Service Manual
CL215
Serial
Revision No 0 27 September 2012
Load Haul Dump SAFETY.CAT.COM
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Number 5003975
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Service Manual Rev. 0 CL215 Load Haul Dump Serial No. 5003975 i TABLE OF CONTENTS Section 1 General Information Introduction ..................................................................................... 1 Description...................................................................................... 1 Safety Labels and Instructions ....................................................... 2 Gauge Colour Code........................................................................ 3 Gauge Alarm Parameters ............................................................... 3 General Arrangements ................................................................... 6 Specifications ................................................................................. 7 Lubrication and Fuel Specifications General ................................................................................. 9 Fuels ..................................................................................... 9 Fuel Specification Table ........................................................ 9 Fuel Additives ...................................................................... 10 Diesel Fuel Relevant Information ........................................ 11 Engine Oil ............................................................................ 12 Torque Converter/Transmission Fluid ................................. 12 Hydraulic Oil ........................................................................ 12 Gear Oil ............................................................................... 12 Multi Purpose EP Grease .................................................... 12 Drive Coupling Grease ........................................................ 13 Exhaust Conditioner Make Up Tanks .................................. 13 Fluid Specification Table ..................................................... 14 Grease Point Reference Drawing........................................ 15 Machine Isolation Engine Isolation ................................................................... 16 Pneumatic Isolation ............................................................. 17 Hydraulic Isolation ............................................................... 18 Engine Coolant Isolation ..................................................... 19 Electrical Isolation ............................................................... 19 Articulation Isolation ............................................................ 20 Lift Arm Isolation ................................................................. 21 Exhaust Conditioner Isolation.............................................. 22 Exhaust Conditioner Make Up Tank Pressure Isolation ...... 23 General Safety and Precaution General ............................................................................... 24 Packing and Supporting the Machine.................................. 27 Maintenance Schedules ............................................................... 25 10 Hours—Daily Off Line Mechanical Inspection ................ 29 50 Hours—Weekly Off Line Mechanical Inspection ............ 37 250 Hours—3 Months Off Line Mechanical Inspection ....... 47 500 Hours—6 Months Off Line Mechanical Inspection ....... 57 1000 Hours—12 Months Off Line Mechanical Inspection ... 67 2000 Hours—2 Yearly Off Line Mechanical Inspection ....... 77 5000 Hours—5 Yearly Off Line Mechanical Inspection ....... 87 10000 Hours—10 Yearly Off Line Mechanical Inspection ... 97 Recommended Bolt Torque........................................................ 107 Section 2 Engine System Fuel System General Description........................................................... 109 Safety Precautions ............................................................ 110 Fuel Tank .......................................................................... 111 BI001927 BI001927
Service Manual ii CL215 Load Haul Dump Serial No. 5003975 Rev. 0 Section 2 Engine System (cont.) Fuel System Fuel Lines .......................................................................... 112 Primary Fuel Filter/Water Separator .................................. 113 Secondary Fuel Filter ........................................................ 114 Fuel System – Priming ...................................................... 116 Lubrication System General Description ........................................................... 117 Safety Precautions ............................................................ 118 Oil Filter ............................................................................. 119 Checking/Filling Engine Oil................................................ 120 Changing Engine Oil.......................................................... 120 Flushing the Lubrication System ....................................... 121 Air Intake System General Description ........................................................... 122 Safety Precautions ............................................................ 122 Air Cleaner/Indicator Assembly ......................................... 123 Emergency Intake Shutoff Valve ....................................... 124 Inlet Flame Trap/Flameproof Joints ................................... 125 Servicing Air Intake System............................................... 126 Cooling System General Description ........................................................... 128 Safety Precautions ............................................................ 128 Engine Package ................................................................ 129 Expansion Tank ................................................................. 130 Header Tank ...................................................................... 130 Fan Assembly .................................................................... 131 Water Pump Belt Tension.................................................. 132 Radiator ............................................................................. 133 Checking/Filling and Flushing Coolant System ................. 135 Flushing a Contaminated Cooling System ........................ 136 Exhaust System General Description ........................................................... 137 Safety Precautions ............................................................ 138 Exhaust Downpipe/Purifier ................................................ 138 Exhaust Make Up Tanks ................................................... 