Cat Bucyrus FBR-15 Coal Hauler Operator Manual (1)

BI643720

BUCYRUS Australia 2008©

FBR-15 Coal Hauler

Operator Manual Serial No. 500 _ _ _ _

BUCYRUS Australia Room and Pillar Division Phone: +61 2 49147000 Fax: +61 2 49147059

BI643720 FBR-15 Serial No.

Operator Manual

Index 1.

GENERAL INFORMATION

2.

GENERAL SAFETY AND PRECAUTIONS

3.

GAUGE INFORMATION

4.

MACHINE ORIENTATION CONTROLS AND FUNCTIONS

5.

MACHINE ISOLATION

6.

PRE-START PROCEDURE

7.

ENGINE STARTING PROCEDURE

8.

POST START CHECKS

9.

STOPPING THE ENGINE

10. TRAMMING THE MACHINE BUCYRUS Australia 2008©

11. STOPPING AND BRAKING 12. DRIVING ON A RAMP 13. PARKING ON A RAMP 14. LOADING 15. EJECTING 16. TOWING THE VEHICLE WHEN DISABLED 17. VENTING THE FUEL AND COOLING SYSTEM 18. SAFETY SYSTEM 19. FLUID SPECIFICATION TABLE

BUCYRUS Australia recommends that all Safe Working procedures should be approved and checked by Mine Officials. BUCYRUS Australia 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 Australia. 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 Australia.

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BI643720 FBR-15 Serial No.

Operator Manual

Index 1.

GENERAL INFORMATION

2.

GENERAL SAFETY AND PRECAUTIONS

3.

GAUGE INFORMATION

4.

MACHINE ORIENTATION CONTROLS AND FUNCTIONS

5.

MACHINE ISOLATION

6.

PRE-START PROCEDURE

7.

ENGINE STARTING PROCEDURE

8.

POST START CHECKS

9.

STOPPING THE ENGINE

BUCYRUS Australia 2008©

10. TRAMMING THE MACHINE 11. STOPPING AND BRAKING 12. DRIVING ON A RAMP 13. PARKING ON A RAMP 14. LOADING 15. EJECTING 16. TOWING THE VEHICLE WHEN DISABLED 17. VENTING THE FUEL AND COOLING SYSTEM 18. SAFETY SYSTEM 19. FLUID SPECIFICATION TABLE

BUCYRUS Australia recommends that all Safe Working procedures should be approved and checked by Mine Officials. BUCYRUS Australia 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 Australia. 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 Australia.

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BI643720 FBR-15 Serial No.

Operator Manual

1.

1.1

General Information

Introduction

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 manual is designed to provide the FBR-15 Coal Hauler Operator with the proper information regarding the equipment’s instrumentation, operating controls and safe working procedures. All operators of this machine must be conversant with the information contained within this manual before operating the machine.

To ensure safe and efficient operation, the FBR-15 Coal Hauler must be adequately maintained by the operators and service personnel. To achieve this, the operator’s pre-start inspection procedure contained in Section 6 of this manual must be performed.

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

BUCYRUS Australia 2008©

1.2

FBR-15 Description

The FBR-15 is a 15m3 capacity Coal Hauler. This allows it to be used for carrying coal from the continuous miner to the feeder breaker station.

The motive force is provided by a 172 kW Caterpillar 3126 six cylinder turbocharged 4 Stroke inline 6 Cylinder diesel engine. Flame proofing of the system includes a “dry” exhaust conditioning system complete with exhaust and intake flame traps. The start system is pneumatic and the safety system is an intrinsically safe electronic monitoring system. The engine power output is connected to the 4 speed bi-directional power shift transmission via a drive coupling on the rear of the engine, the power is then transmitted to heavy duty axles. The rear axle drives the rear wheels via 90o bevel gear boxes to the rear planetary hub complete with liquid cooled POSI STOP brakes.

The FBR-15 utilises a dry exhaust system complete with a replaceable particulate filter, catalysed exhaust post treatment purifier and a exhaust outlet flame trap.

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

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BI643720 FBR-15 Serial No.

Operator Manual

1.

FBR-15 Dimensions

BUCYRUS Australia 2008©

1.3

General Information

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BI643720 FBR-15 Serial No.

Operator Manual

1.

1.3

General Information

FBR-15 Dimensions 6 5 Y

11103

BUCYRUS Australia 2008©

3258

35° ANGLE OF REPOSE

4

X

1000

3

3330

1 2 Rev 0

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BI643720 FBR-15 Serial No.

Operator Manual

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1.3

General Information

FBR-15 Dimensions

Table 1.

TYRE BRAND

TYRE SIZE

TYRE TYPE

DIMENSION 1 (mm) CANOPY DOWN

DIMENSION 2 (mm) CANOPY RAISED

DIMENSION 3 DIMENSION 4 (mm) GROUND (mm) WIDTH CLEARENCE TRAILER END

MITCHELIN

20.5R25

XMD2 AIR FILLED

1870

2060

454

3330

MITCHELIN

17.5R25

XMD2 AIR FILLED

1753

2006

400

3292

Table 2.

LOAD CAPACITIES AND SIZE CODE BOARD SIZE Y/X

STRUCK

HEAPED

A

200/NONE

10.44m³

14.57m³

B

300/100

11.57m³

15.4m³

C

400/200

12.66m³

16.22m³

D

500/300

13.71m³

17.03m³

E*

200/NONE

8.71m³

18.03m³

BUCYRUS Australia 2008©

SIZE CODE

* NO TAILGATE FITTED

NOTE SPECIFIC GRAVITY Coal Broken: 0.8- 1.2t/m³ Road Base: 1.5 - 2.0t/m³ Broken Rock (Skulls): 1.5 - 2.0t/m³ Maximum Trailer Carry Capacity 20,000kg Table 3.

LOAD HEIGHTS

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SIZE CODE

TYRE SIZE

DIMENSION 5 (mm)

DIMENSION 6 (mm)

A

MICHELIN 20.5R25

1565

2510

B

MICHELIN 20.5R25

1665

2610

C

MICHELIN 20.5R25

1765

2710

D

MICHELIN 20.5R25

1865

2810

A

MICHELIN 17.5R25

1511

2456

B

MICHELIN 17.5R25

1611

2556

C

MICHELIN 17.5R25

1711

2656

D

MICHELIN 17.5R25

1811

2756

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BI643720 FBR-15 Serial No.

Operator Manual

1.

BUCYRUS Australia 2008©

1.4

General Information

FBR-15 Specifications

All specifications may vary. Always consult BUCYRUS Axles Outboard planetary Australia Pty Limited to obtain current information Type before applying critical loads.

