Technical Manual
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BI620123
BUCYRUS
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LHD/Utility
Number 80042 Service Manual BI620123
FBL-10
Serial
Service Manual Rev. 0 FBL-10 LHD/Utility Serial No. 80042 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...................................................................5 Specifications..................................................................................6 Lubrication and Fuel Specifications General..................................................................................8 Fuels......................................................................................8 Fuel Specification Table........................................................8 Fuel Additives........................................................................9 Diesel Fuel Relevant Information........................................10 Engine Oil............................................................................11 Torque Converter/Transmission Fluid.................................11 Hydraulic Oil........................................................................11 Gear Oil...............................................................................11 Multi Purpose EP Grease....................................................11 Drive Coupling Grease........................................................12 Exhaust Conditioner Make Up Tanks..................................12 Fluid Specification Table.....................................................13 Grease Point Reference Drawing........................................14 Machine Isolation Engine Isolation...................................................................15 Pneumatic Isolation.............................................................15 Hydraulic Isolation...............................................................16 Engine Coolant Isolation......................................................18 Electrical Isolation................................................................18 Articulation Isolation............................................................19 Lift Arm Isolation..................................................................20 Exhaust Conditioner Isolation..............................................21 General Safety and Precaution General................................................................................22 Packing and Supporting the Machine..................................25 Maintenance Schedules...............................................................26 10 Hours—Daily Off Line Mechanical Inspection................27 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.......59 1000 Hours—12 Months Off Line Mechanical Inspection...71 2000 Hours—2 Yearly Off Line Mechanical Inspection.......83 5000 Hours—5 Yearly Off Line Mechanical Inspection.......95 10000 Hours—10 Yearly Off Line Mechanical Inspection.107 Recommended Bolt Torque........................................................119 Section 2 Engine System Fuel System General Description...........................................................121 Safety Precautions............................................................122 Fuel Tank...........................................................................123 Fuel Lines..........................................................................123 BI620123
Service Manual ii FBL-10 LHD/Utility Serial No. 80042 Rev. 0 Section 2 Engine System (cont.) Fuel System Primary Fuel Filter/Water Separator..................................124 Secondary Fuel Filter........................................................126 Fuel System – Priming......................................................127 Lubrication System General Description...........................................................128 Safety Precautions............................................................129 Oil Filter.............................................................................130 Checking/Filling Engine Oil...............................................131 Changing Engine Oil.........................................................131 Flushing the Lubrication System.......................................132 Air Intake System General Description...........................................................133 Safety Precautions............................................................133 Air Cleaner/Indicator Assembly.........................................134 Emergency Intake Shutoff Valve.......................................135 Inlet Flame Trap/Flameproof Joints...................................136 Servicing Air Intake System..............................................137 Cooling System General Description...........................................................139 Safety Precautions............................................................129 Engine Package................................................................140 Expansion Tank.................................................................141 Header Tank......................................................................141 Fan Assembly....................................................................142 Water Pump Belt Tension.................................................143 Radiator.............................................................................144 Checking/Filling and Flushing Coolant System.................146 Flushing a Contaminated Cooling System........................147 Exhaust System General Description...........................................................148 Safety Precautions............................................................149 Exhaust Downpipe/Purifier................................................149 Exhaust Make Up Tanks...................................................151 Exhaust Conditioner..........................................................152 Exhaust Outlet Flame Trap...............................................156 Flame Paths or Fixed Connections...................................157 Exhaust Emission Testing Procedure...............................157 Throttle Control General Description...........................................................159 Safety Precautions............................................................159 Cable Adjustment..............................................................160 Engine System Trouble Shooting...............................................161 Section 3 Transmission and Drive Train Engine Drive Coupling General Description...........................................................167 Safety Precautions............................................................167 Checking and Greasing Drive Coupling............................168 Removal and Installation of Drive Coupling......................169 Transmission/Torque Converter General Description...........................................................170 Safety Precautions............................................................172 BI620123
