either the towing machine or the feeder breaker. The primary towing device being used (cables, bars, etc.) and the towing machine must have load limits strong enough and heavy enough to maintain control through all conditions that may be encountered at any time. Safety chains or other safety devices must be used in case of failure of the primary towing device. All operators must be alert at all times to prevent either machine from running out of control during towing. Failure to follow the above warning could cause serious injury or death to you or other workers.

To tow the feeder breaker proceed as follows:  Couple the towing machine securely to the feeder breaker.  Chock front and rear of both crawler drives.

WARNING! Failure to chock the front and rear of both crawlers could allow uncontrolled movement of the feeder breaker. Failure to follow this warning could cause serious injury or death to you or other workers.  Rotate the torque hub end cap on both right and left sides of the feeder to the free position as follows (Fig. 10).  Remove the two (2) bolts that retains the end cover to the center of the torque hub.  Rotate cover and reinstall with the two (2) bolts to disengage torque hub. Torque bolts to 120 in lb.

WARNING! At no time during towing should anyone ride in or on the machine being towed or stand in between the towing machine and the machine being towed. Failure to follow the above warning could cause serious injury or death to you or other workers.

WARNING! Do not exceed 5 mph during towing. Exceeding 5 mph could cause serious injury or death to you or other workers or damage to machine.  Remove chocks from crawler and begin towing.

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Installation ______________________________________________________  Once the destination is reached, stop both machines and chock both feeder crawlers in both directions to prevent accidental movement.

WARNING! Failure to chock the front and rear of both crawlers could allow uncontrolled movement of the feeder breaker. Failure to follow this warning could cause serious injury or death to you or other workers.  Rotate the torque hub end cap on both right and left sides of the feeder breaker to the drive position.  Remove the two (2) bolts that retains the end cap to the center of the torque hub.  Rotate end cap and reinstall with the two (2) bolts to engage torque hubs to the drive position. Torque bolts to 120 in lb.

Fig. 10: Torque hub disengagement

Retaining bolts (2)

Normal tram position

End cap button pointing outward

Retaining bolts (2)

End cap button pointing inward Freewheel position

________________________________________________________________ FB140 Feeder Breaker 4.10

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5

Operation

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_______________________________________________________ Operation

Operation This chapter contains important information on the operation and maintenance of the machine. It also includes instructions on the replacement of wear parts.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

How to operate the feeder breaker DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the feeder breaker?

The feeder breaker is only allowed to be operated by persons with adequate knowledge of the complete machine.

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can conveying be started?

Operation must not be started until the safe condition and proper function of the complete machine has been checked and the daily maintenance operations have been carried out.

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Operation _______________________________________________________ Controls and indicators Operator’s station The primary controls for the machine are located on the left hand side.

The operator’s station (Fig. 11) consists of the following controls and indicators: primary valve bank, auxiliary function pressure gauges, conveyor speed pressure gauge, conveyor speed control valve, conveyor direction control valve, starter enclosure, oil level sight gauge, tram/ conveyor mode control valve and fire suppression actuator.

NOTICE! Once either of the hydraulic control valve handles is released by the operator, the lever will automatically return to the centered (neutral) position.

Fig. 11: Operator’s station Fire suppression actuator

Primary system pressure gauge

Oil Level sight gauge Starter enclosure

Primary valve bank

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_______________________________________________________ Operation Primary valve bank The primary valve bank (Fig. 12) consists of the following hydraulic controls: “POWER FILL”

The first lever from the operator’s right controls the “POWER FILL”. To operate the power fill, connect a hose from a fresh oil source to the power fill flow diverter, turn the ball valve on the flow diverter, and push the handle on the valve bank to engage the function. When finished release the handle on the valve bank, return the ball valve on the power fill flow divider and stow the hose (taking care to avoid introducing contaminants into the system).

NOTICE! After oil filling operation is completed, return “POWER FILL” lever to the neutral position or overheating of the machine will occur.

“RIGHT FRAME LIFT”

The second lever from the operator’s right controls the movement of the right cylinder at the pivot point of the crawler, which adjusts the ground clearance on the right side of the machine. To increase the ground clearance, slowly push the control lever away from the operator and to decrease the ground clearance, slowly pull the control lever towards the operator.

“RIGHT TRAM”

The third lever from the operator’s right controls the right hand crawler functions. To tram in the direction of the receiving end, slowly push the control lever towards the machine and to tram in the direction of the discharge end, slowly pull the control lever towards the operator.

“LEFT TRAM”

The fourth lever from the operator’s right controls the left hand crawler functions. To tram in the direction of the receiving end, slowly push the control lever towards the machine and to tram in the direction of the discharge end, slowly pull the control lever towards the operator.

WARNING! When tramming the machine from the operator’s station, the operator should stand beside the machine facing the conveyor with the tram control levers at arms length. Care should be taken to ensure that the operator’s feet do not get under the crawler tracks while the machine is moving.

The tram/steering control levers are used for tramming and positioning the machine. To tram the machine in a straight direction towards the receiving end, push both tram control levers towards the machine and to tram the machine in a straight direction towards the discharge end, pull both tram control levers towards the operator. To steer left in the direction of the receiving end, push the right tram control lever towards the machine while the left tram control lever is in the neutral position or for tighter turns, pull the left tram control lever towards the operator. To steer right in the direction of the receiving end, push the left tram control lever towards the machine while the right tram control lever is in the neutral position or for tighter turns, pull the right tram control lever towards the operator.

NOTICE! The feeder breaker has skid type steering; it is capable of turning within its own limits.

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Operation _______________________________________________________ “LEFT FRAME LIFT”

“FRAME TILT”

The fifth lever from the operator’s right controls the movement of the left cylinder at the pivot point of the crawler, which adjusts the ground clearance on the left side of the machine. To increase the ground clearance, slowly push the control lever away from the operator and to decrease the ground clearance, slowly pull the control lever towards the operator.

The sixth lever from the operator’s right controls the movement of the cylinders mounted to the underside to the hopper and end of the crawlers, which adjust the discharge height of the machine. To raise the height, slowly push the control lever away from the operator and to lower the height, slowly pull the control lever towards the operator.

Fig. 12: Primary valve bank

“TANK FILL”

“LEFT TRAM”

“RIGHT TRAM”

“LEFT LIFT”

“RIGHT LIFT”

“TILT”

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_______________________________________________________ Operation function pressure gauge

The function pressure gauge is located to the side of the primary valve bank. This gauge provides a pressure reading for each active function on the machine.

oil level sight gauge

The oil level sight gauge (Fig. 13) is located on the side of the oil tank.

The oil level should not be allowed to drop below the bottom of the sight glass.

power fill ball valve

The power fill ball valve (Fig. 13) is located on the left hand side of the discharge section of the machine on top of the oil tank and is used to control the flow of hydraulic fluid from the power fill pump.

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators (Fig. 13). One is located adjacent to the operator’s station on the left side of the machine. The other is located adjacent to the crawler on the right side of the machine. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

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Operation _______________________________________________________ Fig. 13: Controls and indicators Fire suppression actuator location

Primary valve bank

Oil level sight glass

Power fill ball valve

Starter enclosure

Panic strip

Emergency stop pull cord switch

Fire suppression actuator location

Panic strip

________________________________________________________________ FB140 Feeder Breaker 5.8

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_______________________________________________________ Operation Starter enclosure The starter enclosure (Fig. 14) is located on the left hand side of the machine houses the electrics necessary to control the machine and consists of the following machine’s electrical functions: “MAN/OFF/AUTO”

The “MAN/OFF/AUTO” selector switch is used to set the mode of operation. Manual mode, “MAN” is used to bypass the outby conveyor sequence switch. When in manual mode, the outby conveyor belt does not need to be running. “AUTO” mode is used for normal operations.

“TRAM/OFF/CONV”

The “TRAM/OFF/CONV” selector switch is used to select tram or conveyor mode of operation. When in “OFF” mode, tram and conveyor functions are not active. “TRAM” mode is used when tramming the machine. When in tram mode, conveyor functions are not active. Conveyor mode, “CONV”, is used for normal operations. When in conveyor mode, tramming functions are not active.

“FWD/OFF/REV”

“15 AMP CB RESET”

“STOP” “EMERGENCY STOP”

“ACKNOWLEDGE ALARMS”

“CONVEYOR START”

“START BREAKER”

circuit breaker reset lever

The “FWD/OFF/REV” selector switch is used to select the conveyor direction. If the switch is in “OFF” mode while the “MAN/OFF/AUTO” switch is in “AUTO” mode, the conveyor will not run. Forward mode, “FWD”, is used for normal operations.

The “15 AMP CB RESET” pushbutton is used to reset the control circuit breaker.

The “STOP” pushbutton is used to stop the breaker motor.

The “EMERGENCY STOP” button is used to trip the master control relay, thereby shutting down the machine. Power is still on the machine.

The “ACKNOWLEDGE ALARMS” pushbutton is used to clear an alarm from the display panel after the condition that generated the alarm is corrected. This pushbutton is also used to engage the master control relay when starting the machine for the first time or after the panic switch/e-stop has been pressed.

The “CONVEYOR START” pushbutton will initiate an automatic conveyor run cycle. The conveyor will run for the time duration preset.

Note: The conveyor will not run until the breaker motor and hydraulic pump are running.

The “START BREAKER” pushbutton is used to start the breaker motor.

When the button is pushed, an alarm sounds for a preset amount of time. After the alarm sound, the breaker motor will start.

The circuit breaker reset lever is used to reset the main circuit breaker when it has tripped. To reset the breaker, push the handle down, past “OFF”, to “RESET” and then back up to “ON”.

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Operation _______________________________________________________ “CONV HOUR METER” digital display

The “CONV. HOUR METER” displays the hours of conveyor motor operation.

“BRKR HOUR METER” digital display

The “BRKR. HOUR METER” displays the hours of breaker motor operation.

Fig. 14: Starter enclosure cover

1

5

6

7

2

8

3

9

4

10

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

11

12

13

“MAN/OFF/AUTO” selector switch “TRAM/OFF/CONV” selector switch “FWD/OFF/REV” selector switch PLC display “CB RESET” pushbutton “CONVEYOR START” pushbutton “CONV. HOUR METER” display “START BREAKER” pushbutton “STOP” pushbutton “ACKNOWLEDGE ALARMS” pushbutton “BRKR. HOUR METER” display “EMERGENCY STOP” pushbutton Main circuit breaker reset lever

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_______________________________________________________ Operation PLC display

The display panel (Fig. A) is located in the starter enclosure. The display is used to monitor machine performance during operation, to troubleshoot the machine, and to change operating parameters.

Fig. A: PLC display (touch screen feature) PLC display

Number pad

Function keys “MAIN SCREEN”

On screen navigation keys

The normal operation display screen is the “MAIN SCREEN” (Fig. B).

This screen displays any active alarm, breaker motor amps, conveyor speed, breaker and motor hours, and mode of operation (with or without belt sequence active). It also provides a login/logout access. The “MAIN SCREEN” and “STATUS SCREEN” are the only screens available without a password. After log in, access to three additional screens is displayed. For alarm information, see the troubleshooting section in this chapter.

Fig. B: “MAIN SCREEN” Operating status

Alarm banner

Conveyor speed

Motor hours

Login access Logout

Screen access

Belt sequence status

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Operation _______________________________________________________ “STATUS SCREEN”

The “STATUS SCREEN” (Fig. C) is accessed by pushing function key “F1”. This screen displays the conveyor speed, hydraulic oil pressure, vacuum pressure, and the current in each phase of the breaker motor.

To return to the “MAIN SCREEN” from the “STATUS SCREEN”, press “F1”.

Fig. C: “STATUS SCREEN”

After logging in, the functions keys “F2” through “F4” (Fig. D) are used to access four additional screens: “PRESETS”, “OPERATION TIMERS”, and “JAM TIMERS” . Currently, function keys “F5” through “F8” are not used.

“PRESETS SCREEN”

The “PRESETS SCREEN” (Fig. D) is accessed from the “MAIN SCREEN” by pushing function key “F2”. This screen allows access to the preset breaker shaft speed designations for low, medium and high speeds. To return to the “MAIN SCREEN” from the “PRESET SCREEN”, press “F1”. The timer screens can be accessed from the “PRESET SCREEN” by pressing “F3” or “F4”.

Fig. D: “PRESET SCREEN”

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_______________________________________________________ Operation “OPERATION TIMERS SETUP SCREEN” (“TIMERS 1”)

The “TIMERS 1 SCREEN” (Fig. E) is accessed from the “MAIN SCREEN” by pushing function key “F3”. This screen allows access to the “OPERATION TIMERS SETUP SCREEN” where the timers for the breaker idle shutdown, the start-up warning horn, and conveyor run timers can be set. To return to the “MAIN SCREEN” from the “TIMERS 1 SCREEN”, press “F1”. The “PRESETS” and “TIMER 2” screens can be accessed from the “TIMERS 1 SCREEN” by pressing “F2” or “F4”.

Fig. E: “OPERATION TIMERS SETUP SCREEN” (“TIMERS 1”)

“JAM TIMERS SETUP SCREEN” (“TIMERS 2”)

The “TIMERS 2 SCREEN” (Fig. F) is accessed from the “MAIN SCREEN” by pushing function key “F4”. This screen allows access to the “JAM TIMERS SETUP SCREEN” where the timers for the breaker overload preset amps, beaker overload delay, conveyor slow backup, and conveyor slow forward timers can be set. To return to the “MAIN SCREEN” from the “TIMERS 2 SCREEN”, press “F1”. The “PRESETS” and “TIMER 1” screens can be accessed from the “TIMERS 1 SCREEN” by pressing “F2” or “F3”.

Fig. F: “JAM TIMERS SETUP SCREEN” (“TIMERS 2”)

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Operation _______________________________________________________ WARNING! The pressure regulator should never be adjusted above 125 psi. dust suppression system regulator

The dust suppression system regulator (Fig. G) is located below the breaker power unit on the right side of the machine and is used to control the water pressure to the six spray nozzles located in the hose crossover tray over the breaker shaft. The water pressure to the nozzles is monitored by the dust suppression system pressure gauge (Fig. E). To increase pressure, turn the regulator handle in (cw). To decrease pressure, turn the regulator handle out (ccw).

dust suppression system pressure gauge

The dust suppression system pressure gauge (Fig. G) is used to monitor the water pressure to the spray nozzles. The gauge should read between 5 and 125 psi.

dust suppression system strainer

The dust suppression system strainer (Fig. G) is located below the breaker power unit on the right side of the machine and is used to filter particles from the mine water supply. The strainer should periodically be flushed to avoid becoming clogged. To flush the strainer, turn the ball valve handle, located on the branch of the strainer body, 90° in-line with the outlet. Allow to flush for approximately thirty seconds to one minute and then close the ball valve handle.

water solenoid

The water solenoid is located beside the regulator/strainer assembly and is used to control flow of water to the six spray nozzles located in the hosed crossover tray over the breaker shaft. The solenoid is controlled by a pressure transducer located in the hydraulic pressure gauge manifold beside the primary valve bank. When the “MAN/OFF/ AUTO” switch on the starter enclosure is set to “AUTO”, the “TRAM/ OFF/CONV” switch is set to “CONV”, and the hydraulic system pressure reaches 1,200 psi, the solenoid will open and allow water to flow through the water/oil cooler and then to the spray bars.

