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Operator’s Manual
FBL-60 Shield Hauler
BI014625
Serial No: 5003704
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Bucyrus to CAT Model Number Cross Reference
Underground Mining Products
Product Line Model Bucyrus CAT Bucyrus CAT Ram Car/Coal Hauler Face Haulage FBR15 FH125 D Compact Loader Load Haul Dump Compact Loader (6 tonne) CL106 Compact Loader (10 tonne) CL110 Load Haul Dump Load Haul Dump FBL10 CL210 MH10 CL210B FBL15 CL215 MH15 CL215B Miner Bolter Miner Bolter 30MB CM845 Shield Hauler Roof Support Carriers MH40 SH640 D FBL55 SH660 D FBL55H/MH55H/FBL60/MH60 SH660 HD Shield Trailer Shield Trailer CHT50 SH150 BI014625
- Room & Pillar
BI014625
Operator’s Manual Rev. 1 FBL-60 Shield Hauler Serial No. 5003704 i TABLE
CONTENTS Section 1 General Information Introduction ..................................................................................... 1 Description...................................................................................... 1 General Arrangement ..................................................................... 2 Specifications ................................................................................. 3 Section 2 General Safety and Precautions ................................................. 5 Section 3 Gauge Parameters and Colour Coding .................................... 11 Section 4 Machine Orientation, Controls and Functions Machine Orientation Basic Machine Layout ......................................................... 15 Control Locations Compartment Door 16 Transmission Gear Control Lever ....................................... 17 Transmission Directional Control Lever .............................. 17 Park Brake Button ............................................................... 18 Four-Way Joystick Control Lever ........................................ 19 No 1—Two-Way Hydraulic Control Lever ........................... 19 No 2—Two-Way Hydraulic Control Lever ........................... 19 Operator’ Seat 20 Accelerator Pedal 20 Brake Pedal 20 Steering Wheel 21 Brake Head Pressure Gauge .............................................. 22 Brake Accumulator Pressure Gauge ................................... 22 Steering Accumulator Pressure Gauge ............................... 22 Engine Start Button ............................................................. 23 Air Pressure Gauge ............................................................. 23 On/Off Toggle Switch .......................................................... 23 Transmission Oil Temperature Gauge ................................ 24 Engine Coolant Temperature Gauge .................................. 24 Load Indicator 25 Horn Button 26 Emergency Fuel Shut Off Valve .......................................... 26 Engine Service Hour Meter ................................................. 27 Air Cleaner Service Indicator............................................... 27 Exhaust Outlet Gas Temperature Gauge ............................ 28 Engine Oil Pressure Gauge................................................. 28 Shutdown System Test Valve ............................................. 28 Engine Fuel Primer Pump ................................................... 29 Attachment Quick Connects Button .................................... 29 Emergency Intake Shut Off Valve ....................................... 30 Manual LOP Fire Suppression System Actuator ................. 31 Section 5 Machine Isolation Engine Isolation ............................................................................ 33 Pneumatic Isolation ...................................................................... 34 Hydraulic Isolation ........................................................................ 35 Engine Coolant Isolation............................................................... 36 Electrical Isolation......................................................................... 37 BI014625
OF
Operator’s Manual ii FBL-60 Shield Hauler Serial No. 5003704 Rev. 1 Section 5 Machine Isolation (cont.) Articulation Isolation...................................................................... 38 Lift Arm Isolation ........................................................................... 39 Exhaust Conditioner Isolation ....................................................... 40 Exhaust Conditioner Mark Up Tank Pressure Isolation ................ 41 Section 6 Pre-Start Procedure .................................................................... 43 Section 7 Engine Starting Procedure ........................................................ 53 Section 8 Post Start Checks ....................................................................... 55 Section 9 Stopping the Engine ................................................................... 59 Section 10 Tramming the Machine ............................................................... 61 Section 11 Stopping and Braking ................................................................ 63 Section 12 Driving on a Ramp ...................................................................... 65 Section 13 Parking on a Ramp ..................................................................... 67 Section 14 Loading ........................................................................................ 69 Section 15 Cookie Plate Use ......................................................................... 71 Section 16 Towing the Machine when Disabled ......................................... 73 Section 17 Towing with the Machine ........................................................... 75 Section 18 Air Venting the Fuel System ...................................................... 77 Section 19 Air Venting the Engine Cooling System ................................... 79 Section 20 Diesel Control System (DCS) ..................................................... 81 Section 21 Fluid Specification Table ........................................................... 85 Revision Detail Rev. 1 Corrections to Table of Contents Corrections to page numbering throughout the manual. Corrections to page footers Sections 17 and 21. Date 24 May 2012 Rev. 0 30 January 2012 Original Issue BI014625
This document is the property of Bucyrus SUBJECT MATTER HEREIN IS PRIVATE, CONFIDENTIAL AND RESTRICTED. Do not use, reproduce, copy, distribute or disclose except with, and only to the extent of, prior written consent of Bucyrus PERSONS RECEIVING THIS DOCUMENT ARE RESPONSIBLE FOR RESTRICTING DISCLOSURE, except as absolutely necessary consistent with the intended use. When such is completed, return immediately to Bucyrus.
