CAT Bucyrus Operator's Manual Compact Loader SN 5001298 - PDF DOWNLOAD

BI014596

Reliability at work

Operator’s Manual Compact Loader Serial No: 5001298

BI014596

BI014596

Operator’s Manual

TABLE OF CONTENTS Section 1

General Information About this Package......................................................................... 1 Introduction ..................................................................................... 2 Dimensions ..................................................................................... 3 Specifications ................................................................................. 5

Section 2

Safety and Precautions General Safety and Precautions..................................................... 7 Control of Energy Sources ........................................................... 12 Machine Isolation ................................................................ 12 Pneumatic Isolation ............................................................. 13 Engine Isolation ................................................................... 14 Engine Coolant Isolation ..................................................... 15 Hydraulic Isolation ............................................................... 16 Electrical Isolation ............................................................... 17 Mechanical Isolation ............................................................ 18

Section 3

Gauge Parameters and Colour Coding .................................... 21

Section 4

Machine Orientation, Controls and Functions Machine Orientation Basic Machine Layout ......................................................... 23 Control Locations Compartment Door .............................................................. 24 Transmission Gear Control Lever ....................................... 25 Transmission Directional Control Lever .............................. 25 Park Brake Button ............................................................... 26 Four-Way Joystick Control Lever ........................................ 27 No 1—Two-Way Hydraulic Control Lever ........................... 27 No 2—Two-Way Hydraulic Control Lever ........................... 27 Operator’ Seat ..................................................................... 28 Accelerator Pedal ................................................................ 28 Brake Pedal ......................................................................... 28 Steering Wheel .................................................................... 29 Brake Head Pressure Gauge .............................................. 30 Engine Start Button ............................................................. 31 Air Pressure Gauge ............................................................. 31 On/Off Toggle Switch .......................................................... 31 Transmission Oil Temperature Gauge ................................ 32 Engine Coolant Temperature Gauge .................................. 32 Horn Button ......................................................................... 33 Emergency Fuel Shut Off Valve .......................................... 33 Engine Service Hour Meter ................................................. 34 Air Cleaner Service Indicator............................................... 34 Exhaust Outlet Gas Temperature Gauge ............................ 35 Engine Oil Pressure Gauge................................................. 35 Shutdown System Test Valve ............................................. 35 Engine Fuel Primer Pump ................................................... 36 QDS Pilot Lock Cylinder Release Button ............................ 36 Attachment Quick Connects Button .................................... 36 Emergency Intake Shut Off Valve ....................................... 37

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Section 5

Pre-Start Procedure .................................................................... 39

Section 6

Engine Starting Procedure ........................................................ 49

Section 7

Post Start Checks ....................................................................... 51

Section 8

Stopping the Engine ................................................................... 57

Section 9

Tramming the Machine ............................................................... 59

Section 10

Stopping and Braking ................................................................ 61

Section 11

Driving on a Ramp ...................................................................... 63

Section 12

Parking on a Ramp ..................................................................... 65

Section 13

Loading ........................................................................................ 67

Section 14

Dumping ...................................................................................... 69

Section 15

Towing the Machine when Disabled ......................................... 71

Section 16

Towing with the Machine ........................................................... 73

Section 17

Air Venting the Fuel System ...................................................... 75

Section 18

Air Venting Engine Cooling System.......................................... 77

Section 19

Attaching Attachments .............................................................. 79

Section 20

Detaching Attachments .............................................................. 81

Section 21

Diesel Control System (DCS) ..................................................... 83

Section 22

Fluid Specification Table ........................................................... 85

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

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General Information ABOUT THIS PACKAGE The operation of heavy mining equipment 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 equipment.

This documentation package is designed to provide the operator of the Compact Loader with the correct information for the equipment’s:  Important Safety Requirements  Energy Isolation  Instrumentation and Operating Controls  Location  Function  Operation  Basic Operator Checks and Maintenance All operators of this equipment must be conversant with the information contained within this manual before operating the machine.

A site specific Risk Assessment is recommended to be conducted before this machine is introduced into service.

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INTRODUCTION The Compact Loader is designed and manufactured by Bucyrus, the loader is an 8000 kg multi-purpose machine. This 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 129 kW MWM turbocharged four-stroke inline six cylinder flameproof diesel engine package. Flameproofing of the system includes a wet scrubber system complete with exhaust and intake flame traps. The start system is pneumatic and the diesel control system (DCS) is an intrinsically safe electronic monitoring and shutdown system which prevents the engine running outside of the predetermined safe operating parameters.

The engine power output is connected to the constant four-wheel drive system via a drive coupling through a torque converter and out to a four speed Dana/Spicer 32000 Series transmission to heavy duty Dana 113 inboard planetary with bevel gear and pinion axles.

The Compact Loader is in a class of its own in today’s arduous mining conditions and is the most advanced machine available to perform the tasks required in the modern mine.

A site specific Risk Assessment is recommended to be conducted before this machine is introduced into service.

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DIMENSIONS

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SPECIFICATIONS All specifications are subject to change without notice.

Always consult Bucyrus to obtain current information Hydraulic Systems Steer/brake system before applying critical loads.

Capacities Depending on Model Bucket payload up to 8000 kg QDS forks, max payload 600 mm load form fork face up to 8000 kg Maximum braked trailer mass Consult Bucyrus TBS required for combinations Standard Ejector Bucket Heaped capacity (SAE) Struck capacity

2.7 m³ 2.25 m³

Weight Unladen with full tanks and bucket Engine (6 Cylinder) Type Cooling system Cooling fan Engine make/model Displacement Maximum power tested Maximum torque tested

800 rpm 2800 rpm

Start System Starter motor type Intake Air Cleaner Type Intake dual element type

Exhaust Conditioner Type Make After treatment

Tank type Hydraulic Filtration Steer/brake system Bucket/PTO system Auxiliary system Common return

Pressure 10 micron nom Pressure 10 micron nom Pressure 10 micron nom Tank mounted, 25 micron replaceable with bypass

Main Hydraulic Pump Type Pressure compensated piston Standard pump output @ 2000 rpm 135 lpm Steering/Brake Pump Type Pressure compensated piston Standard pump output @ 2000 rpm 90 lpm Cylinders Type Rods Counterbalance load lock valves

Air

Dry Primary and secondary

Bucket System Control valve Actuation

Flameproof water bath conditioner Bucyrus Catalytic exhaust purifier and particulate filters