140 Exhaust Conditioner .......................................................... 141 Exhaust Particulate Filter................................................... 150 Flame Paths or Fixed Connections ................................... 152 Exhaust Emission Testing Procedure................................ 152 Throttle Control General Description ........................................................... 154 Safety Precautions ............................................................ 154 Cable Adjustment .............................................................. 155 Engine System Troubleshooting ................................................. 156 Section 3 Transmission and Drive Train Engine Drive Coupling General Description ........................................................... 161 Safety Precautions ............................................................ 161 Checking and Greasing Drive Coupling ............................ 162 Removal and Installation of Drive Coupling....................... 163 BI001927 BI001927
Service Manual Rev. 0 CL215 Load Haul Dump Serial No. 5003975 iii Section 3 Transmission and Drive Train (cont.) Transmission and Torque Converter General Description........................................................... 164 Safety Precautions ............................................................ 166 Checking/Filling the Transmission Oil ............................... 167 Changing the Transmission Oil Filter Element .................. 168 Changing the Transmission Oil ........................................ 169 Troubleshooting Guide ...................................................... 170 Service Data ...................................................................... 172 Front and Rear Axle General Description........................................................... 175 Safety Precautions ............................................................ 175 Checking/Filling the Planetary Wheel End Oil Level ......... 176 Checking/Filling the Axle Centre Oil Level ........................ 177 Changing the Oil In Axle Centres, Wheel Ends, and Liquid Cooled Brakes ................................................................... 178 Checking Wear of the Brake Assemblies .......................... 179 Drive Lines General Description........................................................... 180 Safety Precautions ............................................................ 181 Greasing and Inspecting Drive Lines ................................ 182 Removing and Installing the Rear Drive Line .................... 182 Removing and Installing the Front Drive Line ................... 183 Removing and Installing the Upper Drive Line ................. 184 Wheel and Tyre Assemblies General Description........................................................... 185 Safety Precautions ............................................................ 185 Removal ............................................................................ 185 Installation ......................................................................... 187 Section 4 Hydraulic System General Description .................................................................... 189 Safety Precautions ..................................................................... 190 Hydraulic Isolation ............................................................. 191 Pumps and Mountings Steering/Brake Pump ........................................................ 192 Main Hydraulic Pump ........................................................ 195 Auxiliary Hydraulic Pumps................................................. 196 Hydraulic Tank Checking and Filling Hydraulic Oil..................................... 197 Changing Hydraulic Oil...................................................... 198 Checking and Replacing Return Filter............................... 199 Steering and Brake Hydraulic Manifold ...................................... 200 Steering/Brake Pump Pressure Filter ......................................... 204 Steering Circuit ........................................................................... 206 Steering Accumulator ........................................................ 206 Steering Control Valve ...................................................... 207 Brake Circuit ............................................................................... 208 Brake Accumulator ............................................................ 208 Brake Valve ....................................................................... 209 Brake Heads...................................................................... 213 Attachment Controls Control Levers ................................................................... 214 BI001927 BI001927
Service Manual iv CL215 Load Haul Dump Serial No. 5003975 Rev. 0 Section 4 Hydraulic System (cont.) Main Control Valve Bank ............................................................ 216 Tilt and Lift Circuits ..................................................................... 218 RAS Attach and PTO Circuits .................................................... 219 Alternator Circuit and Cooling Fan .............................................. 220 Hydraulic Schematic ................................................................... 221 Section 5 Electrics, Instruments and Controls Electrical System General Description ........................................................... 223 Safety Precautions ............................................................ 223 Alternator, Lights and Hour Meter General Arrangement .. 224 Electric Lighting Components ............................................ 225 Engine Service Hour Meter ............................................... 228 Electrical System Troubleshooting .................................... 229 Alternator and Drive Assembly General Description ........................................................... 230 Safety Precautions ............................................................ 230 Alternator Assembly .......................................................... 230 Alternator Drive Assembly ................................................. 232 Diesel Control System (DCS) General Description ........................................................... 233 Control Unit........................................................................ 234 Power Supply .................................................................... 235 DCS Looms ....................................................................... 