CAT BUCYRUS FBL-10 LHD Utility Load Haul Dump Operation Manual SN 5003739

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Reliability at work

Operator’s Manual FBL-10 LHD/Utility Serial No: 5003739

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Operator’s Manual

TABLE OF CONTENTS Section 1

General Information Introduction ..................................................................................... 1 Description...................................................................................... 1 General Arrangement ..................................................................... 2 Specifications ................................................................................. 3

Section 2

General Safety and Precautions ................................................. 5

Section 3

Gauge Parameters and Colour Coding ...................................... 9

Section 4

Machine Orientation, Controls and Functions Machine Orientation Basic Machine Layout ......................................................... 13 Control Locations Compartment Door .............................................................. 14 Transmission Gear Control Lever ....................................... 15 Transmission Directional Control Lever .............................. 15 Park Brake Button ............................................................... 16 Four-Way Joystick Control Lever ........................................ 17 No 1—Two-Way Hydraulic Control Lever ........................... 17 No 2—Two-Way Hydraulic Control Lever ........................... 17 Operator’ Seat ..................................................................... 18 Accelerator Pedal ................................................................ 18 Brake Pedal ......................................................................... 18 Steering Wheel .................................................................... 19 Brake Head Pressure Gauge .............................................. 20 Brake Accumulator Pressure Gauge ................................... 20 Steering Accumulator Pressure Gauge ............................... 20 Engine Start Button ............................................................. 21 Air Pressure Gauge ............................................................. 21 On/Off Toggle Switch .......................................................... 21 Transmission Oil Temperature Gauge ................................ 22 Engine Coolant Temperature Gauge .................................. 22 Horn Button ......................................................................... 23 Emergency Fuel Shut Off Valve .......................................... 23 Engine Service Hour Meter ................................................. 24 Air Cleaner Service Indicator............................................... 24 Exhaust Outlet Gas Temperature Gauge ............................ 25 Engine Oil Pressure Gauge................................................. 25 Shutdown System Test Valve ............................................. 25 Engine Fuel Primer Pump ................................................... 26 QDS Pilot Lock Cylinder Release Button ............................ 26 Attachment Quick Connects Button .................................... 26 Emergency Intake Shut Off Valve ....................................... 27

Section 5

Machine Isolation Engine Isolation ............................................................................ 29 Pneumatic Isolation ...................................................................... 30 Hydraulic Isolation ........................................................................ 31 Engine Coolant Isolation............................................................... 32 Electrical Isolation......................................................................... 33

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Section 5

Machine Isolation (cont.)

Articulation Isolation ...................................................................... 34 Lift Arm Isolation ........................................................................... 35 Exhaust Conditioner Isolation ....................................................... 36

Section 6

Pre-Start Procedure .................................................................... 37

Section 7

Engine Starting Procedure ........................................................ 47

Section 8

Post Start Checks ....................................................................... 49

Section 9

Stopping the Engine ................................................................... 51

Section 10

Tramming the Machine ............................................................... 53

Section 11

Stopping and Braking ................................................................ 55

Section 12

Driving on a Ramp ...................................................................... 57

Section 13

Parking on a Ramp ..................................................................... 59

Section 14

Loading ........................................................................................ 61

Section 15

Dumping ...................................................................................... 63

Section 16

Towing the Machine when Disabled ......................................... 65

Section 17

Towing with the Machine ........................................................... 67

Section 18

Air Venting the Fuel System ...................................................... 69

Section 19

Air Venting Engine Cooling System.......................................... 71

Section 20

Attaching Attachments .............................................................. 73

Section 21

Removing Attachments .............................................................. 75

Section 22

Diesel Control System (DCS) ..................................................... 77

Section 23

Fluid Specification Table ........................................................... 81

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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 INTRODUCTION The operation of heavy mining machinery can be hazardous. To ensure safe operation, operators and personnel must be alert, competent, correctly trained, tested and licensed in the principles, capabilities and correct operating and isolation procedures of the machinery.