Service Manual Rev. 0 FBL-10 LHD/Utility Serial No. 80042 iii Section 3 Transmission and Drive Train (cont.) Transmission and Torque Converter Checking/Filling the Transmission Oil...............................173 Changing the Transmission Oil Filter Element..................174 Changing the Transmission Oil ........................................175 Troubleshooting Guide......................................................176 Service Data......................................................................178 Front and Rear Axle General Description...........................................................181 Safety Precautions............................................................181 Checking/Filling the Planetary Wheel End Oil Level.........182 Checking/Filling the Axle Centre Oil Level........................183 Changing the Oil In Axle Centres, Wheel Ends, and Liquid Cooled Brakes...................................................................185 Checking Wear of the Posi-Stop Brake Assemblies..........186 Drive Lines General Description...........................................................187 Safety Precautions............................................................188 Greasing and Inspecting Drive Lines.................................189 Removing and Installing the Rear Drive Line....................189 Removing and Installing the Front Drive Line....................190 Removing and Installing the Upper Drive Line .................191 Wheel and Tyre Assemblies General Description...........................................................192 Safety Precautions............................................................192 Removal............................................................................192 Installation.........................................................................194 Section 4 Hydraulic System General Description....................................................................195 Safety Precautions......................................................................196 Hydraulic Isolation.............................................................191 Pumps and Mountings Steering/Brake Pump........................................................198 Main Hydraulic Pump........................................................201 Auxiliary Hydraulic Pumps.................................................202 Hydraulic Tank Checking and Filling Hydraulic Oil.....................................203 Changing Hydraulic Oil......................................................204 Checking and Cleaning Filler Neck Screen.......................205 Checking and Replacing Return Filter...............................206 Steering and Brake Hydraulic Manifold......................................207 Steering/Brake Pump Pressure Filter.........................................211 Steering Circuit Steering Accumulator........................................................213 Steering Control Valve.......................................................214 Brake Circuit Brake Accumulator............................................................215 Brake Valve.......................................................................216 Brake Heads......................................................................220 Attachment Controls Control Levers...................................................................221 Main Control Valve Bank...................................................223 Tilt and Lift Circuits............................................................225 BI620123
Service Manual iv FBL-10 LHD/Utility Serial No. 80042 Rev. 0 Section 4 Hydraulic System (cont.) RAS Attach and PTO Circuits ..........................................226 Alternator Circuit and Cooling Fan.............................................227 Hydraulic Schematic...................................................................229 Section 5 Electrics, Instruments and Controls Electrical System General Description...........................................................231 Safety Precautions............................................................231 Alternator, Lights and Hour Meter General Arrangement..232 Electric Lighting Components............................................233 Engine Service Hour Meter...............................................236 Electrical System Troubleshooting....................................237 Alternator and Drive Assembly General Description...........................................................239 Safety Precautions............................................................239 Alternator Assembly..........................................................239 Alternator Drive Assembly.................................................241 Instruments and Controls Electronic Shut down system......................................................242 Display Assemblies.....................................................................244 Sensors and Locations................................................................247 Methane Sensor Head................................................................252 Checks and Calibration.....................................................253 Air Cleaner Service Indicator.......................................................254 Bypass Switch............................................................................254 Testing Methane Sensor............................................................256 Fault Guide.................................................................................257 Compartment Door.....................................................................259 Transmission Gear Control Lever...............................................260 Transmission