Torque Converter Type Make/model

Mounted on engine, single element Dana/Spicer integral

Axles (Front/Rear) Type Make/model Differential type Brakes

Inboard planetary Dana 113 Bevel gear and pinion SAHR

3 piece (heavy duty)

Tyres - Standard Size Ply rating Inflation media Load/speed rating

14x24 L3 *** Radial Air Max 6 km/h when loaded 8t

Size Ply rating Inflation media Load/speed rating

17.5x25 L3 ** Radial Air Max 6 km/h when loaded 10t

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Auxiliary system

Steering System Control valve Actuation

Transmission Type Power shift with fwd/rev modulation Make/model Dana/Spicer 32000 series Speeds, forward and reverse 4

Wheels Make/model

Bucket/PTO system

21200 kg

Diesel, turbocharged and 4 cycle Water based radiator Hydraulic driven fan MWM 6.45 litre 117 kW @ 2200 rpm 585 Nm @ 1400 rpm

Engine Speeds Low idle High idle

Closed centre, pressure compensated Closed centre, pressure compensated Closed centre, pressure compensated Sealed

Articulation Bearing type and size Bush material Pin material Degrees of turn either side Oscillation Type Degrees up and down from horizontal Seating (Operator) Type Suspension Canopy Type

Electrical System Type Voltage Polarity Lights Number /location Type Alternator Drive Type

Compact Loader Serial No. 5001298

Double acting Hard chromed Lift and tilt

Closed centre Mini Orbitral EHPS Pilot Valve

Closed centre Hydraulic pilot

Pin and bearing Hardened steel Hardened steel 45 degree

Ball bearing at articulation 8 degree

Cross seated Adjustable spring/shock absorb.

Adjustable CAB To (MDG1)

Approved flameproof 24 V Floating

2 front, 2 rear Exlec Flameproof Hydraulic LJH Flameproof

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Pneumatic System Compressor type Governed pressure Relief pressure Air receiver volume Service Capacities Hydraulic tank Fuel tank

Piston engine gear driven 120 psi 130 psi 40 litre

250 litre 150 litre

Maximum Tractive Effort Refer to engineering for information dependant on the applications.

Grade Ability Front to rear Side to side (empty) QDS raised 300 mm from floor Side to side (laden bucket load fully raised)

1:4 1:4 1:8

Vehicle Speeds Maximum speeds are limited to the load being carried 2nd gear max.

1st gear 5 kph max 2nd gear 9 kph max 3rd gear 18 kph max 4th gear 28 kph max

Overloading machinery could cause personal injury, death or machinery 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 or death. Replacement with correctly torqued fasteners is mandatory.

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Safety and Precautions GENERAL SAFETY AND PRECAUTIONS 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 machine 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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Personnel are required to acquaint themselves with, and understand, the safety information prior to operating, maintaining or servicing the Compact Loader Utility Vehicle.

It is the responsibility of the site employer to ensure that the installation of the machine and the way in which it is operated and maintained complies with any specific requirements outlined in this manual and those personnel associated with the installation, commissioning, operation, servicing, maintaining and disposal/relocation of the machine are appropriately trained, competent and supervised in all activities undertaken.

All work processes and systems employed are to be in accordance with the relevant Occupational Health and Safety legislation presiding over the operation.

Any conflict of information, question or doubt about the continued safe operation of the machine should be immediately referred to Bucyrus for clarification.

This machine must not be subject to any form of modification constituting a change to the design material, fit, form function without the prior written approval of Bucyrus.

Bucyrus will not be liable for any losses, damage or Occupational Health and Safety breaches incurred as a result of unauthorised repairs or modifications to the equipment as originally supplied.

Ensure personal protective apparel to worn and appropriate for the task undertaken. Typical hazards associated with operating and maintaining the Compact Loader, where personal protective equipment would apply include, but are not limited to, the following:

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

Hearing protection appropriate to the daily noise dosages received from the mining operations



Eye protection to protect against dust, fly rock, fluid release, ground fall



Leather gloves for manoeuvring heavy equipment and working in proximity to heat sources and hot fluids



Dust exclusion masks during coal cutting operations

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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 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

use tie down or tow equipment such as chains or slings that are not rated for the capacity of the machine.

DO NOT

operate the machine unless:   

DO NOT

start the machine unless:     

DO NOT

There are no tags attached.

The area around the machine is clear.

The park brake is applied.

Transmission is in neutral.

All water and oil levels are checked.

leave the machine unless:     

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There are no tags attached.

All covers and guards are correctly installed.

Personal protective equipment is worn.

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 QDS attachment is flat on the ground.

The engine is stopped.

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

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

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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

ensure the area is clear of any obstructions and area is fit for carrying out safe operation and maintenance.

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’s compliance plate.

ALWAYS

be aware of the hazard sources on the machine:           

ALWAYS

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

ALWAYS

use correct boarding and dismounting procedures:    

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Engine coolant pressure Engine coolant temperature Engine exhaust temperature Rotating radiator fan.

Stored hydraulic pressure Stored air pressure Engine oil pressure/temperature.

Transmission oil temperature.

Articulation area Lift arm area Machine mass

Check floor.

Hold on, step down.

Three points of contact at all times.

Board using hand holds only.

ALWAYS

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

NEVER

operate the machine under unsecured roof.

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

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.



Be aware of, and stay away from the no go zones surrounding the machine, should you be required to access these areas always ensure that the correct isolation procedures have been followed and are in place and the articulation locked by mechanical means – articulation lock

E M A R F T N O R F E M A R F R A E R E N O Z O G O N -

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CONTROL OF ENERGY SOURCES Electrical energies, fluid temperatures and pressures, as well, mechanical forces present or generated within this equipment are capable of inflicting serious bodily injury, death or significant damage to plant and the working environment.

Six levels of energy isolation are specified for the Compact Loader. All require the operation of the main battery isolation switch at some stage of each isolation procedure. The isolation switch is located on the left hand end of the Compact Loader at the battery enclosure on board the machine.

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.

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.

1.

Main Air Isolation

2.

Engine Isolation

3.

Engine Coolant Isolation

4.

Hydraulic System Isolation

5.

Electrical System Isolation

6.

Mechanical Isolation  

Articulation Lock Lift Arm Lock Before working on, near, any part of the equipment, the appropriate level of isolation must be applied. Failure to comply with the appropriate isolation level could cause serious injury or fatality

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.

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PNEUMATIC ISOLATION To isolate the pneumatic system perform the following procedure: 1.

2.

3.

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.

Locate the main air isolation valve located in the articulation area and rotate to the off position.

Relieve air pressure in the system lines by successively switching the on/off toggle switch until the air pressure gauge reads zero when the on/off toggle switch is in the on position.