This manual is designed to provide the FBL-10 LHD/Utility operator with the proper information regarding the machine’s instrumentation, operating controls and general safe working procedures. All operators of this machine must be conversant with the information contained within this manual before operating the machine.

To ensure safe and efficient operation, the FBL-10 LHD/Utility must be adequately maintained by the operators and service personnel. To achieve this, the operator’s pre-start inspection procedure contained in Section 6 of this manual must be performed before any use of this machinery is undertaken.

Any abnormalities should be reported immediately to service personnel to avoid costly machine repairs, production downtime and unsafe operation of the machine.

DESCRIPTION The FBL-10 is a 10000 kg Load Haul Dump/Utility 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 172 kW Caterpillar 3126 turbocharged four-stroke inline six cylinder flameproof diesel engine package. Flameproofing of the system includes a wet bath exhaust conditioning system complete with exhaust and intake flame traps. The start system is pneumatic. The Diesel Control System (DCS) is an intrinsically safe electronic monitoring system. The engine power output is connected to the constant four-wheel drive system via a drive coupling and converter through a four-speed bidirectional power shift transmission to heavy duty axles.

The FBL-10 LHD/Utility utilises a wet bath exhaust system complete with an exhaust purifier.

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

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GENERAL ARRANGEMENT

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SPECIFICATIONS All specifications are subject to change without notice. Always Axles consult BUCYRUS to obtain current information before Type Front axle make/model applying critical loads.

Rear axle make/model Differential type Capacities Differential lock type - front Bucket Payload 8000 kg Differential lock type - rear RAS Forks, Max Payload 10000 kg Overall ratio RAS Slewing Jib, Max Payload 7000 kg RAS Belt / Cable Reeler, Max Payload 7000 kg Wheels Maximum un-braked trailer mass 10000 kg Make/model Maximum braked trailer mass Consult BUCYRUS Standard Ejector Bucket Heaped capacity (SAE) Struck capacity Break out force standard bucket tip (hydraulic) Tractive effort, Maximum Bucket Motion Times Lift to full raised position Lower fully to floor Roll bucket fully back Roll bucket fully forward

7.0 sec 4.0 sec 7.0 sec 5.0 sec

Weight Unladen with full tanks and bucket Laden with forks and 10T load Engine Type Cooling system Cooling fan Engine make/model Displacement Maximum power Maximum torque

3.5 m3 2.7 m3 15000 kg 21300 kg

19000 kg 29000 kg

Diesel, turbocharged, and 4 cycle Water based radiator Hydraulic driven fan Caterpillar 3126 7.2 litre 172 kW @ 2200 RPM 720 Nm @ 1400 RPM

Engine Speeds Low idle High idle Governed

700 RPM 2600 RPM 2100 RPM

Stall Speeds Converter stall Full stall Hydraulic stall

2100 RPM 1700 RPM 2050 RPM

Fuel Consumption At full power Average mine duty

37.5 litre/hr 8-30 litre/hr

Start System Starter motor type

Air (Auststart)

Intake Air Cleaner Type/make Dual element type

Dry/Donaldson Primary and secondary

Exhaust Conditioner Type Make Exhaust Flame trap After treatment

Flameproof water bath conditioner BUCYRUS Fitted Catalytic exhaust purifier

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

Tyres - Standard Type Size Ply rating Inflation media Inflation pressure* *Pneumatic tyres only

Outboard planetary Dana 16D Dana 16D Bevel gear and pinion Posi-Torque Posi-Torque 31.06:1

3 piece (heavy duty)

Michelin XKA 17.5 x 25 Radial Insert 110 psi front, 110 psi rear

Hydraulic Systems Steering Closed centre, pressure compensated 2500 psi Brakes Closed centre, pressure compensated 2500 psi Bucket/lift Open centre 3000 psi PTO (2 on machine) Open centre 3000 psi Tank type Sealed and pressurised Tank pressure 10 psi Hydraulic Filtration Hydraulics return

Return 25 micron replaceable with bypass Pressure10 micron replaceable with bypass In line, 25 micron

