Cat Feeder Breaker FBL-10 LHD/Utility Service Manual – PDF DOWNLOAD
DESCRIPTION:
Cat Feeder Breaker FBL-10 LHD/Utility Service Manual – 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-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 serviceal 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-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.
TABLE OF CONTENTS:
Cat Feeder Breaker FBL-10 LHD/Utility Service Manual – PDF DOWNLOAD
M01368.pdf................................................................................................................................................ 0 Section 1 General Information.pdf..................................................................................................................... 0 Introduction ..................................................................................................................................... 10 Description ...................................................................................................................................... 10 SAFETY LABELS AND INSTRUCTIONS ................................................................................................................... 11 Gauge colour code ................................................................................................................................ 12 Gauge alarm parameters ........................................................................................................................... 12 GENERAL ARRANGEMENT .............................................................................................................................. 14 specifications ................................................................................................................................... 15 All specifications are subject to change without notice. Always consult BUCYRUS to obtain current information before applying critical loads. .... 15 Capacities ....................................................................................................................................... 15 Electronic Shutdown System ....................................................................................................................... 16 Pneumatic System ................................................................................................................................. 16 All specifications are subject to change without notice. ......................................................................................... 16 Lubrication and Fuel Specifications .............................................................................................................. 17 General .......................................................................................................................................... 17 Fuels ............................................................................................................................................ 17 Fuel Specification Table ......................................................................................................................... 17 Fuel Additives ................................................................................................................................... 18 Diesel Fuel Relevant Information ................................................................................................................. 19 Fuel handling .................................................................................................................................... 19 Low Temperature Effects .......................................................................................................................... 19 Exhaust Emissions ................................................................................................................................ 19 Engine Maintenance ............................................................................................................................... 19 Engine Oil ....................................................................................................................................... 20 Torque Converter/Transmission Fluid .............................................................................................................. 20 Hydraulic Oil .................................................................................................................................... 20 Gear Oil ......................................................................................................................................... 20 Multi-Purpose EP Grease .......................................................................................................................... 20 Drive Coupling Grease ............................................................................................................................ 21 Exhaust Conditioner Make Up Tanks ................................................................................................................ 21 Fluid specification table ........................................................................................................................ 22 Machine Isolation ................................................................................................................................ 24 Engine Isolation ................................................................................................................................. 24 Pneumatic Isolation .............................................................................................................................. 25 Hydraulic isolation .............................................................................................................................. 26 Engine Coolant Isolation ......................................................................................................................... 27 Electrical Isolation ............................................................................................................................. 27 Articulation ISOLATION ........................................................................................................................... 28 LIFT ARM Isolation ............................................................................................................................... 29 General Safety and Precautions ................................................................................................................... 30 General .......................................................................................................................................... 30 Packing/Supporting the Machine ................................................................................................................... 33 MAINTENANCE SCHEDULES ............................................................................................................................ 34 Maintenance Inspections .......................................................................................................................... 34 FBL-10 LHD/Utility Vehicle – Lubrication Reference ............................................................................................... 44 FBL-10 LHD/Utility Vehicle – Lubrication Reference ............................................................................................... 55 FBL-10 LHD/Utility Vehicle – Lubrication Reference ............................................................................................... 66 FBL-10 LHD/Utility Vehicle – Lubrication Reference ............................................................................................... 78 FBL-10 LHD/Utility Vehicle – Lubrication Reference ............................................................................................... 90 FBL-10 LHD/Utility Vehicle – Lubrication Reference ...............................................................................................102 FBL-10 LHD/Utility Vehicle – Lubrication Reference ...............................................................................................114 FBL-10 LHD/Utility Vehicle – Lubrication Reference ...............................................................................................127 Recommended Bolt Torque ..........................................................................................................................128 Section 2 Engine System.pdf........................................................................................................................... 0 Fuel System ......................................................................................................................................130 General Description ..............................................................................................................................130 Safety Precautions ...............................................................................................................................131 Fuel Tank ........................................................................................................................................132 Fuel Lines .......................................................................................................................................132 Primary Fuel Filter/Water Separator ..............................................................................................................133 Secondary Fuel Filter ............................................................................................................................135 Fuel System - Priming ............................................................................................................................136 Lubrication System ...............................................................................................................................137 General Description ..............................................................................................................................137 Safety Precautions ...............................................................................................................................138 Oil Filter .......................................................................................................................................139 