Fig. G: Dust suppression system regulator and pressure gauge Regulator Gauge

Strainer

Ball valve

Machine wash down port

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_______________________________________________________ Operation Control features The following is a list of control features that could affect the running of the feeder breaker. high temperature switch

low oil cut off switch

belt sequence sensor and pick breaker sensor

There are two high temperature switches for the feeder breaker, one is located onboard the machine at the oil tank and the second one is on the remote power unit at the oil tank. If either one detects a high temperature at either oil tank both motors will be turned off and a light (high temperature) will be illuminated. This light is located on the cover of the electrical enclosure (Fig. 19).

There is one low oil cut off switch for the feeder breaker, it is located onboard the machine at the oil tank. If it detects a low oil issue at the oil tank the motor will be turned off and a light (low oil) will be illuminated. This light is located on the cover of the electrical enclosure (Fig. 19).

These sensors are used to detect the state of the belt conveyor (running or not running) and to detect the state of the pick breaker (turning or not turning). If the selector switch (man-off-auto) is in the “AUTO” position and the conveyor belt that is used to convey the coal from the feeder breaker stops, then both motors will be shut down. If this selector switch is turned to the “MAN” position the belt sequence sensor is not in the circuit. If the pick breaker rotation stops or slows down the pick break sensor will detect this and shut down the motor.

motor overloads (OL1 and OL2)

There is an overload on each of the motors (crusher & pump motor) if either one of these overloads detects an over current condition it will trip and both motors will be stopped. These overloads will also detect a phase unbalance (10%) and will trip and stop both motors.

photo eye pump motor controls

The photo eye sensors are used to control conveyor operation. When the conveyor is started, an adjustable timer with a default value of 2-1/2 minutes is initiated through the PLC. If, during this 2-1/2 minutes, a light is shone on either photo eye sensor for 4 continuous seconds, the conveyor timer is reset and the conveyor will continue running. If this action is not taken, the conveyor will shut down. When the conveyor shuts down, an adjustable timer with a default value of 15 minutes is activated. If, during this 15 minute period, neither photo eye sensor is activated, the breaker motor will shut down. If action is taken, the timers will reset and the conveyor will restart. Both timer settings are adjustable through the touch screen.

Note: A siren will sound upon initial start up and every time the conveyor is restarted after timing out. There will be a start up delay while the siren sounds.

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Operation _______________________________________________________ Conveyor Perform daily start-up procedure (see Start-up procedure in this chapter). The conveyor is controlled by a 200 hp crusher motor. The conveyor may be started utilizing the “TRAM/CONVEYOR” mode and conveyor speed/direction control valves located on the left side of the machine.

There is a timer in the conveyor circuit that only allows the conveyor to run for a preset time then times out. If during this time a start button is engaged the timer is reset back to zero and the timer starts timing again.

In the event the conveyor becomes jammed and it is necessary to reverse the chain, this may be done by changing the conveyor two position control valve from forward to reverse.

IMPORTANT! If it is necessary to reverse the conveyor, it should be jogged only. Running the conveyor in the reverse direction for a period of time with material in the hopper, will jam the conveyor and it will be necessary to empty the machine hopper before the conveyor will restart.

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_______________________________________________________ Operation Daily starting procedure After reading the previous descriptions and locating each control, the operator is ready to operate the feeder breaker. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

WARNING! The machine should not be started if it’s core temperature is below 30° Fahrenheit. If the machine is started at extremely low temperatures pump and pump motor failure could occur.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.  Operate all valve control levers to ensure that they are free and in neutral position.  Check conveyor for any foreign material or objects.  Check that all other personnel are within a safe distance of the machine.

WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the machine.  Apply power to the machine. (Line side of the main circuit breaker)  Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET” position and then to the “ON” position.

Remote tram - Cattron Radio safety features (toggle controller) switch diagnostic mode

In this mode the operator can easily check that all function switches (motion and non-motion) are all fully operational.

WARNING! Electrical power to the feeder breaker MUST BE COMPLETELY ISOLATED to prevent operation under remote control in the switch diagnostic mode. Failure to comply with the above WARNING may result in the undesired operation of the feeder breaker which in turn, could result in SERIOUS INJURY OR DEATH to personnel and damage to the feeder breaker.

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Operation _______________________________________________________ This mode (switch diagnostic) is accomplished by first turning off power to the Toggle Controller using the Power “ON/OFF” toggle switch. Then place the Toggle Controller in a horizontal position (battery door face down). To enable the switch diagnostic mode, re-apply power using the power “ON/OFF” toggle switch while the Toggle Controller is in the horizontal position. The beeper is activated when (1) each non-motion toggle switch changes state, (2) when any motion toggle switch, provided the PTO bar is pressed and held down each time the function switch changes state. If the switches are functioning correctly a beep will be heard each time each switch changes state. To disable the switch diagnostic mode, simply turn the Toggle Controller power to “OFF”, then reapply power to the controller while it is in an upright position. power on self test diagnostics

When the operator first turns the power toggle switch on, a sophisticated self test routine tests the microcomputer and all critical switch inputs to detect unwanted commands in the system. A small speaker beeps two (2) times when the test has been completed satisfactorily.

transmitter/battery charge indicator

The low battery detection circuit is a two stage design. With a good battery, this indicator light flashes green for each burst of transmitted data.

If the battery voltage drops below the normal level, this LED flashes red during each transmission. A beeping sound every ten (10) seconds alerts the operator, when this happens the battery has approximately one hour of operating time remaining. At this point the toggle controller stops transmitting before the voltage drops so low that erratic operation could occur. To change the battery pack simply unlatch and open the gasketed battery door, drop the battery pack in place, close and latch the battery door. There are no wires or connectors to insert into the battery, which improves long-reliability of this unit.

battery saver

If the toggle controller has not been operated for fifteen (15) minutes, a battery management system detects this inactivity and puts the battery into a “deep sleep” mode. To reset the toggle controller, the Power “ON/ OFF” switch must be set to “OFF” and then set to “ON” again.

safety bar

A safety bar is provided to function as an enable device to all motion switches. It is a large full-length switch that is easily and naturally activated by a convenient and comfortable part of the operator’s hand any time he or she activates a motion switch. This push-to-operate (PTO) safety bar electronically disconnects all motion switches when it is released, thus stopping motion commands from these switches.

Remote tram - Cattron Radio safety features (receiver/decoder) The receiving and decoding hardware, along with relay interface, is housed within a NEMA 12 enclosure. The decoder has a two digit display to show system status and act as central test point. The output interface is handled by plug-in relays rated for heavy duty resistive and inductive loads. Each output function relay has two (2) screw terminals, an output fuse, and an LED indicator. The decoder uses a secondary contact on each relay to sense and verify each of the outputs. Upon detection of a fault condition, the OPR relay and all outputs are disabled. This is the Automatic Safety Override function.

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_______________________________________________________ Operation Receiver/Decoder components: EMI/RFI shielded chassis (gold box)

This enclosure, commonly known as the “gold box” due to its gold anodized coating, contains the receiver and decoder circuit boards along with the power supply for the entire receiver/decoder.

relay output boards

The relay output boards provide a common connection point for all user connections to the output relays.

receiver

The receiver contains the electronic circuits that perform the radio reception functions. Several LEDs mounted on the receiver circuit board indicate the status of the radio communications link with the controller.

decoder

The decoder contains the electronic circuits that control system functions. This includes checking the address of incoming signals, interpreting the controller’s commands, and controlling the status of the output relays.

antenna

The antenna provides radio reception for the receiver/decoder. If the mounting location of the receiver/decoder does not provide good radio reception, optional remote mount antennas are available.

power supply

The power supply inside the gold box provides all required power for the receiver/decoder. The power supply requires 115 vac at 50 -60 hz.

Safety considerations: CATTRON-THEIMEG believes that to safely operate any remote controlled equipment, the overall system needs to be configured so that movement or operation of the equipment will take place only when the device is commanded to move or operate. In keeping with this philosophy “NO COMMAND, NO MOVEMENT” CATTRON-THEIEMG has designed a radio remote control system with the following safety and security features.

Unique address code

Each controller and receiver/decoder pair is configured with a unique address code so that the equipment will respond only to the controller whose address code matches that of the decoder.

power “ON/OFF” switch

The controller has a power “ON/OFF” toggle switch that must be set to “ON” in order to send commands to the receiver/decoder. If the power “ON/OFF” switch is set to “OFF”, the decoder will remove all commands from the controlled machinery, stopping all movement.

operator relay (OPR)

The operate (OPR) output relay shall be wired to control a userprovided electro-magnetic power contactor. This contactor opens and closes the main electrical supply circuit to the controlled device (motor).

automatic safety override

The Automatic Safety Override (ASO) function continually monitors all selected decoder directional relay outputs. If a directional relay closes without command from the controller, the OPR relay immediately deenergizes. This prevents any movement of the controlled machine without command from the controller.

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Operation _______________________________________________________ push-to-operate (PTO) bar

This easily activated switch bar MUST BE RELEASED when power is turned on, then pressed and held to enable the motion switch functions.

Releasing the PTO during normal operation causes the controller to send neutral commands to the receiver or decoder.

Principle of operation:

radio remote control

The target receiver/decoder is controlled by a remote toggle controller.

Provided the correct address and frequency is programmed into the controller, the receiver/decoder receives signals from the controller using a UHF radio link. The signal is picked up by the antenna and passed on to the receiver. If the signal is the correct frequency and passes all required data tests, the signal is passed on to the decoder.

The decoder compares the address code of the signal to its own address code. If the signal’s address code does not match its address code, it is ignored and a message is displayed on a system status display located in the receiver/decoder unit. If the address code is correct, the decoder processes the message and energizes and de-energizes the appropriate relay mounted on the relay output boards. The relay output boards provides a mounting location for all the relays in the system. The relays control the high current loads required by the controlled machine. Mounted next to each relay is a fuse to provide over current protection. All remote wiring for the output relays takes place at the relay output boards. During operation, the microprocessor on the decoder board resets multiple watchdog timer circuits whenever valid messages are received and decoded. If the microprocessor fails to reset the watchdog timers, the timer circuits shut down and de-activate all relay outputs. The decoder microprocessor requires continuously valid transmitted signals to be received and decoded or all relay outputs functions will be de-activated.

System status display and LED indicators: A two character LED display is mounted on the decoder circuit board. A clear plastic window in the cover of the gold box provides for viewing of the display without removing the cover.

LED indicators - relay status (relay output boards) receiver power (receiver board)

The red relay status LEDs energize whenever the corresponding relay is energized.

This red LED indicates the presence of DC power on the receiver circuit board.

carrier detect (receiver board)

The green Carrier Detect LED on the receiver circuit board indicates that the receiver is receiving an RF signal.

data (receiver board)

This yellow LED on the receiver circuit board indicates that the message received contains data.

Q-SYNC (receiver board)

This orange LED on the receiver circuit board indicates that the receiver has synchronized with the incoming message.

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_______________________________________________________ Operation vco lock (receiver board)

This red LED is located on the receiver circuit board underneath the EMI/RFI shield. This Led lights when the receiver frequency synthesizer is unable to lock onto the required frequency.

IMPORTANT! During normal operation the Carrier Detect, Data, and Q-Sync LEDs will flash when a signal is received from the controller. The flashing will match the flashing of the green transmit LED on the controller.

Fig. 14: Radio remote transmitter

2 1 3

4

5

6

7

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Push to operate bar (deadman switch) Battery good indicator Battery low indicator Left tram Right tram Left lift cylinder Right lift cylinder Tilt cylinder Pump (breaker motor) start/stop Emergency stop Radio remote power on/off Reset

9 8 11

10

12

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Operation _______________________________________________________ “AUTO” mode starting procedure The feeder breaker is normally operated in “AUTO” mode. While in “AUTO” mode, the belt sequence switch is active (the outby belt must be running for the feeder breaker to run).

After reading the previous descriptions and locating each control, the operator is ready to operate the feeder breaker. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

WARNING! The machine should not be started if it’s core temperature is below 30° F. If the machine is started at extremely low temperatures pump and pump motor failure could occur.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.

1. Operate all primary and secondary valve bank (if equipped) control levers to ensure that they are free and in neutral position.

2. Position the primary valve bank handle neutral start lock guard over the valve handles so that they cannot be operated. Make sure the magnetic contactors are fully seated and are in direct contact.

IMPORTANT! The machine will not start unless all valve control levers on the primary valve bank are in neutral position and the guard is fully closed, engaging the magnetic switch.

3. Check conveyor for any foreign material or objects.

4. Check that all other personnel are clear of the machine.

WARNING! Before start-up, check the conveyor for foreign material or objects and check that all other personnel are clear of the machine.

5. Set the main circuit breaker using the lever located on the door of the starter enclosure by first moving the lever to the “RESET” position and then to the “ON” position.

6. Turn the “MAN/OFF/AUTO” selector switch located on the cover of starter enclosure to the “AUTO” position, Turn the TRAM/OFF/ CONV selector switch to “CONV”, and turn the FWD/OFF/REV selector switch to “FWD”.

7. Push the “ACKNOWLEDGE ALARMS” button once to engage the MCR. Press the button a second time to clear any faults.

8. Engage the “START BREAKER” pushbutton located on the cover of the starter enclosure. An alarm will sound for a preset amount of time and then the breaker motor will start.

9. The conveyor chain can be started either by the “Conveyor start” push button on the electrical case, or by the photo eye senors.

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_______________________________________________________ Operation “MANUAL” mode starting procedure If the machine needs to be operated while the outby belt is off (belt sequence switch by-passed), start the machine in “MANUAL” mode.

After reading the previous descriptions and locating each control, the operator is ready to operate the feeder breaker. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.

WARNING! The machine should not be started if it’s core temperature is below 30° F. If the machine is started at extremely low temperatures pump and pump motor failure could occur.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.

1. Operate all primary and secondary valve bank (if equipped) control levers to ensure that they are free and in neutral position.

2. Position the primary valve bank handle neutral start lock guard over the valve handles so that they cannot be operated. Make sure the magnetic contactors are fully seated and are in direct contact.

IMPORTANT! The machine will not start unless all valve control levers on the primary valve bank are in neutral position and the guard is fully closed, engaging the magnetic switch.

3. Check conveyor for any foreign material or objects.

4. Check that all other personnel are clear of the machine.

WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel clear of the machine.

5. Set the main circuit breaker using the lever located on the door of the starter enclosure by first moving the lever to the “RESET” position and then to the “ON” position.

6. Turn the “MAN/OFF/AUTO” selector switch located on the cover of starter enclosure to the “MAN” position, Turn the TRAM/OFF/ CONV selector switch to “CONV”, and turn the FWD/OFF/REV selector switch to “FWD”.

7. Push the “ACKNOWLEDGE ALARMS” button once to engage the MCR. Press the button a second time to clear any faults.

8. Engage the “START BREAKER” pushbutton located on the cover of the starter enclosure. An alarm will sound for a preset amount of time and then the pick break motor will start.

The conveyor will start after a pre-determined time period has elapsed.

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Operation _______________________________________________________ Shutdown procedures 1. Allow the machine to run until the hopper is empty. Continue to run the machine until all material that has been carried back into the return line has been cleaned out.