Steer/brake system Optional return PTO

Main Hydraulic Pump Type Standard pump output @ 2600 RPM

Gear open centre 161.2 lpm

Steering/Brake Pump Type Pressure compensated piston Standard pump output @ 2600 RPM 117 lpm Cylinders Type Rods Counterbalance valves Cushion stops

Double acting Case hardened and hard chromed Lift and tilt Steering and tilt

Steering System Control valve Actuation Pressure compensated Cushion relief

Closed centre Orbital 2500 psi 3000 psi

Accumulator Steering Type Quantity x capacity Operating pre-charge pressure

Piston 1 x 5.7 litre 900 psi Nitrogen

Accumulator Brakes Type Quantity x capacity Operating pre-charge pressure

Piston 1 x 1.96 litre 900 psi Nitrogen

Bucket System Control valve Actuation Main relief

Open centre Remote hydraulic pilot 3000 psi

Torque Converter Type Mounted in transmission, Single element Make/model Dana 13.1 integral

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Cylinder Reliefs Lift arm raise Lift arm lower Bucket roll back Bucket dump RAS in port relief RAS out port relief Electrical System Type Voltage Polarity Lights Number /location Type Alternator Drive Type

3200 psi 3200 psi 3200 psi 3200 psi 3200 psi 3200 psi

Approved flameproof 12 V Floating

Service Brake Type Make/model Application Location

Seating (Operator) Type Make Suspension

2 front, 2 rear High performance approved flameproof

Hydraulic Customer preference approved flameproof

Centre articulated, hydraulic

Totally enclosed, liquid-cooled Posi-Stop Dana 16150 Spring applied hydraulic release Each wheel end

Park Brake Type Totally enclosed, liquid cooled Posi-Stop Make/ model Dana 16150 Application Spring applied hydraulic release Location Each wheel end Articulation Bearing type and size Pin and spherical bearing (top), bush (bottom) fully sealed Bush material Hardened steel Pin material Hardened steel Degrees of turn either side 43°

Rear bolster Hardened steel Hardened steel 7.5°

Cross-seated BUCYRUS Adjustable spring/shock absorption

Canopy Type

Service Brake Hydraulic System Type Reverse modulated, pressure reducing Control valve Open centre Actuation Foot pedal Operating pressure 2500 psi Brake release pressure 1450 psi Steering Type

Oscillation Type Bush material Pin material Degrees up and down from horizon

Pneumatic System Compressor type Air flow Governed pressure Relief pressure Air receiver volume

Adjustable Protective device MDG1 and MDG17

Piston engine gear driven 0.340 m3/min @ 1500 RPM 120 psi 130 psi 80 litre

Vehicle Speeds 1st gear 2nd gear 3rd gear 4th gear

4.3 kph 8.7 kph 14.6 kph 24.2 kph

Maximum Tractive Effort 1st gear 2nd gear 3rd gear 4th gear

22165 kg 10700 kg 6160 kg 3565 kg

Grade Ability Front to rear Side to side (empty) Side to side (laden bucket load fully raised) Service Capacities Hydraulic tank Fuel tank Transmission/converter oil Engine crankcase oil Engine cooling system water Axle oil (each)

1:4 1:4 1:8

300 litre 300 litre 40 litre 22 litre 72 litre 35 litre

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, safety devices, interlocks and structures etc., could cause serious injury of death.

Replacement with correctly torqued fasteners is mandatory.

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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:   

DO NOT

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

DO NOT

There are no tags attached stating otherwise.

All covers and guards are correctly installed.

Personal protective equipment is worn.

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.

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

The machine is parked in a safe place.

The transmission is in neutral.

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

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

The engine is stopped.

DO NOT

work on the machine in low ventilated areas while the engine is running.

ALWAYS

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

ALWAYS

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

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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

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

ALWAYS

Engine coolant pressure (see Section 5).

Engine coolant temperature (see Section 5).

Engine exhaust 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).

Lift arm area (see Section 5).

Machine mass.

