Cat DBT FBL-10 LHD/UTILITY VEHICLE OPERATORS MANUAL - PDF DOWNLOAD

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

FBL-10 LHD/UTILITY VEHICLE

OPERATORS MANUAL DENDROBIUM UNDERGROUND MINE

DBT Development & Diesel Phone: 49 583 133 Fax : 49 508 112

5/12/2004

Operators manual

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

INDEX 1.

GENERAL INFORMATION…………………………………………………. 3 1.1

INTRODUCTION ………………………………………………. .. 3

1.2

FBL-10 DESCRIPTION ………………………………………….. 3

1.3

FBL-10 DIMENSIONS ………………………………………….. .. 4

1.4

FBL-10 SPECIFICATIONS………………………………….. 5-6-7

2.

GENERAL SAFETY AND PRECAUTIONS…………………………….8-9-10

3.

MACHINE ORIENTATION FUNCTIONS AND CONTROLS……… ..11-22

4.

MACHINE ISOLATION…………………………………………….……..23-28

5.

PRE-START INSPECTION…………………………………………….… 29-32

6.

ENGINE STARTING PROCEDURE……………………………………….. 33

7.

POST START CHECKS……….…………………………………….…….34-37

8.

STOPPING THE ENGINE…………………………………………………… 38

9.

TRAMMING THE MACHINE……………………………………………… 39

10.

STOPPING AND BRAKING………………………………………………… 40

11.

DRIVING ON A RAMP……………………………………………………… 41

12.

PARKING ON A RAMP……………………………………………………... 42

13.

LOADING…………………………………………………………………...43-44

14.

DUMPING…………………………………………………………………….. 45

15.

TOWING THE VEHICLE WHEN DISABLED………………………….46-47

16.

AIR VENTING THE FUEL SYSTEM………………………………………. 48

17.

AIR VENTING ENGINE COOLANT SYSTEM…………………………… 48

18.

GENERAL INFORMATION………………………………………………. 49

19.

ATTACHING RAS IMPLEMENTS...………………………………………. 50

20.

DETACHING RAS IMPLEMENTS .…………………………….…………...51

21.

SAFETY SHUTDOWN SYSTEM……………………………………...52-53-54

22.

FBL-10 FLUID SPECIFICATION TABLE…………………………………..55

5/12/2004

Operators manual

2

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

GENERAL INFORMATION 1.1

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 FBL-10 utility vehicle 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 FBL-10 utility vehicle must be adequately maintained by the operators and service personnel. To achieve this, the Operator’s pre-start inspection procedure contained in section 5 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.

1.2

FBL-10 Description



The FBL-10 is a 10,000 kg capacity Tractor/Utility/Load Haul Dump machine that can be fitted with a number of ( RAS ) Rapid Attachments . 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 3216 six cylinder turbo charged 4 Stroke inline 6 Cylinder FLAMEPROOF diesel engine package. 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 constant 4 wheel drive system via a drive coupling through a Dana-Spicer 32000 series 4 speed bi-directional power shift transmission to Dana-Spicer 16D heavy duty axles with liquid cooled POSI -STOP brakes.



The FBL-10 utilises a dry exhaust system complete with a replaceable particulate filter and a catalysed exhaust post treatment purifier A removeable flame-trap for ease of cleaning is fitted on the out-let of the exhaust filter housing.

5/12/2004

Operators manual

3

BI643717

DBT Diesel Pty Limited FBL-10

1.3

Operators Manual

FBL-10 Dimensions

1.3.1

FBL-10 General Arrangement

5/12/2004

Operators manual

4

BI643717

DBT Diesel Pty Limited FBL-10

1.4

Operators Manual

FBL-10 Specifications

All specifications may vary, Always consult DBT Diesel Pty Limited to obtain current information before applying critical loads.

Capacities Bucket Payload RAS forks Max, Payload RAS Slewing jib max, Payload RAS Belt Reeler POD System, Max Payload Maximum un-braked trailer mass Maximum braked trailer mass

8,000 kg 10,000 kg 7,000 kg 7,000 kg 10,000 kg 10,000 kg Consult DBT

Type Make/model 7.0 secs 4.0 secs 7.0 secs 4.0 secs

19,000 kg 29,000 kg

Engine speeds 700 rpm 2600 rpm 2600 rpm

Stall speeds 2100 rpm 1700 rpm 2050 rpm

Fuel consumption At full power Average mine duty 5/12/2004

Flameproof dry type DBT Diesel Pty Limited Replaceable element Fitted Catalytic Exhaust purifier

Torque converter

Engine

Converter stall Full stall Hydraulic stall

Exhaust Conditioner Type Make Exhaust Filter Exhaust Flame trap After treatment

21,300 kg

Type Diesel,Turbo charged, 4 cycle Cooling system Water based radiator Cooling fan Hydraulic driven fan Engine Make/model Caterpillar 3126 Displacement 7.2 litre Maximum pwer.

172 kW @ 2600 rpm Maximum torque 720 Nm @ 1950 rpm Ventilation (NSW Req) 8 m3/s

Low idle High idle Governed

Dry / Caterpillar Primary & Secondary

Type Make/model Speeds,

Weight Unladen with full tanks Laden with forks and 10T load

Intake air cleaner Type / Make Intake Dual element type

3.5 m 2.7 m3 15,000 kg

3

Bucket Motion Times Lift to full raised Lower fully to floor Roll bucket fully back Roll bucket fully forward

Air (Auststart)

Transmission

Standard Ejector Bucket Heaped Capacity Struck Capacity Break out force std bucket tip ( Hydraulic ) Tractive effort, Maximum

Start system Starter motor type

50 Litres/hr 25-30 Litres/hr

Power shift with Fwd/Rev mod.