IMPORTANT! If material is very wet or sticky, it is recommended that the return line be flushed with water and the conveyor be allowed to run and clean out the return line before shutting the machine down.

To shutdown the feeder breaker from the starter enclosure: 2. Engage the “PICK BKR STOP” pushbutton located on the starter enclosure to stop the breaker motor.

3. Move the circuit breaker reset switch to the “OFF” position .

4. Move the “TRAM/OFF/CONV” switch to the “OFF” position.

5. Move the “MAN/OFF/AUTO” switch to the “OFF” position.

To shutdown the feeder breaker from the radio remote: 2. Move the “PUMP” start/stop toggle switch to the “STOP” position to stop the breaker motor.

3. Move the radio remote “ON/OFF” toggle switch to “OFF”.

4. Move the circuit breaker reset switch, located on the starter enclosure, to the “OFF” position.

5. Move the “TRAM/OFF/CONV” switch located on the starter enclosure to the “OFF” position.

6. Move the “MAN/OFF/AUTO” switch located on the starter enclosure to the “OFF” position.

Emergency stop procedures: The machine can also be shutdown in emergency situations using: 1. Either panic strip 2. The “EMERGENCY STOP” button on the starter enclosure 3. The “EMERGENCY STOP” button on the radio remote, or Activating any one of the emergency stop devices will open the master control relay, “MCR”. Power will still be on the machine and the machine can be restarted using normal starting procedures.

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_______________________________________________________ Operation remote control batteries

Battery Options The remote control is battery powered. There are two different battery pack options: 

Disposable Alkaline Battery Pack (standard—machine ships with this battery pack) - provides approximately 75 hours of life (based on continuous transmission).



Rechargeable Ni-Cad Battery Pack (optional) - provides approximately 23 hours of life (based on continuous transmission).

Battery Replacement When the “TRANSMIT/LOW BATTERY” LED begins to flash red, there is approximately one hour of continuous operation remaining.

To replace the battery pack: 1. Set the remote control power switch to “OFF”.

2. Unlatch and open the battery door and remove the battery pack from the tray.

3. Insert a fully charged battery pack into the remote control. Ensure that the contacts on the underside of the battery pack align with the corresponding contacts on the battery tray.

4. closs and latch the battery door.

5. Move the remote control power switch to the “ON” position. The “TRANSMIT/LOW BATTERY” LED should flash yellow and two quick beeps will be heard.

6. Operate a non-motion function such as the lights. The “TRANSMIT LOW/BATTERY” LED should flash green, indicating the remote control is fully operational.

Battery Charging (optional) The Ni-Cad battery pack is rechargeable using the appropriate charging station. Contact your Cat Service Representative for battery and battery charging options.

To recharge: 1. Remove the Ni-Cad battery pack from the radio remote.

2. Connect the charger to a standard 120VAC outlet.

3.

Insert the battery pack into the charger. The battery charger red “CHARGING” LED will be lit until the end of the charging process.

When fully charged, the green “FULLY CHARGED” LED will illuminate.

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Operation _______________________________________________________ Tramming using the hydraulic control levers 1. Turn the “FWD/OFF/REV” selector switch located on the cover of the starter enclosure to the “OFF” position.

2. Turn the “TRAM/OFF/CONV” selector switch located on the cover of the starter enclosure to the “TRAM” position.

3. Turn the “MAN/OFF/AUTO” selector switch located on the cover of starter enclosure to the “MAN” position.

4. Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET” position and then to the “ON” position.

5. Push the “ACKNOWLEDGE ALARMS” button once to engage the MCR. Press the button a second time to clear any faults.

6. Engage the “START BREAKER” pushbutton located on the cover of the starter enclosure to start the pump motor.

7. Lift up the neutral start valve handle guard all the way back so that the guard will not fall on the operator’s hands.

The machine can now be trammed.

Tramming using the radio remote 1. Turn the “FWD/OFF/REV” selector switch located on the cover of the starter enclosure to the “OFF” position.

2. Turn the “TRAM/OFF/CONV” selector switch located on the cover of the starter enclosure to the “TRAM” position.

3. Turn the “MAN/OFF/AUTO” selector switch located on the cover of starter enclosure to the “OFF” position.

4. Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET” position and then to the “ON” position.

5. Remove the tram valve handles from the primary valve bank.

6. Position the neutral start guard over the primary valve bank.

7. Push the “ACKNOWLEDGE ALARMS” button once to engage the MCR. Press the button a second time to clear any faults.

8. Move the radio remote “POWER” button to the “ON” position. Listen for 2 beeps.

9. Press the “RESET” button on the radio remote. Listen for 2 beeps.

10. Press and hold the push to operate (deadman) switch on the top of the radio remote.

11. Move the “PUMP START” button on the radio remote to the “START” position.

12. While holding the push to operate switch in, tram the machine using the left and right “TRAM” switches.

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_______________________________________________________ Operation Conveyor forward 1. Start the machine in either “AUTO” or “MAN” mode (see Starting procedures in this chapter).

2. Turn the “TRAM/OFF/CONV” selector switch located on the cover of the starter enclosure to the “CONV” position.

3. Push the “START BREAKER” button to start the breaker motor.

4. Turn the “FWD/OFF/REV” selector switch located on the cover of the starter enclosure to the “FWD” position.

It is important to note the following concerning the operation of the conveyor in the forward direction: –

The current of the breaker shaft motor is constantly monitored by the PLC. If the current remains below 100% of the full load current (FLA), the conveyor will continue to run at the set speed.

–

If the current increases above 125% FLA and stays at that level for three seconds, the PLC will assume there is a conveyor jam. The PLC will try to clear the jam by stopping the conveyor, running it in reverse for three seconds at 10% speed, and then running it forward for ten seconds at 25% speed.

–

If the current at this point is still above 125% FLA, the conveyor will repeat the above reverse/forward sequence for a second time.

–

If the current at this point is still above 125% FLA, the conveyor will repeat the above reverse/forward sequence for a third time.

–

If the current at this point is still above 125% FLA, the machine will shutdown and the display will read “BIG JAM”. The conveyor will need to be cleared before operation resumes.

–

If the current drops below 125% FLA at any time during the three reverse/forward sequences, the speed of the conveyor will ramp back up to the set speed.

5. Press the “START CONVEYOR” button on the front of the starter enclosure or the “START” button on either one of the remote pushbutton stations. A siren will sound warning that the conveyor is starting. The siren will sound any time the conveyor has timed out and is restarted.

Notes: 1. The PLC controls the speed of the conveyor based upon the amperage monitoring of the breaker motor. There are three preset forward conveyor speeds that are, by default, 20%, 50%, and 100%. These speeds are adjustable and can be reset to suit the operating conditions.

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Operation _______________________________________________________ 2. The conveyor operating time is controlled by a timer that is reset by pushing a start button on the starter enclosure or either remote pushbutton station or shining a light on the photo eye sensor mounted above the hopper. If the timer is not reset within the allotted time, the conveyor will stop.

3. There is a second adjustable timer that will shut down the electric motor if, within a preset amount of time, there is no conveyor activity. If, within this amount of time, the conveyor is idle and a conveyor start button is pushed, the PLC will allow the pump to ramp back up to full flow.

Conveyor reverse IMPORTANT! If it is necessary to reverse the conveyor, it should be jogged only. Running the conveyor in the reverse direction for even a short period of time with material in the hopper may cause the conveyor to jam. It will then be necessary to empty the machine hopper before the conveyor can be restarted.

Operating the conveyor in reverse 1. Turn the “FWD/OFF/REV” selector switch located on the cover of the starter enclosure to the “REV” position. The conveyor chain will now run in reverse at 25% full speed as long as the switch is in the “REV” position. Note: the conveyor should not be run in reverse for extended periods; only jog the conveyor when in reverse.

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_______________________________________________________ Operation Control system operating parameters The following parameters affect the operation of the machine as indicated: Breaker under-speed If the breaker under-speed sensor does not pick up within five seconds of the breaker motor starting, the control system will shutdown the breaker motor and a “BREAKER UNDERSPEED ALARM” will be displayed.

Breaker motor overload If the breaker motor current exceeds a preset value, the control system will shutdown the machine and the “BREAKER MOTOR OVERLOAD ALARM” will be displayed.

Breaker idle shutdown timer If the conveyor is running and no cars dump on the conveyor within a 21/2 minute time period (adjustable within the PLC), the control system will shutdown the conveyor motor.

If no conveyor function is engaged on a running machine within a 15 minute time period (adjustable within the PLC), the control system will shutdown the breaker motor.

High oil temperature If the hydraulic oil temperature exceeds a preset value of 165° F, the control system will shutdown the machine and the “HIGH OIL TEMPERATURE ALARM” will be displayed.

Low oil level If the hydraulic oil level falls below a preset level for more than three seconds, the control system will shutdown the machine and the “LOW OIL LEVEL ALARM” will be displayed.

High oil pressure If the hydraulic oil pressure exceeds 4,800 psi for more than three second, the control system will shutdown the machine and the “HIGH OIL PRESSURE ALARM” will be displayed.

Low pump suction If the vacuum in the main suction line in the hydraulic oil tank is less than two psi for three seconds, the control system will shutdown the machine and the “LOW PUMP SUCTION ALARM” will be displayed.

The vacuum transducer is located in the suction line fitting of the pump suction port.

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Operation _______________________________________________________ Pressure transducer If the hydraulic system pressure transducer reads greater than 1,200 psi (adjustable within the PLC), the water solenoid is turned on and the water sprays are activated. This transducer also activates the high oil pressure alarm and is located in the gauge manifold at the main operator’s station.

Tram control magnet switch If the neutral start switch (see Controls and Indicators section of this chapter) is not in place when the pump motor is started, the control system will not allow the motor to start and the “TRAM CONTROL MAGNET SWITCH ALARM” will be displayed.

Emergency stop If the master control relay is opened by activating an emergency stop device, the machine will shutdown and the “EMERGENCY STOP ALARM” will be displayed.

Big jam shutdown If the machine fails to clear a jam after three attempts (see Conveyor operation in this section), the control system will shutdown the machine and the “BIG JAM SHUTDOWN ALARM” will be displayed.

Conveyor speed There is a mag pulse sensor located on the head shaft that counts how many revolutions per minute the head shaft turns. This information is sent to the PLC where it is converted to feet per minute (fpm) and displayed as conveyor speed.

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________________________________________________ Electrical system Electrical system The following pages contain a brief description of the major electrical components and assemblies that are on the feeder breaker.

The machine receives electrical power through a heavy-duty trailing cable. Be sure that the box connector is correctly identified and is securely connected; also check that the cable entrance is in good mechanical condition. Walk along the trailing cable from the power center to the feeder breaker and check the condition of the trailing cable. Give special attention to points most apt to cause damage, such as corners, intersections, and where cable may be run over by moving equipment.

Never use trailing cable with exposed wires or splices which heat up or spark under load.

WARNING! This section is intended only to familiarize the user with the major electrical components of the feeder breaker. All electrical maintenance should be performed only by a qualified electrician with the knowledge of the function of the components involved.

WARNING! Before removing the cover from the starter enclosure and attempting any maintenance or troubleshooting on the machine, the main power must be disconnected and locked out at the main power center.

Fig. 15: Major electrical component locator Starter enclosure

Remote transmitter

Radio receiver

Electric motor 200 HP

Tape switch

Emergency stop pull cord switch

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Electrical system _________________________________________________ Fig. 15: Major electrical component locator

10

7

1

3 4

9 2

6

5 6 5

8

11

1. Breaker shaft motor 2. Breaker shaft underspeed sensor 3. Starter enclosure 4. High temp switch

5.

6.

7.

8.

9.

Photo cell (2) 10. Headshaft tachometer Panic strips 11. Emergency pull cord switch Radio control box Photo eye control box Low oil switch (inside oil tank)

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________________________________________________ Electrical system Fig. 16: Electrical layout

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Electrical system _________________________________________________ Starter enclosure The starter enclosure (Fig. 17) located on the left hand side of the discharge end of the machine houses the primary electrical control components.

On the cover of the starter enclosure is the electrical switches . These are labeled and control the start and stop functions for the electric motor. Also, located on the cover is the selector handle for turning the main circuit breaker “ON” and “OFF”. This allows the main power to the machine from the section power supply to be disconnected.

WARNING! Before removing the cover from the starter enclosure and attempting any maintenance or troubleshooting on the machine, the main power must be disconnected and locked out at the main power center.

Fig. 17: Starter enclosure components Swing panel Door components

Circuit breaker

Back wall components

Overload relay

Motor Contactor

Control Transformer

Current Transducer

Current Current Transformer Transformer

Back wall components

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________________________________________________ Electrical system Fig. 17: Starter enclosure components (continued) CompactLogix power supply

Power supply

CompacyLogix with Ethernet & 64 MB flash memory card

8 channel analog input module 2 channel analog input module

120VAC input module module

TAC monitor 8 point output module

5 port Ethernet switch

24VDC dual switching repeater

3 amp relays (x7) 12 amp time delay fuse (x6)

Multi-circuit terminal block

Multi-circuit terminal block (behind offset panel)

Swing panel components

Circuit Breaker (CB1)

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Electrical system _________________________________________________ Major electrical components (Reference Fig. 15 and 16) electric motor

The machine has a (200 hp 950 VAC non/X/P) electric motor that drives the pick breaker and hydraulic pump for the feeder breaker.

emergency stop pull cord switch

The emergency stop pull cord switch is located on the receiving end of the machine. To actuate the switch, pull the cord that is across the conveyor. When the cord is pulled, all machine functions are shutdown immediately.

belt sequence sensor and pick breaker sensor

high temperature switch

low oil cut off switch

panic strip (s)

These sensors are used to detect the state of the belt conveyor (running or not running) and to detect the state of the pick breaker (turning or not turning). If the selector switch (“REGULAR/OFF/ REMOTE”) is in the “REGULAR” or “REMOTE” position and the conveyor belt that is used to convey the coal from the feeder breaker stops, the motor will be shut down. If the pick breaker rotation stops or slows down the pick break sensor will detect this and shut down the motor.

There is a high temperature switch for the feeder breaker located onboard the machine at the oil tank. If it detects a high temperature at the oil tank the motor will be shut down and a light (high temperature) will be illuminated. This light is located on the cover of the electrical enclosure.

There is a low oil cut off switch for the feeder breaker located onboard the machine at the oil tank. If it detects a low oil issue the motor will be shut down and a light (low oil) will be illuminated. This light is located on the cover of the electrical enclosure.

One panic strip is located at the operator’s station on the left hand side of the machine and the other is located on the right side above the crawler assembly. Striking with a small amount of force will actuate either of the panic strips. The panic strip (s) is used to break the control circuit in emergency situations. When either of the panic strips are struck, all machine functions are shutdown immediately.

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________________________________________________ Hydraulic system Hydraulic system The following pages contain a brief description of the hydraulic components and assemblies that are on the feeder breaker.

The primary hydraulic system for this machine has been designed to provide hydraulic power for the conveyor drive motor, tram motors, tilt cylinders and lift cylinders.