MAIN AIR ISOLATION VALVE

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

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

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ENGINE ISOLATION To isolate the engine perform the following procedure: 1.

2.

3.

4.

5.

6.

Lower the lift arms or any attachment to the ground.

Apply the park brake.

Shutdown the engine.

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

Connect the articulation lock and chock the wheels.

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

Be careful of hot surfaces, allow time for them to cool down.

ON/OFF TOGGLE SWITCH AND AIR PRESSURE INDICATION

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ENGINE COOLANT ISOLATION To isolate the engine cooling system perform the following procedure: 1.

2.

3.

4.

5.

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

Isolate the pneumatic circuit.

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

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.

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

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.

COOLANT HEADER TANK

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HYDRAULIC ISOLATION To isolate the hydraulic system perform the following procedure: 1.

2.

Lower the lift arm and QDS Attachment to the ground, shutdown the engine using toggle switch, fit a danger tag to the on/off toggle switch, connect the articulation lock and chock the wheels.

Depress the attachment quick connects button. This will remove any residual pressure stored in the PTO lines.

QDS Pilot Cylinder Release

3.

4.

QDS Pressure Release

Observe brake pressure gauge located in the operator's compartment.

Remove hydraulic tank pre-charge pressure (68 kPa [10 psi]) by cracking hydraulic tank filler cap.

HYDRAULIC TANK CAP AND BREATHER

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.

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

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ELECTRICAL ISOLATION 1.

2.

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

Electrical energy is isolated once the breaker on the equipment enclosure is switched to the off position and locked out if required.

This action should only be performed by authorised electrical personnel.

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.

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

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.

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MECHANICAL ISOLATION FITTING AND REMOVAL OF LIFT ARM LOCK To fit the lift arm lock: 1.

2.

3.

4.

5.

6.

7.

Remove any attachments from the QDS back plate.

Chock the wheels.

Fit the articulation lock.

Raise the lift arms until the locking pin holes are in line with holes in the front frame and the lock pins can be placed through the lift arms on both sides in the location points.

Remove the lock pins from storage locations and install in the aligned holes on the lift arms.

Note that the lock pins are to be fully inserted into the holes.

It is now safe to work under the lift arms.

To remove the lift arm lock: 1.

2.

Remove the lock pins from the locating holes and secure in the respective storage locations.

Lower the lift arms to the ground.

The lift arms 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, the attachment has been removed and the lift arms have been supported in the raised position.

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FITTING AND REMOVAL OF ARTICULATION LOCK To fit the articulation lock: 1.

2.

3.

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.

Locate the articulation lock at the articulation area on both sides of the machine.

Remove articulation lock pin from storage location and install in correct position as show below.

To remove the articulation lock: 1.

With the park brake applied, remove the pins from the articulation lock point and return to storage position.

Location to Install Lock Pin

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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EXHAUST CONDITIONER ISOLATION To isolate the exhaust conditioner perform the following procedure: 1.

2.

Isolate the machine.

Isolation of the wet bath exhaust conditioner is carried out via a valve located between the water inlet hose and 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.

Low Water Shutdown/Make Up Tank Ball Valve

Drain Valve

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.

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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.

GAUGE ALARM PARAMETERS Engine Coolant Temperature

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0-50° C 50-104° C 104-107° C

Yellow Green 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.

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Exhaust Gas Temperature 0-70° C Green 70-80° C Orange 80-100° C

Red

Engine Oil Pressure 0-100 kPa Red 100-600 kPa Green 600-800 kPa Red

Normal operating temperature range.

Above normal operating temperature. Engine shutdown imminent.

Above normal operating temperature. Engine should have shutdown.

Engine oil pressure too low. Engine should have shutdown.

Normal operating pressure range.

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

Load Gauge Load Gauge Pressure

Load @ 600mm from Fork Face

138 Bar

10000 kg max

109 Bar

8000 kg

82 Bar

6000 kg

55 Bar

4000 kg

28 Bar

2000 kg

14 Bar

1000 kg

Park Brake Head Pressure Gauge 0-2500 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.

2500-3500 kPa Green Normal operating pressure range.

3500-4000 kPa Red Pressure too high. Damage to brake units may occur.

Transmission Temperature 0-120° C Green 120-150° C Orange 150-200° C

Red

Normal operating temperature range.

Above normal operating temperature. May result in damage to components.

Above normal operating range. Stop machine and report.

Service Brake Head Pressure 0-7200kPa Normal operating pressure range.

7200kPa Above normal operating range. Stop machine and report.

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

22

Green Red

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

Normal operating pressure range.

Air pressure too high. Continued long periods of operation could result in damage to the machine.

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Section

4

Machine Orientation, Controls and Functions MACHINE ORIENTATION BASIC MACHINE LAYOUT The Compact Loader consists of two main sections a front and rear frame. Housed in the front frame is the lift arm assembly, axle and main hydraulic control valve bank. The rear frame houses the transmission and hydraulic pumps, cooling system radiator, flameproof engine package (which utilises a wet bath exhaust conditioner), the operator’s compartment and all the storage reservoirs, (hydraulic, pneumatic, exhaust conditioner make up and fuel tanks).

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CONTROL AND FUNCTIONS COMPARTMENT DOOR The operator’s compartment door must be closed and locked after entering the compartment before the park brake button can be released and the declutch valve be deactivated.

Never use the door to apply the park brake. Always manually apply by pressing 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.

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.

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TRANSMISSION GEAR CONTROL LEVER The transmission gear control lever has four positions, first, second, third and fourth.

Shifting to a higher or lower speed may be made at full engine RPM. 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 and direction of travel. 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.

The transmission must be placed in the neutral position for the starter motor to engage when starting the engine.

If the engine starts when the transmission is not in neutral, the machine should be tagged out of service until the problem is rectified.

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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.

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 the machine and the machine could run away resulting in serious damage or injury.

The park brake must be applied for the starter motor to engage whenever an engine start is required.

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FOUR-WAY JOYSTICK CONTROL LEVER This lever has five positions, roll back, roll forward, lift, lower and hold. Pushing the lever to the right rolls the QDS back plate back for loading or tramming. Pulling the lever to the left rolls the QDS 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.

Two functions may be engaged at the same time by pushing the fourway 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 QDS 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.

To release attachments, the QDS 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 QDS 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.

On some machines an auxiliary hydraulic PTO (Power Take Off) may be fitted to the rear of the machine. This lever controls this function.

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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.

