CAT BUCYRUS FBL-10 LHD Utility Service Manual SN80042 – PDF DOWNLOAD

Description

CAT BUCYRUS FBL-10 LHD Utility Service Manual SN80042 – PDF DOWNLOAD

FILE DETAILS:

CAT BUCYRUS FBL-10 LHD Utility Service Manual SN80042 – PDF DOWNLOAD

Language : English
Pages : 344
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT BUCYRUS FBL-10 LHD Utility Service Manual SN80042 – 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 172 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 and intake flame traps. The start system is pneumatic.
• The diesel control system is an intrinsically safe electronic monitoring system. The engine power output is connected to the constant four-wheel 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. A removable flame trap for ease of cleaning is fitted on the outlet of the exhaust conditioner housing.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT BUCYRUS FBL-10 LHD Utility Service Manual SN80042 – PDF DOWNLOAD

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 15
Hydraulic Isolation 16
Engine Coolant Isolation 18
Electrical Isolation 18
Articulation Isolation 19
Lift Arm Isolation 20
Exhaust Conditioner Isolation 21
General Safety and Precaution
General 22
Packing and Supporting the Machine 25
Maintenance Schedules 26
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
BI620123
Service Manual
ii FBL-10 LHD/Utility Serial No 80042 Rev 0
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 129
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 Outlet Flame Trap 156
Flame Paths or Fixed Connections 157
Exhaust Emission Testing Procedure 157
Throttle Control
General Description 159
Safety Precautions 159
Cable Adjustment 160
Engine System Trouble Shooting 161
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
Transmission/Torque Converter
General Description 170
Safety Precautions 172
BI620123
Service Manual
Rev 0 FBL-10 LHD/Utility Serial No 80042 iii
Section 3 Transmission and Drive Train (cont )
Transmission and Torque Converter
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 185
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 191
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
Steering Accumulator 213
Steering Control Valve 214
Brake Circuit
Brake Accumulator 215
Brake Valve 216
Brake Heads 220
Attachment Controls
Control Levers 221
Main Control Valve Bank 223
Tilt and Lift Circuits 225
BI620123
Service Manual
iv FBL-10 LHD/Utility Serial No 80042 Rev 0
Section 4 Hydraulic System (cont )
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 237
Alternator and Drive Assembly
General Description 239
Safety Precautions 239
Alternator Assembly 239
Alternator Drive Assembly 241
Instruments and Controls
Electronic Shut down system 242
Display Assemblies 244
Sensors and Locations 247
Methane Sensor Head 252
Checks and Calibration 253
Air Cleaner Service Indicator 254
Bypass Switch 254
Testing Methane Sensor 256
Fault Guide 257
Compartment Door 259
Transmission Gear Control Lever 260
Transmission Directional Control Lever 260
Park Brake Button 261
Four-Way Joystick Control Lever 262
No 1 Two-Way Hydraulic Control Lever 262
No 2 Two-Way Hydraulic Control Lever 262
Control Lever Maintenance 263
Operator’s Seat 264
Accelerator Pedal 264
Brake Pedal 264
Steering Wheel 265
Brake Head Pressure Gauge 266
Brake Accumulator Pressure Gauge 266
Steering Accumulator Pressure Gauge 266
Engine Start Button 267
Air Pressure Gauge 267
ON/OFF Toggle Switch 267
Transmission Oil Temperature Gauge 268
Engine Coolant Temperature Gauge 268
Horn Button 269
Emergency Fuel Shut Off Valve 269
Engine Service Hour Meter 270
BI620123
Service Manual
Rev 0 FBL-10 LHD/Utility Serial No 80042 v
Section 5 Electrical cont
Air Cleaner Service Indicator 270
Engine Oil Pressure Gauge 271
Shutdown System Test Valve 271
Engine Fuel Primer Pump 272
RAS Pilot Lock Cylinder Release Button 272
Attachment Quick Release Button 272
Emergency Intake Shut Off Valve 273
Section 6 Frame Components
General Description 275
Safety Precautions 275
Front Frame
Chassis 276
Lift Arm
General 278
Fitting and Removal of Lift Arm Lock 279
Rapid Attach Back Plate (RAS) Assembly 280
Rear Frame
Chassis 282
Operator’s Compartment 283
Compartment Door Assembly 284
Canopy Assembly 285
Operator’s Seating 287
Articulation Joint 288
Covers 289
Section 7 Pneumatic System
General Description 293
Safety Precautions 295
Air Compressor
Compressor Mounting 296
Compressor 296
Air Receiver 297
Starter Motor 300
Safety Circuit
Electronic Shutdown System 301
Make Up Tank Head Pressure 301
Safe Start System 302
Brake and Transmission Interlock System 303
Operator’s Horn 304
Pneumatic System Troubleshooting 305
Room & Pillar Division
20 Kullara Close, PO Box 373
Beresfield NSW 2322 Australia
Phone: +61 2 49147000
Fax: +61 2 49147059
Section 8 Attachments
General Description … 307
Safety Precautions … 309
Spade Lip Ejector Blanket 310
Straight Lip Ejector Blanket 311
RAS Ejector Blanket …312
15000 KG Side Shit Forks 313
10000 KG Fixed Jib Crane 315
5th Wheel Adaptor … 317
Materials Pod 319
Hydraulic Reeler 321
Elevated Work Platform … 327
Concrete Hopper 331
Fuel Pod 332

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