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TABLE OF CONTENTS
Operator’s Manual Rev. 0 FBR-15 Coal Hauler Serial No. 5002937 i
Section 1 General Information Introduction.....................................................................................1 Description......................................................................................1 General Arrangement.....................................................................2 Specifications..................................................................................4 Section 2 General Safety and Precautions..................................................7 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 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 Horn Button.........................................................................25 Exhaust Coolant Temperature Gauge.................................25 Exhaust Gas Temperature Gauge.......................................25 Emergency Fuel Shut Off Valve..........................................26 Engine Service Hour Meter.................................................26 Air Cleaner Service Indicator...............................................27 Exhaust Back Pressure Gauge...........................................27 Engine Oil Pressure Gauge.................................................28 Engine Fuel Primer Pump...................................................28 Emergency Intake Shut Off Valve.......................................30 Section 5 Machine Isolation Engine Isolation............................................................................31 Pneumatic Isolation......................................................................32 Hydraulic Isolation........................................................................33 Engine and Heat Exchanger Coolant Isolation.............................34 Electrical Isolation.........................................................................35 Articulation Isolation......................................................................36 Tailgate Isolation...........................................................................37 BI180771
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.
Operator’s Manual ii FBR-15 Coal Hauler Serial No. 5002937 Rev. 0
BUCYRUS Australia Room & Pillar Division 20 Kullara Close, PO Box 373 Beresfield NSW 2322 Australia Phone: +61 2 49147000 Fax: +61 2 49147059 Section 6 Pre-Start Procedure....................................................................39 Section 7 Engine Starting Procedure........................................................51 Section 8 Post Start Checks.......................................................................53
9 Stopping the Engine...................................................................57
Tramming the Machine..............................................................59
Stopping and Braking................................................................61
12 Driving on a Ramp......................................................................63
13 Parking on a Ramp.....................................................................65 Section 14 Loading........................................................................................67 Section 15 Ejecting........................................................................................69 Section 16 Towing the Machine when Disabled.........................................71 Section 17 Air Venting the Fuel and Engine Cooling System...................73 Section 18 Diesel Control System (DCS)....................................................75 Section 19 Fluid Specification Table...........................................................79 BI180771
Section
Section 10
Section 11
Section
Section
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 FBR-15 Coal 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 FBR-15 Coal 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 FBR-15 is a 15m³ capacity Coal Hauler. This allows it to be used for carrying coal from the continuous miner to the feeder breaker station.
The motive force is provided by a 172 kW Caterpillar 3126 turbocharged four-stroke inline six cylinder diesel engine package. Flameproofing of the system includes a dry 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 four speed bidirectional power shift transmission via a drive coupling on the rear of the engine, the power is then transmitted to heavy duty axles. The rear axle drives the rear wheels via 90° bevel gear boxes to the rear planetary hub complete with liquid-cooled Posi-Stop brakes.
The FBR-15 utilises a dry exhaust system complete with a replaceable particulate filter, catalysed exhaust post treatment purifier and a exhaust outlet flame trap.
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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Operator’s Manual
SPECIFICATIONS
All specifications are subject to change without notice. Always consult BUCYRUS to obtain current information before applying critical loads.
