Bucyrus Australia
Version 1
Version 2
Blakefield South FBL-55H Service Manual
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Photo’s updated and index updated draft removed
Bucyrus recommends that all Safe Working procedures should be approved and checked by Mine Officials. Bucyrus Australia declines all liability for direct or indirect consequences of printing errors.
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Manual No.M01335r1 2 of 311 October 2009
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October 2009 3 of 311 Manual No. M01335r1 Contents SECTION 1...........................................................................................................................................................7 GENERAL INFORMATION.............................................................................................................................7 INTRODUCTION..............................................................................................................................................7 DESCRIPTION...................................................................................................................................................7 GENERAL ARRANGEMENT...........................................................................................................................8 SAFETY LABELS AND INSTRUCTIONS.....................................................................................................14 GAUGE COLOUR CODE................................................................................................................................15 GAUGE ALARM PARAMETERS..................................................................................................................15 LUBRICATION AND FUEL SPECIFICATIONS...........................................................................................17 DIESEL FUEL RELEVANT INFORMATION................................................................................................19 ENGINE OIL....................................................................................................................................................20 TORQUE CONVERTER / TRANSMISSION FLUID.....................................................................................20 HYDRAULIC OIL............................................................................................................................................20 GEAR OIL........................................................................................................................................................20 MULTI-PURPOSE EP GREASE.....................................................................................................................20 DRIVE COUPLING GREASE......................................................................................................................... 20 EXHAUST CONDITIONER MAKE UP TANKS............................................................................................20 FLUID SPECIFICATION TABLE...................................................................................................................21 GREASE POINT REFERENCE DRAWING...................................................................................................22 MACHINE ISOLATION..................................................................................................................................23 ENGINE ISOLATION......................................................................................................................................23 PNEUMATIC ISOLATION.............................................................................................................................24 HYDRAULIC ISOLATION.............................................................................................................................25 ENGINE COOLANT PRESSURE ISOLATION.............................................................................................26 EXHAUST CONDITIONER MAKE UP TANK PRESSURE ISOLATION...................................................27 ELECTRICAL ISOLATION............................................................................................................................28 ARTICULATION ISOLATION.......................................................................................................................28 EXHAUST CONDITIONER ISOLATION......................................................................................................31 GENERAL SAFETY AND PRECAUTIONS...................................................................................................32 SAFETY RELATED TO LEAD POCKET REGIONS ON FRAME................................................................34 PACKING/SUPPORTING THE MACHINE...................................................................................................35 GRAB HANDLE FOR MACHINE TOP ACCESS..........................................................................................37 10 HOUR – DAILY OFF LINE MECHANICAL INSPECTION.....................................................................39 FLUID SPECIFICATION TABLE...................................................................................................................45 50 HOUR – WEEKLY OFF LINE MECHANICAL INSPECTION.................................................................46 250 HOUR – 3 MONTHLY OFF LINE MECHANICAL INSPECTION.........................................................54 FLUID SPECIFICATION TABLE...................................................................................................................62 500 HOUR – 6 MONTHS OFF LINE MECHANICAL INSPECTION............................................................63 FLUID SPECIFICATION TABLE...................................................................................................................71 1000 HOUR – 12 MONTHS OFF LINE MECHANICAL INSPECTION........................................................72 FLUID SPECIFICATION TABLE...................................................................................................................80 2000 HOUR – 2 YEARLY OFF LINE MECHANICAL INSPECTION...........................................................81 FLUID SPECIFICATION TABLE...................................................................................................................90 5000 HOUR – 5 YEARLY OFF LINE MECHANICAL INSPECTION...........................................................91 FLUID SPECIFICATION TABLE.................................................................................................................100 10000 HOUR – 10 YEARLY OFF LINE MECHANICAL INSPECTION.....................................................101 FLUID SPECIFICATION TABLE.................................................................................................................110 RECOMMENDED BOLT TORQUE.............................................................................................................111 SECTION 2.......................................................................................................................................................113 ENGINE SYSTEM ...........................................................................................................................................113 FUEL SYSTEM..............................................................................................................................................113 FUEL TANK...................................................................................................................................................115 FUEL LINES..................................................................................................................................................115 PRIMARY FUEL FILTER / WATER SEPARATOR.....................................................................................116 BI620094