ACCELERATOR PEDAL The accelerator pedal is connected to the engine fuel pump governor via a hydraulic slave and master cylinder system. When the accelerator pedal is depressed the engine speed increases. The accelerator pedal is spring returned so that when pedal pressure is removed, the engine returns to low idle.

Always keep the operator’s compartment clean. Dirt, etc. can build up under the accelerator pedal restricting its movement.

SERVICE BRAKE PEDAL The service brake pedal when depressed applies the service brakes on the front and rear axles. There are two liquid-cooled hydraulically applied brakes located internally in each axle. 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.

Do not ride the brakes while tramming the machine.

If the engine should stall, the machine is fitted with fail-safe brake system that will fully apply the park brakes.

Always keep the operator’s compartment clean. Dirt, etc. can build up under the brake pedal restricting its movement.

Accelerator Pedal

Brake Pedal

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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 arms 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 arms end).

The machine will turn in the opposite directions when travelling in forward and reverse. Operator training and familiarity with LHD/utility operation is important to ensure that collisions are avoided.

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.

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PARK BRAKE HEAD PRESSURE GAUGE This gauge shows park brake system’s brake head pressure. Operators should check this gauge on each application. The gauge will read zero pressure when the brakes are fully applied via the park brake control.

When the park brake is released, the indicated pressure shall be a minimum of 2500 kPa (360 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.

Observe that the brake head pressure is on zero after applying the park brake.

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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.

2.

3.

4.

5.

The transmission is in neutral.

The park brake is applied.

The diesel control system shows no fault.

The on/off toggle switch is on.

Sufficient air is in the receiver and air valve is turned on.

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).

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.

2.

To start the engine, place the on/off toggle switch in the on position.

To shutdown the engine place the on/off toggle switch in the off position.

Engine Start Button

On/Off Toggle Switch

Air Pressure Gauge

RIGHT HAND SIDE OPERATOR’S DISPLAY PANEL

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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.

2.

Bring the machine to a halt, lower the QDS back plate to the ground and apply the park brake.

Put the transmission in neutral and rev the engine to about 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.

Do not operate the machine if the oil temperature is above 121°C.

ENGINE COOLANT TEMPERATURE GAUGE This shows the coolant temperature circulating through the engine, exhaust and radiator systems. Normal operating temperature is between 82°C-95°C. The engine should not be operated under heavy load until it has 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.

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.

Engine Coolant Temperature Gauge

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Transmission Temperature Gauge

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HORN BUTTON Pushing this button sounds the air horns.

It is good operating procedure to sound the horn 2-3 seconds before an engine start or whenever approaching blind intersection.

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.

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ENGINE SERVICE HOUR METER This electric meter is mounted on the main electrical enclosure.

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 INDICATOR

AIR CLEANER ASSEMBLY

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EXHAUST OUTLET GAS TEMPERATURE GAUGE This shows the exhaust gas temperature entering the mine atmosphere from the exhaust outlet. Machine will shutdown if this temperature exceeds 77°C. ENGINE OIL PRESSURE GAUGE This gauge indicates the engine lubricating oil pressure. Normal pressure is between 210 kPa-550 kPa (30 psi-80 psi).

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 (10 psi).

Do not run the engine with low oil pressure, as engine damage will result. Immediately report the problem to service personnel.

Engine Exhaust Gas Temperature Gauge

Engine Oil Pressure Gauge

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).

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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.

QDS PILOT LOCK CYLINDER RELEASE BUTTON This valve prevents accidental release of the attachment lock cylinder. Fully depress this button to allow lock cylinder to retract. This control is used with the No. 1 two-way control lever to engage and disengage the QDS lock cylinder.

The QDS release valve need not be depressed to lock (engage) the QDS lock tongue.

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.

QDS Pilot Cylinder Release

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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.

Intake Shutoff Valve with Reset Lever Inset

Intake Shutoff Stop Button

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.

Restarting of the engine should be done in compliance with the Manager’s Rules.

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Section

5

Pre-Start Procedure Walk around the machine: 1.

2.

3.

4.

5.

6.

7.

Check condition of all tyres. Inspect for sidewall cuts, tread cuts and separation.

Look for damaged or missing wheel nuts and studs.

Check for loose wheel nuts.

Guards and covers are in place and secure.

Missing or loose bolts.

Oil leaks.

Visible hose damage.

Never start or operate the machine if the diesel control system has been bypassed, report to service personnel.

Always ensure the machine is correctly isolated before undertaking any tasks.

Check the hydraulic tank oil level: 1.

2.

3.

4.

5.

Be sure the machine is on a level surface when checking oil level.

Ensure the lift arms are in the lowered position, the engine is turned off and the machine is isolated as per Section 2 - Pneumatic Isolation.

Check the level at normal operating temperature.

When the oil level has dropped below the mark shown below, add hydraulic oil to restore the correct operating level.

The tank fill cap is located on the off driver’s side of the machine on the top of the hydraulic tank.

Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 22)

HYDRAULIC TANK CAP AND BREATHER Rev. 0

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Check the engine oil level: 1.

2.

3.

4.

Check the engine oil level via the dipstick, the dipstick has to be screwed in and out using the locking nut.

If required the engine should be filled to the full mark on the engine dipstick. The oil fill plug is a screw type fitted to the rocker cover of the engine.

Ensure the correct engine oil is used. Oil specifications are listed in Section 22 - Fluid Specifications Table.

Do not over fill.

Always ensure the machine is correctly isolated before undertaking any tasks.

Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 22).

The oil level should only be checked with the engine stopped, the engine should be allowed to sit for five minutes before checking.

Engine Oil Fill Point

Engine Oil Dipstick

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Check the fuel level: 1.

2.

3.

Gauge fitted to the fuel tank.

Check the filler cap is secure and not damaged.

Ensure the filler cap seal is in place.

Always ensure the machine is correctly isolated before undertaking any tasks.

Do not operate the machine with the fuel level below empty level on the fuel tank. It is recommended procedure to fill the fuel tanks at the end of each shift

Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 22).

Check the condition and tension of the water pump drive belt: 1.

2.

Located at the rear of the machine, through the rear hinged door.

Damaged or loose belts should be reported to service personnel.

Running the machine with loose or damaged belts will cause the machine to overheat.

Fuel Level Sight Gauge Fuel Tank Fill Point

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Check the condition of the fuel water separator: 1.

2.

3.

Located at rear driver’s side of machine.

Replace filter and drain if any sign of water or cloudy fuel.

Check fuel lines for leaks or damage.

Check the articulation lock (see Section 5): 1.

2.