Directional Control Lever......................................260 Park Brake Button.......................................................................261 Four-Way Joystick Control Lever................................................262 No 1 Two-Way Hydraulic Control Lever.....................................262 No 2 Two-Way Hydraulic Control Lever.....................................262 Control Lever Maintenance.........................................................263 Operator's Seat...........................................................................264 Accelerator Pedal.......................................................................264 Brake Pedal................................................................................264 Steering Wheel...........................................................................265 Brake Head Pressure Gauge......................................................266 Brake Accumulator Pressure Gauge..........................................266 Steering Accumulator Pressure Gauge......................................266 Engine Start Button.....................................................................267 Air Pressure Gauge....................................................................267 ON/OFF Toggle Switch...............................................................267 Transmission Oil Temperature Gauge........................................268 Engine Coolant Temperature Gauge..........................................268 Horn Button.................................................................................269 Emergency Fuel Shut Off Valve.................................................269 Engine Service Hour Meter.........................................................270 BI620123
Service Manual Rev. 0 FBL-10 LHD/Utility Serial No. 80042 v Section 5 Electrical cont. Air Cleaner Service Indicator......................................................270 Engine Oil Pressure Gauge........................................................271 Shutdown System Test Valve.....................................................271 Engine Fuel Primer Pump...........................................................272 RAS Pilot Lock Cylinder Release Button....................................272 Attachment Quick Release Button..............................................272 Emergency Intake Shut Off Valve...............................................273 Section 6 Frame Components General Description....................................................................275 Safety Precautions......................................................................275 Front Frame Chassis..............................................................................276 Lift Arm General..............................................................................278 Fitting and Removal of Lift Arm Lock.................................279 Rapid Attach Back Plate (RAS) Assembly........................280 Rear Frame Chassis.......................................................................................282 Operator’s Compartment...................................................283 Compartment Door Assembly...........................................284 Canopy Assembly..............................................................285 Operator’s Seating.............................................................287 Articulation Joint................................................................288 Covers...............................................................................289 Section 7 Pneumatic System General Description....................................................................293 Safety Precautions .....................................................................295 Air Compressor Compressor Mounting.......................................................296 Compressor.......................................................................296 Air Receiver................................................................................297 Starter Motor...............................................................................300 Safety Circuit Electronic Shutdown System.............................................301 Make Up Tank Head Pressure..........................................301 Safe Start System..............................................................302 Brake and Transmission Interlock System........................303 Operator’s Horn.................................................................304 Pneumatic System Troubleshooting..................................305 BI620123
Section 8 Attachments
General Description……………………………………….307
Safety Precautions………………………………………...309
Spade Lip Ejector Blanket………………………………..310
Straight Lip Ejector Blanket………………………………311
RAS Ejector Blanket………………………………………312
15000 KG Side Shit Forks………………………………..313
10000 KG Fixed Jib Crane……………………………….315
5th Wheel Adaptor………………………………………...317
Materials Pod………………………………………………319
Hydraulic Reeler…………………………………………...321
Elevated Work Platform…………………………………..327
Concrete Hopper…………………………………………..331
Fuel Pod…………………………………………………….332
This document is the property of Bucyrus 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 Bucyrus 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 Bucyrus.
Bucyrus recommends that all Safe Working procedures should be approved and checked by Mine Officials. Bucyrus 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 Bucyrus. 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 Bucyrus.
BUCYRUS 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 FBL-10 LHD/Utility Serial No. 80042 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 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.
A site specific Risk Assessment is recommended to be conducted before this machine is introduced into service.
Service Manual Rev. 0 FBL-10 LHD/Utility Serial No. 80042 1
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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.
Service Manual 2 FBL-10 LHD/Utility Serial No. 80042 Rev. 0
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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.
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.
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.
Service Manual Rev. 0 FBL-10 LHD/Utility Serial No. 80042 3
Brake Head Pressure Gauge
GAUGE ALARM PARAMETERS
