Cat Feeder Breaker FBL-10 LHD/Utility Service Manual – PDF DOWNLAOD
DESCRIPTION:
Cat Feeder Breaker FBL-10 LHD/Utility Service Manual – PDF DOWNLAOD
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 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.
TABLE OF CONTENTS:
Cat Feeder Breaker FBL-10 LHD/Utility Service Manual – PDF DOWNLAOD
M01379.pdf......................................................................................................................................................................................................................................................................................... 0 Service Manual - Cover Page.................................................................................................................................................................................................................................................................... 2 Table of Contents.............................................................................................................................................................................................................................................................................. 3 Section 1 General Information.................................................................................................................................................................................................................................................................. 9 Introduction .............................................................................................................................................................................................................................................................................. 9 Description ............................................................................................................................................................................................................................................................................... 9 SAFETY LABELS AND INSTRUCTIONS ............................................................................................................................................................................................................................................................ 10 Gauge colour code ......................................................................................................................................................................................................................................................................... 11 Gauge alarm parameters .................................................................................................................................................................................................................................................................... 11 GENERAL ARRANGEMENT ....................................................................................................................................................................................................................................................................... 13 specifications ............................................................................................................................................................................................................................................................................ 14 All specifications are subject to change without notice. Always consult BUCYRUS to obtain current information before applying critical loads. ............................................................................................................................................. 14 Capacities ................................................................................................................................................................................................................................................................................ 14 Weight .................................................................................................................................................................................................................................................................................... 14 Pneumatic System .......................................................................................................................................................................................................................................................................... 15 Lubrication and Fuel Specifications ....................................................................................................................................................................................................................................................... 16 General ................................................................................................................................................................................................................................................................................... 16 Fuels ..................................................................................................................................................................................................................................................................................... 16 Fuel Specification Table .................................................................................................................................................................................................................................................................. 16 Fuel Additives ............................................................................................................................................................................................................................................................................ 17 Diesel Fuel Relevant Information .......................................................................................................................................................................................................................................................... 18 Fuel handling ............................................................................................................................................................................................................................................................................. 18 Low Temperature Effects ................................................................................................................................................................................................................................................................... 18 Exhaust Emissions ......................................................................................................................................................................................................................................................................... 18 Engine Maintenance ........................................................................................................................................................................................................................................................................ 18 Engine Oil ................................................................................................................................................................................................................................................................................ 19 Torque Converter/Transmission Fluid ....................................................................................................................................................................................................................................................... 19 Hydraulic Oil ............................................................................................................................................................................................................................................................................. 19 Gear Oil .................................................................................................................................................................................................................................................................................. 19 Multi-Purpose EP Grease ................................................................................................................................................................................................................................................................... 19 Drive Coupling Grease ..................................................................................................................................................................................................................................................................... 20 Exhaust Conditioner Make Up Tanks ......................................................................................................................................................................................................................................................... 20 Fluid specification table ................................................................................................................................................................................................................................................................. 21 Machine Isolation ......................................................................................................................................................................................................................................................................... 23 Engine Isolation .......................................................................................................................................................................................................................................................................... 23 Pneumatic Isolation ....................................................................................................................................................................................................................................................................... 24 Hydraulic isolation ....................................................................................................................................................................................................................................................................... 25 Engine Coolant Isolation .................................................................................................................................................................................................................................................................. 26 Electrical Isolation ...................................................................................................................................................................................................................................................................... 26 Articulation Isolation .................................................................................................................................................................................................................................................................... 27 Lift Arm Isolation ........................................................................................................................................................................................................................................................................ 28 Exhaust Conditioner 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 ........................................................................................................................................................................................................................................ 43 FBL-10 LHD/Utility Vehicle – Lubrication Reference ........................................................................................................................................................................................................................................ 54 FBL-10 LHD/Utility Vehicle – Lubrication Reference ........................................................................................................................................................................................................................................ 65 FBL-10 LHD/Utility Vehicle – Lubrication Reference ........................................................................................................................................................................................................................................ 77 FBL-10 LHD/Utility Vehicle – Lubrication Reference ........................................................................................................................................................................................................................................ 