Differential type Bevel gear and pinion Differential lock type front (engine end) POSI TORQ Differential lock type rear (trailer end) standard Capacities Payload (nominal with hungry boards) 15 m3 Other capacities available Wheels Make/model 5 piece (heavy duty) Payload (maximum weight all material) 20000 kg Consult Bucyrus for weight over 15000 kg Tyres - Standard Type Michelin X mine D2 Weight Size 17.5 x 25 Unladen with full tanks 25000 kg Ply rating Radial Laden with 15T load 42000 kg Inflation media (front) Air (rear) Engine Hutchinson insert Type Diesel, turbocharged, after cooled, 4 cycle Cooling system Water based radiator Tyres - Option Cooling fan Hydraulic driven fan Type L3 R Lug Engine make/model Caterpillar 3126 Size 20.5 x 25 Displacement 7.6 litre Ply rating 24 bias ply Maximum power 171.5 kW (230 hp) @ 2600 rpm Inflation media (front) Air Maximum torque 779 Nm @ 1950 rpm (rear) 3 Ventilation (NSW Australia Requirement) 10.3 m /s Hutchinson insert Engine Speeds Low idle High idle Governed

800 rpm 2600 rpm 2500 rpm

Stall Speeds Converter stall Full stall Hydraulic stall

2271 rpm 2100 rpm 2500 rpm

Fuel Consumption At full power Average mine duty

37.5 Litres/hr 8-10 Litres/hr

Start System Starter motor type

Air turbine type

Engine Intake system Type/make Intake flame trap

Dry/Donaldson Dual element type BUCYRUS spiral wound type

Exhaust Conditioner Type Flameproof dry type Make BUCYRUS Australia Exhaust filter Replaceable element Exhaust flame trap BUCYRUS spiral wound type After treatment Catalytic exhaust purifier Shutdown system (standard) Pneumatic Shutdown system (standard) Electronic Intrinsically Safe approved Transmission Type Power shift with forward/reverse modulated Speeds, forward and reverse 4 Torque Converter Type Mounted in transmission, single element Make/model Dana 13.0 integral

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Hydraulic Systems Steering Brakes Ejecting Tray PTO (1 on machine) Tank type Tank pressure Hydraulic Filtration Suction

Steer/brake system

Closed centre 20.7 MPa Closed centre 20.7 MPa Open centre 20.7 MPa Open centre 20.7 MPa Sealed and pressurised 50 kPa

In line, strainer Return 25 micron Replaceable with bypass Pressure10 micron Replaceable with bypass

Main Hydraulic Pump Type Gear Standard pump output @ 2400 rpm

Open centre 150 lpm

Steering/Brake Pump Type Piston pressure compensated Standard pump output @ 2400 rpm 75 lpm Engine Fan Pump Type

Gear open centre

Alternator Drive Pump Type

Gear open centre

Steering System Control valve Actuation Unloader valve Crossover relief Accumulator Steering Type Quantity x capacity Operating Pre charge pressure

Closed centre Orbital (steering wheel) 20.7 MPa 21.7 MPa

Piston 1 x 4 litre 6.2 MPa

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General Information

FBR-15 Specifications

Accumulator Brakes Type Quantity x capacity Operating pre-charge pressure

Piston 1 x 2 litre 6.2 MPa

Accumulator Ejector System Type Quantity x capacity Operating pre-charge pressure

Piston 2 x 10 litre 6.2 MPa

Ejector Tray System Control valve

Open centre

Actuation Main relief

Canopy Type

Electrical System Type Voltage Shutdown system

Remote hydraulic pilot 21.7 MPa

Cylinder Reliefs Load eject Load retract PTO out PTO in

BUCYRUS Australia 2008©

Seating (Operator) Type Make Suspension

21.7 MPa 21.7 MPa 21.7 MPa 21.7 MPa

Cylinders Type Cushion stops

Double acting Steering

Service Brake Hydraulic System Type Actuation

Reverse modulating Foot pedal

Service Brake Type Totally enclosed, liquid cooled POSI STOP Make/ model Heavy duty 6 plate Application Spring applied hydraulic release Park and Emergency Brake Type Totally enclosed, liquid cooled POSI STOP Make/model Dana 16150 Heavy duty 6 plate Application Spring applied hydraulic release Location Each wheel end built into axle Steering Type

Lights Number /location Type

Alternator Drive Type Pneumatic System Compressor type Governed pressure Relief pressure Air receiver volume

Cross-seated BUCYRUS Australia Adjust spring/shock absorber

Adjustable protective device MDG1 and MDG17

Approved flameproof 12 V Electronic Intrinsically Safe approved

2 front, 2 rear High performance Approved flameproof

Hydraulic approved flameproof

Piston engine gear driven 800 kPa 830 kPa 80 litres

Service Capacities Hydraulic tank Fuel tank Transmission/converter oil Engine crankcase oil Engine cooling system water Axle oil (each)

300 litres 300 litres 80 litre 22 litre 72 litre 60 litre

Vehicle Speeds (unladen) 17.5 x 25 tyres 1st gear 2nd gear 3rd gear 4th gear

3.8 kph 7.9 kph 13.3 kph 22.5 kph

Maximum Tractive Effort 17.5 x 25 tyres 1st gear 2nd gear 3rd gear 4th gear

203 kN 96 kN 55 kN 32 kN

Centre articulated, hydraulic

Articulation Bearing type Degrees of turn either side

Pin and spherical bearing +/- 48 degrees

Oscillation Type Centre articulation bearing Degrees up and down from horizontal +/- 30°

Grade Ability Front to rear Side to side (empty)

1:4 1:4

WARNING Overloading equipment could cause personal injury, death or equipment damage. Due to configuration or options these weights can vary up to 20%.

BUCYRUS Australia recommends that relevant standards and safety procedures should always be used when operating this equipment. Removal of a protective canopies, doors, interlocks and structures etc., could cause serious injury of death. Replacement with correctly torqued fasteners is mandatory.

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Operator Manual

General Safety and Precautions

This section contains specific safety precautions that shall be followed whilst the machine is being operated. This list is NOT all inclusive and a measure of commonsense should always be applied.

BUCYRUS Australia 2008©

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 maintenance 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: 1.

2.

DO NOT:

Start the machine unless: 1.

2.

3.

4.

DO NOT:

All covers and guards are correctly installed.

All personal protective equipment is worn as required by site rules.

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: 1.

2.

3.

4.

The vehicle is parked in a safe place.

The transmission is in NEUTRAL. The park brake is applied and brake head pressure is zero.

The engine is stopped.

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 vehicle.

ALWAYS:

Keep head 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.

ALWAYS:

Travel on declines with the machine in low gear.

ALWAYS:

Follow the correct isolation and tag out procedure before performing any maintenance on the machine.

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Operator Manual

General Safety and Precautions

ALWAYS:

Operate carefully and in a responsible manner and observe all managers transport rules.

ALWAYS:

Ensure sufficient ventilation is available to dilute exhaust gases. A nominal 8 m3/sec is recommended based on NSW mines regulations of 0.06 m3/sec.

ALWAYS:

Stop machine and allow persons past if in the area of operation.

ALWAYS:

Ensure area around tailgate is clear and nobody is within one metre of rear of the trailer when using the trailer ramplate and tailgate controls.

BUCYRUS Australia 2008©

Potential Crush Point Articulation

One Metre No Go Zone When Trailer in Ejected or Retracted

Potential Crush Point Against Rib When Articulating

•

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.

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Operator Manual

General Safety and Precautions

Notes, Cautions and Warnings ALL applicable NOTES, CAUTIONS and WARNINGS listed in this manual are included in the support documents following the same format as defined below.

NOTE Indicates a procedure or condition that is essential for personnel working on the equipment to know.

CAUTION Indicates an action or condition that, if not followed, could cause damage to the vehicle or other equipment.

