PDF Operation and Maintenance Manual Cat FB110 Feeder Breaker - 2 MB
This comprehensive operation and maintenance manual is essential for anyone working with the Cat FB110 Feeder Breaker.
It provides detailed instructions on daily checks, routine servicing, and correct operational procedures to ensure maximum uptime.
Following the guidelines in this manual will help prevent costly breakdowns and extend the life of your equipment.
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BI001899
A6474X258
October 2012
Operation and
Maintenance
Manual
FB110 Feeder Breaker
SAFETY.CAT.COM
--- Page 3 ---
_______________________________________________________________
2 Your safety
________________________________________________________________
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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 repre-
sents 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 elec-
trical shock.
Always follow all safety procedures of each particular mine when per-
forming 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 pan-
els 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
■ the hoses have no bubbles or blisters
■ the hose or outer sheathes of the hose are not abnormally rigid or
hard
■ the outer sheath of the hoses is not damaged
■ the connectors are securely inserted into the sockets
■ 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 sys-
tem! Flush out the hydraulic lines thoroughly before connecting.
If hydraulic hose couplers are difficult to disconnect or cannot be dis-
connected, the hydraulic line may still be pressurized. Be sure to de-
pressurize the line before disconnecting couplers.
______________________________________________________________
A6474X258 Rev 3 2.11
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_______________________________________________________________
3 Storage and transport
________________________________________________________________
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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 re-
ceived adequate training to perform this task.
Work on:
the safety components (pressure relief valves, fire extinguishing equip-
ment, 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 General 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:
■ hoists with adequate lifting capacity
■ means of attachment with adequate lifting capacity
■ unloading dock
■ jacks with adequate lifting capacity
______________________________________________________________
A6474X258 Rev 3 4.3
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___________________________________________________ Operation
Operation
This chapter contains important information on the operation and main-
tenance of the machine. It also includes instructions on the replace-
ment 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 seri-
ous accidents! Operate the unit only when you have been suffi-
ciently 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 ade-
quate knowledge of the complete machine.
This also includes:
■ what safety devices are installed on the machine,
■ where these safety devices are located, and
■ how these safety devices are to be operated.
When can conveying be started?
Operation must not be started until the safe condition and proper func-
tion of the complete machine has been checked and the daily mainte-
nance operations have been carried out.
______________________________________________________________
A6474X258 Rev 3 5.3
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___________________________________________________ Operation
– “MOTOR OIL TEMP HEALTHY” light will be on.
– “HYDR OIL LEVEL HEALTHY” light will be on.
– “SPRAY WATER PROVED” light will be off.
– “WATER FLOW” light will be off.
– “OUT BAY CONVEYOR RUNNING” light will be on.
– “NORMAL OPERATION” light will be on.
– “SEQ & WATER MONITORING” light will be off.
To start the motor
Ensure that the “NORMAL/MAINTENANCE” switch located on the
door of the starter enclosure is in the “NORMAL” position.
Ensure the water to the mist spray system is in the “OFF” position.
Push and release the “START” pushbutton located on the starter
enclosure door.
Pre-start warning consisting of a flashing light and siren will operate
for the period set by timer TR4. (Adjustable from 0-30 seconds)
Provided all other control systems are healthy the motor will start
immediately following the completion of the pre-start warning
period below.
NOTICE:
The crusher scroll is directly coupled to the motor. TR5 will also
be energized (adjustable 0-30 seconds) normally set at 7 secs,
temporarily overriding the rotational under speed sensor. If the
rotational speed is not achieved during this period, the motor will
shut down.
To start the discharge conveyor
Turn on the water supply. Both water monitoring switches will
operate.
Push and release one of the remote “START” pushbuttons or the
“START’ pushbutton on the starter enclosure door. The conveyor
will now run for the preset period set by TR3 timer. Operating a
remote “START” pushbutton or the “START” pushbutton on the
door of the starter enclosure will reset the TR3 timer.
