CAT BUCYRUS Blakefield South FBL 55H Service Manual BI620094 – PDF DOWNLOAD

Description

CAT BUCYRUS Blakefield South FBL 55H Service Manual BI620094 – PDF DOWNLOAD

FILE DETAILS:

CAT BUCYRUS Blakefield South FBL 55H Service Manual BI620094 – PDF DOWNLOAD

Language : English
Pages :312
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT BUCYRUS Blakefield South FBL 55H Service Manual BI620094 – PDF DOWNLOAD

General Information
INTRODUCTION

• The operation of heavy mining machinery can be hazardous. To ensure safe operation, operators and personnel must be alert, competent, correctly trained, tested and licensed in the principles, capabilities and correct operating and isolation procedures of the machinery.
• This manual is designed to provide the FBL-55H operator and service personnel with the proper information regarding the machine’s instrumentation, operating controls and general safe working procedures. All operators and service personnel of this machine must be conversant with the information contained within this manual before operating the machine or performing services tasks on the machine.
• To ensure safe and efficient operation, the FBL-55H must be adequately maintained by the operators and service personnel. The operator’s pre-start inspection procedure contained in Section 6 of the Operator’s Manual must be performed, before the machine is returned to active service. Any abnormalities should be reported immediately to maintenance personnel to avoid costly machine repairs, production down time and unsafe operation of the machine.

DESCRIPTION

• The FBL-55H is a 60000 kg high capacity articulated, free steered vehicle. It has been designed for lifting and carrying heavy pieces of equipment and machinery in underground coal mines. Its main function will be carrying and placing of longwall equipment and shields.
• The machine comes standard with a set of fork tynes and winch for this purpose. The motive force is provided by a 153 kW Caterpillar 3216 six cylinder turbo charged 4 Stroke Inline 6 Cylinder FLAMEPROOF diesel engine package. Flame proofing of the system includes a “wet” exhaust conditioning system. The start system is pneumatic and the safety system is an intrinsically safe electronic monitoring system.
• The engine power output is connected to the constant 4 wheel drive system via a drive coupling through a 4 speed bi-directional power shift transmission to heavy duty axles with liquid cooled POSI –STOP brakes. The FBL-55H utilises a wet exhaust system complete with an optional replaceable particulate filter and a purifier

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT BUCYRUS Blakefield South FBL 55H Service Manual BI620094 – PDF DOWNLOAD