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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

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 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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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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Exhaust Gas Temperature

Brake Accumulator Pressure

Brake Head Pressure

Engine Oil Pressure

Air Pressure

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Steering Accumulator Pressure

Transmission Oil Temperature

Exhaust Back Pressure

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Machine Orientation, Controls and Functions MACHINE ORIENTATION BASIC MACHINE LAYOUT The FBL-10 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).

Lift Arm Assembly

Front Axle

Main Hydraulic Control Valve Bank

Hydraulic Tank Operator’s Compartment Transmission and Hydraulic Pumps

Rear Axle

Fuel Tank

Air Receiver Wet Bath Exhaust Conditioner

Make Up Tank Cooling System Radiator

Flameproof Engine

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

DOOR INTERLOCK VALVE

COMPARTMENT DOOR

DOOR ASSEMBLY

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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.

Transmission Gear Control Lever

Transmission Directional Control Lever TRANSMISSION CONTROLS

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PARK BRAKE BUTTON The park brake button has two positions and it is held in the release position by pilot air pressure. By pushing the button inwards, the park brake is applied, and by pulling the button out the park brake will be released. The park brake cannot be released until the system pressure is sufficient to overcome the spring force of the brake control, it also will not release unless the door is closed (there is a roller cam valve inside the door lock which needs to be activated to release the park brake).

If the engine shuts down the park brake will automatically apply itself by dumping the pilot air pressure via the low oil pressure pilot valve. The brake head pressure gauge must read zero when the brake is applied.

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.

PARK BRAKE BUTTON

BRAKE HEAD PRESSURE GAUGE

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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.

No. 1 - Two-Way Hydraulic Control Lever

No. 2 - Two-Way Hydraulic Control Lever

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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.

BRAKE PEDAL The brake pedal when depressed applies the brakes on the front and rear axles. There are four liquid-cooled Posi-Stop 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 brakes. The operator can apply the brakes at any time following an engine stall to immediately bring the machine to a controlled stop.

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

Foot Rest

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 engine should stall, the machine is fitted with a system that will dump the steering pressure. The operator can steer the machine via a 6 litre back up accumulator at any time following an engine stall to immediately bring the machine to a safe controlled stop.

If the door is opened or the park brake is applied, the machine is fitted with fail-safe steering system that will immediately dump the steering system pressure. This is to protect the operator or personnel from being crushed in the articulation area. Steering cannot be used until the door is shut and latched and the park brake button pulled out to the released position.

STEERING WHEEL

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BRAKE HEAD PRESSURE GAUGE This gauge shows the service and park brake system’s brake head pressure. Operators should periodically check this gauge. The gauge will read zero pressure when the brakes are fully applied via the service and/or park brake controls.

If the operator’s foot is off the brake pedal and the park brake is released, the indicated pressure shall be a minimum of 12000 kPa (1750 psi). If the pressure is below this it is likely that the brakes are dragging. The machine shall not be operated with dragging brakes as fire or brake failure may result. Immediately report the problem to service personnel.

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

BRAKE ACCUMULATOR PRESSURE GAUGE This gauge indicates the service and park brake system’s accumulated pressure. Normal operating system pressure is 17200 kPa (2500 psi).

Do not operate the machine if the brake accumulator pressure gauge is less than 17200 kPa (2500 psi). Immediately report the problem to service personnel.

STEERING ACCUMULATOR PRESSURE GAUGE This gauge indicates the steering system’s accumulated pressure. Normal operating system pressure is 17200 kPa (2500 psi).

If the pressure constantly drops below or will not hold 17200 kPa (2500 psi), steering may become difficult. The machine should not be operated and the problem shall be reported immediately to service personnel.

Steering Accumulator Pressure

Brake Accumulator Pressure

Brake Head Pressure

RIGHT HAND SIDE OPERATOR’S PANEL

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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.

Air Pressure Gauge Engine Start Button

On/Off Toggle Switch

RIGHT HAND SIDE OPERATOR’S 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.