If the mist spray fails to reach the preset parameters set within the
monitoring switches the conveyor will stop after the TR1 timer
(adjustable from 0-30 seconds) usually set at 3 seconds times out.
______________________________________________________________
A6474X258 Rev 3 5.13
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_____________________________________________Electrical system
Fig. 18: Starter enclosure door
Serial number 54-2168
Door panel components
1 6 7 2 8 3 9 4 1. Indicator lights
2. Mode of operation switch
3. Indicator lights
4. Hour meter
5. Overload reset button
5 10
6. Start button
7. Emergency stop button
8. 12V Earth leakage test
button
9. 12V/110V Earth leakage
reset button
10. 110V Earth leakage test
button
11. “CR7”
12. “TR3”
13. “CR6”
14. “TR5”
15. “TR4”
16. “TR2”
23 22 21 20 19 18 17 16 15 14 13 12 11
17. “RR”
18. “CR5”
19. “CR3”
20. “CR4”
Serial number 54-2184 21. “TR1”
22. “TR6”
23. “CR1”
4 3 6 7 2 8 9 1
10
5
23 20 19 22 21 18 17 16 15 14 13 12 11
______________________________________________________________
A6474X258 Rev 3 5.23
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____________________________________________ Hydraulic system
loop flushing valve The machine is equipped with a loop flush valve located on the dis-
charge end of the machine on the frame side plate behind the hydro-
static pump. The valve is used to dump approximately 30% of the
charge oil to the low pressure side of the circuit.
heat exchanger The oil to air type heat exchanger is located on the right side of the ma-
chine. It used to remove heat from the hydraulic circuit prior to dumping
into tank.
conveyor direction/speed The two (2) position conveyor control valve located above the left hand
control valve crawler is used to control the conveyor direction of travel and speed.
charge filter The charge filter located under the gear pump on the right hand side of
the machine is used to filter the charge fluid. The filter removes hot oil
from the circuit, allowing the charge pump to replenish the circuit with
cooler oil.
pressure filter (s) Two (2) pressure filter (s) are located above the crawler on the left
hand side of the machine and are used to filter fluid on the pressure
side of the circuit.
return filter The return filter located on the left hand side of the discharge end of
the machine is used to filter fluid from the case drains of the hydraulic
pump and motors.
tank fill filter 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.
pressure filter (hydrostatic) The pressure filter located above the gear pump is used to filter fluid
that is being pumped by the hydrostatic pump.
ball valve The ball valve 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 tank fill pump.
“TRAM/CONVEYOR” The tram/conveyor control valve allows the operator to select either
control valve “TRAM” or “CONVEYOR” mode. Push the control lever down for con-
veyor mode and pull the control lever up for tram mode.
tram circuit system The tram circuit system pressure gauge is a high pressure gauge
pressure gauge (6,000 psi) located on the right side of the discharge end. This gauge
gives the operator a constant reading of the tram circuit system pres-
sure.
tram circuit charge The tram circuit charge pressure gauge is a low pressure gauge (600
pressure gauge psi) located on the right side of the discharge end. This gauge gives
the operator a constant reading of the tram circuit charge pressure.
auxiliary function The auxiliary function pressure gauges are high pressure gauge (6,000
pressure gauges psi) located to the left of the tram control levers. These gauges give
the operator a constant reading of the auxiliary system pressures.
______________________________________________________________
A6474X258 Rev 3 5.33
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________________________________________________ Maintenance
Lubrication and inspection
Maintenance includes
■ Lubrication of the machine in accordance with the lubrication
schedule.
■ Inspection of the machine for faults and proper function.
■ Inspection for wear parts.
Table 1: Lubricants: Fluids and capacities
Location Specification Approximate capacity
Hydraulic oil tank Spec. 100-1 162 gal (613 L)
Breaker reducer Spec. 100-6 10 gal (38 L)
Tram Reducer Spec. 100-2 2.5 gal per side
or (10 L per side)
Spec. 100-13
Grease points Spec. 100-3 As required
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. 30) is located on the left hand
side of the receiving end of the feeder breaker. This allows the follow-
ing to be easily lubricated from a central point; head shaft, breaker
shaft and tail shaft.