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Manual No.M01335r1 4 of 311 October 2009 SECONDARY FUEL FILTER........................................................................................................................118 LUBRICATION SYSTEM..............................................................................................................................120 SAFETY PRECAUTIONS..............................................................................................................................121 OIL FILTER....................................................................................................................................................122 CHECKING/FILLING ENGINE OIL.............................................................................................................123 CHANGING ENGINE OIL.............................................................................................................................123 FLUSHING THE LUBRICATION SYSTEM.................................................................................................124 AIR CLEANER / INDICATOR ASSEMBLY.................................................................................................126 EMERGENCY INTAKE SHUT OFF VALVE...............................................................................................127 INLET FLAME TRAP/FLAMEPROOF JOINTS...........................................................................................128 ENGINE PACKAGE.......................................................................................................................................132 EXPANSION TANK.......................................................................................................................................133 HEADER TANK.............................................................................................................................................133 FAN ASSEMBLY...........................................................................................................................................134 RADIATOR....................................................................................................................................................136 CHECKING/FILLING AND FLUSHING COOLANT SYSTEM..................................................................137 FLUSHING A CONTAMINATED COOLING SYSTEM..............................................................................138 EXHAUST SYSTEM......................................................................................................................................139 EXHAUST DOWNPIPE/PURIFIER..............................................................................................................140 EXHAUST MAKE UP TANK........................................................................................................................142 EXHAUST CONDITIONER...........................................................................................................................143 EXHAUST PARTICULATE FILTER............................................................................................................148 FLAME PATH JOINTS OR FIXED CONNECTIONS...................................................................................150 EXHAUST EMISSION TESTING PROCEDURE.........................................................................................150 THROTTLE CONTROL.................................................................................................................................152 ENGINE SYSTEM TROUBLESHOOTING..................................................................................................153 SECTION 3.......................................................................................................................................................157 TRANSMISSION AND DRIVE TRAIN........................................................................................................157 ENGINE DRIVE COUPLING........................................................................................................................157 CHECKING AND GREASING OF DRIVE COUPLING...............................................................................158 REMOVAL AND INSTALLATION OF DRIVE COUPLING .......................................................................159 TRANSMISSION / TORQUE CONVERTER................................................................................................160 CHECKING/FILLING THE TRANSMISSION OIL......................................................................................162 CHANGING THE TRANSMISSION OIL FILTER ELEMENT....................................................................163 CHANGING THE TRANSMISSION OIL......................................................................................................164 TROUBLESHOOTING GUIDE.....................................................................................................................165 SERVICE DATA.............................................................................................................................................167 FRONT AND REAR AXLES.......................................................................................................................... 170 CHECKING/FILLING THE PLANETARY WHEEL END OIL LEVEL.......................................................171 CHECKING/FILLING THE AXLE CENTRE OIL LEVEL...........................................................................172 CHANGING OIL IN AXLE CENTRES, WHEEL ENDS AND LIQUID COOLED BRAKES......................174 CHECKING WEAR OF THE POSI-STOP BRAKE ASSEMBLIES..............................................................175 DRIVE LINES.................................................................................................................................................176 GREASING AND INSPECTING DRIVE LINES...........................................................................................178 REMOVING AND INSTALLING THE REAR DRIVE LINE.......................................................................178 REMOVING AND INSTALLING THE FRONT DRIVE LINES...................................................................179 REMOVING AND INSTALLING THE UPPER DRIVES LINES.................................................................180 WHEEL AND TYRE ASSEMBLIES.............................................................................................................181 SECTION 4.......................................................................................................................................................185 HYDRAULIC SYSTEM..................................................................................................................................185 GENERAL DESCRIPTION............................................................................................................................185 SAFETY