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
CAT FEEDER BREAKER FBL-10 LHD/UTILITY SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
Cat Feeder Breaker FBL-10 LHD/Utility Service Manual – PDF DOWNLOADCat Feeder Breaker FBL-10 LHD/Utility Service Manual – PDF DOWNLOAD
PLEASE NOTE:
This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.M
✹
What Our Customers Say
★★★★★Live reviews from customers
Loading customer reviews...
🌟 Related Products
Discover more professional manuals for your equipment
