CAT BUCYRUS FBL-10 LHD Utility Service Manual SN 1600 – PDF DOWNLOAD

Description

CAT BUCYRUS FBL-10 LHD Utility Service Manual SN 1600 – PDF DOWNLOAD

FILE DETAILS:

CAT BUCYRUS FBL-10 LHD Utility Service Manual SN 1600 – PDF DOWNLOAD

Language : English
Pages : 367
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT BUCYRUS FBL-10 LHD Utility Service Manual SN 1600 – PDF DOWNLOAD

• 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-10 LHD/Utility 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 or performing service tasks on the machine.
• To ensure safe and efficient operation, the FBL-10 LHD/Utility 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.

DESCRIPTION

• The FBL-10 is a 10000 kg Load Haul Dump/Utility machine. It allows it to be used for general purpose work throughout the mine, which includes carrying heavy loads, materials and supplies.
• The motive force is provided by a 153 kW Caterpillar 3126 turbocharged four-stroke inline six cylinder flameproof diesel engine package.
• Flameproofing of the system includes a wet exhaust conditioning system complete with exhaust filtration and intake flame traps.
• The start system is pneumatic. The Electronic Shutdown System is an intrinsically safe electronic monitoring system. The engine power output is connected to the constant fourwheel drive system via a drive coupling through a four-speed bidirectional power shift transmission to heavy duty axles.
• The FBL-10 utilises a wet bath exhaust conditioning system and a catalysed exhaust post treatment purifier.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT BUCYRUS FBL-10 LHD Utility Service Manual SN 1600 – PDF DOWNLOAD