236 DCS Sensors ..................................................................... 237 DCS Display Unit ............................................................... 240 Display Illustrations............................................................ 242 DSC Display Menus .......................................................... 246 System Operation .............................................................. 252 Instructions for Diesel Control System Methane Head ..... 254 Section 6 Frame Components General Description .................................................................... 261 Safety Precautions ...................................................................... 261 Front Frame Chassis .............................................................................. 262 Lift Arm General .............................................................................. 264 Lift Arm Isolation ................................................................ 265 Rapid Attach Back Plate (RAS) Assembly ........................ 266 Rear Frame Chassis .............................................................................. 268 Operator’s Compartment ................................................... 269 Compartment Door Assembly ........................................... 269 Canopy Assembly.............................................................. 270 Operator’s Seating............................................................. 272 Articulation Joint ................................................................ 273 Covers ............................................................................... 275 Fire Suppression System .................................................. 277 BI001927 BI001927
Service Manual Rev. 0 CL215 Load Haul Dump Serial No. 5003975 v Section 7 Pneumatic System General Description .................................................................... 279 Pneumatic Schematic ................................................................. 280 Safety Precautions .................................................................... 281 Air Compressor Compressor Mounting ....................................................... 282 Compressor ....................................................................... 282 Air Receiver ................................................................................ 283 Starter Motor............................................................................... 286 Safety Circuit Diesel Control System ....................................................... 287 Make Up Tank Head Pressure .......................................... 287 Safe Start System ............................................................. 288 Brake and Transmission Interlock System ........................ 289 Operator’s Horn ................................................................. 290 Pneumatic System Troubleshooting.................................. 291 Section 8 Attachments and Accessories General Description .................................................................... 293 Safety Precautions .................................................................... 295 Spade Lip Ejector Bucket ........................................................... 296 5th Wheel Adaptor ...................................................................... 298 BI001927 BI001927
This document is the property of Caterpillar SUBJECT MATTER HEREIN IS PRIVATE, CONFIDENTIAL AND RESTRICTED. Do not use, reproduce, copy, distribute or disclose except with, and only to the extent of, prior written consent of Caterpillar PERSONS RECEIVING THIS DOCUMENT ARE RESPONSIBLE FOR RESTRICTING DISCLOSURE, except as absolutely necessary consistent with the intended use. When such is completed, return immediately to Caterpillar.
Caterpillar recommends that all Safe Working procedures should be approved and checked by Mine Officials. Caterpillar declines all liability for direct or indirect consequences of printing errors.
This document is copyright. All intellectual property rights and copyright in the document (or any part of this document remains the property of Caterpillar. Except as provided for in the Copyright Act 1968 (Ctn) no part of this document may in any form or by any means (including without limitation electronic, mechanical, micro copying, photocopying, recording or otherwise) be reproduced, stored in a retrieval system or transmitted without the prior written permission of Caterpillar.
Caterpillar Australia Room & Pillar Division
20 Kullara Close, PO Box 373
Beresfield NSW 2322 Australia
Phone: +61 2 49147000
Fax: +61 2 49147059
Service Manual vi CL215 Load Haul Dump Serial No. 5003975 Rev. 0
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Section 1
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 CL215 Load Haul Dump 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 CL215 Load Haul Dump 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 CL215 is a 15000 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 a 172 kW (230 HP) Caterpillar 3126 turbocharged fourstroke 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 (DCS) 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 CL215 Load Haul Dump utilises a wet bath exhaust system complete with replaceable particulate filter.
A site specific Risk Assessment is recommended to be conducted before this machine is introduced into service.
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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.
Points in the text marked with this symbol draw attention to immediately impending danger. Possible consequences are very serious or fatal injury.
These points contain information on potentially dangerous situations. Possible consequences are very serious or fatal injury.
This symbol draws attention to potentially dangerous situations. Possible consequences are light to moderately serious injury and machine damage.
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
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
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Exhaust Gas Temperature
Brake Accumulator Pressure
Brake Head Pressure
Engine Oil Pressure
Air Pressure
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Steering Accumulator Pressure
Transmission Oil Temperature
Exhaust Back Pressure
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Service Manual 6 CL215 Load Haul Dump Serial No. 5003975 Rev. 0
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GENERAL ARRANGEMENT
SPECIFICATIONS
All specifications are subject to change without notice. Always consult the Dealer to obtain current information before applying critical loads.