Dana/Spicer 32,000 series MHR forward and reverse 4

Mounted in trans Single element Dana/Spicer 13.1 integral

Axles Type Front axle make/model Rear axle make/model Diff. type Diff. lock type Front Diff. lock type Rear Overall ratio

Outboard planetary Dana/Spicer 16D Dana/Spicer 16D Bevel gear and pinion POSI TORQ POSI TORQ 27.452:1

Wheels Make/model

3 piece (Heavy Duty)

Tyres - Standard Type Size Ply rating Inflation media Inflation pressure.

Michelin X mine D2 17.5 x 25 Radial Air 115 psi Front , 115 psi rear

Tyres - Option 1 Type Size Ply rating Inflation media Inflation press.

L3 R Lug 20.5 x 25 24 Bias ply Air TBA psi front ,TBA psi rear

Tyres - Option 2 Type Size Inflation media

Operators manual

SETCO 1220 diam x 510 mm Solid

5

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

Hydraulic Systems Steering Closed centre, Pressure Comp 2500 psi Brakes Closed centre, Pressure Comp 2500 psi Bucket/Lift Open Centre 3000 psi PTO Open centre 3000 psi Tank type Sealed and pressurised Tank pressure 50 kpa

Hydraulic Filtration Ejector system Steer/brake system Optional return PTO

Return 10 micron replaceable with Bypass Pressure 10 micron replaceable with Bypass In line, 25 micron

Main hydraulic pump Type Make Std pump output @ 2000 rpm

Gear Open centre Parker 150 lpm

Type Pressure compensated piston Make Parker Std pump output @ 2000 rpm.

75 lpm

Cylinders Double acting Case hardened and hard chromed Steering

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 5.9 litre 900 psi Nitrogen

Accumulator Brakes Type Quantity x capacity Operating Pre charge pressure

Type Reverse modulated, Pressure reducing Control valve open centre Actuation Foot pedal Operating pressure 2,500 psi Brake release pressure 1,500 psi

Steering Type

Piston 1 x 2 litre 900 psi Nitrogen

Type Make/ model Application Location

Open centre Remote Hydraulic pilot 3000 psi

Cylinder reliefs Lift arm raise Lift arm lower Bucket roll back Bucket dump

5/12/2004

3050 psi 3050 psi 3050 psi 3050 psi

Totally enclosed, liquid cooled POSI STOP Dana/Spicer16150 Spring Applied Hyd. Release Each wheel end

Park brake Make/ model Application Location

Totally enclosed, liquid cooled POSI STOP Dana./Spicer16150 Spring Applied Hyd. Released Each wheel end

Articulation Bearing type and size Pin & Spherical brg (top), bush (bottom) Fully sealed Bush material Hardened steel Pin material Hardened steel Degrees of turn either side 43°

Oscillation Type Bush material Pin material Degrees up and down from horiz.

Rear Bolster Hardened steel Hardened steel +/-7 1/2 °

Seating (driver) Type Make Suspension

Cross-seated DBT Diesel Pty Limited Adjust spring / shock absorb.

Canopy Type (Both)

Bucket system Control valve Actuation Main relief

Centre articulated, hydraulic

Service brake

Type

Steering/ Brake pump

Type Rods Cushion stops

Service brake hydraulic system

Protective device MDG1 And MDG17

Electrical system Type Voltage Polarity

Approved flameproof 12 V Floating

Lights Number /location Type

Operators manual

2 front, 2 rear High Performance Approved flameproof

6

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

Alternator

Vehicle speeds

Drive Type

Hydraulic Customer preference Approved flameproof

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

Piston engine gear driven 0.340 m3/min @ 1500 rpm 120 psi 130 psi 80 litres

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

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

4 kph 9 kph 16 kph 26 kph

Maximum tractive effort 1 st gear 2 nd gear 3 rd gear 4 th gear

21,300 kg 10,100 kg 5,800 kg 3,400 kg

Grade ability 250 litre 200 litre 40 litre 22 litre 72 litre 32 litre

Front to rear Side to side (empty) Side to side (laden bucket fully raised )

1:4 1:4 1:8

WARNING Overloading equipment could cause personal injury, death or equipment damage.

Due to configuration or options these weights can vary up to 20%. DBT Diesel Pty Limited recommends that relevant standards and safety procedures should always be used when operating this equipment.

Removal of protective canopies, doors, interlocks and structures etc., could cause serious injury of death. Replacement with correctly torqued fasteners is mandatory.

5/12/2004

Operators manual

7

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

2. GENERAL SAFETY AND PRECAUTIONS This section contains specific safety precautions that shall be followed whilst FBL-10 is being operated. This list is NOT all-inclusive and a measure of common sense should always be applied.

ONLY TRAINED AND AUTHORISED OPERATOR’S SHALL OPERATE THIS MACHINE. 

DO NOT use the FBL-10 for any purpose other than its intended use.



DO NOT for any reason exceed the indicated capacity of the FBL-10



DO NOT operate the FBL-10 unless all operator checks and scheduled maintenance have been performed. Report any damage or faulty operation immediately and DO NOT operate the FBL-10 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 FBL-10.



DO NOT operate the machine unless: ( a) All covers and guards are correctly installed. ( b) Personnel protective equipment is worn.

1) Eye protection 2) Hearing Protection 3) Hard hat 4) Appropriate protective clothing 5) Dust mask and gloves as required



DO NOT start the machine unless: ( a ) The area around the machine is clear. ( b ) The park brake is applied. ( c ) Transmission is in NEUTRAL. ( d ) All water and oil levels are checked.



DO NOT leave the machine unless: ( a ) The vehicle is parked in a safe place. ( b ) The transmission is in NEUTRAL. ( c ) The park brake is applied and brake head pressure is zero. ( d ) The engine is stopped.



