CAT Bucyrus CL215 Load Haul Dump Service Manual SN:5003974 – PDF DOWNLOAD

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CAT Bucyrus CL215 Load Haul Dump Service Manual SN:5003974 – PDF DOWNLOAD

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CAT Bucyrus CL215 Load Haul Dump Service Manual SN:5003974 – PDF DOWNLOAD

Language : English
Pages : 311
Downloadable : Yes
File Type : PDF

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CAT Bucyrus CL215 Load Haul Dump Service Manual SN:5003974 – PDF DOWNLOAD

INTRODUCTION
The operation of heavy mining machinery can be hazardous. To ensure safe operation, operators and personnel must be alert, competent, correctly trained, tested and licensed in the principles, capabilities and correct operating and isolation procedures of the machinery.
This manual is designed to provide the CL215 Load Haul Dump operator and service personnel with the proper information regarding the machine’s instrumentation, operating controls and general safe working procedures. All operators and service personnel of this machine must be conversant with the information contained within this manual before operating or performing service tasks on the machine.
To ensure safe and efficient operation, the CL215 Load Haul Dump must be adequately maintained by the operators and service personnel. The operator’s pre-start inspection procedure contained in Section 6 of the Operator’s Manual must be performed before the machine is returned to active service.
DESCRIPTION
The CL215 is a 15000 kg Load Haul Dump/Utility machine. It allows it to be used for general purpose work throughout the mine, which includes carrying heavy loads, materials and supplies.
The motive force is provided by a a 172 kW (230 HP) Caterpillar 3126 turbocharged fourstroke inline six cylinder flameproof diesel engine package. Flameproofing of the system includes a wet exhaust conditioning system complete with exhaust and intake flame traps.
The start system is pneumatic. The Diesel Control System (DCS) is an intrinsically safe electronic monitoring system. The engine power output is connected to the constant fourwheel drive system via a drive coupling through a four-speed bidirectional power shift transmission to heavy duty axles.
The CL215 Load Haul Dump utilises a wet bath exhaust system complete with replaceable particulate filter.

TABLE OF CONTENTS:

