Cat Feeder Breaker FBL 55H Blakefield South Service Manual – PDF DOWNLOAD

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BUCYRUS R

Technical Manual

BI620094

Blakefield South FBL 55H Service Manual M01335r1

BI620094

Bucyrus Australia

Blakefield South FBL-55H Service Manual

Version 1 Version 2

Draft Release requires final checking 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.

This document is copyright. All intellectual property rights and copyright in the document (or any part of this document remains the property of Bucyrus Australia. 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 Australia.

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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

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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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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

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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-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 Distance From Fork Face (mm)

Maximum Load (kg) Standard

700

60000

900

53000

1200

45500

1500

39700

1800

35200 Weight

Unladen with full tanks

Engine

Engine Speeds

Unladen with full tanks & Cookie Plate Maximum laden with Cookie Plate

57600 kg 59220 kg 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

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Air turbine type

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Intake Air Cleaner Dry dual element/Caterpillar

Type/make

Intake flame trap

Spiral wound type

Exhaust Conditioner Type

Flameproof wet type

Make

Bucyrus

Exhaust flame trap

Reversible

After treatment

Catalytic exhaust purifier Transmission Power shift with fwd/rev modulation

Type 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/model

Dana 19D

Differential lock type front

Posi-Torque

Differential lock type rear

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

Manual No.M01335r1

Lift

Open centre 3000 psi

PTO

Open centre 3000 psi

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Tank type

Sealed and pressurised

Tank pressure

50 kPa

Steer/brake system

Pressure 10 micron

Hydraulic Filtration 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 Steering Centre articulated, hydraulic

Type

Service Brake Totally enclosed, liquid cooled Posi-Stop

Type

Park Brake Totally enclosed, liquid cooled Posi-Stop

Type

Articulation Bearing type and size

Pin & Spherical

Degrees of turn either side

45°

Oscillation Type

Rear bolster Seating (Operator)

Type

Cross-seated

Make

Bucyrus

Suspension

Air Adjustable Canopy

Type (both)

Protective device MDG1 And MDG17

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Electrical System Type

Approved flameproof

Voltage

12 V Lights

Number/location

2 front, 2 rear

Type

High performance Approved flameproof Alternator

Drive

Hydraulic

Type

Approved flameproof Pneumatic System

Compressor type

Piston engine gear driven

Governed pressure

120 psi

Relief pressure

130 psi

Air receiver volume

80 litre

Service Capacities 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 Vehicle Speeds

1st gear

3 kph

2nd gear

7 kph

3rd gear

12 kph

4th gear

20 kph (Max at Tare weight) Maximum Tractive Effort

1st gear

36500 kg

2nd gear

15200 kg

3rd gear

8700 kg

4th gear

4950 kg Grade ability

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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

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(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 Machine speed at Tare weight GVM weight

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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 50-104°C Green 104-107°C Orange 107-120°C Red

Coolant temperature too low.

Normal operating temperature range.

Above normal operating temperature. Engine shutdown imminent.

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 100-600 kPa 600-800 kPa

Air Pressure Gauge 0-275 kPa 275-827 kPa 827-1000 kPa

Red Engine oil pressure too low. Engine should have shutdown.

Green Normal operating pressure range.

Red Engine oil pressure too high. Continued operation could result in damage to the engine.

Orange Air pressure low. Machine will not start. Machine may shutdown.

Green Normal operating pressure range.

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 Property

Test Method

Unit

Appearance

Visual Inspection ASTM D4176 Procedure No 2 @ 25°C Numerical Rating

Specified Values Clear and bright Clear and bright

Ash

ASTM D 482 (Notice 1) % Mass

0.01 max

Carbon Residue

ASTM D 524

0.15 max

Cetane Number (Notice 2)

ASTM D 613

% Mass

45 min

Calc. Cetane Index (Notice 2) ASTM D 4737

45 min °

Cloud Pt (Notice 3)

ASTM D 2500

C

Copper strip corrosion

ASTM D 130

Density @ 15°C

ASTM D 1298 or ASTM D 4052

Distillation 90% rec @

-10 max (0 max Notice 4) 1 B max

kg/L

0.80- 0.83

ASTM D 86

°

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°C 1.5- 2.5

Water & Sediment

ASTM D 1796

% Vol

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NOTICE! Equivalent IP tests may be used throughout.

NOTICE! Supplier may elect to meet either the Cetane Number or the calculated Cetane Index. Calculated Cetane Index is to be based on finished fuel before any Cetane Number improving additives are incorporated.

NOTICE! See Diesel Fuel Relevant Information - Low Temperature Effects.

NOTICE! The specification represents an optimal fuel, based on the control of exhaust contaminates and available refining technology. If commercial considerations prevent the use of fuels meeting the specification, then the alternative values indicated by Notice 4 may allow the use of a slightly modified fuel without severely compromising the health aspects. See also Fuel Additives below.

Fuel Additives The range and use of additives varies widely. Most are proprietary products. For fuels containing Cetane Number improves the Calculated Cetane Index (ATSM D 4737) may be unreliable and the Cetane Number, determined by ASTM D 613 should be specified in such cases. Some smoke suppressants may contain copper barium or manganese compounds and associated exhaust emissions may contain measurable amounts of these potentially toxic metals.

Accordingly, suppliers who consider the use of additives advantageous from an exhaust emission control aspect should be encouraged to offer this benefit, provided they advise the amount, nature, purpose and likely affect on exhaust emissions and the health of mineworkers, of additives included in the fuel offered against this specification.

Unless expressly approved in writing by the Mine Management Nominated Representative no additives containing metals or metallic compounds shall be present in the fuel.

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DIESEL FUEL RELEVANT INFORMATION Fuel handling The most common causes of fuel contamination are condensation (water) and biological matter.

Condensation (water) occurs when damp air is drawn into partly filled storage tanks during normal temperature variations. If this phenomenon is likely to occur, appropriate precautions, such as a separate low level water drain should be included in the storage tank, or the tank protected from being strongly heated by direct sunlight, etc. Biological matter may be controlled by ensuring the fuel system does not allow the accumulation of pockets of water; by good housekeeping and regular maintenance; or by the inclusion of anti-fungal or anti-bacterial additives in the fuel. Keeping storage tanks reasonably full also assists.

Low Temperature Effects Fuels with higher alkaline (parrafinic) contents (indicated approximately by lower densities) may be more likely to become cloudy at low temperatures than more aromatic fuels. This is due to the formation of minute wax crystals, which may plug filters. This cloudiness may be minimised by protecting the storage tank from extremely cold conditions (undercover insulated or buried), or by the addition of a Cloud Point depressing additive AS3570-1988, Automotive Diesel Fuel contains a table and figure (pages 5 and 6) which may assist. Cloud Point in itself does not influence emissions, but fuel with a Cloud Point close to minimum ambient temperatures will often contribute to poor engine performance which may lead to increased exhaust contaminants.

Exhaust Emissions On combustion in internal combustion engines, all hydrocarbon fuels produce carbon monoxide, carbon dioxide and oxides of nitrogen and particulate matter (soot consisting mainly of carbon, and often minor amounts of other more complex hydrocarbons) with minor amounts of other products such as aldehydes. Those fuels which contain sulphur will also produce oxides of sulphur, while those containing fixed nitrogen will tend to produce more oxides of nitrogen. All these gases are toxic above certain ambient concentrations and some have unpleasant odours. The propensity to produce oxides of sulphur is controlled by specifying a low sulphur content for the fuel. The intent of this specification is to design a fuel with low emissions of these gases and particulates, but the production of exhaust emissions is also a function of engine operating conditions, which vary from engine to engine.

Engine Maintenance This specification has been prepared with the aim of reducing the amount of and modifying the nature of certain components of exhaust emissions. Before operating this machine on any alternative fuel specification a check should be made to see if engine adjustments are necessary to ensure optimal performance is achieved. It should also be recognised that regular maintenance will prolong the time during which emissions will be minimised. In particular, attention to the fuel supply system, especially filters, the injectors, compression maintenance and regular flushing of the exhaust conditioning system should be key components in such a program.

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ENGINE OIL The proper SAE viscosity grade oil is determined by the minimum outside temperature at cold engine start up, and the maximum out engine temperature during the engine operation. Use the minimum temperature column on the chart to determine the oil viscosity to start a cold soaked engine. Use the maximum temperature column on the table to determine the oil viscosity for operation at the highest temperature anticipated. In general, use the highest viscosity oil to meet the start up temperature requirement.

TORQUE CONVERTER / TRANSMISSION FLUID Transmission Fluid Shell Donax TC30 is suitable for use in the Torque Converter and Transmission.

Refer to the Fluid Specification Table for the oils which may be used under given conditions.

CAUTION! Do not use Dextron II in the torque converter/transmission.

HYDRAULIC OIL Use high quality anti-wear hydraulic oil or engine oil for the hydraulic (steering, brakes and attachment actions) system. Referring to the Fluid Specification Table. ISO/VG 68 Oil and SAE 20W20 Engine Oil both have a viscosity of 300 to 350 SUS at 38°C and therefore fit into these temperature ranges. For colder ambient temperatures, ISO/VG 32 Hydraulic Oil or SAE 10 W Engine Oil (150-200 SUS at 38°C) are better suited. The viscosities given are for use as guidelines only; however, do not use an oil which will exceed 4000 SUS at start up or be less than 80 SUS during operation. Also any oil used must have a viscosity index of no less than 90. Consult your oil dealer or manufacturer for oils that meet these requirements.

CAUTION! Engine oil being used as hydraulic oil must meet MiI-L-46152 or 2014C and API class CC or CD standards. No similar standards have been written for anti-wear hydraulic oil; it is therefore up to the machine owner to ensure that the oil is of a high quality.

GEAR OIL Use Shell differential oil HP gear oil LS 90 or equivalent SAE90LS oil suitable for limited slip differentials.

MULTI-PURPOSE EP GREASE Use multi-purpose EP grease, which contains both 1% to 5% molybdenum disulphide conforming to MIL-L-7866, and a suitable corrosion inhibitor. National Lubricating Grease Institute (NLGI) Grade No. 2 is suitable for most temperatures. NLGI No. 1 or No. 0 are suitable for extremely low temperatures.

DRIVE COUPLING GREASE Shell Stamina RL2 grease is to be only used on the latest engine drive couplings with tapered roller bearings fitted. The distinguishing feature of the drive coupling with these bearings are a conical shaped housing, the other housing has more of a 90° housing with webbing welded to sections.

EXHAUST CONDITIONER MAKE UP TANKS Clean potable water only is to be used for the make up tank water.

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FLUID SPECIFICATION TABLE SPEC.

COMPONENT

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

1

Engine

26

Engine Oil

Fuchs Titan Universal MF 1540

2

Transmission

45

Mineral Gear Oil

Fuchs Titan Universal MF 1540

3

Hydraulic

400

Hydraulic

4

Axle / Wheel Ends

53 (Each Axle)

Mineral Gear Oil with Limited Slip Additive

5

Cooling System

72

Pre-mixed Coolant Conditioner

6

Fuel

400

Distillate “Diesel” Fuel

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin - Diff Pinion Oil Seal

As required

Multi-purpose EP Grease

8

Winch Gearbox

5

Gear Oil

Fuchs Powergear M460

9

Winch Planetary

2.5

Gear Oil

Fuchs Powergear M460

10

Engine Drive Coupling

Refer Service Manual

High Temperature

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Fuchs renolin B 68

SAE90LS Fuchs Titan Gear LS 90

Hardy Manufacturing Inhibit To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

Fuchs Polyplex 2

NLGI no. 2 (Shell Stamina RL2)

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GREASE POINT REFERENCE DRAWING Uni-joint-front axle Front drive line slip joint Uni-joints-articulation

Fork Frame Cradle

Tilt cylinder front pins

Winch drum bearing

Differential pinion seal MANIFOLD Lift cylinder top pin Lift cylinder bottom pin Outside lift arm pin Inside lift arm pin Drive line carrier bearing

MANIFOLD Steer cylinder front pin Lift cylinder pins Drive line bearing MANIFOLD Articulation top pin Articulation bottom pin Rear axle front bolster bush Rear axle rear bolster bush Steer cylinder rear pin Service brake pedal grease point Accelerator pedal grease point

Transmission uni-joint underneath Rear axle drive line slip joint underneath Rear axle uni-joint Underneath

Engine drive line slip joint Engine drive line unis Engine Centamax coupling

Radiator hinge points

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MACHINE ISOLATION Before commencing work on the machine, it is imperative to ensure the system to be worked on is correctly isolated. This may also require the isolation of other systems that affect the safe completion of the job.

NOTICE! Any site / mine specific isolation procedures override those listed on the following pages. The procedures presented here are the minimum required to perform any work on the machine. Before commencing check with the relevant people regarding any site / mine specific isolation procedures.

ENGINE ISOLATION To isolate the engine perform the following procedure: 1) Ensure the area is clear of any obstructions and area is fit for carrying out safe operation and maintenance.

2) Ensure the machine is in a straight line (not articulated).

3) Lower the lift arm to the ground.

4) Select neutral on transmission directional control lever.

5) Apply the park brake.

6) Shutdown the engine.

7) Fit a danger tag to the on/off toggle switch.

8) Connect the articulation lock and chock the wheels.

9) Close the main air isolation valve and fit a danger tag (see Pneumatic Isolation).

WARNING! Be careful of hot surfaces, when working on or around the machine, allow time for them to cool down.

ON/OFF Toggle Switch

Air Pressure Gauge

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PNEUMATIC ISOLATION To isolate the pneumatic system perform the following procedure: 1) Ensure the area is clear of any obstructions and area if fit for carrying out safe operation and maintenance.

2) Lower the lift arms to the ground, shutdown the engine, fit a danger tag to the on/off toggle switch, connect the articulation lock and chock the wheels.

3) Locate the main air isolation valve at the driver’s side rear of the engine compartment and rotate to the off position. This isolates the air supply from the air receiver to the safety circuit and the starter motor relay valve at the same time the air is vented from the circuit through the bleed port in the isolation valve body.

NOTICE! If work is required on the air receiver it will be necessary to remove air pressure from the air receiver by actuating the air receiver drain valve located next to the fill point. Stored air pressure will be safely released to the atmosphere. Ensure that the air charge three-way ball valve is not connected to an external pressure source.

WARNING! Compressed air can be hazardous. Wear suitable protective equipment such as safety glasses and hearing protection.

Main Air Isolation Valve with integral bleed port

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Air receiver Drain Valve

Air Charge Valve

Main Air Manifold

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HYDRAULIC ISOLATION To isolate the hydraulic system perform the following procedure: 1) Ensure the area is clear of any obstruction and area is fit for carrying out safe operation and maintenance.

2) Lower the lift arms to the ground, shutdown the engine, fit a danger tag to the on/off toggle switch, connect the articulation lock and chock the wheels.

3) Depress the attachment quick connects button located in the operator's compartment. This will remove any residual pressure stored in the PTO lines.

4) Observe both steering and brake pressure gauges located in the operator's compartment. The hydraulic system features a steering and brake accumulator automatic drain which depletes the hydraulic pressure from both accumulators when the park brake is applied. This is immediate.

5) Remove hydraulic tank pre-charge pressure (50 kPa) by cracking hydraulic tank filler cap WARNING! Ensure all loads are mechanically supported before removal of any hydraulic lines. Hydraulic fluid may be hot. Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves.

WARNING! Always assume there is hydraulic pressure in hydraulic lines or components unless it has been isolated by yourself.

NOTICE! Crack hose end fitting (if pressure is present in line tighten fitting and remove pressure as above) but do not remove till any residual pressure is removed.

Steering Accumulator Pressure Gauge Brake Accumulator Pressure Gauge

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ENGINE COOLANT PRESSURE ISOLATION To isolate the engine cooling system performs the following procedure: 1) Ensure the area is clear of any obstruction and area is fit for carrying out safe operation and maintenance.

2) Lower the lift arm to the ground, shutdown the engine and isolate the machine in accordance with the site isolation procedure.

3) Locate the header tank relief cap located at the rear of the machine on the driver’s side.

4) Remove coolant circuit pressure (105 kPa) by slowly lifting up the red relief lever on the relief cap and hold up till pressure is released.

5) Slowly remove relief cap with relief lever held in the up position.

WARNING The coolant fluid will be under pressure and hot (up to 100°C). Always relieve pressure by lifting the relief lever on relief cap before removal.

Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves to avoid scalds and burns from hot coolant.

Engine Coolant Relief Cap

Coolant Header Tank

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EXHAUST CONDITIONER MAKE UP TANK PRESSURE ISOLATION To isolate the pressurised make up tank, perform the following procedure: 1) Ensure the area is clear of any obstruction and area is fit for carrying out safe operation and maintenance.

2) Lower the lift arm to the ground, shutdown the engine and isolate the machine in accordance with the site isolation procedure.

3) Locate the make up tank filler cap located at the rear of the machine on the off driver’s side.

4) Remove the make up tank air pressure by slowly rotating the filler cap and hold un till the air pressure is released.

5) Slowly remove filler cap WARNING The make up tank is pressurised via the pneumatic system to provide a positive head feed to the exhaust conditioner.

Always relieve pressure first by slowly rotating the filler cap before removal. Wear personal protective equipment such as safety glasses.

Exhaust Conditioner Make Up tank Filler Cap

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ELECTRICAL ISOLATION 1) Ensure the area is clear of any obstruction and area is fit for carrying out safe operation and maintenance.

2) Lower the lift arms or any attachment to the ground, shutdown the engine, connect the articulation lock and chock the wheels.

3) All electrical energy is isolated once the engine has stopped.

WARNING The electrical system installed on this machine is approved / certified as explosion protected for use in Australian underground coal mines and may cause an atmospheric explosion if not maintained and used in its approved state. Such equipment is to be inspected and maintained in accordance with the relevant regulatory authorities rules and regulations and the conditions for which the apparatus has been approved.

NOTICE If any fault or damage is detected to the electrical system it should be reported to the service personnel.

Do not bypass shutdown.

NOTICE Isolating the main air isolation valve or completely draining the pneumatic system of air will render the machine unable to be started until it is re-energised.

ARTICULATION ISOLATION To fit the articulation lock: 1) Ensure the area is clear of any obstructions and area is fit for carrying out safe operation and maintenance.

2) Bring the machine to a stop and manually apply the park brake by pressing the red park brake button located in the operator’s compartment.

3) Locate the articulation lock at the articulation area on the off driver’s side of the machine and remove its mounting by removing the locking clamp.

4) Remove the two lynch pins and place the articulation lock over the locating pins mounted on top of the front and rear frames at each side of the articulation.

5) Install the two lynch pin through the retaining holes in the locating pins.

6) To remove the articulation lock: 7) With the park brake applied, remove the lynch pins from the locating pins.

8) Remove the articulation lock from the locating pins and secure it in the support bracket by tightening the clamp bar.

WARNING The articulation area of this machine can cause fatal crush injuries if extreme caution is not observed. Always ensure that the park brake is applied and the operator’s compartment is vacant when accessing the articulation area to fit or remove the articulation lock. NEVER work in the vicinity of the articulation joint unless the articulation lock has been correctly installed.

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Articulation Lock in Stored Position

Articulation Lock in Locked Position

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LIFT ARM ISOLATION To install the lift arm lock pin: 1) Ensure the area is clear of any obstructions and area is fit for carrying out safe operation and maintenance.

2) Remove any load from the fork tines.

3) Park the machine on flat level ground. Ensure the ground is stable.

4) Raise the lift arm to its full height and roll back the fork tines.

5) Install the lift arm lock pin as shown in the photograph below.

6) Turn off the machine and apply the park brake.

WARNING! The lift arm on this machine can cause fatal crush injuries if extreme caution is not observed. Never access or perform work under the lift arms unless the engine has been shutdown, the articulation lock fitted, the park brake applied, and the lift arm lock pin has been fitted.

Lift arm lock pin in position

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EXHAUST CONDITIONER ISOLATION To isolate the exhaust conditioner make up tank water supply perform the following procedure: 1) Isolate the machine.

2) Isolation of the wet bath exhaust conditioner is carried out via a valve located between the water inlet hose and the to the conditioner and the shutdown float chamber. The main isolation valve has two positions closed and open, this regulates the water flow from the make up tanks.

IMPORTANT! If the exhaust conditioner remains isolated after testing or maintenance to the system and the machine is returned to service it will be purged of water causing the machine to shutdown via the safety system.

Main Isolation Valve

Wet Bath Exhaust Conditioner

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GENERAL SAFETY AND PRECAUTIONS General This section contains specific safety precautions that shall be followed whilst the machine is being operated or serviced. This list is NOT all inclusive and a measure of commonsense should always be applied together with established and ongoing site specific risk assessment and safety procedures.

ONLY TRAINED AND AUTHORISED OPERATORS SHALL OPERATE AND SERVICE THIS MACHINE. DO NOT use the machine for any purpose other than its intended use.

DO NOT for any reason exceed the indicated capacity of the machine.

DO NOT operate the machine unless all operator checks and scheduled servicing have been performed. Report any damage or faulty operation immediately and do not operate the machine until the fault has been corrected.

DO NOT tie down or tow equipment such that the chains or slings are not rated for the capacity of the machine and equipment.

DO NOT operate the machine unless: There are no tags attached stating otherwise.

All covers and guards are correctly installed.

Personal protective equipment is worn.

DO NOT start the machine unless: There are no tags attached stating otherwise The area around the machine is clear.

The park brake is applied.

Transmission is in neutral.

All water and oil levels are checked.

All site specific checks are completed.

DO NOT leave the machine unless: The machine is parked in a safe place.

The transmission is in neutral.

The park brake is applied and brake head pressure is zero.

The lift arms are lowered or any attachment is flat on the ground or supported.

The engine is stopped.

DO NOT work on the machine in low ventilated areas while the engine is running.

ALWAYS sound the horn before starting the engine to alert anyone who may be around the machine.

ALWAYS: ensure that the operator’s compartment door is closed and made secure before operating the machine.

ALWAYS keep head, body and arms inside the operator’s compartment at all times.

ALWAYS travel at low speeds in congested areas. Slow down while travelling around corners and sound the horn frequently in areas of limited visibility.

ALWAYS drive carefully, observing all traffic rules and regulations at your colliery and be in full control of the machine at all times.

WARNING Travelling at high speeds, on cross grades or articulating the machine with raised loads may cause the machine to become unstable.

ALWAYS ALWAYS

follow the correct isolation and tag out procedure before performing any servicing or accessing beneath or on the machine. operate carefully and in a responsible manner and observe all Manager’s Transport Rules.

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ALWAYS ALWAYS

refer to site JSA and SOP’s prior to towing with the machine. ensure sufficient ventilation is available to dilute exhaust gases. As stated on the machine’s compliance plate.

ALWAYS be aware of the hazard sources on the machine: Engine coolant pressure Engine coolant temperature Engine exhaust temperature Rotating radiator fan Stored hydraulic pressure Stored air pressure (Air receiver) Engine oil pressure/temperature Transmission oil temperature Articulation area Lift arm area Machine mass ALWAYS use correct boarding and dismounting procedures: Check floor.

Hold on, step down.

Three points of contact at all times.

Board using hand holds provided and not the steering wheel.

ALWAYS drive the machine to suit the conditions, report or rectify any holes and ruts that may cause injury or damage to the equipment.

NEVER operate the machine under unsecured roof.

Keep your machine clean. A clean machine makes for a safer machine.

No diesel engine should be operated underground if it is smoky, running unevenly, or if the exhaust system is not in good condition.

In areas where auxiliary ventilation is used, the operator should make sure fans are operating before starting the machine.

The engine shall not for any reason be left running unattended underground.

The engine should not be shutdown from full load and must be allowed to idle for a few minutes before stopping.

Never operate a machine that you feel is mechanically unsafe.

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SAFETY RELATED TO LEAD POCKET REGIONS ON FRAME The FBL-55H rear frame has areas of steel cladded lead filled counter weights as shown in the diagram below.

WARNING Be aware of the lead pocket regions on the machine.

Cutting into these regions on the machine via any method which could induce elevated temperatures into the lead could create severe health & safety concerns. Please ensure that material safety data sheets for the handling of lead and mine safe working systems are undertaken and adhered to prior to any work being carried out in these areas.

If in doubt, please consult Bucyrus.

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PACKING/SUPPORTING THE MACHINE To support the machine or to raise the body of the machine perform the following: Park the machine on flat, level ground. Ensure the machine is in a straight line.

Lower the lift arm.

Fit the articulation lock.

Isolate the machine in accordance with the site rules.

Follow the procedure for isolating the machine hydraulic system. Check that both the steering and brake pressure gauges in the operator’s compartment are reading zero pressure.

Raise the wheel to be changed with a suitable rated device (e.g. chain block, hydraulic jack, air bag, etc). See diagram for the suitable lifting and support points for the machine’s chassis.

Place the machine on suitable stands or blocks that will allow the removal of the wheels.

WARNING Do not rely on the lifting equipment alone to support the machine when working beneath it. The machine must be supported by stands or similar.

NOTICE These are recommended jacking, chocking, lifting and tow positions for anything outside this scope contact Bucyrus.

WARNING Do not rely on the lifting equipment alone to support the machine when working beneath it. The machine must be supported by stands or similar.

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GRAB HANDLE FOR MACHINE TOP ACCESS At the rear of the machine, a grab handle and areas of checker plate have being installed to aid in safe access to the top of the machine.

WARNING! Prior to accessing the top of the machine ensure the top surfaces are free of any material that could pose a trip or slip hazard.

Use grab handle and keep footing on checker plate to avoid injury.

Grab handle

Checker plate areas

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MAINTENANCE SCHEDULES Maintenance Inspections The maintenance inspections are to be carried out by a competent and authorized person.

Adhere to site specific rules and regulations.

All faults found are to be rectified before the machine is returned to service, if it is not rectified site tagging procedure is to be followed.

NOTICE Manufacturer and site specific isolation procedures must be followed.

NOTICE The preventative maintenance inspections are to be used in conjunction with a Job Safety Analysis.

CAUTION If the job sequence changes a new Job Safety Analysis needs to be completed for the changes. Failure to do so may result in personal injury or equipment damage.

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BUCYRUS Australia Preventative Maintenance Inspection Job Description: 10 HOUR – DAILY OFF LINE MECHANICAL INSPECTION BUCYRUS FBL-55H LHD/Utility Vehicle Job No:

Type:

Customer:

Mine:

FBL55H

Technical References BUCYRUS FBL-55H Service Manual AS3584-3 Diesel Engine Systems for Underground Coal Mines-Maintenance Safety Advice

Determine which energy source will need isolating before starting work.

Isolate and tag all forms of energy that could put you at risk.

Work safely and ensure your actions do not put others at risk.

General Notes Use only the correct tools for the job.

Examine any lifting device is fit for purpose before use.

While performing service, additional work may be identified, depending on the severity this work may need to be performed immediately. However if the work is of lesser priority it must be documented so it can be planned and scheduled.

Check infers “look, listen, feel” References

Personal Protection Equipment Policies

Occupational Health and Safety Regulations

Mine Manager’s Rules

Isolation and Tagging procedures

SOPs where relevant Condition Codes

No fault found

Fault found and fixed, record fault and parts used.

Fault found and not fixed, record fault, parts required (including a full description and Part No.) and the reason why it was not rectified.

Procedure

Perform activity.

Indicate condition by placing a tick against the appropriate code.

Document any comments including any defects found.

Print name or initial to indicate the activity is complete.

Print name and sign and date in the “Completed By” table at the end of the service sheet.

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SERIAL No.

PLANT No. Activity Required

1

DATE 2

3

Defects/Comment

Record Hour Meter Reading _________ hrs Clean machine completely, pay particular attention to loose material, oil and coal dust 1.

ENGINE – General

Inspect the complete engine assembly and mounts for damage, any signs of oil, coolant and fuel leaks, looseness and any abnormal vibration, noise and temperature (test drive).

Inspect the engine for the correct oil level. Top up as required.

Indicate litres used.

Ref: Spec 1

If fitted with Hydraulic throttle, inspect throttle fluid reservoir and fill as required. Indicate litres used

Ref: Spec 3

If fitted with cable throttle, inspect condition of cable.

1.2

ENGINE – Intake

Check the air filter restriction indicator for signs of filter contamination/blockage.

Check condition of filter housing.

Check the Primary air filter element and replace if required.

BUCYRUS Part No. 505090

Check Inner air filter element and replace if required.

BUCYRUS Part No. 505089

Check all fasteners, intake joints and brackets of the Shutdown valve for security and tightness Check all other intake joints for security and tightness Check all air intake hoses, pipes and fittings for damage, leaks and looseness.

1.3

ENGINE - Fuel System

Inspect all fuel lines/connections/clamps for damage, looseness and any leakage. Change/repair as required.

Check fuel water separator and drain off any water as required.

Check fuel level in fuel tank and fill as required. Indicate litres used.

1.4

Ref: Spec 6

ENGINE - Cooling System

Inspect the cooling system header/expansion tank for the correct coolant level. Top up as required. Indicate litres used.

Ref: Spec 5

Inspect the radiator and cooling system for signs of leakage, blockage, contamination and security.

Check radiator assembly and clean if required.

Inspect the cooling pump drive belt for wear, damage and correct adjustment. Correct tension = 12 to 14mm deflection.

Adjust/replace as required.

BUCYRUS Part No. 504611

Check fan blades and cowl for correct operation and alignment.

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Activity Required 1.5

1

2

3

Defects/Comment

ENGINE - Exhaust System

Inspect the exhaust pipes and wet bath for security and signs of leaks / damage.

2.

DRIVETRAIN - Transmission

Inspect the transmission assembly and mounts for oil leaks, looseness, damage and any abnormal vibration, noise and heat (test drive).

Check transmission oil level and top up as required. Indicate litres used.

2.1

Ref: Spec 2

DRIVETRAIN - Drive Line

Inspect all drive shaft, slip joints and CV joints for damage, looseness, wear and contamination build up. Clean / tighten as required.

2.2

DRIVETRAIN - Wheels and Tyres

Inspect wheel studs / nuts for damage, looseness and any missing. Tighten / replace as required.

Inspect the tyre assemblies for damage (tears/splits) and wear.

2.3

DRIVETRAIN - Axles and Planetaries

Check for any oil leaks.

Check pinion oil seals 3.

HYDRAULICS

Check the main hydraulic oil level and fill as required. Indicate litres used.

Ref: Spec 3

Ensure the hydraulic filler cap is secure and sealing.

Check and record the following gauge pressures: Steering Accumulator pressure (2500psi / 17250kPa) Brake Accumulator pressure (2500psi / 17250kPa) Brake Head Pressure (1750psi / 12100kPa) Note : Machine Not To Be Operated if Brake Head pressure is below 1750 PSI. Check the Steering circuit pressure filter indicator, replace filter if required.

BUCYRUS Part No. 501800

Check the Hydraulic Return filter indicator, replace if required.

BUCYRUS Part No. 502126

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Activity Required 4.

1

2

3

Defects/Comm ent

PNEUMATICS - Air Receiver

Drain away all condensation from the air receiver vessel.

Drain air circuit water trap.

Inspect the circuit and relief valve for damage, leaks and correct operation.

4.1

PNEUMATICS - Main Isolation Valve

Inspect the 2-way valve for correct operation, leaks and locking mechanism. Replace/repair as required.

4.2

PNEUMATICS – Horn

Inspect the air horn and its operating valve for correct operation, abnormal noise (bypass), security and any leaks. Ensure the valve is clearly labeled. Repair as required.

5.

ELECTRICS, INSTRUMENTS and CONTROLS Operator’s Compartment Ensure compartment is clean of all loose materials, coal, dirt etc.

Inspect the condition of the operator’s gauges. Check for correct operation : Brake Head Pressure Brake Accumulator Pressure Steering Accumulator Pressure Engine Water Temperature Engine Exhaust Temperature Transmission Temperature Air Pressure Engine Oil Pressure Inspect the operators seat for physical damage, including cushions and pads.

Inspect all control devices (pedals, levers, handles, switches etc) for signs of wear damage, and incorrect operation. Repair as required.

Check door hinges and latches for correct operation. Repair as required.

5.1 ELECTRICS, INSTRUMENTS and CONTROLS - Electrical System Check Lights for correct operation.

Check cables, hoses and flameproof joints are secure.

Check DCS installation for security.

Check alignment, condition and mounting of alternator, drive coupling and motor.

6.

FRAME RELATED – Canopy

Check for damage, security of fasteners 6.1

FRAME RELATED - Guards and Covers

Inspect all guards and covers for security, damage and any missing covers/retainers. Repair or replace as required.

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Activity Required 6.2

1

2

3

Defects/Comm ent

FRAME RELATED - Fire Extinguisher

Inspect the fire extinguisher mounting/holding bracket for security, damage and that the extinguisher is easy to remove and secure when clamped in.

Check the charge pressure indicator, where fitted, is registering within the operable range and appears to be free and operating correctly.

6.3

FRAME RELATED - Fire Suppression System – If Fitted

Inspect the security of all fittings and components of the fire suppression systems.

Check the fire suppression bottle for the correct pre-charge. The indicator needle should be in the green zone.

6.4

FRAME RELATED - Towing Equipment

Check the tow pin and securing chain for damage and replace as required.

7.

OPERATIONAL CHECKS - Safety System

With engine stopped, check operation of Emergency Intake Shut Off valve and reset.

Check the transmission neutral start valve for correct operation.

Select a gear and check if the engine will attempt to start. Repair as required.

Check the door interlock system for correct operation, moving in 1st gear slow.

Perform exhaust conditioner low water shutdown est.

Perform DCS Low Engine Oil Shutdown with Park brake off. When the engine shuts down ensure Park brake applies.

Note : Machine Not To Be Put In Operation If Safety Systems Are Not Working.

7.1 OPERATIONAL CHECKS – Hydraulic Function Test all Hydraulic Operations Steering; left and right Fork TyneTilt; forward and back Fork Tyne Lift; raise and lower Inspect all hydraulic cylinders and hosing: Steer cylinder 2 x Tilt Cylinder 2 x Lift Cylinders 2 x

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COMMENTS

INSPECTED BY

DATE

CHECKED BY

DATE

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FLUID SPECIFICATION TABLE SPEC.

COMPONENT

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

1

Engine

26

Engine Oil

Fuchs Titan Universal MF 1540

2

Transmission

45

Mineral Gear Oil

Fuchs Titan Universal MF 1540

3

Hydraulic

400

Hydraulic

4

Axle / Wheel Ends

53 (Each Axle)

Mineral Gear Oil with Limited Slip Additive

5

Cooling System

72

Pre-mixed Coolant Conditioner

6

Fuel

400

Distillate “Diesel” Fuel

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin - Diff Pinion Oil Seal

As required

Multi-purpose EP Grease

8

Winch Gearbox

5

Gear Oil

Fuchs Powergear M460

9

Winch Planetary

2.5

Gear Oil

Fuchs Powergear M460

10

Engine Drive Coupling

Refer Service Manual

High Temperature

October 2009

45 of 311

Fuchs renolin B 68

SAE90LS Fuchs Titan Gear LS 90

Hardy Manufacturing Inhibit To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

Fuchs Polyplex 2

NLGI no. 2 (Shell Stamina RL2)

Manual No. M01335r1

BI620094

Bucyrus Australia

Blakefield South FBL-55H Service Manual

BUCYRUS Australia Preventative Maintenance Inspection Job Description: 50 HOUR – WEEKLY OFF LINE MECHANICAL INSPECTION BUCYRUS FBL-55H LHD/Utility Vehicle Job No:

Type:

Customer:

Mine:

Technical References BUCYRUS AS3584-3 Maintenance

FBL55H

FBL-55H Service Manual Diesel Engine Systems for Underground Coal Mines-

Safety Advice

Determine which energy source will need isolating before starting work.

Isolate and tag all forms of energy that could put you at risk.

Work safely and ensure your actions do not put others at risk.

General Notes Use only the correct tools for the job.

Examine any lifting device is fit for purpose before use.

While performing service, additional work may be identified, depending on the severity this work may need to be performed immediately. However if the work is of lesser priority it must be documented so it can be planned and scheduled.

Check infers “look, listen, feel” References

Personal Protection Equipment Policies

Occupational Health and Safety Regulations Mine Manager’s Rules Isolation and Tagging procedures SOPs where relevant Condition Codes

No fault found

Fault found and fixed, record fault and parts used.

Fault found and not fixed, record fault, parts required (including a full description and Part No.) and the reason why it was not rectified.

Procedure

Perform activity.

Indicate condition by placing a tick against the appropriate code.

Document any comments including any defects found.

Print name or initial to indicate the activity is complete.

Print name and sign and date in the “Completed By” table at the end of the service sheet.

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SERIAL No.

PLANT No.

Activity Required

DATE 1

2

3

Defects/Comment

Record Hour Meter Reading _________ hrs Clean machine completely, pay particular attention to loose material, oil and coal dust.

1.

ENGINE – General

Inspect the complete engine assembly and mounts for damage, any signs of oil, coolant and fuel leaks, looseness and any abnormal vibration, noise and temperature (test drive).

Inspect the engine for the correct oil level. Top up as required.

Indicate litres used.

Ref: Spec 1

Check engine breather.

Inspect condition of accelerator cable.

1.2

ENGINE – Intake

Check the air filter restriction indicator for signs of filter contamination/blockage.

Check condition of filter housing.

Check the Primary air filter element and replace if required.

BUCYRUS Part No. 505090

Check Inner air filter element and replace if required.

BUCYRUS Part No. 505089

Check all fasteners, intake joints and brackets of the Shutdown valve for security and tightness.

Check all other intake joints for security and tightness.

Check all air intake hoses, pipes and fittings for damage, leaks and looseness.

1.3

ENGINE - Fuel System

Inspect all fuel lines/connections/clamps for damage, looseness and any leakage. Change/repair as required.

Inspect condition and security of seal in cap for diesel tank manual fill point.

Check fuel water separator and drain off any water as required.

Check fuel level in fuel tank and fill as required. Indicate litres used.

1.4

Ref: Spec 6

ENGINE - Cooling System

Inspect the cooling system header/expansion tank for the correct coolant level. Top up as required. Indicate litres used.

Ref: Spec 5

Check condition of header tank pressure caps and necks.

Inspect the cooling pump for signs of leakage, wear and security.

Inspect the radiator and cooling system for signs of leakage, blockage, contamination and security.

Activity Required

1

2

3

Defects/Comment

Pressure clean radiator assembly and check mounts.