Tyres - Standard BI180771
Michelin X mine D2
x 25 Ply rating Radial Inflation media (front) Air (rear) Hutchinson insert
Safe approved
Torque Converter Type Mounted in transmission, single element Make/model Dana 13.0 integral
Axles Type Outboard planetary
Differential type Bevel gear and pinion
Differential lock type - front (engine end) Posi-Torque
4 FBR-15 Coal Hauler Serial No. 5002937 Rev. 0
Capacities Payload (nominal with hungry boards) 15 m³ Other capacities available: Payload (maximum weight all material) 20000 kg Consult Bucyrus for weight over 15000 kg Weight Unladen with full tanks 25000 kg Laden with 15T load 42000 kg Engine Type Diesel, turbocharged, after cooled, 4 cycle Cooling system Water based radiator Cooling fan Hydraulic driven fan Engine make/model Caterpillar 3126 Displacement 7.6 litre Maximum power 171.5 kW (230 hp) @ 2600 RPM Maximum torque 779 Nm @ 1950 RPM Ventilation (NSW Requirement) 10.3 m³/s Engine Speeds Low idle 800 RPM High idle 2600 RPM Governed 2500 RPM Stall Speeds Converter stall 2271 RPM Full stall 2100 RPM Hydraulic stall 2500 RPM Fuel Consumption At full power 37.5 litre/hr Average mine duty 8-10 litre/hr Start System Starter motor type Air turbine type Engine Intake System Type/make Dry/Donaldson Dual element type Intake flame trap Spiral wound type Exhaust Conditioner Type Flameproof dry type Make BUCYRUS Exhaust filter Replaceable element Exhaust flame trap Spiral wound type After treatment Catalytic exhaust purifier Shutdown system (standard) Pneumatic Shutdown system (standard) Electronic Intrinsically
Transmission
Type Power shift with forward/reverse modulated Speeds, forward and reverse 4
Type
Size 17.5
Hydraulic Systems Steering Closed centre 20.7 MPa Brakes Closed centre 20.7 MPa Ejecting Tray Open centre 20.7 MPa PTO (one on machine) Open centre 20.7 MPa Tank type Sealed and pressurised Tank pressure 50 kPa Hydraulic Filtration Suction In line, strainer Return 25 micron
bypass
Pressure10 micron Replaceable
Differential lock type - rear (trailer end) Standard Wheels Make/model 5 piece (heavy duty) Main Hydraulic Pump Type Gear Standard pump output @ 2600 RPM 160 lpm Steering/Brake Pump Type Piston pressure compensated Standard pump output @ 2600 RPM 117 lpm Engine Fan Pump Type Gear Alternator Drive Pump Type Gear Steering System Control valve Closed centre Actuation Orbital (steering wheel) Unloader valve 20.7 MPa Crossover relief 21.7 MPa Accumulator Steering Type Piston Quantity x capacity 1 x 4 litre Operating pre-charge pressure 6.2 MPa Accumulator Brakes Type Piston Quantity x capacity 1 x 2 litre Operating pre-charge pressure 6.2 MPa Accumulator Ejector System Type Piston Quantity x capacity 2 x 10 litre Operating pre-charge pressure 6.2 MPa Ejector Tray System Control valve Open centre Actuation Remote hydraulic pilot Main relief 21.7 MPa Cylinder Reliefs Load eject 21.7 MPa Load retract 21.7 MPa PTO out 21.7 MPa PTO in 21.7 MPa Cylinders Type Double acting Cushion stops Steering
Replaceable with
Steer/brake system
with bypass
Cylinders Type Double acting
Cushion stops Steering
Service Brake Hydraulic System Type Reverse modulating Actuation Foot pedal
Service Brake Type Totally enclosed, liquid cooled Posi-Stop
Make/model Heavy duty six plate
Application Spring applied hydraulic release
Park Brake Type Totally enclosed, liquid cooled Posi-Stop
Make/model Dana 16150
Heavy duty 6 plate
Application Spring applied hydraulic release Location Each wheel end built into axle
Steering Type Centre articulated, hydraulic Articulation Bearing type Pin and spherical bearing Degrees of turn either side +/- 48°
Oscillation Type Centre articulation bearing Degrees up and down from horizontal +/- 30° Seating (Operator)
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.
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Type
Make
Suspension
Canopy Type Adjustable protective device MDG1 and MDG17 Electrical System Type Approved flameproof Voltage 12 V Shutdown system Electronic Intrinsically safe approved 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 800 kPa Relief pressure 830 kPa Air receiver volume 80 litre Service Capacities Hydraulic tank 300 litre Fuel tank 300 litre Transmission/converter oil 80 litre Engine crankcase oil 22 litre Engine cooling system water 72 litre Axle oil (each) 60 litre Vehicle Speeds (unladen) 17.5 x 25 tyres 1st gear 3.8 kph 2nd gear 7.9 kph 3rd gear 13.3 kph 4th gear 22.5 kph Maximum Tractive Effort 17.5 x 25 tyres 1st gear 203 kN 2nd gear 96 kN 3rd gear 55 kN 4th gear 32 kN Grade Ability Front to rear 1:4 Side to side (empty) 1:4
Cross-seated
BUCYRUS
Adjust spring/shock absorber
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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 and ongoing 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 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.