ALWAYS

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



ALWAYS

insure that the operator’s cab door is CLOSED and made secure before operating the vehicle.

5/12/2004

Operators manual

8

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

2. GENERAL SAFETY AND PRECAUTIONS 

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

use extreme caution when moving or tramming the machine with the bucket raised. Whenever possible lower the bucket to the “ Carry “ position before moving machine



ALWAYS

travel on inclines or declines with the front of the machine( Bucket) pointing down grade where possible. The bucket can be lowered and dug into the ground to stop the vehicle in case of an emergency.



ALWAYS

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



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



ALWAYS

Be aware of the hazard sources on the FBL-10 a) Engine coolant pressure ( See Section 4 ) b) Engine coolant temperature c) Engine Exhaust temperature d) Exhaust coolant temperature ( See Section 4 ) e) Rotating radiator fan f) Stored Hydraulic pressure ( See Section 4 ) g) Stored air pressure ( Air receiver ) h) Engine oil pressure / temperature i) Transmission oil temperature j) Articulation Area ( See Section 4 ) k) Lift arm area ( See Section 4 ) l) Machine mass



ALWAYS

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

5/12/2004

Operators manual

9

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

2. GENERAL SAFETY AND PRECAUTIONS 

ALWAYS

Use correct boarding and dismounting procedures a) Check floor b) Hold on, step down c) Three points of contact at all times d) Board using hand holds only, and not the steering wheel



Never

operate FBL-10 under unsecured roof



Never

operate FBL-10 near unsecured ribs



Always

drive FBL-10 to suit the conditions, report or rectify any holes that may cause injury or damage the equipment

5/12/2004

Operators manual

10

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

3. MACHINE ORIENTATION CONTROLS AND FUNCTIONS 3.1

Control Locations

3.1.1

Driver’s Cabin Door

The operator’s cab door must be closed and locked after entering the cab 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: 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.

Transmission Controls

RAS Pressure release valve

RAS Tongue lock pilot valve

Park Brake valve RAS control levers

SEMS Shutdown indicators 4/way Bucket control lever

Figure 3.1.1 Operators Controls 5/12/2004

Operators manual

11

BI643717

DBT Diesel Pty Limited FBL-10

3.1.2

Operators Manual

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 FBL-10 is modulated. This prevents severe shocks being transmitted through the drive train when the transmission is shifted between gears.

3.1.3

Transmission Directional Control Lever

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 machine shall be tagged out until the problem is rectified

Transmission Speed Control Lever

Transmission Directional Control Lever

Figure 3.1.2 Transmission Controls

5/12/2004

Operators manual

12

BI643717

DBT Diesel Pty Limited FBL-10

3.1.4

Operators Manual

Driver’s 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 FBL-10 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: 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 3.1.4 Brake Head Pressure Figure 3.1.3 Park brake valve

5/12/2004

Operators manual

13

BI643717

DBT Diesel Pty Limited FBL-10

3.1.5

Operators Manual

Four way bucket control lever

This lever has five positions, ROLLBACK, DUMP, LIFT, LOWER and HOLD. Pushing the lever to the RIGHT rolls the bucket back for loading and tramming. Pulling the lever to the LEFT rolls the bucket down into the digging position or dumps the load. Pushing the FORWARD lowers the lift arm. Pulling the lever BACK raises the lift arm. The lever is spring centred to the HOLD position.

NOTE: Two functions may be engaged at the same time by pushing the control lever at 45º in the direction of the two required functions.

3.1.6

No. 1 2 Way Hydraulic RAS Control Lever

There are 2 (Two) hydraulic RAS (Rapid Attach System) control levers fitted to the machine. The first lever closest to the driver is used to control attachments and engage and disengage the RAS attachment. This lever has three positions, UP, DOWN, and HOLD. Pulling the lever DOWN ( And depressing the RAS release button at the same time see 3.1.29 Page 22 ) unlocks the RAS adaptor. Pushing the lever UP locks the RAS adaptor.

The lever is spring centred to the HOLD position. When operating an attachment, the function of this lever alters depending on the attachment fitted.

NOTE: To release RAS attachments, the RAS release button must be pushed simultaneously whilst pulling down on the lever. This is to prevent an accidental uncoupling of the attachment 3.1.7

No. 2 2 Way Hydraulic RAS Control Lever

The second lever, furthest from the driver, is used to control RAS 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.

NOTE: 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. 2 2 Way Hydraulic RAS Control Lever

No. 1 2 Way Hydraulic RAS Control Lever Figure 3.1.6 Four way bucket control lever

Figure 3.1.5 RAS Controls 5/12/2004

Operators manual

14

BI643717

DBT Diesel Pty Limited FBL-10

3.1.8

Operators Manual

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.

3.1.9

Accelerator Pedal

The accelerator pedal is connected to the diesel engine fuel pump governor via a hydraulic slave and master cylinder system. 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: Always keep the operator’s station clean. Dirt, etc. can build up under the accelerator pedal restricting its movement.

3.1.10

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 on the FBL-10 located internally in each axle. Whenever possible use the engine compression to slow the vehicle on a grade or decline by selecting a lower gear and driving the machine using engine revs.

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. 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 station clean. Dirt, etc. can build up under the brake pedal restricting its movement.

5/12/2004

Operators manual

15

BI643717

DBT Diesel Pty Limited FBL-10

3.1.11

Operators Manual

Orbital Steering Control 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 away from the driver. This effectively turns the vehicle to the LEFT in the forward direction (bucket end).

Turning the wheel CLOCKWISE articulates the vehicle towards the operator. This effectively turns the vehicle to the RIGHT in the forward direction (bucket end).