October 2009

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Blakefield South FBL-55H Service Manual

Inspect the cooling pump drive belt for wear, damage and correct adjustment. Correct tension = 12 to 14mm deflection. Adjust/replace as required.

BUCYRUS Part No. 504611

Check fan blades and cowl for correct operation and alignment.

1.5

ENGINE - Exhaust System

Inspect the exhaust pipes and wet bath for security and signs of leaks / damage. Check filters for contamination and holes.

1.6

ENGINE - Exhaust Conditioner

Clean float chamber every week. Drain, remove covers. Flush out, remove exhaust build up around floats and make up valve.

2.

DRIVETRAIN – Transmission

Inspect the transmission assembly and mounts for oil leaks, looseness, damage and any abnormal vibration, noise and heat (test drive) Check transmission breather.

Check transmission oil level and top up as required. Indicate litres used.

2.1

Ref: Spec 2

DRIVETRAIN - Drive Line

Inspect all drive shaft, slip joints and CV joints for damage, looseness, wear and contamination build up. Clean / tighten as required.

2.2

DRIVETRAIN - Wheels and Tyres

Inspect wheel studs / nuts for damage, looseness and any missing.

Tighten / replace as required. lnspect the tyre assemblies for damage (tears/splits).

2.3 DRIVETRAIN - Axles and Planetaries Check for any oil leaks.

Check levels and fill as required. Indicate litres used.

Front Rear

Ref: Spec 4

Check pinion oil seals Check differential breathers Front Rear 2.4 DRIVETRAIN – Brakes Check wear measurements on all brake units ODSF ODSR DSF DSR

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Activity Required 3.

1

2

3

Defects/Comment

HYDRAULICS

Check the main hydraulic oil level and fill as required. Indicate litres used.

Ref: Spec 3

Ensure the hydraulic filler cap is secure and sealing.

Check and record the following gauge pressures: Steering Accumulator pressure (2500psi / 17250kPa) Brake Accumulator pressure (2500psi / 17250kPa) Brake Head Pressure (1750psi / 12100kPa) Note : Machine Not To Be Operated if Brake Head pressure is below 1750 PSI Check the Steering circuit pressure filter indicator, replace filter if required.

BUCYRUS Part No. 501800

Check the Hydraulic Return filter indicator, replace filter if required

BUCYRUS Part No. 502126

4.

PNEUMATICS - Air Receiver

Drain away all condensation from the air receiver vessel.

Drain air circuit water trap.

Inspect the circuit and relief valve for damage, leaks and correct operation.

4.1

PNEUMATICS - Main Isolation Valve

Inspect the 2-way valve for correct operation, leaks and locking mechanism. Replace/ repair as required.

4.2

PNEUMATICS – Horn

Inspect the air horn and its operating valve for correct operation, abnormal noise (bypass), security and any leaks. Ensure the valve is clearly labeled. Repair as required.

5.

ELECTRICS, INSTRUMENTS and CONTROLS - Operator’s Compartment Ensure compartment is clean of all loose materials, coal, dirt etc.

Inspect the condition of the operator’s gauges. Check for correct operation : Brake Head Pressure Brake Accumulator Pressure Steering Accumulator Pressure Engine Water Temperature Engine Exhaust Temperature Transmission Temperature Air Pressure Engine Oil Pressure Inspect the operators seat for physical damage, including cushions and pads

October 2009

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Manual No. M01335r1

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Blakefield South FBL-55H Service Manual

Activity Required

1

2

3

Defects/Comment

Inspect all control devices (pedals, levers, handles, switches etc) for signs of wear, damage, missing parts and incorrect operation.

Repair as required.

Inspect tilt/lift and implement control valve boots for damage and replace if necessary.

Check door hinges and latches for correct operation. Repair as required.

5.1 ELECTRICS, INSTRUMENTS and CONTROLS Electrical System Check Lights for correct operation.

Check cables, hoses and flameproof joints are secure.

Check DCS installation for security.

Check alignment, condition and mounting of alternator, drive coupling and motor.

6.

FRAME RELATED – Canopy

Check for damage, security of fasteners.

6.1

FRAME RELATED - Guards and Covers

Inspect all guards and covers for security, damage and any missing covers/retainers. Repair or replace as required.

6.2

FRAME RELATED - Fire Extinguisher

Inspect the fire extinguisher mounting/holding bracket for security, damage and that the extinguisher is easy to remove and secure when clamped in.

Check the charge pressure indicator, where fitted, is registering within the operable range and appears to be free and operating correctly.

6.3

FRAME RELATED - Fire Suppression System

Inspect the security of all fittings and components of the fire suppression systems.

Check the fire suppression bottle for the correct pre-charge. The indicator needle should be in the green zone.

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Blakefield South FBL-55H Service Manual

Activity Required

1

6.4 FRAME RELATED – Lubrication Lubricate the following grease point. Lubricate until grease is purged from the bushes.

Articulation Pillow Block Drive line Cylinder Pins Zone Manifolds 3 x Lift cylinder top pivot points 2 x Tilt cylinder pins 6 x Steer cylinder pins 2 x Lift arm pivot pins 2 x Pedal pivot points 2 x Radiator pivot points 4 x Diff Pinion Oil Seals 2 x 6.5

2

3

Defects/Comment Ref: Spec 7

FRAME RELATED - Towing Equipment

Check the tow pin and securing chain for damage and replace as required.

7.

OPERATIONAL CHECKS - Safety System

Check the transmission neutral start valve for correct operation.

Select a gear and check if the engine will attempt to start. Repair as required.

Check the door interlock system for correct operation, moving in 1st gear slow.

Perform DCS Low Engine Oil Shutdown with Park brake off. When the engine shuts down ensure Park brake applies.

Perform exhaust conditioner low water shutdown est.

Perform Engine Intake Shutdown Valve test. When the engine shuts down ensure engine will not start until Shutdown Valve is reset.

Note : Machine Not To Be Put In Operation If Safety Systems Are Not Working 7.1

OPERATIONAL CHECKS – Hydraulic

Function Test all Hydraulic Operations Steering; left and right Fork TyneTilt; forward and back Fork Tyne Lift; raise and lower Inspect all hydraulic cylinders and hosing : Steer cylinder 2 x Tilt Cylinder 2 x Lift Cylinders 2 x 7.2

OPERATIONAL CHECKS—Tyres

Check tyres for cuts, punctures, tread depth and correct pressure.

October 2009

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Manual No. M01335r1

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Blakefield South FBL-55H Service Manual

COMMENTS

INSPECTED BY

DATE

CHECKED BY

DATE

Manual No.M01335r1

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October 2009

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Blakefield South FBL-55H Service Manual

FLUID SPECIFICATION TABLE SPEC.

COMPONENT

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

1

Engine

26

Engine Oil

Fuchs Titan Universal MF 1540

2

Transmission

45

Mineral Gear Oil

Fuchs Titan Universal MF 1540

3

Hydraulic

400

Hydraulic

4

Axle / Wheel Ends

53 (Each Axle)

Mineral Gear Oil with Limited Slip Additive

5

Cooling System

72

Pre-mixed Coolant Conditioner

6

Fuel

400

Distillate “Diesel” Fuel

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin - Diff Pinion Oil Seal

As required

Multi-purpose EP Grease

8

Winch Gearbox

5

Gear Oil

Fuchs Powergear M460

9

Winch Planetary

2.5

Gear Oil

Fuchs Powergear M460

10

Engine Drive Coupling

Refer Service Manual

High Temperature

October 2009

53 of 311

Fuchs renolin B 68

SAE90LS Fuchs Titan Gear LS 90

Hardy Manufacturing Inhibit To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

Fuchs Polyplex 2

NLGI no. 2 (Shell Stamina RL2)

Manual No. M01335r1

BI620094

Bucyrus Australia

Blakefield South FBL-55H Service Manual

BUCYRUS Australia Preventative Maintenance Inspection Job Description: 250 HOUR – 3 MONTHLY OFF LINE MECHANICAL INSPECTION BUCYRUS FBL-55H/Utility Vehicle Job No:

Type:

Customer:

Mine:

FBL55H

Technical References BUCYRUS FBL-55H Service Manual AS3584-3 Diesel Engine Systems for Underground Coal Mines-Maintenance Safety Advice

Determine which energy source will need isolating before starting work.

Isolate and tag all forms of energy that could put you at risk.

Work safely and ensure your actions do not put others at risk.

General Notes Use only the correct tools for the job.

Examine any lifting device is fit for purpose before use.

While performing service, additional work may be identified, depending on the severity this work may need to be performed immediately. However if the work is of lesser priority it must be documented so it can be planned and scheduled.

Check infers “look, listen, feel” References

Personal Protection Equipment Policies

Occupational Health and Safety Regulations

Mine Manager’s Rules

Isolation and Tagging procedures

SOPs where relevant Condition Codes

No fault found

Fault found and fixed, record fault and parts used.

Fault found and not fixed, record fault, parts required (including a full description and Part No.) and the reason why it was not rectified.

Procedure

Perform activity.

Indicate condition by placing a tick against the appropriate code.

Document any comments including any defects found.

Print name or initial to indicate the activity is complete.

Print name and sign and date in the “Completed By” table at the end of the service sheet.

Manual No.M01335r1

54 of 311

October 2009

BI620094

Bucyrus Australia

Blakefield South FBL-55H Service Manual

SERIAL No.

PLANT No.

Activity Required

DATE 1

2

3

Defects/Comment

Record Hour Meter Reading _________ hrs Clean machine completely, pay particular attention to loose material, oil and coal dust.

1.

ENGINE – General

Inspect the complete engine assembly and mounts for damage, any signs of oil, coolant and fuel leaks, looseness and any abnormal vibration, noise and temperature (test drive).

Drain and refill engine oil

Ref: Spec 1

Replace Engine oil filter

BUCYRUS Part No. 503469

Inspect the engine for the correct oil level. Top up as required.

Indicate litres used.

Ref: Spec 1

Check engine breather Inspect condition of accelerator cable.

1.2

ENGINE – Intake

Check the air filter restriction indicator for signs of filter contamination/blockage.

Check condition of filter housing.

Check the Primary air filter element and replace if required.

BUCYRUS Part No. 505090

Check Inner air filter element and replace if required.

BUCYRUS Part No. 505089

Check all fasteners, intake joints and brackets of the Shutdown valve for security and tightness Check all other intake joints for security and tightness.

Check all air intake hoses, pipes and fittings for damage, leaks and looseness.

1.3

ENGINE - Fuel System

Inspect all fuel lines/connections/clamps for damage, looseness and any leakage. Change/repair as required.

Inspect condition and security of seal in cap for diesel tank manual fill point.

Replace Primary fuel filter.

BUCYRUS Part No. 503467

Replace Secondary fuel filter.

BUCYRUS Part No. 506604

Check fuel water separator and drain off any water as required.

Check fuel level in fuel tank and fill as required. Indicate litres used.

Activity Required 1.4

Ref: Spec 6 1

2

3

Defects/Comment

ENGINE - Cooling System

October 2009

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Manual No. M01335r1

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Blakefield South FBL-55H Service Manual

Inspect the cooling system header/expansion tank for the correct coolant level. Top up as required. Indicate litres used.

Ref: Spec 5

Check condition of header tank pressure cap and neck.

Inspect the cooling pump for signs of leakage, wear and security.

Inspect the radiator and cooling system for signs of leakage, blockage, contamination and security.

Pressure clean radiator assembly and check mounts.

Inspect the cooling pump drive belt for wear, damage and correct adjustment. Correct tension = 12 to 14mm deflection. Adjust/replace as required.

BUCYRUS Part No. 504611

Check fan blades and cowl for correct operation and alignment.

1.5

ENGINE - Exhaust System

Inspect the exhaust pipes and wet bath for security and signs of leaks / damage.

Check filters for damage, blockage and change as required.

1.6

ENGINE - Exhaust Cooling System

Clean float chamber every week. Drain, remove covers. Flush out, remove exhaust build up around floats and make up valve.

Clean exhaust chamber. Drain, remove covers. Flush out, remove exhaust build up.

2.

DRIVETRAIN - Transmission

Inspect the transmission assembly and mounts for oil leaks, looseness, damage and any abnormal vibration, noise and heat (test drive).

Check transmission breather.

Check transmission oil level and top up as required. Indicate litres used.

2.1

Ref: Spec 2

DRIVETRAIN - Drive Line

Inspect all drive shaft, slip joints and CV joints for damage, looseness, wear and contamination build up. Clean / tighten as required.

2.2

DRIVETRAIN - Wheels and Tyres

Inspect wheel studs / nuts for damage, looseness and any missing.

Tighten / replace as required.

Inspect the tyre assemblies for damage (tears/splits) and wear.

Manual No.M01335r1

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Blakefield South FBL-55H Service Manual

Activity Required 2.3

1

2

3

Defects/Comment

DRIVETRAIN - Axles and Planetaries

Check for any oil leaks.

Check levels and fill as required. Indicate litres used.

Ref: Spec 4 Front Rear

Check pinion oil seals.

Check differential breathers Front Rear 2.4

DRIVETRAIN – Brakes

Check wear measurements on all brake units ODSF ODSR DSF DSR 3.

HYDRAULICS

Check the main hydraulic oil level and fill as required. Indicate litres used.

Ref: Spec 3

Ensure the hydraulic filler cap is secure and sealing.

Check and record the following gauge pressures: Steering Accumulator pressure (2500psi / 17250kPa) Brake Accumulator pressure (2500psi / 17250kPa) Brake Head Pressure (1750psi / 12100kPa) Note: Machine Not To Be Operated if Brake Head pressure is below 1750 PSI Check the Steering circuit pressure filter indicator, replace filter if required.

BUCYRUS Part No. 501800

Check the Hydraulic Return filter indicator, replace if required.

BUCYRUS Part No. 502126

4.

PNEUMATICS - Air Receiver

Drain away all condensation from the air receiver vessel.

Drain air circuit water trap.

Inspect the circuit and relief valve for damage, leaks and correct operation.

Replace Air compressor filter.

4.1

BUCYRUS Part No. 503715

PNEUMATICS - Main Isolation Valve

Inspect the 2-way valve for correct operation, leaks and locking mechanism. Replace/repair as required.

October 2009

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Manual No. M01335r1

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Bucyrus Australia

Blakefield South FBL-55H Service Manual

Activity Required 4.2

1

2

3

Defects/Comment

PNEUMATICS – Horn

Inspect the air horn and its operating valve for correct operation, abnormal noise (bypass), security and any leaks. Ensure the valve is clearly labeled. Repair as required.

5.

ELECTRICS, INSTRUMENTS and CONTROLS - Operator’s Compartment Ensure compartment is clean of all loose materials, coal, dirt etc.

Inspect the condition of the operator’s gauges. Check for correct operation : Brake Head Pressure Brake Accumulator Pressure Steering Accumulator Pressure Engine Water Temperature Engine Exhaust Temperature Transmission Temperature Air Pressure Engine Oil Pressure Inspect the operators seat for physical damage, including cushions and pads.

Inspect all control devices (pedals, levers, handles, switches etc) for signs of wear damage, and incorrect operation. Repair as required.

Inspect tilt/lift and implement control valve boots for damage and replace if necessary.

Check door hinges and latches for correct operation. Repair as required.

Inspect and clean under dash.

Drain Safety System air circuit water trap.

5.1 ELECTRICS, INSTRUMENTS and CONTROLS - Electrical System Check Lights for correct operation.

Check cables, hoses and flameproof joints are secure.

Check DCS installation for security.

Check alignment, condition and mounting of alternator, drive coupling and motor.

6.

FRAME RELATED – Canopy

Check for damage, security of fasteners.

6.1

FRAME RELATED - Guards and Covers

Inspect all guards and covers for security, damage and any missing covers/retainers. Repair or replace as required.

Manual No.M01335r1

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October 2009

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Blakefield South FBL-55H Service Manual

Activity Required 6.2

1

2

3

Defects/Comment

FRAME RELATED - Fire Extinguisher

Inspect the fire extinguisher mounting/holding bracket for security, damage and that the extinguisher is easy to remove and secure when clamped in.

Check the charge pressure indicator, where fitted, is registering within the operable range and appears to be free and operating correctly.

6.3

FRAME RELATED - Fire Suppression System

Inspect the security of all fittings and components of the fire suppression systems.

Check the fire suppression bottle for the correct pre-charge. The indicator needle should be in the green zone.

6.4

FRAME RELATED – Lubrication

Lubricate the following grease point. Lubricate until grease is purged from the bushes.

Articulation Pillow Block Drive line Cylinder Pins Zone Manifolds 3 x Lift cylinder top pivot points 2 x Tilt cylinder pins 6 x Steer cylinder pins 2 x Lift arm pivot pins 2 x Pedal pivot points 2 x Radiator pivot points 4 x Diff Pinion Oil Seals 4 x Lubricate the engine drive coupling 6.5

Ref: Spec 7

Ref: Spec 8

FRAME RELATED - Towing Equipment

Check the tow pin and securing chain for damage and replace as required.

7.

OPERATIONAL CHECKS - Safety System

Check the transmission neutral start valve for correct operation. Select a gear and check if the engine will attempt to start. Repair as required.

Check the door interlock system for correct operation, moving in 1st gear slow.

Perform DCS Low Engine Oil Shutdown with Park brake off. When the engine shuts down ensure Park brake applies.

Perform wet bath low water test.

Perform Engine Intake Shutdown Valve test. When the engine shuts down ensure engine will not start until Shutdown Valve is reset.

Note: Machine Not To Be Put In Operation If Safety Systems Are Not Working

October 2009

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Manual No. M01335r1

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Bucyrus Australia

Blakefield South FBL-55H Service Manual

Activity Required 7.1

1

2

3

Defects/Comment

OPERATIONAL CHECKS – Hydraulic

Function Test all Hydraulic Operations Steering; left and right Tilt; forward and back Lift; raise and lower Inspect all hydraulic cylinders and hosing : Steer cylinder 2 x Tilt Cylinder 2 x Lift Cylinders 2 x

Manual No.M01335r1

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October 2009

BI620094

Bucyrus Australia

Blakefield South FBL-55H Service Manual

COMMENTS

INSPECTED BY

DATE

CHECKED BY

DATE

October 2009

61 of 311

Manual No. M01335r1

BI620094

Bucyrus Australia

Blakefield South FBL-55H Service Manual

FLUID SPECIFICATION TABLE SPEC.

COMPONENT

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

1

Engine

26

Engine Oil

Fuchs Titan Universal MF 1540

2

Transmission

45

Mineral Gear Oil

Fuchs Titan Universal MF 1540

3

Hydraulic

400

Hydraulic

4

Axle / Wheel Ends

53 (Each Axle)

Mineral Gear Oil with Limited Slip Additive

5

Cooling System

72

Pre-mixed Coolant Conditioner

6

Fuel

400

Distillate “Diesel” Fuel

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin - Diff Pinion Oil Seal

As required

Multi-purpose EP Grease

8

Winch Gearbox

5

Gear Oil

Fuchs Powergear M460

9

Winch Planetary

2.5

Gear Oil

Fuchs Powergear M460

10

Engine Drive Coupling

Refer Service Manual

High Temperature

Manual No.M01335r1

62 of 311

Fuchs renolin B 68

SAE90LS Fuchs Titan Gear LS 90

Hardy Manufacturing Inhibit To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

Fuchs Polyplex 2

NLGI no. 2 (Shell Stamina RL2)

October 2009

BI620094

Bucyrus Australia

Blakefield South FBL-55H Service Manual

Preventative Maintenance Inspection Job Description: 500 HOUR – 6 MONTHS OFF LINE MECHANICAL INSPECTION BUCYRUS FBL-55H LHD/Utility Vehicle Job No:

Type:

Customer:

Mine:

FBL55H

Technical References BUCYRUS FBL-55H Service Manual AS3584-3 Diesel Engine Systems for Underground Coal Mines-Maintenance Safety Advice

Determine which energy source will need isolating before starting work.

Isolate and tag all forms of energy that could put you at risk.

Work safely and ensure your actions do not put others at risk.

General Notes Use only the correct tools for the job.

Examine any lifting device is fit for purpose before use.

While performing service, additional work may be identified, depending on the severity this work may need to be performed immediately. However if the work is of lesser priority it must be documented so it can be planned and scheduled.

Check infers “look, listen, feel” References

Personal Protection Equipment Policies

Occupational Health and Safety Regulations

Mine Manager’s Rules

Isolation and Tagging procedures

SOPs where relevant Condition Codes

No fault found

Fault found and fixed, record fault and parts used.

Fault found and not fixed, record fault, parts required (including a full description and Part No.) and the reason why it was not rectified.

Procedure

Perform activity.

Indicate condition by placing a tick against the appropriate code.

Document any comments including any defects found.

Print name or initial to indicate the activity is complete.

Print name and sign and date in the “Completed By” table at the end of the service sheet.

October 2009

63 of 311

Manual No. M01335r1

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Bucyrus Australia

Blakefield South FBL-55H Service Manual

SERIAL No.

PLANT No.

Activity Required

DATE 1

2

3

Defects/Comment

Record Hour Meter Reading _________ hrs Clean machine completely, pay particular attention to loose material, oil and coal dust.

1.

ENGINE – General

Inspect the complete engine assembly and mounts for damage, any signs of oil, coolant and fuel leaks, looseness and any abnormal vibration, noise and temperature (test drive).

Drain and refill engine oil

Ref: Spec 1

Replace Engine oil filter

BUCYRUS Part No. 503469

Inspect the engine for the correct oil level. Top up as required.

Indicate litres used.

Ref: Spec 1

Check engine breather Inspect condition of accelerator cable.

1.2

ENGINE – Intake

Check the air filter restriction indicator for signs of filter contamination/blockage.

Check condition of filter housing.

Check the Primary air filter element and replace if required.

BUCYRUS Part No. 505090

Check Inner air filter element and replace if required.

BUCYRUS Part No. 505089

Check all fasteners, intake joints and brackets of the Shutdown valve for security and tightness.

Check all other intake joints for security and tightness.

Check all air intake hoses, pipes and fittings for damage, leaks and looseness.

1.3

ENGINE - Fuel System

Inspect all fuel lines/connections/clamps for damage, looseness and any leakage. Change/repair as required.

Inspect condition and security of seal in cap for diesel tank manual fill point.

Replace Primary fuel filter.

BUCYRUS Part No. 503467

Replace Secondary fuel filter

BUCYRUS Part No. 506604

Check fuel water separator and drain off any water as required.

Check fuel level in fuel tank and fill as required. Indicate litres used.

Manual No.M01335r1

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Ref: Spec 6

October 2009

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Bucyrus Australia

Blakefield South FBL-55H Service Manual

Activity Required 1.4

1

2

3

Defects/Comment

ENGINE - Cooling System

Inspect the cooling system header/expansion tank for the correct coolant level. Top up as required. Indicate litres used.

Ref: Spec 5

Visually check condition of header tank pressure cap and neck.

Inspect the cooling pump for signs of leakage, wear and security.

Inspect the radiator and cooling system for signs of leakage, blockage, contamination and security.

Pressure clean radiator assembly, check mounts and re-torque as required.

Inspect the cooling pump drive belt for wear, damage and correct adjustment. Correct tension = 12 to 14mm deflection. Adjust/replace as required.

BUCYRUS Part No. 504611

Check fan blades and cowl for correct operation and alignment.

1.5

ENGINE - Exhaust System

Inspect the exhaust pipes and wet bath for security and signs of leaks / damage.

Check particulate filter and change if necessary.

1.6

ENGINE - Exhaust Cooling System

Clean float chamber every week. Drain, remove covers. Flush out, remove exhaust build up around floats and make up valve.

Clean exhaust chamber. Drain, remove covers. Flush out, remove exhaust build up.

2.

DRIVETRAIN - Transmission

Inspect the transmission assembly and mounts for oil leaks, looseness, damage and any abnormal vibration, noise and heat (test drive).

Check transmission breather.

Replace Transmission filter element.

2x BUCYRUS Part No. 501471

Check transmission oil level and top up as required. Indicate litres used.

Ref: Spec 2

2.1

DRIVETRAIN - Drive Line

Inspect all drive shaft, slip joints and CV joints for damage, looseness, wear and contamination build up. Clean / tighten as required.

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Activity Required 2.2

1

2

3

Defects/Comment

DRIVETRAIN - Wheels and Tyres

Inspect wheel studs / nuts for damage, looseness and any missing.

Tighten / replace as required.

Inspect the tyre assemblies for damage (tears/splits) and wear.

2.3

DRIVETRAIN - Axles and Planetaries

Check for any oil leaks.

Check levels and fill as required. Indicate litres used.

Ref: Spec 4 Front Rear

Check pinion oil seals.

Check differential breathers Front Rear 2.4

DRIVETRAIN - Brakes

Check wear measurements on all brake units ODSF ODSR DSF DSR 3.

HYDRAULICS

Check the main hydraulic oil level and fill as required. Indicate litres used.

Ref: Spec 3

Ensure the hydraulic filler cap is secure and sealing.

Check and record the following gauge pressures: Steering Accumulator pressure (2500psi / 17250kPa) Brake Accumulator pressure (2500psi / 17250kPa) Brake Head Pressure (1750psi / 12100kPa) Note: Machine Not To Be Operated if Brake Head pressure is below 1750 PSI Replace Steering circuit pressure filter.

BUCYRUS Part No. 501800

Replace Hydraulic Return filter

BUCYRUS Part No. 502126

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Activity Required 4.

1

2

3

Defects/Comment

PNEUMATICS - Air Receiver

Drain away all condensation from the air receiver vessel.

Drain air circuit water trap.

Check governor setting.

Inspect the circuit and relief valve for damage, leaks and correct operation.

Replace Air compressor filter.

4.1

BUCYRUS Part No. 503715

PNEUMATICS - Main Isolation Valve

Inspect the 2-way valve for correct operation, leaks and locking mechanism. Replace/repair as required.

4.2

PNEUMATICS - Horn

Inspect the air horn and its operating valve for correct operation, abnormal noise (bypass), security and any leaks. Ensure the valve is clearly labeled. Repair as required.

5.

ELECTRICS, INSTRUMENTS and CONTROLS - Operator’s Compartment Ensure compartment is clean of all loose materials, coal, dirt etc.

Inspect the condition of the operators gauges. Check for correct operation and compare against readings on DCS display: Brake Head Pressure Brake Accumulator Pressure Steering Accumulator Pressure Engine Water Temperature Engine Exhaust Temperature Transmission Temperature Air Pressure Engine Oil Pressure Check and record DCS display controller and configuration software revision No. Inspect the operators seat for physical damage, including cushions and pads.

Inspect all control devices (pedals, levers, handles, switches etc) for signs of wear damage, and incorrect operation. Repair as required.

Inspect tilt/lift and implement control valve boots for damage and replace if necessary.

Check door hinges and latches for correct operation. Repair as required.

Inspect and clean under dash.

Drain Safety System air circuit water trap.

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Activity Required

1

2

3

Defects/Comment

5.1 ELECTRICS, INSTRUMENTS and CONTROLS - Electrical System Check Lights for correct operation.

Check cables, hoses and flameproof joints are secure.

Check DCS installation for security.

Check alignment, condition and mounting of alternator, drive coupling and motor.

6.

FRAME RELATED - Canopy

Check for damage, security of fasteners.

6.1

FRAME RELATED - Guards and Covers

Inspect all guards and covers for security, damage and any missing covers/retainers. Repair or replace as required.

6.2

FRAME RELATED - Fire Extinguisher

Inspect the fire extinguisher mounting/holding bracket for security, damage and that the extinguisher is easy to remove and secure when clamped in.

Check the charge pressure indicator, where fitted, is registering within the operable range and appears to be free and operating correctly.

6.3

FRAME RELATED - Fire Suppression System

Inspect the security of all fittings and components of the fire suppression systems.

Check the fire suppression bottle for the correct pre-charge. The indicator needle should be in the green zone.

6.4

FRAME RELATED – Lubrication

Lubricate the following grease point. Lubricate until grease is purged from the bushes.

Articulation Pillow Block Drive line Cylinder Pins Zone Manifolds 3 x Lift cylinder top pivot points 2 x Tilt cylinder pins 6 x Steer cylinder pins 2 x Lift arm pivot pins 2 x Pedal pivot points 2 x Radiator pivot points 4 x Diff Pinion Oil Seals 4 x Lubricate the engine drive coupling.

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Ref: Spec 7

Ref: Spec 8

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Activity Required 6.5

1

2

3

Defects/Comment

FRAME RELATED - Towing Equipment

Check the tow pin and securing chain for damage and replace as required.

7.

OPERATIONAL CHECKS - Safety System

Check the transmission neutral start valve for correct operation. Select a gear and check if the engine will attempt to start. Repair as required.

Check the door interlock system for correct operation, moving in 1st gear slow.

Perform DCS Low Engine Oil Shutdown with Park brake off. When the engine shuts down ensure Park brake applies.

Perform wet bath low water test.

Perform Engine Intake Shutdown Valve test. When the engine shuts down ensure engine will not start until Shutdown Valve is reset.

Note : Machine Not To Be Put In Operation If Safety Systems Are Not Working 7.1

OPERATIONAL CHECKS – Hydraulic

Function Test all Hydraulic Operations Steering; left and right Tilt; forward and back Lift; raise and lower Inspect all hydraulic cylinders and hosing : Steer cylinder 2 x Tilt Cylinder 2 x Lift Cylinders 2 x 7.2

OPERATIONAL CHECKS—Tyres

Check tyres for cuts, punctures, tread depth and correct pressure.

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COMMENTS

INSPECTED BY

DATE

CHECKED BY

DATE

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FLUID SPECIFICATION TABLE SPEC.

COMPONENT

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

1

Engine

26

Engine Oil

Fuchs Titan Universal MF 1540

2

Transmission

45

Mineral Gear Oil

Fuchs Titan Universal MF 1540

3

Hydraulic

400

Hydraulic

4

Axle / Wheel Ends

53 (Each Axle)

Mineral Gear Oil with Limited Slip Additive

5

Cooling System

72

Pre-mixed Coolant Conditioner

6

Fuel

400

Distillate “Diesel” Fuel

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin - Diff Pinion Oil Seal

As required

Multi-purpose EP Grease

8

Winch Gearbox

5

Gear Oil

Fuchs Powergear M460

9

Winch Planetary

2.5

Gear Oil

Fuchs Powergear M460

10

Engine Drive Coupling

Refer Service Manual

High Temperature

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Fuchs renolin B 68

SAE90LS Fuchs Titan Gear LS 90

Hardy Manufacturing Inhibit To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

Fuchs Polyplex 2

NLGI no. 2 (Shell Stamina RL2)

Manual No. M01335r1

BI620094

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Blakefield South FBL-55H Service Manual

Room and Pillar Preventative Maintenance Inspection Job Description: 1000 HOUR – 12 MONTHS OFF LINE MECHANICAL INSPECTION BUCYRUS FBL-55H LHD/Utility Vehicle Job No:

Type:

Customer:

Mine:

FBL55H

Technical References BUCYRUS FBL-55H Service Manual AS3584-3 Diesel Engine Systems for Underground Coal Mines-Maintenance Safety Advice

Determine which energy source will need isolating before starting work.

Isolate and tag all forms of energy that could put you at risk.

Work safely and ensure your actions do not put others at risk.

General Notes Use only the correct tools for the job.

Examine any lifting device is fit for purpose before use.

While performing service, additional work may be identified, depending on the severity this work may need to be performed immediately. However if the work is of lesser priority it must be documented so it can be planned and scheduled.

Check infers “look, listen, feel” References

Personal Protection Equipment Policies

Occupational Health and Safety Regulations

Mine Manager’s Rules

Isolation and Tagging procedures

SOPs where relevant Condition Codes

No fault found

Fault found and fixed, record fault and parts used.

Fault found and not fixed, record fault, parts required (including a full description and Part No.) and the reason why it was not rectified.

Procedure

Perform activity.

Indicate condition by placing a tick against the appropriate code.

Document any comments including any defects found.

Print name or initial to indicate the activity is complete.

Print name and sign and date in the “Completed By” table at the end of the service sheet.

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SERIAL No.

PLANT No.

Activity Required

DATE 1

2

3

Defects/Comment

Record Hour Meter Reading _________ hrs Clean machine completely, pay particular attention to loose material, oil and coal dust.

1.

ENGINE - General

Inspect the complete engine assembly and mounts for damage, any signs of oil, coolant and fuel leaks, looseness and any abnormal vibration, noise and temperature (test drive).

Drain and refill engine oil

Ref: Spec 1

Replace Engine oil filter

BUCYRUS Part No. 503469

Inspect the engine for the correct oil level. Top up as required.

Indicate litres used.

Ref: Spec 1

Check engine breather If fitted with cable throttle, inspect condition of cable.

1.2

ENGINE - Intake

Check the air filter restriction indicator for signs of filter contamination/blockage.

Check condition of filter housing.

Check the Primary air filter element and replace if required.

BUCYRUS Part No. 505090

Check Inner air filter element and replace if required.

BUCYRUS Part No. 505089

Check all fasteners, intake joints and brackets of the Shutdown valve for security and tightness.

Check all other intake joints for security and tightness Check all air intake hoses, pipes and fittings for damage, leaks and looseness.

1.3

ENGINE - Fuel System

Inspect all fuel lines/connections/clamps for damage, looseness and any leakage. Change/repair as required.

Inspect condition and security of seal in cap for diesel tank manual fill point.

Replace Primary fuel filter

BUCYRUS Part No. 503467

Replace Secondary fuel filter

BUCYRUS Part No. 506604

Check fuel water separator and drain off any water as required.

Check fuel level in fuel tank and fill as required. Indicate litres used.

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Ref: Spec 6

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Activity Required 1.4

1

2

3

Defects/Comment

ENGINE - Cooling System

Inspect the cooling system header/expansion tank for the correct coolant level. Top up as required. Indicate litres used.

Ref: Spec 5

Check condition of header tank pressure caps and necks.

Inspect the cooling pump for signs of leakage, wear and security.

Inspect the radiator and cooling system for signs of leakage, blockage, contamination and security.

Pressure clean radiator assemblies, check mounts and re-torque as required.

Inspect the cooling pump drive belt for wear, damage and correct adjustment. Correct tension = 12 to 14mm deflection. Adjust/replace as required.

BUCYRUS Part No. 504611

Check fan blades and cowl for correct operation and alignment.

Replace thermostat and gasket.

1.5

BUCYRUS Part No. 506647 (Thermostat) 505782 (Gasket)

ENGINE - Exhaust System

Inspect the exhaust pipes and wet bath for security and signs of leaks / damage.

Check particulate filter and replace.

1.6

ENGINE - Exhaust Cooling System

Clean float chamber every week. Drain, remove covers. Flush out, remove exhaust build up around floats and make up valve.

Clean exhaust chamber. Drain, remove covers. Flush out, remove exhaust build up.

2.

DRIVETRAIN - Transmission

Inspect the transmission assembly and mounts for oil leaks, looseness, damage and any abnormal vibration, noise and heat (test drive).

Check Transmission Strainer Check transmission breather Drain and refill Transmission oil

Ref: Spec 2

Replace Transmission filter element

2x BUCYRUS Part No. 501471

Check transmission oil level and top up as required. Indicate litres used.

Ref: Spec 2

2.1

DRIVETRAIN - Drive Line

Inspect all drive shaft, slip joints and CV joints for damage, looseness, wear and contamination build up. Clean / tighten as required.

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Activity Required 2.2

1

2

3

Defects/Comment

DRIVETRAIN - Wheels and Tyres

Inspect wheel studs / nuts for damage, looseness and any missing.

Tighten / replace as required.

Inspect the tyre assemblies for damage (tears/splits) and wear.

2.3

DRIVETRAIN - Axles and Planetaries

Check for any oil leaks.

Drain, flush and refill front and rear Axle and wheel end oils.

Ref: Spec 4

Check levels and fill as required. Indicate litres used.

Ref: Spec 4 Front Rear

Check pinion oil seals.

Check differential breathers Front Rear 2.4

DRIVETRAIN - Brakes

Check wear measurements on all brake units ODSF ODSR DSF DSR 3.

HYDRAULICS

Check the main hydraulic oil level and fill as required. Indicate litres used.

Ref: Spec 3

Ensure the hydraulic filler cap is secure and sealing.

Check and record the following gauge pressures: Steering Accumulator pressure (2500psi / 17250kPa) Brake Accumulator pressure (2500psi / 17250kPa) Brake Head Pressure (1750psi / 12100kPa) Note: Machine Not To Be Operated if Brake Head pressure is below 1750 PSI Replace Steering circuit pressure filter

BUCYRUS Part No. 501800

Replace Hydraulic Return filter

BUCYRUS Part No. 502126

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Activity Required 4.

1

2

3

Defects/Comment

PNEUMATICS - Air Receiver

Drain away all condensation from the air receiver vessel.

Drain air circuit water trap.

Check governor setting.

Inspect the circuit and relief valve for damage, leaks and correct operation.

Replace Air compressor filter.

4.1

BUCYRUS Part No. 503715

PNEUMATICS - Main Isolation Valve

Inspect the 2-way valve for correct operation, leaks and locking mechanism. Replace/repair as required.

4.2

PNEUMATICS - Horn

Inspect the air horn and its operating valve for correct operation, abnormal noise (bypass), security and any leaks. Ensure the valve is clearly labeled. Repair as required.

5.

ELECTRICS, INSTRUMENTS and CONTROLS - Operator’s Compartment Ensure compartment is clean of all loose materials, coal, dirt etc.

Inspect the condition of the operator’s gauges. Check for correct operation : Brake Head Pressure Brake Accumulator Pressure Steering Accumulator Pressure Engine Water Temperature Engine Exhaust Temperature Transmission Temperature Air Pressure Engine Oil Pressure Inspect the operators seat for physical damage, including cushions and pads.

Inspect all control devices (pedals, levers, handles, switches etc) for signs of wear damage, and incorrect operation. Repair as required.

Inspect tilt/lift and implement control valve boots for damage and replace if necessary.

Check door hinges and latches for correct operation. Repair as required.

Inspect and clean under dash.

Drain Safety System air circuit water trap.

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Activity Required

1

2

3

Defects/Comment

5.1 ELECTRICS, INSTRUMENTS and CONTROLS - Electrical System Check Lights for correct operation.

Check cables, hoses and flameproof joints are secure.

Check DCS installation for security.