Bucyrus recommends that all Safe Working procedures should be approved and checked by Mine Officials. Bucyrus declines all liability for direct or indirect consequences of printing errors.
This document is copyright. All intellectual property rights and copyright in the document (or any part of this document remains the property of Bucyrus. Except as provided for in the Copyright Act 1968 (Ctn) no part of this document may in any form or by any means (including without limitation electronic, mechanical, micro copying, photocopying, recording or otherwise) be reproduced, stored in a retrieval system or transmitted without the prior written permission of Bucyrus.
BUCYRUS Australia
Room & Pillar Division
20 Kullara Close, PO Box 373
Beresfield NSW 2322 Australia
Phone: +61 2 49147000
Fax: +61 2 49147059
Operator’s Manual Rev. 1 FBL-60 Shield Hauler Serial No. 5003704 iii
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Operator’s Manual iv FBL-60 Shield Hauler Serial No. 5003704 Rev. 1
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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-60 Shield Hauler operator with the proper information regarding the machine’s instrumentation, operating controls and general safe working procedures. All operators of this machine must be conversant with the information contained within this manual before operating the machine.
To ensure safe and efficient operation, the FBL-60 Shield Hauler must be adequately maintained by the operators and service personnel. To achieve this, the operator’s pre-start inspection procedure contained in Section 6 of this manual must be performed before any use of this machinery is undertaken.
Any abnormalities should be reported immediately to service personnel to avoid costly machine repairs, production downtime and unsafe operation of the machine.
DESCRIPTION
The FBL-60 is a 60000 kg high capacity Shield Hauler. It has been designed for lifting and carrying heavy pieces of equipment and machinery in underground coal mines. Its main function is carrying and placing of longwall equipment and shields. The machine comes standard with a set of fork tines and winch for this purpose.
The motive force is provided by a 195 kW Caterpillar 3126 turbocharged four-stroke inline six cylinder flameproof diesel engine package. Flameproofing of the system includes a wet exhaust conditioning system complete with exhaust and intake flame traps. The start system is pneumatic. The diesel control system is an intrinsically safe electronic monitoring system. The engine power output is connected to the constant four-wheel drive system via a drive coupling through a four-speed bidirectional power shift transmission to heavy duty axles.
The FBL-60 utilises a wet bath exhaust conditioning system complete with an optional replaceable particulate filter and a purifier.
A site specific Risk Assessment is recommended to be conducted before this machine is introduced into service.
Operator’s Manual Rev. 1 FBL-60 Shield Hauler Serial No. 5003704 1
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Operator’s Manual 2 FBL-60 Shield Hauler Serial No. 5003704 Rev. 1
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GENERAL ARRANGEMENT
SPECIFICATIONS
All specifications are subject to change without notice. Always consult BUCYRUS to obtain current information before applying critical loads.
Capacities
Tractive effort 36500 kg
Winch (front) 20000 kg
Maximum unbraked trailer mass Consult Bucyrus
Differential lock type - front Posi-Torque
Differential lock type - rear Posi-Torque
Maximum braked trailer mass Consult Bucyrus Capacity of tow
Fork
38750 kg
Engine Type Diesel, turbocharged, 4 cycle
Service Brake Hydraulic System
with fwd/rev modulation.