Transmission Oil Temperature Gauge

Engine Coolant Temperature Gauge

LEFT HAND SIDE OPERATOR’S PANEL

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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.

Horn Button

RIGHT HAND SIDE OPERATOR’S PANEL

EMERGENCY FUEL SHUT OFF VALVE This valve is located after the fuel filter/water separator. Closing this valve will stop the flow of fuel to the engine.

This provides a second means of shutting down the engine should the on/off toggle switch fail.

EMERGENCY FUEL SHUT OFF VALVE

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ENGINE SERVICE HOUR METER This electric meter is mounted on the off driver’s side at the rear of the machine.

Use the hour meter to determine servicing intervals.

ENGINE HOUR METER

AIR CLEANER SERVICE INDICATOR The air cleaner service indicator is located at the air cleaner and indicates the condition of the air cleaner element. When the service indicator is in the red zone, the air cleaner elements should be removed and serviced.

AIR CLEANER

AIR CLEANER INDICATOR

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EXHAUST GAS TEMPERATURE GAUGE This shows the exhaust gas temperature entering the mine atmosphere from the exhaust outlet. Machine will shutdown if this temperature exceeds 140 °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 Oil Pressure Gauge

RIGHT HAND SIDE OPERATOR’S PANEL

SHUTDOWN SYSTEM TEST VALVE The test valve is used to check the integrity of the Fail-Safe Shutdown System. This test should be carried out on a daily basis as part of the 10 Hour Daily Off Line Mechanical Inspection. (Refer to Section 8 - Post Start Checks).

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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.

ENGINE FUEL PRIMER PUMP

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.

Attachment Quick Connects Button

QDS Pilot Lock Cylinder Release Button

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EMERGENCY INTAKE SHUT OFF VALVE This valve is used in the event that the machine fails to shutdown under normal circumstances as stated in Section 9. Closing this valve will stop the flow of air to the engine. This provides a second means of shutting down the engine should the on/off toggle switch fail.

EMERGENCY INTAKE SHUT OFF VALVE RESET LEVER EMERGENCY INTAKE SHUT OFF VALVE 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.

This engine system is fitted with a wet exhaust conditioner.

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

ONLY OPERATE THE EMERGENCY INTAKE SHUT OFF VALVE IN THE EVENT THAT THE ENGINE SHUTDOWN SYSTEM FAILS TO STOP THE ENGINE. Restarting of the engine should be done in compliance with the Manager’s Rules.

ONLY RESTART THE ENGINE AFTER VERIFYING THAT THERE HAS BEEN NO INGRESS OF WATER FROM EXHAUST CONDITIONER INTO THE ENGINE. THIS IS TO BE VERIFIED BY SERVICE PERSONNEL PRIOR TO ATTEMPTING ENGINE START.

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Section

5

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.

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

2.

3.

4.

5.

6.

7.

8.

9.

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

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

Lower the lift arms or any attachment to the ground.

Select neutral on the transmission directional control lever.

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, when working on or around the machine , allow time for them to cool down.

On/Off Toggle Switch Air Pressure Gauge

RIGHT HAND SIDE OPERATOR’S DISPLAY PANEL

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

2.

3.

4.

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

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 at the driver’s side rear of the engine compartment 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.

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 equipment such as safety glasses and hearing protection.

Main Air Isolation Valve

protective

Main Air Charge Valve Main Air Drain Valve

MAIN AIR MANIFOLD

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

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

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.

Depress the attachment quick connects button located in the operator's compartment.

This will remove any residual pressure stored in the PTO lines.

Observe both steering and brake pressure gauges located in the operator's compartment. The hydraulic system features a steering and brake accumulator automatic dump off which removes hydraulic pressure from both accumulators once the engine and main air has been stopped. This is immediate. This is done by an air pilot from the air circuit.

Remove hydraulic tank pre-charge pressure (50 kPa) by cracking hydraulic tank filler cap.

2.

3.

4.

5.

Ensure all loads are mechanically supported before removal of any hydraulic lines. Hydraulic fluid may be hot. Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves.