Check alignment, condition and mounting of alternator, drive coupling and motor.

6.

FRAME RELATED - Canopy

Check for damage, security of fasteners 6.1

FRAME RELATED - Guards and Covers

Inspect all guards and covers for security, damage and any missing covers/retainers. Repair or replace as required.

6.2

FRAME RELATED - Fire Extinguisher

Inspect the fire extinguisher mounting/holding bracket for security, damage and that the extinguisher is easy to remove and secure when clamped in.

Check the charge pressure indicator, where fitted, is registering within the operable range and appears to be free and operating correctly.

6.3

FRAME RELATED - Fire Suppression System – If Fitted

Inspect the security of all fittings and components of the fire suppression systems.

Check the fire suppression bottle for the correct pre-charge. The indicator needle should be in the green zone.

LOP detection tubing has an installed life of 1 year. Replace all associated LOP tubing.

6.4

FRAME RELATED - Lubrication

Lubricate the following grease point. Lubricate until grease is purged from the bushes.

Articulation Pillow Block Drive line Cylinder Pins Zone Manifolds 3 x Lift cylinder top pivot points 2 x Tilt cylinder pins 6 x Steer cylinder pins 2 x Lift arm pivot pins 2 x Pedal pivot points 2 x Radiator pivot points 4 x Diff Pinion Oil Seals 4 x Lubricate the engine drive coupling 6.5

Ref: Spec 7

Ref: Spec 8

FRAME RELATED - Towing Equipment

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Check the tow pin and securing chain for damage and replace as required.

6.6

FRAME RELATED – Non-Destructive Testing

Conduct Non-destructive testing for the machine areas identified as per Periodic Non-Destructive Testing of Load Bearing Structures (in Section 6).

Activity Required 7.

1

2

3

Defects/Comment

OPERATIONAL CHECKS - Safety System

Check the transmission neutral start valve for correct operation. Select a gear and check if the engine will attempt to start. Repair as required.

Check the door interlock system for correct operation, moving in 1st gear slow.

Perform DCS Low Engine Oil Shutdown with Park brake off. When the engine shuts down ensure Park brake applies.

Perform wet bath low water test.

Perform Engine Intake Shutdown Valve test. When the engine shuts down ensure engine will not start until Shutdown Valve is reset.

Note: Machine Not To Be Put In Operation If Safety Systems Are Not Working 7.1

OPERATIONAL CHECKS - Hydraulic

Function Test all Hydraulic Operations Steering; left and right Tilt; forward and back Lift; raise and lower Inspect all hydraulic cylinders and hosing : Steer cylinder 2 x Tilt Cylinder 2 x Lift Cylinders 2 x 7.2

OPERATIONAL CHECKS—Tyres

Check tyres for condition

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COMMENTS

INSPECTED BY

DATE

CHECKED BY

DATE

October 2009

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Blakefield South FBL-55H Service Manual

FLUID SPECIFICATION TABLE SPEC.

COMPONENT

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

1

Engine

26

Engine Oil

Fuchs Titan Universal MF 1540

2

Transmission

45

Mineral Gear Oil

Fuchs Titan Universal MF 1540

3

Hydraulic

400

Hydraulic

4

Axle / Wheel Ends

53 (Each Axle)

Mineral Gear Oil with Limited Slip Additive

5

Cooling System

72

Pre-mixed Coolant Conditioner

6

Fuel

400

Distillate “Diesel” Fuel

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin - Diff Pinion Oil Seal

As required

Multi-purpose EP Grease

8

Winch Gearbox

5

Gear Oil

Fuchs Powergear M460

9

Winch Planetary

2.5

Gear Oil

Fuchs Powergear M460

10

Engine Drive Coupling

Refer Service Manual

High Temperature

Manual No.M01335r1

80 of 311

Fuchs renolin B 68

SAE90LS Fuchs Titan Gear LS 90

Hardy Manufacturing Inhibit To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

Fuchs Polyplex 2

NLGI no. 2 (Shell Stamina RL2)

October 2009

BI620094

Bucyrus Australia

Blakefield South FBL-55H Service Manual

Preventative Maintenance Inspection Job Description: 2000 HOUR – 2 YEARLY OFF LINE MECHANICAL INSPECTION BUCYRUS FBL-55H LHD/Utility Vehicle Job No:

Type:

Customer:

Mine:

FBL55H

Technical References BUCYRUS FBL-55H Service Manual AS3584-3 Diesel Engine Systems for Underground Coal Mines-Maintenance Safety Advice

Determine which energy source will need isolating before starting work.

Isolate and tag all forms of energy that could put you at risk.

Work safely and ensure your actions do not put others at risk.

General Notes Use only the correct tools for the job.

Examine any lifting device is fit for purpose before use.

While performing service, additional work may be identified, depending on the severity this work may need to be performed immediately. However if the work is of lesser priority it must be documented so it can be planned and scheduled.

Check infers “look, listen, feel” References

Personal Protection Equipment Policies

Occupational Health and Safety Regulations Mine Manager’s Rules Isolation and Tagging procedures SOPs where relevant Condition Codes

No fault found

Fault found and fixed, record fault and parts used.

Fault found and not fixed, record fault, parts required (including a full description and Part No.) and the reason why it was not rectified.

Procedure

Perform activity.

Indicate condition by placing a tick against the appropriate code.

Document any comments including any defects found.

Print name or initial to indicate the activity is complete.

Print name and sign and date in the “Completed By” table at the end of the service sheet.

October 2009

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SERIAL No.

PLANT No.

Activity Required

DATE 1

2

3

Defects/Comment

Record Hour Meter Reading _________ hrs Clean machine completely, pay particular attention to loose material, oil and coal dust.

1.

ENGINE - General

Inspect the complete engine assembly and mounts for damage, any signs of oil, coolant and fuel leaks, looseness and any abnormal vibration, noise and temperature (test drive).

Drain and refill engine oil

Ref: Spec 1

Replace Engine oil filter

BUCYRUS Part No. 503469

Inspect the engine for the correct oil level. Top up as required.

Indicate litres used.

Ref: Spec 1

Check engine breather If fitted with Hydraulic throttle, inspect throttle fluid reservoir and fill as required. Indicate litres used.

Ref: Spec 3

If fitted with cable throttle, inspect condition of cable.

1.2

ENGINE - Intake

Check the air filter restriction indicator for signs of filter contamination/blockage.

Check condition of filter housing.

Check the Primary air filter element and replace if required.

BUCYRUS Part No. 505090

Check Inner air filter element and replace if required.

BUCYRUS Part No. 505089

Check all fasteners, intake joints and brackets of the Shutdown valve for security and tightness.

Check all other intake joints for security and tightness Check all air intake hoses, pipes and fittings for damage, leaks and looseness.

1.3

ENGINE - Fuel System

Inspect all fuel lines/connections/clamps for damage, looseness and any leakage. Change/repair as required.

Inspect condition and security of seal in cap for diesel tank manual fill point.

Replace Primary fuel filter

BUCYRUS Part No. 503467

Replace Secondary fuel filter

BUCYRUS Part No. 506604

Check fuel water separator and drain off any water as required.

Check fuel level in fuel tank and fill as required. Indicate litres used.

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Ref: Spec 6

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Blakefield South FBL-55H Service Manual

Activity Required 1.4

1

2

3

Defects/Comment

ENGINE - Cooling System

Inspect the cooling system header/expansion tank for the correct coolant level. Top up as required. Indicate litres used.

Ref: Spec 5

Check condition of header tank pressure caps and necks.

Inspect the cooling pump for signs of leakage, wear and security.

Inspect the radiator and cooling system for signs of leakage, blockage, contamination and security.

Pressure clean radiator assemblies, check mounts and re-torque as required.

Inspect the cooling pump drive belt for wear, damage and correct adjustment. Correct tension = 12 to 14mm deflection. Adjust/replace as required.

BUCYRUS Part No. 504611

Check fan blades and cowl for correct operation and alignment.

1.5

ENGINE - Exhaust System

Inspect the exhaust pipes and wet bath for security and signs of leaks / damage.

Check particulate filter and replace.

1.6

ENGINE - Exhaust Cooling System

Clean float chamber every week. Drain, remove covers. Flush out, remove exhaust build up around floats and make up valve.

Clean exhaust chamber. Drain, remove covers. Flush out, remove exhaust build up.

2.

DRIVETRAIN - Transmission

Inspect the transmission assembly and mounts for oil leaks, looseness, damage and any abnormal vibration, noise and heat (test drive).

Check Transmission Strainer Check transmission breather Drain and refill Transmission oil

Ref: Spec 2

Replace Transmission filter element

2x BUCYRUS Part No. 501471

Check transmission oil level and top up as required. Indicate litres used.

Ref: Spec 2

2.1

DRIVETRAIN - Drive Line

Inspect all drive shaft, slip joints and CV joints for damage, looseness, wear and contamination build up. Clean / tighten as required.

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Activity Required 2.2

1

2

3

Defects/Comment

DRIVETRAIN - Wheels and Tyres

Inspect wheel studs / nuts for damage, looseness and any missing.

Tighten / replace as required.

Inspect the tyre assemblies for damage (tears/splits) and wear.

2.3

DRIVETRAIN - Axles and Planetaries

Check for any oil leaks.

Drain, flush and refill front and rear Axle and wheel end oils.

Ref: Spec 4

Check levels and fill as required. Indicate litres used.

Ref: Spec 4 Front Rear

Check pinion oil seals.

Check differential breathers Front Rear 2.4

DRIVETRAIN - Brakes

Check wear measurements on all brake units ODSF ODSR DSF DSR

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Activity Required 3.

1

2

3

Defects/Comment

HYDRAULICS

Check the main hydraulic oil level and fill as required. Indicate litres used.

Ref: Spec 3

Ensure the hydraulic filler cap is secure and sealing.

Check Main relief pressure and reset as required: Main relief pressure: 3200psi / 22.6MPa Check Accumulator pressures and recharge as required: Accumulator pressures: 900psi / 6.2MPa Flow test Brake/Steer pump: Pump Capacity: 98.8 lpm @ 2600 rpm Check and record the following gauge pressures: Steering Accumulator pressure (2500psi / 17250kPa) Brake Accumulator pressure (2500psi / 17250kPa) Brake Head Pressure (1750psi / 12100kPa) Note: Machine Not To Be Operated if Brake Head pressure is below 1750 PSI Replace Brake head hoses and fittings Replace Steering circuit pressure filter

BUCYRUS Part No. 501800

Replace Hydraulic Return filter

BUCYRUS Part No. 502126

4. PNEUMATICS - Air Receiver Drain away all condensation from the air receiver vessel.

Drain air circuit water trap.

Check governor setting.

Inspect the circuit and relief valve for damage, leaks and correct operation.

Replace Air compressor filter.

4.1

BUCYRUS Part No. 503715

PNEUMATICS - Main Isolation Valve

Inspect the 2-way valve for correct operation, leaks and locking mechanism. Replace/repair as required.

4.2

PNEUMATICS – Horn

Inspect the air horn and its operating valve for correct operation, abnormal noise (bypass), security and any leaks. Ensure the valve is clearly labeled. Repair as required.

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Activity Required

1

2

3

Defects/Comment

5.

ELECTRICS, INSTRUMENTS and CONTROLS - Operator’s Compartment Ensure compartment is clean of all loose materials, coal, dirt etc.

Inspect the condition of the operators gauges. Check for correct operation : Brake Head Pressure Brake Accumulator Pressure Steering Accumulator Pressure Engine Water Temperature Engine Exhaust Temperature Transmission Temperature Air Pressure Engine Oil Pressure Inspect the operators seat for physical damage, including cushions and pads.

Inspect all control devices (pedals, levers, handles, switches etc) for signs of wear damage, and incorrect operation. Repair as required.

Inspect tilt/lift and implement control valve boots for damage and replace if necessary.

Check door hinges and latches for correct operation. Repair as required.

Inspect and clean under dash.

Drain Safety System air circuit water trap.

5.1 ELECTRICS, INSTRUMENTS and CONTROLS - Electrical System Check Lights for correct operation.

Check cables, hoses and flameproof joints are secure.

Check DCS installation for security.

Check alignment, condition and mounting of alternator, drive coupling and motor.

6.

FRAME RELATED - Canopy

Check for damage, security of fasteners 6.1

FRAME RELATED - Guards and Covers

Inspect all guards and covers for security, damage and any missing covers/retainers. Repair or replace as required.

6.2

FRAME RELATED - Fire Extinguisher

Inspect the fire extinguisher mounting/holding bracket for security, damage and that the extinguisher is easy to remove and secure when clamped in.

Check the charge pressure indicator, where fitted, is registering within the operable range and appears to be free and operating correctly.

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Activity Required 6.3

1

2

3

Defects/Comment

FRAME RELATED - Fire Suppression System – If Fitted

Inspect the security of all fittings and components of the fire suppression systems.

Check the fire suppression bottle for the correct pre-charge. The indicator needle should be in the green zone.

LOP detection tubing has an installed life of 1 year. Replace all associated LOP tubing.

6.4

FRAME RELATED - Lubrication

Lubricate the following grease point. Lubricate until grease is purged from the bushes.

Articulation Pillow Block Drive line Cylinder Pins Zone Manifolds 3 x Lift cylinder top pivot points 2 x Tilt cylinder pins 6 x Steer cylinder pins 2 x Lift arm pivot pins 2 x Pedal pivot points 2 x Radiator pivot points 4 x Diff Pinion Oil Seals 4 x Lubricate the engine drive coupling 6.5

Ref: Spec 7

Ref: Spec 8

FRAME RELATED - Towing Equipment

Check the tow pin and securing chain for damage and replace as required.

6.6

FRAME RELATED – Non-Destructive Testing

Conduct Non-destructive testing for the machine areas identified as per Periodic Non-Destructive Testing of Load Bearing Structures (in Section 6).

7.

OPERATIONAL CHECKS - Safety System

Check the transmission neutral start valve for correct operation. Select a gear and check if the engine will attempt to start. Repair as required.

Check the door interlock system for correct operation, moving in 1st gear slow.

Perform DCS Low Engine Oil Shutdown with Park brake off. When the engine shuts down ensure Park brake applies.

Perform Engine Intake Shutdown Valve test. When the engine shuts down ensure engine will not start until Shutdown Valve is reset.

Note: Machine Not To Be Put In Operation If Safety Systems Are Not Working

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Activity Required 7.1

1

2

3

Defects/Comment

OPERATIONAL CHECKS - Hydraulic

Function Test all Hydraulic Operations Steering; left and right Tilt; forward and back Lift; raise and lower Inspect all hydraulic cylinders and hosing : Steer cylinder 2 x Tilt Cylinder 2 x Lift Cylinders 2 x 7.2

OPERATIONAL CHECKS—Tyres

Check tyres for cuts and condition.

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COMMENTS

INSPECTED BY

DATE

CHECKED BY

DATE

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FLUID SPECIFICATION TABLE SPEC.

COMPONENT

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

1

Engine

26

Engine Oil

Fuchs Titan Universal MF 1540

2

Transmission

45

Mineral Gear Oil

Fuchs Titan Universal MF 1540

3

Hydraulic

400

Hydraulic

4

Axle / Wheel Ends

53 (Each Axle)

Mineral Gear Oil with Limited Slip Additive

5

Cooling System

72

Pre-mixed Coolant Conditioner

6

Fuel

400

Distillate “Diesel” Fuel

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin - Diff Pinion Oil Seal

As required

Multi-purpose EP Grease

8

Winch Gearbox

5

Gear Oil

Fuchs Powergear M460

9

Winch Planetary

2.5

Gear Oil

Fuchs Powergear M460

10

Engine Drive Coupling

Refer Service Manual

High Temperature

Manual No.M01335r1

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Fuchs renolin B 68

SAE90LS Fuchs Titan Gear LS 90

Hardy Manufacturing Inhibit To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

Fuchs Polyplex 2

NLGI no. 2 (Shell Stamina RL2)

October 2009

BI620094

Bucyrus Australia

Blakefield South FBL-55H Service Manual

Preventative Maintenance Inspection Job Description: 5000 HOUR – 5 YEARLY OFF LINE MECHANICAL INSPECTION BUCYRUS FBL-55H LHD/Utility Vehicle Job No:

Type:

Customer:

Mine:

FBL55H

Technical References BUCYRUS FBL-55H Service Manual AS3584-3 Diesel Engine Systems for Underground Coal Mines-Maintenance Safety Advice

Determine which energy source will need isolating before starting work.

Isolate and tag all forms of energy that could put you at risk.

Work safely and ensure your actions do not put others at risk.

General Notes Use only the correct tools for the job.

Examine any lifting device is fit for purpose before use.

While performing service, additional work may be identified, depending on the severity this work may need to be performed immediately. However if the work is of lesser priority it must be documented so it can be planned and scheduled.

Check infers “look, listen, feel” References

Personal Protection Equipment Policies

Occupational Health and Safety Regulations

Mine Manager’s Rules

Isolation and Tagging procedures

SOPs where relevant Condition Codes

No fault found

Fault found and fixed, record fault and parts used.

Fault found and not fixed, record fault, parts required (including a full description and Part No.) and the reason why it was not rectified.

Procedure

Perform activity.

Indicate condition by placing a tick against the appropriate code.

Document any comments including any defects found.

Print name or initial to indicate the activity is complete.

Print name and sign and date in the “Completed By” table at the end of the service sheet.

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SERIAL No.

PLANT No.

Activity Required

DATE 1

2

3

Defects/Comment

Record Hour Meter Reading _________ hrs Clean machine completely, pay particular attention to loose material, oil and coal dust.

1.

ENGINE - General

Inspect the complete engine assembly and mounts for damage, any signs of oil, coolant and fuel leaks, looseness and any abnormal vibration, noise and temperature (test drive).

Drain and refill engine oil

Ref: Spec 1

Replace Engine oil filter

BUCYRUS Part No. 503469

Inspect the engine for the correct oil level. Top up as required.

Indicate litres used.

Ref: Spec 1

Check engine breather If fitted with Hydraulic throttle, inspect throttle fluid reservoir and fill as required. Indicate litres used.

Ref: Spec 3

If fitted with cable throttle, inspect condition of cable.

1.2

ENGINE – Intake

Check the air filter restriction indicator for signs of filter contamination/blockage.

Check condition of filter housing.

Check the Primary air filter element and replace if required.

BUCYRUS Part No. 505090

Check Inner air filter element and replace if required.

BUCYRUS Part No. 505089

Check all fasteners, intake joints and brackets of the Shutdown valve for security and tightness.

Check all other intake joints for security and tightness Check all air intake hoses, pipes and fittings for damage, leaks and looseness.

1.3

ENGINE - Fuel System

Inspect all fuel lines/connections/clamps for damage, looseness and any leakage. Change/repair as required.

Inspect condition and security of seal in cap for diesel tank manual fill point.

Replace Primary fuel filter

BUCYRUS Part No. 503467

Replace Secondary fuel filter

BUCYRUS Part No. 506604

Check fuel water separator and drain off any water as required.

Check fuel level in fuel tank and fill as required. Indicate litres used.

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Ref: Spec 6

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Activity Required 1.4

1

2

3

Defects/Comment

ENGINE - Cooling System

Inspect the cooling system header/expansion tank for the correct coolant level. Top up as required. Indicate litres used.

Ref: Spec 5

Check condition of header tank pressure caps and necks.

Inspect the cooling pump for signs of leakage, wear and security.

Inspect the radiator and cooling system for signs of leakage, blockage, contamination and security.

Pressure clean radiator assemblies, check mounts and re-torque as required.

Inspect the cooling pump drive belt for wear, damage and correct adjustment. Correct tension = 12 to 14mm deflection. Adjust/replace as required.

BUCYRUS Part No. 504611

Check fan blades and cowl for correct operation and alignment.

1.5

ENGINE - Exhaust System

Inspect the exhaust pipes and wet bath for security and signs of leaks / damage.

Check particulate filter and replace.

1.6

ENGINE - Exhaust Cooling System

Clean float chamber every week. Drain, remove covers. Flush out, remove exhaust build up around floats and make up valve.

Clean exhaust chamber. Drain, remove covers. Flush out, remove exhaust build up.

2.

DRIVETRAIN - Transmission

Inspect the transmission assembly and mounts for oil leaks, looseness, damage and any abnormal vibration, noise and heat (test drive).

Check Transmission Strainer Check transmission breather Drain and refill Transmission oil

Ref: Spec 2

Replace Transmission filter element

2x BUCYRUS Part No. 501471

Check transmission oil level and top up as required. Indicate litres used.

2.1

Ref: Spec 2

DRIVETRAIN - Drive Line

Inspect all drive shaft, slip joints and CV joints for damage, looseness, wear and contamination build up. Clean / tighten as required.

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Activity Required 2.2

1

2

3

Defects/Comment

DRIVETRAIN - Wheels and Tyres

Inspect wheel studs / nuts for damage, looseness and any missing.

Tighten / replace as required.

Inspect the tyre assemblies for damage (tears/splits) and wear.

2.3

DRIVETRAIN - Axles and Planetaries

Check for any oil leaks.

Drain, flush and refill front and rear Axle and wheel end oils.

Ref: Spec 4

Check levels and fill as required. Indicate litres used.

Ref: Spec 4 Front Rear

Check pinion oil seals.

Check differential breathers Front Rear 2.4

DRIVETRAIN - Brakes

Check wear measurements on all brake units ODSF ODSR DSF DSR

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Activity Required 3.

1

2

3

Defects/Comment

HYDRAULICS

Check the main hydraulic oil level and fill as required. Indicate litres used.

Ref: Spec 3

Ensure the hydraulic filler cap is secure and sealing.

Remove, reseal and test the Service brake valve.

Check and record the following gauge pressures: Steering Accumulator pressure (2500psi / 17250kPa) Brake Accumulator pressure (2500psi / 17250kPa) Brake Head Pressure (1750psi / 12100kPa) Note: Machine Not To Be Operated if Brake Head pressure is below 1750 PSI Replace Steering circuit pressure filter

BUCYRUS Part No. 501800

Replace Hydraulic Return filter

BUCYRUS Part No. 502126

4. PNEUMATICS - Air Receiver Drain away all condensation from the air receiver vessel.

Drain air circuit water trap.

Check governor setting.

Inspect the circuit and relief valve for damage, leaks and correct operation.

BUCYRUS Part No. 503715

Replace Air compressor filter.

4.1

PNEUMATICS - Main Isolation Valve

Inspect the 2-way valve for correct operation, leaks and locking mechanism. Replace/repair as required.

4.2

PNEUMATICS – Horn

Inspect the air horn and its operating valve for correct operation, abnormal noise (bypass), security and any leaks. Ensure the valve is clearly labeled. Repair as required.

4.3

PNEUMATICS - Brake valves

Replace the Park/Emergency Brake valve.

BUCYRUS Part No. 500438

Replace the Park Brake Air Pilot valve

BUCYRUS Part No. 502103

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Activity Required

1

2

3

Defects/Comment

5.

ELECTRICS, INSTRUMENTS and CONTROLS - Operator’s Compartment Ensure compartment is clean of all loose materials, coal, dirt etc.

Inspect the condition of the operator’s gauges. Check for correct operation : Brake Head Pressure Brake Accumulator Pressure Steering Accumulator Pressure Engine Water Temperature Engine Exhaust Temperature Transmission Temperature Air Pressure Engine Oil Pressure Inspect the operator’s seat for physical damage, including cushions and pads.

Inspect all control devices (pedals, levers, handles, switches etc) for signs of wear damage, and incorrect operation. Repair as required.

Inspect tilt/lift and implement control valve boots for damage and replace if necessary.

Check door hinges and latches for correct operation. Repair as required.

Inspect and clean under dash.

Drain Safety System air circuit water trap.

5.1

ELECTRICS, INSTRUMENTS and CONTROLS - Electrical System

Check Lights for correct operation.

Check cables, hoses and flameproof joints are secure.

Check DCS installation for security.

Check alignment, condition and mounting of alternator, drive coupling and motor.

6.

FRAME RELATED - Canopy

Check for damage, security of fasteners 6.1

FRAME RELATED - Guards and Covers

Inspect all guards and covers for security, damage and any missing covers/retainers. Repair or replace as required.

6.2

FRAME RELATED - Fire Extinguisher

Inspect the fire extinguisher mounting/holding bracket for security, damage and that the extinguisher is easy to remove and secure when clamped in.

Check the charge pressure indicator, where fitted, is registering within the operable range and appears to be free and operating correctly.

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Activity Required 6.3

1

2

3

Defects/Comment

FRAME RELATED - Fire Suppression System – If Fitted

Inspect the security of all fittings and components of the fire suppression systems.

Check the fire suppression bottle for the correct pre-charge. The indicator needle should be in the green zone.

LOP detection tubing has an installed life of 1 year. Replace all associated LOP tubing.

6.4

FRAME RELATED - Lubrication

Lubricate the following grease point. Lubricate until grease is purged from the bushes.

Articulation Pillow Block Drive line Cylinder Pins Zone Manifolds 3 x Lift cylinder top pivot points 2 x Tilt cylinder pins 6 x Steer cylinder pins 2 x Lift arm pivot pins 2 x Pedal pivot points 2 x Radiator pivot points 4 x Diff Pinion Oil Seals 4 x Lubricate the engine drive coupling 6.5

Ref: Spec 7

Ref: Spec 8

FRAME RELATED - Towing Equipment

Check the tow pin and securing chain for damage and replace as required.

6.6

FRAME RELATED – Non-Destructive Testing

Conduct Non-destructive testing for the machine areas identified as per Periodic Non-Destructive Testing of Load Bearing Structures (in Section 6).

7.

OPERATIONAL CHECKS - Safety System

Check the transmission neutral start valve for correct operation. Select a gear and check if the engine will attempt to start. Repair as required.

Check the door interlock system for correct operation, moving in 1st gear slow.

Perform DCS Low Engine Oil Shutdown with Park brake off. When the engine shuts down ensure Park brake applies.

Perform wet bath low water shutdown test.

Perform Engine Intake Shutdown Valve test. When the engine shuts down ensure engine will not start until Shutdown Valve is reset.

Note: Machine Not To Be Put In Operation If Safety Systems Are Not Working

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Activity Required 7.1

1

2

3

Defects/Comment

OPERATIONAL CHECKS - Hydraulic

Function Test all Hydraulic Operations Steering; left and right Tilt; forward and back Lift; raise and lower Inspect all hydraulic cylinders and hosing : Steer cylinder 2 x Tilt Cylinder 2 x Lift Cylinders 2 x 7.2

OPERATIONAL CHECKS—Tyres

Check tyres for cuts and condition.

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Blakefield South FBL-55H Service Manual

COMMENTS

INSPECTED BY

DATE

CHECKED BY

DATE

October 2009

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Blakefield South FBL-55H Service Manual

FLUID SPECIFICATION TABLE SPEC.

COMPONENT

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

1

Engine

26

Engine Oil

Fuchs Titan Universal MF 1540

2

Transmission

45

Mineral Gear Oil

Fuchs Titan Universal MF 1540

3

Hydraulic

400

Hydraulic

4

Axle / Wheel Ends

53 (Each Axle)

Mineral Gear Oil with Limited Slip Additive

5

Cooling System

72

Pre-mixed Coolant Conditioner

6

Fuel

400

Distillate “Diesel” Fuel

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin - Diff Pinion Oil Seal

As required

Multi-purpose EP Grease

8

Winch Gearbox

5

Gear Oil

Fuchs Powergear M460

9

Winch Planetary

2.5

Gear Oil

Fuchs Powergear M460

10

Engine Drive Coupling

Refer Service Manual

High Temperature

Manual No.M01335r1

100 of 311

Fuchs renolin B 68

SAE90LS Fuchs Titan Gear LS 90

Hardy Manufacturing Inhibit To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

Fuchs Polyplex 2

NLGI no. 2 (Shell Stamina RL2)

October 2009

BI620094

Bucyrus Australia

Blakefield South FBL-55H Service Manual

Preventative Maintenance Inspection Job Description: 10000 HOUR – 10 YEARLY OFF LINE MECHANICAL INSPECTION BUCYRUS FBL-55H LHD/Utility Vehicle Job No:

Type:

Customer:

Mine:

FBL55H

Technical References BUCYRUS FBL-55H Service Manual AS3584-3 Diesel Engine Systems for Underground Coal Mines-Maintenance Safety Advice

Determine which energy source will need isolating before starting work.

Isolate and tag all forms of energy that could put you at risk.

Work safely and ensure your actions do not put others at risk.

General Notes Use only the correct tools for the job.

Examine any lifting device is fit for purpose before use.

While performing service, additional work may be identified, depending on the severity this work may need to be performed immediately. However if the work is of lesser priority it must be documented so it can be planned and scheduled.

Check infers “look, listen, feel” References

Personal Protection Equipment Policies

Occupational Health and Safety Regulations

Mine Manager’s Rules

Isolation and Tagging procedures

SOPs where relevant Condition Codes

No fault found

Fault found and fixed, record fault and parts used.

Fault found and not fixed, record fault, parts required (including a full description and Part No.) and the reason why it was not rectified.

Procedure

Perform activity.

Indicate condition by placing a tick against the appropriate code.

Document any comments including any defects found.

Print name or initial to indicate the activity is complete.

Print name and sign and date in the “Completed By” table at the end of the service sheet.

October 2009

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Manual No. M01335r1

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Blakefield South FBL-55H Service Manual

SERIAL No.

PLANT No.

Activity Required

DATE 1

2

3

Defects/Comment

Record Hour Meter Reading _________ hrs Clean machine completely, pay particular attention to loose material, oil and coal dust.

1.

ENGINE – General

Inspect the complete engine assembly and mounts for damage, any signs of oil, coolant and fuel leaks, looseness and any abnormal vibration, noise and temperature (test drive).

Drain and refill engine oil

Ref: Spec 1

Replace Engine oil filter

BUCYRUS Part No. 503469

Inspect the engine for the correct oil level. Top up as required.

Indicate litres used.

Ref: Spec 1

Check engine breather If fitted with Hydraulic throttle, inspect throttle fluid reservoir and fill as required. Indicate litres used.

Ref: Spec 3

If fitted with cable throttle, inspect condition of cable.

1.2

ENGINE – Intake

Check the air filter restriction indicator for signs of filter contamination/blockage.

Check condition of filter housing.

Check the Primary air filter element and replace if required.

BUCYRUS Part No. 505090

Check Inner air filter element and replace if required.

BUCYRUS Part No. 505089

Check all fasteners, intake joints and brackets of the Shutdown valve for security and tightness.

Check all other intake joints for security and tightness Check all air intake hoses, pipes and fittings for damage, leaks and looseness.

1.3

ENGINE - Fuel System

Inspect all fuel lines/connections/clamps for damage, looseness and any leakage. Change/repair as required.

Inspect condition and security of seal in cap for diesel tank manual fill point.

Replace Primary fuel filter

BUCYRUS Part No. 503467

Replace Secondary fuel filter

BUCYRUS Part No. 506604

Check fuel water separator and drain off any water as required.

Check fuel level in fuel tank and fill as required. Indicate litres used.

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Ref: Spec 6

October 2009

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Blakefield South FBL-55H Service Manual

Activity Required 1.4

1

2

3

Defects/Comment

ENGINE - Cooling System

Inspect the cooling system header/expansion tank for the correct coolant level. Top up as required. Indicate litres used.

Ref: Spec 5

Check condition of header tank pressure caps and necks.

Inspect the cooling pump for signs of leakage, wear and security.

Inspect the radiator and cooling system for signs of leakage, blockage, contamination and security.

Pressure clean radiator assemblies, check mounts and re-torque as required.

Inspect the cooling pump drive belt for wear, damage and correct adjustment. Correct tension = 12 to 14mm deflection. Adjust/replace as required.

BUCYRUS Part No. 504611

Check fan blades and cowl for correct operation and alignment.

1.5

ENGINE - Exhaust System

Inspect the exhaust pipes and wet bath for security and signs of leaks / damage.

Check particulate filter and replace.

1.6

ENGINE - Exhaust Cooling System

Clean float chamber every week. Drain, remove covers. Flush out, remove exhaust build up around floats and make up valve.

Clean exhaust chamber. Drain, remove covers. Flush out, remove exhaust build up.

2.

DRIVETRAIN – Transmission

Inspect the transmission assembly and mounts for oil leaks, looseness, damage and any abnormal vibration, noise and heat (test drive).

Check Transmission Strainer Check transmission breather Drain and refill Transmission oil

Ref: Spec 2

Replace Transmission filter element

2x BUCYRUS Part No. 501471

Check transmission oil level and top up as required. Indicate litres used.

2.1

Ref: Spec 2

DRIVETRAIN - Drive Line

Inspect all drive shaft, slip joints and CV joints for damage, looseness, wear and contamination build up. Clean / tighten as required.

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Activity Required 2.2

1

2

3

Defects/Comment

DRIVETRAIN - Wheels and Tyres

Inspect wheel studs / nuts for damage, looseness and any missing.

Tighten / replace as required.

Inspect the tyre assemblies for damage (tears/splits) and wear.

2.3

DRIVETRAIN - Axles and Planetaries

Check for any oil leaks.

Drain, flush and refill front and rear Axle and wheel end oils.

Ref: Spec 4

Check levels and fill as required. Indicate litres used.

Ref: Spec 4 Front Rear

Check pinion oil seals.

Check differential breathers Front Rear 2.4

DRIVETRAIN – Brakes

Check wear measurements on all brake units ODSF ODSR DSF DSR

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Activity Required 3.

1

2

3

Defects/Comment

HYDRAULICS

Check the main hydraulic oil level and fill as required. Indicate litres used.

Ref: Spec 3

Ensure the hydraulic filler cap is secure and sealing.

Replace Main relief pressure: Main relief pressure: 3200psi / 22.6Mpa Re-seal Accumulators and recharge Accumulator pressures: Accumulator pressures: 900psi / 6.2Mpa BUCYRUS Part No. 836126 BUCYRUS Part No. 500139

Replace Brake/Steer pump Replace Service brake valve Check and record the following gauge pressures: Steering Accumulator pressure (2500psi / 17250kPa) Brake Accumulator pressure (2500psi / 17250kPa) Brake Head Pressure (1750psi / 12100kPa) Note: Machine Not To Be Operated if Brake Head pressure is below 1750 PSI Replace Brake head hoses and fittings Replace Steering circuit pressure filter

BUCYRUS Part No. 501800

Replace Hydraulic Return filter

BUCYRUS Part No. 502126

4. PNEUMATICS - Air Receiver Drain away all condensation from the air receiver vessel.

Drain air circuit water trap.

Check governor setting.

Inspect the circuit and relief valve for damage, leaks and correct operation.

BUCYRUS Part No. 503715

Replace Air compressor filter.

4.1

PNEUMATICS - Main Isolation Valve

Inspect the 2-way valve for correct operation, leaks and locking mechanism. Replace/repair as required.

4.2

PNEUMATICS – Horn

Inspect the air horn and its operating valve for correct operation, abnormal noise (bypass), security and any leaks. Ensure the valve is clearly labeled. Repair as required.

October 2009

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Activity Required 4.3

1

2

3

Defects/Comment

PNEUMATICS - Brake valves

Replace the Park/Emergency Brake valve.

BUCYRUS Part No. 500438

Replace the Park Brake Air Pilot valve

BUCYRUS Part No. 502103

5.

ELECTRICS, INSTRUMENTS and CONTROLS - Operator’s Compartment Ensure compartment is clean of all loose materials, coal, dirt etc.

Inspect the condition of the gauges in the operators cab.

Check for correct operation : Brake Head Pressure Brake Accumulator Pressure Steering Accumulator Pressure Engine Water Temperature Engine Exhaust Temperature Transmission Temperature Air Pressure Engine Oil Pressure Inspect the operators seat for physical damage, including cushions and pads.

Inspect all control devices (pedals, levers, handles, switches etc) for signs of wear damage, and incorrect operation. Repair as required.

Inspect tilt/lift and implement control valve boots for damage and replace if necessary.

Check door hinges and latches for correct operation. Repair as required.

Inspect and clean under dash.

Drain Safety System air circuit water trap.

5.1 ELECTRICS, INSTRUMENTS and CONTROLS - Electrical System Check Lights for correct operation.

Check cables, hoses and flameproof joints are secure.

Check DCS installation for security.

Check alignment, condition and mounting of alternator, drive coupling and motor.

6.

FRAME RELATED – Canopy

Check for damage, security of fasteners 6.1

FRAME RELATED - Guards and Covers

Inspect all guards and covers for security, damage and any missing covers/retainers. Repair or replace as required.

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Activity Required 6.2

1

2

3

Defects/Comment

FRAME RELATED - Fire Extinguisher

Inspect the fire extinguisher mounting/holding bracket for security, damage and that the extinguisher is easy to remove and secure when clamped in.

Check the charge pressure indicator, where fitted, is registering within the operable range and appears to be free and operating correctly.

6.3

FRAME RELATED - Fire Suppression System – If Fitted

Inspect the security of all fittings and components of the fire suppression systems.

Check the fire suppression bottle for the correct pre-charge. The indicator needle should be in the green zone.

LOP detection tubing has an installed life of 1 year. Replace all associated LOP tubing.

6.4

FRAME RELATED – Lubrication

Lubricate the following grease point. Lubricate until grease is purged from the bushes.

Articulation Pillow Block Drive line Cylinder Pins Zone Manifolds 3 x Lift cylinder top pivot points 2 x Tilt cylinder pins 6 x Steer cylinder pins 2 x Lift arm pivot pins 2 x Pedal pivot points 2 x Radiator pivot points 4 x Diff Pinion Oil Seals 4 x Lubricate the engine drive coupling 6.5

Ref: Spec 7

Ref: Spec 8

FRAME RELATED - Towing Equipment

Check the tow pin and securing chain for damage and replace as required.

6.6

FRAME RELATED – Non-Destructive Testing

Conduct Non-destructive testing for the machine areas identified as per Periodic Non-Destructive Testing of Load Bearing Structures (in Section 6).

7.

OPERATIONAL CHECKS - Safety System

Check the transmission neutral start valve for correct operation. Select a gear and check if the engine will attempt to start. Repair as required.

Replace the Door interlock valve. Check system for correct operation, moving in 1st gear slow.

BUCYRUS Part No. 500439

Perform DCS Low Engine Oil Shutdown with Park brake off. When the engine shuts down ensure Park brake applies.

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Perform wet bath low water shutdown test.