PRECAUTIONS..............................................................................................................................188 HYDRAULIC ISOLATION............................................................................................................................189 PUMPS AND MOUNTINGS..........................................................................................................................190 HYDRAULIC TANK......................................................................................................................................195 STEERING AND BRAKE HYDRAULIC MANIFOLD................................................................................199 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October 2009 5 of 311 Manual No. M01335r1 STEERING / BRAKE PUMP PRESSURE FILTER.......................................................................................203 STEERING CIRCUIT.....................................................................................................................................205 STEERING ACCUMULATOR......................................................................................................................205 STEERING CONTROL UNIT / PILOT OPERATED STEERING VALVE..................................................206 BRAKE CIRCUIT..........................................................................................................................................207 BRAKE ACCUMULATOR...........................................................................................................................207 BRAKE VALVE.............................................................................................................................................208 BRAKE UNITS..............................................................................................................................................212 ATTACHMENT CONTROLS....................................................................................................................... 213 MAIN CONTROL VALVE BANK................................................................................................................215 TILT AND LIFT CIRCUITS..........................................................................................................................217 ALTERNATOR CIRCUIT AND COOLING FAN........................................................................................218 SECTION 5.......................................................................................................................................................219 ELECTRICS, INSTRUMENTS AND CONTROLS.....................................................................................219 ELECTRICAL SYSTEM ..219 ELECTRIC LIGHTING COMPONENTS......................................................................................................220 ENGINE SERVICE HOUR METER .................................................................................................................222 ELECTRICAL SYSTEM TROUBLESHOOTING........................................................................................224 ALTERNATOR AND DRIVE ASSEMBLY.................................................................................................225 ALTERNATOR ASSEMBLY........................................................................................................................225 ALTERNATOR DRIVE ASSEMBLY...........................................................................................................227 DCS CONCEPT..............................................................................................................................................228 DCS CONTROLLER UNIT ..232 SENSORS & LOCATIONS ....233 WET SCRUBBER SYSTEM .................................................................................................................................237 MENU STRUCTURE ............239 OPERATIONAL STATE DIAGRAM ......................................................................................................................242 DISPLAY ILLUSTRATIONS .................................................................................................................................243 MACHINE OPERATION & SHUTDOWN ..............................................................................................................253 INSTRUMENTS AND CONTROLS .............................................................................................................255 SECTION 6.......................................................................................................................................................275 FRAME COMPONENTS................................................................................................................................275 GENERAL DESCRIPTION...........................................................................................................................275 SAFETY PRECAUTIONS.............................................................................................................................275 FRONT FRAME.............................................................................................................................................276 LIFT ARM......................................................................................................................................................278 REAR FRAME...............................................................................................................................................286 PERIODIC NON-DESTRUCTIVE TESTING OF LOAD BEARING STRUCTURES.................................298 SECTION 7.......................................................................................................................................................299 PNEUMATIC SYSTEM..................................................................................................................................299 GENERAL DESCRIPTION...........................................................................................................................299 SAFETY PRECAUTIONS.............................................................................................................................301 AIR COMPRESSOR......................................................................................................................................302 AIR RECEIVER.............................................................................................................................................303 START CIRCUIT AND AUXILIARIES........................................................................................................306 PNEUMATIC SYSTEM TROUBLE SHOOTING.........................................................................................310 SECTION 8........................................................................................................................................................311 BI620094
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INTRODUCTION
Section 1
General Information
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-55H 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 the machine or performing services tasks on the machine.
To ensure safe and efficient operation, the FBL-55H 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.
Any abnormalities should be reported immediately to maintenance personnel to avoid costly machine repairs, production down time and unsafe operation of the machine.