NOTE: The machine will turn in the opposite directions when travelling in forward and reverse. Operator training and familiarity with LHD 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. 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 3.1.7 Orbital control steering wheel 5/12/2004

Operators manual

16

BI643717

DBT Diesel Pty Limited FBL-10

3.1.12

Operators Manual

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 (1400 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: Observe that the brake head pressure is on zero after applying the Park brake.

3.1.13

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).

DO NOT: Operate the vehicle if the brake pressure gauge is less than 17200 kPa (2500 psi). Immediately report the problem to service personnel.

3.1.14

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 3.1.8 Right hand side operators panel 5/12/2004

Operators manual

17

BI643717

DBT Diesel Pty Limited FBL-10

3.1.15

Operators Manual

Engine Start Button

Depressing the engine start button engages the starter motor to start the engine. The start button will not activate the starter motor unless: 1.

The transmission is in Neutral 2.

The park brake is applied 3.

The engine safety shutdown circuit shows no fault 4.

The ON / OFF valve is “ON”

NOTE: 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.

3.1.16

Air Starting Pressure Gauge

This gauge indicates the air starting pressure in the air receiver. Normal air pressure is set at 760 - 860 kPa (110-120 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.

3.1.17

On / Off Toggle Switch

The ON / OFF switch controls the supply of pilot air pressure to the air pressure switch on the SEMS Type 02 electronic safety system, which allows air to pilot the starter motor.

1.

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

2.

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

Engine start button

On / Off Toggle Switch

Air Starting Pressure Gauge

Figure 3.1.9 Right hand side operators panel 5/12/2004

Operators manual

18

BI643717

DBT Diesel Pty Limited FBL-10

3.1.19

Operators Manual

Transmission Oil Temperature Gauge

This gauge indicates the oil temperature in the transmission and torque converter Normal oil temperature is between 82ºC - 93ºC. If the temperature should rise above 121ºC, carry out the following procedure; (a) Bring the machine to a halt, lower the RAS attachments to the ground and apply the park brake. (b) 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: DO NOT operate the vehicle if the oil temperature is above 121ºC. 3.1.20

Engine Water 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 5 minutes.

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

3.1.21

Driver’s Horn Button

Pushing this button sounds the air horns.

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

Transmission Oil Temperature Gauge

Engine Coolant Temperature Gauge Figure 3.1.10 Left hand side operators panel 5/12/2004

Operators manual

19

BI643717

DBT Diesel Pty Limited FBL-10

3.1.22

Operators Manual

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 the FBL-10 with a second means of shutting down the engine should the ON - OFF toggle switch fail.

Figure 3.1.11 Fuel shut-off valve 3.1.23

Engine Service Hour Meter

This electric meter is mounted on the off driver side at the rear of the FBL-10 Use the hour meter to determine servicing intervals.

Figure 3.1.12 Engine hour meter 3.1.24

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

5/12/2004

Operators manual

Figure 3.1.13 Air Cleaner and Indicator

20

BI643717

DBT Diesel Pty Limited FBL-10

3.1.25

Operators Manual

Exhaust Back Pressure Gauge

The exhaust back pressure gauge located in the operators compartment indicates the condition of the filter element. When the backpressure is above 10 Kpa, the elements should be removed and replaced also the flame-trap should be cleaned.

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 and will block the flame-trap. Remove and replace the filter if the backpressure gauge reads above 10 kpa and clean the flame-trap.

NOTE: Dirty filters should be disposed of correctly. Appropriate personnel protective equipment should be worn. Operators should minimise skin contact with dirty filters.

The dirty element should be placed in the plastic bag that is supplied with the new Filter, completely seal. The contaminated element must be removed from the underground environment and disposed of safely.

NOTE: The diesel particulates can be safely handled when wet with gloves.

3.1.26

Engine Oil Pressure Gauge

This gauge indicates the engine lubricating oil pressure. Normal pressure is between 207 - 413 kPa (30-80 psi) at rated rpm

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).

DO NOT: Run the engine with low oil pressure, as engine damage will result.

Immediately report the problem to service personnel.

Exhaust Backpressure gauge

Engine Oil Pressure Gauge Figure 3.1.17 Engine oil & Backpressure Gauges 5/12/2004

Operators manual

21

BI643717

DBT Diesel Pty Limited FBL-10

3.1.27

Operators Manual

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 motor.

Figure 3.1.15 Engine Hand Fuel Primer Pump 3.1.28

RAS Pilot Release Valve

This valve prevents accidental release of the attachment lock cylinder. Fully depress this valve to allow lock cylinder to retract. This control is used with the No 1 RAS hydraulic PTO control lever to engage and disengage the RAS lock cylinder.

NOTE: The RAS Release valve need not be depressed to lock (engage) the RAS lock tongue 3.1.29

RAS Attachment Pressure Release Valve

This valve releases all of the pressure in the RAS attachment lines to allow the couplings to be easily released. To release the pressure, release both of the RAS / PTO control levers to the hold position and press in the pressure release button for 2 seconds.

RAS Attachment Pressure Release Valve

RAS Pilot Release Valve

Figure 3.1. 18 RAS Release Valves 5/12/2004

Operators manual

22

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

4. 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.

4.1 Engine Isolation To isolate the engine perform the following procedure: 1.

Select “NEUTRAL” on transmission directional control lever 2.

Apply the “Park Brake” 3.

Shutdown the diesel engine.

4.

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

5.

Connect the steering lock and chock the wheels.

6.

Close the Main air Isolating valve ( See Pneumatic isolation Section 4.2 )

Figure 4.1.1 Air pressure isolation and indication in operators compartment Figure 4.1.2 Main Air Isolating Valve

5/12/2004

Operators manual

23

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

4. MACHINE ISOLATION 4.2 Pneumatics Isolation To Isolate the pneumatic system perform the following procedure 1.

Lower the bucket / attachment to the floor, shutdown the diesel engine, fit a Danger tag to the ON/OFF toggle valve, connect the steering lock and chock the wheels.