Perform Engine Intake Shutdown Valve test. When the engine shuts down ensure engine will not start until Shutdown Valve is reset.

Note: Machine Not To Be Put In Operation If Safety Systems Are Not Working Activity Required 7.1

1

2

3

Defects/Comment

OPERATIONAL CHECKS – Hydraulic

Function Test all Hydraulic Operations Steering; left and right Tilt; forward and back Lift; raise and lower Inspect all hydraulic cylinders and hosing : Steer cylinder 2 x Tilt Cylinder 2 x Lift Cylinders 2 x 7.2

OPERATIONAL CHECKS—Tyres

Check tyres for cuts and condition.

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COMMENTS

INSPECTED BY

DATE

CHECKED BY

DATE

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FLUID SPECIFICATION TABLE SPEC.

COMPONENT

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

1

Engine

26

Engine Oil

Fuchs Titan Universal MF 1540

2

Transmission

45

Mineral Gear Oil

Fuchs Titan Universal MF 1540

3

Hydraulic

400

Hydraulic

4

Axle / Wheel Ends

53 (Each Axle)

Mineral Gear Oil with Limited Slip Additive

5

Cooling System

72

Pre-mixed Coolant Conditioner

6

Fuel

400

Distillate “Diesel” Fuel

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin - Diff Pinion Oil Seal

As required

Multi-purpose EP Grease

8

Winch Gearbox

5

Gear Oil

Fuchs Powergear M460

9

Winch Planetary

2.5

Gear Oil

Fuchs Powergear M460

10

Engine Drive Coupling

Refer Service Manual

High Temperature

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Fuchs renolin B 68

SAE90LS Fuchs Titan Gear LS 90

Hardy Manufacturing Inhibit To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

Fuchs Polyplex 2

NLGI no. 2 (Shell Stamina RL2)

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RECOMMENDED BOLT TORQUE NOTICE! Torques listed are for plain finish (uncoated) fasteners. Multiply the torque values in the tables by 0.7 when heavily greased fasteners are used (“never-seize” qualifies as heavy greasing).

Metric Use the following chart to determine torque ranges for metric fasteners. (M) Recommended Torque Range for Metric Capscrews Class 10.9

Nominal Size

Class 12.9

(Nm)

(ft-lbs)

(Nm)

(ft-lbs)

M5

7.5

5.5

9

6.6

M6

13

9.6

15

11

M8

30

22

37

27

M10

60

44

72

53

M12

105

77

126

93

M16

255

190

308

227

M20

500

370

600

443

M24

865

640

1038

765

M30

1710

1260

2050

1510

M36

2970

2190

3560

2626

Imperial Use the following chart to determine torque ranges for imperial fasteners. (UNC) Recommended Torque Range for Imperial Capscrews Nominal Size

Grade 5

Grade 8/Socket Head

(Nm)

(ft-lbs)

(Nm)

(ft-lbs)

1/4

9

6.5

13

9.5

5/16

19

14

26

19

3/8

32

24

46

34

7/16

52

38

73

54

1/2

80

60

110

82

9/16

113

83

160

117

5/8

155

115

220

160

3/4

275

203

388

286

7/8

440

325

620

460

1

660

488

930

687

1-1/8

815

600

1320

974

1-1/4

1137

840

1840

1360

1-3/8

1500

1106

2430

1970

1-1/2

1980

1460

3200

2360

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Section

2

Engine System FUEL SYSTEM General Description The diesel engine fuel system consists of the fuel injectors, fuel lines, transfer pump, fuel/ water separator, fuel filter, hand primer pump, fuel cooler and fuel tank. Fuel is delivered from the fuel tank to the suction side of the fuel transfer pump via a primary filter/water separator. The transfer pump delivers diesel fuel to the injector assemblies (via a secondary filter) through drilled galleries in the cylinder head. The fuel injector assemblies provide internal pressure intensification for discharge into the cylinders with excess fuel returned to the storage tank via the vent valve and fuel cooler. Fuel supply is controlled by the transfer pump which opens the racks on the unit injectors via mechanical linkages. The fuel injectors and transfer pump are factory set precision components and no adjustments should be attempted without the necessary tools and training. If either the transfer pump or injectors are suspected to be faulty consult your local Bucyrus representative.

WARNING! Tampering with the engine transfer pump and fuel injector settings will result in adverse engine performance and may void the conditions for which the engine system has been certified such as operating temperature and exhaust emissions. Consult your local Bucyrus representative before attempting to adjust the engine governor and fuel injectors

Fuel System Line Drawing

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Safety Precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

When the temperature of diesel fuel is elevated, which occurs when fuel is circulated through an operating engine, the following hazards exist:

Scalding or burns from contact with hot liquid.

Presence of combustible vapour around the fuel source.

ALWAYS give the engine an opportunity to cool down before performing fuel system servicing.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing.

ALWAYS perform fuel system servicing in a well ventilated area.

ALWAYS keep naked flames, sparks and other heat sources away from the machine.

ALWAYS clean up any spilled fuel immediately to remove the potential for ignition and slip or fall injuries.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

ALWAYS avoid oxy-cutting or welding near or onto any unshielded fuel system components.

IMMEDIATELY wash off spilled fuel when exposure to the skin has occurred.

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FUEL TANK Care and Maintenance Daily: Keep the fuel tank full and refill to prevent condensation and the growth of microorganisms which may contaminate the fuel and cause system blockage.

Servicing Check supply lines for leaks and/or degradation and check the condition of the seal in the fuel filler cap, level gauge and breather every 1000 service hours.

Open the drain plug and drain the water from the fuel tank every 250 hours or sooner if water collection bowl on the water trap filter has water in it. The drain plug is located underneath the machine at the front of the fuel tank (directly under fuel gauge). Completely drain and clean the fuel tank every 2000 service hours. Remove any sediment in the bottom of the fuel tank with a clean, lint free cloth. A bolt on the inspection hatch may be removed from the top and the side of the tank to gain access.

WARNING Ensure park brake is on and the wheels are chocked before draining fuel tank as access is from under the machine

Fuel fill cap

Fuel tank inspection cover and level gauge drain plug underneath

FUEL LINES Care and Maintenance Daily: carry out a visual inspection for fuel leaks on all external fuel lines and connections. Check that hoses are not resting on or touching sharp edges, rotating elements or heat sources such as exhaust system components.

Servicing As hoses and associated fittings have a finite service life, carry out a thorough inspection every 1000 service hours. Inspect all fuel lines for signs of deterioration, including hose clamps and anchor ties and replace as required. Replace all fuel system hoses at major overhaul or every five years

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PRIMARY FUEL FILTER / WATER SEPARATOR Care and Maintenance Daily: visually inspect the filter/separator collection bowl for the presence of water. If water or sediments are present, draining is required.

To drain the filter/separator collection bowl: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Place a suitable container under the collection bowl.

3) Loosen the brass T-handle on top of the filter unit and remove the lid to break the vacuum.

4) Remove the drain plug at the bottom of the unit to expel any contaminants.

5) Replace the drain plug.

6) Re-prime the unit by filling with clean fuel.

7) Replace the lid and snugly tighten the T-handle (hand tight only).

8) Hand prime fuel system before attempting to start machine.

Primary filter 9) Discard expelled fuel in a responsible manner.

Priming pump

Secondary filter

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Servicing The filter element should be replaced every 250 service hours.

To replace filter element: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Loosen the brass T-handle on top of the filter unit and remove the lid.

3) Remove the filter element by grasping the moulded handle and slowly pulling upward with a twisting motion until the filter element is clear of the housing.

4) Discard the used filter element, lid and T-handle seals in a responsible manner.

5) Insert the new filter element by grasping the moulded handle and slowly pushing downward with a twisting motion.

6) Replace the lid and T-handle seals with those supplied with the new filter element. Apply a coating of fuel to the new seals prior to assembly.

7) Refill the unit with clean fuel.

8) Replace the lid and snugly tighten the T-handle (hand tight only).

9) Hand prime the fuel system before attempting to start the machine.

10) Start the engine and check for any leaks CAUTION Do not use tools to tighten the water separator T-handle. Over tightening will result in damage. Ensure that the seal between the filter body and lid is in the correct position before tightening the Thandle. Remedy any leaks.

T-Handle

Filter Element

Water Collection Bowl

Drain Screw

Primary Filter Housing

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SECONDARY FUEL FILTER Servicing To replace filter element (every 250 hours): 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Have the replacement filter element filled with fuel and ready to install immediately after the used filter element is removed. This will prevent fuel system aeration. Fill via the outer ring of small holes (inlet holes) and coat the sealing gasket with clean fuel.

3) Place a suitable container under the filter element and unscrew the cartridge.

4) Unscrew the used cartridge and dispose of in a responsible manner.

5) Immediately install the new filter element and tighten until the sealing gasket just touches the mounting adaptor head, then tighten a further ¾ turn (hand tight only).

6) Hand prime the fuel system before attempting to start the engine.

7) Start the engine and check for leaks. (Remedy any leaks immediately).

CAUTION Do not use tools to tighten the filter element cartridge. Over tightening will result in damage. Ensure that the seal between the filter element cartridge and mounting adaptor head is in the correct position before tightening the last ¾ turn.

SECONDARY FILTER

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Fuel System Priming Pump If the engine fails to start after filter replacement or has run out of fuel when operating, the following procedure is to be used to prime the fuel system to purge trapped air.

The fuel system should be primed under the following conditions: 1) Running out of fuel.

2) Storage.

3) Replacement of fuel filters.

To prime the fuel system: 1) Fill the fuel tank with the recommended grade of fuel. If it is not possible to completely fill the tank then add a minimum 50 litres to the tank.

2) Unlock the fuel priming pump plunger and operate in an in and out motion until resistance is felt, a considerable amount of stroke may be required.

3) Push in the plunger and tighten by hand.

4) Promptly start the engine, if the engine runs rough increase the engine RPM to approximately ½ the rated RPM and check for fuel leaks CAUTION Do not use the starter motor and fuel pump to prime the fuel filters. Continuous use of the starter motor can result in damage. Allow the starter motor to cool for two or three minutes before cranking the engine again.

NOTICE. If the engine will not start, further priming may be necessary. If the engine continues to misfire or smoke after starting, further priming may be required.

Fuel Priming Pump

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LUBRICATION SYSTEM General Description The engine lubrication system provides essential lubrication for the engine working components. The system consists of an engine oil reservoir (sump), and level gallery, oil pump, oil pressure regulator and relief valve, oil cooler, and filter assembly. Lubricating oil is drawn by suction from the oil pan (sump) via the intake screen to the pump where it is pressurized. Oil then passes through a short gallery in the engine cylinder block to the oil cooler housing. At the same time oil is directed to the relief valve where excess oil is discharged back to the sump when the pump pressure exceeds 600 kPa (88 psi). From the oil cooler adaptor plate oil passes through the full flow filter, through the oil cooler then back into the cylinder block where the oil is internally routed. Bypass valves are located at the oil cooler and filter assemblies to maintain flow if either become blocked.

Stabilised oil pressure is maintained within the cylinder block by a pressure regulator valve located in the cylinder block oil gallery opposite to the cooler. The regulator discharges oil back to the sump if the pressure at the valve exceeds 345 kPa (50 psi). Regulated oil is forced through the various working components within the engine.

A low oil pressure sensor is located behind the operator’s display panel. This sensor activates at an oil pressure below 70 kPa (10 psi) and shuts down the engine via the electronic shutdown system.

Engine Dipstick

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SAFETY PRECAUTIONS The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS give the engine an opportunity to cool down before performing lubrication system servicing.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing ALWAYS clean up any spilled oil immediately to remove the potential for slip, trip or fall injuries.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

ALWAYS ensure that the engine is not running and the machine’s park brake is applied before working on the engine lubrication system

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OIL FILTER The spin on type engine oil filter should be replaced when the engine oil is changed every 250 service hours.

Servicing To replace the engine oil filter: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Remove the oil filter cartridge, located adjacent to the fuel/water separator, using a strap wrench.

3) Dispose of the used oil filter cartridge in a responsible manner.

4) Clean the oil filter adaptor with a clean, lint free, cloth.

5) Lightly coat the oil filter gasket with clean engine oil.

6) Screw the new oil filter cartridge onto the adaptor by hand until the gasket just touches the mounting adaptor head. Tighten an additional ⅔ of a turn.

CAUTION Over tightening the oil filter cartridge may damage the seal resulting in an oil leak.

7) 8) 9)

Start and run the engine for a short period and check for leaks.

After any leaks have been rectified stop the engine and allow the oil to return to the sump (this will take approximately five minutes).

Add oil as required to bring the level up to the full mark on the dipstick

Engine Oil Filter

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CHECKING/FILLING ENGINE OIL Care and Maintenance Check engine oil level and fill as required daily.

CAUTION If the oil level is constantly above the full mark on the dipstick, and there has been no oil added, this may indicate that either fuel or coolant dilution has occurred. This can result in serious engine damage and should be investigated and rectified immediately.

To check the engine oil: 1) Park the machine on flat, level ground.

2) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

3) Allow five minutes for the engine oil to return to the sump.

4) Locate the dipstick at the front of the engine compartment on the driver’s side.

5) Remove the dipstick by pulling upward and wipe with a clean, lint free, cloth.

6) Reinsert dipstick into the spout, remove and check oil level.

7) Fill engine as required to full mark on engine dipstick.

CHANGING ENGINE OIL Change engine oil every 250 service hours.

CAUTION If either fuel or coolant dilution is evident in the engine oil investigate and rectify immediately as serious engine damage will result.

To change the engine oil: 1) Park the machine on flat, level ground.

2) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

3) Place a suitable container under the drain valve.

4) Locate the remote drain valve on the driver’s side at the rear of machine.

5) Remove the drain plug and open the drain valve allowing warm oil and waste particles to drain from the crankcase of the engine.

6) Close drain valve, fit the drain plug and refill engine as described above.

Engine Oil Drain

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FLUSHING THE LUBRICATION SYSTEM When the engine lubrication system is contaminated by coolant (ethylene glycol antifreeze solution or water soluble material) the following cleaning procedure is recommended.

Use “Cellosolve” or equivalent solution.

WARNING Use extreme care when handling these solvents to avoid serious injury to personnel or damage to finished surfaces. Always consult the Material Safety Data Sheet before use.

1) 2) 3) 4) 5) 6) 7) 8)

Drain all engine lubrication oil.

Remove and discard the oil filter element and replace.

Mix two parts Cellosolve (or equivalent) with one part SAE 10 engine oil and fill the engine crankcase to the correct operating level as indicated on the dipstick.

Start and run the engine at fast idle (1000 RPM to 1200 RPM) for 30 minutes to one hour, checking engine oil pressure regularly.

Stop the engine and immediately drain the crankcase and filters.

Replace the drain plug, fill the engine with SAE 10 oil and run the engine again at fast idle for 10-15 minutes then drain the oil.

Remove and replace the oil filter element.

Replace the drain plug and fill the engine with the specified grade of oil for normal operation (see Section 1).

CAUTION Ensure that the source of contamination has been corrected before returning the engine to service.

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AIR INTAKE SYSTEM General Description The scavenging process in the 3126 Caterpillar engine system forces a charge of air into the cylinders by the turbocharger. This air sweeps out all of the burned gases through the exhaust valve ports. This air also helps cool the internal engine parts. At the beginning of the compression stroke each cylinder is filled with fresh, clean air which provides for efficient combustion.

The air, entering the turbocharger via the air cleaner is picked up by the turbo rotor blades and carried to the discharge side of the turbo. The continuous discharge of air from the turbo enters the air chamber of the cylinder block via the flame trap and sweeps through the intake ports of the cylinder liners.

The turbocharger is mounted on the outlet flange of the exhaust manifold. After the engine has started exhaust gases flowing through the turbine housing cause the turbine wheel and shaft to rotate. The intake turbocharger impellor, mounted on the opposite end of the turbine shaft, draws in fresh air via the air cleaner. The turbocharger delivers high pressure fresh air to the intake side of the heat exchanger. The air delivered from the turbocharger is at elevated temperature due to the compression process. To increase the efficiency of the combustion process the heated air is cooled via a heat exchanger (aftercooler) mounted in the cylinder block opening between the cylinders.

Engine coolant flows from rear to front, through the aftercooler while air flows downward through the cooler and is cooled before entering the combustion chambers.

Safety Precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS give the engine an opportunity to cool down before performing air intake system servicing.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing, particularly when cleaning filters using compressed air.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

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AIR CLEANER / INDICATOR ASSEMBLY The caterpillar dry type air cleaner is a dual element system which provides clean engine intake air via replaceable primary and secondary replaceable impregnated paper filters. The filter assembly is fitted with a service indicator device that provides a visual indication of excessive intake vacuum caused by a dirty or blocked air intake filter.

Servicing The air intake system should be visually inspected for signs of a bypass of the air cleaner and any signs of external damage daily or every 10 service hours.

Inspect the air intake system for: 1) External damage to flange joints, rubber intake pipe joiners retaining bolt security.

2) Air cleaner assembly mounting security.

3) Check the dust cap is secured and sealed around the air cleaner body.

4) Check the air inlet hood for blockage or damage.

5) Check the intake flame arrester for damage.

The air cleaner filter service indicator should be checked daily or every 10 service hours.

To check the air cleaner indicator: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Locate the service indicator mounted on air cleaner assembly outlet pipe.

3) Observe the position of the red indicator signal. If the indicator signal is locked in full view, filter cartridge service is necessary.

4) After the filter cartridge has been cleaned or replaced depress the reset button on the service indicator to remove the red signal from view.

To remove and service the air cleaner filter elements: 1) Ensure that the engine had had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Locate the air cleaner assembly on the off driver’s side over the fuel tank.

3) Undo the clamp assembly by loosening the retaining wing nut and remove the dust cap.

4) Remove the filter elements from the housing assembly and wipe the inside of the housing assembly and the inside of the dust cap clean with a dry cloth.

5) To clean the filter element, position it on a clean surface on its end.

6) Using a hand-held pneumatic blower, carefully reverse blow compressed air through the filter element removing captured dust.

WARNING Wear suitable eye and hearing protection when using compressed air. Do not exceed 30 kPa pressure.

NOTICE If the filter element is damaged or ruptured replacement is necessary. Replace the filter element if the red indicator signal is showing after servicing.

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EMERGENCY INTAKE SHUT OFF VALVE The emergency intake shut off valve (strangler valve) is fitted between the air filter housing and the intake side of the turbocharger. The valve is used to shut the engine off when the engine shutdown system fails to stop the engine.

Emergency Intake Shut Off Valve Stop Button

Emergency Intake Shut Off Valve Reset Lever

The valve is activated from the operator’s compartment by a stop button. The valve must be in the open position before starting the engine. The valve can be reset by rotating the reset lever to the latched position. The engine will not start if the valve is closed.

WARNING This engine system is fitted with a wet exhaust conditioner.

Operation of the Emergency Intake Shut Off valve while the engine is running may result in exhaust conditioner water being drawn back into the engine. This may result in catastrophic damage to the engine.

Maintenance Daily: 1) Check that all the fasteners locating the valve and any associated intake systems or support bracket are securely tightened.

2) Check that all flexible hoses between the valve and engine are free from damage and suitable for further service.

3) Carry out function test of Emergency Intake Shut Off valve and reset with engine stopped Weekly (50 hours) Testing of Valve: 1) Carry out this test when exhaust conditioner water has been drained and low water shutdown sensors temporarily defeated 2) Run the engine preferably at high idle.

3) Press the stop button in the operator’s compartment to activate the emergency intake shut off valve.

4) The engine should shut off within a few seconds.

If the engine does not shut off items to check are: 1) The cable from the stop button to the valve is correctly adjusted and in good working order.

2) The integrity of the intake system between the valve and the engine.

3) That the valve is not sticking when actuated (possible internal/external restriction).

If this does not resolve the problem, contact Bucyrus.

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INLET FLAME TRAP/FLAMEPROOF JOINTS The Caterpillar 3126 diesel engine system is approved as a flameproof diesel engine system suitable for use in underground coal mines. The flameproof design allows the engine to be used in the designated hazardous or potentially gassy areas within the mine.

The principle of flameproofing the engine system involves designing it to withstand an internal explosion without damaging the structural integrity of the engine components. This ensures that the internal explosion will not propagate to the outside atmosphere with sufficient energy to cause an external explosion.

In the case of the air intake system the flameproofing commences at the aftercooler flame trap and proceeds to the intake manifold, engine block gasket.

WARNING This engine system is tested and approved for use in an atmosphere with a maximum methane (CH4 ) concentration of 1% by volume. If higher levels are encountered the machine must be driven immediately to a ventilation intake area within the mine where the methane concentration is less than 1% by volume.

Flame Trap Housing

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SERVICING AIR INTAKE SYSTEM As with other maintenance and examination schedules the flameproof intake system should be inspected, by a suitably appointed and qualified person, at intervals consistent with mine site and statutory maintenance schemes. The following is the suggested intervals for maintenance and inspection of the flameproof air intake components.

Daily or every 10 service hours: Visually check joint fasteners (nuts, bolts and studs) securing flameproof joints i.e. flame trap flange to after cooler, and after cooler to cylinder head NOTICE Refer to the Diesel Engine System approval drawings for flame path dimensions and conditions.

Indicator Assembly

Air Cleaner Assembly

Air Intake System

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NOTICE! When system has been disassembled and reassembly is complete, check all flameproof joints for integrity using soapy water solution and 0.2 mm feeler gauge.

Every 250 service hours: 1) Check tightness of all joint fasteners (nuts, bolts and studs) securing flameproof joints i.e. flame exhaust manifold to engine block, exhaust manifold to turbo, turbo to exhaust downpipe, exhaust downpipe to exhaust conditioner. Use soapy water around joints to check for any leaks.

Every 2000 service hours or 2 service years. (Code D): 1) Disassemble all flameproof joint connections clean and inspect for surface finish, flatness, corrosion or damage. Repair as required.

2) Hydrostatically pressure test all exhaust system exhaust and water jacket chambers external to the engine block i.e. exhaust downpipe and purifier.

Water jacket Hydrostatic test 250 kPa (35 psi) Gas path Hydrostatic test 1000 kPa (145 psi) 3) After testing and inspection are completed and passed, reassemble using new gaskets and correct torque settings.

4) When reassembly is complete check all flameproof joints for integrity using soapy water solution and 0.2 mm feeler gauge.

See you engineering staff for correct inspection sheets

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COOLING SYSTEM General description The cooling system performs two prime functions: 1) To effectively dissipate the heat generated by the engine and the engine lubricant during the combustion process.

2) To effectively limit the surface temperature of the engine external components, including exhaust gases, to the maximum allowable limit of 150°C. For the engine cooling, the coolant is drawn from the cool radiator core by the engine water pump and is forced through the oil cooler housing and into the cylinder block. A parallel cooling circuit commencing from the water pump outlet and runs continuously back to the hot core of the radiator.

From the cylinder block coolant passes up through the air compressor cylinder head, manifolds, cylinder head and when the engine is at normal operating temperature, through the thermostats and back into the hot core of the radiator. It also flows from the engine water pump to the exhaust conditioner flange through to the downpipe and back to the water pump. Coolant then flows through the radiator where the temperature is lowered by the air stream generated by the radiator fan.

Upon starting a cold engine, or when the coolant is below thermostat operating temperature, the coolant flow to the radiator is blocked or restricted by the thermostat. A bypass provides coolant circulation within the engine during this warm up period.

A header tank provides top up coolant into the suction side of the water pump and the cold radiator core via gravity feed.

WARNING The cooling system run at a nominal 100 kPa pressure and can reach temperatures of more than 100°C. Release stored pressure and wear personal protective equipment when accessing.

Safety Precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS give the engine an opportunity to cool down before performing cooling system servicing.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing, particularly when accessing the coolant system.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys) when accessing the engine compartment including pneumatic stored pressure, coolant pressure and other heat sources such as engine block and exhaust system components.

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ENGINE PACKAGE

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EXPANSION TANK The expansion tank is situated on the rear driver’s side of the machine. Coolant is drawn from and returned to the tank as the coolant expands and retracts with heat. The expansion tank is nonpressurised and is fitted with sight gauges for filling the system. The system should be filled from this point.

WARNING Fill only from the expansion tank as this is non-pressurised.

Ensure only recommended coolants are used and mixed with the correct percentage of coolant to water, otherwise serious damage can be caused to the engine cooling system.

NOTICE The coolant level should run approximately ½ in the sight glass.

Expansion Tank Sight Glass

Non-pressurised Expansion Tank

HEADER TANK The header tank provides additional coolant via gravity feed and provides system pressure relief via a relieving cap. It is connected to an expansion tank which is non-pressurised and is used for topping up the coolant. The expansion tank also has a visual inspection glass for determining coolant level during maintenance.

WARNING Cooling system fluid will be under pressure and hot. Always relieve pressure by lifting the relief lever on relief cap before removal. Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves to avoid scalds and burns from hot coolant.

Engine Coolant Relief Cap

di

Pressurised Header Tank

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FAN ASSEMBLY The hydraulically driven fan assembly provides the necessary air flow through the radiator to remove the heat absorbed by the coolant. (See Section 4 ‘Hydraulic System - Fan Drive’).

The fan assembly and blades should be inspected every 250 service hours.

Check fan tip speed with tachometer every 1000 hours (fan speed high idle 2800 RPM).

To inspect the fan assembly: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Check the fan blades for cracks and/or chips and replace the fan if required.

Fan replacement is achieved by the following: 1) Removing the hold down bolts on the radiator.

2) Lift the hinged radiator up, and ensure that the gas strut that holds the radiator in position is in good working order.

3) Remove the four bolts from the transmission oil cooler and remove the cooler.

4) The tapered bush is released by removing both grub screws, and screwing one grub screw into removal hole to detach the fan and spacer from the hub; the fan is then able to be removed.

5) The assembly can then be replaced.

WARNING Replace all fan shrouds, guards and machine covers before returning the machine to service.

View under side of fan Grub screws in Locking position

Grub screw to release position

Top side of fan showing taper bush

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WATER PUMP BELT TENSION To check and adjust the water pump belt tension: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Loosen the tension on the idler pulley adjusting bolts.

3) Adjust the idler pulley to obtain the correct belt tension.

4) Tighten the idler pulley in position.

WARNING! Replace all guards and machine covers before returning the machine to service.

NOTICE! Correct belt tension is achieved when a firm push with the thumb midway between the two pulleys creates a deflection of no more than the belt depth.

Water Pump V-Belt

Engine Water Pump

Tensioner Idler Pulley

Idler Pulley Adjustment

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RADIATOR The machine is fitted with one radiator which provides cooling for the engine. This radiator is situated beside the top make up tank and is hinged for ease of cleaning and access to the cooling fan which is used to draw air through the radiator.

The coolant in the cooling circuit of the engine is circulated through the engine and the radiator by means of the engine water pump. The coolant passing through the radiator is then cooled by forcing air through the radiator fins by means of a hydraulically driven fan. The flow is regulated by the engine thermostat which opens and closes when the temperature is higher or lower than the normal operating temperature of 80°C-85°C. A metal shroud is located around the fan to increase the efficiency of the cooling system. A radiator that is dirty decreases the efficiency of the cooling system and will cause the engine to overheat. The radiator core should be inspected every 50 service hours and cleaned as required.

To clean the radiator core: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Lift the hinged radiator cover to give access to the radiator.

3) Remove hold-down bolts on radiator.

4) Lift the hinged radiator to vertical position and secure.

5) Use an air hose with a suitable blower nozzle to remove loose dirt from the core.

WARNING Wear suitable eye protection when using compressed air. Do not exceed 30 kPa pressure.

6)

With a manual spray gun apply a mineral solvent to the radiator core to remove grease/oil dirt mix.

WARNING DO NOT use petrol, kerosene or fuel oil as a solvent.

7) Relocate the radiator in place and install hold down bolts.

8) Rinse the radiator with low pressure water to remove solvent/dirt.

9) Replace the radiator guards before returning the machine to service.

Every 250 service hours the radiator, grill and fan shroud mountings should be checked and tightened as necessary. Refer to Section 1 - Recommended Bolt Torque Charts NOTICE High pressure cleaning may result in damage to the cooling fins.

Supply to Engine

Return from Engine

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CHECKING/FILLING AND FLUSHING COOLANT SYSTEM The coolant level should be checked and topped up daily with the recommended coolant conditioner.

The level can be checked by observing the sight glass level on the expansion tank. The upper level indicates the full level and the lower level indicates the low level. The recommended level is the mid point of the sight glass.

To top up the cooling system: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Locate the expansion tank fill cap.

3) Remove the fill cap by turning counter-clockwise.

4) Fill the expansion tank until coolant level is at the ⅔ position on the sight glass.

If refilling after flushing, the engine must be run for at least ten minutes at high idle with the fill cap removed to ensure system de-aeration. Check the coolant level after running and add if required.

WARNING Engine coolant fluid will be under pressure and hot. Always relieve pressure by lifting the relief lever on relief cap before removal. Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves to avoid scalds and burns from hot coolant.

The cooling system should be drained and flushed every 3000 service hours.

To drain the coolant system: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Relieve the pressure on the engine header tank by lifting the relief lever on the relief cap, once pressure is relieved remove the relief cap.

3) Remove the engine cooling system hose at the water pump. Allow the coolant to drain.

To flush the cooling system: 1) After the cooling system is completely drained. Clean and refit the hose on the engine water pump.

2) Refill with clean demineralised water and Caterpillar Fast Acting Cooling System Cleaner. Add 0.5 litres of cleaner per 15 litres of cooling system capacity. Install the header tank relief cap.

3) Start the engine and run for 30 minutes to circulate the water to reach the temperature to 82°C, stop the engine and allow the engine to cool down.

4) Drain the engine as above flushing the cooling system with fresh water until the dirty water is clean.

5) Clean and refit the hose on the engine water pump.

To fill the cooling system: 1) After the cooling system is completely flushed. Refill with coolant to the specification in Section 1.

2) Start the engine with the relief cap on the header tank removed. Allow the coolant to warm, the thermostat to open and the coolant level stabilize.

3) Check the coolant level. Add coolant mixture if necessary to bring the coolant to the correct level.

4) Refit header tank relief cap.

5) Start the engine and check any coolant leaking at the operational temperature.

The use of water containing minerals will form scale and silt deposits within the cooling system resulting in decreased cooling system efficiency and possible engine overheating. Scale formation must be chemically removed using a reputable de-scaling solvent. Thoroughly follow the mixing and neutralizing directions on the de-scaling solvent container. The thermostats must be removed from the engine when de-scaling solvent is used.

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FLUSHING A CONTAMINATED COOLING SYSTEM If the cooling system becomes contaminated it should be thoroughly flushed before the engine becomes contaminated. One possible cause is with a cracked oil cooler, oil will be forced into the cooling system.

To flush the cooling system: 1) Ensure the source of contamination has been rectified.

2) Prepare a mixture of Calgon, or equivalent, at a ratio of 300 grams (dry) to 20 litres of water.

3) Remove the engine thermostat as previously described.

4) Fill the engine with Calgon solution and run for five minutes.

5) Drain the system and repeat the Calgon solution.

6) Drain the system again and fill with clean, demineralised water.

7) Run the engine for five minutes and drain completely.

8) Install the thermostat and refill the system with coolant to the specification in Section 1.

WARNING Engine coolant fluid will be under pressure and hot. Always relieve pressure by lifting the relief lever on relief cap before removal. Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves to avoid scalds and burns from hot coolant.

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EXHAUST SYSTEM General description The exhaust system is designed to be used in a hazardous zone of an underground coal mine.

The system comprises of: 1) Exhaust Manifold 2) Turbocharger 3) Downpipe/Purifier 4) Exhaust Conditioner 5) Particulate Filter 6) Outlet Pipe.

The surface temperature of the system is controlled by water jacketed components. While the exhaust gas temperature is controlled via a wet bath type exhaust conditioner.

Engine Package

Safety precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be applied to heavy machinery operation and servicing.

ALWAYS give the engine an opportunity to cool down before performing lubrication system servicing.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing, and dust mask particularly when accessing the exhaust system.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

ALWAYS replace all guards and covers before returning the machine to service.

WARNING Wear suitable eye protection, gloves and dust mask when performing work on the exhaust systems as particulates may be harmful to the respiratory system. Immediately wash any particulate matter from skin with warm, soapy water.

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EXHAUST DOWNPIPE/PURIFIER The exhaust downpipe/purifier is one complete unit and provides a flameproof link between the watercooled turbocharger and the exhaust conditioner. It comprises of an exhaust path which is watercooled by means of a water jacket to maintain the surface temperature below 150°C. Exhaust gas is delivered into the top of the purifier via the water jacketed downpipe. Gases are channeled through the purifier element and into the exhaust conditioner.

Each end of the downpipe/purifier are fixed flameproof connections which bolt to the turbocharger and the exhaust conditioner.

To remove the downpipe: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1 2) Drain the engine cooling system as described in this Section.

3) Undo the exhaust downpipe to turbo flange joint by removing the four retaining bolts.

4) Undo the exhaust downpipe/purifier to exhaust conditioner flange joint by removing the eight retaining bolts and remove.

5) Discard the old gaskets in an appropriate manner.

6) The downpipe can now be inspected.

To replace the downpipe: 1) Check the downpipe for any cracks or damage and repair or replace if necessary.

2) Check the water jacket for free flow.

3) Hydrostatically pressure test the purifier water jacket and exhaust path as per the requirements of AS3584.

4) Using new gaskets, plugs and hoses reinstall the exhaust downpipe ensuring that the flange gaskets provide an air tight seal.

5) Refill the engine with specified coolant, run the engine and check for any exhaust leaks.

Exhaust Emissions Test Point Bleed Point

Purifier

Water outlet Port

Water Jacketed Exhaust Downpipe/Purifier

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The purifiers functions:

Converts up to 95% harmful carbon monoxide (CO) into carbon dioxide (CO2) and removes up to 50% of particulate matter (smoke) to aid in emission control.

The purifier needs to be inspected for deterioration or damage every six months or 1000 service hours To remove the purifier: The procedure for the removal of the purifier is the same as the downpipe as they are one unit.

To test downpipe for Code D inspection: 1) Blank of both ends of downpipe with blanking plates.

2) Hydrostatically test gas path to 1000 kPa using calibrated pressure gauges.

3) Hydrostatically test water jacket to 250 kPa using calibrated pressure gauges.

4) Check the fixed connections on both ends of the downpipe to conform with surface and flatness tolerances nominated on the approval drawing.

Flatness and Surface Finish

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Size mm

Accuracy for Grade H Tolerance mm

< 10

0.02

> 10 < 30

0.05

> 30 < 100

0.1

> 100 < 300

0.2

> 300 < 1000

0.3

> 1000

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EXHAUST MAKE UP TANK There is one make up tank that supplies water to the exhaust conditioner. Water flows from the tank to the exhaust conditioner via one hose. There is also a breather on the top of the tank.

The make up tank is pressurised at 7 psi from a pressure reducing valve in the pneumatic circuit.

Engine Assembly

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EXHAUST CONDITIONER Exhaust gas is piped from the engine through a water-cooled manifold and downpipe/purifier to the exhaust conditioner. The exhaust gas then passes through a water barrier which cools it below 70°C. The exhaust then passes through the particulate filter and is directed via the outlet pipe and is dispersed by the radiator fan. Make up water is taken directly via a two-way ball valve to the make up valve and into the low water shutdown chamber. This valve maintains a constant safe water level.

The shutdown float is positioned in the low water shutdown chamber in the exhaust conditioner, they will shutdown the engine if the water level in the exhaust conditioner goes below the set level.

WARNING Wear suitable eye protection, gloves, hearing protection and dust mask when performing maintenance tasks on the exhaust system as particulate matter may be harmful to the respiratory system.

WARNING Immediately wash any particulate matter from skin with warm, soapy water.

WARNING Ensure Mine Manager’s Rules are followed and the equipment is correctly isolated and tagged while maintenance tasks are being performed.

WARNING Allow sufficient time for the exhaust items to cool prior to performing maintenance tasks on the exhaust conditioner assembly.

Exhaust Conditioner

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Maintenance Daily: 1) Flame path and connecting bolts inspection.

2) Exhaust conditioner low water shutdown testing.

To test the low water shutdown system: 1) Ensure the machine is parked on level surface.

2) Ensure that the make up tank is full of water.

3) With the engine running close the float chamber inlet valve to the exhaust conditioner.

4) Open the lower water shutdown test valve at the side of the exhaust conditioner.

5) Once the water drops below the prescribed level in the float chamber the shutdown float sensors will shutdown the machine. The engine should shutdown before water stops flowing out of the lower water shutdown test valve.

6) Enter the Operator’s compartment and view the DCS display screen. The error message on the screen should be alternating between Scrubber Level 1 and Scrubber Level 2. The sensor LED will be red.

7) To ensure that both Scrubber level switches work independently of each other push the enter button. Select Digital Input Status using up/down arrows. Scrubber Level 1 and Scrubber Level 2 should indicate that switch is open “o/o”.

8) Reset the on / off toggle switch and try to start the machine, it should not start.

9) Close the lower water shutdown test valve and open the main float chamber inlet valve to allow the exhaust conditioner to fill again.

10) Once the exhaust conditioner has filled restart the machine as per the start up procedure in Section 7.

WARNING If the engine fails to stop or the water stops flowing out the test valve before the engine stops report to service personnel. DO NOT use the machine until the fault is rectified and tested.

Low Water Shutdown Test Valve

Float Chamber Inlet Valve

Wet Bath Exhaust Conditioner

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Maintenance Weekly (50 hours): Procedure: 1) Ensure that the engine has sufficient time to cool and is isolated and tagged in accordance with the manufacturer’s procedures and mine site rules.

2) Remove inspection covers on front of exhaust conditioner and on top of exhaust conditioner float chamber.

3) Close float chamber make up valve.

4) Open exhaust conditioner drain valve on the bottom of the conditioner.

5) Using clean water hose out both the float chamber and the main body of the conditioner to remove all build up of particulate matter.

6) Inspect condition of float assemblies and repair / replace if necessary.

7) Refit inspection covers and tighten bolts to correct torque.

8) Close drain valve on bottom.

9) Open float chamber make up tank valve and refill exhaust conditioner.

10) Start engine and check for leaks around inspection covers.

11) Perform exhaust conditioner low water shutdown test.

Inspection Holes

Shutdown Float Chamber

Wet Bath Exhaust Conditioner

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Maintenance Every 2000 service hours: Adjust the floats.