DESCRIPTION
The FBL-55H is a 60000 kg high capacity articulated, free steered vehicle. It has been designed for lifting and carrying heavy pieces of equipment and machinery in underground coal mines. Its main function will be carrying and placing of longwall equipment and shields. The machine comes standard with a set of fork tynes and winch for this purpose.
The motive force is provided by a 153 kW Caterpillar 3216 six cylinder turbo charged 4 Stroke Inline 6 Cylinder FLAMEPROOF diesel engine package. Flame proofing of the system includes a “wet” exhaust conditioning system. The start system is pneumatic and the safety system is an intrinsically safe electronic monitoring system. The engine power output is connected to the constant 4 wheel drive system via a drive coupling through a 4 speed bi-directional power shift transmission to heavy duty axles with liquid cooled POSI –STOP brakes.
The FBL-55H utilises a wet exhaust system complete with an optional replaceable particulate filter and a purifier.
IMPORTANT
A site specific Risk Assessment is recommended to be conducted before this machine is introduced into service.
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GENERAL ARRANGEMENT
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SPECIFICATIONS
All specifications are subject to change without notice. Always consult BUCYRUS to obtain current information before applying critical loads. Capacities
Tractive effort 36500 kg
Winch (front) 20000 kg
Maximum un-braked trailer mass Consult Bucyrus
Maximum braked trailer mass Consult Bucyrus
Capacity of tow hitch 38750 kg
Fork Loading Chart
Engine
Engine Speeds
Weight
Unladen with full tanks57600 kg
Unladen with full tanks & Cookie Plate 59220 kg
Maximum laden with Cookie Plate 119220 kg
Type Diesel, turbocharged, 4 cycle
Cooling system Water based radiator
Cooling fan Hydraulic driven fan
Engine make/model Caterpillar 3126
Displacement 7.2 litre
Low idle 800 rpm
High idle 2700 rpm
Fuel Consumption
At full power 45 litre/hr
Average mine duty 12-40 litre/hr
Start System
Starter motor type Air turbine type
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Distance From Fork Face (mm) Maximum Load (kg) Standard 700 60000 900 53000 1200 45500 1500 39700 1800 35200
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Intake Air Cleaner
Type/make Dry dual element/Caterpillar
Intake flame trap Spiral wound type
Exhaust Conditioner
Type Flameproof wet type
Make Bucyrus
Exhaust flame trap Reversible
After treatment Catalytic exhaust purifier
Transmission
Type
Power shift with fwd/rev modulation
Make/model Dana 36000 series MHR
Speeds Forward and reverse 4
Torque Converter
Type Mounted in transmission single element
Make/model Dana 14.0 integral
Axles
Type Outboard planetary
Front axle make/model Dana 21D
Rear axle make/modelDana 19D
Differential lock typefront Posi-Torque
Differential lock typerear Posi-Torque
Wheels
Type Solid Size 54’OD x 28’ wide
Inflation media Solid
Hydraulic Systems
Steering Closed centre
Pressure compensated 2500 psi
Brakes Closed centre
Pressure compensated 2500 psi
Lift Open centre 3000 psi
PTO Open centre 3000 psi
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Hydraulic Filtration
Tank type Sealed and pressurised
Tank pressure 50 kPa
Steer/brake system Pressure 10 micron replaceable with bypass
Optional return PTO In line, 25 micron
Service Brake Hydraulic System
Type Reverse modulated, pressure reducing
Control valve Open centre
Actuation Foot pedal
Operating pressure 0 to 17.10 MPa
Brake release pressure 12.1 MPa Type Centre articulated, hydraulic Type Totally enclosed, liquid cooled Posi-Stop Type Totally enclosed, liquid cooled Posi-Stop
Steering
Service Brake Park Brake Articulation
Bearing type and size Pin & Spherical Degrees of turn either side 45°
Oscillation
Type Rear bolster Type Cross-seated Make Bucyrus Suspension Air Adjustable
Seating (Operator)
Canopy
Type (both) Protective device MDG1 And MDG17
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Electrical
Service
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System Lights Alternator
System
Pneumatic