CAT Bucyrus CL215 Load Haul Dump Service Manual SN:5003974 – PDF DOWNLOAD

Section 1 General Information
Introduction …………………………………………………………………………. 1
Description ………………………………………………………………………….. 1
Safety Labels and Instructions ………………………………………………. 2
Gauge Colour Code ……………………………………………………………… 3
Gauge Alarm Parameters ……………………………………………………… 3
General Arrangements …………………………………………………………. 6
Specifications ……………………………………………………………………… 7
Lubrication and Fuel Specifications
General ……………………………………………………………………… 9
Fuels …………………………………………………………………………. 9
Fuel Specification Table ……………………………………………….. 9
Fuel Additives ……………………………………………………………. 10
Diesel Fuel Relevant Information …………………………………. 11
Engine Oil …………………………………………………………………. 12
Torque Converter/Transmission Fluid …………………………… 12
Hydraulic Oil ……………………………………………………………… 12
Gear Oil ……………………………………………………………………. 12
Multi Purpose EP Grease ……………………………………………. 12
Drive Coupling Grease ……………………………………………….. 13
Exhaust Conditioner Make Up Tanks ……………………………. 13
Fluid Specification Table …………………………………………….. 14
Grease Point Reference Drawing …………………………………. 15
Machine Isolation
Engine Isolation …………………………………………………………. 16
Pneumatic Isolation ……………………………………………………. 17
Hydraulic Isolation ……………………………………………………… 18
Engine Coolant Isolation …………………………………………….. 19
Electrical Isolation ……………………………………………………… 19
Articulation Isolation …………………………………………………… 20
Lift Arm Isolation ……………………………………………………….. 21
Exhaust Conditioner Isolation………………………………………. 22
Exhaust Conditioner Make Up Tank Pressure Isolation …… 23
General Safety and Precaution
General ……………………………………………………………………. 24
Packing and Supporting the Machine……………………………. 27
Maintenance Schedules ……………………………………………………… 25
10 Hours—Daily Off Line Mechanical Inspection ……………. 29
50 Hours—Weekly Off Line Mechanical Inspection ………… 37
250 Hours—3 Months Off Line Mechanical Inspection ……. 47
500 Hours—6 Months Off Line Mechanical Inspection ……. 57
1000 Hours—12 Months Off Line Mechanical Inspection … 67
2000 Hours—2 Yearly Off Line Mechanical Inspection ……. 77
5000 Hours—5 Yearly Off Line Mechanical Inspection ……. 87
10000 Hours—10 Yearly Off Line Mechanical Inspection … 97
Recommended Bolt Torque ……………………………………………….. 107
Section 2 Engine System
Fuel System
General Description………………………………………………….. 109
Safety Precautions …………………………………………………… 110
Fuel Tank ……………………………………………………………….. 111
Section 2 Engine System (cont.)
Fuel System
Fuel Lines ……………………………………………………………….. 112
Primary Fuel Filter/Water Separator ……………………………. 113
Secondary Fuel Filter ……………………………………………….. 114
Fuel System – Priming ……………………………………………… 116
Lubrication System
General Description ………………………………………………….. 117
Safety Precautions …………………………………………………… 118
Oil Filter ………………………………………………………………….. 119
Checking/Filling Engine Oil ………………………………………… 120
Changing Engine Oil …………………………………………………. 120
Flushing the Lubrication System ………………………………… 121
Air Intake System
General Description ………………………………………………….. 122
Safety Precautions …………………………………………………… 122
Air Cleaner/Indicator Assembly ………………………………….. 123
Emergency Intake Shutoff Valve ………………………………… 124
Inlet Flame Trap/Flameproof Joints …………………………….. 125
Servicing Air Intake System ……………………………………….. 126
Cooling System
General Description ………………………………………………….. 128
Safety Precautions …………………………………………………… 128
Engine Package ………………………………………………………. 129
Expansion Tank ……………………………………………………….. 130
Header Tank ……………………………………………………………. 130
Fan Assembly ………………………………………………………….. 131
Water Pump Belt Tension ………………………………………….. 132
Radiator ………………………………………………………………….. 133
Checking/Filling and Flushing Coolant System …………….. 135
Flushing a Contaminated Cooling System …………………… 136
Exhaust System
General Description ………………………………………………….. 137
Safety Precautions …………………………………………………… 138
Exhaust Downpipe/Purifier ………………………………………… 138
Exhaust Make Up Tanks …………………………………………… 140
Exhaust Conditioner …………………………………………………. 141
Exhaust Particulate Filter …………………………………………… 150
Flame Paths or Fixed Connections …………………………….. 152
Exhaust Emission Testing Procedure ………………………….. 152
Throttle Control
General Description ………………………………………………….. 154
Safety Precautions …………………………………………………… 154
Cable Adjustment …………………………………………………….. 155
Engine System Troubleshooting …………………………………………. 156
Section 3 Transmission and Drive Train
Engine Drive Coupling
General Description ………………………………………………….. 161
Safety Precautions …………………………………………………… 161
Checking and Greasing Drive Coupling ………………………. 162
Removal and Installation of Drive Coupling ………………….. 163
Section 3 Transmission and Drive Train (cont.)
Transmission and Torque Converter
General Description………………………………………………….. 164
Safety Precautions …………………………………………………… 166
Checking/Filling the Transmission Oil …………………………. 167
Changing the Transmission Oil Filter Element ……………… 168
Changing the Transmission Oil …………………………………. 169
Troubleshooting Guide ……………………………………………… 170