Clean exhaust conditioner.

CAUTION The water in the exhaust conditioner is very hot. Personal protective equipment and long sleeve clothing should be worn.

To adjust the make up float: 1) Remove the cover on top of the float chamber to allow access to the floats.

2) Open make up supply valve.

3) Allow the water to flow into the scrubber and float chamber.

4) Once the water has stopped measure the water against the prescribed level.

5) If the level is incorrect adjust the make up float to achieve a static water level in the float chamber of 145 mm.

The shutdown floats normally shutdown the engine, however it is important to test floats individually.

Should the system not shutdown at the correct level, the float assemblies can be removed and the floats adjusted to compensate for shutdown levels.

IMPORTANT The engine should not be running while this test takes place.

To adjust the shutdown floats 1) Close the make up tank isolation valve.

2) Turn on the electronic shutdown system display – The machine does not have to be running.

3) Open the test valve in the tank and allow the water to drain.

4) Watch the electronic shutdown system display.

5) When the light comes on for low water close the test valve.

6) Record the water level in the float chamber.

7) Adjust the shutdown float level until a water level of 100 mm is achieved.

8) At this point ensure that water is flowing out of the drain tap when the light comes on – if not float adjustment is necessary.

9) Repeat for the second float.

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Drain Valve

Exhaust Conditioner

To clean exhaust conditioner: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Shut off the main supply/isolation valve.

3) Locate the drain valve at the bottom of exhaust conditioner.

4) Open valve to release all water in conditioner.

5) Remove the two inspection covers on the side of conditioner and the float assembly.

6) Remove the exhaust flame trap and clean with detergent and clean water.

7) Clean all soot deposit buildup from the exhaust conditioner components.

8) Clean and inspect gasket surfaces.

9) Reinstall the inspection covers and float assembly with new gaskets.

10) Check and fill water in the make up tank and supply/isolation valve.

11) Check for leaks.

12) Start the engine and see if any leakage or shortage of water, and fill if necessary.

Over time particulate matter (the small particles that are present in exhaust smoke) will build up on the exhaust conditioner components which may result in decreased efficiency. To minimise build up the exhaust conditioner should be cleaned every 2000 hours.

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EXHAUST PARTICULATE FILTER The filter housing is installed on the outgoing side of the exhaust conditioner and contains a replaceable filter element.

Exhaust Particulate Filter Housing

The filter element housing has a backpressure indicator which signifies filter blockage this is located in the operator’s compartment. The indicator should be checked daily or every 10 service hours.

Exhaust Back Pressure Gauge

WARNING If the particulate filter usage or engine smoke emissions are excessive the engine will require servicing.

To check the particulate filter indicator: 1) Locate the gauge in the operator’s compartment.

2) Run the engine at high idle and observe the indicator position.

3) If the indicator is in the red zone the filter requires replacement.

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To replace the particulate filter: 1) Position the machine in an area with the least amount of air movement.

2) Ensure that the engine has had sufficient time to cool and is Isolated and personal danger tag/lock is fitted.

3) Use correct PPE supplied with new filter; remove the filter housing lid by removing the four cover retaining bolts.

4) Undo filter retaining nuts.

5) Place a garbage bag over the filter housing until the base of the bag is at the top of the housing.

WARNING Ensure that the filter element is cool enough to handle other wise the garbage bag will melt causing skin burns. .

6)

7) 8)

With the filter element clear of the housing invert the garbage bag. Grasp the filter element through the garbage bag base and remove the filter element clear of the housing ensuring the garbage bag covers the filter as it is removed.

Discard the used element in an appropriate manner taking care not to puncture the bag.

Place the new filter element inside the housing and secure the lid.

WARNING Wear suitable eye protection, gloves and dust mask when performing filter replacement as particulate caught by the filter may be harmful to the respiratory system. Immediately wash any particulate matter from skin with warm, soapy water.

Exhaust Particulate Filter

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FLAME PATH JOINTS OR FIXED CONNECTIONS As with other maintenance and examination schedules the flameproof exhaust system should be inspected, by a suitably appointed and qualified person, at intervals consistent with mine site and statutory maintenance schemes. The following is the suggested intervals for maintenance and inspection of the flameproof components.

Daily: 1) Visually check joint fasteners (nuts, bolts and studs) securing flameproof joints i.e. exhaust manifold to engine block, exhaust manifold to turbo, turbo to exhaust downpipe, exhaust downpipe to exhaust conditioner, exhaust conditioner to particulate filter.

Every 50 service hours: 1) Check tightness of all joint fasteners (nuts, bolts and studs) securing flameproof joints i.e. flame exhaust manifold to engine block, exhaust manifold to turbo, turbo to exhaust downpipe, exhaust downpipe to exhaust conditioner, exhaust conditioner to particulate filter. Use soapy water around joints to check for any leaks.

Every 2000 service hours or 2 service years (Code D): 1) Disassemble all flameproof joint connections and inspect for finish, flatness, corrosion or damage. Repair as required.

2) Discard and replace all fixed joint gaskets.

3) Hydrostatically pressure test all exhaust system exhaust and water jacket chambers external to the engine block i.e. exhaust downpipe and purifier.

Water Jacket Hydrostatic test 250 kPa (35 psi) Gas Path Hydrostatic test 1589.9 kPa (229 psi) Exhaust Conditioner Hydrostatic test 100 kPa (14.5 psi)

EXHAUST EMISSION TESTING PROCEDURE Statutory requirements specify intervals for testing diesel engine exhaust emissions. For accurate testing the engine must be loaded as near as practical to maximum output power. The following procedure should be carried out for loading the engine to near maximum power.

WARNING Wear personal protection equipment when working in proximity to a running engine as long term hearing loss may result.

WARNING Position wheel chocks at both front wheels to eliminate sudden machine movement

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WARNING Position all persons clear of the machine to avoid impact if the machine suddenly lurches forward.

NOTICE A gas sampling point is located on the incoming side of the exhaust conditioning system so that raw exhaust samples can be taken.

Behind this guard

Exhaust Test Point

To test exhaust gas emissions: 1. Find a suitable location for testing with sufficient clearance around the machine.

2. Run the machine to bring the engine up to operating temperature.

3. With the park brake released and the service brake fully actuated, engage the transmission in 4th gear and in the forward direction (direction of the lift arms).

4. Slowly actuate the accelerator pedal to full throttle with the brake applied.

5. When the accelerator is at full throttle actuate the joystick control lever until hydraulic stall is achieved i.e. relief pressure of 20.1 MPa (2900 psi).

6. The machine is now in full transmission and hydraulic stall (as close as practical to maximum output power).

7. With an operator maintaining transmission and hydraulic stall take gas readings at the exhaust downpipe test point or outlet pipe.

WARNING Observe the transmission temperature gauge during stall and remove engine load if temperatures approach the maximum indicated on the transmission temperature gauge. Full stall should only be carried out for a minimal period.

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THROTTLE CONTROL General Description A throttle cable connects directly from the accelerator pedal to the throttle lever. The lever is activated manually when pressure is applied to the accelerator pedal. Pedal actuation provides proportional throttle control.

Safety precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS give the engine an opportunity to cool down before performing throttle control system servicing.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing, particularly when servicing cable connections.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys, drive lines) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

Throttle Control Group

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Blakefield South FBL-55H Service Manual

ENGINE SYSTEM TROUBLESHOOTING The following Engine System Troubleshooting Guide is intended to provide basic guidance for analysing poor engine performance and determining probable causes. This guide is not intended to be exhaustive as particular engine tuning and adjustments, such as exhaust valve adjustment, fuel injector timing, governor adjustment and fuel modulator setting are only intended to be performed by Caterpillar representatives WARNING Tampering with the engine governor and fuel injector settings will result in adverse engine performance and may void the conditions for which the engine system has been certified such as operating temperature and exhaust emissions.

Symptom Excessive crankcase pressure.

Abnormal quantity of black or grey exhaust.

Probable cause

Caused by

Cylinder blow-by.

Remedy

Cylinder head gasket leaking.

Consult Bucyrus for analysis.

Piston or liner damage.

Consult Bucyrus for analysis.

Piston rings worn or broken.

Consult Bucyrus for analysis.

Breather restriction.

Obstruction or damage to engine oil breather.

Remove breather and clean out or replace as required.

Excessive exhaust back pressure.

Restriction in exhaust system.

Clean exhaust system.

Incompletely burned fuel.

Restricted air inlet to the cylinders.

Inspect, clean or replace air cleaner filter (Section 2).

Inspect, clean or replace inlet flame trap (Section 2).

Clean exhaust system.

Excessive fuel or irregular fuel distribution.

Blue exhaust smoke present.

Engine hard starting.

Improperly timed injectors.

Consult Bucyrus for analysis.

Improper fuel specification used.

Verify fuel specification (Section 1).

Lubricating oil not burned in cylinder (blown through cylinder during scavenging period).

Internal lubricating oil leaks.

See high lubricating oil consumption symptom.

Engine will not rotate.

Faulty pneumatic start circuit.

See Section 7.

Internal engine seizure (if engine can not be hand cranked at least one revolution).

Consult Bucyrus for analysis

Improper lubricating oil viscosity.

Verify lubricating oil specification (Section 1).

Faulty pneumatic start circuit.

See Section 7.

Worn or damaged starter motor.

See Section 7.

Slow engine cranking speed.

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Consult Bucyrus for analysis.

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Abnormal engine operation.

Probable cause

Caused by

Remedy

Low pneumatic system air pressure.

Verify correct system air pressure and top up with external source if required.

No fuel delivery to cylinders.

Faulty fuel system.

See no fuel or insufficient fuel symptom.

Low cylinder compression.

Burned or sticking exhaust valves.

Consult Bucyrus for analysis.

Compression rings worn or broken.

Consult Bucyrus for analysis.

Cylinder head gasket leaking.

Consult Bucyrus for analysis.

Improper valve clearance adjustment.

Consult Bucyrus for analysis.

Low coolant temperatures.

Check coolant temperature gauge. If the temperature does not reach 71°C–92°C see low coolant temperature symptom.

Insufficient fuel.

See no fuel or insufficient fuel symptom.

Faulty injectors.

Consult Bucyrus for analysis.

Low compression pressures.

Consult Bucyrus for analysis.

Governor instability (hunting).

Consult Bucyrus for analysis.

Improper engine tune adjustments or gear train timing.

Consult Bucyrus for analysis.

Insufficient fuel.

See no fuel or insufficient fuel symptom.

Restricted air inlet to the cylinders.

Inspect, clean or replace air cleaner filter (Section 2).

Uneven running or frequent stalling.

Lack of engine power.

Inspect, clean or replace inlet flame trap (Section 2).

No fuel or insufficient fuel.

Fuel system air leaks.

Low fuel supply.

Check the fuel tank level and adjust as required.

Loose, broken connections or cracked lines between the fuel tank and fuel pump.

Inspect for loose connections and damaged lines and replace as required. Carry out a fuel flow test to check for aerated fuel (see Section 2).

Faulty injectors.

Carry out a fuel flow test to check for aerated fuel (see Section 2).

If supply lines are OK consult Bucyrus for further analysis.

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Symptom

High lubricating oil consumption.

Probable cause

Symptom

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Remedy

Flow obstruction.

Fuel/water separator, fuel filter or fuel lines restricted.

Carry out a fuel flow test to check for correct fuel flow (see Section 2). Check supply lines for kinks or blockage.

Faulty fuel pump.

Relief valve not seating.

Carry out a fuel flow test to check for correct fuel flow (see Section 2).

Clean and inspect valve seat assembly if inadequate flow is present

Worn fuel pump gears or body.

Replace fuel pump or overhaul existing assembly.

Consult Bucyrus for fuel pump overhaul.

Fuel pump not rotating.

Check condition of the fuel pump drive. Replace defective parts.

Oil lines or connections leaking.

Visually inspect and rectify as required.

Gasket or oil seal leaks.

Clean engine with degreaser and run at operating temperature to reveal leaks. Replace gaskets as required.

Overfilled crankcase.

Check oil level after allowing sufficient time for the oil to settle and drain as required.

Obstruction or damage to engine oil breather.

Remove breather and clean out or replace as required.

Blower oil seals leaking.

Remove air inlet housing and flame trap. Operate the engine at half throttle and idle and inspect blower end plates for leakage past the seals.

Overhaul blower is excessive leakage is evident.

Consult Bucyrus for overhaul.

Turbo oil seals leaking.

Remove intake air and exhaust piping and check for oil on the compressor or turbine sides of the turbocharger.

Oil cooler core leaking.

Pressure test cooling system.

Replace oil cooler if leak is found.

Check for coolant/oil contamination and flush as described in Sections 2.

Worn exhaust valve guides.

Replace valve guides. Consult Bucyrus for valve guide replacement.

Suction loss.

Check the oil level and bring the full level on the dipstick.

External leaks.

Internal leaks.

Low oil pressure.

Caused by

Lubricating oil.

Probable cause

Caused by

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Poor lubricating oil circulation.

Oil pump faulty.

Incorrect lubricating oil viscosity.

Verify correct lubricating oil specification. See Section 1.

Clogged cooler (indicated by high oil temperature).

Remove and clean the oil cooler core.

Cooler bypass valve not functioning.

Remove bypass valve, clean valve and valve seat, inspect spring.

Pressure regulator valve not functioning.

Remove pressure regulator valve, clean valve and valve seat, inspect spring.

Excessive wear on crank shaft bearings.

Consult Bucyrus for bearing replacement.

Gallery, crank shaft or cam shaft plugs missing.

Replace missing plugs.

Intake screen clogged.

Remove and clean oil pan and intake screen.

Relief valve faulty.

Remove relief valve, clean valve and valve bore, inspect spring.

Consult Bucyrus for overhaul.

Air leak in pump suction.

Disassemble piping and install new gaskets.

Pump worn or damaged.

Overhaul or replace pump.

Consult Bucyrus for overhaul.

Abnormal engine coolant operating temperature.

Coolant temperature too low.

Coolant temperature too high.

Improper circulation from thermostat not closing.

Remove test and replace thermostat as required. See Section 2.

Excessive leakage at thermostat seal.

Replace thermostat seals when thermostat is removed. See Section 2.

Insufficient heat transfer through the radiator core.

Clean exterior of core to permit normal air flow. See Section 2.

Descale cooling system internals to remove flow restrictions. See Section 2.

Check, adjust and replace fan pulley belts as required. See Section 2.

Improper circulation from flow restriction.

Remove test and replace thermostat as required. See Section 2.

Descale cooling system internals to remove flow restrictions. See Section 2.

Inspect hoses for undue bends, kinks or crushing.

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Section

3

Transmission and Drive Train ENGINE DRIVE COUPLING General description The machine is fitted with a direct drive coupling from the output of the engine via a drive shaft to the input of the torque converter on the transmission, allowing the engine to sit lower in the frame. The flywheel on the engine is coupled to the engine drive coupling via a flexible coupling. The output of the drive coupling is coupled to the transmission by an end yoke drive line coupling.

WARNING The engine drive coupling is directly coupled to the engine flywheel so whenever the engine is running the drive coupling output and input drive line to the torque converter is rotating.

Isolate the engine if access to the engine drive coupling or drive lines is required.

Safety precautions The following safety precautions are not intended to be exhaustive. Safe Work Practices should be used when servicing or operating heavy machinery.

ALWAYS give the engine an opportunity to cool down before performing any servicing.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys and drive lines) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components

Drive Coupling

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CHECKING AND GREASING OF DRIVE COUPLING Care and maintenance To check the drive coupling: 1) Park the machine on flat, level ground.

2) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

3) Check for excessive free play in bearings.

4) Locate the remote grease point to the side of the air cleaner assembly.

5) Greasing of the coupling bearings should be carried out at 250 hour service intervals.

CAUTION ONLY Shell Stamina RL2 grease should be used for drive coupling bearing lubrication.

NOTICE DO NOT over grease drive coupling assembly. The greasing of the assembly is to replenish the lubricant not to replace it.

Greasing Port and Relief Port

Round Headed Grease nipple

Engine Drive Coupling (Centamax)

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REMOVAL AND INSTALLATION OF DRIVE COUPLING Removal 1) 2) 3) 4) 5) 6)

Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

Remove output drive line.

Remove bolts from drive coupling housing and sling housing for lifting.

Take weight of drive hosing and slide back towards front of machine until rubber drive clears the engine fly wheel housing.

Remove the outer ring bolted to the flywheel by removing the bolts shown as TA2.

The rubber disc is removed by removing the bolts shown as TA1 and withdrawing it off the taper.

Installation 1) 2) 3) 4) 5) 6)

Fit the new ring to the flywheel.

Tighten the bolts in a cross sequence to pull the ring up squarely to the flywheel face.

Torque the bolts (Reference TA2) to 110 Nm. Ensure ring is fully bedded against the flywheel face.

The driven hub is fitted onto the driven shaft.

The rubber disc with the vulcanised ring is then assembled to the driven hub with bolts (Reference TA1) which must be tightened to the correct torque of 85 Nm. 7) After these are fitted slide the drive coupling assembly back and line up the rubber coupling teeth with the corresponding teeth on the ring bolted to the flywheel.

8) Fit the bolts and bolt drive assembly to the engine flywheel housing.

9) Fit the output drive line and replace all covers.

10) Grease coupling.

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TRANSMISSION / TORQUE CONVERTER General description The transmission used on the FBL-55H has four forward and reverse speeds with forward and reverse modulation.

When the engine is running the converter charge pump draws oil from the transmission sump through the removable oil suction screen and directs it through the pressure regulating valve and the oil filter.

The pressure regulating valve maintains pressure to the transmission control cover for actuating the direction and speed clutches. This requires a small portion of the total volume of oil used in the system. The remaining volume of oil is directed through the torque converter circuit to the oil cooler and returns to the transmission for positive lubrication. This regulator valve consists of a hardened valve spool operating in a closely fitted bore. The valve spool is spring loaded to hold the valve in the closed position. When a specific pressure is achieved, the valve spool works against the spring until a port is exposed along the side of the bore. This sequence of events provides the proper system pressure.

After entering the converter housing the oil is directed through the stator support to the converter blade cavity and exits in the passage between the turbine shaft and converter support. The oil then flows out of the converter to the oil cooler. After leaving the cooler, the oil is directed to a fitting on the transmission. Then through a series of tubes and passages which lubricates the transmission bearings and clutches. The oil then gravity drains to the transmission sump.

The hydraulic torque converter consists basically of three elements and related parts to multiply engine torque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components for torque multiplication.

This element can be compared to a centrifugal pump in that it picks up fluid at its centre and discharges at its outer diameter.

The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter. This element receives fluid at its outer edge and discharges at its centre. Fluid directed by the impeller out into the blades in the turbine and reaction member. This is the means by which the hydraulic torque converter multiplies torque.

The reaction member of the torque converter is located between and at the centre of inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element.

The torque converter will multiply engine torque to its designed maximum multiplication ratio when the output shaft is at zero RPM. Therefore, we can say that when the output shaft is decreasing in speed the torque multiplication is increasing.

The shift control valve assembly consists of a valve body with selector valve spools. A detent ball and spring in the selector spool provides one position for each speed range. A detent ball and spring in the direction of the spool provides three positions, one each for forward, neutral and reverse.

With the engine running and the directional control lever in the neutral position, oil pressure from the regulating valve is blocked at the control valve, and the transmission is in neutral. Movement of the forward and reverse spool will direct oil, under pressure to either the forward or reverse direction clutch as desired. When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selector spool. The same procedure is used in the speed selector.

The direction or speed clutch assembly consists of a drum with internal splines and a bore to receive a hydraulically actuated piston. The piston is oil tight by the use of sealing rings. A steel disc with external splines is inserted into the drum and rests against the piston. Next, a friction disc with splines at the inner diameter is inserted. Discs are alternated until the required total is achieved. A heavy backup plate is then inserted and secured with a snap ring. A hub with outside diameter splines is inserted into the splines of the discs with teeth on the inner diameter. The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch.

To engage the clutch, as previously stated, the control valve is placed in the desired position. This allows oil under pressure to flow from the control valve, through a tube, to the chosen clutch shaft.

This shaft has a drilled passage way for oil under pressure to enter the shaft. Oil pressure sealing

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rings are located on the clutch shaft. These rings direct oil under pressure to a desired clutch.

Pressure of the oil forces the piston and discs against the heavy backup plate. The disc, with teeth on the outer diameter, clamping against the disc with teeth on the inner diameter, enables the hub and clutch shaft to be locked together and allows them to drive as a unit.

There are bleed balls in the clutch piston which allow quick escape of oil when the pressure to the piston is released.

Safety precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS give the transmission an opportunity to cool down before servicing.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing.

ALWAYS clean up any spilled oil immediately to remove the potential for slip, trip or fall injuries.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys and drive lines) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

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CHECKING/FILLING THE TRANSMISSION OIL Care and Maintenance Check the transmission oil level daily and fill as required.

To check and fill the transmission oil level: The oil temperature must be between 82.2°C and 93.3°C. This can be read from the transmission temperature gauge in the operator’s compartment. Do not check the level of the transmission with cold oil. To raise the transmission oil temperature to its operating level it is necessary to work the machine or to stall out the torque converter. To stall out the machine apply the brakes and engage the transmission control levers in the forward and high speed positions. Release the park brake and accelerate the engine to ½ throttle. Hold the engine at stall until the desired transmission oil temperature is reached.

CAUTION Excessive transmission stall will overheat and damage the torque converter.

1) 2) 3) 4) 5) 6) 7) 8)

Once the correct transmission oil temperature has been reached park the machine on flat, level ground and leave it running.

Place the transmission in neutral, apply the park brake.

The transmission dipstick is located on the off driver’s side of the transmission and is accessible through the transmission bay cover.

The engine should be idling at 800 RPM. Remove the dipstick by pulling it upwards and wipe it with a clean, lint free cloth.

Reinsert the dipstick into the spout and push it all the way home.

Withdraw the dipstick and check the oil level. The level is to be maintained at the full mark.

If necessary top up the oil level via the fill point with the correct transmission lubricant specified in Section 1.

Dipstick Position

Transmission Dipstick

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CHANGING THE TRANSMISSION OIL FILTER ELEMENT The transmission oil filter should be changed at 500 service hours. The machine is fitted with a dual element filter assembly that includes two spin-on type filters.

To change the transmission oil filter: 1) Park the machine on flat, level ground. If possible in a low dust environment.

2) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

3) Remove the transmission cover.

4) Locate the oil filter element housing mounted in the transmission bay near the off driver's side rear wheel arch.

5) Ensure the transmission oil has had sufficient time to cool. Check by feeling the surface temperature of the oil filter element housing.

6) If necessary clean down the area around the oil filter element housing with a hose and dry the area to minimize the possibility of any contaminants getting into the system.

7) Place a suitable container beneath the oil filter element housing.

8) Using a suitable filter strap turn the filters counter-clockwise to remove the filters.

9) Ensure the old filter elements o-rings are removed.

10) Clean the sealing surface area with a clean lint free cloth.

11) Lightly coat the new oil filter element housing sealing surface area and new oil filter elements with clean transmission oil.

12) Install the new oil filter elements into the oil filter element housing by turning them clockwise.

(Do not over tighten).

CAUTION Over tightening the oil filter element housing may distort or crack the filter housing resulting in an oil leak.

13) Add oil as required to bring the oil level to the low mark on the dipstick.

14) Start and run the engine idle at 800 RPM to prime the converter and lines. Check for any leaks around the oil filter elements.

15) When oil temperature is hot (between 82.2°C and 93.3°C on the transmission temperature gauge in the operator’s compartment) check the level of the oil again and bring it up to the full mark on the dipstick.

Filters Position

Transmission Oil Filters

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CHANGING THE TRANSMISSION OIL The transmission oil is to be changed every 1000 service hours. When the transmission oil is changed the oil filter elements should be replaced and the charge pump suction strainer should be cleaned.

Servicing To change the transmission oil: 1) Park the machine on flat, level ground. If possible in a low dust environment.

2) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

3) The transmission drain plug is located at the bottom of the front side of the main transmission case. If necessary clean down the area around the drain plug to minimise the possibility of any contaminants getting into the system.

4) Place a suitable container beneath the transmission drain point.

NOTE:The approximate volume of the transmission and torque converter is 45litres).

5) Remove the drain plug and allow the transmission to drain.

6) Check the condition of the o-ring on the drain plug and replace if necessary.

7) Refit the drain plug.

8) Replace the transmission oil filter elements.

CAUTION Over tightening the oil filter element housing may distort or crack it resulting in an oil leak.

9) Add oil via the dipstick orifice as required to bring the oil level to the low mark on the dipstick.

10) Start and run the engine and run at 650 RPM to prime the converter and lines. Check for any leaks around the filters.

11) Recheck the oil level with the engine running at 650 RPM and add oil till the level is at the low mark.

12) Stall the torque converter as previously described and when the oil temperature is between 82.2 °C and 93 °C check the level of the oil again and bring it up to the full mark on the dipstick.

13) Recheck all drain plugs, lines, filters, etc for leaks and tighten where necessary.

Transmission Drain plug

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TROUBLESHOOTING GUIDE The following information has been provided to aid in identifying the cause of a problem when examining a malfunctioning transmission. It is necessary to consider the torque converter charging pump, transmission, oil cooler and all connecting lines as a complete unit when determining the source of the problem since the condition and proper operation of all of these components effects the performance. By referring to how the unit operates together with this information service personnel should be able to correct any malfunction that may occur with the transmission.

The troubleshooting procedure consists of two classifications: Mechanical and Hydraulic.

Mechanical Checks Before examining the transmission from a hydraulic point of view, the following mechanical checks should be made: 1) Check all control linkages are properly connected and adjusted at all connecting points.

Check all transmission control levers and cables for bindings and restrictions in travel that would prevent full engagement. Shift the transmission control levers by hand at the control valve, if full engagement cannot be obtained the cause may be in the control cover and valve assembly.

Check the input shaft is rotating when the engine is running.

Hydraulic Checks Before checking the torque converter, transmission or associated hydraulic system for pressures and

Cause

Remedy

1.

Low oil level

Fill to correct level

2.

Clutch pressure regulating valve stuck open

Clean valve spool and housing or replace

3.

Faulty charging pump

Replace pump

4.

Broken or worn clutch shaft or piston sealing rings Replace sealing rings

5.

Clutch piston bleed valve stuck open

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Remove piston and clean bleed valves

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Low Converter Charging Pump Outlet Cause

Remedy

1 Low oil level

1 Fill to correct level

2 Suction screen blocked

2 Clean suction screen

3 Defective oil pump

3 Replace pump

Overheating Cause

Remedy

1 Worn oil sealing rings

1 Remove, disassemble and rebuild converter assembly

2 Defective oil pump

2 Replace pump

3 Low oil level

3 Fill to correct level

4 Excessive load

4 Ensure machines are not overloaded

Noisy Converter Cause

Remedy

1 Worn coupling gear

1 Replace

2 Worn oil pump

2 Replace pump

3 Worn or damaged bearings

3 Remove, disassemble and rebuild converter

Lack of power Cause

Remedy

1 Low engine RPM at converter stall

1 Check engine governor and injectors

2 High engine RPM at converter stall

2 Check clutch pressure and pump output

3 See ‘ Overheating’ and make the same checks

3 Remove, disassemble and rebuild converter

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SERVICE DATA Converter Outlet Pressure To test the converter outlet pressure perform the following steps: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Remove the cover over the top of the transmission. This panel is located in front of the operator’s compartment.

3) Attach a 0-500 kPa pressure gauge to the port adjacent to the converter outlet temperature pick up.

4) Start the machine and bring the transmission oil temperature to between 82.2 °C and 93.3 °C. This can be read from the transmission temperature gauge in the operator’s compartment. To bring the temperature to this level it is necessary to work the machine or to stall out the converter. To stall out the machine apply the brakes and engage the transmission control levers in the forward and high gear positions. Accelerate the engine to ½ to ¾ throttle. Hold the engine at stall until the desired outlet temperature is reached.

CAUTION Excessive transmission stall will overheat and damage the torque converter.

5) 6) 7) 8) 9)

Once the correct transmission oil temperature has been reached park the machine on flat, level ground and leave it running.

Place the transmission in neutral and apply the park brake.

The minimum converter outlet pressure is 172.4 kPa (25 psi) when the engine speed is 2000 RPM. The maximum converter outlet pressure is 482.6 kPa (70 psi) when the engine is at no load governed speed (2250 RPM).

Shutdown the machine, allow sufficient time for the transmission to cool, remove the pressure gauge and replace the test port plug.

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Clutch Pressure The clutch pressure is measured from the clutch pressure port on the top of the transmission.

The normal clutch pressure operating range is 1680 kPa to 1930 kPa (240 psi to 280 psi).

To check the transmission clutch pressure: 1) Release the park brake as the transmission is fitted with a park brake actuated declutch valve in the forward and reverse directions and pressures will not be a true reading.

2) Allow the transmission oil to warm up to 82.2 °C to 93.3 °C (180 °F to 200 °F).

3) With the brake applied and the engine at idle speed (800 RPM) shift through the directional and gear clutches taking note of the pressures indicated at each shift.

4) All clutch pressures must be within 35 kPa (5 psi) of each other. If pressure varies outside the 35 kPa tolerance then clutch repair is required.

Transmission Assembly

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FRONT AND REAR AXLES General description The only difference between the front and rear axles is the mounting arrangement. The front axle is rigidly mounted to the front frame and the rear axle is mounted via a bolster to allow an 8° side to side pivot.

The axle assembly consists of a spiral bevel type ring gear and pinion in the centre section with further reduction via a planetary gear set within each wheel hub. Both of the differentials are limited slip. These differentials contain a set of discs that are mounted between the differential side gears and differential case. These discs limit the amount of differential according to the amount of torque transmitted through the differential assembly. As the discs wear through normal use, the side gears move further outward however the differential is self-adjusting or self-compensating. It is extremely important that the oil level is kept at the level plug because if the level becomes too low the discs will not receive sufficient lubrication premature wear will result.

Both differential centres are described as Posi-Torque with springs. The differentials are both limited slip. Posi-Torque performs in a range dependent upon the size and design variation of the differential.

The inclusion of springs creates pressure on the clutch plates that can increase the tractive effort to the high traction wheel to as much as five times over the wheel with the poor traction. As operating conditions improve and the torque level in the axle increases, the effect of the springs diminishes and the bias ratio declines.

The wheel ends are also fitted with multi-disc liquid cooled brakes. The brakes are fitted with a lining wear indicator to measure the wear of the disc and inform service personnel when it is necessary to replace them.

Safety precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS allow the differential and wheel ends an opportunity to cool down before servicing.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing ALWAYS clean up any spilled oil immediately to remove the potential for slip or fall injuries.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys and drive lines) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

ALWAYS carry out the correct lifting and/or chocking procedure if access underneath a supported machine is required.

NEVER access underneath the machine unless it has been isolated and tagged as appropriate and the wheels have been chocked.

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CHECKING/FILLING THE PLANETARY WHEEL END OIL LEVEL Care and Maintenance The planetary wheel end oil levels should be checked and topped up if required every 250 service hours.

To check the oil level of the planetary wheel ends: 1) Run the machine for approximately five minutes to heat the oil.

2) Park the machine on flat, level ground. The wheel end should be orientated as per the label on its outside face.

3) Allow it to stand for a minimum of five minutes. Doing this will allow the oil to drain back to its normal level.

NOTICE The machine will have to be driven forward or backward to achieve the correct orientation for each wheel end.

4) 5)

6) 7) 8) 9)

Isolate and tag as described in Section 1.

Locate the planetary wheel end filler plugs on the outside face of the planet carriers. If necessary clean the areas to minimize the possibility of any contaminants getting into the system. When the level is measured in the wheel ends the oil fill plugs should be in the 3 o’clock position. Move the machine either forward or reverse to achieve this.

Allow five minutes settling time then remove the oil filler plug.

The oil levels should be to the bottom of the filler hole. If not, fill up with the lubricant specified in Section 1.

Allow a few minutes for the lubricant to attain its level as it flows through the various internal compartments and recheck the levels on each wheel end. Add lubricant if necessary.

Reinstall the filler plug, ensure o-ring is in good condition (replace as necessary).

NOTICE The self-contained liquid cooled brake system uses the same lube as the axle centre section and wheel ends. There are no seals between the spindles and wheel hubs. Oil that lubricates the differential and planetary wheel ends also lubricates and cools the brake assembly. The oil level is the same height as the planet and axle centre and the brake may be filled and the oil level checked at the planet carrier assembly or planet carrier cover.

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CHECKING/FILLING THE AXLE CENTRE OIL LEVEL Care and Maintenance The oil level at the front and rear axle centres should be checked and topped up if required every 250 service hours.

To check the oil level of the axle centres and planetary wheel ends: 1) Run the machine for approximately five minutes to heat the oil.

2) Park the machine on flat, level ground. The wheel end should be orientated as per the label on its outside face. Allow it to stand for a minimum of five minutes. Doing this will allow the oil to drain back to its normal level.

3) Isolate and tag as described in Section 1.

4) Locate the axle centre filler plug adjacent to the differential and carrier assembly. If necessary clean the areas to minimise the possibility of any contaminants getting into the system.

5) Allow five minutes settling time then remove the oil filler plug.

6) The oil levels should be to the bottom of the filler hole. If not, fill up with the lubricant specified in Section 1.

7) Allow a few minutes for the lubricant to attain its level as it flows through the various internal compartments and recheck the levels on each wheel end. Add lubricant if necessary.

8) Reinstall the filler plug; ensure o-ring is in good condition (replace as necessary).

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CHANGING OIL IN AXLE CENTRES, WHEEL ENDS AND LIQUID COOLED BRAKES Servicing The oil in the axle centres, wheel ends, and liquid cooled brakes is to be changed every 1000 service hours.

To change the oil perform the following: 1) Run the machine for approximately five minutes to heat the oil.

2) Park the machine on flat, level ground. The wheel end should be orientated as per the label on its outside face. Allow it to stand for a minimum of five minutes. Doing this will allow the oil to drain back to its normal level.

3) Isolate and tag out as described in Section 1.

4) Drain each wheel end: rotate each wheel end until the filler hole is at the lowest point on the housing. If necessary clean around the filler hole to minimise the possibility of contaminants entering the system. Place a suitably sized container beneath the filler hole (the volume in each wheel end is approximately 4.7 litres). Remove the filler plug. Allow sufficient time for the wheel end to drain completely.

5) Drain the brake housings: if necessary clean around the drain plug beneath the bottom of the brake housing and inlet plug beneath the bleeder screw to minimise the possibility of contaminants from entering the system. Place a suitably sized container beneath the drain plug (the volume in brake housing is approximately 4.7 litres). Remove the drain plug and the inlet plug from the brake housing. Allow sufficient time for the housing to drain completely. Replace the drain plug.

6) Drain the axle housing: if necessary clean around the drain plug on the bottom of the housing and oil filler plug adjacent to the differential and carrier assembly to minimise the possibility of contaminants from entering the system. Place a suitable size container beneath the drain plug (the volume of the differential centre is approximately 34.5 litres). Remove the drain plug and allow sufficient time for the housing to drain completely. Inspect the magnetic drain plug. If there is a considerable increase in the amount of metal particles found on the magnetic drain plug this indicates the necessity to replace the disc inside the limited slip differential centre.

Replace the drain plug with Loctite Pipe Sealant with Teflon. Tighten to 41-47 Nm. 7) Refill the wheel ends: The wheel ends should be orientated as per the label on its outside face.

Fill the wheel ends to the bottom of the filler holes with the lubricant specified in Section 1.

8) Refill the axle housing: fill the axle housing to the bottom of the filler hole with the lubricant specified in Section 1.

CAUTION After filling has been completed wait a few minutes for the lubricant to attain its actual level. Recheck the oil level and add lubricant if necessary.

9)

Reinstall the fill plugs with Loctite Pipe Sealant with Teflon if they have a tapered thread and apply o-ring grease to UN o-ring type plugs. Torque to 41-47 Nm.

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CHECKING WEAR OF THE POSI-STOP BRAKE ASSEMBLIES Care and Maintenance The wear indicator on the brakes should be inspected every 50 service hours.

Each Posi-Stop brake housing assembly is fitted with its own brake wear indicator. The lining wear indicator is located on the inside of the brake housing beneath where the axle centre is attached on to the brake housing.

Checking Brake Wear 1)

The machine must be parked on a level surface with lift arms lowered to the ground or all attachments removed.

2) Isolate and tag as described in Section 1.

3) Using minimal force and a suitable drift and hammer, the indicator should be tapped in until it comes to a stop, the amount of indicator that remains protruding is the amount of brake wear that is still present in the brake pack.

As the discs wear the indicator pin will be able to be pushed further into the mounting nut and when it is flush with the mounting nut face the discs should be replaced.

The wear indicator pin can seize in the mounting nut when the brakes are operated in dusty environments and therefore the pin will not show the true condition of the discs. Remove the indicator and free up the pin. Brake performance should be monitored with testing equipment. If the performance is deteriorating and the pin is protruding the wear indicator pin will need to be repaired or replaced.

Brake Wear Indicator

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DRIVE LINES General Description There are five drive shafts used on the machine.

Upper Drive Line The upper drive line transmits power from the output of the engine drive coupling via a drive line to the input of the converter which is an integral part of the transmission.

The upper drive line consists of a tube assembly, slip joint assembly and two universal joints. The drive line also has two safety brackets either side of the slip joint assembly to retain the assembly should a universal joint fail.

Rear Drive Line The rear drive line transmits power from the transmission to the rear axle. It consist of a tube assembly, slip joint assembly and two universal joints.

Articulation and Front Drive Lines The front drive line transmits power from the transmission to the front axle. The front drive line consists of two drive shafts that allow for the machine to articulate. The first drive shaft is attached to the output at the front of the transmission and consists of a tube assembly, slip joint assembly, bearing carrier assembly and two universal joints. The second drive shaft attaches between the first drive shaft and the third drive shaft and consists of a tube assembly, slip joint assembly and two universal joints. The third drive shaft attaches between the second drive shaft and bolts to the front axle and consists of a tube assembly, slip joint assembly, a carrier bearing and two universal joints.

Transmission - Articulation Drive Line

Upper or Input Driveline

Rear Drive Line

Front Axle Drive Line

Driveline Carrier Bearings

NOTICE Later model machine drive lines are fitted with grease for life Unijoints.