Accumulator Pressure Gauge
Steering
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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.
Exhaust Gas Temperature
0-70 °C Green Normal operating temperature range. 70-80 °C Orange Above normal operating temperature. Engine shutdown imminent.
80-120 °C Red Above normal operating temperature. Engine should have shutdown.
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 equipment.
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.
Service Manual 4 FBL-10 LHD/Utility Serial No. 80042 Rev. 0
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Service Manual Rev. 0 FBL-10 LHD/Utility Serial No. 80042 5
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GENERAL ARRANGEMENT
SPECIFICATIONS
All specifications are subject to change without notice. Always consult BUCYRUS to obtain current information before applying critical loads.
16D
Rear axle make/model Dana/Spicer 16D
Differential type Bevel gear and pinion
Differential lock type - front Posi-Torque
Differential lock type - rear Posi-Torque Overall ratio 31.06:1
Wheels Make/model 3 piece (heavy duty)
Tyres - Standard Type Michelin X mine D2
17.5 x 25 Ply rating Radial Inflation media Air Inflation pressure 110 psi front, 110 psi rear
Hydraulic Systems
Steering Closed centre, pressure compensated 2500 psi
Brakes Closed centre, pressure compensated 2500 psi
Bucket/lift Open centre 3000 psi
PTO (2 on machine) Open centre 3000 psi
Tank type Sealed and pressurised
Tank pressure 10 psi
Hydraulic Filtration
Hydraulics return Return 25 micron replaceable with bypass
Steer/brake system Pressure10 micron replaceable with bypass
Optional return PTO In line, 25 micron Main Hydraulic Pump
Cylinders
Accumulator Steering
Service Manual 6 FBL-10 LHD/Utility Serial No. 80042 Rev. 0
Capacities Bucket Payload 8000 kg RAS Forks, Max Payload 10000 kg RAS Slewing Jib, Max Payload 7000 kg RAS Belt / Cable Reeler, Max Payload 7000 kg Maximum un-braked trailer mass 10000 kg Maximum braked trailer mass Consult BUCYRUS Standard Ejector Bucket Heaped capacity (SAE) 3.5 m3 Struck capacity 2.7 m3 Break out force standard bucket tip (hydraulic) 15000 kg Tractive effort, Maximum 21300 kg Bucket Motion Times Lift to full raised position 7.0 sec Lower fully to floor 4.0 sec Roll bucket fully back 7.0 sec Roll bucket fully forward 5.0 sec Weight Unladen with full tanks and bucket 19000 kg Laden with forks and 10T load 29000 kg Engine Type Diesel, turbocharged, and 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 700 RPM High idle 2600 RPM Governed 2100 RPM Stall Speeds Converter stall 2100 RPM Full stall 1700 RPM Hydraulic stall 2050 RPM Fuel Consumption At full power 37.5 litre/hr Average mine duty 8-30 litre/hr Start System Starter motor type Air (Auststart) Intake Air Cleaner Type/make Dry/Donaldson Dual element type Primary and secondary Exhaust Conditioner Type Flameproof water bath conditioner Make BUCYRUS Exhaust Flame trap Fitted After treatment Catalytic exhaust purifier Transmission Type Power shift with forward/reverse modulation Make/model Dana/Spicer 32000 series MHR Speeds, forward and reverse 4
Converter Type Mounted in transmission, Single element Make/model Dana/Spicer 13.1 integral Axles Type Outboard planetary Front axle make/model Dana/Spicer
Torque
Size
Type
Standard pump output
2600 RPM 161.2 lpm
Gear Open centre
@
Type Pressure
piston Standard pump output @ 2600 RPM 117 lpm
Steering/Brake Pump
compensated
Type Double acting Rods Case hardened and hard chromed Counterbalance valves Lift and tilt
stops Steering and tilt
Control valve Closed centre Actuation Orbital Pressure compensated 2500 psi
Cushion
Steering System
psi
Cushion relief 3000
Type Piston Quantity x capacity 1
5.7
pre-charge pressure 900 psi Nitrogen
Type Piston Quantity x capacity 1 x 1.96 litre Operating pre-charge pressure 900 psi Nitrogen Bucket System Control valve Open centre Actuation Remote hydraulic pilot Main relief 3000 psi BI620123
x
litre Operating
Accumulator Brakes
Overloading equipment could cause personal injury, death or equipment damage. Due to configuration or options these weights can vary up to 20%. Bucyrus 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 of death. Replacement with correctly torqued fasteners is mandatory.
Service Manual Rev. 0 FBL-10 LHD/Utility Serial No. 80042 7 Cylinder Reliefs Lift arm raise 3200 psi Lift arm lower 3200 psi Bucket roll back 3200 psi Bucket dump 3200 psi RAS in port relief 3200 psi RAS out port relief 3200 psi Electrical System Type Approved flameproof Voltage 12 V Polarity Floating Lights Number /location 2 front, 2 rear Type SETCO High performance approved flameproof Alternator Drive Hydraulic Type Customer preference approved flameproof Service Brake Hydraulic System Type Reverse modulated, pressure reducing Control valve Open centre Actuation Foot pedal Operating pressure 2500 psi Brake release pressure 1450 psi Steering Type Centre articulated, hydraulic Service Brake Type Totally
Make/model Dana/Spicer
Application Spring
hydraulic release Location Each wheel end Park Brake Type
Make/ model Dana/Spicer
Application Spring applied hydraulic release Location Each wheel end Articulation Bearing type and size Pin and spherical bearing (top), bush (bottom)
sealed Bush material Hardened steel Pin material Hardened steel Degrees of turn either side 43° Oscillation Type Rear bolster Bush material Hardened steel Pin material Hardened steel Degrees up and down from horizon 7.5° Seating (Operator) Type Cross-seated Make BUCYRUS Suspension Adjustable spring/shock absorption Canopy Type Adjustable Protective device MDG1 and MDG17 Pneumatic System Compressor type Piston engine gear driven Air flow 0.340 m3/min @ 1500 RPM Governed pressure 120 psi Relief pressure 130 psi Air receiver volume 80 litre Vehicle Speeds 1st gear 4.3 kph 2nd gear 8.7 kph 3rd gear 14.6 kph 4th gear 24.2 kph Maximum Tractive Effort 1st gear 22165 kg 2nd gear 10700 kg 3rd gear 6160 kg 4th gear 3565 kg Grade Ability Front to rear 1:4 Side to side (empty) 1:4 Side to side (laden bucket load fully raised) 1:8 Service Capacities Hydraulic tank 300 litre Fuel tank 300 litre Transmission/converter oil 40 litre Engine crankcase oil 22 litre Engine cooling system water 72 litre Axle oil (each) 35 litre
enclosed, liquid-cooled Posi-Stop
16150
applied
Totally enclosed, liquid cooled Posi-Stop
16150
fully
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