SECTION 1 7
GENERAL INFORMATION 7
INTRODUCTION 7
DESCRIPTION 7
GENERAL ARRANGEMENT 8
SAFETY LABELS AND INSTRUCTIONS 14
GAUGE COLOUR CODE 15
GAUGE ALARMPARAMETERS 15
LUBRICATION AND FUEL SPECIFICATIONS 17
DIESEL FUEL RELEVANT INFORMATION 19
ENGINE OIL 20
TORQUE CONVERTER / TRANSMISSION FLUID 20
HYDRAULIC OIL 20
GEAR OIL 20
MULTI-PURPOSE EP GREASE 20
DRIVE COUPLING GREASE 20
EXHAUST CONDITIONERMAKE UP TANKS 20
FLUID SPECIFICATION TABLE 21
GREASE POINT REFERENCE DRAWING 22
MACHINE ISOLATION 23
ENGINE ISOLATION 23
PNEUMATIC ISOLATION 24
HYDRAULIC ISOLATION 25
ENGINE COOLANT PRESSURE ISOLATION 26
EXHAUST CONDITIONERMAKE UP TANK PRESSURE ISOLATION 27
ELECTRICAL ISOLATION 28
ARTICULATION ISOLATION 28
EXHAUST CONDITIONER ISOLATION 31
GENERAL SAFETY AND PRECAUTIONS 32
SAFETY RELATED TO LEAD POCKET REGIONS ON FRAME 34
PACKING/SUPPORTING THE MACHINE 35
GRAB HANDLE FORMACHINE TOP ACCESS 37
10 HOUR – DAILY OFF LINEMECHANICAL INSPECTION 39
FLUID SPECIFICATION TABLE 45
50 HOUR – WEEKLY OFF LINE MECHANICAL INSPECTION 46
250 HOUR – 3MONTHLY OFF LINE MECHANICAL INSPECTION 54
FLUID SPECIFICATION TABLE 62
500 HOUR – 6MONTHS OFF LINEMECHANICAL INSPECTION 63
FLUID SPECIFICATION TABLE 71
1000 HOUR – 12MONTHS OFF LINE MECHANICAL INSPECTION 72
FLUID SPECIFICATION TABLE 80
2000 HOUR – 2 YEARLY OFF LINE MECHANICAL INSPECTION 81
FLUID SPECIFICATION TABLE 90
5000 HOUR – 5 YEARLY OFF LINE MECHANICAL INSPECTION 91
FLUID SPECIFICATION TABLE 100
10000 HOUR – 10 YEARLY OFF LINE MECHANICAL INSPECTION 101
FLUID SPECIFICATION TABLE 110
RECOMMENDED BOLT TORQUE 111
SECTION 2 113
ENGINE SYSTEM 113
FUEL SYSTEM 113
FUEL TANK 115
FUEL LINES 115
PRIMARY FUEL FILTER / WATER SEPARATOR 116
BI620094
Bucyrus Australia
Blakefield South FBL-55H Service Manual
Manual No M01335r1 4 of 311 October 2009
SECONDARY FUEL FILTER 118
LUBRICATION SYSTEM 120
SAFETY PRECAUTIONS 121
OIL FILTER 122
CHECKING/FILLING ENGINE OIL 123
CHANGING ENGINE OIL 123
FLUSHING THE LUBRICATION SYSTEM 124
AIR CLEANER / INDICATOR ASSEMBLY 126
EMERGENCY INTAKE SHUT OFF VALVE 127
INLET FLAME TRAP/FLAMEPROOF JOINTS 128
ENGINE PACKAGE 132
EXPANSION TANK 133
HEADER TANK 133
FAN ASSEMBLY 134
RADIATOR 136
CHECKING/FILLING AND FLUSHING COOLANT SYSTEM 137
FLUSHING A CONTAMINATED COOLING SYSTEM 138
EXHAUST SYSTEM 139
EXHAUST DOWNPIPE/PURIFIER 140
EXHAUSTMAKE UP TANK 142
EXHAUST CONDITIONER 143
EXHAUST PARTICULATE FILTER 148
FLAME PATH JOINTS OR FIXED CONNECTIONS 150
EXHAUST EMISSION TESTING PROCEDURE 150
THROTTLE CONTROL 152
ENGINE SYSTEM TROUBLESHOOTING 153
SECTION 3 157
TRANSMISSION AND DRIVE TRAIN 157
ENGINE DRIVE COUPLING 157
CHECKING AND GREASING OF DRIVE COUPLING 158
REMOVAL AND INSTALLATION OF DRIVE COUPLING 159
TRANSMISSION / TORQUE CONVERTER 160
CHECKING/FILLING THE TRANSMISSION OIL 162
CHANGING THE TRANSMISSION OIL FILTER ELEMENT 163
CHANGING THE TRANSMISSION OIL 164
TROUBLESHOOTING GUIDE 165
SERVICE DATA 167
FRONT AND REAR AXLES 170
CHECKING/FILLING THE PLANETARY WHEEL END OIL LEVEL 171
CHECKING/FILLING THE AXLE CENTRE OIL LEVEL 172
CHANGING OIL IN AXLE CENTRES, WHEEL ENDS AND LIQUID COOLED BRAKES 174
CHECKING WEAR OF THE POSI-STOP BRAKE ASSEMBLIES 175
DRIVE LINES 176
GREASING AND INSPECTING DRIVE LINES 178
REMOVING AND INSTALLING THE REAR DRIVE LINE 178
REMOVING AND INSTALLING THE FRONT DRIVE LINES 179
REMOVING AND INSTALLING THE UPPER DRIVES LINES 180
WHEEL AND TYRE ASSEMBLIES 181
SECTION 4 185
HYDRAULIC SYSTEM 185
GENERAL DESCRIPTION 185
SAFETY PRECAUTIONS 188
HYDRAULIC ISOLATION 189
PUMPS AND MOUNTINGS 190
HYDRAULIC TANK 195
STEERING AND BRAKE HYDRAULIC MANIFOLD 199
BI620094
Bucyrus Australia
Blakefield South FBL-55H Service Manual
October 2009 5 of 311 Manual No M01335r1
STEERING / BRAKE PUMP PRESSURE FILTER 203
STEERING CIRCUIT 205
STEERING ACCUMULATOR 205
STEERING CONTROL UNIT / PILOT OPERATED STEERING VALVE 206
BRAKE CIRCUIT 207
BRAKE ACCUMULATOR 207
BRAKE VALVE 208
BRAKE UNITS 212
ATTACHMENT CONTROLS 213
MAIN CONTROL VALVE BANK 215
TILT AND LIFT CIRCUITS 217
ALTERNATOR CIRCUIT AND COOLING FAN 218
SECTION 5 219
ELECTRICS, INSTRUMENTS AND CONTROLS 219
ELECTRICAL SYSTEM 219
ELECTRIC LIGHTING COMPONENTS 220
ENGINE SERVICE HOUR METER 222
ELECTRICAL SYSTEM TROUBLESHOOTING 224
ALTERNATOR AND DRIVE ASSEMBLY 225
ALTERNATOR ASSEMBLY 225
ALTERNATOR DRIVE ASSEMBLY 227
DCS CONCEPT 228
DCS CONTROLLER UNIT 232
SENSORS & LOCATIONS 233
WET SCRUBBER SYSTEM 237
MENU STRUCTURE 239
OPERATIONAL STATE DIAGRAM 242
DISPLAY ILLUSTRATIONS 243
MACHINE OPERATION & SHUTDOWN 253
INSTRUMENTS AND CONTROLS 255
SECTION 6 275
FRAME COMPONENTS 275
GENERAL DESCRIPTION 275
SAFETY PRECAUTIONS 275
FRONT FRAME 276
LIFT ARM 278
REAR FRAME 286
PERIODIC NON-DESTRUCTIVE TESTING OF LOAD BEARING STRUCTURES 298
SECTION 7 299
PNEUMATIC SYSTEM 299
GENERAL DESCRIPTION 299
SAFETY PRECAUTIONS 301
AIR COMPRESSOR 302
AIR RECEIVER 303
START CIRCUIT AND AUXILIARIES 306
PNEUMATIC SYSTEM TROUBLE SHOOTING 310
SECTION 8 3

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• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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