For proper storage and loose fasteners.

For damage.

Check the lift arm locks (see Section 5): 1.

2.

For proper storage and loose fasteners.

For damage.

Check the expansion tank coolant level: 1.

2.

3.

4.

Ensure coolant is to correct level on sight gauge (⅔).

Check for coolant leaks.

Ensure the correct coolant mix is being added (if required).

Report to service personnel if coolant is low.

Check the radiator: 1.

2.

For coolant leaks.

For build up of dirt (Clean if radiator fins are blocked or dirty).

Check the headlights: 1.

2.

Are securely mounted and operational.

For cables and glands for damage.

Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 22).

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Check the air cleaner (see Section 4): 1.

2.

3.

Filter condition indicator.

Replace filter element if indicator is in the red area.

Check intake pipes and hoses for loose or damaged connections.

Indicator Air Cleaner

Do not operate the machine with loose intake pipe connection, this will allow particles of dust into engine and cause serious damage.

Check air receiver: 1.

2.

For damage.

Drain condensate from main air drain valve.

It is important to drain the condensate from the air receiver on a daily basis to stop it contaminating the air circuit and the starter motor.

Personal Protective Equipment must be worn when operating main air drain valve.

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Check the fire extinguisher: 1.

2.

3.

4.

44

Located on both front mudguards.

Check inspection date.

Check contents indicator is reading in the green area.

If fire suppression system fitted check actuation points.

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The wet bath exhaust conditioning system on the CMP-LDR carries out four major functions:    

To cool and dilute exhaust gases.

To act as an approved flame trap.

To prevent hot gases from entering the mine atmosphere.

To reduce air borne exhaust particulates and hydrocarbons that enter the mine

Flameproof diesel engine maintenance must be carried out by a qualified and authorised person.

Inlet

Ins

p

io ect

s ole nH

Shutdown Float Chamber

Outlet

WET BATH EXHAUST CONDITIONER

Check exhaust system: 1.

2.

3.

4.

5.

6.

For damage.

Check joints for signs of leakage.

Check cooling hoses for security and condition.

Check and clean the exhaust flame trap.

Check the valves are in the correct position.

Check the make up tanks are full of water.

Do not operate the machine with loose or damaged exhaust components, report to service personnel immediately. Using the machine in an unsafe condition may cause serious damage or loss of life.

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Flameproof diesel engine maintenance must be carried out by a qualified and authorised person.

WET EXHAUST CONDITIONER

MAKE UP TANK SIGHT GLASS

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The float chamber inlet valve should be in the open position as shown in the picture below.

Low Water Shutdown/Make Up Tank Ball Valve

Drain Valve

Wear suitable eye protection, gloves and dust mask when performing maintenance tasks as particulate may be harmful to the respiratory system. Immediately wash any particulate matter from skin with warm, soapy water.

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Emergency Intake Shut Off Valve: The emergency intake shutoff valve (strangler valve) should be inspected before attempting to start the engine. The stop button should be pulled out and the reset lever latch into the operating position (see Section 4).

The engine will not start if the emergency shut off valve is activated, continued attempts to start the engine may result in damaged components.

If the emergency intake shut off valve has been activated, the restarting of the engine should be done in compliance with the relevant regulations and Manager’s Rules.

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Section

6

Engine Starting Procedure Always sound the horn and make sure the area around the machine, especially between the front and rear frames, is clear before starting the engine. Never attempt to start an engine without first knowing how to shut it off.

Do not start the engine if machine is tagged out or safety notice is affixed.

If the machine is to be put into operation, make certain that the articulation lock is disconnected.

1.

2.

3.

4.

5.

Turn the main air isolation valve, located in the engine compartment to the on position.

Enter the operator’s compartment and close and latch the door.

Place the transmission directional control lever in the neutral position.

Make sure the park brake is applied. Check the air pressure gauge. If the start pressure is below 275 kPa (39 psi) the engine may not start. If the air pressure is below 275 kPa (39 psi) , recharge the air receiver up to maximum 827 kPa (120 psi).

Turn the on/off toggle switch to the on position.

The diesel control system display will not activate if the air pressure is below 275 kPa

6.

7.

8.

9.

10.

Wait for the DCS display to indicate “waiting for start” approximately 1-2 seconds (all green lights).

Hold the accelerator pedal approximately ⅓ to ½ open.

Press the engine start button and release it when the engine has fired.

DCS display should indicate “engine running”.

Carry out post start checks and operate machine normally.

See Section 21 - Operating Diesel Control System As soon as the engine starts, check all gauges and indicators to ensure that all systems are functioning correctly. Always let the engine warm up slowly. Never load up a cold engine.

Do not engage the starter motor when the flywheel is moving.

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Excessive use of starting fluid can cause serious backfire and violent explosions within the engine. Serious engine damage may occur.

Avoid the use of starting aids and DO NOT use starting fluid (Aerostart) underground.

The steering and brake pressure gauges register in normal operating range only when the park brake is released.

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Section

7

Post Start Checks The following tests are required to be performed with the engine running: Check all gauges are on correct operational pressure: 1.

Gauges are colour coded (should read in green area).

Check function of lift arm assembly hydraulic system.

Check steering function.

Check park brake operation, gauge must read at least 2500 kPa (360 psi) with brake off: 1.

2.

To test move off slowly and apply the park brake.

To test service brake move off slowly and apply the service brake.

Check that all of the lights are working: 1.

There are two forward and rear facing headlights.

Check the transmission oil level: 1.

2.

3.

4.

5.

6.

7.

8.

Always check when the transmission is warm.

Once the correct transmission oil temperature has been reached park the machine on flat, level ground and leave it running.

Place the machine in neutral and apply the park brake.

Access the dipstick from the operator’s compartment through the cover over the top of the transmission. This panel is located between the operator’s compartment and the hydraulic tank.

The engine should be idling at 650 RPM-750 RPM. Remove the dipstick by pulling upwards and wipe with a clean, lint free cloth.

Reinsert the dipstick into the spout, push it all the way home.

Withdraw the dipstick and check the oil level. The level is to be maintained at the full mark.

Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 23).

Transmission Dipstick

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Check the diesel control system operation: 1.

2.

3.

4.

Run the engine at high idle.

Press the shutdown test button and hold for ten seconds.

Machine should shutdown and the low oil pressure display should be on.

The engine should not restart until the on/off toggle switch is reset.

If the engine does not shutdown do not use the machine. Report it to the service personnel for repairs.

Check low exhaust water shutdown test: 1.

Start DES and ensure all shutdown systems are operational, allow engine to warm up and run for several minutes.