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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.
Travelling at high speeds, on cross grades or articulating the machine with raised loads may cause the machine to become unstable.
ALWAYS follow the correct isolation and tag out procedure before performing any servicing or accessing beneath or on the machine.
ALWAYS operate carefully and in a responsible manner and observe all Manager’s Transport Rules.
ALWAYS refer to site JSA and SOP’s prior to towing with the machine.
ALWAYS ensure sufficient ventilation is available to dilute exhaust gases. As stated on the machine’ compliance plate.
ALWAYS ensure area around tailgate is clear and nobody is within one metre of rear of trailer when using the trailer ramplate and tailgate controls.
ALWAYS be aware of the hazard sources on the machine:
Engine coolant pressure (see Section 5).
Engine coolant temperature (see Section 5).
Engine exhaust temperature (see Section 5).
Exhaust coolant temperature (see Section 5)
Rotating radiator fan.
Stored hydraulic pressure (see Section 5).
Stored air pressure (air receiver) (see Section 5).
Engine oil pressure and temperature.
Transmission oil temperature.
Articulation area (see Section 5).
Tailgate area (see Section 5).
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 only, and not the steering wheel.
ALWAYS drive the machine to suit the conditions, report or rectify any holes, ruts, that may cause injury or damage to the equipment.
NEVER operate the machine under unsecured roof.
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Potential Crush Point Articulation
One Metre No Go Zone When Trailer in Ejected or Retracted
Potential Crush Point Against Rib When Articulating
Keep the 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 or electrically unsafe.
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SAFETY LABELS AND INSTRUCTIONS
This manual contains important information affecting the safety of personnel and the equipment being used.
The safety instructions and behavioural rules are intended to protect operators from potentially dangerous situations and assist in the safe operation of the trailer and associated equipment.
The following symbols are used with safety instructions and identify varying degrees of hazardous conditions.
The safety instructions associated with these symbols are to be considered the minimum requirements for effective hazard and operational control.
Points in the text marked with this symbol draw attention to immediately impending danger. Possible consequences are very serious or fatal injury.
These points contain information on potentially dangerous situations. Possible consequences are very serious or fatal injury.
This symbol draws attention to potentially dangerous situations. Possible consequences are light to moderately serious injury and machine damage.
Points in the text marked with this symbol draw attention to potentially harmful situations. Possible consequences are damage to machine or equipment in immediate vicinity
Text marked with this symbol contains useful information associated with the machine and its application.
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Section 3
Gauge Parameters and Colour Coding
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.
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GAUGE ALARM PARAMETERS
Engine Coolant Temperature
0-50 °C Yellow Coolant temperature too low.
50-104 °C Green Normal operating temperature range.
104-107 °C Orange Above normal operating temperature. Engine shutdown imminent.
107-120 ° C Red Above normal operating temperature. Engine should have shutdown. Coolant will be boiling.
Exhaust Coolant Temperature
0-100 °C Green Normal operating temperature range.
100-108 °C Orange Above normal operating temperature. Engine shutdown imminent.
107-120 °C Red Above normal operating temperature. Engine should have shutdown. Coolant will be boiling.
Exhaust Gas Temperature
0-140 °C Green Normal operating temperature range.
140-150 °C Orange Above normal operating temperature. Engine shutdown imminent.
150-200 °C Red Above normal operating temperature. Engine should have shutdown.
Exhaust Pressure
0-10 kPa Green
Normal operating pressure.
10-12 kPa Orange Exhaust pressure getting high indicating that exhaust filter needs to be changed.
12-25 kPa Red Exhaust pressure too high. Exhaust filter needs to be replaced. Continued long periods of operation will result in damage to engine.
Engine Oil Pressure
0-100 kPa Red Engine oil pressure too low. Engine should have shutdown.
100-600 kPa Green Normal operating pressure range.
600-800 kPa Red Engine oil pressure too high. Continued operation could result in damage to the engine.
Air Pressure Gauge
0-275 kPa Orange Air pressure low. Machine will not start. Machine may shutdown.
275-827 kPa Green Normal operating pressure range.
827-1000 kPa Red Air pressure too high. Continued long periods of operation could result in damage to the machine.
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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.
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