Axles Standard Type Outboard planetary Front axle Fixed Rear axle Trunnion mount Diff. type Bevel gear and pinion
Wheels
Hydraulic
Seating (Driver) Type Cross-seated
Pneumatic
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Capacities Bucket Payload 12000 kg RAS forks max, Payload 15000 kg RAS Fixed Jib max Payload 10000 kg RAS Slewing Jib max Payload 8000 kg RAS Belt reeler 12000 kg Max un-braked trailer mass 15000 kg Max braked trailer mass Consult Caterpillar Standard Ejector Bucket Heaped capacity (SAE) 4.5 m3 Struck capacity 3.5 m3 Weight Operating with bucket only 29000 kg Operating without bucket 26500 kg Maximum Laden 44000 kg Engine Type Diesel, Turbo charged, 4 cycle Cooling system Water based radiator Cooling fan Hydraulic driven fan Engine Make/model Caterpillar 3126 Displacement 7.2 litre Maximum power 172 kW @ 2200 rpm Maximum torque 720 Nm @ 1400 rpm Engine Speeds Low idle 800 rpm High idle 2700 rpm Governed 2600 rpm Fuel Consumption At full power 37.5 Litres/hr Average mine duty 8-30 Litres/hr Start System Starter motor type Air turbine type Intake Air Cleaner Type / Make Dry dual element / Caterpillar Intake flame trap spiral wound type Exhaust Conditioner Type Flameproof Wet Make Caterpillar Exhaust Filter Replaceable element except China Exhaust Flame trap Replaceable China and RSA After treatment Catalytic Exhaust purifier Transmission Type Power shift with Fwd/Rev mod Speeds, forward and reverse 4
Make/model 5 pieces (Heavy Duty)
20.5
Tyres - Standard Type XKA Tyres Size
x 25 Ply rating Radial Inflation media Air Inflation pres. 800 kPa
Filtration Bucket system Return 10 micron replaceable with bypass
Steer/brake system Pressure10 micron replaceable with bypass Articulation Degrees of turn either side 43 degree Oscillation Degrees up and down from horizon. 7.5 degree
Engine
Canopy Type Protective Device MDG1 Optional ROPS/FOPS Electrical system Type Approved flameproof Voltage 12 V Polarity Floating chassis Shutdown System System type DCS electronic Intrinsically Safe approved Standard shutdowns Low engine oil pressure Exhaust temperature Engine coolant level
coolant temperature Turbo temperature Scrubber level 1 Scrubber level 2 Optional shutdowns High Methane Low hydraulic oil Exhaust scrubber temperature Lights Number /location 2 front, 2 rear Approved flameproof Alternator Drive Hydraulic Type Approved flameproof
Air
0.340
800
Relief pressure 830
Air
volume 80
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system Compressor type Piston engine gear driven
flow
m3/min @ 1500 rpm Governed pressure
kPa
kPa
receiver
litres
Overloading equipment could cause personal injury, death or equipment damage. Due to configuration or options these weights can vary up to 20%. Caterpillar recommends that relevant standards and safety procedures should always be used when operating this machine. Removal of protective canopies, doors, safety devices, interlocks and structures etc., could cause serious injury or death. Replacement with correctly torqued fasteners is mandatory.
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Vehicle Speeds 1st gear 3.1 km/hr 2nd gear 7.4 km/hr 3rd gear 13 km/hr 4th gear 23 km/hr Grade Ability Front to rear 1:4 Side to side (empty) 1:4 Side to side 1:8 Service Capacities Hydraulic tank 300 litres Fuel tank 300 litres Main air receiver 80 litres Transmission/converter oil 45 litres Engine crankcase oil (with filter) 22 litres Engine cooling system water 72 litres Axle oil (each) 71 litres Water make up tank 450 litres BI001927 BI001927
LUBRICATION AND FUEL SPECIFICATIONS
GENERAL
This section provides Caterpillar standard requirements for the use of fuels and lubricants. Consult the Dealer 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 below 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 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 ° C 1.5- 2.5 Water & Sediment ASTM D 1796 % Vol 0.05 max BI001927 BI001927
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