2.

Locate the pneumatic air receiver at the rear of the engine bay on the driver's side of the machine.

3.

Locate the isolating ball valve adjacent to the air receiver and rotate to the OFF position.

4.

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.

NOTICE: 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 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.

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

Figure 4.1.3 Main Air Isolating Valve

5/12/2004

Operators manual

24

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

4. MACHINE ISOLATION 4.3 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 steering lock and chock the wheels.

2.

Depress the RAS pressure release button located in the Operator's compartment.

This will remove any residual pressure stored in the PTO / RAS attachment circuit.

3.

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 thirty 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 shut down.

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

WARNING: 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.

WARNING: Always assume there is hydraulic pressure in hydraulic lines or components unless it has been isolated by yourself Steering accumulator pressure gauge

Brake accumulator pressure gauge

Figure 4.1.4 Steering and brake accumulator pressure indication 5/12/2004

Operators manual

25

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

4. MACHINE ISOLATION 4.4 Engine Coolant Isolation To isolate the engine cooling system perform the following procedure 1.

Lower the bucket / attachment, shutdown the diesel engine, fit a danger tag to the ON/OFF toggle valve, connect the steering lock and chock the wheels.

2.

Isolate the Pneumatic circuit as described in section 4.2.

3.

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

4.

Remove coolant circuit pressure (105kPa) by slowly unscrewing the filler cap.

WARNING: Engine coolant fluid will be hot. Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves to avoid burns from hot coolant.

Heat Exchanger Coolant relief cap

Engine Coolant relief cap Figure 4.1.6 Coolant pressure relief

4.5 Electrical Isolation 1.

Lower the bucket / attachment, shutdown the diesel engine, connect the steering lock and chock the wheels.

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.

5/12/2004

Operators manual

26

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

4. MACHINE ISOLATION 4.6 Articulation Isolation or Steering Lock 4.6.1

Fitting and Removal of Steering Lock

To fit the steering lock:1.

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

2.

Locate the steering lock at the articulation area on the off drivers side of the machine and remove the locking clamp on the bottom location 3.

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

4.

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

To remove the steering lock:1.

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.

2.

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

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 drivers compartment is vacant when accessing the articulation area to fit or remove the steering lock.

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

Figure 4.6.1 Articulation lock in locked position 5/12/2004

Operators manual

Figure 4.6.2 Articulation lock in stored position 27

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

4. MACHINE ISOLATION 4.7

Lift arm Isolation or Lift arm lock

4.7.1

Fitting and Removal of Lift arm Lock

To fit the lift arm lock:1.

Remove the bucket or any attachments from the RAS attach cradle.

2.

Chock the wheels 3.

Fit the articulation lock ( 4.6.1 ) 4.

Raise the lift arm until the locking pin holes are clear and the pins can be placed under the lift arm on both sides in the location points.

5.

Remove the lock pins from Storage locations and install in the aligned holes on the lift arm.

6.

Note that the pin is to be fully inserted into the holes.

7.

It is now safe to work under the lift arm To remove the lift arm lock:1.

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

2.

Lower the lift arm to the ground.

WARNING: The lift arm on this machine can cause fatal crush injuries if extreme caution is not observed. NEVER access or perform work under the lift arm unless the engine has been shut down, the articulation lock fitted, the park brake applied, the attachment has been removed and the lift arm has been supported in the raised position.

Lift Arm Lock Pins

Figure 4.7.1 Lift Arm Locks installed 5/12/2004

Figure 4.7.2 Storage position on both front guards Operators manual

28

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

5. PRE-START PROCEDURE Refer to preventive maintenance checklist in section 20.1.

5.1

Walk around the machine a) Check condition of all tyres. Inspect for sidewall cuts, tread cuts and separation. b) Look for damaged or missing wheel nuts and studs. c) Check for loose wheel nuts d) Guards and covers are in place and secure e) Missing or loose bolts f) Oil leaks

5.2 Check the following 5.2.1 Hydraulic reservoir oil level. a) Be sure the machine is level when checking fluid level. b) Check the level at normal operating temperature. c) When the fluid level has dropped below the full mark, add hydraulic oil to restore the proper operating level. d) The Reservoir fill cap is located on the off drivers side of the machine on the side of the hydraulic reservoir

Figure 5.2.1 Hydraulic level sight gauge

5.2.3 Check the engine oil level a) If required the engine should be filled to the full mark on the engine dip stick. b) Insure the correct engine oil is used Oil specifications are listed in the Fluid specifications table section. 22 c) Do not over fill

NOTE: The oil level can be checked with the engine stopped

Figure 5.2.2 Engine oil Dipstick 5/12/2004

Operators manual

29

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

5. PRE-START PROCEDURE CON’T 5.2.4 Check the fuel level a) Gauge fitted to the fuel tank. b) Check the filler cap is secure and not damaged

Figure 5.2.3 Fuel sight gauge

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.