89 FBL-10 LHD/Utility Vehicle – Lubrication Reference ........................................................................................................................................................................................................................................101 FBL-10 LHD/Utility Vehicle – Lubrication Reference ........................................................................................................................................................................................................................................113 FBL-10 LHD/Utility Vehicle – Lubrication Reference ........................................................................................................................................................................................................................................126 Recommended Bolt Torque ...................................................................................................................................................................................................................................................................127 Section 2 Engine System........................................................................................................................................................................................................................................................................129 Section 3 Transmission and Drive Train.........................................................................................................................................................................................................................................................175 Section 4 Hydraulic System_Danfoss.............................................................................................................................................................................................................................................................203 General description .......................................................................................................................................................................................................................................................................203 Safety precautions ........................................................................................................................................................................................................................................................................204 Hydraulic Isolation .......................................................................................................................................................................................................................................................................205 Pumps and mountings .......................................................................................................................................................................................................................................................................206 Steering/Brake Pump .......................................................................................................................................................................................................................................................................206 Main Hydraulic Pump .......................................................................................................................................................................................................................................................................209 Auxiliary hydraulic pumps .................................................................................................................................................................................................................................................................210 Hydraulic tank ............................................................................................................................................................................................................................................................................211 Checking and filling hydraulic oil ........................................................................................................................................................................................................................................................211 Changing hydraulic oil ....................................................................................................................................................................................................................................................................212 Checking and cleaning filler neck screen ..................................................................................................................................................................................................................................................213 Checking and replacing the return filter ..................................................................................................................................................................................................................................................214 Steering/brake pump pressure filter .......................................................................................................................................................................................................................................................219 Steering circuit ..........................................................................................................................................................................................................................................................................221 Steering accumulator ......................................................................................................................................................................................................................................................................221 Steering control valve ....................................................................................................................................................................................................................................................................222 Brake circuit .............................................................................................................................................................................................................................................................................223 Brake accumulator .........................................................................................................................................................................................................................................................................223 Brake Valve ...............................................................................................................................................................................................................................................................................224 Brake Heads ...............................................................................................................................................................................................................................................................................228 CONTROL LEVERS ............................................................................................................................................................................................................................................................................229 Main Control Valve Bank ...................................................................................................................................................................................................................................................................231 Tilt and Lift Circuits ....................................................................................................................................................................................................................................................................233 RAS Attach and PTO Circuits ...............................................................................................................................................................................................................................................................234 Alternator Circuit and Cooling Fan ........................................................................................................................................................................................................................................................235 Section 4 Hydraulic Schematic..................................................................................................................................................................................................................................................................237 Hydraulic schematic .......................................................................................................................................................................................................................................................................237 Section 5 Electrics, Instruments and Controls..................................................................................................................................................................................................................................................239 Electrical system .........................................................................................................................................................................................................................................................................239 General description .......................................................................................................................................................................................................................................................................239 Safety Precautions ........................................................................................................................................................................................................................................................................239 Electric lighting components ..............................................................................................................................................................................................................................................................241 ENGINE SERVICE HOUR meter .................................................................................................................................................................................................................................................................244 Electrical system troubleshooting .........................................................................................................................................................................................................................................................246 ALTERNATOR AND DRIVE ASSEMBLY .............................................................................................................................................................................................................................................................247 GENERAL DESCRIPTION .......................................................................................................................................................................................................................................................................247 Safety precautions ........................................................................................................................................................................................................................................................................247 ALTERNATOR ASSEMBLY .......................................................................................................................................................................................................................................................................247 Alternator Drive Assembly .................................................................................................................................................................................................................................................................249 Electronic Shutdown System ................................................................................................................................................................................................................................................................250 General Description .......................................................................................................................................................................................................................................................................250 Power supply ..............................................................................................................................................................................................................................................................................250 Display assemblies ........................................................................................................................................................................................................................................................................252 General Arrangements ......................................................................................................................................................................................................................................................................254 switches ..................................................................................................................................................................................................................................................................................255 SENSORS ...................................................................................................................................................................................................................................................................................255 Sensor locations ..........................................................................................................................................................................................................................................................................255 INSTRUCTIONS FOR electronic shutdown system METHANE SENSOR HEAD ...........................................................................................................................................................................................................................260 Checks and Calibration of the TX6383 CH4 TROLEX ...........................................................................................................................................................................................................................................261 Unit should be in fresh air, or fresh air is to be supplied. The unit should have the GREEN LED illuminated. ..............................................................................................................................................................................261 Check reading. If not zero go to Step 3. If the unit reads zero there is no need to zero. (Go to Step 6). .................................................................................................................................................................................261 To calibrate zero hold both buttons in for three seconds LED will go to RED which means the unit is in Calibration Mode. ..................................................................................................................................................................261 Whilst the RED LED is illuminated press and hold the bottom button until the LED is flashing GREEN. .......................................................................................................................................................................................261 Release button and the unit will auto zero, after auto zeroing the unit will go to normal operating mode. The LED will go to GREEN. .......................................................................................................................................................261 Turn the zero gas off. ....................................................................................................................................................................................................................................................................261 Apply the nominal span gas. Allow for sufficient time for reading to be stable. The reading should be ±10% of reading or ±5% of full scale whichever is least. ............................................................................................................................261 If reading is outside of tolerance got to the Step 9. If the reading is within the tolerance turn gas off and allow reading to go back to zero. (Go to Step 12) ..........................................................................................................................261 Press and hold both buttons for three seconds. Span gas must be left on at this stage. The LED will go to RED ............................................................................................................................................................................261 Press and hold the top button until the LED is flashing ORANGE. With the buttons adjust the reading on the display to match that of the nominal gas applied. You have five seconds to press a button. If you do not press a button in this time the unit will go to normal operations. ....261 Take gas off the sensor and allow it to go back to zero. Reapply gas to verify the calibration. ...........................................................................................................................................................................................261 Let sensor zero in air and turn off gas cylinders. The LED should be back to GREEN. .......................................................................................................................................................................................................261 System Operation ..........................................................................................................................................................................................................................................................................263 Testing methane sensor ....................................................................................................................................................................................................................................................................264 Fault diagnosis guide .....................................................................................................................................................................................................................................................................265 INSTRUMENTS AND CONTROLS ..................................................................................................................................................................................................................................................................267 Compartment door ..........................................................................................................................................................................................................................................................................267 Transmission gear control lever ...........................................................................................................................................................................................................................................................268 Transmission Directional Control Lever ....................................................................................................................................................................................................................................................268 Park Brake button .........................................................................................................................................................................................................................................................................269 FOUR-WAYJOYSTICK control lever ............................................................................................................................................................................................................................................................270 No. 2 - TWO-WAY HYDRAULIC Control Lever ...................................................................................................................................................................................................................................................270 No. 1 - TWO-WAY HYDRAULIC control lever ...................................................................................................................................................................................................................................................270 CONTROL LEVER MAINTENANCE .................................................................................................................................................................................................................................................................271 Operator’s Seat ...........................................................................................................................................................................................................................................................................272 Accelerator Pedal .........................................................................................................................................................................................................................................................................272 Brake pedal ...............................................................................................................................................................................................................................................................................272 STEERING WHEEL ............................................................................................................................................................................................................................................................................273 Brake head pressure gauge .................................................................................................................................................................................................................................................................274 Brake accumulator pressure gauge ..........................................................................................................................................................................................................................................................274 Steering accumulator pressure gauge .......................................................................................................................................................................................................................................................274 Engine Start Button .......................................................................................................................................................................................................................................................................275 On/Off Toggle Switch ......................................................................................................................................................................................................................................................................275 Air pressure gauge ........................................................................................................................................................................................................................................................................275 Transmission Oil Temperature Gauge ........................................................................................................................................................................................................................................................276 Engine Coolant Temperature Gauge ..........................................................................................................................................................................................................................................................276 Horn button ...............................................................................................................................................................................................................................................................................277 Emergency Fuel Shut Off Valve .............................................................................................................................................................................................................................................................277 Air Cleaner Service Indicator .............................................................................................................................................................................................................................................................278 Engine SERVICE Hour Meter .................................................................................................................................................................................................................................................................278 Engine Oil Pressure Gauge .................................................................................................................................................................................................................................................................279 Shutdown System Test Valve ................................................................................................................................................................................................................................................................279 ENGINE fuel Primer Pump ...................................................................................................................................................................................................................................................................280 RAS Pilot lock cylinder release button ....................................................................................................................................................................................................................................................280 Attachment quick connects button ..........................................................................................................................................................................................................................................................280 Emergency Intake Shut Off Valve ...........................................................................................................................................................................................................................................................281 Section 6 Frame Components.....................................................................................................................................................................................................................................................................283 Section 7 Pneumatic System.....................................................................................................................................................................................................................................................................301 Section 8 Attachments..........................................................................................................................................................................................................................................................................315
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