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

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

Steering Accumulator Pressure Gauge

Brake Accumulator Pressure Gauge

RIGHT HAND SIDE OPERATOR’S DISPLAY PANEL

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

Engine Coolant Relief Cap

COOLANT HEADER TANK AND RELIEF VALVE

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ELECTRICAL ISOLATION 1.

2.

3.

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

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

All electrical energy is isolated once the engine has stopped.

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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ARTICULATION ISOLATION To fit the articulation lock: 1.

2.

3.

4.

5.

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

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 and isolate the engine.

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

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

Install the two lynch pin through the retaining hole in the locating pins.

To remove the articulation lock: 1.

2.

With the park brake applied, remove the lynch pins from the locating pins.

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

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

ARTICULATION LOCK IN STORAGE POSITION

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LIFT ARM ISOLATION To install the lift arm lock: 1.

2.

3.

4.

5.

6.

7.

8.

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

Remove any attachments from the QDS back plate.

Chock the wheels.

Fit the articulation lock (see Articulation Isolation).

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

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

Note that the locking 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 locking pines 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.

Lift Arm Locking Pin Installed

Storage Position on Both Front Guards

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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 the to the conditioner and the shutdown float chamber. The main isolation valve has two positions closed and open, this regulates the water flow from the make up tanks.

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

Main Supply/Isolation Valve

WET BATH EXHAUST CONDITIONER

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Section

6

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 5 - 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 23).

HYDRAULIC LEVEL SIGHT GAUGE 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 23 - 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 23).

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 FILLER CAP

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 23).

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.

WATER PUMP DRIVE BELT

FUEL FILLER CAP AND FUEL SIGHT GAUGE

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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 radiators: 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 23).

Filler Cap

Sight Gauge

COOLANT EXPANSION TANK FUEL WATER TRAP

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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.

AIR CLEANER

AIR CLEANER INDICATOR

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.

Main Air Drain Valve

MAIN AIR MANIFOLD

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Check the fire extinguisher: 1.

2.

3.

4.

Located on front driver’s side mudguard.

Check inspection date.

Check contents indicator is reading in the green area.

If fire suppression system fitted check actuation points.

Fire Extinguisher

Fire Suppression

FIRE SUPPRESSION SYSTEM

FIRE EXTINGUISHER

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The wet bath exhaust conditioning system on the FBL-10 carries out four major functions:   

To cool and dilute exhaust gases.

To prevent hot gases from entering the mine atmosphere.

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

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

Inlet

Ins

pe c

tio n

Ho le s

Shutdown Float Chamber

WET BATH EXHAUST CONDITIONER

Check exhaust system: 1.

2.

3.

4.

5.

For damage.

Check joints for signs of leakage.

Check cooling hoses for security and condition.

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 BATH EXHAUST CONDITIONER

Fill Point and Breather

Sight Glass

MAKE UP TANK

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

INLET 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.

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.

EMERGENCY INTAKE SHUT OFF VALVE RESET LEVER EMERGENCY INTAKE SHUT OFF VALVE STOP BUTTON

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Section

7

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 Emergency Intake Shut Off valve has been operated, restarting of the engine should be done in compliance with the Manager’s Rules.

ONLY RESTART THE ENGINE AFTER VERIFYING THAT THERE HAS BEEN NO INGRESS OF WATER FROM EXHAUST CONDITIONER INTO THE ENGINE. THIS IS TO BE VERIFIED BY SERVICE PERSONNEL PRIOR TO ATTEMPTING ENGINE START. 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 display to indicate waiting for start.

Hold the accelerator pedal approximately ⅓ to ½ open.

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

Check the display indicates “Engine Running”.

Carry out post start checks and operate machine normally.

See Section 22 - 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

8

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 11377 kPa (1650 psi) with brake off: 1.

To test move off slowly and apply the park brake.

Check that all of the lights are working: 1.

2.

There are two forward and rear facing headlights.

Directional control is working.

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).

Dipstick Access

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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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Main Supply/Isolation Valve

Low Water Shutdown Test 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.