DCS DISPLAY DIGITAL INPUT SCREEN

2.

Shut make up tank ball valve and open the low water shutdown test ball valve.

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Low Water Shutdown/Make Up Tank Ball Valve

3.

4.

5.

6.

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Observe machine taking note of water flow out of the low water shutdown test point when DES shuts down. Ensure the display on the DCS shutdown system indicates both proximity switches/magnetic reed switches are open.

Shut low water shutdown ball valve as soon as the DES shuts down and remove top cover from the float chamber Measure the water level from the bottom of the float chamber (this is required to be between 100mm and 110mm) and water must still be coming from low water shutdown test valve when the DES shuts down.

Once shutdown water level is achieved refit top cover to float chamber.

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7.

8.

To carry out individual shutdown float tests disconnect 1 x proximity switch/magnetic reed switch and connect “dummy plug” into the cable going to the DES shutdown system.

Power up shutdown system and start DES, carry out low water shut down test taking note of which light illuminated/message displayed on screen

Status: CH4 = 0.32% Engine shut down Scrubber Level 1 Scrubber Level 2 Alternator Off

o/o o-o

DCS DISPLAY DIGITAL INPUT SCREEN

9.

10.

54

Remove “dummy plug” and reconnect cable to the proximity switch/magnetic reed switch.

Repeat process 7-9 to test the 2nd proximity switch/magnetic reed switch.

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Status: CH4 = 0.32% Engine shut down Scrubber Level 1 Scrubber Level 2 Alternator Off

o/o o-o

DCS DISPLAY DIGITAL INPUT SCREEN

11.

Once both sensors have been individually tested a full low water shutdown test is to be carried out and results recorded.

The machine must not be used under any circumstance if it fails the low water shutdown test.

If the machine does not shutdown on a test it must be reported to service personnel for immediate rectification.

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Section

8

Stopping the Engine 1.

2.

3.

4.

5.

6.

Ensure the area is clear of any obstructions and area is fit for carrying out safe operation and maintenance.

Lower the lift arms and any attachment completely to the ground and remove any load from the engine.

Put the transmission directional control lever into the neutral position.

Remove any hydraulic load from the engine.

Apply the park brake. Observe that the brake head pressure gauge is on zero.

Allow the engine to run at idle speed for five minutes. This will allow internal temperatures to reduce gradually.

As the engine is turbocharged, shutting down the engine when the engine’s operating temperature is high may cause damage to the turbocharger and the lubrication system.

6.

7.

Turn the on/off toggle switch to the off position and the engine will shutdown.

Open the door, check floor, hold on and step down using three points of contact at all times.

Any problems with the normal engine shut off mechanism must be corrected before the engine is restarted.

If the engine fails to shutdown under the normal procedure the Emergency Intake Shut Off Valve should be used (see Section 4).

9.

Close the main air isolation valve on the air manifold after the engine has stopped.

Ensure the lift arms or any attachment are flat on the ground before leaving the operator’s compartment.

Ensure the machine is parked in an area that will not block traffic or in a blind intersection that may result in a collision.

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Section

9

Tramming the Machine 1.

2.

3.

4.

5.

The machine is designed to travel in both forward or reverse direction with equal ease and performance.

The transmission is controlled by a directional control lever and a gear control lever.

The machine has the same gear ratios in forward and reverse. This is to provide equal speeds and performance in each direction.

The engine should be at idle and the machine stationary when either forward or reverse gears are selected.

Always start in the low speed and shift into the next higher speed as the machine accelerates and as conditions permit.

Do not coast the machine in neutral. Excessive speed may result in an uncontrollable runaway.

6.

Use the transmission to slow the machine whenever possible, as this avoids excessive brake wear.

Do not downshift the transmission unless the machine is travelling at a speed suitable for the lower range.

Always ensure that the transmission control levers are fully shifted.

7.

8.

Shifting from one range to another can be made at any time. conditions permitting.

Momentarily decrease engine revs when selecting a lower gear.

If the transmission should overheat: a. b. c.

Stop machine in a suitable place and apply park brake.

Select neutral and run the engine at ½ speed until the oil temperature has dropped to a safe operating level.

If this does not work follow the shutdown procedure and advise the service personnel.

Hearing and eye protection shall be worn by the operator of this machine at all times whilst the engine is running.

The machine speed can be regulated by using the brakes, the accelerator pedal or by changing up and down gear ratios.

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10

Stopping and Braking 1.

2.

3.

4.

5.

6.

Use the transmission to help slow down the machine, by shifting down gears and utilising the brakes.

Apply the brakes and bring the machine to a halt at the side of the roadway, turn the machine toward the rib and lower the lift arms or any attachment to the ground.

Apply the park brake.

The engine should not be shutdown from full load. To stabilise temperatures allow it to idle for a few minutes before stopping.

Shut off the engine by turning the on/off toggle switch to the off position.

After stepping off the machine, switch off the main air isolation valve.

The brakes fitted to the machine are extremely effective to cope with towing large loads. Operators should be prepared for rapid deceleration when the brakes are applied.

In an emergency immediately apply the brake. If this fails to activate the brakes, immediately apply the park brake.

The seat belt should be worn whilst operating the machine at all times.

If the brakes fail on the machine you should:     

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Use the gears to help slow the machine.

Lower the lift arms or any attachment.

Gradually turn machine to the rib.

Apply the park brake.

Shutdown the engine.

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11

Driving on a Ramp 1.

2.

3.

4.

Stop and shift into first gear, and check the park and service brakes before travelling up or down a ramp.

Always use a low gear when travelling down a ramp.

Avoid changing gears while travelling on a steep ramp If you have a mechanical or brake failure: a. b. c.

Immediately apply the brakes.

If the service brakes do not function, apply park brake.

If the machine does not stop, turn the machine into the rib.

The machine should not be operated on more than the recommended grades (Section 1).

Operators must be competent in Emergency Stop Procedure.

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12

Parking on a Ramp

Do not park on a ramp unless absolutely necessary.

1.

2.

3.

4.

5.

6.

7.

Use the engine braking to help slow down the machine by letting up on the accelerator pedal.

Apply the brakes and bring the machine to a halt at the side of the road.

Turn the machine toward the rib.

If possible remove the load from the attachment.

Apply the park brake. Observe that the park brake head pressure gauge is on zero.

Always chock the wheels.

Inform mine management of the position of machine.

When on steep grades (more than 1:4). Do not rely on the park brake to hold the machine.

Always park with attachment into the rib and chock the wheels when on grades of more than 1:4.