Capacities Vehicle Speeds Maximum Tractive Effort Grade ability Type Approved flameproof Voltage 12 V Number/location 2 front, 2 rear Type High performance Approved flameproof Drive Hydraulic Type Approved flameproof Compressor type Piston engine gear driven Governed pressure 120 psi Relief pressure 130 psi Air receiver volume 80 litre Hydraulic tank 400 litre Fuel tank 400 litre Transmission/converter oil 40 litre Engine crankcase oil 22 litre Engine cooling system water 72 litre Axle oil (each) 32 litre 1st gear 3 kph 2nd gear 7 kph 3rd gear 12 kph 4th gear 20 kph (Max at Tare weight) 1st gear 36500 kg 2nd gear 15200 kg 3rd gear 8700 kg 4th gear 4950 kg Front to rear at GVM 1:5 Front to rear (empty) 1:4 Side to side (empty) 1:4 Side to side at GVM 1:8 BI620094
(Laden forks fully raised)
WARNING
Overloading equipment could cause personal injury, death or equipment damage. Due to configuration or options these weights can vary up to 20%. For example if the machine is fitted with tyre chains then an additional weight of 330kg per wheel would apply. Bucyrus recommends that relevant standards and safety procedures should always be used when operating this machine. Removal of protective canopies, doors, interlocks and structures etc, could cause serious injury of death. Replacement with correctly torqued fasteners is mandatory.
Maximum
speed at Tare weight = 20kph
Machine
GVM weight = 6kph
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SAFETY LABELS AND INSTRUCTIONS
This manual contains important information affecting the safety of personnel and the equipment being used.
The safety instructions and behavioural rules are intended to protect operators from potentially dangerous situations and assist in the safe operation of the trailer and associated equipment. The following symbols are used with safety instructions and identify varying degrees of hazardous conditions.
The safety instructions associated with these symbols are to be considered the minimum requirements for effective hazard and operational control.
DANGER!
Points in the text marked with this symbol draw attention to immediately impending danger. Possible consequences are very serious or fatal injury.
WARNING!
These points contain information on potentially dangerous situations. Possible consequences are very serious or fatal injury.
CAUTION!
This symbol draws attention to potentially dangerous situations. Possible consequences are light to moderately serious injury and machine damage.
NOTICE!
Points in the text marked with this symbol draw attention to potentially harmful situations. Possible consequences are damage to machine or equipment in immediate vicinity.
IMPORTANT!
Text marked with this symbol contains useful information associated with the machine and its application.
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GAUGE COLOUR CODE
The gauges in the operator’s compartment are colour coded to assist the operator to recognise if the temperatures and pressures are within the correct operating parameters. During normal operation some gauges may, at times, read outside of the indicated normal operating range e.g. during normal operation, when the operator applies the brake the brake head pressure gauge will drop below the minimum pressure and indicate that the pressure is too low. This is because the pressure is being released from the brakes to allow the springs to apply the brakes. When the operator releases the brake the gauge should then return to the green zone.
RED: The gauge is indicating an unsafe condition. When this occurs the operator should stop the machine and rectify the problem or have service personnel rectify the problem before placing the machine back in service.
ORANGE: The gauge is indicating a temperature or pressure outside of the normal operating range. The operator should closely monitor the gauge and report the problem to service personnel for rectification.
YELLOW: The gauge is indicating a temperature or pressure below the normal operating range. This will not cause immediate damage if operated for short periods. Report to service personnel for rectification if machine continually operates in this area.
GREEN: The gauge is indicating that the temperature or pressure being monitored is within the normal operating range.
GAUGE ALARM PARAMETERS
Engine Coolant Temperature
0-50°C Yellow Coolant temperature too low.
50-104°C Green Normal operating temperature range.
104-107°C Orange Above normal operating temperature. Engine shutdown imminent. 107-120°C Red Above normal operating temperature. Engine should have shutdown. Coolant will be boiling
Transmission oil Temperature
0-120°C Green Normal operating temperature range (82 - 95°C).