WARNING BUCYRUS Australia 2008©

Indicates an action or condition that, if not followed, could cause serious injury or even death to the operator or other personnel.

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3 3.1

Gauge Information

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 service brake the brake head pressure gauge will drop below the minimum pressure and indicate that the pressure is to 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 service 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 maintenance personnel rectify the problem before placing the machine back in service.

BUCYRUS Australia 2008©

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 maintenance personnel for rectification.

Rev 0

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 maintenance personnel for rectification if machine continually operates in this area.

GREEN:

The gauge is indicating that the temperature or pressure being monitored is within the normal operating range.

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Operator Manual

3 3.2

Gauge Information

Gauge Alarm Parameters

Engine Coolant Temperature 0-50°C 50-104°C 104-107°C

Yellow Green Orange

107-120°C

Red

Coolant temperature to low.

Normal operating temperature range.

Above normal operating temperature. Engine shutdown imminent.

Above normal operating temperature. Engine should have shutdown. Coolant will be boiling

Exhaust Coolant Temperature 0-100°C 100-108°C

Green Orange

107-120°C

Red

Normal operating temperature range.

Above normal operating temperature. Engine shutdown imminent.

Above normal operating temperature Engine should have shutdown. Coolant will be boiling.

BUCYRUS Australia 2008©

Exhaust Gas Temperature 0-140°C 140-150°C

Green Orange

150-200°C

Red

Normal operating temperature range.

Above normal operating temperature. Engine shutdown imminent.

Above normal operating temperature. Engine should have shutdown.

Exhaust Pressure 0-10 kPa 10-12 kPa

Green Orange

12-25 kPa

Red

Normal operating pressure.

Exhaust pressure getting high indicating that exhaust filter needs to be changed.

Exhaust pressure to high. Exhaust filter needs to be replaced. Continued long periods of operation will result in damage to engine.

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

Red Green Red

Engine oil pressure to low. Engine should have shutdown.

Normal operating pressure range.

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

0-275kPa

Orange

275-827kPa 827-1000kPa

Green Red

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

Normal operating pressure range.

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

Air Pressure Gauge

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3 3.2

Gauge Information

Gauge Alarm Parameters

Brake Accumulator Pressure Gauge 0-13790kPa

13790-18616kPa 18616-25000kPa

Red

Green Red

Pressure to low. Brakes may not fully release. Premature brake wear may result if operated for prolonged periods.

Needle may drop into this area for a short period when brakes are operating.

Normal operating pressure range.

Above normal operating range. Damage to brake components may result if operated for prolonged periods.

Brake Head Pressure Gauge

BUCYRUS Australia 2008©

0-11377kPa

11377-12756kPa 12756-16000kPa

Red

Green Red

Pressure below normal operating range. During normal operation 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.

Normal operating pressure range.

Pressure to high. Damage to brake units may occur.

Steering Accumulator Pressure Gauge 0-13790kPa

13790-18616kPa 18616-25000kPa

Rev 0

Red

Green Red

Pressure to low. Steering may become heavy to operate.

Needle will drop into this area for a short period when steering is operating.

Normal operating pressure range.

Above normal operating range. Damage to steering components may result if operated for prolonged periods.

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BI643720 FBR-15 Serial No.

4.

Operator Manual

Machine Orientation, Controls and Functions

4.1

Machine Orientation

4.1.1

Basic Machine Layout

The FBR-15 consists of two main sections a tractor and trailer frame. Housed in the trailer frame is the tailgate assembly, telebody assembly, axle assembly and one main hydraulic control valve bank.

The tractor frame houses the transmission and hydraulic pumps, both cooling system radiators, flameproof engine package, which utilises a dry exhaust conditioner, the operator’s compartment and all the storage reservoirs, (Hydraulic, Pneumatic, Brake Flushing and Fuel tanks).

BUCYRUS Australia 2008©

Tailgate Assembly

Telebody Assembly

Front Axle

Main Hydraulic Control Valve Banks

Transmission and Hydraulic Pumps

Operator’s Compartment

Hydraulic Tank

Fuel Tank Rear Axle Air Receiver

Dry Exhaust Conditioner Cooling System Radiators

Flameproof Engine

Figure 4.1.1.1 - Basic Machine Layout

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Operator Manual

Machine Orientation, Controls and Functions

4.2

Control Locations

4.2.1

Operator’s Compartment Door

The operator’s compartment door must be closed and locked after entering the compartment before the park brake can be released and the declutch valve de-activated.

WARNING Never use the door to apply the park brake. Always manually apply by the park brake actuatation control and ensure the brake head pressure gauge reads zero.

The steering pressure will automatically bleed down, never assume the steering pressure has bleed down unless the steering pressure gauge reads ZERO

NOTE BUCYRUS Australia 2008©

When the door is open the machine can not be operated, as the park brake will be on and the transmission will be de-clutched as 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.

Figure 4.2.1.1 - Operator’s Compartment and Door Assembly

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Machine Orientation, Controls and Functions

4.2

Control Locations

4.2.2

Transmission Gear Control Lever

The 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.

NOTE The transmission in the machine is modulated. This prevents severe shocks being transmitted through the drive train when the transmission is shifted between gears.

4.2.3

Transmission Directional Control Lever

BUCYRUS Australia 2008©

A directional control lever controls the transmission. 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.

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

WARNING If the engine starts when the transmission is not in neutral the neutral start valve on the transmission needs to be adjusted or replaced.

NOTE The transmission is fitted with a audible reverse alarm.

Transmission Directional Control Lever

Transmission Speed Control Lever

Figure 4.2.2.2 - Reverse Alarm Figure 4.2.2.1 - Transmission Controls Rev 0

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Machine Orientation, Controls and Functions

4.2

Control Locations

4.2.4

Park Brake/Emergency Brake Control

The park brake valve 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 of the machine shuts down the emergency 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.

WARNING BUCYRUS Australia 2008©

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 brake could possibly not apply when exiting machine and the machine could run away resulting in serious damage or injury.

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

Figure 4.2.4 2 - Brake Head Pressure

Figure 4.2.4.1 - Park Brake Valve

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Operator Manual

Machine Orientation, Controls and Functions

4.2

Control Locations

4.2.5

No 1 Two-Way Trailer Eject/Retract Control Lever

This lever has three positions, EJECT, RETRACT, and HOLD: 1.

2.

3.

Pushing the lever to the up moves the ejector tray out to dump the load.

Pulling the lever to the down retracts the ejector plate.

The lever is spring centred to the HOLD position.

4.2.6

No 2 Two-Way PTO Control Lever

This lever has three positions, PTO, PTO, and HOLD: Pushing the lever to the up supplies pressure to one side of PTO function.

Pulling the lever to the down supplies pressure to other side of PTO function.

The lever is spring centred to the HOLD position.

BUCYRUS Australia 2008©

1.

2.

3.

No. 1 - Two-Way Hydraulic Trailer Eject/Retract Control Lever

No. 2 - Two-Way Hydraulic PTO Control Lever

Figure 4.2.5.1 - Pilot Controls

Park/Emergency Brake

Eject Pilot Control Lever

Operator’s Door

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Operator Manual

Machine Orientation, Controls and Functions

4.2

Control Locations

4.2.7

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.