Service Data ……………………………………………………………. 172
Front and Rear Axle
General Description………………………………………………….. 175
Safety Precautions …………………………………………………… 175
Checking/Filling the Planetary Wheel End Oil Level ……… 176
Checking/Filling the Axle Centre Oil Level …………………… 177
Changing the Oil In Axle Centres, Wheel Ends, and Liquid
Cooled Brakes …………………………………………………………. 178
Checking Wear of the Brake Assemblies …………………….. 179
Drive Lines
General Description………………………………………………….. 180
Safety Precautions …………………………………………………… 181
Greasing and Inspecting Drive Lines ………………………….. 182
Removing and Installing the Rear Drive Line ……………….. 182
Removing and Installing the Front Drive Line ………………. 183
Removing and Installing the Upper Drive Line …………….. 184
Wheel and Tyre Assemblies
General Description………………………………………………….. 185
Safety Precautions …………………………………………………… 185
Removal …………………………………………………………………. 185
Installation ………………………………………………………………. 187
Section 4 Hydraulic System
General Description ………………………………………………………….. 189
Safety Precautions …………………………………………………………… 190
Hydraulic Isolation ……………………………………………………. 191
Pumps and Mountings
Steering/Brake Pump ……………………………………………….. 192
Main Hydraulic Pump ……………………………………………….. 195
Auxiliary Hydraulic Pumps…………………………………………. 196
Hydraulic Tank
Checking and Filling Hydraulic Oil ………………………………. 197
Changing Hydraulic Oil……………………………………………… 198
Checking and Replacing Return Filter …………………………. 199
Steering and Brake Hydraulic Manifold ……………………………….. 200
Steering/Brake Pump Pressure Filter ………………………………….. 204
Steering Circuit ………………………………………………………………… 206
Steering Accumulator ……………………………………………….. 206
Steering Control Valve ……………………………………………… 207
Brake Circuit ……………………………………………………………………. 208
Brake Accumulator …………………………………………………… 208
Brake Valve …………………………………………………………….. 209
Brake Heads……………………………………………………………. 213
Attachment Controls
Control Levers …………………………………………………………. 214
Section 4 Hydraulic System (cont.)
Main Control Valve Bank …………………………………………………… 216
Tilt and Lift Circuits …………………………………………………………… 218
RAS Attach and PTO Circuits ……………………………………………. 219
Alternator Circuit and Cooling Fan ………………………………………. 220
Hydraulic Schematic …………………………………………………………. 221
Section 5 Electrics, Instruments and Controls
Electrical System
General Description ………………………………………………….. 223
Safety Precautions …………………………………………………… 223
Alternator, Lights and Hour Meter General Arrangement .. 224
Electric Lighting Components …………………………………….. 225
Engine Service Hour Meter ……………………………………….. 228
Electrical System Troubleshooting ……………………………… 229
Alternator and Drive Assembly
General Description ………………………………………………….. 230
Safety Precautions …………………………………………………… 230
Alternator Assembly …………………………………………………. 230
Alternator Drive Assembly …………………………………………. 232
Diesel Control System (DCS)
General Description ………………………………………………….. 233
Control Unit ……………………………………………………………… 234
Power Supply ………………………………………………………….. 235
DCS Looms …………………………………………………………….. 236
DCS Sensors …………………………………………………………… 237
DCS Display Unit ……………………………………………………… 240
Display Illustrations …………………………………………………… 242
DSC Display Menus …………………………………………………. 246
System Operation …………………………………………………….. 252
Instructions for Diesel Control System Methane Head ….. 254
Section 6 Frame Components
General Description ………………………………………………………….. 261
Safety Precautions ……………………………………………………………. 261
Front Frame
Chassis …………………………………………………………………… 262
Lift Arm
General …………………………………………………………………… 264
Lift Arm Isolation ………………………………………………………. 265
Rapid Attach Back Plate (RAS) Assembly …………………… 266
Rear Frame
Chassis …………………………………………………………………… 268
Operator’s Compartment …………………………………………… 269
Compartment Door Assembly ……………………………………. 269
Canopy Assembly …………………………………………………….. 270
Operator’s Seating ……………………………………………………. 272
Articulation Joint ………………………………………………………. 273
Covers ……………………………………………………………………. 275
Fire Suppression System ………………………………………….. 277
Section 7 Pneumatic System
General Description ………………………………………………………….. 279
Pneumatic Schematic ……………………………………………………….. 280
Safety Precautions ………………………………………………………….. 281
Air Compressor
Compressor Mounting ………………………………………………. 282
Compressor …………………………………………………………….. 282
Air Receiver …………………………………………………………………….. 283
Starter Motor ……………………………………………………………………. 286
Safety Circuit
Diesel Control System ………………………………………………. 287
Make Up Tank Head Pressure …………………………………… 287
Safe Start System ……………………………………………………. 288
Brake and Transmission Interlock System …………………… 289
Operator’s Horn ……………………………………………………….. 290
Pneumatic System Troubleshooting ……………………………. 291
Section 8 Attachments and Accessories
General Description ………………………………………………………….. 293
Safety Precautions ………………………………………………………….. 295
Spade Lip Ejector Bucket ………………………………………………….. 296
5th Wheel Adaptor ……………………………………………………………. 298

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