5.2.5 Check the condition and tension of the water pump drive belts a) located at the rear of the machine under the rear hinged door. b) Damaged or loose belts should be reported to maintenance personnel

Figure 5.2.4 Water pump drive belt

WARNING: Running the machine with loose or damaged belts will cause the machine to overheat 5.2.6 a) b)

Check the condition of the fuel water separator Located at rear drivers side of machine Replace filter and drain if any sign of water or cloudy fuel

Figure 5.2.5 Fuel water trap 5/12/2004

Operators manual

30

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

5. PRE-START PROCEDURE CON’T 5.2.7

Check the articulation safety lock bar ( See section 4.6 ) a) For proper storage and loose fasteners b) For damage

5.2.8

Check the Lift Arm safety lock bars ( See section 4.7 ) a) For proper storage and loose fasteners b) For damage

5.2.9

Check the expansion tank coolant level a) Insure coolant is to correct level on sight gauge b) Check for coolant leaks c) Insure to correct coolant mix is being added if required d) Report to maintenance if coolant is low

Overflow

Filler Cap

Sight Gauge Figure 5.2.6 Coolant Expansion tank 5.2.10

Radiator a) Check for coolant leaks b) Check for build up of dirt ( Clean if radiator fins are blocked or dirty )

5.2.11

Headlights a) Check lights are securely mounted b) Check cables and glands for damage

5.2.12

Air Cleaner ( See Section 3.1.26 ) a) Check the air cleaner filter condition indicator b) Replace filter element if indicator is in the red area c) Check intake pipes and hoses for loose or damaged connections

Figure 5.2.7 Air Cleaner & Indicator

Warning Do not operate the machine with loose intake pipe connection, this will allow particles of dust into engine and cause serious damage 5/12/2004

Operators manual

31

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

5. PRE-START PROCEDURE CON’T 5.2.13

Check Air Receiver a) Check for damage b) Drain Condensate from drain valve.

Note: 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 5.2.14

5.2.15

Check the fire extinguisher a) Located on front drivers side mudguard b) Check inspection date c) Check contents indicator is reading in the green area d) If fire suppression system fitted check actuation points Check Exhaust System a) Check for damage b) Check Joints for signs of leakage c) Check and clean flame trap

Figure 5.2.8 Fame trap in location on machine

Figure 5.2.9 Flame trap element

To Clean the flame trap element a) Remove flame-trap from the machine b) Blow out flame trap with compressed air

NOTE: The Flame trap is designed to be reversible in its location in the machine, this allows for it to be reversed and blown clean by the exhaust when compressed air is unavailable

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.

5/12/2004

Operators manual

32

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

6. 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.

6.

7.

8.

9 10 11

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

Enter the cabin 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 482 kPa (70 psi) the engine may not start. If the air pressure is below 482 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 SEMs electronic shutdown system display for the RUN 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 21.1 OPERATING SEMs 02

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

5/12/2004

Operators manual

33

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

7. POST START CHECKS The following test are required to be performed with the engine running.

7.1 Check gauges are on correct operational pressure a) Gauges colour coded ( Should read in green area ) 7.2

Check Function of Bucket Hydraulic system

7.3

Check steering function

7.4

Check park brake operation (Gauge must read 1500 psi with brake off ) a) Move off slowly and apply the park brake

7.5

Check that all of the lights are working. a) There are two forward and rear facing headlights b) Control switch is operational

7.6

Check the transmission oil level. a) Always check when the transmission is warm b) Once the correct transmission fluid temperature has been reached park the FBL-10 on flat, level ground and leave it running. c) Place the FBL-10 in neutral and apply the park brake d) Access the dipstick from the operators cabin through the access hole cut in the cover over the top of the transmission. This panel is located between the Driver's compartment and the hydraulic tank. e) The engine should be idling at 500-600 rpm. f) Remove the dip stick by pulling upwards and wipe with a clean, lint free cloth. g) Re-insert the dipstick into the spout, remove and push it all the way home. h) Withdraw the dipstick and check the oil level. The level is to be maintained at the FULL mark.

7.7

Check the shutdown system a) Run the engine at high idle b) Press the shutdown test button and hold for two seconds c) Machine should shutdown and low oil pressure LED light should be on

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

5/12/2004

Operators manual

34

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

7. POST START CHECKS CON’T 7.7

Check the particulate filter indicator:a) Locate the indicator in the operators compartment. b) Run the engine at high idle and observe the indicator position. c) If the indicator above 10 Kpa the filter requires replacement.

WARNING Ensure that the filter element is cool enough to handle other wise the garbage bag will melt causing skin burns 7.7.1 To replace the particulate filter:a) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in section 4.1engine isolation b) Remove the filter housing lid by unhitching the locking mechanism and un screwing the housing lid c) Place a large tie type garbage bag over the filter housing until the base of the bag is at the top of the housing d) 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. e) With the filter element clear of the housing invert the element and garbage bag and secure the ties. f) Discard the used element in the appropriate manner. g) Place the new filter element inside the housing. h) Check the sealing O’ring on the housing lid and replace the O’ring if damaged i) 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 80 kPa (11 psi). Extended operations with the filter in bypass should be avoided. Remove the filter if the backpressure gauge reads above 10 kpa.

5/12/2004

Operators manual

35

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

7. POST START CHECKS CON’T 7.8

The exhaust system on the FBL-10 carries out four major functions a) To cool and dilute exhaust gases b) To act as an approved flame trap c) To prevent hot gases from entering the mine atmosphere d) To filter out particulates to prevent them entering the mine atmosphere

Over time particulate matter(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 7.8.1 To clean the heat exchanger elements:1.Ensure that the engine has had sufficient time to cool and is isolated and tagged.

2.Remove the particulate filter element from the housing

Particulate filter housing 5/12/2004

Heat exchanger cooling fins Operators manual

36

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

7. POST START CHECKS CON’T 7.8

Cleaning The heat exchanger

3.

Fill the heat exchanger to just above the higher set of cooling fins with 1 part “Polo Conditioner”( Diesel Scrubber DBT part No 502254 ) to 100 parts water.

Allow the detergent to soak for 15 minutes Start and run the diesel engine for a minimum of 10 minutes to create a turbulent action inside the heat exchanger housing.

Shut down and isolate the diesel engine and remove the drain plug from the bottom of the heat exchanger and completely drain the water / detergent mix from the housing.