4.2.8

Accelerator Pedal

The accelerator pedal is connected to the diesel engine fuel pump governor via a cable connected the fuel pump throttle control lever. When the accelerator pedal is depressed the engine speed increases. The throttle pedal is spring returned so that when pedal pressure is removed, the engine returns to low idle.

CAUTION

BUCYRUS Australia 2008©

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

4.2.9

Brake Pedal

The brake pedal when depressed applies the service brakes on the front and rear axles. There are four liquid cooled POSI STOP service brakes located internally in each axle. Whenever possible use the engine compression to slow the vehicle on a grade or decline by revving the engine to speed after selecting a lower gear.

NOTE DO NOT ride the service brakes while tramming the vehicle.

NOTE If the engine should stall, the machine is fitted with failsafe brake system that will fully apply the brakes in under 10 seconds. The operator can apply the brakes at any time following an engine stall to immediately bring the vehicle to a controlled stop.

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

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4.2

Operator Manual

Machine Orientation, Controls and Functions Control Locations

4.2.10 Steering Wheel The steering wheel controls the flow of hydraulic oil to the steering cylinder. As the cylinder strokes, the vehicle articulates to the LEFT or to the RIGHT. Turning the wheel ANTI-CLOCKWISE articulates the vehicle toward the operator. This effectively turns the vehicle to the LEFT in the forward direction (tractor end).

Turning the wheel CLOCKWISE articulates the vehicle away from the operator. This effectively turns the vehicle to the RIGHT in the forward direction (tractor end).

NOTE

BUCYRUS Australia 2008©

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

NOTE If the engine should stall, the machine is fitted with a system that will dump the steering pressure in under 30 seconds. The operator can steer the machine via a 6 litre back up accumulator at any time following an engine stall to immediately bring the vehicle to a safe controlled stop.

NOTE If the door is opened or the park brake is applied, the machine is fitted with failsafe 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 control reset to the OFF position.

Figure 4.2.10.1 - Steering Wheel

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4.2

Operator Manual

Machine Orientation, Controls and Functions Control Locations

4.2.11 Brake Head Pressure Gauge This gauge shows the service, park and emergency brake system brake head oil pressure.

Operators should periodically check this gauge. The gauge will read zero pressure when the brakes are fully applied via the emergency or service brake controls.

NOTE If the operator’s foot is off the service brake pedal and the park brake is released the indicated pressure shall be a minimum of 10342 kPa (1500 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.

CAUTION BUCYRUS Australia 2008©

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

4.2.12 Brake Accumulator Pressure Gauge This gauge indicates the service, park and emergency brake system oil and accumulator pressure.

Normal operating system pressure is 17200 kPa (2500 PSI).

CAUTION DO NOT operate the vehicle if the brake pressure gauge is less than 17200 kPa (2500 PSI). Immediately report the problem to service personnel.

4.2.13 Steering Accumulator Pressure Gauge This gauge indicates the steering system oil and accumulator pressure. The normal steering system hydraulic oil pressure is 17200 kPa (2500 PSI).

NOTE 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

Figure 4.2.11.1 - Left Hand Side Operator’s Panel Rev 0

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4.2

Operator Manual

Machine Orientation, Controls and Functions Control Locations

4.2.14 Engine Start Button Depressing the engine start button engages the starter motor to start the engine. There is a delay of approximately 4-5 seconds from when the button is depressed till when the starter engages.

The start button will not activate the starter motor unless: 1.

2.

3.

4.

The transmission is in neutral.

The park brake is applied.

The engine safety shutdown circuit shows no fault.

The ON/OFF valve is “ON”.

NOTE

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Depress the throttle pedal 1/3 before a start to ensure sufficient fuel is available.

Immediately remove finger from the start button when the engine fires.

4.2.15 Air Starting Pressure Gauge This gauge indicates the air starting pressure in the air receiver. Normal air pressure is set at 760860 kPa (110-125 PSI).

NOTE An air isolation valve is mounted on the air receiver. Turn this valve on before entering the machine. The gauge will read “0” when the valve is shut.

4.2.16 On/Off Toggle Switch The ON/OFF switch controls the supply of pilot air pressure to the air pressure switch on the electronic safety system, which allows air to pilot the starter motor.

1.

2.

To start the engine, place the switch in the ON position.

To shutdown the engine place the switch in the OFF position.

Engine Start Button

On/Off Toggle Switch

Air Starting Pressure Gauge

Figure 4.2.14.1 - Left Hand Side Operator’s Panel

Rev 0

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4.2

Operator Manual

Machine Orientation, Controls and Functions Control Locations

4.2.17 Transmission Oil Temperature Gauge This gauge indicates the oil temperature in the transmission and torque converter normal operating temperature is between 82ºC-93ºC. If the temperature should rise above 121ºC, carry out the following procedure: 1.

2.

Bring the machine to a halt, and apply the park brake.

Put the transmission in NEUTRAL and rev the engine to about half 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.

CAUTION BUCYRUS Australia 2008©

DO NOT operate the vehicle if the oil temperature is above 121ºC.

4.2.18 Engine Coolant Temperature Gauge This shows the coolant temperature circulating through the engine, exhaust and radiator systems.

Normal operating temperature is between 82ºC-95ºC. The engine should not be operated under heavy load until it has time to warm up approximately five minutes.

WARNING Shut off the engine immediately if the coolant temperature gauge goes above 105ºC. The engine safety shutdown system should shutdown the engine at 105ºC. The engine must also be shut off and cooled when the coolant level is to be topped up.

Engine Coolant Temperature Gauge

Transmission Oil Temperature Gauge

Figure 4.2.17.1 - Right Hand Side Operator’s Panel Rev 0

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4.2

Operator Manual

Machine Orientation, Controls and Functions Control Locations

4.2.19 Horn Button Pushing this button sounds the air horns.

Figure 4.2.19.1 - Horn Button

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

4.2.20 Exhaust Heat Exchanger Coolant Temperature Gauge This shows the coolant temperature circulating through the exhaust heat exchanger and radiator systems. Normal operating temperature is between 70OC-80OC.

WARNING Shut off the engine immediately if the water temperature gauge goes above 105ºC. The engine safety shutdown system should shutdown the engine at 105ºC.

4.2.21 Exhaust Outlet Gas Temperature Gauge Shows the exhaust gas temperature entering the mine atmosphere from the exhaust outlet.

Machine will shutdown if this temperature exceeds 140OC.

Exhaust Coolant Temperature Gauge

Exhaust Outlet Gas Temperature Gauge

Figure 4.2.20.1 - Right Hand Side Operator’s Panel Rev 0

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4.2

Operator Manual

Machine Orientation, Controls and Functions Control Locations

4.2.22 Emergency Fuel Shut Off Valve

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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.

Figure 4.2.22.1 - Fuel Shut Off Valve

4.2.23 Engine Service Hour Meter This electric meter is mounted on the operator’s side in the articulation area of the machine.

Use the hour meter to determine servicing intervals.

Figure 4.2.23.1 - Engine Hour Meter

4.2.24 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 Service Indicator

Figure 4.2.24.1 - Air Cleaner and Indicator Rev 0

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4.2

Operator Manual

Machine Orientation, Controls and Functions Control Locations

4.2.25 Exhaust Back Pressure Gauge The exhaust back pressure gauge located in the operator’s compartment indicates the condition of the filter element. When the back pressure is above 12 kPa or the green area on the back pressure gauge, the elements should be removed and replaced.