Section 1 General Information
Introduction 1
Description 1
Safety Labels and Instructions 2
Gauge Colour Code 3
Gauge Alarm Parameters 3
General Arrangements 5
Specifications 6
Lubrication and Fuel Specifications
General 8
Fuels 8
Fuel Specification Table 8
Fuel Additives 9
Diesel Fuel Relevant Information 10
Engine Oil 11
Torque Converter/Transmission Fluid 11
Hydraulic Oil 11
Gear Oil 11
Multi Purpose EP Grease 11
Drive Coupling Grease 12
Exhaust Conditioner Make Up Tanks 12
Fluid Specification Table 13
Grease Point Reference Drawing 14
Machine Isolation
Engine Isolation 15
Pneumatic Isolation 16
Hydraulic Isolation 17
Engine Coolant Isolation 18
Electrical Isolation 18
Articulation Isolation 19
Lift Arm Isolation 20
General Safety and Precaution
General 21
Packing and Supporting the Machine 24
Maintenance Schedules 25
10 Hours—Daily Off Line Mechanical Inspection 27
50 Hours—Weekly Off Line Mechanical Inspection 37
250 Hours—3 Months Off Line Mechanical Inspection 47
500 Hours—6 Months Off Line Mechanical Inspection 59
1000 Hours—12 Months Off Line Mechanical Inspection 71
2000 Hours—2 Yearly Off Line Mechanical Inspection 83
5000 Hours—5 Yearly Off Line Mechanical Inspection 95
10000 Hours—10 Yearly Off Line Mechanical Inspection 107
Recommended Bolt Torque 119
Section 2 Engine System
Fuel System
General Description 121
Safety Precautions 122
Fuel Tank 123
Fuel Lines 123
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ii FBL-10 LHD/Utility Serial No 1600 Rev 2
Section 2 Engine System (cont )
Fuel System
Primary Fuel Filter/Water Separator 124
Secondary Fuel Filter 126
Fuel System – Priming 127
Lubrication System
General Description 128
Safety Precautions 129
Oil Filter 130
Checking/Filling Engine Oil 131
Changing Engine Oil 131
Flushing the Lubrication System 132
Air Intake System
General Description 133
Safety Precautions 133
Air Cleaner/Indicator Assembly 134
Emergency Intake Shutoff Valve 135
Inlet Flame Trap/Flameproof Joints 136
Servicing Air Intake System 137
Cooling System
General Description 139
Safety Precautions 139
Engine Package 140
Expansion Tank 141
Header Tank 141
Fan Assembly 142
Water Pump Belt Tension 143
Radiator 144
Checking/Filling and Flushing Coolant System 146
Flushing a Contaminated Cooling System 147
Exhaust System
General Description 148
Safety Precautions 149
Exhaust Downpipe/Purifier 149
Exhaust Make Up Tanks 151
Exhaust Conditioner 152
Exhaust Particulate Filter 157
Flame Paths or Fixed Connections 159
Exhaust Emission Testing Procedure 159
Throttle Control
General Description 161
Safety Precautions 161
Engine System Troubleshooting 162
Section 3 Transmission and Drive Train
Engine Drive Coupling
General Description 167
Safety Precautions 167
Checking and Greasing Drive Coupling 168
Removal and Installation of Drive Coupling 169
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Rev 2 FBL-10 LHD/Utility Serial No 1600 iii
Section 3 Transmission and Drive Train (cont )
Transmission and Torque Converter
General Description 170
Safety Precautions 172
Checking/Filling the Transmission Oil 173
Changing the Transmission Oil Filter Element 174
Changing the Transmission Oil 175
Troubleshooting Guide 176
Service Data 178
Front and Rear Axle
General Description 181
Safety Precautions 181
Checking/Filling the Planetary Wheel End Oil Level 182
Checking/Filling the Axle Centre Oil Level 183
Changing the Oil In Axle Centres, Wheel Ends, and Liquid
Cooled Brakes 184
Checking Wear of the Posi-Stop Brake Assemblies 186
Drive Lines
General Description 187
Safety Precautions 188
Greasing and Inspecting Drive Lines 189
Removing and Installing the Rear Drive Line 189
Removing and Installing the Front Drive Line 190
Removing and Installing the Upper Drive Line 191
Wheel and Tyre Assemblies
General Description 192
Safety Precautions 192
Removal 192
Installation 194
Section 4 Hydraulic System
General Description 195
Safety Precautions 196
Hydraulic Isolation 197
Pumps and Mountings
Steering/Brake Pump 198
Main Hydraulic Pump 201
Auxiliary Hydraulic Pumps 202
Hydraulic Tank
Checking and Filling Hydraulic Oil 203
Changing Hydraulic Oil 204
Checking and Cleaning Filler Neck Screen 205
Checking and Replacing Return Filter 206
Steering and Brake Hydraulic Manifold 207
Steering/Brake Pump Pressure Filter 211
Steering Circuit 213
Steering Accumulator 213
Steering Control Valve 214
Brake Circuit 215
Brake Accumulator 215
Brake Valve 216
Brake Heads 220
Attachment Controls
Control Levers 221
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iv FBL-10 LHD/Utility Serial No 1600 Rev 2
Section 4 Hydraulic System (cont )
Main Control Valve Bank 223
Tilt and Lift Circuits 225
RAS Attach and PTO Circuits 226
Alternator Circuit and Cooling Fan 227
Hydraulic Schematic 229
Section 5 Electrics, Instruments and Controls
Electrical System
General Description 231
Safety Precautions 231
Alternator, Lights and Hour Meter General Arrangement 232
Electric Lighting Components 233
Engine Service Hour Meter 236
Electrical System Troubleshooting 238
Alternator and Drive Assembly
General Description 239
Safety Precautions 239
Alternator Assembly 239
Alternator Drive Assembly 241
Instruments and Controls
Compartment Door 243
Transmission Gear Control Lever 244
Transmission Directional Control Lever 244
Park Brake Button 244
Four-Way Joystick Control Lever 246
No 1 Two-Way Hydraulic Control Lever 246
No 2 Two-Way Hydraulic Control Lever 246
Control Lever Maintenance 247
Operator’s Seat 248
Accelerator Pedal 248
Brake Pedal 248
Steering Wheel 249
Brake Head Pressure Gauge 250
Brake Accumulator Pressure Gauge 250
Steering Accumulator Pressure Gauge 250
Engine Start Button 251
Air Pressure Gauge 251
ON/OFF Toggle Switch 251
Transmission Oil Temperature Gauge 252
Engine Coolant Temperature Gauge 252
Horn Button 253
Emergency Fuel Shut Off Valve 253
Engine Service Hour Meter 254
Air Cleaner Service Indicator 254
Engine Oil Pressure Gauge 255
Shutdown System Test Valve 255
Engine Fuel Primer Pump 256
RAS Pilot Lock Cylinder Release Button 256
Attachment Quick Connects Button 256
Emergency Intake Shut Off Valve 257
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Rev 2 FBL-10 LHD/Utility Serial No 1600 v
Section 5 Electrics, Instruments and Controls (cont )
Electronic Shut down system 258
Methane Sensor Head 266
Checks and Calibration 267
Bypass Switch 268
System Operation 269
DCS Concept 270
System Hardware 273
DCS Control Unit 274
Sensors and Locations 275
Wet Scrubber System 279
Display Unit 279
System Operation 280
Menu Structure 280
Display Illustrations 284
Startup Screen 293
DCS Shutdown Modes 294
Starting Machine 294
Testing Methane Sensor 295
Fault Guide 296
Section 6 Frame Components
General Description 298
Safety Precautions 298
Front Frame
Chassis 299
Lift Arm
General 301
Fitting and Removal of Lift Arm Lock 302
Rapid Attach Back Plate (RAS) Assembly 303
Rear Frame
Chassis 305
Operator’s Compartment 306
Compartment Door Assembly 307
Canopy Assembly 308
Operator’s Seating 310
Articulation Joint 311
Covers 312
Section 7 Pneumatic System
General Description 315
Safety Precautions 315
Air Compressor
Compressor Mounting 318
Compressor 318
Air Receiver 319
Starter Motor 322
Safety Circuit
Electronic Shutdown System 323
Make Up Tank Head Pressure 323
Safe Start System 324
Brake and Transmission Interlock System 325
Operator’s Horn 326
Pneumatic System Troubleshooting 327
Section 8 Attachments
General Description 329
Safety Precautions 331
Spade Lip Ejector Blanket 332
Straight Lip Ejector Blanket 333
RAS Ejector Blanket 334
15000 KG Side Shit Forks 335
10000 KG Fixed Jib Crane 337
5th Wheel Adaptor 339
Materials Pod 341
Hydraulic Reeler 343
Elevated Work Platform 349
Concrete Hopper 352
Fuel Pod 354

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