Checking/Filling Engine Oil ......................................................................................................................140 Changing Engine Oil ..............................................................................................................................140 Flushing the Lubrication System ..................................................................................................................141 Air Intake System ................................................................................................................................142 General Description ..............................................................................................................................142 Safety Precautions ...............................................................................................................................142 Air Cleaner/Indicator Assembly ...................................................................................................................143 Emergency Intake Shut Off Valve ..................................................................................................................144 Inlet Flame Trap/Flameproof Joints ...............................................................................................................145 Servicing Air Intake System ......................................................................................................................146 Cooling system ...................................................................................................................................148 General description ..............................................................................................................................148 Safety Precautions ...............................................................................................................................148 Engine Package ...................................................................................................................................149 Header tank ......................................................................................................................................150 Expansion tank ...................................................................................................................................150 Fan assembly .....................................................................................................................................151 Water Pump Belt Tension ..........................................................................................................................152 radiator .........................................................................................................................................153 Checking/Filling and Flushing Coolant System .....................................................................................................155 Flushing a contaminated cooling system ...........................................................................................................156 Exhaust system ...................................................................................................................................157 General description ..............................................................................................................................157 Safety precautions ...............................................................................................................................158 Exhaust downpipe/purifier ........................................................................................................................158 EXHAUST Make up tank .............................................................................................................................160 Exhaust conditioner ..............................................................................................................................161 Flame path joints or fixed connections ...........................................................................................................168 Exhaust emission testing procedure ...............................................................................................................168 Throttle Control .................................................................................................................................170 General Description ..............................................................................................................................170 Safety precautions ...............................................................................................................................170 Engine system troubleshooting ....................................................................................................................171 Section 4 Hydraulic System.pdf........................................................................................................................ 0 General description ..............................................................................................................................204 Safety precautions ...............................................................................................................................205 Hydraulic Isolation ..............................................................................................................................206 Pumps and mountings ..............................................................................................................................207 Steering/Brake Pump ..............................................................................................................................207 Main Hydraulic Pump ..............................................................................................................................210 Auxiliary hydraulic pumps ........................................................................................................................211 Hydraulic tank ...................................................................................................................................212 Checking and filling hydraulic oil ...............................................................................................................212 Changing hydraulic oil ...........................................................................................................................213 Checking and cleaning filler neck screen .........................................................................................................214 Checking and replacing the return filter .........................................................................................................215 STEERING AND BRAKE HYDRAULIC MANIFOLD ............................................................................................................216 Steering/brake pump pressure filter ..............................................................................................................220 Steering circuit .................................................................................................................................222 Steering accumulator .............................................................................................................................222 Steering control valve ...........................................................................................................................223 Brake circuit ....................................................................................................................................224 Brake accumulator ................................................................................................................................224 Brake Valve ......................................................................................................................................225 Brake Heads ......................................................................................................................................229 attachment controls ..............................................................................................................................230 control levers ...................................................................................................................................230 Main Control Valve Bank ..........................................................................................................................232 Tilt and Lift Circuits ...........................................................................................................................234 RAS Attach and PTO Circuits ......................................................................................................................235 Alternator Circuit and Cooling Fan ...............................................................................................................236 Section 4 Hydraulic Schematic.pdf..................................................................................................................... 0 Hydraulic schematic ..............................................................................................................................238 Section 5 Electrics, Instruments and Controls.pdf..................................................................................................... 0 Electrical system ................................................................................................................................240 General description ..............................................................................................................................240 Safety Precautions ...............................................................................................................................240 Electric lighting components .....................................................................................................................242 ENGINE SERVICE HOUR meter ........................................................................................................................245 Electrical system troubleshooting ................................................................................................................247 ALTERNATOR AND DRIVE ASSEMBLY ....................................................................................................................248 GENERAL DESCRIPTION ..............................................................................................................................248 Safety precautions ...............................................................................................................................248 ALTERNATOR ASSEMBLY ..............................................................................................................................248 Alternator Drive Assembly ........................................................................................................................250 Electronic Shutdown System .......................................................................................................................251 General Description ..............................................................................................................................251 INSTRUMENTS AND CONTROLS .........................................................................................................................252 Compartment door .................................................................................................................................252 Transmission gear control lever ..................................................................................................................253 Transmission Directional Control Lever ...........................................................................................................253 Park Brake button ................................................................................................................................254 FOUR-WAYJOYSTICK control lever ...................................................................................................................255 No. 2 - TWO-WAY HYDRAULIC Control Lever ..........................................................................................................255 No. 1 - TWO-WAY HYDRAULIC control lever ..........................................................................................................255 CONTROL LEVER MAINTENANCE ........................................................................................................................256 Operator’s Seat ..................................................................................................................................257 Accelerator Pedal ................................................................................................................................257 Brake pedal ......................................................................................................................................257 STEERING WHEEL ...................................................................................................................................258 Brake head pressure gauge ........................................................................................................................259 Brake accumulator pressure gauge .................................................................................................................259 Steering accumulator pressure gauge ..............................................................................................................259 Engine Start Button ..............................................................................................................................260 On/Off Toggle Switch .............................................................................................................................260 Air pressure gauge ...............................................................................................................................260 Transmission Oil Temperature Gauge ...............................................................................................................261 Engine Coolant Temperature Gauge .................................................................................................................261 Horn button ......................................................................................................................................262 Emergency Fuel Shut Off Valve ....................................................................................................................262 Air Cleaner Service Indicator ....................................................................................................................263 Engine SERVICE Hour Meter ........................................................................................................................263 Engine Oil Pressure Gauge ........................................................................................................................264 Shutdown System Test Valve .......................................................................................................................264 ENGINE fuel Primer Pump ..........................................................................................................................265 RAS Pilot lock cylinder release button ...........................................................................................................265 Attachment quick connects button .................................................................................................................265 Emergency Intake Shut Off Valve ..................................................................................................................266 ELECTRONIC SHUTDOWN SYSTEM service section 5.pdf...................................................................................................... 0 ELECTRONIC SHUTDOWN SYSTEM........................................................................................................................267 General Description...........................................................................................................................267 Power supply..................................................................................................................................267 DISPLAY ASSEMBLIES...............................................................................................................................267 GENERAL ARRANGEMENTS..............................................................................................................................270 SWITCHES..........................................................................................................................................270 SENSORS...........................................................................................................................................270 SENSOR LOCATIONS..................................................................................................................................270 Engine Coolant Level Sensor...................................................................................................................270 Exhaust Gas Temperature Sensor................................................................................................................271 Engine Coolant Temperature Sensor.............................................................................................................271 Engine Oil Pressure Sensor Testing............................................................................................................272 Low Exhaust Conditioner Water Sensors.........................................................................................................273 INSTRUCTIONS FOR ELECTRONIC SHUTDOWN SYSTEM METHANE SENSOR HEAD...................................................................................275 Purpose.......................................................................................................................................275 General.......................................................................................................................................275 CHECKS AND CALIBRATION OF THE TX6383 CH4 TROLEX...................................................................................................276 OPERATION OF THE BYPASS SWITCH....................................................................................................................277 Latching:.....................................................................................................................................277 Bypass:.......................................................................................................................................277 Straight:.....................................................................................................................................277 SYSTEM OPERATION..................................................................................................................................277 DCS CONCEPT.......................................................................................................................................279 General Inputs and Outputs....................................................................................................................279 System Hardware ..............................................................................................................................281 Display Unit..................................................................................................................................282 Power Supply..................................................................................................................................282 DCS Controller Unit...........................................................................................................................283 Fuel Solenoid.................................................................................................................................283 Sensors & Locations...........................................................................................................................284 Wet Scrubber