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Safety precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS chock all wheels before removing any of the drive lines.

ALWAYS be careful of hot surfaces when accessing the drive lines.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing.

ALWAYS clean up any spilled grease immediately to remove the potential for slip or fall injuries.

ALWAYS fit the articulation lock before commencing work on the drive lines.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

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GREASING AND INSPECTING DRIVE LINES Care and Maintenance The drive lines are to be lubricated at every weekly service. Failure to maintain proper lubrication is one of the most frequent causes of drive line failure. Lubrication of the drive line points is important due to the large loads that the needle bearings in the universal joints transmit.

Lubricant should be applied with either a hand operated grease gun or a pressure gun. The specification of the lubricant can be found in Section 1.

To lubricate and inspect the drive lines perform the following: 1) Park the machine on flat, level ground. Ensure the machine is in a straight line.

2) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

3) Lubricate each universal joint until grease is visible at the journal cross bearing caps. This will ensure the grease will fully lubricate the universal joint and purge the old lubricant.

4) Using a small pinch or wrecking bar check the flanges on the transmission and differential flanges for tightness. If either is loose drop that end of the drive shaft. Twist the flange to check any backlash between the splines and the flange. Replace any flange that is not a snug fit. If there is play in any of the universal joints replace it. Inspect the splines at the slip joints and replace that drive shaft if there is excessive wear. If the front drive line is removed, take off the carrier bearing and inspect it for wear.

5) Inspect the tightness of the bolts in the universal joints and if necessary re-tighten to the correct torque (see Section 1).

6) Check the condition of the rubber boots over the slip joints and ensure they are properly secured.

7) Grease the slip joints.

8) Grease the carrier bearing on the front drive shaft.

REMOVING AND INSTALLING THE REAR DRIVE LINE Removing the Rear Drive Line To remove the rear drive shaft: 1) Park the machine on flat, level ground. Ensure the machine is in a straight line.

2) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

3) Support the drive shaft.

4) Remove the bolts from the universal joints at the transmission and rear differential.

5) Compress the drive shaft at the slip joint using a small pinch or wrecking bar.

6) Lower the drive shaft out of position.

Installing the Rear Drive Line To install the rear drive shaft perform the following: NOTICE All drive shafts are to be installed so that the solid shaft end of the slip joint is attached to the power output and the tube end attaches to the input.

1) 2) 3)

Make sure that the yokes are aligned in the same direction. If they are not aligned they will be out of phase and cause excessive vibration.

Raise each end into position and bolt together.

Tighten the bolts to the appropriate torque (see Section 1).

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REMOVING AND INSTALLING THE FRONT DRIVE LINES Removing the Front Drive Lines To remove the front drive shafts perform the following: 1) Park the machine on flat, level ground. Ensure the machine is in a straight line.

2) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

3) Remove the intermediate drive line by removing the bolts on the universals.

4) Compress the drive shaft at the slip joint using a small pinch or wrecking bar.

5) Remove the intermediate drive shaft from the machine through the articulation point.

6) Remove the universal bolts on the transmission-intermediate drive shaft attached to the transmission yoke. Then support the drive line and remove the carrier bearing support bolts.

7) Lift the drive shaft out of position.

8) Remove the bolts connecting the front drive line to the front universal. Then support the drive line and remove the carrier bearing support bolts.

9) Lift the drive shaft out of position through the articulation joint.

Installing the Front Drive Lines To install the front drive shafts perform the following: 1) Lift the front drive line into position and install the universal bolts to the yoke on the differential.

Tighten the bolts to the appropriate torque (see Section 1). Then support the drive line and install the carrier bearing support bolts.

2) Install the universal bolts on the transmission-intermediate drive shaft attached to the transmission yoke. Tighten the bolts to the appropriate torque (see Section 1). Then support the drive line and install the carrier bearing support bolts.

3) Install the intermediate drive line by installing the bolts on the universals. Tighten the bolts to the appropriate torque (see Section 1).

NOTICE All drive shafts are to be installed so that the solid shaft end of the slip joint is attached to the power output and the tube end attaches to the input. Make sure all the yokes are aligned in the same direction. If they are not aligned they will be out of phase and cause excessive vibration.

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REMOVING AND INSTALLING THE UPPER DRIVES LINES Removing the Upper Drive Line To remove the upper drive line then perform the following: 1) Park the machine on flat, level ground. Ensure the machine is in a straight line.

2) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

3) Support each drive shaft at both ends.

4) Remove the bolts from the universal joints at either end of the drive shaft.

5) Unbolt the safety brackets from either end of the drive line.

6) Compress the drive shaft at the slip joint using a small pinch or wrecking bar.

7) Raise the drive shaft out of position.

Installing the Upper Drive Line To install the upper drive line perform the following: NOTICE All drive shafts are to be installed so that the solid shaft end of the slip joint is attached to the power output and the tube end attaches to the input..

1) 2) 3)

Make sure all the yokes are aligned in the same direction. If they are not aligned they will be out of phase and cause excessive vibration.

Lower the drive shaft into position and fasten the safety brackets into position. This will hold the drive line in position as the universal joints are bolted together.

Tighten the universal bolts to the appropriate torque (see Section 1).

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WHEEL AND TYRE ASSEMBLIES General DESCRIPTION There are three different combinations of wheel and tyre assemblies available. See Section 1 Specifications for wheel assembly options.

Safety precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS wear personal protective equipment including safety glasses, gloves and suitable clothing.

ALWAYS allow sufficient time for the engine, cooling system, and exhaust system sufficient time to cool before commencing work as burns may result with contact with hot surfaces.

ALWAYS fit the articulation lock before removing/installing the tyre/wheel assemblies.

ALWAYS ensure the area around the machine is safe. For example do not change the wheel against a rib to prevent the possibility of being pinned.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

NEVER access underneath the machine unless the machine has been isolated and tagged as appropriate and the wheels have been chocked.

Removal To remove the wheel and tyre assemblies perform the following: 1) Remove any attachments and lower the lift arms to the ground 2) Park the machine on flat, level ground. Ensure the machine is in a straight line.

3) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

4) Check that both the steering and brake pressure gauges in the operator’s compartment are reading zero pressure.

5) Raise the wheel to be changed with a suitable rated device (e.g. chain block, hydraulic jack, air bag, etc). See diagram for the suitable lifting and support points for the machine’s chassis.

6) Place the machine on suitable stands or blocks that will allow the removal of the wheel.

7) Remove the 32 wheel bolts and remove the wheel assembly from the wheel end.

8) Using suitable lifting equipment, remove the wheel assembly. If the wheel is difficult to remove, insert ¾" UNC jacking bolts into the four threaded holes around the wheel rim. The threaded holes are on a slightly smaller PCD. Evenly screw the bolts in, to jack the wheel away from the wheel end.

WARNING DO NOT rely on the lifting equipment alone to support the machine when working beneath it. The machine MUST be supported by stands or similar.

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NOTICE These are recommended jacking, chocking, lifting and tow positions for anything outside this scope contact Bucyrus.

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Installation To install the wheel and tyre assemblies to the machine perform the following: 1) Check the wheel studs for any damage and replace any damaged or missing wheel studs.

2) Apply anti-seize compound to the wheel studs.

3) Clean all parts and mating surfaces. Remove all sharp edges and burrs. Apply anti-seize compound to all mating surfaces.

4) Raise the wheel assembly over the wheel end and align the tyre valve with the notch in the flange on the wheel end.

5) Fit the 32 wheel bolts and hard washers.

6) Tighten the wheel nuts to a torque of 440 Nm (325 ft lbs) using the sequence shown.

NOTICE The first 50 hours after installing a new wheel, loosen the wheel nuts and re-tighten them back up to 440 Nm.

Wheel Nut Tightening Sequence

Care and Maintenance Daily service: visually inspect each tyre assembly for wear or damaged tread and side wall or rim.

Every 250 service hours check tyre pressure using a good quality pneumatic tyre pressure gauge.

Every 1000 service hours re torque each wheel nut.

NOTICE All wheel rims to be crack tested whenever a new tyre is fitted.

Damaged or heavily corroded rims and components should not be reused.

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Section

4

Hydraulic System GENERAL DESCRIPTION This section describes the functional operation of the hydraulic system and contains the procedures for performing basic maintenance and servicing of the major components within the system.

The machine’s hydraulic system consists of four independent circuits that are supplied from a common reservoir. The reservoir is pressurised to 50 kPa to prime the four hydraulic pumps and aid in reducing foreign contaminants into the system.

These circuits are the steering and brake circuit, the main implement hydraulic circuit and the auxiliary circuits for the cooling fan drive and alternator drive.

Steering Brake Circuit The steering and brake circuit is supplied from a pressure compensated/variable displacement piston pump driven from the output of the transmission torque converter. Circuit filtration is via a pressure filter, which has a 354 kPa (51 psi) bypass feature. Oil is fed into a main steering and brake circuit manifold where a system relief valve set at 20.7 MPa (3000 psi) is provided for circuit protection. The pump pressure compensator is set at 17.24 Mpa (2500 psi). The circuit is split to separate steering and brake circuits. Both circuits are fitted with hydraulic accumulators which act as pressure storage.

This allows the pump not to have to come on stroke with every application of the brakes or steering.

The brake circuit is interlocked with the pneumatic system for automatic and manual application and release of the spring applied hydraulic release Posi-Stop brakes. Braking is achieved via actuation of the brake pedal reverse modulating valve which bleeds pressure from the Posi-Stop brakes proportional to the pedal stroke.

The steer circuit is controlled via an orbital control valve that directs oil to the steering valve bank to supply oil to the steering cylinders.

The steering and brake manifold also supplies a pilot pressure, reduced to 4.5 MPa (650 psi), to the 4-way joystick and 2-way joysticks that operate the pilot control functions for the Lift, Tilt, Winch and PTO sections in the main implement valve bank.

Main Hydraulic Circuit The main hydraulic circuit is supplied via fixed displacement gear pump driven from an output of the transmission torque converter. Hydraulic oil is supplied to the open centre main valve bank at a fixed displacement, depending on engine speed. System relief of 22.6 MPa (3200 psi) is provided at the inlet to the main valve bank.

Each working section of the valve bank is fitted with port relief valves. The working sections of the main hydraulic valve bank control; lift and tilt (lift arms) and the various attachment functions when fitted. These are pilot activated via a four-way joystick control lever for the lift and tilt. The attachment functions are controlled by 2 two-way hydraulic control levers. Relief pressure is via separate inline port relief valves and the main relief valve all situated in the valve bank.

Auxiliary Circuits There are two auxiliary circuits on the FBL55H, one for the cooling fan and one for the alternator drive circuit. These are supplied by a tandem pump driven from the transmission.

Fan Circuit The fan motor receives a constant flow of 87 lpm at 2600 RPM. Hydraulic oil is supplied through the fan motor which then returns back to tank. There is a pressure relief in the anti-cavitation block mounted on the fan motor set at 20.7 MPa (3000 psi).

Alternator Circuit The alternator motor is supplied oil through a logic block to control the speed of the alternator to a maximum of 4000 RPM.

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Beltana FBL-55H Service Manual Hydraulic schematic 888003rev2

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SAFETY PRECAUTIONS NOTICE All personnel performing maintenance tasks on this machine should have been trained, assessed and be deemed competent.

They should be appointed by the mine management.

The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS Give the engine an opportunity to cool down before performing servicing around the rear frame as engine components around this location are hot and could cause burns or scalding.

ALWAYS Be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys and drive lines) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure, hydraulic oil pressure and other heat sources such as engine block and exhaust system components.

ALWAYS Install the articulation lock when accessing the machine articulation area as machine articulation will result in crush injuries.

ALWAYS Install the lift arm lock when access underneath the lift arm assembly is required.

Remove any attachments before raising and locking the lift arm assembly.

NEVER Assume that all forms of energy have been isolated unless you have confirmed for yourself.

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HYDRAULIC ISOLATION To isolate the hydraulic system perform the following procedure: 1) Lower the lift arms or any attachment to the ground, shutdown the engine, fit a danger tag to the on/off toggle switch, connect the articulation lock and chock the wheels.

2) Depress the attach quick connects button located in the operator's compartment. This will remove any residual pressure stored in the PTO lines.

3) Observe both steering and brake pressure gauges located in the operator's compartment. The hydraulic system features a steering and brake accumulator automatic bleed circuit which will remove hydraulic pressure from both accumulators once the engine has stopped. This normally takes around 30 seconds. The steering and brake accumulators can also be bled via rotation of the steering wheel and actuation of the brake pedal, once the engine has been shutdown.

4) Remove hydraulic tank pre-charge pressure (50 kPa) by cracking hydraulic tank filler cap.

Brake Accumulator Pressure Gauge Steering Accumulator Pressure Gauge

Right Hand Side Operators Display Panel

WARNING Serious injuries can occur from hydraulic oil under pressure.

Always ensure that the hydraulics are isolated and safety eyewear is worn when working on hydraulic systems.

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PUMPS AND MOUNTINGS Brake / Steer Pump The brake / steer pump is a pressure compensated piston pump. While system pressure is below the pressure setting, full flow is available from the pump. When system pressure reaches or exceeds the preset value the pump is de-stroked to maintain the pressure setting. The brake / steer pump is mounted on the drivers side of the transmission.

The compensator pressure setting should be checked by the operator daily, by checking the pressure on the steering and brake accumulator gauges.

To adjust the brake / steer pump compensator pressure setting: 1) Park the machine in a clear area, apply the park brake and install the articulation lock and chock the four wheels.

2) With the engine running at idle, release the park brake, access the steering/brake pump by removing the transmission cover and locate the pressure compensator adjustment on the back of the pump housing.

3) Loosen the grub screw locking the pressure compensator adjusting screw nut and rotate the adjusting screw clockwise to increase the compensating pressure or counter-clockwise to decrease the compensating pressure.

4) Pressure can be observed at either the steering or brake accumulator pressure gauges located in the operator’s compartment, alternatively a gauge may be fitted into the test port on the steering/brake manifold.

5) When the correct pressure is set tighten the grub screw locking the adjusting screw

Adjustor locking grubscrew Compensator adjusting screw

Brake / Steer Pump Pressure Compensator Adjustment

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Implement Pump Auxiliary pump

Brake /Steer Pump

Steering and Brake Pump

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Installation Pump Priming: When mounting the pump on the transmission the fluid level is below the mounting position, carry out the priming procedure 1) Disconnect the case drain hose from the pump 2) Charge the hydraulic tank via the recharge valve located on the top of the tank to ensure there is 50 kPa of air pressure in the tank to assist in pushing the hydraulic fluid through the suction hose.

3) When a constant flow of oil is coming out of the case drain fitting reconnect the hose 4) Start motor and run until pump primes or a maximum of 30 seconds. If pump does not prime in 30 seconds, stop motor and repeat until pump primes.

WARNING DO NOT run the pump if in a dry state as this will reduce its service life.

Case Drain Fitting

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Main Hydraulic Pump The main hydraulic pump is single section, fixed displacement gear type that has a fixed flow rate dependant on engine speed. Oil is fed from the suction side of the pump and directed to the pressure port via the internally rotating gear. Flow is independent of system pressure and the circuit is connected as open centre with oil passing through the main control valve and back to tank when the implement spools are in the neutral position.

Pressure Line Out

Main Hydraulic Pump

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Auxiliary hydraulic pumps The auxiliary pumps are fixed displacement gear pumps piggybacked using the same suction line supply.

The first section supplies the fan motor and is fitted with an inline relief valve set at 20.7 MPa and anti-cavitation make up check. The second section supplies the alternator drive motor and the circuit is regulated by a logic manifold for maximum motor speed control and circuit overpressure via arelief valve set at 19.3 MPa.

Auxiliary Pumps

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HYDRAULIC TANK Checking and filling hydraulic oil The hydraulic oil tank is integral with the rear frame chassis and located on the off driver’s side. The oil level should be checked daily.

To check the hydraulic oil level: 1) Locate the sight gauge on the hydraulic tank side wall on the off driver’s side of the machine.

2) Observe the oil level indicated in the sight glass. The level should be adjusted if the oil level is below the top of the sight glass.

To top up the hydraulic oil level: 1) Locate the hydraulic tank filler cap on the rear frame on the off driver’s side. The cap is accessible from outside the machine.

2) Slowly unscrew the filler cap to release air pressure from the tank.

WARNING The hydraulic tank is charged with 50 kPa of air pressure. Hot hydraulic fluid can cause burns or scalding. Wear eye protection and long sleeve clothing when accessing the oil filler cap.

3) 4) 5) 6)

Remove the filler cap and top up the hydraulic tank with clean oil to the specification shown in Section 1.

Observe the oil level on the sight glass rise as oil is added to the tank. Do not over fill.

Replace the filler cap when filling is complete.

Locate the pre-charge valve on the hydraulic tank, above the sight glass and outside the machine covers, and apply an external air pressure above 50 kPa (7.25 psi) until bypass is evident at the filler cap. This will provide the required pre-charge to the hydraulic tank.

Hydraulic Tank Sight Glass

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Changing Hydraulic Oil The hydraulic oil should be changed every 2000 service hours.

To change the hydraulic oil: 1) Park the machine in a straight line and ensure all other cylinders except for the steering cylinder are fully retracted.

2) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described on Section 1.

3) Release hydraulic tank pressure by slowly removing the filler cap.

4) Remove the filler cap to allow breathing when draining hydraulic oil.

5) Locate the hydraulic tank drain plug on the underside of the hydraulic tank.

6) Place a suitable container under the drain plug. The hydraulic tank contains approximately 400 litres.

7) Remove the drain plug and allow hydraulic oil to drain out of the tank.

8) When the oil has drained from the tank remove the inspection covers from the tank wall to enable the inside of the tank to be accessed. Clean around the floor of the tank with clean lint free rags.

9) Replace the inspection cover and the drain plug then refill the tank.

CAUTION Ensure that the hydraulic pumps are primed after refilling the hydraulic tank. Failure to prime pump will result in pump failure.

Fill Cap

Pre-charge Valve

Sight Glass

Drain Plug

Inspection Cover

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Checking and cleaning filler neck screen The hydraulic tank fill point is fitted with a screen for filtering large contaminants that may be introduced during the filling process. This screen is not intended to provide system filtration but rather as a preventative measure to screen contaminants from the system, such as large dirt or rock particles accidentally introduced via a filling hose.

The filler neck screen should be removed and cleaned every 250 service hours.

To remove and clean the filler neck screen: 1) Locate the hydraulic tank filler cap on the top of the hydraulic tank.

2) Slowly unscrew the filler cap to release air pressure from the tank.

WARNING The hydraulic tank is charged with 50 kPa of air pressure. Hot hydraulic fluid can cause burns or scalding. Wear eye protection and long sleeve clothing when accessing the oil filler cap.

3) 4) 5) 6) 7)

Remove the filler cap and locate the filler neck screen inside the filler neck.

Remove the filler neck screen from the filler neck.

Clean the screen with fuel oil and inspect for damage. Replace if necessary.

Relocate the screen inside the filler neck and replace the filler cap.

Locate the pre-charge valve on the hydraulic tank, to the rear of the return filter on the top of the hydraulic tank, and apply an external air pressure above 50 kPa (7.25 psi) until bypass is evident at the filler cap. This will provide the required pre-charge to the hydraulic tank.

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Checking and replacing the return filter The hydraulic system return filter is flange mounted onto the hydraulic tank, on the opposite end to the filler cap, with the filter bowl assembly inside the tank. Return oil enters the filter housing and passes through a ten micron filter element before entering the tank. The filter element will be bypassed when the return pressure differential reaches 172 kPa (25 psi).

The return filter indicator should be checked every 250 service hours and filters replaced if necessary.

CAUTION The filter element should be replaced on the 250 hour service.

Failure to carry out this will result in return filter bypass and possible system contamination.

To replace the return filter element: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Release hydraulic tank pressure by slowly removing the filler cap.

3) Locate the return filter housing on top of the hydraulic tank.

4) Undo the return filter cover bolts and remove the cover. Take care not to damage the cover spigot o-ring.

5) Remove the filter element and dispose of it in a responsible manner.

6) Insert the new filter element ensuring the element is seated over the bottom spigot in the bowl assembly.

7) Replace the cover and fasten the retaining bolts.

Filter Indicator

Filter Housing Lid

Filter Housing Hydraulic Return Filter Assembly

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STEERING AND BRAKE HYDRAULIC MANIFOLD The main hydraulic manifold interfaces the steering/brake pump to the steering and brake circuits and provides steering interlocking as well as accumulator automatic drain on loss of brake release pressure. The manifold also provides reduced pressure to the controls for the lift arm and attachment functions. Machine hosing is simplified with the manifold, providing only one tank return line and one pressure line connection.

The steering/brake system pressure is primarily governed by the compensated pressure setting of the steering/brake pump. The system normally is set to a compensated pressure of 17.2 MPa (2500 psi).

The system is backed up by a system relief valve mounted in the main hydraulic manifold set to divert flow to tank at a relief pressure of 20.7 MPa (3000 psi). The relief valve would not factor into normal system operation however, should a system failure occur the relief valve will limit available pressure to 20.7 MPa (3000 psi).

The steering/brake system relief valve setting should be checked at 2000 service hours.

To check and adjust the relief valve setting: 1) Park the machine in a clear area, apply the park brake and install the articulation lock and chock the wheels.

2) With the engine running at idle access the steering/brake pump by removing the transmission cover and locate the pressure compensator adjustment on the side of the pump housing.

3) Release the park brake.

4) Loosen the adjusting screw locking grub screw and rotate the adjusting screw clockwise to increase the compensating pressure.

5) Have an observer watch the steering or brake accumulator pressure gauge while increasing the pump compensating pressure.

6) When the pressure approaches 20.7 MPa (3000 psiI) the relief valve will operate forcing the pump to remain on stroke. If this is the case then the relief valve is correctly set.

7) If the pump fails to come off stroke it will be necessary to adjust the relief valve pressure setting.

8) Locate the relief valve on the main hydraulic manifold.

9) Loosen the lock nut and rotate the relief valve adjusting screw clockwise to increase the relief pressure and counter-clockwise to decrease the relief pressure.

10) When the correct main relief valve adjustment is achieved tighten the adjusting screw lock nut.

11) Adjust the compensator valve back and reduce the pressure in the system to below 2500 psi by working the steering or brakes.

12) Adjust the compensator on the steering/brake pump screw to bring the pressure back to 2500 psi when this is correct lock the compensator adjustment screw.

13) Refit the covers.

The main hydraulic control valve is supplied at reduced system pressure via a pressure reducing valve located in the main hydraulic manifold.

The pressure reducing valve setting should be checked every 2000 service hours.

To check and adjust the pressure reducing valve setting: 1) Ensure the machine is isolated and tagged as described in Section 1.

2) Ensure that both accumulators are completely drained of oil pressure as per Section 1.

3) Locate the main hydraulic manifold.

4) Locate port PJ on the main manifold block. This port is a supply port from the manifold to the hydraulic control joysticks at reduced pressure.

5) Remove the hose from PJ and install a pressure gauge with a full scale deflection of 6.89 MPa (1000 psi).

6) With the engine running at idle observe the pressure at the gauge. This pressure should read 4.5 MPa (650 psi).

7) If the pressure requires adjustment locate the pressure reducing valve on the main manifold.

8) Loosen the lock nut and rotate the reducing valve adjusting screw clockwise to increase the

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pressure and counter-clockwise to decrease the pressure.

9) When the pressure reaches 4.5 MPa (650 psi) the reducing valve is correctly set.

10) Tighten the adjusting screw lock nut, shutdown the machine, isolate hydraulic pressure, remove the gauge and reconnect the hose.

WARNING Ensure that all accumulator pressure is removed before disconnecting hydraulic hoses.

WARNING The drive line inside the compartment which contains the main manifold is rotating whenever the engine is running. Keep clear of the rotating parts when accessing this compartment with the engine running.

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Pilot supply port PJ

Main relief valve

Pressure reducing relief valve

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STEERING / BRAKE PUMP PRESSURE FILTER The hydraulic steering/brake system utilises a pressure inline filter which is remote mounted adjacent to the air cleaner. Fluid enters the filter housing and passes through a five micron filter element before entering the main manifold. A pop up type blocked filter indicator is located on the filter housing cover and indicates when the return pressure reaches 250 kPa (36 psi) and will bypass the filter element when the return pressure reaches 350 kPa (50 PSI).

The pressure filter indicator should be checked daily and the filter replaced every 250 hours or if red indicator is showing.

To check the condition of the pressure filter element: 1) Park the machine in a clear area, apply the park brake and install the articulation lock.

2) Locate the pressure filter housing adjacent the air cleaner.

3) With a helper in the operator’s compartment run the engine at high idle and depress the brake pedal several times to allow the brake accumulator to be drained and the pump to come on stroke.

4) Observe the position of the indicator on top of the housing cover when the pump is on stroke.

The indicator will be in the red position if the filter is blocked. As the indicator is an auto reset type, oil flow needs to be present through the filter for the indicator to sense differential pressure.

CAUTION Change the pressure filter element if the indicator is showing blocked. Failure to change the filter element will result in pressure filter bypass and possible contamination of the main manifold valves.

To replace the pressure filter element every 250 hours: 1) Ensure the machine is isolated and tagged as described in Section 1.

2) Ensure that both accumulators are completely drained of oil pressure as per Section 1.

3) Access the filter housing via the air cleaner compartment.

4) Locate the pressure filter housing adjacent to the air cleaner.

5) Undo the pressure filter by unscrewing the filter cover from the housing.

6) Remove the filter element and dispose of in responsible manner.

7) Insert the new filter element ensuring the element is seated on the spigot.

8) Replace the cover and tighten.

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Steering/Brake Pump Pressure Filter

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STEERING CIRCUIT The steering circuit consists of an oil accumulator, steering control unit, pilot operated steering valve, and a steering cylinder, this circuit enables the machine to be articulated. The operator controls the amount of articulation via rotating the steering wheel in the operator’s compartment. As the steering wheel is rotated oil flow is delivered to the respective cylinder ports at steering/brake pump pressure.

The steering cylinder is actuated at opposite ports to steer left and right, protection from external shocks is achieved by relief valves fitted in the pilot operated steering valve.

STEERING ACCUMULATOR The steering system accumulator provides reserve oil at pressure to provide emergency steering should a loss of pump pressure occur and is used to minimise the number of times the pump is required to come on stroke.

The accumulator has a 5.7 litre oil capacity and is of a piston type construction. Oil is fed into one end of the accumulator and is pressurised by compression of an internal piston against a pre-charge of nitrogen gas. The gas pre-charge pressure is preset at 6.2 MPa (900 psi). A poppet type gas valve is located at the top of the accumulator for checking and setting the pre-charge pressure. Access to the gas valve is via removal of a bolt on valve protector bracket. When the bracket is removed the gas valve is available for access.

The accumulator pre-charge pressure should be checked every 2000 service hours.

WARNING The pre-charge pressure should be maintained at 6.2 MPa (900 psi) when the accumulator is drained. Stored nitrogen under pressure may cause personal injury when expelled. Wear suitable eye protection when servicing accumulator pre-charge. DO NOT attempt to access the gas valve connection unless you are suitably trained in recharging pressure vessels and accumulators.

Oil Port

Gas Valve

Steering Accumulator

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STEERING CONTROL UNIT / PILOT OPERATED STEERING VALVE The orbital steering control unit controls the direction of flow of oil to and from the steering cylinder by acting as a pilot unit to deliver oil at low pressure and low flow to the EHPS steering valve. This is achieved at a metered rate and is unaffected by pump flow. The EHPS pilot operated steering valve is fitted with cross relief valves, set at 20.68 MPa (3000 psi) to provide pressure relief for the cylinder in the event of an excessive external force.

No routine servicing is required on the steering control unit and pilot operated steering valve other than routine checking for the presence of oil leaks. A service kit is available for seal and spring replacement and is detailed in the FBL-55H Parts Manual.

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Steering Control Unit

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BRAKE CIRCUIT The brake circuit consists of two parallel circuits, providing independent brake and park brake actuation. The system consists of an oil accumulator, brake reverse modulating valve and an air pilot operated valve located in the main manifold.

When the engine is running the pressure compensated pump charges the accumulator to system pressure. Actuation of the park brake release directs oil at system pressure into the brake reverse modulating valve where pressure is regulated to 10.3 MPa (1500 psi) and supplied to the spring applied pressure released brakes.

Actuation of the park brake will drain pressure and apply the brakes. Similarly actuation of the brake pedal will release brake pressure proportional to the stroke of the modulating valve push rod, actuated by the brake pedal. When the brake pedal is released oil pressure will be delivered to the brake units to a maximum of 10.3 MPa as set by the reverse modulating valve.

BRAKE ACCUMULATOR The brake system accumulator provides reserve oil at pressure to allow brake release operation should a loss of pump pressure occur and to minimise the amount of times the pump is required to come on stroke when actuating the brakes.

The accumulator has a 1.9 litre oil capacity and is of a piston type construction. Oil is fed into one end of the accumulator and is pressurised by compression of an internal piston against a pre-charge of nitrogen gas. The gas pre-charge pressure is preset at 6.2 MPa (900 psi). A poppet type gas valve is located at the top of the accumulator for checking and setting the pre-charge pressure. Access to the gas valve is via removal of a bolt on valve protector bracket. When the bracket is removed the gas valve is available for access. The accumulator pre-charge pressure should be checked every 2000 service hours.

WARNING The pre-charge pressure should be maintained at 6.2 MPa (900 psi) when the accumulator is drained. Stored nitrogen under pressure may cause personal injury when expelled. Wear suitable eye protection when servicing accumulator pre-charge. DO NOT attempt to access the gas valve connection unless you are suitably trained in recharging pressure vessels and accumulators.

Brake Accumulator

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BRAKE VALVE The brake pedal operates a brake valve which delivers oil to the brake units at a pressure, set by its own regulator, and proportionally dumps this pressure relative to the stroke of its actuating push rod when the operator applies the brakes.

The brake valve is mechanically linked to the brake pedal. Application of the brake pedal will stroke the valve push rod, removing pressure from the spring applied, hydraulic released brake units back to tank. The amount of pressure removed from the brake units, hence the severity of brake application, will be proportional to the stroke of the push rod.

When the brake pedal is released maximum regulated pressure (1650 psi-1750 psi) is delivered to the brake units, releasing the brakes.

Pressure regulation and reverse modulation is achieved via internal shimming inside the valve block head. No serviceable components exist in the brake valve. If the brake head pressure, indicated by the pressure gauge in the operator’s compartment is outside the normal operating range the valve should be replaced.

A high pressure delivered to the brake heads can damage the piston seals.

A pressure below 1600 psi will cause the brake plates to drag cause heat build up and excessive wear. The brake valve should be resealed and bench tested every 5000 hours.

Brake head pressure should be checked daily.

To verify brake head pressure: 1) With the machine running release the park brake.

2) Remove your foot from the brake pedal and record the brake head pressure on the gauge in the operator’s compartment.

3) Brake head pressure should be 1750psi.

4) Remove and replace the brake valve if release pressure is outside this range.

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Disassembly: 1) 2) 3) 4) 5) 6)

7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18)

19) 20) 21) 22) 23) 24)

Depress pedal and remove pedal stop screw and jam nut from base. Also loosen jam nut for later removal of clevis.

Remove cap screws and lock washers from base.

Remove e-rings from ends of pins. Remove pins.

NOTE: Some models use threaded studs, in place of pins and e-rings.

Remove set screw from pedal. Remove e-rings from both ends of pin.

NOTE: Not all models use e-rings.

Separate pedal and base by removing pin through clearance hole in pedal. Remove pedal and base.

Temporarily insert pin into clevis and record distance from top of pin to mounting flange of housing. This measurement will be necessary for reassembly purposes.

NOTE: Apply slight downward force on clevis while taking measurement to assure that rod is in contact with piston.

Remove clevis and jam nut from rod.

Separate housings by removing cap screws and lock washers.

Remove rod, piston, spring, spring and washer from housing. Remove boot (2) from housing.

NOTE: Not all models use spring or washer.

Remove piston, shim(s) (6) and spring (7) from housing bore. Note number of shims being removed for reassembly purposes.

Remove o-ring (2) from housing bore.

NOTE: Be careful not to scratch or mark the housing bore.

Remove retaining ring from housing bore NOTE: Be careful not to scratch or mark the housing bore.

Remove retainer from housing bore.

Remove retaining ring (2) from housing bore.

Remove piston and sleeve assembly (5) from housing bore. Separate piston (5) from sleeve.

Remove o-ring (2) and backup ring (2) from sleeve.

Remove spring from housing bore.

Remove cup (2) and backup ring (2) from piston (5).

NOTE: A check ball is located inside piston (5). Make sure ball is clean and moves freely. Some models use an o-ring in place of cup (2) and backup ring (2).

Remove plug from housing.

Remove o-ring (2), cup (2), backup ring (2), washer, spring and guide (4) from plug.

NOTE: Some models use an o-ring in place of cup (2).

Remove cage (2) from housing bore.

Remove valve assembly (3) from housing bore.

Remove o-ring (2) from valve assembly (3).

Remove plug and ball (2) from housing. Remove o-ring (2) from plug.

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Assembly: Clean and inspect all parts for wear. Lubricate all rubber components from repair kit with clean system fluid.

1) Install new o-ring (2) on plug. Install new ball (2) and plug in housing. Torque plug 88.1-101.7 N-m (65-75 Ib-in).

2) Install new o-ring (2) on valve assembly (3) and insert into housing bore. Note the direction of valve assembly.

NOTE: Be sure valve assembly seat is fully seated into housing.

3) Install new cage (2) into housing bore.

4) Install new o-ring (2) on plug.

5) Insert new backup ring (2) and new cup (2) inside end of plug. Note order of back up ring and cup.

NOTE: Some models use an o-ring in place of cup (2).

6) Install guide (4), spring and washer in end plug. Install plug in housing and torque 54.3-67.8 Nm (40-50 Ib-ft).

7) Install new cup (2) and new backup ring (2) on piston (5) and insert into sleeve. Note direction of piston and sleeve.

NOTE: Some models use an o-ring in place of cup (2) and backup ring (2).

8) Install new backup ring (2) and new o-ring (2) on sleeve.

9) Install spring on piston (5).

10) Install piston and sleeve assembly (5) in housing bore. Note direction of assembly.

11) Install new retaining ring (2) in housing bore.

12) Install retainer and retaining ring in housing bore.

NOTE: Be careful not to scratch or mark housing bore 13) Install new o-ring (2) in housing bore.

14) Install spring (7), shim(s) (6) and piston in housing bore. Be sure to install the same number of shim(s) as were removed during disassembly.

15) Lightly coat inside bore of housing with graphite based grease and install new boot (2) on housing.

16) Apply graphite based grease sparingly to piston in chamfered area where rod makes contact.

17) Insert rod, piston, spring, spring and washer into housing (34). NOTE: Not all models use spring or washer.

18) Attach housings using cap screws and lock washers. Torque 29.8-36.6 N-m (22-27 Ib-ft).

19) Install jam nut and clevis on end of rod. Adjust the clevis to the distance recorded during disassembly. Lubricate all bushings and pins with graphite based grease before assembling the pedal and base.

20) Fully depress pedal and torque jam nut 27.1-32.5 N-m (20-24 Ib-ft) against clevis.

21) Install pedal stop screw and jam nut.

NOTE: With pedal in the release position, adjust pedal stop screw and jam nut so there is .38 mm-.76 mm (.015"-.030") of clearance between the pedal and top of pedal stop screw. Torque jam nut 27.1-32.5 N-m (20-24 Ib-ft).

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BRAKE UNITS The brake units are located behind each wheel.

The brakes are released by supplying oil from the brake valve at a pressure of 1750 psi. This pressure is shown in the operator’s compartment on the brake head pressure gauge. Pressurised oil is supplied to the brake heads via the brake; this oil exerts pressure against the springs by means of a piston in the brake heads.

When the brake is applied oil is dumped back to tank and the springs in the brake head force the pressure plate against the fiction disc thus applying the brakes.

Brake Seals

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Hydraulic Release Pressure In

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ATTACHMENT CONTROLS Control Levers Three separate control levers are provided in the operator’s compartment. These controls operate the machine’s lift and tilt functions, operate the attachments and winch.

The four-way joystick control operates the machine’s lift and tilt functions. The lever has five positions tilt back, tilt forward, lift, lower and hold. The lever is spring centered to the hold position.

The No. 1 and No. 2 two-way hydraulic control levers operate the winch and PTO. These levers have three positions up, down and hold. The levers are spring centered to the hold position.

The oil pressure for these controls is supplied from the main control manifold at a reduced pressure of 650 psi.

No. 1- Two-Way Hydraulic Control Lever

No. 2- Two-Way Hydraulic Control Lever

Two-Way Control Levers

Four Way Joystick

Maintenance Inspections are to be carried out on the four-way joystick and two-way control levers as per Preventative Maintenance Inspection Schedules.

1) Inspect the control lever boots for damage.

2) Inspect operational performance.

Replace any worn or damaged parts and retest the operation of the machine or system.

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Pilot Pressure Supply to Pilot Control Valves Pressure Reducing Valve Set at 650 PSI.

Lift Arm Control Valve

No 1 Winch Valve

No 2 PTO Valve

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MAIN CONTROL VALVE BANK The main control valve bank is an open centre, four section configuration, supplied from the main pump. Oil flows through the main control valve bank and returns to tank whenever the engine is running. The oil flow rate is proportional to the engine speed as the pump is a fixed displacement type. Main relief, set at 22.6 MPa (3200 psi), is via an adjustable valve located on the inlet section of the main control valve bank. Each of the working sections are fitted with individual port relief valves.

The attachment and PTO controls provide pilot pressure to activate the main control valve bank respective working sections. Pilot pressure activates the main valve bank spool and directs oil from the main pump to the outlet ports of the actuated section. When pilot pressure is removed the spool returns to centre.

The main relief valve setting should be checked every 2000 service hours.

To check and adjust the main relief valve: 1) Ensure the machine is isolated as described in Section 1.

2) Locate the main valve bank at the articulation joint on the front frame assembly.

3) Run the machine at low idle and operate the lift function down until the lift arms drive against the mechanical stops.

4) Install a system pressure gauge 0-4000 psi on the inlet side of the main control valve.

5) With the lift arm tilt in hydraulic stall it should read 22.6 MPa (3200 psi ).

6) If the pressure requires adjustment locate the main relief valve on the inlet section of the valve bank.