Dana 36000 series MHR Speeds Forward and reverse 4
Torque Converter
Mounted in transmission single element
14.0 integral
Operator’s Manual Rev. 1 FBL-60 Shield Hauler Serial No. 5003704 3
hitch
Unladen
Loading Chart Weight Unladen with full tanks 57600 kg
with full tanks and cookie plate 59220 kg Maximum laden with cookie plate 119220 kg
Cooling
Cooling
Engine
Displacement
Engine Speeds Low idle 800 rpm High idle 2700 rpm Fuel Consumption At full power 45 litre/hr Average mine duty 12-40 litre/hr Start System Starter motor type Air
Intake Air Cleaner Type/make Dry
Intake flame trap Spiral
system Water based radiator
fan Hydraulic driven fan
make/model Caterpillar 3126
7.2 litre
turbine type
dual element/Caterpillar
wound type
Type
Exhaust Conditioner
Flameproof wet type Make Bucyrus Exhaust flame trap Reversible After treatment Catalytic exhaust purifier Transmission Type Power shift
Make/model
Type
Make/model Dana
Axles Type Outboard planetary Front axle make/model Dana 21D Rear axle make/model Dana 21D
Solid Size 54’OD x 28’ wide Inflation
Solid
Steering Closed
Pressure
psi
Closed
Pressure
Lift
PTO Open
Tank
Wheels Type
media
Hydraulic Systems
centre
compensated 2500
Brakes
centre
compensated 2500 psi
Open centre 3000 psi
centre 3000 psi Tank type Sealed and pressurised
pressure 50 kPa
Steer/brake
Hydraulic Filtration
system Pressure 10 micron replaceable with bypass Optional return PTO In line, 25 micron
Type
Control
Actuation Foot
Operating pressure 0
Brake
12.1
Steering Type
Service
Type Totally
liquid
Posi-Stop Park Brake Type Totally enclosed, liquid cooled Posi-Stop Articulation Bearing type and size Pin & Spherical Degrees of turn either side 45°
Type
Electrical
Type
Voltage 12
Lights Number/location 2
Type High performance Approved flameproof Distance From Fork Face (mm) Maximum Load (kg) Standard 700 60000 900 53000 1200 45500 1500 39700 1800 35200 BI014625
Reverse modulated, pressure reducing
valve Open centre
pedal
to 17.10 MPa
release pressure
MPa
Centre articulated, hydraulic
Brake
enclosed,
cooled
Oscillation
Rear bolster Seating (Operator) Type Cross-seated Make Bucyrus Suspension Adjustable spring/shock absorption Canopy Type (both) Protective device MDG1 And MDG17
System
Approved flameproof
V
front, 2 rear
Overloading equipment could cause personal injury, death or equipment damage. Due to configuration or options these weights can vary up to 20%. Bucyrus recommends that relevant standards and safety procedures should always be used when operating this machine. Removal of protective canopies, doors, interlocks and structures etc., could cause serious injury of death. Replacement with correctly torqued fasteners is mandatory.
4 FBL-60 Shield Hauler Serial No. 5003704 Rev. 1
Operator’s Manual
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 oil 32 litre Engine cooling system water 72 litre Axle oil (each) 60 litre Vehicle Speeds 1st gear 3 kph 2nd gear 7 kph 3rd gear 12 kph 4th gear 20 kph Maximum Tractive Effort 1st gear 36500 kg 2nd gear 15200 kg 3rd gear 8700 kg 4th gear 4950 kg Grade ability Front to rear 1:4 Side to side (empty) 1:4 Side to side 1:8 (laden forks fully raised) Maximum Machine speed at Tare Weight 20 kph GVM Weight 6 kph BI014625
Section 2
General Safety and Precautions
This section contains specific safety precautions that shall be followed whilst the machine is being used by suitably qualified operators. This list is NOT all inclusive and a measure of commonsense should always be applied together with established site specific risk assessment and safety procedures.
ONLY TRAINED AND AUTHORISED OPERATORS SHALL OPERATE 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.
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.
Operator’s Manual Rev. 1 FBL-60 Shield Hauler Serial No. 5003704 5
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• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