NOTE The filter has a bypass system that allows the exhaust to bypass the filter for pressures over 80 kPa (11 PSI). Extended operations with the filter in bypass should be avoided. Remove the filter if the indicator is tripped.

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NOTE Dirty filters should be disposed of correctly. Appropriate personal protective equipment should be worn. Operators should minimise skin contact with dirty filters. The dirty element should be placed in the plastic bag that the new filter came in and completely sealed. The contaminated element must be removed from the underground environment and disposed of safely.

NOTE The diesel aerosol particulates can be safely handled when wet.

4.2.26 Engine Oil Pressure Gauge This gauge indicates the engine lubricating oil pressure. Normal pressure is between 210-550 kPa (30-80 PSI).

CAUTION Shut off the engine if the oil pressure drops and stays below 70 kPa (10 PSI). The engine safety shutdown system should shutdown the engine at 70 kPa (10 PSI).

CAUTION 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

Exhaust Back Pressure Gauge

Figure 4.2.25.1 - Engine Oil and Back Pressure Gauges Rev 0

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4.2

Operator Manual

Machine Orientation, Controls and Functions Control Locations

4.2.27 Engine Hand Fuel Primer Pump If the diesel 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.

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Figure 4.2.27.1 - Engine Hand Fuel Primer Pump

Fuel Shut Off Valve

Fuel Priming Pump Air Filter

Engine Hour Meter

Rev 0

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Operator Manual

Machine Orientation, Controls and Functions Control Locations

4.2.28 Emergency Intake Shut-off Valve

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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 the FBR-15 with a second means of shutting down the engine should the ON/OFF toggle valve fail.

Figure 4.2.28.1 Emergency Intake Shut Off Valve Activation Button

Figure 4.2.28.2 Emergency Intake Shut Off Valve Reset Lever

The valve is activated from the operator’s compartment by a button which is pushed, once activated and the engine shuts down the valve will need to be reset before restarting. Ensure that the button in the operator’s compartment has been pulled out and there is a 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 valve has been reset the engine can be started.

WARNING Restarting of the engine should be done in compliance with the manager’s rules.

Rev 0

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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.

5.1

Engine Isolation

To isolate the engine perform the following procedure: 1.

2.

3.

4.

5.

6.

Select “NEUTRAL” on transmission directional control lever.

Apply the “Park Brake”.

Shutdown the diesel engine.

Fit a danger tag to the ON/OFF toggle valve.

Connect the articulation lock and chock the wheels.

Close the main air isolating valve (see Section 5.2 - Pneumatic Isolation).

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On/Off Toggle Switch

Air Starting Pressure Gauge

Figure 4.2.10.1 - Left Hand Side Operator’s Panel

Main Isolating Valve

Air Starting Pressure Gauge

On/Off Toggle Switch

Rev 0

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5.

5.2

Machine Isolation

Pneumatic Isolation

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

2.

3.

Shutdown the diesel engine, fit a danger tag to the ON/OFF toggle valve, connect the articulation lock and chock the wheels.

Locate the isolating ball valve in front of operator above the eject control lever and rotate to the OFF position.

Relieve air pressure in the system lines by successively switching the ON/OFF toggle valve in the operator's compartment until the air pressure gauge on the dash board reads zero when the toggle switch is in the ON position.

NOTE If work is required on the air receiver it will be necessary to remove air pressure from the receiver by actuating the drain valve located at the bottom of the air receiver. 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.

WARNING BUCYRUS Australia 2008©

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

Figure 5.2.1 - Main Air Isolating Valve

Figure 5.2.2- Main Air Isolating Valve

Figure 5.2.3 - Main Air Drain Valve Rev 0

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5.

5.3

Machine Isolation

Hydraulic Isolation

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

Shutdown the diesel engine, fit a danger tag to the ON/OFF toggle valve, connect the articulation lock and chock the wheels.

Observe both steering and brake pressure gauges located in the operator's compartment.

The hydraulic system features a steering and brake accumulator automatic bleed circuit which will remove hydraulic pressure from both accumulators once the diesel engine has stopped.

This normally takes around 30 seconds. The steering and brake accumulators can also be bled via rotation of the steering wheel and actuation of the service brake pedal, once the engine has been shutdown.

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

2.

3.

Brake Accumulator Pressure

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Steering Accumulator Pressure

Figure 5.3.1 - Left Hand Side Operator’s Panel

Rev 0

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5.

5.4

Machine Isolation

Engine and Heat Exchanger Coolant Isolation

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

2.

3.

4.

5.

Shutdown the diesel engine, fit a danger tag to the ON/OFF toggle valve, connect the articulation lock and chock the wheels.

Isolate the pneumatic circuit as described in Section 5.2.

Locate the header tank relief cap located at the rear of the machine on the operator's side.

Remove coolant circuit pressure (105 kPa) by slowly lifting up the RED relief lever on the filler cap and hold up till pressure is released.

Slowly remove filler cap with relief valve held in the up position.

WARNING

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Engine coolant fluid will be under pressure and hot (up to 100OC). Always relieve pressure by lifting the relief valve on pressure 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 Header Tank

Heat Exchanger Header Tank

Figure 5.4.1 - Engine and Heat Exchanger Header Tanks

Engine Header Tank

Heat Exchanger Header Tank

Rev 0

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5.

5.5 1.

2.

Machine Isolation

Electrical Isolation Shutdown the diesel engine, connect the articulation lock and chock the wheels.

All electrical energy is isolated once the diesel engine has stopped.

WARNING 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.

WARNING

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DO NOT carry out any welding on the machine unless the power supply, the Electronic Engine Control System is disconnected.

NOTE If any fault or damage is detected to the electrical system it should be reported to the maintenance department.

NOTE The locking of the main isolation valve or completely draining the pneumatic system of air will render the machine unable to be started until it is re-energised.

Rev 0

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5.

5.6

Machine Isolation

Fitting and Removal of Articulation Lock

To fit the articulation lock: 1.

2.

3.

4.

Bring the machine to a stop and manually apply the park brake by depressing the red palm button located in the operator’s compartment.

Locate the articulation lock at the articulation area on the off operator’s side of the machine and remove the locking clamp on the bottom location.

Swing the articulation lock up until it lines up with the pin location on the rear half of the machine.

Install the 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 and swing the bar down to locate on the lower locating pin.

Ensure the lynch pin is installed in the locating pin and secure it in the support bracket by tightening the clamp bar.

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WARNING 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.

Figure 5.6.1 - Articulation Lock in Locked Position

Rev 0

Figure 5.6.2 - Articulation Lock in Storage Position

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5.

5.6

Machine Isolation

Fitting and Removal of Tailgate Lock

To fit the tailgate lock: 1.

Bring the machine to a stop and manually apply the park brake by depressing the red palm button located in the operator’s compartment.

Raise tailgate to the fully open position.

Locate the tailgate locks at the tailgate area on both the off operator’s side and operator’s side of the machine and remove the location.

Install the lock pins through the retaining holes.

2.

3.

4.

To remove the tailgate lock: 1.