WARNING! This section is intended only to familiarize the user with the hydraulic components of the feeder breaker. All hydraulic maintenance should be performed only by a qualified technician with the knowledge of the function of the components involved.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

Major hydraulic components (Reference Fig. 18) hydraulic oil tank

The hydraulic oil tank located on the left hand side of the machine has a 175 gallon capacity and is equipped with a oil level sight glass, high temperature switch and low oil level switch.

open loop load sense pump

The open loop load sense pump located within the power unit supplies all hydraulic power for the conveyor, tram drive motors, lift cylinders, tilt cylinders, power fill functions.

gear pump

The gear pump located within the power unit supplies hydraulic power used to provide cooling flow for the load sense pump and both conveyor drive motors.

valve bank

The valve bank located on the left hand side of the machine is used to control the machines conveyor function, tilt, lift, tram and power fill functions. All sections of the valve bank are spring return (self centering) except for the power fill section which is detented.

tank fill pump

The tank fill pump is located on the left hand side of the discharge section of the machine on top of the oil tank and is used to replenish fluid to the hydraulic tank from an external source. The pump is capable of delivering approximately 10 gallons of fluid per minute.

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Hydraulic system _________________________________________________

tilt hydraulic cylinders

lift hydraulic cylinders

The tilt hydraulic cylinders are located at the end of the crawler under the hopper on each side of the machine and are used to adjust the discharge height of the machine. Both cylinders are controlled by one section of the valve bank.

The lift hydraulic cylinders are located at the pivot point of the crawler on each side of the machine and are used to adjust the ground clearance of the machine. Each cylinder is individually controlled by separate sections of the valve bank.

WARNING! The tilt and lift hydraulic cylinders have counterbalance cartridges which serve as load holding valves. Do not replace these cylinders with different style cylinders or the machine may fall. The machine could be damaged or you or other personnel could be seriously injured or killed by the falling machine.

The machine is equipped with lock pins that should be installed when the unit is not being moved. Pin are located near the lift cylinders on both sides of the machine.

tram motors

conveyor motors

oil/water heat exchanger

The tram motors are located to the inside of each crawler assembly and are used to supply power to the torque hubs for tramming operations. Each tram motor is individually controlled by separate sections of the valve bank.

The conveyor motors are located on the left & right side of the head shaft and are radial piston motors that receives hydraulic fluid from the hydraulic pump. The motor is controlled from the two position conveyor direction control valve.

The heat exchanger located on the left side of the machine is used to remove heat from the hydraulic circuit prior to dumping into tank.

pressure filter

The pressure filter located on the left hand side of the of the discharge end of the machine is used to filter fluid on the pressure side of the circuit.

return filter

The return filter located on the left hand side of the of the discharge end of the machine is used to filter fluid on the return side of the circuit.

tank fill filter (optional)

system function pressure gauge (6,000 psi)

The tank fill filter located on top of the oil tank is used to filter fluid that is being pumped with the power fill system from an external source to the hydraulic oil tank.

The system function pressure gauge is a high pressure gauges (6,000 psi) located to the right of the valve bank control levers. The gauge give the operator a constant reading of the pressure of the function that is being engaged.

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________________________________________________ Hydraulic system Fig. 18: Hydraulic component locator feeder breaker 7

7 2

3

1

4 10

11 9 12 6 6

8

13

14 14

5

5

1.

2.

3.

4.

5.

6.

Return filter Pressure filter Piggyback gear pump Open loop load sense pump Frame lift cylinder (2) Frame tilt cylinder (2)

7.

8.

9.

10.

11.

12.

Conveyor motors Valve bank Hydraulic power fill ball valve Air / oil heat exchanger Hydraulic oil tank Hydraulic oil level/temperature

13. System pressure gauge 14. Tram motor (2)

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Hydraulic system _________________________________________________ Fig. 19: Hydraulic schematic feeder breaker

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___________________________________________ Mechanical assemblies Mechanical assemblies The following pages contain a brief description of the major mechanical assemblies that are on the feeder breaker.

WARNING! This section is intended only to familiarize the user with the major mechanical assemblies of the feeder breaker. All mechanical maintenance should be performed only by a qualified technician with the knowledge of the function of the assemblies involved.

Crawler assembly (s) The feeder breaker is trammed by two (2) hydraulically driven crawlers (Fig. 20); one is located on each side of the machine. The complete drive assemblies are housed in crawler frames which enclose, guide and support the tram components. Each tram drive is independently controlled by the operator for moving the machine forward, backward and for making turns.

The crawlers on the machine are hydraulic driven through torque hub gear reducers. Attached to the torque hub is a single sprocket that engages the crawler tracks directly. The crawler track loops around the take-up roller assembly located on the opposite end of the crawler assembly. The idler assembly, along with a grease take-up is used to adjust the tension on the crawler tracks. (See Maintenance section in this chapter for Crawler track adjustment procedure) Fig. 20: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

Torque hub Take-up cylinder & shims Take-up roller assembly

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Mechanical assemblies ____________________________________________ Conveyor chain The feeder breaker is equipped with a conveyor chain assembly (Fig. 21) that carries mined material along the conveyor trough from the receiving section and out through the discharge end. The conveyor chain is made up of one basic chain assembly, which repeats sequentially along the entire chain loop. (See Maintenance section in this chapter for Conveyor chain maintenance) Fig. 21: Conveyor chain components

Roll pin Chain link section

Flight bar

Grease take-up The feeder breaker is equipped with two (2) conveyor chain grease take-up assemblies (Fig. 22) that provide ease of adjustment for the conveyor chain. The take-up assemblies provide constant tension on the tail shaft around which the conveyor chain rides at the receiving end of the machine. (See Conveyor chain adjustment in this chapter) Fig. 22: Grease take-up main components Stop valve (2)

Grease manifold

Grease fitting (2)

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___________________________________________ Mechanical assemblies Head shaft The feeder breaker is equipped with a head shaft (Fig. 23 and 24) located on the discharge end of the conveyor. The head shaft is driven from the left hand side via a hydraulic motor that is directly connected to the head shaft.

Fig. 23: Head shaft main components Bearing (2)

Key (2)

Set screw (2)

Head shaft Sprocket (2)

Fig. 24: Conveyor torque arm and hydraulic motor

Torque arm

Coupling

Hydraulic motor

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Mechanical assemblies ____________________________________________ Power unit The power unit drives the hydraulic pump (s) and pick breaker reducer (Fig. 25). It consists of a 200 HP electric motor, coupled to a reducer, hydrostatic pump and piggyback gear pump. The power unit has been assembled as a unit and can be removed as a unit or as individual components.

Fig. 25: Power unit main components Taperlock bushing Reducer Torque limiter Motor (200 HP)

Coupling

Coupling Hydrostatic pump

Companion flange Connecting tube Connecting tube Gear pump

Tail shaft The feeder breaker is equipped with a tail shaft (Fig. 26) located on the receiving end of the conveyor. The tail shaft is an idler shaft that is driven by the tension of the conveyor chain. There is a slide plate arrangement attached to the tail shaft, which fills the gap between the receiving impact plate and the shaft.

Fig. 26: Tail shaft components Set screw (2)

Slide plate

Adapter (2)

Key (2)

Sprocket (2)

Head shaft

Bearing (2)

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___________________________________________ Mechanical assemblies Breaker assembly The breaker assembly (Fig. 27) on the machine has a 25” (635 mm) pick circle with a 5 point star arrangement. It has a 8” shaft diameter turned down to 6 3/16” (157 mm) thru the bearings. The breaker has a under speed sensor mounted on the left hand side that will shutdown the machine should the breaker be stalled due to a jam.

NOTICE! In the event that a sudden jam occurs which could damage the power unit, the breaker is protected by a shear pin.

Fig. 27: Breaker assembly main components Flange Seal housing Bearing retainer Pick (30) End cap Breaker shaft Side plate Bearing backing ring Bearing housing Bearing

Bearing

Side plate Bearing backing ring Seal housing

Bearing retainer Bearing housing Under speed sensor

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Mechanical assemblies ____________________________________________

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____________________________________________________ Maintenance Instructions on the maintenance of the feeder breaker Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine.

In particular, observe the safety instructions in chapter 2 “Your safety”.

Important notes Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

■

Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original spare parts when replacing components.

■

All electrical work must be supervised and inspected by a certified electrician.

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this guide.

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power. The circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

■

Test the controls to ensure that the unit will not move.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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Maintenance _____________________________________________________ ■

During maintenance or servicing, if either of the tram drives are to be run, the side that is to be run must be jacked clear of the ground and securely blocked.

■

Do not perform maintenance on either boom while there is a load resting on the hydraulic cylinder. Booms must be securely blocked if maintenance is to be performed with either boom in the raised position.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■

Cleanliness can not be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

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____________________________________________________ Maintenance Lubrication and inspection Maintenance of the feeder breaker includes: ■

Lubrication of the machine in accordance with the lubrication schedule.

■

Inspection of the machine for faults and proper function.

■

Inspection for wear parts.

Lubrication IMPORTANT! The feeder breaker is equipped with a central lubrication system that allows several lubrication points to be lubricated from one central point. See the following section.

Central lubrication system The central lubrication manifold (Fig. 28) is located on the left hand side of the receiving end of the feeder breaker. This allows the following to be easily lubricated from a central point; head shaft, breaker shaft and tail shaft.

Fig. 28: Central lubrication Note: Outboard bearing port used only if applicable on machine.

Tail shaft

Outboard bearing

Breaker

Head shaft

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Maintenance _____________________________________________________ NOTICE! All hydraulic filter elements should be changed after one week of the initial start-up of machine or pre-mature wear of hydraulic components could occur.

Table 1: Lubrication and maintenance schedule (feeder breaker) Item

Description

Places

Lubricant

Every 8 hours of operation 1

Head shaft bearings

2

Cat Prime Application Grease

2

Breaker bearings

2

Cat Prime Application Grease

3

Tail shaft and slide tube bearings

4

Cat Prime Application Grease

4

Hydraulic oil level (check)

1

Cat Hydo Advanced 20

7

Return filter (check)

1

8

Pressure filter (check)

1

9

Bits (breaker)

Inspect

Weekly 10

Crawler track take-up bearings

2

Cat Prime Application Grease

11

Conveyor chain tension

1

12

Fasteners (nuts, bolts and screws)

Inspect

13

Electrical cables, conduits and glands

Inspect

14

Hydraulic hoses and connections

Inspect

15

Hydraulic system pressures

Check

16

Tram reducer (s) (check oil level)

2

80W-90

17

Breaker reducer (Check)

1

Cat Compactor Oil 220

18

Dust system strainer (Check)

1

Every 2 weeks 21

Return filter (change)

1

22

Pressure filter (hydrostatic) (change)

1

Monthly 23

Optional Power fill filter (change)

1

24

Conveyor tilt and lift cylinders

8

Cat Prime Application Grease

25

Crawler anchor pin (s)

2

Cat Prime Application Grease

Every 3 months 26

Electric motor

2

Cat Ball Bearing Grease

27

Breaker reducer

2

Cat Prime Application Grease

28

Torque limiter (check clutch wear)

1

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____________________________________________________ Maintenance Table 1 Continued: Lubrication and maintenance schedule (feeder breaker) Item

Description

Places

Lubricant

1

Cat Compactor Oil 220

Every 2500 hours 29

** Breaker reducer (Change) Every 6 months

30

Hydraulic oil tank (change)

1

Cat Hydo Advanced 20

31

Tram reducer (change oil)

2

80W-90

** Change breaker reducer oil after first 500 hours of operation and every 2500 hours afterwards.

Fig. 29: Lubrication chart (feeder breaker)

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Maintenance _____________________________________________________ Specific lubrication and maintenance procedures Every 8 hours of operation: head shaft bearings

tail shaft and slide tube bearings

breaker bearings

Lubricate the feeder breaker head shaft bearings through the grease fittings located on the central lubrication panel (Fig. 30) located on the left side of the receiving section. Pump grease into the two (2) fittings until new grease can be observed coming out of the bearings.

Lubricate the feeder breaker tail shaft and slide tube bearings through the grease fittings located on the central lubrication panel (Fig. 30) located on the left side of the receiving section. Pump grease into the three (3) fittings until new grease can be observed coming out of the tail shaft and bearings.

Lubricate the breaker bearings through the grease fittings located on the central lubrication panel (Fig. 30) located on the left side of the receiving section. Pump grease into the fittings until new grease can be observed coming out of the bearing return lines.

Fig. 30: Central lubrication panel

Central lubrication panel

hydraulic oil tank

Check the feeder breaker hydraulic oil level by looking at the sight glass located on the side of the oil tank (Fig. 31). The oil level should not be allowed to drop below the bottom of the sight glass. If the hydraulic oil level is low, add oil via the power fill system.

Fig. 31: Hydraulic tank oil level

Oil level sight glass

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____________________________________________________ Maintenance

return filter

Check the feeder breaker return filter’s pop-up style dirt alarm (Fig. 32) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

pressure filter

Check the feeder breaker hydrostatic pressure filter’s pop-up style dirt alarm (Fig. 32) located on the top of the filter housing. If the alarm indicates the filter element is dirty, replace element.

breaker bits

Check the breaker bits to see if they will rotate in their holders and for damaged or missing bits (Fig. 32). The bits may be inspected by looking into the receiving end of the machine. If bits need to be replaced, see Bit replacement in this chapter.

Fig. 32: Filter and breaker bit location Pressure filter

Return filter

Breaker bits

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Maintenance _____________________________________________________ Weekly crawler track take-up bearings

Lubricate the right and left hand crawler track take-up bearings (Fig. 33). The fittings (one per side) may be reached through the slot in the end of the crawler frame on the outside of each crawler. Pump grease into the fitting until new grease can be observed coming out of the bearings.

Fig. 33: Crawler track take-up lubrication

Crawler take-up grease fitting location (Typical both sides)

conveyor chain tension

fasteners

electrical cables, conduits and glands hydraulic hoses and fittings

Check the conveyor chain tension. With the machine running, visually inspect tail shaft to ensure shaft is turning and conveyor shaft is not sliding across tail shaft. If adjustment is necessary, see Conveyor chain adjustment procedure in this chapter.

Due to the machine being subjected continual shock loading and vibration, close attention to all mounting bolts and screws is required. Loose fasteners will cause premature wear and failure to bearings, couplings, etc. Inspect and tighten as required the following fasteners: ■

head shaft bearing bolts

■

breaker shaft side plate bolts

■

conveyor drive motor mounting bolts

■

tail shaft retainer hold down bolts

■

all cover and guard retaining bolts

Visually inspect all electrical cables and glands for signs of wear or damage.

Visually inspect all hydraulic hoses and fittings for signs of wear, damage or leakage. This inspection should be performed with machine running.

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____________________________________________________ Maintenance

hydraulic system pressure (s)

Check the hydraulic system pressure (s) by visually looking at the pressure gauges. Refer to the hydraulic schematic in your parts manual for correct pressure (s).

Check the oil level in both tram reducer torque hubs (Fig. 35): tram reducer (s)  Oil level/fill plug should be at the 3 o’clock and 12 o’clock position.  Remove the oil level/fill plugs.  The oil level should be kept at the level of the level/fill plug.  Should it be necessary to add oil, add 80W-90 oil through the fill plug hole until it begins to flow out of the check hole.  Do not overfill the reducer.