Fig. 30: Central lubrication
Note:
Outboard bearing
Outboard bearing port used only if applicable on ma-
chine.
Tail shaft Breaker Head shaft
______________________________________________________________
A6474X258 Rev 3 5.43
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________________________________________________ Maintenance
Every 3 months
electric motor Lubricate the feeder breaker’s electric motor with Spec. 100-14 or 100-
16 through the two (2) grease fittings located on each end of the motor
(Fig. 42) . 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 with Spec. 100-3 through the two (2) grease fit-
tings located on the central lubrication panel (Fig. 42) located on the
right side of the discharge section. Pump only one or two pumps of
grease into each fitting.
power fill filter Change the power fill filter element (Fig. 42). If the element is ex-
tremely dirty, a more frequent interval may be required.
Fig. 42: Electric motor and reducer lubrication
Power fill filter
Reducer
lubrication panel
Electric motor central
lubrication panel
______________________________________________________________
A6474X258 Rev 3 5.53
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_______________________________________ Adjustment procedures
Instructions on the adjustment procedures
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 con-
veyor.
To adjust tension on the conveyor chain with the take-up cylinders pro-
ceed as follows (Fig. 47):
Close the stop valve on manifold assembly securely.
Attach a grease gun to the grease fitting located on the manifold
and apply grease until 2” - 3” (50 mm - 75 mm) of sag is achieved
underneath the head shaft sprockets.
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.
______________________________________________________________
A6474X258 Rev 3 5.63
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_______________________________________ Adjustment procedures
Fig. 52: Flow control valve adjustment
Heat exchanger motor Flow control valve Flow control valve
adjustment
Pump and charge system reliefs
The pump and charge system reliefs are non-adjustable. If settings are
incorrect, the cartridges must be replaced. See the pump drawing in
the parts book for your machine.
______________________________________________________________
A6474X258 Rev 3 5.73
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____________________________________ Replacement of wear parts
How to remove the tail shaft
To remove the tail shaft assembly from the receiving boom proceed as
follows (Fig. 58):
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. Ob-
serve 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. 58):
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 Spec. 100-3 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.
______________________________________________________________
A6474X258 Rev 3 5.83
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____________________________________ Replacement of wear parts
Crawler assembly
The crawler assembly (Fig. 63) 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 com-
ponent 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. 63: Crawler assembly main components
Sprocket
Hydraulic motor
(not shown)
Cat pad assembly
Torque hub
Take-up cylinder
& shims
Take-up roller
assembly
______________________________________________________________
A6474X258 Rev 3 5.93
--- Page 18 ---
____________________________________ Replacement of wear parts
How to disassemble the breaker power unit
To disassemble the power unit proceed as follows (Fig. 69):
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
17) and remove pump.
Open access cover on connecting tube (item 8) and loosen the two
(2) bolts on the pump end and set screw on the motor end of the
coupling.
Remove the four (4) bolts and lockwashers from hydrostatic pump
(item 12). With the aid of a lifting device, slowly pull pump from
coupling (item 7) and connecting tube (item 8).
WARNING!
You could be seriously injured or even killed by falling loads. Ob-
serve 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 8) and remove connecting tube from motor (item 5).
Remove coupling (item 7) and key from motor shaft.
Remove the four (4) bolts and nuts from motor base and the eight
(8) bolts, lockwashers and nuts from the reducer base. With the aid
of a lifting device, slowly lift motor and reducer from mounting base
(item 11).
Remove sprocket (item 6) and key from reducer shaft.
Separe motor and reducer coupling halfs by removing the twelve
(12) bolts from around the center of coupling (item 3).
With the aid of a lifting device, slowly separate motor (item 5) and
reducer (item 1).
Remove the bolt, lockwasher and end cap (item 22) the end of the
reducer shaft.
Remove the three (3) bolts that secures the taper lock (item 2) to
the reducer shaft.