2.

3.

With the park brake applied, remove the lock pins from the locating holes.

Ensure the lock pins are installed in the storage holes.

Start machine and lower the tailgate.

WARNING BUCYRUS Australia 2008©

The tailgate 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 tailgate area to fit or remove the tailgate locks.

NEVER work in the vicinity of the tailgate joint unless the articulation lock has been correctly installed.

Figure 5.6.2 - Tailgate Lock in Storage Position

Figure 5.6.1 - Tailgate Lock in Locked Position

Rev 0

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6.

Pre-Start Procedure

Walk around the machine: 1.

2.

3.

4.

5.

6.

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.

Check the hydraulic reservoir oil level: 1.

2.

3.

4.

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5.

Be sure the machine is level when checking fluid level.

Check the level at normal operating temperature.

When the fluid level has dropped below the full mark, add hydraulic oil to restore the proper operating level.

The reservoir fill cap is located on the off operator’s side of the machine on the side of the hydraulic reservoir.

Check the hydraulic oil filter indicator is in the green area.

Figure 6.1 - Hydraulic Level Sight Gauges and Filler Cap

CAUTION ALWAYS Use the specified lubricant for the application and the regions seasonal temperatures. (See Section 19).

Check the engine oil level: 1.

2.

3.

4.

If required the engine should be filled to the full mark on the engine dipstick.

Ensure to correct engine oil is used.

Oil specifications are listed in Section 19 - Fluid Specification Table Do not over fill

Figure 6.2 - Engine Fill Point

Figure 6.3 - Engine Oil Dipstick

NOTE The oil level should be checked with the engine off.

Rev 0

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6.

Pre-Start Procedure

Check the fuel level: 1.

2.

3.

4.

Gauge fitted to the fuel tank.

Check the filler cap is secure and not damaged.

Check for leaks.

Always fill machine completely.

CAUTION DO NOT operate the loader with the fuel level below the empty level on the fuel tank. It is recommended procedure to fill the fuel tanks at the end of each shift.

CAUTION ALWAYS Use the specified lubricant for the application and the regions seasonal temperatures. (See Section 19).

BUCYRUS Australia 2008©

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

2.

3.

Located at the rear of the machine under the rear hinged door.

Damaged or loose belts should be reported to maintenance personnel or replaced or tensioned immediately.

Check for coolant leaks around water pump hoses and connections.

Figure 6.4 - Fuel Sight Gauges

Figure 6.5 - Water Pump Drive Belt

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

Check the condition of the fuel water separator: 1.

2.

3.

Located at rear operator’s side of machine.

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

Check fuel lines for leaks or damage.

Figure 6.6 - Fuel Water Trap Rev 0

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6.

7.

Pre-Start Procedure

Check the articulation lock bar (see Section 5.6): a. b.

For proper storage and loose fasteners.

For damage.

Figure 6.7 - Articulation Lock Bar

8.

Check the expansion tank coolant level: Filler Cap

a. b. c.

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d.

Ensure coolant is to correct level on sight gauge.

Check for coolant leaks.

Ensure to correct coolant mix is being added if required.

Ensure cap is secured.

Overflow

Sight Level Indicators

Figure 6.8 - Coolant Expansion Tank

9.

Radiator: a. b.

10.

Check for coolant leaks on hoses.

Check for build up of dirt in the radiator fins (clean if radiator fins are blocked or dirty).

Headlights: a. b.

Check lights are securely mounted.

Check cables and glands for damage.

CAUTION ALWAYS Use the specified lubricant for the application and the regions seasonal temperatures. (See Section 19).

Rev 0

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6.

11.

Pre-Start Procedure

Air cleaner (see Section 4.2.24): a. b. c. d.

Check the air cleaner filter condition indicator.

Replace filter element if indicator is in the red area.

Check intake pipes and hoses for loose or damaged connections.

Check flame path joints are secured.

Figure 6.9 - Air Cleaner and Indicator

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

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12.

Check air receiver: a. b.

For damage.

Drain condensate from drain valve.

Figure 6.10 - Air Receiver Drain Valve

NOTE It is important to drain the condensate from the air receiver on a daily basis to stop the starter motor and relay valve from being contaminated.

Rev 0

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6.

13.

Pre-Start Procedure

Brake Flushing Oil Level: The brake flushing system flushes and cools the brake heads situated behind each wheel hub on the machine: To check the brake flushing oil level:

BUCYRUS Australia 2008©

a. b.

Check sight gauge at rear of machine.

Fill as required.

Figure 6.11 - Brake Flushing Sight Gauges

Figure 6.12- Brake Flushing Fill Point

Rev 0

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6.

14.

Pre-Start Procedure

Check the fire extinguisher: Located on front operator’s side mudguard.

Check inspection date.

Check contents indicator is reading in the green area.

If fire suppression system fitted check actuation points.

BUCYRUS Australia 2008©

a. b. c. d.

Rev 0

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6.

Pre-Start Procedure

The dry exhaust conditioning system on the FBR-15 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 filter out particulates to prevent them entering the mine atmosphere.

CAUTION

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Flameproof Diesel Engine maintenance must be carried out by a qualified and authorised person.

Figure 6.13 - Exhaust Gas Flow

Check Exhaust System • • • • • •

Check for damage.

Check joints for signs of leakage.

Check cooling hoses for security and condition.

Check the exhaust flame trap is in place and secured with all locking devices.

Check the drain and flushing plugs are fitted.

Check the filter housing lid is fitted and securely tightened past the safety pin.

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

Rev 0

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6.

Pre-Start Procedure CAUTION

Flameproof Diesel Engine maintenance must be carried out by a qualified and authorised person.

Heat Exchanger Drain Plug

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Flushing Plug

Filter Lid Lock Pin in Position

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

Rev 0

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6.

Pre-Start Procedure CAUTION

Flame trap maintenance must be carried out by a qualified and authorised person.

BUCYRUS Australia 2008©

Safety clip fitted

Flame trap nut handle below the spring returned safety pin

Figure 6.14 - Flame Trap in Location on Machine

NOTE DO NOT over tighten the flame trap nut handle, it should be firm so the flame trap does not move.

Rev 0

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6.

Pre-Start Procedure

Emergency Intake Shutoff Valve The emergency intake shutoff valve should be inspected before attempting to start the engine. The activation button should be pulled out and the reset lever latch into the operating position (See Section 4).

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

WARNING

BUCYRUS Australia 2008©

If the emergency intake shutoff valve has been activated, the restarting of the engine should be done in compliance with the relevant regulations and manager’s rules.

Figure 6.15 - Emergency Intake Shut Off Valve Activation Button

Rev 0

Figure 6.16 - Emergency Intake Shut Off Valve Reset Lever

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7. Engine Starting Procedure WARNING Always sound the horn and make sure the area around the vehicle, 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.

NOTE If the vehicle is to be put into operation, make certain that the centre pivot safety link is disconnected.

1.

2.

3.

4.

5.

BUCYRUS Australia 2008©

6.

7.

8.

9.

10.

11.

12.

Turn the air system isolation valve, located at the air receiver to the OPEN position.

Enter the compartment close and latch the door.

Place the transmission FORWARD/NEUTRAL/REVERSE lever in the NEUTRAL position.