Spray scrubber detergent inside to particulate housing and pressure clean Fit drain plug temporarily and fill the heat exchanger with water to the top side of the cooling fins and run for 2 minutes at high idle.

Remove the Drain Plug and drain all the water Carry out (item 8) Until all detergent is removed and water is clear Start and run the diesel engine again at high free idle for a minimum of 10 minutes to dry out the conditioner housing.

Shut down the engine and re-install the Drain plug and particulate filter element before returning the vehicle to service

4 5.

6.

7.

8.

9.

10.

11.

12.

Heat Exchanger drain plug

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

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

5/12/2004

Operators manual

37

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

8. STOPPING THE ENGINE 1.

2.

3.

4.

5.

Lower the bucket or RAS 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 PARKING 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 turbo charged, shutting down the engine when the engine’s operating temperature is high may cause damage to the turbo-charger and the lubrication system 6.

7.

Turn the ON / OFF switch located on the instrument panel to the OFF position and the engine will shut down.

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

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

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

WARNING: Ensure the bucket is flat on the ground 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

5/12/2004

Operators manual

38

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

9. TRAMMING THE MACHINE     

The FBl-10 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.

DANGER: DO NOT coast the vehicle in NEUTRAL. Excessive speed may result in an uncontrollable “run-away”. 

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

DO NOT: Down shift 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. 

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 over heat:a) Stop machine and apply park brake, b) Select NEUTRAL and run the engine at half speed until the oil temperature has dropped to a safe operating level. c) If this does not work follow the shutdown procedure and advise the maintenance department.

WARNING: Hearing and eye protection shall be worn by the driver 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.

5/12/2004

Operators manual

39

BI643717

DBT Diesel Pty Limited FBL-10

10.

Operators Manual

STOPPING AND BRAKING



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 and lower the bucket to the ground.



Set the Park brake.



The engine should not be shut down 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 isolation valve.

NOTE: 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

5/12/2004

Operators manual

40

BI643717

DBT Diesel Pty Limited FBL-10

11.

Operators Manual

DRIVING ON A RAMP



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 ramp



Avoid changing gears while travelling on a steep ramp.



If you have a mechanical or brake failure: a) Immediately apply the service brakes. b) If they don’t function, apply park / emergency brake. c) If the machine doesn’t stop, turn the machine into the rib.

NOTE: Operators must be competent in Emergency Stop Procedure.

NOTE: As the machine has a dry exhaust system there are NO flameproof limits to driving on grade. Traction and control is the safety issue

5/12/2004

Operators manual

41

BI643717

DBT Diesel Pty Limited FBL-10

12.

Operators Manual

PARKING ON A RAMP

WARNING: Do not park on a ramp unless absolutely necessary. 

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 Bucket



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.

ALWAYS: Park with bucket into rib and Chock the wheels when on grades of more than 1:4.

5/12/2004

Operators manual

42

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

13.

LOADING



The LHD method of loading is called “crowd loading” which combines the tractive effort of the machine with the break out force of the bucket. With the 172 kW of power from the FBL-10 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 break out force in excess of 15,000 kg. Maximum loading efficiency is obtained by adjusting the loading cycle to the operating conditions.

The proper use of traction and break out 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 your tyres

DO NOT: Go under a hung up draw point or under any unsupported roof.

DO NOT: Use your 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.

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, let up on the accelerator pedal slightly as you move the bucket crowd control slightly faster

DO NOT: Exceed the machines 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 driver.

5/12/2004

Operators manual

43

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

13.

3.

LOADING

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

FBL-10 Fully Loaded with bucket in the “ Carry “ Position

5/12/2004

Operators manual

44

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

14.

DUMPING ALWAYS:

Keep your dump area clean and clear of chunks on the roadway 1.

Standard Dumping

1.

As you approach to dump a load, release your foot from the throttle pedal and reduce speed (Apply service brakes).

Raise your boom to clear any guards or obstructions When you are in dumping position the boom should be fully raised.

Push the bucket control joystick 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 arm raised sufficiently to clear the tailgate.

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

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

2.

3.

4.

5.

6.

7.

DO NOT: Carry load with the boom in a raised position 2.

Ejecting

1.

2.

For limited height application raise the bucket as high as possible Roll it forward until the bottom of the bucket is level with the floor or tilted slightly downward.

Push the RAS ejector bucket control lever (Lever closest to the driver) forward to eject the load.

3.

5/12/2004

Operators manual

45

BI643717

DBT Diesel Pty Limited FBL-10

15.

Operators Manual

TOWING THE VEHICLE WHEN DISABLED WARNING:

Set the park brake, lower the bucket to the carry position and stop the engine. The towing vehicle must have sufficient braking capacity to stop and hold both vehicles.

1.

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

2.

If the machine must be towed and the distance is less than 1000 meters, a) connect the machine to the towing vehicle, b) place the transmission in NEUTRAL, c) 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

NOTE: 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 driver’s cabin. The operator is to stay in the operator’s station 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.

Pressure port Connect porta-power to this port When releasing the brakes

CAUTION: Do not over-pressurise the brake system or serious damage will be done to the seals in the brake heads 5/12/2004

Operators manual

46

BI643717

DBT Diesel Pty Limited FBL-10

15.

Operators Manual

TOWING THE VEHICLE WHEN DISABLED WARNING:

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

ALWAYS: Connect the disabled FBL-10 to the towing vehicle before releasing the FBL-10 park brakes. Make sure the FBL-10 park brake is re-applied before the towing vehicle is disconnected.

NOTE: Maximum Towing speed is 3 kph.

5/12/2004

Operators manual

47

BI643717

DBT Diesel Pty Limited FBL-10

16.

Operators Manual

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.