Fig. 35: Tram reducer oil level

Fill plug location

Check plug location

Drain plug location

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Maintenance _____________________________________________________ breaker reducer

Check oil level in the breaker drive reducer (Fig. 36). Oil level should be maintained inside the sight glass on the side of the reducer when it is in operation. If the reducer does not have a sight glass, a pipe plug will be installed in the side of the reducer slightly below the input shaft center line. This is the level that the fluid should be maintained at. The oil should be changed after the first 500 hours of operation. Use Century 220 lubricant.

Fig. 36: Breaker reducer Inspection cover

Breather

Drain plug

dust system strainer

Clean the strainer mounted inside the dust suppression system. Open ball valve (Fig. 37) and allow water to flow from the short attached hose. The flowing water will flush out the filter strainer.

IMPORTANT! A short hose is attached to ball valve in dust suppression system to allow water to be directed away from other machine components.

Fig. 37: Dust system

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____________________________________________________ Maintenance Every 2 weeks return filter pressure filter

Change the return filter’s element (Fig. 38). If the element is extremely dirty, a more frequent interval may be required.

Change the pressure filter’s element (Fig. 38). If the element is extremely dirty, a more frequent interval may be required.

Fig. 38: Filter location Pressure filter

Return filter

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Maintenance _____________________________________________________ Monthly (optional) power fill filter

Change the power fill filter element (Fig. 39). If the element is extremely dirty, a more frequent interval may be required.

conveyor lift and tilt cylinders

Lubricate grease fittings on the rod and base ends of the conveyor lift and tilt cylinders. Pump grease into the fittings until new grease can be observed coming out of the pins.

crawler anchor pins

Lubricate grease fittings on both left and right side crawler anchor pins.

Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 39: Power fill filter and lubrication point location

Power fill filter

Tilt cylinder (s) (grease fitting located on rod and base end)

Crawler anchor pin (s) (grease fitting located inside crawler frame)

Lift cylinder (s) (grease fitting located on rod and base end)

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____________________________________________________ Maintenance Every 3 months electric motor

Lubricate the feeder breaker’s electric motor through the two (2) grease fittings located on the central lubrication panel (Fig. 40) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

NOTICE! Incorrect grease or over greasing may cause serious damage to the electric motor.

reducer

Lubricate the reducer through the two (2) grease fittings located on the central lubrication panel (Fig. 40) located on the right side of the discharge section. Pump only one or two pumps of grease into each fitting.

Fig. 40: Electric motor and reducer lubrication Reducer central lubrication panel

torque limiter

Electric motor central lubrication panel

Check torque limiter clutch disk wear as shown. Clutch disk must be changed when 3.46” is measured as shown in Fig. 41.

Fig. 41: Torque limiter clutch wear 3.55” New thickness 3.46” Worn thickness

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Maintenance _____________________________________________________ Every 2500 hours reducer

Change the oil in the breaker drive reducer (Fig. 42). The reducer oil should be changed after the first 500 hours of operation and ever 2500 hours afterwards. Remove the drain plug and allow the oil to completely drain. Clean and reinstall drain plug.  Remove inspection cover.  Add Cat Compactor Oil 220 lubricant as required until fluid is visible in sight glass or begins to flow from the check plug that is slightly below the center line of the input shaft.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Install inspection cover.

Fig. 42: Breaker reducer Inspection cover

Breather

Drain plug

Sight glass plug

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____________________________________________________ Maintenance Every 6 months hydraulic oil tank

Change the hydraulic fluid in the feeder breaker oil tank (Fig. 43).  Clean all dirt and debris from and around the fill cap and drain plug.  Remove the drain plug and allow the oil tank to completely drain.  Clean and reinstall drain plug.  Add oil as required via the power fill system until fluid is visible in sight glass.  Install fill cap.  Start the machine and allow the hydraulic pump to run in order to purge air from the system.  Shut down the machine and recheck the oil level. Add oil if necessary.

Fig. 43: Hydraulic tank oil level

Oil level sight glass

Drain plug

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Maintenance _____________________________________________________ tram reducer

Change oil in the tram reducer (Fig. 44).  Clean all dirt and debris from and around the level and fill plugs.  Rotate reducer until drain plug is at the 6 o’clock position and remove drain plug and allow the oil to completely drain.  Clean and reinstall drain plug.  Rotate reducer until plugs are at the 12 o’clock and 3 o’clock positions.  Add oil (80W-90) through the fill hole until fluid begins to flow from the check plug.  When filling the reducer, allow enough time for all cavities inside the reducer to fill.  Install level and fill plugs.  Do not overfill reducer.

Fig. 44: Tram reducer oil change Fill plug location

Check plug location

Drain plug location

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____________________________________________________ Maintenance Inspection of the feeder breaker CAUTION! During inspection, report any damage, missing parts or other faults to your immediate supervisor.

Prior to each shift the following points should be inspected:  Clean and remove any foreign material from the operator’s station.  Inspect all electrical cables, conduits, hydraulic hoses, fittings and warning devices for signs of wear or damage.  Visually inspect the condition and readability of all tags, labels and reflectors.  Check the “STOP” button (s) for correct operation.  Check the hydraulic oil level in the feeder breaker by looking at the sight glass. The oil level should be kept at the level of the top sight glass.  Check oil level in the crawler reducers.  Inspect the condition of all electrical and hydraulic components.  Check for proper conveyor chain tensioning.  Check for proper crawler chain tensioning.  Lubricate per the lubrication schedule.  Check power input cable to power source insuring that the voltage and breaker settings are correct.  Check that the cable handling device is intact and oriented correctly.  Check that all covers are installed and secure.  Check the tightness of all connecting elements.

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Maintenance _____________________________________________________ Inspection of wear parts on the feeder breaker In order to be able to determine in good time when a repair shift has to be scheduled and to avoid damage to other components, it is essential to inspect all the following wear parts as to their degree of wear.

Inspect: ■

the conveyor chain

■

the conveyor chain flights

■

the conveyor drive sprockets

■

the conveyor tail shaft

■

the conveyor wear plates

■

the crawler pads

■

the crawler drive sprockets

■

the crawler idler rollers

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____________________________________________________ Maintenance Inspection of fire suppression system on the feeder breaker To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 45).  Note general appearance for mechanical damage or corrosion.  Check nameplate for readability, corrosion or looseness.  Remove fill cap assembly.  Examine gaskets for elasticity, clean and coat lightly with a good grade of high heat resistant grease.  Inspect threads on fill cap and in fill opening for nicks, burrs, cross threading, rough or feathered edges.  Check pressure relief vent in fill opening threads for obstruction.  Make certain extinguisher is filled with free flowing Ansul dry chemical to a level of not more than 3” from bottom of fill opening.  Unscrew cartridge and weigh (replace if weight is ½ oz. less than stamped on cartridge).  Inspect thread on cartridge and in receiver/actuator for nicks, burrs, cross threading, rough or feathered edges.  Check pressure vents in receiver/actuator for obstruction.  Examine cartridge receiver gasket for elasticity, clean and coat lightly with a good grade of high heat resistant grease. Return cartridge to receiver/actuator, hand tighten.  Lift extinguisher partially out of bracket and examine bursting disc; should be installed with full disc side facing extinguisher, properly seated and undamaged (scored or ruptured).  Reposition extinguisher, engage bursting disc union (wrench tighten) and close bracket clamp.  Check hoses, fittings and nozzles for mechanical damage.  Check nozzle openings; slot should be closed (capped) with silicone grease.  Check remote actuator (dashboard type).  Remove cartridge and weigh (replace if weight is ¼ oz. less than stamped on cartridge.

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Maintenance _____________________________________________________  Inspect threads on cartridge and in actuator for nicks, burrs, cross threading, rough or feathered edges.  Check pressure safety vent in actuator body for obstruction.  Examine actuator cartridge gasket for elasticity, clean and lightly coat with a good grade of high heat resistant grease.  Pull ring pin and operate actuator button several times to check for free movement.  Seal ring pin to puncture lever with lead and wire seal. Return cartridge to remote actuator, hand tighten.  Record date of maintenance and notify operating personnel that system is back in service.

________________________________________________________________ FB140 Feeder Breaker 5.66

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____________________________________________________ Maintenance Recharge of fire suppression system on the feeder breaker To return your fire suppression system to service after use (Fig. 45).  Pull ring on safety valve to relieve actuator system pressure.  Disconnect actuation system hose at cartridge receiver/actuator assembly.  Open bursting disc union assembly.  Remove extinguisher from bracket.  Replace ruptured bursting disc with new disc. (Full disc side must face extinguisher).  Fill extinguisher to rated capacity with Ansul dry chemical specified on nameplate.  Clean fill opening threads and gasket seating surface.  Secure fill cap, hand tighten.  Remove cartridge guard assembly.  Remove empty cartridge.  Make certain that receiver/actuator puncture pin is fully retracted.  Screw full charged cartridge into receiver/actuator assembly, hand tighten.  Replace cartridge guard.  Secure extinguisher in bracket.  Assemble bursting disc union, wrench tighten.  Connect actuation system hose at cartridge receiver/actuator assembly, wrench tighten.  Replace cartridge in remote actuator (dashboard type). Pull out button, insert ring pin and remove empty cartridge. Screw fully charged cartridge into actuator, hand tighten. Seal ring pin to actuator button stem with lead and wire seal.  Record date of recharge and notify operating personnel that system is back in service.

______________________________________________________________ REV 2 5.67

BI632977

Maintenance _____________________________________________________ Fig. 45: Fire suppression system Remote actuator Nozzle

Nozzle Nozzle

Propellant Propellant

Nozzle

Nozzle

Nozzle

Nozzle

Expellant Expellant

Remote actuator

________________________________________________________________ FB140 Feeder Breaker 5.68

BI632977

____________________________________________________ Maintenance Procedure to set Amplifier Card (EV1M2-12/24) 1. Start the pick breaker 2. Go to the valve bank and lift the valve bank handle retainer bar out of the way, so you can visibly see the movement of the conveyor handles (when the conveyor is running).

3. Place the machine in Conveyor, Forward and then Manual mode.

The conveyor will start.

4. On the display, go to the “Present Screen” (see fig. A1) Fig. A1: Preset Screen

5. Select “Low Speed” and change the percentage to “20%”. (Note: this percentage can be anything you want, as long as it is large enough to get the conveyor to start moving). The conveyor will be running full speed because Imin and Imax are at the same reference point (the valve handles will be visibly all the way forward). Next the Imin must be set.

6. Go to the amplifier cards on the back of the door, there will be two.

Find the Imin set screw (shown on Fig. A2 as item #9) Fig. A2: Imin & Imax set screw Imin Imax

______________________________________________________________ REV 2 5.69

BI632977

Maintenance _____________________________________________________

7. Turn Imin set screw counter clockwise. Visually verify (that the handles are moving) for which solenoid you are controlling, and get the handle to where it is 20% displaced from its rest position. This will have to be done to both amp cards.

8. Once you have both valve handles in the same position, you can go to the display and select “High Speed” on the “Preset Screen” (verify high percentage is set to 100%), your conveyor should be running at full speed (the valve handles should be fully displaced). If the handles are not fully displaced, you will need to adjust the Imax. Go to the amplifier cards, turn the Imax set screw (shown on Fig. A2 as item #10) clockwise, until you see the valve handles fully displaced (all the way forward).

9. Go back to the “Preset Screen” and select “Low Speed” and verify the valve handles went to your set low speed (handles displaced 20%) and reselect “High Speed” to verify high speed was set (handles fully displaced).

10. Go to the “Preset Screen” and select “Medium Speed” and enter your medium speed percentage. You do not need to adjust the amplifier card for the medium set point.

11. Once you have set the Imin and Imax set points you can change the percentages on the “Preset Screen” to what you want between your two set point percentages.

________________________________________________________________ FB140 Feeder Breaker 5.70

BI632977

___________________________________________ Adjustment procedures Instructions on the adjustment procedures on the feeder breaker It is essential that adjustments be made periodically to the conveyor chain, breaker drive chain and crawler tracks, as otherwise damage can be caused to other parts of the machine or to the assembly itself.

Inspect the adjustments at regular intervals.

Conveyor chain adjustment The conveyor chain is a complete assembly and should be checked for correct tension at regular intervals.

NOTICE! The following adjustment procedure for conveyor chain take-up must be performed on both right and left hand sides of the conveyor.

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 46):  Close the stop valve on manifold assembly securely.  Attach a grease gun to the grease fitting located on the manifold and apply grease until the required pressure is attained. Sight across the bottom of the head shaft sprocket. The chain should sag 1 1/2” to 2” below the bottom of the head shaft sprocket.  After tensioning chain, remove the allen head bolts from the tail shaft retainers and lift out retainers.  Insert shims over cylinder rod to maintain gap between bearing and end plate of box.  Allow tail shaft pressure to rest completely on shims.

NOTICE! Make certain that the same amounts of shims are used on both sides of the conveyor to prevent chain from stretching unevenly.

Incorrect tension or adjustment can cause premature wear of sprockets and chain.  Replace retainers.  Release pressure on the take-up cylinders by opening the top valve to vent grease. After grease has vented, close valve.

WARNING! Due to grease cylinders being under high pressure, do not stand in direct line of grease fitting or bleeder valve when releasing pressure. You could be seriously injured from high pressure grease.  Store any unused shims under cover plate.

______________________________________________________________ REV 2 5.71

BI632977

Adjustment procedures ___________________________________________ Fig. 46: Conveyor chain adjustment

Tail shaft retainer

Stop valve

Grease fitting

________________________________________________________________ FB140 Feeder Breaker 5.72

BI632977

___________________________________________ Adjustment procedures Crawler track The crawler track is a complete assembly and should be checked for wear and correct tension at regular intervals.

To adjust tension on the crawler track with the take-up cylinders proceed as follows (Fig. 47):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Chain sag should be 1 3/4” at the center of the crawler.  Remove the access cover located on the side of the crawler and locate the needle valve inside crawler frame. Turn valve knob counter clockwise (CCW) to open valve and pump grease into the fitting until the correct adjustment is achieved. Chain sag should be 1 3/4” at the center of the crawler.  Turn needle valve knob clockwise (CW) to close.

DANGER! If only one side of the machine is raised, be careful and only move the control lever for that particular side. Moving the wrong control lever could cause the machine to move and fall off its supports.

You could be seriously injured or even killed by falling loads.  Run crawler in forward direction for 3 minutes at slow speed.  Run crawler in reverse direction for 3 minutes at slow speed.  Shutdown machine.  If necessary, re-adjust chain sag.  Add or remove required amount of shims to maintain correct tension.  Release grease pressure in the cylinder with the needle by turning the knob counter clockwise (CCW), allowing the shims to maintain the correct tension.

WARNING! Due to grease cylinder being under high pressure, do not visually inspect to see if grease is released. You could be seriously injured from high pressure grease.  Store and secure any unused shims on back of crawler cover plate.

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Adjustment procedures ___________________________________________ Fig. 47: Crawler track adjustment

When properly tensioned, chain sag should be 1 3/4” at center of crawler.

Idler assembly

Access cover

Take-up cylinder

Grease fitting

Needle valve

________________________________________________________________ FB140 Feeder Breaker 5.74

BI632977

________________________________________ Replacement of wear parts

Instructions on the replacement of wear parts on the feeder breaker It is essential that wear parts are replaced before they reach the lowest wear limit, as otherwise damage can be caused to other parts of the machine. Inspect the wear parts at regular intervals.