Make sure the PARKING BRAKE is applied.

Check the AIR PRESSURE GAUGE. If the start pressure is below 600 kPa (80 PSI) the engine may not start. If the air pressure is below 600 kPa, recharge the air receiver to 890 kPa (120 PSI).

Turn the ON/OFF switch located in the instrument panel to the ON position.

Wait for the electronic shutdown system display for the NO SOLENOID light to go off (approximately 20 seconds).

Hold the THROTTLE PEDAL approximately one-third to halfway open.

Depress the START button located on the instrument panel and release the start button when the engine has started.

Check the NO CHARGE display light has gone out.

Operate machine normally.

SEE SECTION 18.2 SYSTEM OPERATION

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

WARNING 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.

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.

NOTE Check the gauges frequently during operation.

WARNING Release the park brake only when the steering and brake pressure gauges register in the normal operating range.

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8.

Post Start Checks

The following tests are required to be performed with the engine running.

1.

Check gauges are on correct operational pressure: a.

2.

Check function of ejector system.

3.

Check steering function: a.

4.

b.

5.

Ensure brake head pressure reads in green area 10342 kPa-11032 kPa when brake is released.

Ensure brake head pressure reads zero when brake is on.

Check that all of the lights are working. a. b.

6.

Ensure machine steers freely from left to right.

Check park brake operation: a.

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Gauges colour coded (should read in green area):

There are two forward and rear facing headlights.

Control switch is operation.

Check the transmission oil level: a. b. c. d. e. f. g. h.

Always check when the transmission is warm.

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

Place the machine in neutral, apply the park brake and install the articulation lock.

Remove 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 500 RPM-600 RPM. Remove the dipstick by pulling upwards and wipe with a clean, lint free cloth.

Re-insert the dipstick into the spout, remove and push it all the way home.

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

CAUTION ALWAYS Use the specified lubricant for the application and the regions seasonal temperatures. (See Section 19).

Figure 8.1 - Transmission Dipstick and Fill Point

Rev 0

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8.

7.

Post Start Checks

Check the particulate filter indicator: a. b. c.

Locate the indicator in the operator’s compartment.

Run the engine at high idle and observe the indicator position.

If the indicator above 2.5 PSI the filter requires replacement.

WARNING Ensure that the filter element is cool enough to handle otherwise the garbage bag will melt causing skin burns 8.

To replace the particulate filter: a. b. c.

BUCYRUS Australia 2008©

d. e. f. g. h. i.

Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 5.

Remove the filter housing lid by unhitching the locking mechanism and unscrewing the housing lid.

Place a large tie type garbage bag over the filter housing until the base of the bag is at the top of the housing.

Grasp the filter element through the garbage bag base and raise the filter element clear of the housing, ensuring that the garbage bag covers the filter element as it is raised.

With the filter element clear of the housing invert the element and garbage bag and secure the ties.

Discard the used element in the appropriate manner.

Place the new filter element inside the housing.

Check the sealing o-ring on the housing lid and replace the o-ring if damaged.

Screw the housing lid down until the locking mechanism closes in the correct location.

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

NOTE The filter has a bypass system that allows the exhaust to bypass the filter for pressures over 80kPa (11PSI). Extended operations with the filter in bypass should be avoided. Remove the filter if the backpressure gauge reads above 10kPa.

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8.

Post Start Checks

Heat Exchanger Cleaning: Over time particulates (the small particles that are present in exhaust smoke) will build up on the heat exchanger elements which may result in decreased heat transfer efficiency. To minimise build up, the heat exchanger should be cleaned weekly (50 hour service).

If exhaust temperature shutdowns occur regularly, check the exhaust filter back pressure and replace if necessary. The machine may require the heat exchanger to be cleaned if the exhaust shutdowns continue. Refer to Service Manual or Safe Work Procedure for correct cleaning sequence.

NOTE If the machine continues to shutdown on an exhaust fault after changing the particulate filter report to maintenance personnel.

WARNING BUCYRUS Australia 2008©

Wear suitable PPE when servicing heat exchanger including dust masks, Gloves and safety glasses.

WARNING All plugs and covers removed must be fitted correctly and new gaskets used as these are flameproof joints.

Check the shutdown 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 LED light should be on.

The engine should not restart until the ON/OFF toggle valve is reset.

WARNING If the engine does not shutdown do not use the machine. Report it to the maintenance department for repairs.

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9. Stopping the Engine 1.

2.

3.

4.

5.

Park the machine in a suitably safe location.

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 about idle speed for five minutes. This will allow internal temperatures to reduce gradually. Reduce engine speed to low idle for 30 seconds.

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

6.

7.

Turn the ON/OFF switch located on the instrument panel 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.

BUCYRUS Australia 2008©

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

NOTE If the engine fails to shutdown under the normal procedure the EMERGENCY INTAKE SHUT OFF VALVE should be used.

8.

CLOSE the air tank isolation valve on the air receiver after the engine has stopped.

WARNING Ensure the trailer tailgate is closed before leaving the operator’s compartment.

WARNING 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 FBR-15 is designed to travel in both forward or reverse direction with equal ease and performance.

The transmission is controlled by a DIRECTION CONTROL LEVER and a SPEED 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 vehicle stationary when either FORWARD or REVERSE gears are selected.

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

WARNING DO NOT coast the vehicle in NEUTRAL. Excessive speed may result in an uncontrollable “run-away”.

BUCYRUS Australia 2008©

6.

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

NOTE DO NOT downshift the transmission unless the machine is travelling at a speed suitable for the lower range.

CAUTION ALWAYS ensure that the transmission control levers are fully shifted.

7.

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

Momentarily decrease the engine revs when shifting to a higher gear and increase when selecting a lower gear.

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

Stop machine and apply park brake.

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

If this does not work follow the shutdown procedure and advise the Maintenance Department.

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

NOTE The vehicle speed can be regulated by using the service brakes, the engine throttle or by changing up and down gear ratios.

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11. Stopping and Braking NOTE The vehicle speed can be regulated by using the service brakes, the engine throttle or by changing up and down gear ratios.

1.

2.

3.

4.

5.

6.

Slow machine down first with brakes then use the transmission to help slow down the vehicle, by shifting down gears and utilising engine braking.

Apply the service brakes and bring the vehicle to a halt at the side of the roadway, turn the machine toward the rib.

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 OFF the ON/OFF switch.

After stepping off the machine, switch off the air isolate valve above the trailer controls in the operator’s compartment.

NOTE

BUCYRUS Australia 2008©

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

WARNING The emergency brakes fitted to the machine are extremely effective to cope with towing large loads. Operators should be prepared for rapid deceleration by holding onto the provided handholds.

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

If the brakes fail on the machine you should: • • • •

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Use the gears to help slow the machine.

Gradually turn machine to the rib.

Apply the park/emergency 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 your brakes before travelling up or down a ramp.

Always use a low gear when travelling down a grade and drive down using the engine to control the vehicle Avoid changing gears while travelling on a steep ramp.

If you have a mechanical or brake failure: a. b. c.

Immediately apply the service brakes.

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

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

NOTE Operators must be competent in emergency stop procedure.

WARNING

BUCYRUS Australia 2008©

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

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13. Parking on a Ramp WARNING 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 vehicle by letting up on the throttle pedal.