7) Loosen the lock nut and rotate the adjusting screw clockwise to increase the pressure and counter-clockwise to decrease the pressure.

8) When the pressure reaches 22.6 MPa (3200 psi) the reducing valve is correctly set.

9) Tighten the adjusting screw nut once the correct pressure has been set.

CAUTION Ensure that all accumulator pressure is removed before disconnecting hydraulic hoses.

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Main Relief Valve

Port Relief Valves

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TILT AND LIFT CIRCUITS The tilt and lift circuits are controlled by the four-way joystick control lever, operating the first two sections of the main valve bank. Pilot oil is delivered to the actuating ends of the relative valve bank working section and operates the main valve bank spool. This spool diverts main hydraulic pump flow into the cylinder lines and the system develops pressure to actuate the cylinders at the pump flow.

Both tilt and lift cylinders are fitted with over centre valves for load hold should hydraulic pressure be removed from the system. These over centre valves are set to relieve at (3500 psi).

The function of the over centre valves can not be confirmed in situ. It is recommended that the over centre valve be removed from each cylinder every 2000 service hours and bench tested WARNING Ensure that the lift arms are lowered completely to ground level and are resting on the stops or the lift arm lock pin is installed before removing cylinder over centre valves. Removal of these valves removes the machine ability to hold load. Removal of the over centre valves when the cylinder is loaded will force pressurised oil from the open port when the valve is removed.

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ALTERNATOR CIRCUIT AND COOLING FAN The auxiliary circuit for the cooling fan is supplied by the first output of a tandem gear pump, with circuit protection via a relief valve set at 20.7 MPa (3000 psi) within an anti-cavitation manifold mounted close to the motor. The fan motor receives a constant flow of 87 lpm at 2600 RPM, hydraulic oil is supplied through the fan motor which then returns back to tank.

The auxiliary circuit for the alternator motor is supplied the second output of the tandem gear pump at 39 lpm at 2600 rpm. A logic block manifold assembly has an inline relief valve R1 set at 17.2 MPa (2500 psi) and R2 is set at 19.3 MPa to regulate the speed of the alternator motor.

Hydraulic oil is supplied through the alternator motor and then back to tank.

Logic Manifold Pressure Filter

Anti-Cav & Relief Manfold

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Section

5

Electrics, Instruments and Controls ELECTRICAL SYSTEM General description The FBL-55H electrical system is a flameproof system consisting of a power supply (alternator), an hour meter, and four 35 W headlight assemblies. The system is interconnected with approved cabling covered in fire resistant, anti-static protective hose.

A self-excited 12 V dc alternator is coupled to a hydraulic motor driven from a pump coupled to the transmission. The motor turns the alternator at a constant speed to deliver 12 V power to the 35 W headlights. The lights are only operational when the engine is running.

WARNING Only suitably qualified personnel should service and inspect flameproof electrical components to ensure that the electrical system explosion protection properties remain in the approved and/or certified condition.

Safety Precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS give the engine an opportunity to cool down before performing electrical system servicing as the location of these components is in the vicinity of hot surfaces.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

WARNING Shut down system may fail to operate if non- genuine sensors are used or if configuration settings are changed from those set by Bucyrus.

The following list of components form part of the approved shut down system.

BUCYRUS P/N 514821 514822 509420 514828 514839 514832 514835 514829 503712

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Description DIESEL MONITOR CONTROL UNIT DIESEL MONITOR DISPLAY UNIT SOLENOID DCS RUN SENSOR PRESSURE SWITCH 35PSI SENSOR FERROUS METAL PROXIMITY SENSOR FLOAT LEVEL ASSEMBLY SENSOR ENGINE OIL PRESSURE SENSOR RTD PT100 50MM CYLINDER SHUTDOWN

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ELECTRIC LIGHTING COMPONENTS Lighting Care and Maintenance Daily: Visually inspect the headlights for correct operation.

Wipe headlight lenses clean and remove any built up debris around the housings.

Check lenses for cracks and damage and ensure that the retaining bolts are in place.

Front Head Light Assemblies

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Servicing Servicing of flameproof electrical components should be conducted in accordance with the mine statutory maintenance schemes.

The following is recommended.

Every 250 service hours: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Carry out inspection as per 50 hour service.

3) Visually inspect cable gland/hose termination on the rear of the headlight for any damage and security.

4) Verify security of the headlight retaining bolts by hand tightening.

5) Record inspection in mine statutory log book.

Every 1000 service hours: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Carry out inspection as per 250 hour service.

3) Remove the covers from each headlight and inspect the electrical connections for signs of heating or fatigue.

4) Clean out interior as required, check the condition of the spigot flame paths and reapply approved fluid film to the spigot flame paths.

5) Secure the headlight retaining bolts by hand tightening.

6) Record inspection in mine statutory log book.

Every 2000 service hours: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Carry out inspection as per 1000 hour service.

3) Remove the covers from each headlight, dimensionally inspect the spigot flame paths against the certification drawings.

4) Ensure the cable gland/hose connection is secure.

5) Verify approval/certification number against the mine log.

6) Record inspection in mine statutory log book.

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ENGINE SERVICE HOUR meter This electric meter is mounted on the off driver’s side at the rear of the machine. Use the hour meter to determine servicing intervals.

Care and Maintenance Daily or every 10 service hours (Code A external examination): 1) Visually inspect the hour meter for correct operation.

2) Wipe lens clean and remove any built up debris around the housing.

3) Check lens for cracking or other damage, ensure that the retaining bolts are in place.

Hour Meter Mounting Position

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Servicing: Servicing of flameproof electrical components should be conducted in accordance with the mine statutory maintenance schemes.

The following is recommended.

Three monthly or every 500 service hours (Code B external examination): 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Carry out inspection as per 10 hour service.

3) Visually inspect cable gland/hose termination on the rear of the housing for any damage and security.

4) Verify security of the cover retaining bolts by hand tightening.

5) Record inspection in mine statutory log book.

Six monthly or every 1000 service hours (Code C semi internal examination): 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Carry out inspection as per 500 hour service.

3) Remove the cover from the housing; inspect the electrical connections for signs of heating or fatigue.

4) Clean out interior as required, check the condition of the flame paths and reapply approved fluid film to the flame paths 5) Secure the cover retaining bolts by hand tightening.

6) Record inspection in mine statutory log book.

Twelve monthly or every 1500 service hours (Code C1 internal examination): 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Carry out inspection as per 1000 hour service.

3) Remove the cover from each housing, dimensionally inspect the flame paths against the certification drawings.

4) Ensure the cable gland/hose connection is secure.

5) Verify approval/certification number against the mine log.

6) Record inspection in mine statutory log book.

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ELECTRICAL SYSTEM TROUBLESHOOTING The following electrical system troubleshooting guide is intended to provide basic guidance for analyzing faults and determining probable causes.

WARNING The electrical system must only be serviced by suitably trained and authorized personnel. This is a flameproof electrical system.

DO NOT energies the electrical system with covers removed in the mine’s hazardous or potentially gassy atmosphere.

Symptom

Probable cause

Caused by

Remedy

One light is not illuminated Blown headlight bulb

Fatigue

Replace suspect bulb

Faulty connections in

Vibration fatigue or heat

Inspect connections and repair

headlight housing

damage

as required

when the engine is running

All headlights not Blown supply fuses in

Locate fault, rectify and replace Short circuit

illuminated when the engine alternator

fuse(s)

is running Check load and remove excess System overload

(Note system maximum load of 20A)

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ALTERNATOR AND DRIVE ASSEMBLY General Description The alternator self-excites when electro magnetic field (EMF) is produced by the rotating magnetic field. This alternating current is rectified and regulated internally and is protected by 32A HRC fuses before leaving the enclosure via cable gland connection. The alternator is hydraulically driven by means of a hydraulic motor and drive coupling.

Safety precautions The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS Isolate the machine and tag out as appropriate before accessing the alternator/drive assembly.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

ALTERNATOR ASSEMBLY Care and Maintenance Daily: Visually inspect the housing for damage, ensure that the retaining bolts are in place.

Servicing Servicing of flameproof electrical components should be conducted in accordance with the mine statutory maintenance schemes.

The following is recommended.

Every 1000 service hours: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Carry out inspection as per daily service.

3) Visually inspect cable gland/hose termination on the alternator housing for any damage and security.

4) Verify security of the cover retaining bolts by hand tightening.

5) Record inspection in mine statutory log book.

Every 2000 service hours: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Carry out inspection as per 1000 hour service.

3) Remove the cover from the alternator; inspect the electrical connections for signs of heating or fatigue.

4) Clean out interior as required, check the condition of the spigot flame paths and reapply approved fluid film to the spigot flame paths 5) Secure the cover retaining bolts by hand tightening.

6) Record inspection in mine statutory log book Every 3000 service hours: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Carry out inspection as per 2000 hour service.

3) Remove the cover from the housing, dimensionally inspect the spigot flame paths against the certification drawings.

4) Ensure the cable gland/hose connection is secure.

5) Verify approval/certification number against the mine log.

6) Record inspection in mine statutory log book.

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Hydraulically driven Alternator

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ALTERNATOR DRIVE ASSEMBLY Every 250 service hours check the condition of drive coupling from the hydraulic drive motor to the alternator.

To check drive coupling: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.

2) Remove coupling guard.

3) Check wear on plastic drive coupling and check alternator and pump sprockets are tight.

NOTICE No lubrication of the alternator coupling is required.

Hydraulic Motor

Drive Coupling

Flameproof Alternator

Hydraulically Driven Alternator and Motor Arrangement

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DCS CONCEPT

DCS is an electronic methane and engine-monitoring shut down system for the use on diesel

engine powered machinery used for underground coal mining. The principle behind this system is to prevent the machine from operating when it may present an increased risk of igniting an explosive atmosphere.

The system achieves this by monitoring a set of sensors, such as methane gas detectors, component temperature sensors, coolant flow sensors and so forth. Due to the DCS being interlinked with the engine control system on the machine the system uses this information to determine if the prevailing conditions and operating parameters are safe or unsafe, and may take action such as denying a request to start the machine, or initiating shutdown of the machine, depending on the result of this safety assessment.

The system also conducts an assessment upon its own integrity. If the system cabling is damaged, any sensors are reporting invalid values, the internal battery is flat, or other abnormal conditions are detected, the system will prevent the machine from operating. The system is “fail safe” in this sense – if it cannot be positively determined that all conditions are safe, then they will assumed to be unsafe and the according actions will be taken by default.

In addition to safety related assessments, the DCS system also monitors a number of operational assessments that may produce a warning to the operator, or may cause the system to shut down. These assessments are intended to avoid damage or excessive wear to the machine, and use the same shutdown mechanism as the safety assessments.

The shutting down of the machine is effected via a solenoid valve that controls the pilot air pressure for the safe start shutdown valve on the machine. Should there be a malfunction in the solenoid circuit, the driver is also alerted with an indicator on the display panel in the operators cabin

General Inputs and Outputs

Display Unit – This is the point of communication with the operator. The display consists of a small screen and keys to navigate menus, select options and so forth. The display consists of a status page, showing the current actions being taken by the system and any warnings or trip indications, along with a menu holding pages showing sensor values, log options etc.

Power-Up Sensor – This sensor is used to determine when the machine is “switched on”, and hence when the DCS should start operation. The DCS will begin operation when the operator activates the air toggle switch

Deputy Switch – Under certain circumstances, an appropriately authorised person may deem it necessary to operate the machine despite a high methane level being sensed. This person can unlock the Deputy Switch and engage it, causing the machine to ignore a high methane level. The machine WILL RUN DESPITE HIGH METHANE LEVEL if the Deputy switch is engaged! Ensure the Deputy Switch is disengaged when it is no longer required. Also configurable for methane reset.

Methane Sensor – The Methane Sensor is used to measure the concentration of methane in the atmosphere around the machine. It is configurable for varied percentage trips.

Fuel Solenoid – The Fuel Solenoid is used to control the availability of fuel to the engine by controlling the air to the fuel rack cylinder. It is engaged when the system is safe, allowing fuel to flow to the engine and the engine to run.

WARNING Deputy Switch should not be used without prior authorisation from mine management

Alternator – The Alternator is driven by the engine of the machine, and supplies current to the DCS. The DCS uses this current to maintain a battery, allowing the DCS to operate as required when the engine is not running. If the Alternator fails, the DCS will begin to discharge its own battery. This condition should be avoided. After 30 minutes the engine will shutdown if the alternator is not charging the battery. This is used as an indication that the engine is running.

Engine Coolant Level – The engine may reach a high temperature if the coolant falls below a particular level. This may damage the engine and produce an unsafe condition.

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Engine Coolant Temperature – Under adverse circumstances, the engine coolant may reach a high temperature. This could damage the engine or produce an unsafe condition. The engine coolant is deemed to be too hot if it exceeds 105°C, and the engine will not be permitted to run.

A warning will be given if it exceeds 100°C.

Engine Oil Pressure – If the engine oil pressure falls too low, the engine may be damaged. In the process, excessive heat may be generated causing an unsafe condition. If the pressure falls below 0.7 Bar, the engine will be halted. Oil pressure is also used as an indication that the engine is running.

Exhaust Outlet Temperature – If the exhaust leaving the machine is too hot, it may cause an unsafe condition. The temperature is measured, and if it exceeds 77°C,the engine will not be permitted to run. If it exceeds 65°C a warning will be given.

Hydraulic Oil Level (Warning only) – If the hydraulic oil level falls too low, the hydraulic components of the machine may be damaged or become heated to an unsafe level. The machine will not be permitted to run in this instance.

Turbo Surface Temperature – If the turbo becomes too hot, it may cause an unsafe condition.

If the measured temperature exceeds 148°C the engine will not be permitted to run. If it exceeds 140°C a warning will be given.

Exhaust Scrubber Temperature – If the exhaust becomes too hot, it may cause an unsafe condition. If the measured temperature exceeds 80°C the engine will not be permitted to run. If it exceeds 75°C a warning will be given.

Fire suppression Pressure – If the fire suppression system pressure falls below 1100 KPa the system will issue a warning. When the fire system is activated and the pressure falls below 900 KPa the engine is shut down.

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WARNING: This cable can not be removed from this enclosure. It forms part of the approval and is encapsulated in the DCS

Start /Initiate switch

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Run Solenoid

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System Hardware Display Unit

Power Supply A small standby battery that is charged by the 12 V alternator driven by the machine's engine

powers the DCS.

The supply from the alternator first passes through the power module that is housed in the control unit.

The control unit which is encapsulated with an integral cable and gland, will work between 9 and 30V and charges the battery The battery pack itself is intrinsically safe. It contains a 12 V dry, sealed lead-acid battery.

When fully charged, the battery can operate for a minimum of 6 hours.

WARNING When Carrying out any welding on the machine unplug the power supply from the Flame-proof enclosure

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DCS Controller Unit DCS Battery

Breather

Matrix Board

Special Enclosure bolts

Ex m Power Module

The controller comes pre cabled and under normal circumstances there is no need to open the cover. A special “snake eye” tool is normally required to open the enclosure.

Fuel Solenoid The Fuel Solenoid causes the shutdown of the diesel engine by controlling a pneumatic circuit which interrupts the flow of diesel fuel to the engine by operating a pneumatically controlled valve. This solenoid energises to allow fuel flow and de-energises to restrict fuel flow. It is also known as the “Run” solenoid as it needs to energise before the DCS will let the machine start.

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Sensors & Locations Engine Coolant Level Sensor

The engine coolant level sensor is located in the engine make up tank adjacent to the engine.

This sensor monitors the engine coolant level and will shut the machine down by stopping power to the fuel solenoid valve. The fuel solenoid valve will open exhausting air pressure from the system thus the fuel shutdown cylinder will close the fuel rack, this closes of fuel to the engine and shuts the engine down. There is no need for routine calibration of the coolant level sensor as long as routine testing is carried out.

Engine Coolant Level Sensor

Engine Header Tank

Low Hydraulic Oil Sensor The low hydraulic oil level sensor is located on the inspection cover of the hydraulic tank, when

the oil level drops below the prescribe level the machine will display a message.

Low Hydraulic Oil Sensor

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Engine Oil Pressure Sensor Located behind dash panel

Shuts the machine down when there is low engine oil pressure by stopping power to the solenoid which in turn dumps the air from the shutdown cylinder Protects the engine in case of major oil loss by shutting engine down Will continuously shut engine down immediately after re-starting if oil pressure is low

Engine Oil Pressure Sensor Testing The engine oil pressure sensor is located under the dash panel in the line to the engine oil

pressure gauge. A test valve is located in the operator’s compartment to verify the oil pressure sensor is operating correctly. This will shutdown the machine by blocking oil pressure to the transducer and drain the remaining oil pressure at the transducer to the engine sump. The DCS will then shut the engine down.

Engine Oil Pressure Sensors

Oil Pressure Test Button

Deputy Bypass Switch Located within the operators compartment

If unlocked allows the machine to be run when it has a methane fault.

Can be configured to reset methane if required by turning the switch to override wait 2 seconds and then go back to off..

Deputy Bypass Switch in drivers cab

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Exhaust Scrubber Tank Float Sensor Located on the bottom LHS front of scrubber tank

Shuts engine down if water level is below safe operating level

Protects from exhaust from being open to atmosphere Shutdown Sensors

Low Exhaust Conditioner Water Sensor

Scrubber level sensors (x2)

Exhaust Temperature sensor Located at the end of the exhaust pipe

Shuts engine down if exhaust gas temperature exceeds 77°C

Shuts engine down if high temperature is detected by de-energising the solenoid valve and dumping the air from the shutdown cylinder

Stops the engine being re-started until exhaust gas temperature is below 77°C

Exhaust Temperature Sensor

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Engine Coolant Temperature Sensor Located on the rear of the engines’ timing case behind the water pump Shuts engine down if temperature reaches 105 °C by de-energising the Solenoid valve and

dumping the air from the shutdown cylinder Protects engine from serious damage from over temperature Stops the engine being re-started until engine temperatures falls below 105°C Different types for different engine packages.

Engine Coolant Temperature sensor

Methane Sensor Located under the operator’s ROPS/FOPS canopy

Shuts engine down if the methane is above the set level

Configurable for region specific values

Methane Head Sensor

WARNING Do not disassemble the sensor whilst in the hazardous area or use a sensor with a damaged housing in the hazardous area.

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Wet Scrubber System

Float Level Switches (2 off )

Run Solenoid

Oil pressure Sensor

Exhaust Temperature Sensor

Engine Coolant Temperature Sensor

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Start initiate Pressure switch

Main IS Control box

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Display Unit The display unit provides a 75mm display, arrow keys and ‘MENU’ and ‘ENTER’ keys for navigation and selecting options.

The display unit presents the Status Display by default, which shows a summary of the action the currently DCS is taking. The “Menu” can be accessed using the enter key and will be explained in further detail later.

The ‘ENTER’ button can be pressed, and the menu browsed to locate the desired information The display unit also provides three dual-colour indicator lamps, above the display to determine the condition of the DCS at a glance. When the DCS is not active, all lamps are extinguished.

Engine

Green indicates the engine is ready to be started.

Red indicates the engine has been stopped, or is not permitted to be started.

Flashing red indicates the DCS is attempting to stop the engine.

Sensor Green indicates all sensors are functioning properly.

Flashing red indicates a fault has developed with a sensor or its wiring.

Methane Extinguished indicates the Methane Sensor is not ready to give a reading (or the system is inactive).

Green indicates a safe methane level (below 1.0%).

Red indicates a warning that the methane level is high (1.0% to 1.25%).

Flashing red indicates the methane level is unsafe and the machine is shutting down (1.25% and above).

System Operation Using Display

During all phases of operation, the operator can use the menu to view sensor values, view/set the time and date, view the machine log etc. Refer to the Menu Structure diagram to see a full overview of the menu structure and an illustration of how to use the menu.

Beginning when the operator powers up the machine, a sequence of displays will be shown as the DCS proceeds through the sequence of states. The DCS Operational State Diagram shows how these states proceed, and what is required of the operator and machine in order to continue. The Display Illustrations section shows the contents of the status display during each of these states, and gives further detail as to the meaning of the display.

The digital inputs will have 4 different states displayed depending on the status of the input.

Closed o-o Open o/o Open Circuit OC Short Circuit SC

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Menu Structure MENU

Status Display

Main Menu

MENU

Digital Input Status ENTER

ENTER

Digital Inputs Engine Coolant Level o-o Hyd. Oil Level o-o Deputy o/o Main Air Sw. o-o

Scroll

Scroll

RTD Input Status

Scroll MENU ENTER

Analogue Status

System Variables

RTD Input Status Displays Temperatures configured in °C

Scroll MENU

Analogue Status

ENTER

Engine Oil Press.

0.6bar Methane

MENU

System Variables ENTER

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Alternator Off Fuel Solenoid Air Solenoid Digital Output 1 Digital Output 2 Digital Output 3 Battery Voltage Battery Current Battery Temperature

DeEn. DeEn. En. En. DeEn. 14.4V 0.28A 25°C

Scroll

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Scroll

Log Utilities MENU

View Log on Screen

Scroll

MENU

Log [E] 15/2113 17/07/2007 13:16:19 Pre run check …

-1

+10

ENTER

-10

ENTER +1

Log Utilities

Upload Log MENU

Log Download Press ENTER to begin…

ENTER

ENTER

Initialise Log Memory

MENU ENTER

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Log Initialisation Press ENTER to begin Initialising log.

May take up to 5 mins.

All entries will be erased!

ENTER

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Scroll MENU

System Setup

Scroll

Language Setup

MENU

Language Selection English Chinese

ENTER

ENTER MENU

Communications Port

ENTER

Modbus Comms (Bps) 19200 9600 4800 2400

Scroll

Set Date and Time MENU

Set Clock

System Setup

ENTER

Increas

DATE:2099-09-09 TIME:19:09:09 Select

Select

2099-09-09 19:09:09 Decrea

MENU ENTER

100% 75% 50% 25% 0%

MENU

System Information

Set Backlight Intensity

System Information

Scroll

Backlight Intensity

ENTER

Scroll

9999-99999 Compact Loader V9.9 S/W Version: 9.9 09 Jan 2099

Scroll

Diagnostic

MENU

Resistance Input

Resistance

Pages 1 to 4

All Configured Resistances And Values

Scroll

ENTER MENU

Diagnostic

ENTER

Analogue Input

MENU ENTER

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Analogue

Pages 1 to 4

All configured analogues in mA Scroll Non configured = 0

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Operational State Diagram OFF The DCS is powered down and nothing is displayed.

Machine switched on (Power-up switch activated)

Methane Sensor Warm Up

If no further action is taken, the DCS will switch itself off.

The operator may press UP to allow the engine to be started again, without having to wait for the DCS to restart and the Methane Sensor to warm up again.

The DCS will wait for some time after the engine is stopped, displaying information for the operator.

Engine Stopped

Manual No.M01335

Pre Run Check

The sensors are checked to determine if it is safe for the engine to start.

Ready to Start

The DCS waits to see if the operator starts the engine.

Engine Running

While the engine is running, the DCS continually monitors the sensors to ensure it is operating safely.

Fuel Cut Shutdown

If the engine must be stopped, the DCS cuts fuel to the engine. The DCS then waits to see if the engine stops.

Manual Shutdown

In all cases except Engine Running, the DCS will power itself down after a predetermined amount of time. This is to ensure the internal battery is not needlessly depleted.

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Before the DCS may continue, the Methane Sensor must warm up.

If the engine doesn’t stop within a pre-determined time, the DCS instructs the operator to take manual action to stop the engine.

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Display Illustrations Methane Sensor Warm-up

This screen is typically displayed as soon as the DCS is powered up. A nominal time period of 20 seconds is provided for the sensor to reach operating status. During this period, the Methane lamp is extinguished and the methane level is reported as “PU”.

Engine

Sensor

Methane

Status: CH4 PU Waiting for methane Sensor warm-up…

15 seconds remaining.

Bucyrus Diesel Machine Display Unit

MENU

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ENTER

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Pre-Run Check

This screen is displayed while the DCS is performing its Pre-Run Check. The display lists the sensors that are preventing the check from passing, and the time remaining for them to be resolved. If the time expires, the DCS will power itself down

Sensor

Engine

Methane

Status: CH4 = 0.32% Pre-run check – trips: Engine Coolant Level OC 15 seconds remaining.

Bucyrus Diesel Machine Display Unit

MENU

ENTER

Sensor name Engine Coolant Level Engine Coolant Temp Exhaust Outlet Temp Exhaust Scrub Temp Turbo Surface Temp Scrubber Float 1 Scrubber Float 2 Methane Fire suppression

Manual No.M01335

Value required to pass check Closed – ‘o-o’ Less than 105 C Less than 77 C Less than 80 C Less than 145 C Closed – ‘o-o’ Closed – ‘o-o’ Less than 1.0% Greater than 1.1MPa

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Ready To Start The operator can now start the machine.

A countdown is displayed – if the machine is not started before the countdown expires, the

DCS will switch itself off.

The DCS will consider the engine to be started if any of the following sensors give the specified signal:

Engine

Sensor

Methane

Status: CH4 = 0.32% Waiting for start…

21 seconds remaining.

Bucyrus Diesel Machine Display Unit

MENU

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ENTER

Sensor name

Value to show running

Alternator

On (supplying current)

Engine Oil Pressure

Greater than 0.7 Bar

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Engine Running The DCS has observed that the engine has started

A list of warnings may be displayed:

Sensor

Engine

Methane

Status: CH4 = 0.32% Engine Running.

Alternator OFF Methane Hi Bucyrus Diesel Machine Display Unit

MENU

ENTER

Sensor name

Value that will cause alarm

Alternator

Off (Not supplying current)

Engine Coolant Temp

Greater than 100 C

Exhaust Scrubber Temp Greater than 75 C

Manual No.M01335

Exhaust Outlet Temp

Greater than 72 C

Turbo Surface Temp

Greater than 145 C

Fire Suppression Pressure

Less than 1.1MPa

Hydraulic Oil Level

Open – ‘o/o’

Methane

Greater than 1.00%

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Engine Running The DCS has observed that the engine has started

A list of trips may be displayed – if they remain tripped for a pre defined amount of time, the engine will be shut down

Sensor

Engine

Methane

Status: CH4 = 0.32% Engine Running.

Alternator OFF Engine Oil Press. LO Bucyrus Diesel Machine Display Unit

MENU

ENTER

Sensor name

Value that will cause trip

Alternator

Off (Not supplying current)

Engine Coolant Level

Open – ‘o/o’

Engine Coolant Temp

Greater than 105 C

Exhaust Outlet Temp

Greater than 77 C

Exhaust Scrubber Temp

Greater than 80 C

Scrubber Level 1

Open – ‘o/o’

Scrubber Level 2

Open – ‘o/o’

Engine Oil Pressure

Less than 0.7 Bar

Fire Suppression Pressure Less than 0.9 Bar Methane

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Greater than 1.25%

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Fuel Cut Shutdown The DCS is attempting to stop the engine by stopping the fuel supply to the engine. In this

screenshot, the DCS is detecting the engine is still running, as Engine Oil Pressure is still being indicated. If this does not cease within the time period shown, the operator will be requested to follow the emergency manual shutdown procedure.

If any of the following sensors give the relevant signal, then the engine will be considered still running

Sensor

Engine

Methane

Status: CH4 = 0.32% Stopping Engine: Engine Oil Pressure Hi Fuel supply stopped.

29 seconds remaining.

Bucyrus Diesel Machine Display Unit

MENU

ENTER

Sensor name

Manual No.M01335

Value to show running

Alternator

On (supplying current)

Engine Oil Pressure

Greater than 0.7 Bar

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Manual Shutdown As mentioned in the last screenshot, this is displayed when the operator must manually shut

the machine down.

The same sensor conditions apply

Engine

Sensor

Methane

Status: CH4 = 0.32% Manual Shutoff: Perform Manual Shutdwn!

Engine indicating/faults: Engine Oil Pressure Hi Bucyrus Diesel Machine Display Unit

MENU

ENTER

Value to show running Alternator

On (supplying current)

Engine Oil Pressure Greater than 0.7 Bar

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Engine Stopped This screen shows that the engine has been successfully stopped, and the original cause of the

shutdown (in this case low Engine Oil Pressure – see Engine Running screenshot for list).

The display will show if either Fuel Cut was successful, or if the Manual Shutdown was required.

The operator may either leave the machine, or press the up key for the DCS to allow the machine to be re-started

Engine

Sensor

Methane

Status: CH4 = 0.32% Engine Stopped.

(Fuel Shutdown) Press UP / Off in 23s

Bucyrus Diesel Machine Display Unit

MENU

Manual No.M01335

ENTER

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Engine Stopped - Pre-Run Check Failed This screen may be displayed if the pre-run check fails, and is not resolved within the time

allowed. The machine may no longer be started until the up key is pressed, or the system shuts itself down and is restarted.

See Pre-Run Check screen for list of failure reasons.

Engine

Sensor

Methane

Status: CH4 = 0.32% Engine Stopped.

Pre-run check failed Engine Coolant Temp OC Press UP / Off in 13s

Bucyrus Diesel Machine Display Unit

MENU

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ENTER

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Display Start Up Screen This will be displayed momentarily as the system powers up. If this is displayed for more than a few seconds, a system fault has occurred and will need to be rectified by service personnel.

Sensor

Engine

Methane

DCS Display Unit

Waiting for control unit… $Rev: 999 $ 57.6kbps

Bucyrus Diesel Machine Display Unit

MENU

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ENTER

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Machine Operation & Shutdown DCS Shutdown Modes The Bucyrus Diesel Control system Consists of 10 Shutdown Modes in a wet configuration.

Engine Oil Pressure

Engine Coolant Level

Engine Coolant Temperature

Exhaust Outlet Temperature

Turbo surface Temperature

Exhaust scrubber Temperature

Scrubber Water Level 1

Scrubber Water Level 2

Low Fire Suppression Pressure

Hi Methane Starting Machine Turn on Start/Reset air pressure switch ( Toggle switch) This will activate the DCS electronics The lights on the display will light up for about five seconds ( This serves to test lights and circuitry ) Any parameters that do not allow safe operation will be indicated Wait for the methane monitor to read ( approximately 15 secs ) The methane monitor needs about 15 seconds to measure the content in the surrounding air When the waiting time is up the solenoid will power up. The machine can now be started

Start Engine Activate the operators start button and start engine The machine is now ready to be operated Start / Reset valve - Toggle Switch

Operate machine

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To shutdown machine When shutting down the machine turn of the START / RESET valve ( Toggle switch ) This will be detected by the DCS and the start solenoid will dump air from the shutdown cylinder and stop the machine Turn the main isolating air valve off

Main Isolation Valve

Start / Reset valve - Toggle Switch

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INSTRUMENTS AND CONTROLS Compartment door The compartment door must be closed and locked after entering the compartment before the park brake button can be released and the declutch valve deactivated.

Maintenance Grease door latch and hinges weekly and ensure interlock door valve is secure.

WARNING Never use the door to apply the park brake. Always manually apply by the park brake button and ensure the brake head pressure gauge reads zero.

The steering pressure will automatically bleed down, never assume the steering pressure has bled down unless the steering pressure gauge reads zero.

NOTICE When the door is open the machine cannot be operated, as the park brake will be on and the transmission will be declutched. There is a roller cam valve in the door lock that needs to be activated, to release the park brake.

Also the brake system pressure is dumped with the door open. The engine will run with the door open.

Compartment Door Latch

Door Interlock Valve

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Transmission gear control lever The gear control lever has four positions, first, second, third and fourth.

Maintenance Lubricate cable and linkages if hard to shift gears.

NOTICE The transmission in the machine is modulated. This prevents severe shocks being transmitted through the drive train when the transmission is shifted between gears.

Transmission Directional Control Lever A directional control lever controls the transmission. This lever has three positions, forward, neutral and reverse. The engine should be at low idle when the transmission is shifted from the neutral position to either forward or reverse direction.

Maintenance Lubricate cables if hard to shift gears.

NOTICE The transmission must be placed in the neutral position for the starter motor to engage when starting the engine.

WARNING If the engine starts when the transmission is not in neutral the neutral start on the transmission needs to be adjusted or replaced.

Transmission Directional Control Lever

Transmission Gear Control Lever

Transmission Controls

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Park Brake button The park brake button has two positions and it is held in the release position by pilot air pressure. By pushing the button inwards, the park brake is applied, and by pulling the button out the park brake will be released. The park brake cannot be released until the system pressure is sufficient to overcome the spring force of the brake control, it also will not release unless the door is closed (there is a roller cam valve inside the door lock which needs to be activated to release the park brake).

If the engine shuts down the park brake will automatically apply itself by dumping the pilot air pressure via the low oil pressure pilot valve. The brake head pressure gauge must read zero when the brake is applied.

WARNING Never use the door interlock to actuate the park brake when exiting the machine. If there is a malfunction on the door interlock system, the park brake could possibly not apply when exiting machine and the machine could run away resulting in serious damage or injury.

NOTICE The park brake must be applied for the starter motor to engage whenever an engine start is required.

Park Brake Button

Brake Head Pressure Gauge

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Four-Way Joystick Control Lever This lever has five positions, tilt back, tilt forward, lift, lower and hold. Pushing the lever to the right tilts the RAS back plate back for loading and tramming. Pulling the lever to the left tilts the RAS back plate forward for digging or unloading. Pushing the lever forward lowers the lift arms. Pulling the lever back raises the lift arms. The lever is spring centred to the hold position.

NOTICE Two functions may be engaged at the same time by pushing the four-way joystick control lever at 45° in the direction of the two required functions.

No. 1 - Two-Way Hydraulic Control Lever There are two hydraulic two-way control levers fitted to the machine. The first lever closest to the operator is used to control attachments and engage and disengage the RAS locking tongue. This lever has three positions, up, down and hold. The lever is spring centred to the hold position. When operating an attachment, the function of this lever alters depending on the attachment fitted.

NOTICE To release attachments, the RAS Pilot Lock Cylinder Release Button must be pushed simultaneously whilst pulling down on the lever. This is to prevent an accidental uncoupling of the attachment

No. 2 - Two-Way Hydraulic Control Lever The second lever, furthest from the operator, is used to control RAS attachments. This lever has three positions, up, down and hold. The lever is spring centred to the hold position. When operating an attachment, the function of this lever alters depending on the attachment fitted.

NOTICE On some machines an auxiliary hydraulic PTO (Power Take Off) may be fitted to the rear of the machine. This lever controls this function.

No. 1 - Two-Way Hydraulic Control Lever

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No. 2 - Two-Way Hydraulic Control Lever

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Four Way Control Lever

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Control Lever Maintenance Maintenance Inspect the tilt/lift and attachment control valve for damaged or missing boot or parts and replace as necessary. Carry out operational performance test as per Section 7.1 of Bucyrus Australia Preventative Maintenance Inspections if replacement is required.

Control Levers

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Operator’s Seat On the operator’s seat the height, backrest tilt and seat suspension are all adjustable. The controls for these functions are beside the seat. Some machines are fitted with a swivel seat which may need lubricating from time to time, a seat belt is fitted to the seat assembly that needs to be inspected for correct operation and replaced if required

Accelerator pedal The accelerator pedal is connected to the engine fuel pump governor via a cable. When the accelerator pedal is depressed the engine speed increases. The accelerator pedal is spring return so that when pedal pressure is removed, the engine returns to low idle.

CAUTION! Always keep the operator’s compartment clean. Dirt, etc. can build up under the accelerator pedal restricting its movement.

Brake pedal The brake pedal when depressed applies the brakes on the front and rear axles. There are four liquidcooled Posi-Stop brakes located internally in each wheel end. Whenever possible use the engine compression to slow the machine on a grade or decline by selecting a lower gear and driving the machine using engine revs.

CAUTION! Do not ride the brakes while tramming the machine.

NOTICE! If the engine should stall, the machine is fitted with fail-safe brake system that will fully apply the brakes. The operator can apply the brakes at any time following an engine stall to immediately bring the machine to a controlled stop.

CAUTION! Always keep the operator’s compartment clean. Dirt, etc. can build up under the brake pedal restricting its movement.

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Steering Wheel The steering wheel controls the flow of hydraulic oil to the steering cylinder via an orbital steering valve. As the cylinder strokes, the machine articulates to the left or to the right.

Turning the wheel anti-clockwise articulates the machine towards the operator. This effectively turns the machine to the left in the forward direction (lift arm end).

Turning the wheel clockwise articulates the machine away from the operator. This effectively turns the machine to the right in the forward direction (lift arm end).

NOTICE The machine will turn in the opposite directions when travelling in forward and reverse. Operator training and familiarity with LHD operation is important to ensure that collisions are avoided.

NOTICE If the engine should stall, the machine is fitted with a system that will dump the steering pressure. The operator can steer the machine via a six litre back up accumulator at any time following an engine stall to immediately bring the machine to a safe controlled stop.

NOTICE If the door is opened or the park brake is applied, the machine is fitted with fail-safe steering system that will immediately dump the steering system pressure. This is to protect the operator or personnel from being crushed in the articulation area. Steering cannot be used until the door is shut and latched and the park brake button pulled out to the released position.

Steering Wheel

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Brake Head Pressure Gauge This gauge shows the service and park brake system’s brake head pressure. Operators should periodically check this gauge. The gauge will read zero pressure when the brakes are fully applied via the service and/or park brake controls NOTICE! If the operator’s foot is off the brake pedal and the park brake is released, the indicated pressure shall be a minimum of 12000 kPa (1750 psi). If the pressure is below this it is likely that the brakes are dragging. The machine shall not be operated with dragging brakes as fire or brake failure may result. Immediately report the problem to service personnel.

CAUTION! Observe that the brake head pressure is on zero after applying the park brake.

Brake Accumulator Pressure Gauge This gauge indicates the service and park brake system’s accumulator pressure. Normal operating system pressure is 17200 kPa (2500 psi).

CAUTION! Do not operate the machine if the brake accumulator pressure gauge is less than 17200 kPa (2500 psi). Immediately report the problem to service personnel.

Steering Accumulator Pressure Gauge This gauge indicates the steering system’s accumulated pressure. Normal operating system pressure is 17200 kPa (2500 psi).

NOTICE! If the pressure constantly drops below or will not hold 17200 kPa (2500 psi), steering may become difficult. The machine should not be operated and the problem shall be reported immediately to service personnel.