Head shaft The head shaft (Fig. 48) transmits the torque of the hydraulic motor to the conveyor chain assembly. It is part of a complete assembly. As soon as any component is worn, the component or complete head shaft must be replaced. Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

The head shaft assembly consists of the following main components: ■

drive shaft

■

sprockets

■

bearings

■

hydraulic motor

Fig. 48: Head shaft main components Sprocket (2)

Head shaft Key (2)

Bearing (2)

______________________________________________________________ REV 2 5.75

BI632977

Replacement of wear parts _________________________________________ How to remove the head shaft To remove the head shaft assembly from the feeder breaker discharge boom proceed as follows (Fig. 49):  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the two (2) sprocket guards located on the end of the discharge boom.  Remove the hydraulic motor. (See Hydraulic motor removal in this chapter).  Disconnect, tag and cap the central lubrication hoses on both head shaft bearings.  Remove the left and right covers from the end of the boom frame.  Remove the four (4) nuts, bolts, and lock washers from each of the head shaft bearings.  Attach an appropriate lifting device to the head shaft and slide out towards the rear of the frame.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

How to install the head shaft To install the head shaft assembly proceed as follows (Fig. 49):  Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the discharge boom.  Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) nuts, bolts, and lock washers. Torque bolts to 645 ft-lbs.  Install the left and right covers to the end of the boom frame.  Connect the central lubrication hoses on both head shaft bearings.  Install the hydraulic motor. (See Hydraulic motor installation in this chapter).

________________________________________________________________ FB140 Feeder Breaker 5.76

BI632977

________________________________________ Replacement of wear parts  Align sprockets with conveyor chain and tighten sprocket set screws (two (2) per sprocket).  Install the two (2) sprocket guards on the end of the discharge boom.   Connect conveyor chain. (See Conveyor chain replacement in this chapter).  Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

Fig. 49: Head shaft removal and installation Conveyor chain (not shown)

Covers

See hydraulic motor removal in this chapter

Head shaft Sprocket guard (s)

______________________________________________________________ REV 2 5.77

BI632977

Replacement of wear parts _________________________________________ Head shaft sprockets The head shaft sprocket transmits the torque of the hydraulic motor to the conveyor chain assembly. It is part of the head shaft assembly. As soon as the sprockets are worn they must be replaced. Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

How to remove the head shaft sprockets To remove the sprockets from the head shaft assembly proceed as follows (Fig. 50):  Remove the drive shaft assembly from the discharge boom (see Drive shaft removal in this chapter).  Remove the two (2) bearings from the head shaft.  Remove the two (2) set screws from each sprocket.  Slide both sprockets from the drive shaft.  Remove old keys.  Inspect all components of the drive shaft for wear and damage.

See parts manual for replacement parts list.

How to install the head shaft sprockets To install the sprockets on the head shaft proceed as follows (Fig. 50):  Thoroughly clean and lubricate the drive shaft with grease.  Insert one of the keys into the shaft keyway and slide first sprocket onto shaft.  Insert the other key into the shaft keyway and slide second sprocket onto shaft.  Slide both bearings onto shaft.  Install the drive shaft assembly in the discharge boom. (See drive shaft installation in this chapter.

________________________________________________________________ FB140 Feeder Breaker 5.78

BI632977

________________________________________ Replacement of wear parts How to install the head shaft temporary split sprockets To install the temporary split sprockets on the head shaft proceed as follows (Fig. 50): IMPORTANT! The split sprocket is designed for temporary use only and should be replaced during the first available maintenance shift.  Release tension on the conveyor chain by removing shims from the conveyor chain take-up. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain and fold back to clear drive shaft. (See Conveyor chain replacement in this chapter).  Remove the two (2) sprocket guards located on the end of the discharge boom.  Remove damaged sprockets and keys from head shaft. Old sprockets may require cutting to remove.  Thoroughly clean and lubricate the drive shaft with grease.  Insert new key into shaft keyway.

NOTICE! Do not mix and match sprocket halves or premature wear of sprockets and chain could occur.  Install both sprocket halves onto shaft and and align with conveyor chain.  Temporarily tack weld sprocket halves to head shaft until welding is complete.

IMPORTANT! Blend and smooth welds to avoid chain roller damage.

Weld notes: 1. Preheat sprocket weld joint to 600°F - 800°F. 2. Maintain preheat temperature during welding process.

3.

Max interpass temperature not to exceed 1500°F.

4.

Use low hydrogen rod (E7018) or wire (class E71T. SPEC AWS A5.20).

5.

Post weld heat sprocket joint 600°F - 800°F.

6.

If possible / practical, bury sprocket with dirt or wrap with a weld blanket for a minimum of eight (8) hours.

______________________________________________________________ REV 2 5.79

BI632977

Replacement of wear parts _________________________________________  Connect conveyor chain. (See Conveyor chain replacement in this chapter).  Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).

Fig. 50: Head shaft sprocket removal and installation

Head shaft

Bearing (2)

Sprocket guard

Split sprocket Hydraulic motor Conveyor chain Hydraulic motor Sprocket (2) & key (2)

________________________________________________________________ FB140 Feeder Breaker 5.80

BI632977

________________________________________ Replacement of wear parts Tail shaft The tail shaft (Fig. 51) allows for even adjustments friction free transition to the conveyor chain assembly. As soon as any component of the tail shaft is worn the component or complete tail shaft assembly must be replaced. Due to the high abrasion forces the tail shaft is subject to a very high level of wear.

The tail shaft assembly consists of the following main components: ■

shaft

■

sprocket (2)

■

slide plate

■

key (2)

■

set screw (2)

■

roller bearing (2)

■

piston rod adapter (2)

Fig. 51: Tail shaft main components Set screw (2)

Slide plate

Adapter (2)

Key (2)

Sprocket (2)

Head shaft

Bearing (2)

______________________________________________________________ REV 2 5.81

BI632977

Replacement of wear parts _________________________________________ How to remove the tail shaft To remove the tail shaft assembly from the receiving boom proceed as follows (Fig. 52):  Release tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).  Remove the five (5) bolts and lock washers from each of the tail shaft retainers and lift out the retainers.  Disconnect, tag and cap the central lubrication hoses to the tail shaft.  Remove the tail shaft shims.  Separate conveyor chain and fold back to clear tail shaft. (See Conveyor chain replacement in this chapter).  Attach an appropriate lifting device to the tail shaft assembly and and slowly lift from machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 52):  With an appropriate lifting device, insert tail shaft into receiving boom.  Fold the conveyor chain over tail shaft.  Connect conveyor chain (see Conveyor chain replacement in this chapter.  Connect central lubrication hoses and lubricate tail shaft and slide plate bearings with grease.  Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).  Install the tail shaft retainers with the five (5) bolts and lock washers in each side.  With machine running, visually inspect tail shaft to ensure that the shaft is turning and conveyor chain is not sliding across tail shaft.

________________________________________________________________ FB140 Feeder Breaker 5.82

BI632977

________________________________________ Replacement of wear parts Fig. 52: Tail shaft removal and installation

Cover Tail shaft retainer plates (2)

Shims Take-up cylinder

Tail shaft

______________________________________________________________ REV 2 5.83

BI632977

Replacement of wear parts _________________________________________ How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 53):  Remove the tail shaft assembly from the receiving boom. (See How to remove the tail shaft in this chapter).  Slide both roller bearings and piston rod adapters from the tail shaft.  Remove the set screws from both tail shaft sprockets and slide sprockets from the shaft.  Remove the tail shaft from the slide plate.  Visually inspect all components for damage or wear and replace as necessary.

How to assemble the tail shaft To assemble the tail shaft assembly proceed as follows (Fig. 53):  Thoroughly clean all parts that will be installed.  Grease tail shaft with grease.  Slide tail shaft into the slide plate.  Insert keys into keyways on tail shaft.  Slide both sprockets onto tail shaft, one on each end.  Install set screws into both rollers, ensuring that rollers and tail shaft slide plate are centered on tail shaft.  Tighten set screws. Torque to 100 ft-lb.  Install both roller bearings and adapter plates on tail shaft, one on each end.  Install grease fittings, if required.  Install assembled tail shaft into machine. (See How to install the tail shaft in this chapter).

________________________________________________________________ FB140 Feeder Breaker 5.84

BI632977

________________________________________ Replacement of wear parts Fig. 53: Tail shaft disassembly and assembly Set screw (2)

Slide plate

Adapter (2)

Key (2)

Sprocket (2)

Head shaft

Bearing (2)

______________________________________________________________ REV 2 5.85

BI632977

Replacement of wear parts _________________________________________ Conveyor chain The conveyor chain (Fig. 54) is made up of one basic chain assembly which repeats sequentially along the entire chain loop. As soon as any component of the conveyor chain is worn the component or complete conveyor chain assembly must be replaced.

Each conveyor chain section consists of the following main components: ■

6 link chain section

■

flight bar

■

spiral pin

Fig. 54: Conveyor chain main components

6 link chain section

Spiral pin

Flight bar

________________________________________________________________ FB140 Feeder Breaker 5.86

BI632977

________________________________________ Replacement of wear parts How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 55):  Lay conveyor chain sections on a clean flat surface.  Insert connector pins through flight end and align holes in spiral pin with holes in flight bar.  Insert spiral pin.  Drive spiral pin in with a hammer and punch. Ensure that spiral pin is recessed on both sides of flight bar.  Repeat the previous assembly instructions until the complete chain has been assembled.

Fig 55: Conveyor chain assembly

Extended pin connecting link Spiral pin (4)

Block link assembly

Flight bar

Side bar

6 link chain section

______________________________________________________________ REV 2 5.87

BI632977

Replacement of wear parts _________________________________________ How to remove the conveyor chain assembly To remove the conveyor chain assembly proceed as follows:  Release tension on the conveyor. (See Conveyor chain adjustment in this chapter).  Separate conveyor chain by removing spiral pins and connecting links in one section of the chain.  Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the conveyor chain and slowly pull the conveyor chain completely out of the machine.

WARNING! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the conveyor chain, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the conveyor chain.

How to install the conveyor chain assembly To install the conveyor chain assembly proceed as follows:  Check to ensure that the conveyor tail shaft is completely retracted.

If not retracted, see Conveyor chain adjustment in this chapter.  Run a cable or pull rope with an adequate load limit through the bottom conveyor pan and connect to the conveyor chain.  Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to the other end of the cable or pull rope and slowly pull the conveyor chain completely through the bottom conveyor pan.

IMPORTANT! If old conveyor chain is still on machine, installation can be facilitated by connecting the new conveyor chain to the old conveyor chain via the chain connectors and pulling it through the bottom conveyor pan.  Fold conveyor chain back over the tail shaft and drive shaft and slowly pull the chain along the conveyor ensuring that the chain is under the chain hold downs.  Ensure that the chain is properly meshed with the drive sprockets and aligned with the tail shaft roller.  Connect conveyor chain (see How to assemble the conveyor chain sections in this chapter for proper connection).  Adjust tension on the conveyor chain (see Conveyor chain adjustment procedure in this chapter.  With machine running, visually inspect tail shaft to ensure that that the shaft is turning and conveyor chain is not sliding across tail shaft.

________________________________________________________________ FB140 Feeder Breaker 5.88

BI632977

________________________________________ Replacement of wear parts Crawler track The crawler track (Fig. 56) assembly (left and right) carries the machine via torque received from the tram drive reducer. The crawler track is made up of one basic crawler pad assembly, which repeats sequentially along the entire pad loop. As soon as any component of the crawler track is worn the component or complete crawler track assembly must be replaced.

Each crawler track consists of the following main components: ■

crawler pad

■

connector pin

■

t-pin

Fig. 56: Crawler track main components

Crawler pad

Connector pin and T-pin

______________________________________________________________ REV 2 5.89

BI632977

Replacement of wear parts _________________________________________ How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 56):  Lay crawler track pads on a clean flat surface.  Align pads with chain connecting holes centered.  Insert connector into center of crawler pad connecting holes.  Drive T-pin through connecting pin and bend end to secure.  Repeat above procedure for remainder of crawler pads.

How to remove the crawler track pad assembly To remove the crawler track pad assembly proceed as follows (Fig. 56):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Crawler track tension must be released (see Crawler track adjustment in this chapter).  Separate the crawler pads.

To separate the crawler pads proceed as follows (Fig. 56) IMPORTANT! Heating or cutting connections with a torch or chisel may be required to ease the removal of T- pins.  Drive or cut T-pin from crawler pad connection using hammer and punch.  Separate crawler track assembly.  Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the crawler track assembly and slowly pull the crawler track completely out from under the machine.

________________________________________________________________ FB140 Feeder Breaker 5.90

BI632977

________________________________________ Replacement of wear parts WARNING! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the crawler track, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the crawler track.  Inspect the crawler drive sprocket and idler rollers for wear or damage. Replace if necessary.

How to install the crawler track pad assembly To install the crawler track pad assembly proceed as follows (Fig. 56):  Remove old crawler track pad assembly (see previous section, How to remove crawler track pad assembly.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Check to ensure that crawler track tension cylinder is completely retracted (see Crawler track adjustment in this chapter).  Slide crawler track pad assembly under crawler assembly.  Fold pad assembly over both ends of crawler assembly. Ensure that pad assembly meshes with drive sprocket and idler roller.  Connect crawler track pad assembly (see How to assemble crawler track pad assembly in this chapter for proper connection).  Adjust tension on the crawler track pad assembly (see Crawler track pad adjustment procedure in this chapter for proper adjustment).

______________________________________________________________ REV 2 5.91

BI632977

Replacement of wear parts _________________________________________ Crawler assembly The crawler assembly (Fig. 57) consists of a take-up assembly and drive assembly that transmits torque to the crawler track via a hydraulic drive motor coupled to the tram drive torque hub. As soon as any component of the drive assembly is worn or damaged, the component must be replaced.

The crawler assembly consists of the following main components: ■

hydraulic drive motor

■

tram drive torque hub

■

cat pad assembly

■

take-up roller assembly

■

grease take-up assembly

■

drive sprocket

Fig. 57: Crawler assembly main components Sprocket Hydraulic motor (not shown) Cat pad assembly

Torque hub Take-up cylinder & shims Take-up roller assembly

________________________________________________________________ FB140 Feeder Breaker 5.92

BI632977

________________________________________ Replacement of wear parts How to remove the crawler take-up assembly To remove the crawler take-up assembly proceed as follows (Fig. 58):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.  Crawler track tension must be released (see Crawler track adjustment in this chapter.  Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear take-up.  Securely block under the crawler frame.  Disconnect, tag and cap hydraulic hoses going to the tilt cylinder.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers  Remove the eight (8) bolts from the tilt cylinder mounting bracket.  swing the tilt cylinder and mounting bracket free of the crawler frame.  Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to the take-up assembly and slowly pull the assembly out of the crawler frame.

WARNING! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the take-up, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the take-up.  Inspect all components for wear or damage.