Apply the service brakes and bring the vehicle to a halt at the side of the drift.

Turn the vehicle toward the rib.

If possible empty the contents of the machine.

Set the park/emergency brake. Observe that the brake head pressure gauge is on ZERO. Always chock the wheels.

Inform Mine Management of the position of vehicle

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

WARNING BUCYRUS Australia 2008©

ALWAYS park with machine articulated into the rib and chock the wheels when on grades of more than 1:4.

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14. Loading To load the machine: Back machine underneath discharge boom of continuous miner.

Select NEUTRAL and APPLY PARK BRAKE. Retract the TELEBODY and RAMPLATE until the rear door is closed.

Fill TELEBODY from discharge boom on miner.

Fully retract TELEBODY. Fill TRAILER BODY from discharge boom on continuous miner.

Once the trailer is fully loaded, shift into FORWARD GEAR. Release PARK BRAKE and start to move away from the miner and travel in a controlled manner to the unloading station.

BUCYRUS Australia 2008©

1.

2.

3.

4.

5.

6.

7.

8.

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15. Ejecting To unload the machine: 1.

2.

3.

4.

5.

Back machine up to FEEDER. Select NEUTRAL. Open TAILGATE by moving the trailer control lever to the UP position.

Empty trailer by moving the trailer control to the RIGHT this will push the telebody and ramplate back to the rear of the trailer emptying out the trailer in the process.

Retract RAMPLATE in the TELEBODY until rear door is closed.

BUCYRUS Australia 2008©

Once the trailer is fully emptied, shift into forward and start to move away from the feeder and travel in a controlled manner to the miner to reload.

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16. Towing the Vehicle when Disabled WARNING Set the park brake and stop the engine. The towing vehicle must have sufficient braking capacity to stop and hold both vehicles.

1.

2.

3.

4.

BUCYRUS Australia 2008©

5.

The vehicle should be secured by 2x15 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, connect the machine to the towing vehicle, place the transmission in NEUTRAL, release the transmission spring applied brake by hydraulically overcoming the spring pressure and tow at low speed.

The brakes can be released with a Porta Power (maximum 11040 kPa [1600 PSI]) connected into the pressure port on the brake valve in the operator’s compartment. The operator is to stay in the operator’s compartment to apply the service brake or park brake if necessary. If these are applied the Porta Power needs to be pumped to 1600 PSI to release the brakes again.

If the vehicle must be towed around sharp bends or corners, disconnect the hydraulic hoses on the steering cylinders.

If the distance is more than 1000 metres, it will be necessary to disconnect the front and rear drivelines from the axle assemblies.

CAUTION Failure to comply to these procedures may result in serious damage to the transmission or converter.

WARNING The transmission will not hold the vehicle when the spring applied park brakes are bypassed by the Porta power pressure.

NOTE ALWAYS connect the disabled machine to the towing vehicle before releasing the machine park brakes. Make sure the machine park brake is re-applied before the towing vehicle is disconnected.

NOTE Maximum towing speed is 3 kph.

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17. Venting the Fuel and Cooling System 17.1 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 the secure the priming pump.

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

NOTE

BUCYRUS Australia 2008©

Check the fuel tank contents gauge before air venting the system.

Figure 17.1.1 - Fuel Priming Pump

17.2 Air Venting the Engine Cooling System To prevent an air lock in the engine coolant system, the cooling system automatically bleeds back to the header tank. Fill the coolant system only with the correct mix of POTABLE water and inhibitor as required in the lubrication specification.

NOTE Add water conditioner as necessary.

NOTE Refer to Sections 5 for isolation of the cooling systems and Section 6 for checking and filling of the cooling systems.

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18. Safety System 18.1 Safety Shutdown The intrinsically safe electronic monitoring system monitors the atmosphere for methane and controls the engine shutdown and will light the appropriate indicator on the LEDs on the display panel.

BUCYRUS Australia 2008©

The following sensors are fitted to the machine: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Hi alarm methane level Lo alarm methane level No charge alternator No oil pressure No exhaust coolant flow Low engine coolant level Heat exchanger coolant over-temperature Engine coolant over temperature Heat exchanger gas temperature Flame trap gas temperature Exhaust outlet temperature Run solenoid Start fault

(shuts engine down) (warning light) (warning light) (shuts engine down) (shuts engine down) (shuts engine down) (shuts engine down) (shuts engine down) (shuts engine down) (shuts engine down) (shuts engine down) (warning light) (warning light)

Figure 18.1.2 - Display Panel as fitted in Operator’s Compartment Figure 18.1.1 - Operator Display Panel

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18. Safety System 18.2 System Operation 1.

Turn on Start/Reset air pressure switch (Toggle Switch): a. b. c.

This will activate the SEMs electronics.

The lights on the display will light up for about five seconds (This serves to test lights and circuitry).

Most of the lights will go out and those remaining indicate relevant conditions. (NOTE If the methane head is not fitted the relevant LEDs will go out with the others).

• • • • • •

2.

Wait for the methane monitor to read (approximately 17 seconds): a.

BUCYRUS Australia 2008©

Hi Methane (1.25%) Lo Methane (1.0%) Charge Failure Engine Oil Pressure Exhaust Coolant Flow Run Solenoid l

The methane monitor needs about 17 seconds to measure the content in the surrounding air, if methane is detected the machine will not start.

WARNING If methane is detected the machine will start, report to supervisor. b. c.

3.

There is a waiting time of 30 seconds for the solenoid to power up and the Run Solenoid display light will go out.

With the machine in neutral it can now be started.

Start Engine: a. b. c.

Activate the operators start valve and start engine.

The “Charge Failure”, “Engine Oil Pressure”, “Exhaust Coolant flow” LED’s will then go out/ The machine is now ready to be operated.

Figure 18.2.1 - Operator Display Panel

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18. Safety System 18.2 System Operation WARNING If any of the LEDs remain illuminated after starting they should be reported to the maintenance staff.

NOTE The display lights will not activate if the air pressure is below 250 kPa.

NOTE

BUCYRUS Australia 2008©

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

Figure 18.2.2 - Operator Display Panel

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18. Safety System 18.2 System Operation 4.

To shutdown machine: a.

BUCYRUS Australia 2008©

b.

When shutting down the machine turn of the START/RESET valve (toggle switch). This will unpower the SEMs and the start solenoid and stop the machine.

Turn the main isolating air valve off.

Figure 18.2.3 - Main Air Isolating Valve

Figure 18.2.4 - Main Air Isolating Valve

Figure 18.2.5 - Start/Reset Valve (Toggle Switch)

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19. Fluid Specification Table SPEC.

1

BUCYRUS Australia 2008©

2

COMPONENT

Engine

Transmission

CAPACITY (Litres)

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)

300

Hydraulic

ISO68 (Valvoline Ultramax HVI 46 or Equivalent)

ISO68 (Valvoline Ultramax 68 or Equivalent)

ISO68 (Valvoline Ultramax 68 or Equivalent)

26

40

3

Hydraulic

4

Axle / Wheel Ends / 90º Drives

As required

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

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 - Diff Pinion Oil Seal

As required

8

Brake Flushing

200

Engine Oil

SAE10W Cat TO-4

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)

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

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

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