Brake Head Pressure

Brake Accumulator Pressure Steering Accumulator Pressure

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Engine Start Button Depressing the engine start button engages the starter motor to start the engine. The engine start button will not activate the starter motor unless: 1) The transmission is in neutral.

2) The park brake is applied.

3) The diesel control system shows no fault.

4) The on/off toggle switch is on.

5) Sufficient air is in the receiver and air valve is turned on.

NOTICE! Depress the accelerator pedal ⅓ before a start to ensure sufficient fuel is available. Immediately remove finger from the engine start button when the engine fires.

Air Pressure Gauge This gauge indicates the air pressure in the air receiver. Normal air pressure is set at 760 kPa-860 kPa (110 psi -125 psi).

NOTICE! The main air isolation valve is mounted in the engine compartment. Turn this valve on before entering the machine. The gauge will read zero when the valve is shut.

On/Off Toggle Switch The on/off toggle switch controls the supply of pilot air pressure to the air pressure switch on the diesel control system, which allows air to pilot the start motor.

1) To start the engine, place the on/off toggle switch in the on position.

2) To shutdown the engine, place the on/off toggle switch in the off position.

Engine Start Button ON/OFF Toggle Switch

Air Pressure Gauge

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Transmission Oil Temperature Gauge This gauge indicates the oil temperature in the transmission and torque converter. Normal oil temperature is between 82°C-93°C. If the temperature should rise above 121°C, carry out the following procedure: 1) Bring the machine to a halt, lower the lift arms to the ground and apply the park brake.

2) Put the transmission in neutral and run the engine to approximately ½ speed.

Observe the temperature gauge for about two minutes. If the temperature does not begin to fall within two minutes, shutdown the machine and do not attempt to operate it until corrective action has been taken. Immediately report the problem to service personnel.

Transmission Oil Temperature Gauge

Left Hand Side Operator’s Panel

WARNING! Do not operate the machine if the oil temperature is above 121°C.

CAUTION! Transmission temperature can be affected by incorrect gear selection for the load being carried and or the road conditions.

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Load Indicator Gauge This gauge indicates the load pressure at the cap end of the lift cylinders. Refer to the load indicator table below for the procedure to determine the load/ pressure relationship.

Load Indicator Gauge

WARNING! Do not operate the machine with a load greater than its rated capacity of 60T (210Bar load gauge pressure).

CAUTION! Overloading the machine beyond its rated load capacity could cause catastrophic machine failure, injury and even death.

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Load Indicator Table

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Engine COOLANT Temperature Gauge This shows the coolant temperature circulating through the engine radiator system. Normal operating temperature is between 82°C-95°C. The engine should not be operated under heavy load until it has had time to warm up approximately five minutes. The engine must also be shut off and cooled when the coolant level is to be topped up.

WARNING! Shut off the engine immediately if the coolant temperature gauge goes above 105°C. The diesel control system will give an alarm at 100°C and should shutdown the engine at 105°C.

Left Hand Side Operator’s Panel

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Engine Coolant Temperature Gauge

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Horn Button Pushing this button sounds the air horns.

NOTICE! It is good operating procedure to sound the horn 2-3 seconds before an engine start or whenever approaching blind intersection.

Horn Button

Right Hand Side Operators Panel

Emergency Fuel Shut Off Valve This valve is located after the fuel filter/water separator. Closing this valve will stop the flow of fuel to the engine. This provides a second means of shutting down the engine should the on/off toggle switch fail.

Emergency Fuel Shutoff Valve Shown in the closed Position

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Engine Service Hour Meter This electric meter is mounted on the off driver’s side at the rear of the machine.

Use the hour meter to determine servicing intervals.

Engine Hour Meter

Air Cleaner Service Indicator The air cleaner service indicator is located at the air cleaner and indicates the condition of the air cleaner element. When the service indicator is in the red zone, the air cleaner elements should be removed and serviced.

Air Cleaner and Indicator

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Engine Oil Pressure Gauge This gauge indicates the engine lubricating oil pressure. Normal pressure is between 210 kPa-550 kPa (30 psi-80 psi) at rated RPM. CAUTION! Shut off the engine if the oil pressure drops and stays below 70 kPa (10 psi). The diesel control system should shutdown the engine at 70 kPa (10psi).

CAUTION! Do not run the engine with low oil pressure, as engine damage will result. Immediately report the problem to service personnel.

Outlet Gas Temperature Gauge

Engine Oil Pressure Gauge

Right Hand Side Operators Panel

Shutdown System Test Valve The test valve is used to check the integrity of the Fail-Safe Shutdown System. This test should be carried out on a daily basis as part of the 10 Hour Daily Off Line Mechanical Inspection. (Refer to Section 8 - Post Start Checks).

Test Button

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Engine Fuel Primer Pump If the engine fuel system has been run dry or serviced, the fuel system should be primed via manual activation of the hand fuel primer pump. The pump is located adjacent to the fuel water separator in the engine compartment. Normally no priming is required to start the engine.

To prime the fuel system: 5) Fill the fuel tank with the recommended grade of fuel. If it is not possible to completely fill the tank then add a minimum 50 litres to the tank.

6) Unlock the fuel priming pump plunger and operate in an in and out motion until resistance is felt, a considerable amount of stroke may be required.

7) Push in the plunger and tighten by hand.

8) Promptly start the engine, if the engine runs rough increase the engine RPM to approximately ½ the rated RPM and check for fuel leaks

Fuel Primer Pump

Engine Fuel Primer Pump

Attachment Quick Connects Button This button releases all of the pressure in the PTO lines to allow the couplings to be easily released.

To release the pressure, release both of the two-way control levers to the hold position and press in the pressure release button for two seconds.

Attachment Quick Release Button

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Emergency Intake Shut Off Valve This valve is used in the event that the machine fails to shutdown under normal circumstances as stated in Section 8. Closing this valve will stop the flow of air to the engine. This provides a second means of shutting down the engine should the on/off toggle switch fail.

Emergency Intake Shut Off Valve Stop Button

Emergency Intake Shut Off Valve Reset Lever Emergency Intake Shut Off Valve Reset Lever

The valve is activated from the operator’s compartment by a stop button which is pushed, once activated and the engine shuts down the valve will need to be reset before restarting. Ensure that the stop button has been pulled out and there is a reset lever down on the main body of the valve that will rotate and latch into the operating position. If the valve has not been reset the engine will not start.

When the valve has been reset the engine can be started.

WARNING! If the emergency intake shutoff valve has been activated, the restarting of the engine should be done in compliance with the relevant regulations and Manager’s Rules.

WARNING! This engine system is fitted with a wet exhaust conditioner. Operation of the Emergency Intake Shut off valve while the engine is running may result in exhaust conditioner water being drawn back into the engine. This may result in catastrophic damage to the engine.

WARNING! ONLY RESTART THE ENGINE AFTER VERIFYING THAT THERE HAS BEEN NO INGRESS OF WATER FROM EXHAUST CONDITIONER INTO THE ENGINE. THIS IS TO BE VERIFIED BY SERVICE PERSONNEL PROIR TO ATTEMPING ENGINE START

Manual LOP Fire Suppression System Actuator This valve should be used in the event that a machine fire occurs to activate the fire suppression system manually. Note that this actuator is used as a manual backup to the automatic fire suppression system. If a fire occurs, the manual LOP actuator can be operated as follows: 1) Remove the safety pin.

2) Strike the knob firmly.

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Manual LOP Fire Suppression System Actuator

Once the fire suppression system is activated, a transducer that monitors the fire suppression system will automatically shutdown the engine within 3 seconds.

WARNING! If a fire occurs, activate the manual fire suppression actuator and flee the area.

WARNING! If the fire suppression system has been activated and it is safe to return to the machine, the restarting of the engine should be done in compliance with the relevant regulations and Manager’s Rules.

WARNING! ONLY RESTART THE ENGINE AFTER VERIFYING THAT THERE HAS BEEN NO INGRESS OF WATER FROM EXHAUST CONDITIONER INTO THE ENGINE. THIS IS TO BE VERIFIED BY SERVICE PERSONNEL PROIR TO ATTEMPING ENGINE START

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Section

6

Frame Components GENERAL DESCRIPTION The frame consists of a front and rear section coupled via an articulation joint. The articulation joint gives the machine the ability to steer left and right via a hydraulic steering cylinders. An operator’s compartment is situated left side of the rear frame with the transmission located in the centre. The diesel engine and main hydraulic and pneumatic components are also located in the rear frame, towards the rear of the machine.

The front frame houses the lift arm, located in the centre of the front frame chassis. The front of the lift arm is attached the fork tine backing plate (cradle) via pinned bottom joints and fixed to the tilt cylinders via pins on the top of the backing plate.

SAFETY PRECAUTIONS The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS give the diesel engine an opportunity to cool down before performing servicing around the rear frame as engine components around this location are hot and could cause burns or scalding.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys and drive lines) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

ALWAYS install the articulation lock when accessing the machine articulation area as machine articulation will result in crush injuries (see Section 1.4.5).

ALWAYS install the lift arm lock when access underneath the lift arm assembly is required. Remove any load before raising and locking the lift arm assembly (see Section 1.4.6).

NEVER Assume that all forms of energy have been isolated unless you have confirmed for yourself.

Figure 6.2.1 –Fire Extinguisher Storage

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FRONT FRAME Chassis The front frame is a welded chassis which facilitates fitment to the rear frame via the articulation joint and houses the lift arm, lift cylinder and tilt cylinder assemblies. The front frame also houses the forward facing headlights, the machine fire extinguisher (operator’s side), articulation lock (operator’s side) and lift arm safety lock in the centre of the machine. Grease manifolds are located each side of the front frame for lubrication of the frame components.

Care and Maintenance Daily: 1) Visually inspect the front frame and associated components for damage.

2) Check the security of the fire extinguisher and articulation lock mountings.

3) Verify that the fire extinguisher is functional.

Servicing Weekly: 1) Grease the pin joints via the remote grease manifolds positioned both sides of the front frame in the articulation joint. These manifolds allow individual greasing to the top and bottom lift cylinder pins, inside and outside lift arm pins. Raise and lock the lift arm to observe purging of grease at the relevant pins to ensure adequate lubrication.

2) Grease the tilt cylinder pins and lift cylinder pins on the operator’s and off operator’s side.

Grease nipples are located on the cover plates on the inside and outside of each pin. Observe purging of grease at the pins to ensure adequate lubrication.

Figure 6.3.1.1 - Front Frame Showing Articulation Lock

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Chassis Continued

Fire Suppression System

Guards

Axle Assembly

Lift Arm Assembly Figure 6.3.1.2 - Front Frame Assembly

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LIFT ARM General The lift arm is a welded member pinned the front frame and lift cylinder top pins. The lift arm facilitates raising and lowering of the carried load. The back plate for the fork tines is pinned to the front of the lift arm and to the tilt cylinder clevises to enable load tilt.

Care and Maintenance Daily: 1) Visually inspect the lift arm for structural damage.

Servicing Weekly: 1) Grease the lift arm to back plate cradle pivot pins. Tilt the back plate forward to gain access to both sides of the operator’s and off operator’s side pins. Observe purging of grease at the pins to ensure adequate lubrication.

2) Grease the rear top lift cylinder pins on the operator’s and off operator’s side. Grease nipples are located on the top pin on the cylinder clevis on each tilt cylinder. Observe purging of grease at the pins to ensure adequate lubrication.

Figure 6.4.1.1 - Lift Arm in Raised Position

WARNING NEVER work or stand underneath lift arm unless the lift arm lock pin is installed. See Section 1 - Isolation.

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To install the lift arm lock pin: 1) 2) 3) 4) 5) 6)

Remove any load from the fork tines.

Park the machine on flat level ground. Ensure the ground is stable and not close to a edge.

Ensure the push plate has been fully retracted.

Raise the lift arm to its full height and roll the back the fork tines.

Install the lift arm lock pin as per the picture below.

DO NOT lift the machine off the ground.

Turn off the machine and apply the park brake.

WARNING The lift arm on this machine can cause fatal crush injuries if extreme caution is not observed. NEVER access or perform work under the lift arm unless the engine has been shutdown, the articulation lock fitted, the park brake applied, the attachment has been removed and the lift arm has been supported in the raised position.

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Fork Cradle Assembly The fork cradle facilitates attachment of the load carrying forks on the front of the machine.

Care and Maintenance Daily: 1) Visually inspect fork cradle for any structural damage.

2) Check the tine for any sign of cracking.

3) Ensure the winch rope guide rollers are free to turn.

Servicing Refer to the Preventative Maintenance Schedule.

Figure 6.4.3.1 - Fork Cradle and Cookie Plate

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Winch Assembly The winch assembly is mounted at the back of the lift arm, it consists of a hydraulically driven motor, planetary box, gearbox, rope drum and winch rope. The planetary and gearbox assemblies are separate units with there own oil capacities (Refer to the Preventative Maintenance Schedules).

Care and Maintenance Daily: 1) Visually inspect the mounting bolts.

2) Inspect for oil leaks from seals, gaskets and hosing.

3) Visually inspect rope anchorage for security and damage.

4) Check the rope and eye for any sign of damage.

5) Ensure the winch rope guide rollers are free to turn.

Servicing Refer to the Preventative Maintenance Schedule.

Gear Box

Planetary Box

Winch Rope Drum

Hydraulic Drive Motor

Figure 6.4.4.1 - Winch Assembly

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Winch Assembly Continued Planetary Box Fill Point

Breather

Gear Box Fill Point

Bearing Grease Point on the Underside of the Lift Arm /Winch Figure 6.4.4.2

Winch Assembly Lube Points

NOTICE! There are no plugs for checking the gearbox and planetary case oil levels, the only measurement is the amount of fluid that is put into them.

Gear case - 5 litres Planetary Case - 2.5 litres

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Winch Rope Assembly The winch rope is mounted to the winch rope drum via a U-bolt that goes through the drum and is tightened, this clamps the swaged end of the rope into the recess of the drum (shown in green). The U-bolt should be positioned approximately in the middle of the swaged section of the rope (shown in blue) and tightened as recommended in Section 1.6 of this manual.

Care and Maintenance Daily: 1) Visually inspect rope anchorage for security and damage.

2) Check the rope for any sign of damage.

3) Ensure the winch rope guide rollers are free to turn.

Servicing Refer to the Preventative Maintenance Schedule.

Swaged End of Rope and Drum Recess

Figure 6.4.4.3 - Winch Rope U-bolt Anchor

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Figure 6.4.4.4 - Winch Rope

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Winch Rope Assembly Continued There are two winch rope options, a Wire rope and a Synthetic rope Synthetic Rope Mounting: The winch rope is mounted to the winch rope drum via a U-bolt that goes through the drum and is tightened, this clamps the end of the rope and one full wrap of the rope around the drum into the recess of the drum (shown in photo). The U-bolt should be tightened as recommended in Section 2.4 of this manual.

Care and Maintenance Daily: 1) Visually inspect rope anchorage for security and damage.

2) Check the rope for any sign of damage. See fibre rope pictures below to aid in damage/degradation detection.

3) Ensure the winch rope guide rollers are free to turn.

Servicing Refer to the Preventative Maintenance Schedule.

Synthetic Winch Rope clamped by U-bolt

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Fibre rope – Volume Reduction (Ref: SamsonRope)

Fibre rope – Cut Stands (Ref: SamsonRope)

Fibre rope – Compression (Ref: SamsonRope)

Fibre rope – Melting or Glazing (Ref: SamsonRope)

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REAR FRAME Chassis The rear frame is a welded chassis coupled to the front frame via the articulation joint. The rear frame houses the diesel engine system, transmission, hydraulic pumps, filters, fluid tanks and operator compartments.

The rear frame also houses the cooling system radiators, rear axle, tow hitch and rearward facing headlights.

There are several different covers which are mounted and hinged of the rear frame.

Care and Maintenance Daily: 1) Visually inspect the rear frame and associated components including access covers for damage.

2) Visually inspect the tow clevis, coupling pin and retaining device for signs of structural damage.

Servicing Refer to the Preventative Maintenance Schedule.

Engine Assembly

Rear Axle Assembly

Transmission Assembly

Operator’s Compartment

Hydraulic Tank

Figure 6.5.1.1 - Rear Frame Assembly

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Operator’s Cabin The operator’s cabin consists of the door assembly and canopy assembly. Other assemblies that are mounted to or from the operator’s compartment are the dash, the pedal and the seat.

Canopy Assembly

Cabin Door

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Cabin Door Assembly The operator’s door assembly is designed to safely contain the operator inside the compartment. The door assembly locks in the closed position and releases a pneumatic interlock which applies the vehicle emergency brakes when opened.

Care and Maintenance Daily: 1) Visually inspect the door assembly for structural damage, including the deflector bar located on the outside of the door plate.

2) Check the door hinge for free operation.

3) Check the locking latching mechanism for free operation.

Servicing No routine servicing is required on the cabin door assembly other than visual inspection for structural integrity and free operation. Occasional lubrication of the door hinges and the door latch mechanism may be required if the operation appears difficult. Use multi-purpose EP grease to lubricate the hinge pins and door latch bolts as required.

Cabin Door Latch

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Cabin Door Interlock Valve

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Canopy Assembly The operator’s canopy assembly is designed to provide safe overhead protection for the operator.

The canopy assembly is of welded construction and is bolted to the operator’s compartment. The canopy assembly may be raised or lowered to suit varying operating conditions. The canopy is fitted with mesh on the front and inside of the assembly to protect the operator in case the winch rope breaks.

Back Plate

Canopy Mesh

Figure 6.5.4.1 - Operator’s Canopy

WARNING Maintain a minimum clearance of 1000mm from the seat horizontal to the underside of the canopy assembly to ensure adequate operator head room clearance. Low operating clearances that require minimum head room below 1000mm should be reviewed via risk assessment to address hazards identified by low head room clearance.

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Canopy Assembly Continued To adjust the canopy height: 1) Place an M16 or 5/8" collared eye bolt through the 20mm hole in the canopy top plate and support the canopy with a suitable lifting device. The lifting device must be rated to support a canopy mass of 300kg.

2) Remove the two 1" bolts and nyloc nuts from the front supports and discard the nuts.

3) Remove the six 3/4" bolts, nyloc nuts and defector plate from the rear supports and discard the nuts.

4) Raise or lower the canopy assembly with the lifting device. Note that the canopy assembly can be raised or lowered in increments of 63mm (2-1/2").

5) Fasten the canopy to the supports with existing 3/4" and 1" bolts and new nyloc nuts.

6) Torque fasteners as per bolt torque specification table.

Care and Maintenance Daily: Visually inspect the canopy assemblies and supports for structural damage.

Servicing Every 250 service hours: Torque the canopy assembly mounting fasteners as per Bolt Torque Specification Table.

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Operator Seating Seating is provided for the operator. The operator’s seat is an in board facing adjustable position seat with suspension fitted. The suspension system consists of mechanical suspension with hydraulic shock dampening. An optional swivel seat base is available. A lap sash seat belt is fitted to the seat assembly for operator security Care and Maintenance Daily: 1) Visually inspect seating and seat belts for damage.

Servicing No routine servicing is required on the seating other than visual inspection for functionality.

Suspension Adjustment

Seat Belt Mounts

Figure 6.5.5.1 - Operator’s Cabin

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Articulation Joint The articulation joint couples the front frame to the rear frame and provides the pivot point for machine steering. The joint consists of a fixed pin and spherical bearing on the top clevis with a floating pin joint on the bottom clevis.

Care and Maintenance Daily: 1) Visually inspect articulation joint for any structural damage.

Servicing Every 250 service hours: 1) Check the bolt torque on the articulation joint retaining plate fasteners as per Bolt Torque Specification Table.

2) Grease the top and bottom articulation pin joints. Grease nipples are located on the articulation pins at the top and bottom joints. Observe purging of grease at the pins to ensure adequate lubrication.

Figure 6.5.6.1 - Articulation Joint

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Covers The rear frame is fitted with various sized covers, doors and grills all of these are an integral part of the machine and should be kept in good working order as they help protect personal from accidental injury, also the machine components from damage.

Each cover on the top of the machine is fitted with one or more gas struts and are pinned.

Care and Maintenance Daily: 1) Visually inspect covers, doors and grills for any structural damage.

Servicing Weekly: 1) Check the bolts and pins for security.

2) Check gas strut for security and leaks.

Engine Bay Covers

Radiator Covers

Transmission Bay Covers

Figure 6.5.7.1 - Covers

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Covers Continued Gas Struts Fitted to Covers

Figure 6.5.7.2 - Engine Cover

Alternator

Exhaust

6.5.7.3 Grill covers

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Covers Continued WARNING Under some of the covers on this machine there are rotating parts which may cause serious injury. The machine must be isolated before any maintenance procedure is under taken, for the isolation procedure see Section 5 of the Operator’s Manual for this machine.

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Automatic Fire Suppression System The automatic fire suppression system is a Loss of Pressure (LOP) system that incorporates strategically placed nozzles; LOP tubing and a stainless steel cylinder charged with foam spray. In the event of a fire the LOP tubing is designed to melt when heated to 160-180 C which causes a loss of pressure allowing the LOP cylinder valve to open. The system also has a manual actuator placed on the forward top panel in the operators cab. The system pressure is monitored by a transducer that will automatically shutdown the engine when the pressure drops below 900kPa. Normal system charge pressure is 1350kPa. If a slow leak exists in the system the DCS unit will provide a warning once the system pressure reaches 1100kPa. Care and Maintenance Daily: 1) Visually inspect fire suppression cylinder pressure, ensure it is in the ‘green’ zone.

Servicing Every 1000 service hours: 3) Visually inspect the fire suppression bottle, all hosing and fittings for signs of damage or degradation.

4) Visually inspect the fire suppression nozzles (5 in engine compartment, 2 in hydraulic/transmission compartment). Ensure the nozzle is clear from fouling/blockage that would impede the spray pattern.

5) LOP detection tubing has an installed life of 1 year. Replace all LOP detection tubing.

6) Please contact Bucyrus or the original fire suppression system supplier for component replacement activities.

Nozzle Locations on the Machine

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Fire Suppression Cylinder

2 x forward nozzles

2 x rear nozzles

Nozzles in Transmission/Hydraulic Compartment

1 x rear nozzle

Nozzles in Engine Compartment 1 x rear nozzle 1 x rear nozzle

Nozzles in Engine Compartment

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PERIODIC NON-DESTRUCTIVE TESTING OF LOAD BEARING STRUCTURES There are a number of key structural joints that should be examined via non-destructive testing on a recurrent basis. Ensuring that the welded joints and structures are free from cracks, defects and deformation will enable safe and efficient machine operation.

Care and Maintenance Daily: Visually inspect the areas identified in the figure below.

Servicing Every 1000 service hours: Conduct NDT examination on lift points, joints, etc. identified in the figure below. For recommended NDT processes please contact Bucyrus.

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Section

7

Pneumatic System GENERAL DESCRIPTION The pneumatic system is used for starting, stopping and activating the electronic safety shutdown system (DCS) of the diesel engine system. Auxiliary circuits are also employed for safety interlocking with the park brakes and a operator activated air horn. The system comprises of an air compressor, storage receiver, air starter motor and auxiliary components for pressure regulation and engine control.

A water cooled air compressor is driven from a mechanical take off on the diesel engine and is constantly running whenever the engine is running. Air compression is controlled via a separately mounted governor valve which acts in conjunction with the unloading mechanism in the compressor cylinder block. The governor starts and stops compression of air by loading and unloading the compressor when the system reaches the desired maximum and minimum pressure.

The air receiver acts as an accumulator, storing a volume of compressed air for system use at start up. The receiver is fitted with a pressure relief valve set at 130 PSI, drain valve and inlet valve to enable external filling. The stored compressed air, governed at 120 PSI, is delivered to the pneumatic system via an isolation valve at the receiver.

Starting is achieved by directing pilot air pressure to the air starter motor relay. This relay pilots the main air supply to the starter motor which engages the starter motor pinion gear to mesh with the engine ring gear which in turn cranks the engine.

The engine safe start circuit assures that the transmission is selected to neutral and the engine monitoring sensors are healthy prior to activating the starter motor. The heat exchanger coolant flow and engine oil pressure sensors are over ridden at start up, this is to allow pressure to be developed by the oil, and flow from the coolant system. Once the engine has started and the start button is released both coolant flow and oil pressure sensors become active, allowing air pressure to be held in the engine fuel shutdown cylinder which, in turn, delivers the fuel supply to the governor. Stopping the engine may be done automatically by activation of one or more engine sensors or by manual activation of the ON/OFF isolator in the operator’s compartment. Both of these actions remove air pressure from the shutdown cylinder, which cuts fuel supply to the engine via a return spring on the governor stop lever.

The manual park brake apply is interlocked with the shutdown cylinder and can only be released with the engine running. Once the park brake is released it supplies air to the transmission de clutch valve.

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Pneumatic Schematic with DCS Fitted

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SAFETY PRECAUTIONS The following safety precautions are not intended to be exhaustive. Safe work practices should be used when servicing or operating heavy machinery.

ALWAYS give the diesel engine an opportunity to cool down before performing servicing around the rear frame as engine components around this location are hot and could cause burns or scalding.

ALWAYS be aware of, and isolate, other forms of energy and pinch points (fan, belts, pulleys) when accessing the engine compartment including pneumatic stored pressure, engine coolant pressure and other heat sources such as engine block and exhaust system components.

ALWAYS install the articulation lock when accessing the machine articulation area as machine articulation will result in crush injuries ALWAYS install the lift arm lock when access underneath the lift arm assembly is required. Remove any RAS attachment before raising and locking the lift arm assembly.

NEVER assume that all forms of energy have been isolated unless you have confirmed for yourself.

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AIR COMPRESSOR The air compressor is driven from engine timing drive gears lubrication is via and oil line from the engine oil gallery in the engine block to the front of the compressor. Cooling is achieved from the cooling lines from the engine cooling system.

Compressor and Mountings Servicing Replace the air compressor inlet filter every month or 250 service hours.

To remove and replace the air compressor inlet filter: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.4.

2) Isolate the pneumatic system using the isolating valve located at the air receiver.

3) Locate the filter housing above the air compressor assembly.

4) Remove the filter by unscrewing the retaining clamp at the base of the filter.

5) Remove the filter and discard in a responsible manner.

6) Fit the new filter and tighten clamp.

Compressor If the pneumatic system fails to maintain sufficient charge pressure the compressor may be faulty and will need to be removed for inspection and overhaul.

To remove and replace the air compressor: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.4.

2) Drain all air pressure from the air receiver to assure full isolation to the compressor.

3) As the air compressor is water cooled the cooling system will need to be drained.

4) See Section 2.4.6 for the correct procedure for draining the cooling system.

WARNING The engine cooling system runs at a nominal 100 kPa pressure and can reach temperatures of more than 100oC. Release stored pressure and wear personal protective equipment when accessing.

5)

Remove the air compressor intake filter, the governor air line and the stainless steel braided delivery hose from the compressor. Plug the hose ends to avoid contamination.

6) Remove the two cooling hoses from the air compressor. Plug the hose ends to avoid contamination.

7) Remove the oil delivery line from the engine to the compressor.

8) Remove the two mounting bolts from the front of the timing cover and three mounting bolts from the rear of the compressor and remove the bracket.

9) Remove compressor assembly clear of the engine.

10) Fit a new gasket to the compressor.

11) Fit the new compressor and secure with the mounting bolts.

12) Re-fit the two cooling hoses, two air hoses, lubricating oil lines and air filter.

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AIR RECEIVER The air receiver accepts air pumped from the air compressor and stores it at a maximum pressure of 830 kPa (120 PSI) as set by the governor valve mounted on the side of the compressor. A pressure relief valve mounted on the receiver assures that the maximum stored pressure does not exceed 860 kPa (125 PSI). The base of the receiver is fitted with a drain cock to enable stored pressure to be safely directed away from personnel, as well as provide low drain point for the removal of water. Air is delivered to the receiver via a one-way check valve to retain air pressure when the diesel engine has stopped.

A three-way ball valve is also fitted to enable receiver filling from an external air supply. The valve has three positions: IN–OFF–TANK To fill the receiver via an external air hose: 1) Connect an external air supply to the MIN-SUP coupling.

2) Rotate the three-way ball valve from the TANK to the OFF position and apply air pressure from the supply hose.

3) Rotate the ball valve from the OFF to the IN position. This allows air to be delivered into the receiver.

4) Once the correct air pressure has been obtained (observed at the air pressure gauge in the operator’s compartment) turn the external air pressure off.

5) Rotate the three-way ball valve to the TANK position. This opens the supply hose to the drain line and closes the inlet to the tank. Pressure in the hose

Drain Valve in the OFF Position

Isolation Valve

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3 Way Air Charge Valve in the OFF Position

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Air Receiver Servicing The air receiver should be drained of accumulated water daily.

To drain the air receiver: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.4.

2) Locate the drain valve at the lower most point on the air receiver.

3) Open the drain valve allowing water to be purged from the tank. It is not necessary to drain all air from the receiver. A short burst of released air is sufficient.

The governor valve should be checked for correct operation every 250 service hours.

To check for correct operation: 1) Start the engine and ensure the external air supply is isolated.

2) Observe the air pressure gauge in the operator’s compartment. The compressor should unload at 120 PSI. 3) To check that the valve is loading, bleed air from the receiver SLOWLY observing the air pressure gauge. The compressor should start pumping air into the receiver at approximately 80 PSI. NOTE: The pressure differential between loaded and unloaded is fixed at 30-40 PSI and it can not be adjusted.

To check for the correct governing pressure simply observe the maximum and minimum pneumatic pressure on the pressure gauge located in the operator’s compartment. Pressure in the system should constantly rise to a maximum of 830 kPa (120 PSI) with a tolerance of –5 PSI. If the governed pressure is outside this range, adjustment is required.

To adjust the governor valve for the correct pressure: 1) Start the engine.

2) Locate the governor valve and remove the dust cap on the bottom of the canister.

3) Loosen the lock nut and rotate the adjusting screw clockwise to increase the governed pressure or counter clockwise to reduce the governed pressure.

4) Verify governed pressure by running the engine and viewing the maximum pressure indicated on the pneumatic pressure gauge located in the operator’s cabin.

5) When 120 PSI is reached lock the locknut and replace the dust cap.

The air receiver pressure relief valve should be checked for correct relief setting every 3000 service hours.

Dust Cap (Remove to locate adjusting screw)

Governor Valve

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Air Receiver Continued To check and adjust the air receiver relief valve: 1) Start the engine.

2) Observe the pressure on the air pressure gauge in the operator’s compartment.

3) Locate the governor valve located on the side of the compressor.

4) Rotate the governor adjusting screw clockwise to increase the pressure to 125 PSI on the gauge in the operator’s compartment.

5) Locate the relief valve on the air receiver and adjust until the air lifts the seat and starts venting to atmosphere.

6) Lock the relief valve at this setting.

7) Rotate the adjusting screw counter clockwise on the governor screw on the side of the compressor to reduce the governed pressure.

8) Drain air from the air receiver till the operators air pressure gauge is 70 PSI. 9) Let the air pressure build up until governed pressure is reached.

10) Rotate the adjusting screw clockwise to increase the pressure.

11) When 120 PSI is reached on the gauge in the operator’s compartment lock the locknut on the adjusting screw and replace the dust cap.

12) Drain some air from the air receiver and let the pressure build up to check NOTE The air receiver is a pressure vessel inspection and certification of the air receiver must be carried out every 12 months by a licensed boiler inspector.

Check Valve

Figure 7.4.2 - Air Receiver Safety Relief Valve

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START CIRCUIT AND AUXILIARIES Starter Motor The diesel engine starter motor is a pneumatic driven motor mounted on the engine flywheel housing.

When air pressure is delivered to the starter motor a drive pinion on the motor shaft engages with the teeth on the engine flywheel ring gear to crank the engine.

Servicing A silencer mounted on the exhaust port of the starter motor is used to minimise starter motor noise emission. The silencer is basically a wire gauze type muffler. Over time the muffler may become clogged with foreign material which will reduce starting efficiency. The silencer should be removed and cleaned every 1000 service hours.

To remove and clean the starter motor silencer: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.4.

2) Isolate the pneumatic system using the isolating valve located at the air receiver.

3) Locate the starter motor silencer at the starter motor exhaust port.

4) Remove the silencer by unscrewing the three bolts at the rear of the starter motor.

5) Clean the silencer with clean fuel oil and allow to dry.

6) Replace the silencer and check for free air flow by activating the starter motor.

Failure of the starter motor to crank the engine could be caused by a faulty starter motor. In this case the starter motor will need to be removed for inspection and overhaul or otherwise replaced.

To remove and install the starter motor: 1) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 1.4.

2) Isolate the pneumatic system using the isolating valve located at the air receiver.

3) Locate the starter motor at the bottom of the engine block at the flywheel housing.

4) Disconnect the air supply hose from the start relay valve and the two pilot hoses to the starter motor. Plug the hose ends to avoid contamination.

5) Remove the three bolts and lock washers that secure it to the flywheel housing.

6) Pull the motor forward of the flywheel housing and remove.

7) Installation is the reverse procedure.

Figure 7.5.1.1 - Starter Motor Assembly

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Safe Start System The safe start system ensures the machine can not be started with the machine in gear (by means of the neutral start switch) or if there are any safety system sensors in the open position.

On start up the heat exchanger coolant flow and engine oil pressure sensors are defeated by a time delay in the DCS control. This allows the engine sufficient time to develop the minimum operating pressures after start up. The engine coolant temperature and exhaust temperature sensors are required to be in a healthy state before starting is available. \ Indicators on each shutdown sensor are provided to determine shut own sensor status. Once engine oil pressure and coolant flow is achieved the start override valve will close. The machine shuts down immediately if these valves are still in the open position.

Start Valve

ON/OFF Toggle Switch

Air Pressure Gauge

ON/OFF Toggle Switch The ON/OFF toggle switch supplies system air to the DCS safety circuit start initiate sensor which activates the DCS system to indicate the relevant conditions. It also supplies the start circuit and park brake circuit when switched to the ON position.

Air System Pressure Gauge The air system pressure gauge shows the air pressure under storage in the air receiver. The normal system pressure should be 120 PSI by means of a regulator mounted on the compressor.

Start Valve Once the toggle switch is on the DCS electronic system will check the relevant conditions. It will then open the RUN SOLENOID VALVE. This pilots the SAFE START VALVE and allows air to be supplied to the START VALVE which when depressed will supply air via the neutral start valve and safe start valve to the relay valve on the main air line to the starter motor.

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Safe Start System Continued Safe Start Valve The safe start valve is piloted by the DCS RUN SOLENOID and ensures that Transmission Neutral Start Valve Ensures air pressure is not supplied from the safe start to the start relay valve unless the transmission is in the neutral position.

Start Relay Valve The start relay valve is piloted by the start valve. The valve opens to allow air from the main air supply to rotate the starter motor thus cranking the engine for start up.

Figure 7.5.2.2 - Transmission Neutral Start Valve

Figure 7.5.2.3 - Start Relay Valve

Brake and Transmission Interlock System Starting is interlocked to the transmission via the neutral start valve.

The transmission forward/reverse control lever must be in the neutral position to allow the starter motor to engage.

A transmission de-clutch valve disengages the transmission if the emergency/park brake is applied.

Engine Off Brake system interlocking is provided at engine shutdown and start up by releasing air to atmosphere via the BRAKE INTERLOCK PILOT VALVE. Before starting lack of air pressure supplied through the SAFE START VALVE stops the actuation of the park brake valve . This is also achieved via the operator’s compartment door interlock valve if the door is not closed and latched. These valves supply system air pressure to the PARK/BRAKE VALVE PILOT VALVE in the operator’s cabin to the PARK BRAKE HYDRAULIC VALVE on the main control manifold which applies and releases the spring applied and pressure released vehicle brakes by means of system oil pressure.

Engine Running When the engine is running air pressure pilots the BRAKE INTERLOCK PILOT VALVE and allows air to be delivered to the PARK/BRAKE VALVE PILOT VALVE which, in turn applies and releases the brakes via pilot air pressure to the PARK BRAKE HYDRAULIC VALVE.

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Operator’s Horn The operator’s horn push button is located in the operator’s cabin. Application of the button delivers air pressure to the air horn for an audible warning.

CAUTION Do not use the vehicle horn with the diesel engine shutdown. As the compressor is not delivering air to the receiver the horn will quickly exhaust the stored air in the receiver and result in an insufficient air supply for starting.

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PNEUMATIC SYSTEM TROUBLE SHOOTING The following pneumatic system trouble shooting guide is intended to provide basic guidance for analysing typical system faults and determining probable causes. This guide is not intended to be exhaustive provide personnel with a basic guide for fast rectification.

Symptom Engine will not crank at start up.

Poor engine cranking performance.

System pressure fails to charge to 120 PSI when engine is running

Manual No.M01335

Probable cause No air pressure to starter motor.

Insufficient air pressure to starter motor.

Insufficient air pressure received from compressor.

Caused by

Remedy

No air pressure in the air receiver.

Fill air receiver from an external supply. (See section 7.4)

Isolating valve at the air receiver is closed.

Open isolating valve. (See section 7.4)

ON/OFF isolator in the operator’s cabin is in the OFF position.

Toggle the isolator to the ON position

Transmission control is not set to the neutral position or is faulty.

Set transmission control to neutral Replace valve if required

Exhaust temperature or exhaust gas temperature sensor activated Engine temperature or coolant level activated

Verify sensor status from indication panel. Allow sufficient time for the sensor to cool or replace sensor if suspected as faulty. Check engine coolant level

Neutral start interlock not functioning

Check neutral start interlock function

Low hydraulic oil

Fill hydraulic tank

Pneumatic system bypass.

Check pneumatic system for leaks and rectify as required.

Low system air pressure.

Check system air pressure.

Re-set Governor pressure if required.

Damaged or faulty relay valve

Check and clean relay valve replace if required

Blocked starter motor silencer.

Check and clean starter motor silencer if required.

Starter motor internal bypass.

Remove and overhaul or replace starter motor.

Governor setting out of adjustment.

B pass in compressor

Test and adjust governor.

(See section 7.4) Remove and overhaul or replace compressor

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Section

8

Contact Us

For Your Information Our service If you need to order spare parts or if technical problems occur, please contact our customer personnel or contact us directly.

Service address Bucyrus Australia Limited Customer Service 20 Kullara cl, Beresfield NSW 2322 Phone: Fax:

02 4914 7100 02 4914 7169

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