______________________________________________________________ REV 2 5.93

BI632977

Replacement of wear parts _________________________________________ How to install the crawler take-up assembly To install the crawler take-up assembly proceed as follows (Fig. 58):  Remove old take-up assembly (see previous section, How to remove crawler take-up assembly).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Inspect all components for wear or damage prior to assembly.  Clean all dirt and debris from inside crawler frame.  Attach appropriate lifting device to take-up assembly and slide assembly completely into the end of crawler frame.  Install and connect crawler and track pad assembly, see How to install the crawler track pad assembly in this chapter.  Swing the tilt cylinder and mounting bracket into crawler frame and secure with the eight (8) bolts, washers and nuts.  Connect hydraulic hoses to tilt cylinder.  Purge hydraulic system of air.  Adjust crawler track pad tension, see How to adjust crawler track pad tension in this chapter.

________________________________________________________________ FB140 Feeder Breaker 5.94

BI632977

________________________________________ Replacement of wear parts Fig. 58: Crawler take-up removal and installation

Tilt cylinder

Crawler frame Tilt cylinder mounting bracket

______________________________________________________________ REV 2 5.95

BI632977

Replacement of wear parts _________________________________________ How to remove the crawler drive assembly To remove the crawler drive assembly proceed as follows (Fig. 59):  Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Crawler track tension must be released (see Crawler track adjustment in this chapter).  Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear sprocket.  Disconnect, cap and tag all hydraulic hoses to hydraulic motor.  Remove slotted nut, roll pin and washer from lift cylinder anchor pin.  Slide anchor pin out of crawler frame and swing tilt cylinder free of the crawler frame.  Remove the six (6) bolts and lock washers that secure the removable side plate to crawler frame and remove side plate.  Remove the twelve (12) bolts and lock washers that secure the torque hub to the crawler frame.  Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.  Remove the four (4) bolts and lock washers that secure the hydraulic motor and adapter plate to the torque hub.  Attach an appropriate lifting device to the torque hub and slide complete assembly out of crawler frame.  Slide adapter plate and motor off of torque hub.  Remove adapter plate gasket.  Remove the four (4) nuts and lock washers that secure the hydraulic motor to the adapter plate. And remove adapter plate.  Remove the twenty (20) bolts and lock washers that secure the sprocket to the torque hub and separate hub and sprocket.  Inspect all components for wear or damage.

________________________________________________________________ FB140 Feeder Breaker 5.96

BI632977

________________________________________ Replacement of wear parts How to install the crawler drive assembly To install the crawler drive assembly proceed as follows (Fig. 59):  Remove old crawler drive assembly (see previous section, How to remove crawler drive assembly).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.  Inspect all components for wear or damage prior to installation.  Place sprocket onto torque hub and secure with the twenty (20) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

■

step 1 – 70 ft-lb

■

step 2 – 140 ft-lb

■

step 3 – 210 ft-lb

 Place hydraulic motor gasket onto motor adapter plate.  Install adapter plate and gasket onto hydraulic motor and secure with the four (4) nuts and lock washers. Apply Loctite 242 (blue) to nuts.  Place adapter plate gasket onto torque hub.  Install motor and adapter plate assembly onto torque hub, being careful not to damage motor shaft or gasket. Secure with the (4) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

■

step 1 – 25 ft-lb

■

step 2 – 50 ft-lb

■

step 3 – 70 ft-lb

 Weld four (4) keepers across motor flanges to prevent motor movement.  Clean all dirt and debris from mounting area of crawler frame.  Attach an appropriate lifting device to the torque hub and slide complete assembly into crawler frame.  Secure torque hub assembly to frame with the twelve (12) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.

______________________________________________________________ REV 2 5.97

BI632977

Replacement of wear parts _________________________________________ ■

step 1 – 50 ft-lb

■

step 2 – 140 ft-lb

■

step 3 – 280 ft-lb

■

step 4 – 420 ft-lb

 Connect hydraulic hoses to drive motor.  Install and connect crawler and track pad assembly, see How to install the crawler track pad assembly in this chapter.  Install the removable side plate and secure with the six (6) bolts and lock washers. Torque incrementally as follows.

■

step 1 – 300 ft-lb

■

step 2 – 600 ft-lb

■

step 3 – 905 ft-lb

 Slide anchor pin through crawler frame and tilt cylinder. Secure pin with slotted nut, washer and roll pin.  Purge hydraulic system of air.  Adjust crawler track pad tension, see How to adjust crawler track pad tension in this chapter.

Fig. 59: Crawler drive disassembly and assembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

crawler frame torque hub Washer (allen lock) bolt sprocket washer (lock) bolt gasket (adaptor plate) plate (adaptor)

10.

11.

12.

13.

14.

15.

16.

17.

18.

washer (lock) bolt gasket washer (flat) nut keeper washer (lock) bolt crawler pad

19.

20.

21.

22.

23.

24.

25.

bushing bushing pin (crawler anchor) washer (flat) nut (castle) pin (cotter) removable sideplate

________________________________________________________________ FB140 Feeder Breaker 5.98

BI632977

________________________________________ Replacement of wear parts Power unit The power unit (Fig. 60) has been assembled as a unit and can be removed as a unit or as individual components. As soon as any component of the power unit is worn or damaged, the component must be replaced.

The power unit consists of the following main components: ■

gear pump

■

hydrostatic pump

■

pump coupling

■

motor (200 hp)

■ reducer/motor coupling ■

reducer

■

torque limiter

■

connecting tube

Fig. 60: Power unit main components Taperlock bushing Reducer Torque limiter Motor (200 HP)

Coupling

Coupling Hydrostatic pump

Companion flange Connecting tube Connecting tube Gear pump

______________________________________________________________ REV 2 5.99

BI632977

Replacement of wear parts _________________________________________ How to remove the power unit To remove the power unit as a complete assembly proceed as follows (Fig. 61).  Remove power unit covers from the machine.  Disconnect and tag all electrical wiring to the drive motor.

WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.  Disconnect, cap and tag all hydraulic hoses to the hydraulic pumps.  Remove the twelve (12) mounting bolts, nuts and lockwashers from the breaker shaft flange and stub shaft.  Remove the power unit reaction pin.  Attach an appropriate lifting device to the complete unit and slowly lift the unit from the machine.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

How to install the power unit To install the power unit as a complete assembly proceed as follows (Fig. 61).  Attach an appropriate lifting device to the complete unit and slowly lift the unit onto the machine and align stub shaft with breaker shaft flange.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Install the twelve (12) bolts, lockwashers, and nuts previously removed from the stub shaft and breaker shaft flange. Torque bolts to 350 ft-lb incrementally and evenly in a crossing pattern.  Install the power unit reaction pin and secure with the two (2) cotter pins.  Connect all hydraulic hoses to the hydraulic pumps.  Connect all electrical wiring to the drive motor.  Install power unit covers.

________________________________________________________________ FB140 Feeder Breaker 5.100

BI632977

________________________________________ Replacement of wear parts Fig. 61: Power unit removal and installation Breaker shaft flange Flange and shaft connecting bolts Torque to 350 ft– lbs

Stub shaft

Pivot mounting lug Power unit reaction pin

Pivot mounting lug will always be this dimension (6.81”) from top of frame side plate.

Top set of holes of pivot mounting plate

Power unit

Use the bottom set of holes on the pivot mounting plate if the breaker shaft assembly is installed using these side plate holes.

Bottom set of holes of pivot mounting plate

Use the bottom set of holes on the pivot mounting plate if the breaker shaft assembly is installed using these side plate holes.

______________________________________________________________ REV 2 5.101

BI632977

Replacement of wear parts _________________________________________ How to disassemble the breaker power unit To disassemble the power unit proceed as follows (Fig. 63):  Remove complete unit from machine. (See How to remove the drive unit in this chapter)  Remove the four (4) bolts and lockwashers from gear pump (item 24) and remove pump.  Open access cover on connecting tube (item 18) and loosen the two (2) bolts on the pump end and set screw on the motor end of the coupling (item 17).  Remove the four (4) bolts and lockwashers from hydrostatic pump (item 21). With the aid of a lifting device, slowly pull pump from coupling (item 17) and connecting tube (item 18).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Remove the eight (8) bolts and lockwashers from connecting tube (item 18) and remove connecting tube from motor (item 13).  Remove coupling (item 17) and key from motor shaft.  Remove access cover (item 26) on connecting tube (item 12) and loosen the four (4) set screws on the flexible coupling (item 9).  Connect a lifting device to motor to aid in holding the weight of the motor.  Remove the eight (8) bolts and lockwashers from connecting tube (item 12) and slowily pull motor from connecting tube and flexible coupling (item 9).  Remove the four (4) expanded matal guards (item 25) from connecting tube (item 12).  Remove the twelve (12) bolts and lockwashers from connecting tube (item 12) and remove connecting tube from reducer (item 1).  Remove the eight (8) bolts and lockwashers from flexible coupling (item 9) and remove flexible coupling.  Remove the twelve (12) bolts and lockwashers from companion flange (item 3) and remove remove torque limiter (item 6).  Remove the three (3) bolts that secures the taper lock (item 2) to the reducer shaft.

________________________________________________________________ FB140 Feeder Breaker 5.102

BI632977

________________________________________ Replacement of wear parts  Insert two (2) of the bolts removed from the taper lock into the jack screw threaded holes located in the end of the taper lock (Fig. 62).

Tighten both bolts equally until the taper lock is free from reducer shaft.  Remove companion flange (item 3) and taper lock bushing (item 2) from reducer shaft.  Visually inspect all components for wear or damage and replace if necessary.

Fig. 62: Taper lock removal and installation

Jack screw holes (2) for bushing removal

Bolt holes (3) for bushing installation

______________________________________________________________ REV 2 5.103

BI632977

Replacement of wear parts _________________________________________ How to assemble the power unit To assemble the power unit proceed as follows (Fig. 63):  Slide reducer companion flange (item 3) onto reducer shaft.  Slide taper lock (item 2) and shaft key onto reducer shaft. Locate reducer companion flange (item 3) and taper lock (item 2) so they are flush with the end of the reducer shaft. Secure taper lock with the three (3) bolts supplied with taper lock. Torque bolts to 105 ftlb.  Connect torque limiter (item 6) to companion flange (item 3) and secure with the twelve (12) bolts and lockwashers. Torque bolts to 65 ft-lb.  Connect flexible coupling (item 9) to torque limiter (item 6) and secure with the eight (8) bolts and lockwashers. Torque bolts to 90 ft-lb.

NOTICE! A 5/16” gap must be maintained on both sides of flexible coupling (item 9) or coupling will be damaged during use if gap is too large or too small.  Connect connecting tube (item 12) to reducer (item 1) and secure with the twelve (12) bolts and lockwashers. Torque bolts to 380 ftlb.  With the aid of a lifting device, slowly lift motor (item 13). Align motor shaft key and slide motor shaft into flexible coupling (item 9).

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Insert key into slot of motor shaft and slide motor coupling half (item 17) onto motor shaft until shaft and coupling face are flush.  Tighten set screw in motor half of coupling.  Insert coupling element into motor half of coupling.  Align the 8 holes of connecting tube (item 18) with motor (item 13) and secure with the eight (8) bolts and lockwashers. Torque bolts to 2400 ft-lb.  Apply never seez to pump half of coupling (item 17) and slide onto hydrostatic pump shaft (item 21) until a 3/16” shaft end gap is acquired. Tighten the two (2) coupling half bolts.

NOTICE! A 3/16” gap must be maintained on both sides of pump coupling (item 17) or coupling will be damaged during use if gap is too large or too small.

________________________________________________________________ FB140 Feeder Breaker 5.104

BI632977

________________________________________ Replacement of wear parts  With the aid of a lifting device, slowly lift hydrostatic pump (item 21) and carefully align pump half and motor half of coupling. Secure pump to connecting tube with four (4) bolts and lockwashers.

Torque bolts to 380 ft-lb. Coupling spacing should be 3/16” after pump mounting bolts are tightened.  Align mounting holes and shaft of gear pump (item 24) with hydrostatic pump (item 21) and secure with four (4) bolts and lockwashers. Torque bolts to 90 ft-lb.  Install completed power unit onto machine. (See How to install the power unit in this chapter)  Fill hydrostatic pump thru case drain port with system oil before running pump.

Fig. 63: Power unit disassembly and assembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

reducer taper lock bushing companion flange washer (lock) bolt 1/2” torque converter washer (lock) bolt 7/16” flexible coupling

10.

11.

12.

13.

14.

15.

16.

17.

18.

washer (lock) bolt M12 connecting tube motor washer (lock) bolt 3/4” Set screw 1/2” coupling connecting tube

19.

20.

21.

22.

23.

24.

25.

26.

27.

washer (lock) bolt 5/8” hydrostatic pump washer (flat) bolt 3/4” tandem gear pump metal guard cover washer (flat)

28. bolt 1’2” 29. bolt M12

______________________________________________________________ REV 2 5.105

BI632977

Replacement of wear parts _________________________________________ Fig. 63: Power unit disassembly and assembly (continued)

________________________________________________________________ FB140 Feeder Breaker 5.106

BI632977

________________________________________ Replacement of wear parts Conveyor drive motor The conveyor drive motor transmits torque to the head shaft assembly.

It is also part of the head shaft assembly. As soon as any component of the assembly is warn or damaged, the component must be replaced.

How to remove the conveyor drive motor To remove the conveyor drive motor proceed as follows (Fig. 64): WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.  Disconnect, cap and tag all hydraulic hoses to the conveyor motor.  Remove the two (2) pins and cotter keys from the torque arm and remove torque arm connecting link.  Remove conveyor motor cover bolts and remove cover.  Remove torque mounting bolt located inside conveyor motor.  Attach an appropriate lifting device to two (2) of the conveyor motor torque arm mounting bolts and slowly slide the the motor from the coupling and headshaft.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Disconnect lifting device and remove the torque arm mounting bolts.  Remove torque arm from conveyor motor.  Slide coupling from headshaft.  Inspect all components for wear or damage.

______________________________________________________________ REV 2 5.107

BI632977

Replacement of wear parts _________________________________________ How to install the conveyor drive motor To install the conveyor drive motor proceed as follows (Fig. 64): WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.  Apply a coat of mineral oil to the splines of the headshaft, coupling and conveyor motor. Do not use never seez.

IMPORTANT! Apply mineral oil or hydraulic oil to splines of head shaft and motor.  Slide coupling onto headshaft.  Install torque arm on conveyor motor with mounting bolts. Torque bolts to 400 ft-lb.  Remove conveyor motor cover bolts and remove cover.  Attach an appropriate lifting device to two (2) of the conveyor motor torque arm mounting bolts and slowly lift and slide the the motor onto the coupling and headshaft.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  Bolt conveyor motor to headshaft with torque mounting bolt located inside conveyor motor. Torque bolt to 280 ft-lb.  Install conveyor motor cover with cover bolts. Torque bolts to 59 ftlb.  Install torque arm connecting link with the two (2) pins and cotter keys.  Connect all hydraulic hoses to the conveyor motor.  Purge hydraulic system of air.