System...........................................................................................................................288 Display Unit..................................................................................................................................288 Menu Structure................................................................................................................................289 Operational State Diagram.....................................................................................................................292 Display Illustrations.........................................................................................................................292 Machine Operation & Shutdown..................................................................................................................302 TESTING METHANE SENSOR............................................................................................................................304 FAULT DIAGNOSIS GUIDE.............................................................................................................................305 Section 7 Pneumatic System.pdf........................................................................................................................ 0 General description ..............................................................................................................................324 Safety precautions ...............................................................................................................................326 Air compressor ...................................................................................................................................327 Compressor and Mountings .........................................................................................................................327 Compressor .......................................................................................................................................327 Air Receiver .....................................................................................................................................328 Starter motor ....................................................................................................................................331 Make up tank head pressure .......................................................................................................................332 SAFETY CIRCUIT ...................................................................................................................................332 Electronic Shutdown system .......................................................................................................................332 Safe start system ................................................................................................................................333 Brake and Transmission Interlock System ..........................................................................................................334 Operator’s horn ..................................................................................................................................335 Section 8 Attachments.pdf............................................................................................................................. 0 General description ..............................................................................................................................338 Safety precautions ...............................................................................................................................340 Spade Lip Ejector Bucket .........................................................................................................................341 Straight Lip Ejector Bucket ......................................................................................................................342 RAS Ejector Bucket ...............................................................................................................................343 15000 kg side shift forks ........................................................................................................................344 10000 kg fixed jib crane .........................................................................................................................346 5TH WHEEL ADAPTOR ................................................................................................................................348 MATERIALS POD ....................................................................................................................................350 HYDRAULIC REELER .................................................................................................................................352 Hydraulic ........................................................................................................................................353 ELEVATED WORK PLATFORM ...........................................................................................................................358 CONCRETE HOPPER ..................................................................................................................................361 FUEL POD .........................................................................................................................................363 Section 3 Transmission and Drive Train.pdf............................................................................................................ 0 Engine drive coupling ............................................................................................................................176 General description ..............................................................................................................................176 Safety precautions ...............................................................................................................................176 Checking and greasing of drive coupling ..........................................................................................................177 Removal and installation OF drive coupling .......................................................................................................178 Transmission/torque converter ....................................................................................................................179 General description ..............................................................................................................................179 Safety precautions ...............................................................................................................................181 Checking/filling the transmission oil ............................................................................................................182 Changing the Transmission Oil Filter element .....................................................................................................183 Changing the Transmission Oil ....................................................................................................................184 Troubleshooting guide ............................................................................................................................185 Service data .....................................................................................................................................187 Front and rear axles .............................................................................................................................190 General description ..............................................................................................................................190 Safety precautions ...............................................................................................................................190 Checking/Filling the Planetary Wheel End Oil Level ...............................................................................................191 Checking/Filling the Axle Centre Oil Level .......................................................................................................192 Changing OIL IN Axle Centres, Wheel Ends and Liquid Cooled Brakes ................................................................................194 Checking Wear of the POSI-STOP Brake Assemblies ..................................................................................................195 Drive lines ......................................................................................................................................196 General DESCRIPTION ..............................................................................................................................196 Safety precautions ...............................................................................................................................197 Greasing and Inspecting Drive Lines ..............................................................................................................198 Removing and Installing the Rear Drive Line ......................................................................................................198 Removing and Installing the Front Drive Lines ....................................................................................................199 Removing and installing the upper drives lines ...................................................................................................200 Wheel and Tyre Assemblies ........................................................................................................................201 General DESCRIPTION ..............................................................................................................................201 Safety precautions ...............................................................................................................................201 Removal ..........................................................................................................................................201 Installation .....................................................................................................................................203
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