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13

Loading The LHD method of loading is called crowd loading which combines the tractive effort of the machine with the breakout force of the bucket. With the 129kW of power from the machine and the torque multiplication of the converter and axles, this machine produces tremendous crowding power. Aggressive tyres, Dana 113 rigid planetary axles and an oscillating articulation joint ensure the power is kept on the ground for loading.

Dana 113 differentials are fitted to the front and rear axles of the machine to ensure positive traction. These differentials are similar to a limited no spin arrangement. At the bucket lip there is maximum breakout force in excess of 10000 kg. Maximum loading efficiency is obtained by adjusting the loading cycle to the operating conditions. The proper use of traction and breakout force makes it possible for a single pass load without spinning the tyres or ramming the muck pile. The following cycle includes operations common to all load-haul-dump situations, it should be modified to suit other operating conditions.

Always when mucking from a pile, work from both sides towards the centre. Keep it trimmed at all times.

Do not ram the muck pile or spin the tyres.

Do not go under a hung up draw point or under any unsupported roof.

Do not use the machine to bar down a hang up.

Always keep all four wheels on the ground during mucking. If you should accidentally raise the rear of the machine off the ground, lower it slowly - not with a sudden jerk.

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LOADING A BUCKET 1.

2.

With the bucket lip engaging the ground. Drive into the muck pile.

Slowly crowd the bucket back as the machine pushes into the muck pile until the bucket is full and is in the carry position. If the tyres start to spin, decrease acceleration slightly as you move the four-way joystick control lever slightly faster.

Do not exceed the machine’s carry capacity.

DO NOT undercut a muck pile. A sudden flow of muck can trap the machine in a draw point and lift the rear of the machine violently against the roof or may swamp the operator.

3.

68

Once the bucket is fully loaded, push the four-way joystick control lever to the right, shift into reverse and start to move away from the pile, lowering the lift arms into the carry position. Rapidly move the four-way joystick control lever side to side a few times to shake the load down to prevent spillage.

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14

Dumping Always keep your dump area clean and clear of chunks on the roadway.

STANDARD DUMPING 1.

2.

3.

4.

5.

6.

7.

8.

When approaching to dump a load, release the accelerator pedal and reduce speed (apply brakes).

Raise the lift arms to clear any guards or obstructions.

In dumping position the lift arms should be fully raised.

Push the four-way joystick control lever to the left - the bucket will fully dump.

When dumping into a boot, care should be taken to avoid damaging the structure of the boot. Approach the boot with the lift arms raised sufficiently to clear the tailgate.

Move in as far as possible without damaging either machine and dump the load.

In most cases it will be necessary to roll back the bucket before moving the machine away from the boot.

Once clear of the boot lower bucket to the carry position.

Do not carry load with the lift arms in a raised position.

EJECTING 1.

2.

3.

4.

5.

6.

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For limited height application raise the bucket as high as possible.

Roll it forward until the bottom of the bucket is level with the ground or tilted slightly downward.

Push the two-way hydraulic control lever (lever closest to the operator) forward to eject the load.

Return the ejector push plate by pulling the two-way hydraulic control lever once all material is removed from the bucket.

Roll back the bucket before moving the machine away from the boot.

Once clear of the boot lower bucket to the carry position.

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15

Towing the Machine when Disabled Apply the park brake, lower the lift arms or any attachment to the carry position and stop the engine. The towing machine must have sufficient braking capacity to stop and hold both machines.

1.

2.

The machine should be secured by 2 x 15 Tonne safety chains in addition to a 30 tonne capacity draw bar.

If the machine must be towed and the distance is less than 1000 metres: a. b. c.

Connect the machine to the towing machine.

Place the transmission in neutral.

Release the spring applied park brakes by hydraulically overcoming the brake spring pressure by use of a Porta-Power (see Note) and tow at low speed.

The brakes can be released with hydraulic Porta-Powers Service Brakes are pressure applied and not operational under tow.

Park Brake Maximum 3500 kPa (507 psi ) Connected to the pressure port on the park brake reducing valve The operator is to stay in the operator’s compartment to apply the brake or park brake if necessary by removing the Porta_Power pressure.

Do not over-pressurise the brake system or serious damage will be done to the seals in the brake heads.

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The transmission will not hold the machine when the spring applied park brakes are bypassed by the Porta-Power pressure.

Always connect the disabled machine to the towing machine before releasing the park brake. Make sure the park brake is reapplied before the towing machine is disconnected.

Maximum towing speed is 3 kph.

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16

Towing with the Machine The transmission will not hold the machine when the spring applied park brakes are bypassed by the Porta-Power pressure.

Maximum towing speed is 3 kph.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Ensure the machine is parked and isolated prior to connecting the trailer or load, park brake on.

Attach the load to the rear tow hitch, ensure tow pin is secure.

The trailer or load should be secured by 2 x 15 Tonne safety chains in a straight line pull in addition to a rated draw bar for the task.

Both chains must be used and adjusted to ensure an even pull.

Both chains have a combined loading of 20000 kg in a straight line.

Both chains must be used for maximum tractive effort pull.

Ensure all connections on the towed piece are in good condition and rated for the maximum pull.

Ensure all holding devices and hitches are in good condition and rated for the maximum pull before connecting the machine.

Always ensure that the trailer and load are secure before towing, and prior to releasing the park brake.

Travel at a speed that is suitable to conditions and load.

Ensure trailer or load has wheels chocked prior to removal from the machine.

Always connect the trailer or load before releasing the park brakes.

Make sure the park brake is reapplied before the towing machine is disconnected.

For towing of loads greater than 10000 kg the mass must be braked.

Prior to towing loads in excess of 10000 kg consult Bucyrus.

Failure to comply to these procedures may result in serious personal injury or damage to the equipment.

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17

Air Venting the Fuel System If the engine misfires or fails to start due to air in the fuel line, the system must be bled as follows: 1.

2.

3.

4.

Ensure the governor control lever is in the shut off position.

Unscrew the knob on the priming pump sufficiently to release it, then pump in and out.

Tighten and secure the priming pump.

Start the engine. If it misfires or smokes with the engine running repeat the above.

Check the fuel tank contents gauge before venting the system.

Check the fuel water separation bowl before venting the system.

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18

Air Venting the Engine Cooling System To prevent an air lock in the engine coolant system, the cooling system automatically bleeds back to the expansion tank. Fill the coolant system expansion tank only with the correct mix of potable water and inhibitor as required in Section 23 - Fluid Specification Table.