________________________________________________________________ FB140 Feeder Breaker 5.108

BI632977

________________________________________ Replacement of wear parts Fig. 64: Conveyor drive motor removal and installation Pin and cotter key (2 places) Connecting link

Head shaft

Torque arm

cover bolts (torque to 59 ft-lb)

Coupling

Mounting bolt (torque to 280 ft-lb)

Mounting bolts (torque to 400 ft-lb)

______________________________________________________________ REV 2 5.109

BI632977

Replacement of wear parts _________________________________________ Breaker assembly The breaker assembly (Fig. 65) is assembled as a complete unit and should be removed as a unit for repairs except for the replacement of the drive flange, bits and magnetic cutoff assembly. As soon as any component of the breaker assembly is worn or damaged, the component or complete assembly must be replaced.

The breaker assembly consists of the following main components: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

breaker shaft drive flange bearing housing (2) bearing (2) bits (30) bearing retainer (2) magnetic cutoff assembly lockwasher (3) breaker side plate (2) end cap dust cover

Fig. 65: Breaker assembly main components Flange Seal housing Bearing retainer Pick (30) End cap Breaker shaft Side plate Bearing backing ring Bearing housing Bearing

Bearing

Side plate Bearing backing ring Seal housing

Bearing retainer Bearing housing Under speed sensor

________________________________________________________________ FB140 Feeder Breaker 5.110

BI632977

________________________________________ Replacement of wear parts How to remove the breaker assembly To remove the breaker assembly from the machine proceed as follows (Fig. 66):  Remove covers and guards as required to gain access to the breaker assembly.  Remove the twelve (12) bolts, lockwashers, nuts and wire tie from the breaker shaft connecting flange.  Disconnect, tag and cap the bearing central lubrication hoses.  Attach an appropriate lifting device around the breaker shaft assembly and apply just enough lift to remove the tweenty (20) bolts, nuts, flatwashers and lockwashers (10 per side) that secure the breaker assembly to the frame.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.  With the aid of the lifting device, slowly lift the complete assembly out of the frame.

How to install the breaker assembly To install the breaker assembly into the machine proceed as follows (Fig. 66):  With the aid of the lifting device, slowly lift the breaker assembly into the frame and align mounting holes.  Secure the breaker with the tweenty (20) bolts, nuts, flatwashers and lockwashers (10 per side) and securely tighten. Apply never seez to bolt threads. Secure bolts with wire tie after tightening.  Connect breaker flange to the reducer stub shaft with thetwelve (12) bolts, lockwashers and nuts previously removed. Torque bolts to 350 ft-lb incrementally and evenly in a crossing pattern.  Connect the bearing central lubrication hoses.  Install covers and guards.

______________________________________________________________ REV 2 5.111

BI632977

Replacement of wear parts _________________________________________ Fig. 66: Breaker assembly removal and installation

Breaker shaft assembly

Breaker shaft connecting flange

Breaker shaft mounting bolts

________________________________________________________________ FB140 Feeder Breaker 5.112

BI632977

________________________________________ Replacement of wear parts How to disassemble the breaker assembly (drive side) To disassemble the breaker assembly (drive side) proceed as follows (Fig. 67 and 68):  Remove the breaker assembly from the machine. (See How to remove the breaker assembly in this chapter).  Remove the three (3) bolts (item 26) from shaft and remove end cap (item 23).  Remove the breaker shaft flange (item 21) from shaft.  Remove the eight (8) bolts and lockwashers (items 18 and 20) and remove seal housing (item 14).  Remove o-ring (item 11), retaining ring (item 16) and seal (item 15) from seal housing (item 14).  Remove side plate (item 13) from shaft.  Remove the eight (8) bolts and lockwashers (items 9 and 10) and remove bearing housing (item 8).

IMPORTANT! Use tool P/N 356549 to aid in disassembly of breaker shaft.  Remove sealing ring (item 7) from shaft.  Remove bearing (item 6) from shaft.  Remove 0-ring (item 5) from shaft.  Remove bearing retainer ring (item 4) from shaft.  Remove seal (item 3) from shaft.  Remove bearing backing (item 2) from shaft.  Visually inspect all components for wear or damage and replace as necessary.

______________________________________________________________ REV 2 5.113

BI632977

Replacement of wear parts _________________________________________ How to disassemble the breaker assembly (underspeed sensor side) To disassemble the breaker assembly (drive side) proceed as follows (Fig. 67 and 68):  Remove the breaker assembly from the machine. (See How to remove the breaker assembly in this chapter).  Remove the three (3) bolts (item 25) and lockwashers (item 24) from shaft and remove end cap (item 22).  Remove the eight (8) bolts (item 19) and lockwashers (item 18) and remove underspeed sensor mount (item 17).  Remove seal housing (item 14).  Remove o-ring (item 11), retaining ring (item 16) and seal (item 15) from seal housing (item 14).  Remove side plate (item 13) from shaft.  Remove the eight (8) bolts and lockwashers (items 9 and 10) and remove bearing housing (item 8).

IMPORTANT! Use tool P/N 356549 to aid in disassembly of breaker shaft.  Remove sealing ring (item 7) from shaft.  Remove bearing (item 6) from shaft.  Remove 0-ring (item 5) from shaft.  Remove bearing retainer ring (item 4) from shaft.  Remove seal (item 3) from shaft.  Remove bearing backing (item 2) from shaft.  Visually inspect all components for wear or damage and replace as necessary.

________________________________________________________________ FB140 Feeder Breaker 5.114

BI632977

________________________________________ Replacement of wear parts How to assemble the breaker assembly (drive side) To assemble the breaker assembly proceed as follows (Fig. 67 and 68):  Thoroughly clean all components with dry and lint free cloth prior to assembly.

IMPORTANT! Apply LOCTITE 518 gasket eliminator before installing bearing backing ring (item 2).  Install bearing backing ring (item 2).

IMPORTANT! Seal bores of bearing backing ring (item 2) and bearing retainer ring (item 4) must be completely free of grease and oil before installing seal (item 3).

IMPORTANT! Clean mating faces of metal seal rings with a lint free cloth. Apply a light coat of 30W oil to the faces only. DO NOT GET GREASE OR OIL ON THE RUBBER RINGS.  Install one half of seal (item 3) into bearing backing ring (item 2).  Install one half of seal (item 3) into bearing retaining ring (item 4).

IMPORTANT! Apply a light coat of grease to o-ring (item 5) to aid in assembly and to avoid cutting during installation. Also apply a light coat grease to bearing housing bore (item 4) to aid in installation.  Install o-ring (item 5) into bearing retaining ring (item 4).  Install bearing retainer ring (item 4) onto breaker shaft.

IMPORTANT! Use bearing installation tool (P/N 323334) to install bearing (item 6), sealing ring (item 7) and bearing backing ring (item 2). Apply 60 tons (10,000 psi) of force to seat bearing. DO NOT APPLY HEAT TO BEARING.  Install bearing (item 6) and sealing ring (item 7) onto breaker shaft.  Install bearing housing (item 8) and secure with eight (8) bolts (item 10) and lockwashers (item 9). Torque bolts to 140 ft-lb.

IMPORTANT! Ensure that 1/4” pipe plugs (item 12) installed in face of bearing housing (item 8) are flush or below face of housing.  Install pipe plugs (item 12) into bearing housing (item 8). Ensure that pipe plugs are flush or below face of housing.

______________________________________________________________ REV 2 5.115

BI632977

Replacement of wear parts _________________________________________ IMPORTANT! Use tool (P/N 333685) to install seal (item 15). Be careful to avoid folding lip of seal under during installation over sealing ring (item 7).   Install seal (item 15) using tool (P/N 333685) and retainer ring (item 16) into seal housing (item 14).  IMPORTANT! Apply a light coat of grease to o-ring (item 11) to aid in assembly and to avoid cutting during installation.   Install o- ring (item 11) into seal housing (item 14).  Install assembled seal housing (item 14) and secure with the eight bolts (item 20) and lockwashers (item 18). Torque bolts to 115 ft-lb.   Install side plate (item 13).  IMPORTANT! Apply never seez to splines of flange (item 21) or breaker shaft (item 1).   Apply never seez to splines of flange (item 21) and install flange on breaker shaft (item 1).  IMPORTANT! Bolt heads of (item 26) must not be above end cap (item 23).  Install end cap (item 23) and secure with three (3) bolts (item 26).

Apply Loctite 242 (blue) to bolts and torque to 400 ft-lb. Retaining wire is not necessary.

________________________________________________________________ FB140 Feeder Breaker 5.116

BI632977

________________________________________ Replacement of wear parts How to assemble the breaker assembly (underspeed sensor side) To assemble the breaker assembly proceed as follows (Fig. 67 and 68):  Thoroughly clean all components with dry and lint free cloth prior to assembly.

IMPORTANT! Apply LOCTITE 518 gasket eliminator before installing bearing backing ring (item 2).  Install bearing backing ring (item 2).

IMPORTANT! Seal bores of bearing backing ring (item 2) and bearing retainer ring (item 4) must be completely free of grease and oil before installing seal (item 3).

IMPORTANT! Clean mating faces of metal seal rings with a lint free cloth. Apply a light coat of 30W oil to the faces only. DO NOT GET GREASE OR OIL ON THE RUBBER RINGS.  Install one half of seal (item 3) into bearing backing ring (item 2).  Install one half of seal (item 3) into bearing retaining ring (item 4).

IMPORTANT! Apply a light coat of grease to o-ring (item 5) to aid in assembly and to avoid cutting during installation. Also apply a light coat grease to bearing housing bore (item 4) to aid in installation.  Install o-ring (item 5) into bearing retaining ring (item 4).  Install bearing retainer ring (item 4) onto breaker shaft.

IMPORTANT! Use bearing installation tool (P/N 323334) to install bearing (item 6), sealing ring (item 7) and bearing backing ring (item 2). Apply 60 tons (10,000 psi) of force to seat bearing. DO NOT APPLY HEAT TO BEARING.  Install bearing (item 6) and sealing ring (item 7) onto breaker shaft.  Install bearing housing (item 8) and secure with eight (8) bolts (item 10) and lockwashers (item 9). Torque bolts to 140 ft-lb.

IMPORTANT! Ensure that 1/4” pipe plugs (item 12) installed in face of bearing housing (item 8) are flush or below face of housing.  Install pipe plugs (item 12) into bearing housing (item 8). Ensure that pipe plugs are flush or below face of housing.

______________________________________________________________ REV 2 5.117

BI632977

Replacement of wear parts _________________________________________  Install side plate (item 13).

IMPORTANT! Use tool (P/N 333685) to install seal (item 15). Be careful to avoid folding lip of seal under during installation over sealing ring (item 7).   Install seal (item 15) using tool (P/N 333685) and retainer ring (item 16) into seal housing (item 14).  IMPORTANT! Apply a light coat of grease to o-ring (item 11) to aid in assembly and to avoid cutting during installation.   Install o- ring (item 11) into seal housing (item 14).  Install assembled seal housing (item 14), underspeed sensor mount (item 17) and secure with the eight bolts (item 19) and lockwashers (item 18). Torque bolts to 115 ft-lb.  Install end cap (item 22) and secure with three (3) bolts (item 25) and lockwashers (item 24). Torque bolts to 400 ft-lb and secure with retaining wire.

________________________________________________________________ FB140 Feeder Breaker 5.118

BI632977

________________________________________ Replacement of wear parts Fig. 67: Breaker shaft assembly and disassembly

1. breaker shaft 2. bearing backing ring 3. seal 4. bearing retainer ring 5. o-ring 6. bearing 7. sealing ring 8. bearing housing 9. lock washer 10. bolt 11. o-ring

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

pipe plug side plate seal housing seal spiral retainer ring underspeed sensor mount lock washer bolt bolt flange end cap

23.

24.

25.

26.

27.

28.

29.

30.

end cap lock washer bolt bolt wire bit pipe plug u-bolt

______________________________________________________________ REV 2 5.119

BI632977

Replacement of wear parts _________________________________________ Fig. 68: Breaker shaft assembly and disassembly

Metal face

Metal ring Rubber ring

________________________________________________________________ FB140 Feeder Breaker 5.120

BI632977

________________________________________ Replacement of wear parts How to remove the breaker bit To remove the breaker bit from the breaker shaft bit holder proceed as follows (Fig. 69):  Remove the external retaining rings from the shank end of the bit with a pair of external retaining ring pliers.  Remove the bit from its holder. If the bit will not pull easily from its holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.

IMPORTANT! If the bit will not pull easily from its holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.

How to install the breaker bit  To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 86):  Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.  Install the external retaining rings (two per bit) on the shank end of the bit with a pair of external retaining ring pliers. Ensure that the retaining ring is completely seated inside grooved area of the bit.

Fig. 69: Breaker bit removal and installation

Retaining rings Bit holder

Breaker bit

______________________________________________________________ REV 2 5.121

BI632977

Tightening torques _______________________________________________ Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Set screws Table 4: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

Table 5: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

________________________________________________________________ FB140 Feeder Breaker 5.122

BI632977

_______________________________________________ Tightening torques Table 6: FSR hex bolts (SAE 5 and 325 steel) Nominal diameter

Recommended torque setting

¼” 5/16” 3/8” 7/16” ½” 9/16” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½” 1 ¾” 2” 2 ¼” 2 ½” 2 ¾” 3”

9 ft-lbs 18 ft-lbs 31 ft-lbs 50 ft-lbs 75 ft-lbs 110 ft-lbs 150 ft-lbs 250 ft-lbs 378 ft-lbs 583 ft-lbs 782 ft-lbs 1,097 ft-lbs 1,461 ft-lbs 1,748 ft-lbs 3,114 ft-lbs 4,504 ft-lbs 6,497 ft-lbs 7,144 ft-lbs 12,092 ft-lbs 15,744 ft-lbs

Table 7: FSR hex bolts (SAE 5 and 325 steel) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting 26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs 30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

______________________________________________________________ REV 2 5.123

BI632977

Tightening torques _______________________________________________ Table 8: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Table 9: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 10: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

________________________________________________________________ FB140 Feeder Breaker 5.124

BI632977

_______________________________________________ Tightening torques Table 11: Untreated screw, black finish (Fine thread) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25

Nm

27

52

95

Ft-lbs

19

38

70

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

Table 12: Untreated screw, black finish (Fine thread, continued) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5

Nm

150

225

325

Ft-lbs

110

165

239

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

Table 13: Untreated screw, black finish (Fine thread, continued)

Property class

Torque Ma

8.8

Nm

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399

Ft-lbs 10.9 12.9

610

780

449

575

Nm

640

860

1100

Ft-lbs

472

634

811

Nm

770

1050

1300

Ft-lbs

567

774

958

______________________________________________________________ REV 2 5.125

BI632977

Tightening torques _______________________________________________ Table 14: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M33 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

Table 15: Electrically zinc plated (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Nm

Recommended torque setting M12 M14 M16 36

58

88

Nominal diameter M18

M20

M22

121

171

230

Ft-lbs

26

42

54

89

126

169

Nm

83

132

200

275

390

530

Ft-lbs

61

97

147

202

287

390

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 16: Electrically zinc plated (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

________________________________________________________________ FB140 Feeder Breaker 5.126

BI632977

_______________________________________________ Tightening torques Table 17: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

Torque Ma Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

Recommended torque setting M8 X 1 25 18 35 25 42 30

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 18: Electrically zinc plated (Fine thread, continued) Property class

Torque Ma

8.8 10.9 12.9

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 19: Electrically zinc plated (Fine thread, continued) Property class

Torque Ma

8.8 10.9 12.9

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

______________________________________________________________ REV 2 5.127