120-150°C Orange Above normal operating temperature.
150-200°C Red Above normal operating temperature.
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Engine Oil Pressure
0-100 kPa Red Engine oil pressure too low. Engine should have shutdown.
100-600 kPa Green Normal operating pressure range.
600-800 kPa Red Engine oil pressure too high. Continued operation could result in damage to the engine.
Air Pressure Gauge
0-275 kPa Orange Air pressure low. Machine will not start. Machine may shutdown.
275-827 kPa Green Normal operating pressure range.
827-1000 kPa Red Air pressure too high. Continued long periods of operation could result in damage to the machine.
Brake Accumulator Pressure Gauge
0-13790 kPa Red Pressure too low. Brakes may not fully release. Premature brake wear may result if operated for prolonged periods. Needle may drop into this area for a short period when brakes are operating.
13790-18616 kPa Green Normal operating pressure range.
18616-25000 kPa Red Above normal operating range. Damage to brake components may result if operated for prolonged periods.
Brake Head Pressure Gauge
0-11377 kPa Red Pressure below normal operating range. Needle will register in this area during normal operation of brakes and when park brake is applied. Gauge must return to normal operating range when brakes are released. Premature brake wear may result if operation continued.
11377-12756 kPa Green Normal operating pressure range.
12756-16000 kPa Red Pressure too high. Damage to brake units may occur.
Steering Accumulator Pressure Gauge
0-13790 kPa Red Pressure too low. Steering may become heavy to operate. Needle will drop into this area for a short period when steering is operating.
13790-18616 kPa Green Normal operating pressure range.
18616-25000 kPa Red Above normal operating range. Damage to steering components may result if operated for prolonged periods
Exhaust Filter Back Pressure
0-10kPa Green Normal operating pressure range.
10-12kPa Orange Above normal pressure range. Filter change required.
Above 12kPa Red Back pressure excessive. Engine performance affected
Exhaust Gas temperature
0-77°C Green Normal operating temperature range.
77- 85°C Orange Above normal temperature range. Engine shutdown is imminent
Above 85°C Red Exhaust gas temperature excessive. Engine should shut down
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LUBRICATION AND FUEL SPECIFICATIONS
General
This section provides Bucyrus standard requirements for the use of fuels and lubricants. Consult Bucyrus or relevant fuel and oil suppliers for recommended alternatives.
Fuels
Diesel fuel for underground use shall consist of petroleum hydrocarbons and shall be free of inorganic acids, visible suspended matter or water.
All diesel fuel should conform to the table of requirements listed in this Section. Diesel fuel may contain additives as indicated on the next page.
The use of speciality low emission fuels is not recommended as engine/fuel pump damage and poor engine performance may result.
Fuel Specification Table
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Property Test Method Unit Specified Values Appearance Visual Inspection ASTM D4176 Procedure No 2 @ 25 ° C Numerical Rating Clear and bright Clear and bright Ash ASTM D 482 (Notice 1) % Mass 0.01 max Carbon Residue ASTM D 524 % Mass 0.15 max Cetane Number (Notice 2) ASTM D 613 45 min Calc. Cetane Index (Notice 2) ASTM D 4737 45 min Cloud Pt (Notice 3) ASTM D 2500 ° C -10 max (0 max Notice 4) Copper strip corrosion ASTM D 130 1 B max Density @ 15°C ASTM D 1298 or ASTM D 4052 kg/L 0.80- 0.83 Distillation 90% rec @ ASTM D 86 ° C 290 max (350 max Notice 4) Flash Point ASTM D 93 ° C 61.5min Sulphur ASTM D 129 or ASTM D 2622 or ASTM D 2785 % Mass 0.05 max Viscosity ASTM D 445 cSt @ 40 ° C1.5- 2.5 Water & Sediment ASTM D 1796 % Vol 0.05 max BI620094
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