Add water conditioner as necessary.

Refer to Section 5 for isolation of the cooling system and Section 6 for checking and filling of the cooling system.

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19

Attaching Attachments 1.

2.

3.

4.

5.

6.

Ensure the PTO lines to the lock cylinder are connected.

Check the QDS locking tongue is retracted.

Drive the machine toward the attachment, roll the QDS back plate forward and engage the upper cradle of the attachment back plate with the top lip of the QDS back plate.

Roll the QDS back plate back fully and engage the QDS lock tongue in the QDS back plate by pulling the QDS Pilot Lock Cylinder Release Button.

Select neutral, apply the park brake and raise the lift arms and attachment 1200 mm 1500 mm above the ground.

Exit the machine and visually inspect the QDS lock tongue is fully engaged into the attachment back plate. The operator should always exit the machine and check for engagement before using the attachment.

Do not stand underneath the raised lift arms.

Never walk under the attachment or lift arms.

The lift arms function and motion test on the raise/lower and tilt forward/back needs to be carried out after connecting an attachment.

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7.

8.

9.

Enter the compartment, fully lower the lift arms and stop the engine. Press the Attachment Quick Connects Button to release the pressure in the PTO lines Exit the compartment and disconnect the lock cylinder lines. These can now be connected to the hydraulic system of the attachment (e.g. push plate bucket) or to the dummy block to prevent the hoses from dragging on the ground and being damaged.

If required the second PTO lines may be connected. Attachments with hydraulic functions use these lines.

ALWAYS disconnect the lines to the lock cylinder to ensure the attachment is not accidentally released.

The emergency stop button on a work platform is connected to the machine via a hose from the work platform to the right front guard as shown in below, ensure the hose has free movement through the hydraulic function tests.

If an elevating work platform has been fitted, an operational test on the emergency stop button inside the basket must be performed before the attachment can be put into service.

Consult attachment OEM Manuals for operation/connection and removal of attachments when using machine with QDS cradle.

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20

Detaching Attachments 1.

2.

3.

4.

5.

Ensure the area that the attachment is to be stowed will not block access and is level.

Lower the attachment to the ground. Select neutral, apply the park brake, switch the machine off and exit the machine.

Press pressure release button to release pressure in hydraulic hoses.

Connect the PTO lines to the QDS Pilot Lock Cylinder Release Button.

If fitted, disconnect the second set of PTO lines to the attachment.

Failure to disconnect the second set of hoses may result in hose and fitting damage when the machine drives off the attachment.

6.

7.

8.

9.

10.

Enter the operator’s compartment.

Release the park brake.

Depress the QDS Pilot Lock Cylinder Release Button and at the same time pull the two-way hydraulic control lever (closest to the operator).

Select reverse and first gear.

Drive away from the attachment whilst rolling the QDS back plate forward.

DO NOT leave the attachment unsecured. An unstable attachment may roll and crush personnel.

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21

Diesel Control System (DCS) DIESEL SHUTDOWN

The purpose of the electronic shutdown system is to prevent the engine running outside of the predetermined safe operating parameters.

The following sensors are fitted to the machine: Charge Failure Warning message/shutdown after 30 minutes Engine Oil Pressure Shuts engine down Engine Coolant Level Shuts engine down Hydraulic Temperature Warning message Engine Coolant Temperature Shuts engine down Exhaust Scrubber Temperature Shuts engine down Exhaust Outlet Temperature Shuts engine down Power Up Pressure Switch (PUPS) System start up Wet Scrubber Water Level 1 Shuts engine down Wet Scrubber Water Level 2 Shuts engine down

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SYSTEM OPERATION 1.

Toggle the on/off toggle switch to the on position: This will activate the DCS electronics. The system will display “Waiting for methane sensor warm up” and the methane LED will be illuminated. After approximately 1 second the screen display will read “Pre run checks” while the DCS checks that the system is ready to start. Once this is completed the screen will display “Waiting for start” and all lights turn green.

The engine can now be started. If the engine is not started within 20 seconds the DCS will shut itself down. To restart the system toggle the on/off toggle switch to off then back to on.

Engine Start Button

On/Off Toggle Switch

Air Pressure Gauge

RIGHT HAND SIDE OPERATOR’S DISPLAY PANEL

2.

Start engine: Activate the engine start button. After the engine has started, the display will read “Engine running”.

3.

After starting the engine if the alternator is not charging the engine will run for a predetermined period of time before shutting down.

4.

Drive machine normally.

5.

Shutdown: When finished with the machine, toggle the on/off toggle switch to the off position. This will deactivate the DCS electronics, thus cutting power to the solenoid and shutting off pilot air pressure to the fuel shut off cylinder and the engine will stop.

6.

After a shutdown whether by the operator or an engine trip, if the up or down arrows are pressed the system will return to “Waiting for start”.

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Fluid Specification Table SPEC

1

2

COMPONENT

Engine

Transmission

CAPACITY (Litres)

17

40

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

Engine Oil

SAE15W-40 API CD-II (Valvoline - Super Diesel 15W -40 or Equivalent)

SAE40 API CD-II (Valvoline - All Fleet Premium 40 or Equivalent)

SAE50 API CD-II (Valvoline - All Fleet Premium 40 or Equivalent)

Mineral Gear Oil

SAE10W CAT TO-4 (Valvoline Valtorque C4 10W or Equivalent)

SAE30 CAT TO-4 (Valvoline Valtorque C4 30 or Equivalent)

SAE50 CAT TO-4 (Valvoline Valtorque C4 50 or Equivalent)

ISO68 (Valvoline Ultramax HVI 46 or Equivalent)

ISO68 (Valvoline Ultramax 68 or Equivalent)

ISO68 (Valvoline Ultramax 68 or Equivalent)

3

Hydraulic

250

Hydraulic

4

Axle/Wheel Ends

18 (each axle)

Mineral Gear Oil with Limited Slip Additive

SAE90LS (Valvoline - HP Gear Oil LS SAE90 or Equivalent)

5

Cooling System

72

Pre-mixed Coolant Conditioner

Ethylene Glycol Antifreeze Inhibitor to GM 6038-M (Valvoline - Heavy Duty Coolant 50 or Equivalent)

6

Fuel

150

Distillate “Diesel” Fuel

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

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin

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As required

Multipurpose EP Grease

NLGI No. 0 or 1 (Shell - Alvania EP 0/1 or equivalent)

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NLGI No. 2 (Valvoline Valplex EP 2 or equivalent)

NLGI No. 2 (Valvoline Valplex EP 2 or equivalent)

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