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.

Shutdown Sensor Cable 1 Shutdown Sensor Cable 2

8.

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.

52

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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9

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.

7.

8.

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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10

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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11

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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12

Driving on a Ramp 1.

2.

3.

4.

Stop and shift into first gear, and check the 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 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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13

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 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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14

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 172 kW of power from the machine and the torque multiplication of the converter and axles, this machine produces tremendous crowding power. Aggressive tyres, Posi-Torque differentials and an oscillating rear axle make sure the power is kept on the ground for loading.

Clark Posi-Torque 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 15000 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.

62

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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15

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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16

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 brake 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 a Porta-Power (maximum 12756 kPa [1850 psi]) connected into the pressure port on the brake valve. The operator is to stay in the operator’s compartment to apply the brake or park brake if necessary. If these are applied the Porta-Power needs to be pumped (minimum 11376 kPa [1650 psi]) to release the brakes again.

Hydraulic Manifold BRK

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

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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17

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 15000 kg the mass must be braked.

Prior to towing loads in excess of 15000 kg consult Bucyrus.

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

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18

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.

FUEL PRIMING PUMP

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19

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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20

Attachments CONNECTION OF QDS ATTACHMENTS The following outlines the process for the installation of any QDS type attachment/ implement to the LHD. Before commencing the installation process ensure the attachment is;   

On level roadway and is accessible from behind by the LHD The QDS hoses are connected to the locking plate cylinder.

No foreign material such as dirt, coal or stone is in or around the attachment backing plate that may prevent the attachment of the implement.

1.

2.

Retract the QDS locking plate.

Position the LHD behind the attachment and ensure it is aligned to the implement attaching lugs.

Using the dump lever, tilt the QDS cradle forward bringing the QDS cradle horns level with the implement attaching lugs.

Drive the machine toward the attachment until the base of the QDS horns meet the implement attaching lugs.

Roll the QDS plate back fully and engage the QDS lock tongue by operating the twoway control lever.

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.

3.

4.

5.

6.

7.

QDS BACK PLATE

Never walk under the attachment or lift arms.

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8.

9.

10.

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 such as the side shift forks and shield trailers use these.

Do not stand underneath the raised 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.

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

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.

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21

Removing Attachments 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

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

Lower the attachment to the ground so it is supported and stable.

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.

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

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) retracting the QDS Locking plate and disengaging the attachment.

Select reverse and first gear.

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

Roll the QDS cradle back onto the stops prior to tramming the LHD

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

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

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22

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: Hi Methane Shutdown (1%) Shuts engine down Lo Methane Warning (0.5%) Warning message Charge Failure Warning message/shutdown after 30 minutes Engine Oil Pressure Shuts engine down Engine Coolant Level Shuts engine down Hydraulic Oil Level Warning message Engine Coolant Temperature Shuts engine down Engine Turbo 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

OPERATOR DISPLAY PANEL

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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 15 seconds 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”. 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.

ON/OFF TOGGLE SWITCH

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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If methane concentration is over 1%, it should be reported immediately!

Bypassing of the electrical safety system is not allowed under any circumstance!

If the air pressure is below 240 kPa (35 psi), the pressure switch can not close, and the DCS will not activate.

The start sequence is the same if the methane monitor is not fitted

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23

Fluid Specification Table SPEC

COMPONENT

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

1

2

3

Engine

Transmission

Hydraulic

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)

300

Hydraulic

ISO68 (Valvoline - Ultramax HVI 46 or Equivalent)

ISO68 (Valvoline Ultramax 68 or Equivalent)

ISO68 (Valvoline Ultramax 68 or Equivalent)

Mineral Gear Oil with Limited Slip Additive

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

22

40

4

Axle/Wheel Ends

35 (each axle)

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

300

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

As required

8

Wet Exhaust Conditioner Make Up Water Tanks

300

Water

Potable

9

Engine Drive Coupling

Refer Service Manual

High Temperature

NLGI no. 2 (Shell Stamina RL2)

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Multi-purpose 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)

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