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,

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

Figure 16.1 Fuel priming pump

17.

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.

5/12/2004

Operators manual

48

BI643717

DBT Diesel Pty Limited FBL-10

18.

Operators Manual

GENERAL INFORMATION



Keep your FBL-10 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 shut down 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.

5/12/2004

Operators manual

49

BI643717

DBT Diesel Pty Limited FBL-10

19.

1.

2.

3.

4.

5.

Operators Manual

ATTACHING IMPLEMENTS

Ensure the RAS pressure lines to the lock cylinder are connected.

Drive the machine toward the attachment, roll the cradle forward and engage the upper cradle into the implement back plate.

Roll the cradle back fully and engage the RAS Lock Tongue in the cradle by pulling the attachment lock control.

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

Exit the machine and visually inspect the lock tongue is fully engaged into the attachment back plate. A lock indicator is fitted to the cradle for checking the tongue position during operation. The operator should always exit the machine and check for engagement before using the attachment.

DO NOT STAND UNDERNEATH RAISED LIFT ARM

WARNING: NEVER walk under the bucket or lift arm 6.

7.

8.

Enter the cab and fully lower the lift arm. Press the RAS pressure release button to release the pressure in the hydraulic lines Exit the cabin and disconnect the lock cylinder lines. These can now either be; a) Connected to the hydraulic system of the attachment. (eg. Push plate bucket). b) Connected into the provided dummy blocks to prevent the hoses from dragging on the ground and being damaged.

If required the second RAS hydraulic lines may be connected. Attachments such as the side shift forks use these hoses.

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

Figure 19.1 Fork attachment hoses 5/12/2004

Operators manual

Figure 19.2 RAS attach Hoses 50

BI643717

DBT Diesel Pty Limited FBL-10

20.

1.

2.

3.

4.

Operators Manual

DETACHING IMPLEMENTS

Ensure the area that the implement is to be installed will not block access and is level.

Lower the implement to the ground. Select neutral, apply the park brake and exit the machine.

Connect the implement hydraulic lines to the RAS lock cylinder.

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

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

5.

6.

7.

8.

9.

Enter the cabin.

Release Park brake Depress the attachment unlock valve and at the same time pull the RAS lock release valve (Hydraulic PTO closest to the driver).

Select Reverse, first gear .

Drive away from the attachment whilst rolling the bucket forward.

DO NOT: Leave the attachment unsecured. An unstable implement may roll and crush personnel.

Figure 20.1 Belt reeler attached to FBL-10

5/12/2004

Operators manual

51

BI643717

DBT Diesel Pty Limited FBL-10

21.

21.1

Operators Manual

SAFETY SYSTEM

SEMs 11 Safety shutdown

The Sems 11 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 The following sensors are fitted to the machine 1.

Hi alarm Methane level ( Shuts engine down ) 2.

Lo alarm methane level ( Warning light ) 3.

No Charge alternator ( Warning light ) 4.

No Oil Pressure ( Shuts engine down ) 5.

No exhaust coolant flow ( Shuts engine down ) 6.

Low engine coolant level ( Shuts engine down ) 7.

Heat exchanger coolant over-temperature( Shuts engine down ) 8.

Engine coolant over-temperature ( Shuts engine down ) 9.

Heat exchanger Gas temperature ( Shuts engine down ) 10. Flame-trap gas temperature ( Shuts engine down ) 11. Exhaust out-let temperature ( Shuts engine down ) 12. Run solenoid ( Warning light ) 13. Start Fault ( warning Light )

Figure 21.2 SEMs 11 as fitted in operators compartment Figure 21.1 Sems 11 operator display panel

5/12/2004

Operators manual

52

BI643717

DBT Diesel Pty Limited FBL-10

21.

21. 2

Operators Manual

SAFETY SYSTEM

Operating SEMs 11

1.

Turn on Start/Reset air pressure switch ( Toggle switch ) a) This will activate the SEMs electronics b) The lights on the display will light up for about five seconds ( This serves to test lights and circuitry ) c) Most of the lights will go out and those remaining indicate relevant conditions  No Charge  No Oil Pressure  No Heat exchanger Coolant Flow  No solenoid signal

2.

Wait for the methane monitor to read ( approximately 20 secs ) a) The methane monitor needs about seventeen seconds to measure the content in the surrounding air b) When the waiting time is up the solenoid will power up and the Solenoid display light will go out c) The machine can now be started

3.

Start Engine a) Activate the operators start valve and start engine b) The “No charge” “No oil Pressure” “ No coolant flow” indicators will then go out c) The machine FBL-10 is now ready to be operated

4.

Operate machine

21.3

Low Hydraulic oil shut down

The safety circuit is also fitted with a Low hydraulic oil sensor, this is a pneumatic valve and will dump the air from the fuel shutdown cylinder. An indicator is fitted to the right hand operators panel.

This will also stop the machine from being started with low hydraulic oil

Figure 21.2 Sems 11 operator display panel 5/12/2004

Figure 21.3Low Hydraulic oil indicator

Operators manual

53

BI643717

DBT Diesel Pty Limited FBL-10

21.

5.

Operators Manual

SAFETY SYSTEM

To shutdown machine a) When shutting down the machine, turn off the START / RESET valve ( Toggle switch )This will unpower the SEMs and the start solenoid. And stop the machine b) Turn the main isolating air valve off

Figure 21.5 Start / Reset valve ( Toggle Switch )

Figure 21.4 Main Air Isolating Valve

5/12/2004

Operators manual

54

BI643717

DBT Diesel Pty Limited FBL-10

Operators Manual

22. FBL-10 FLUID SPECIFICATION TABLE SPEC 1

COMPONENT Engine

2

Transmission

40 litres (as required)

Mineral gear oil

3

Engine drive assembly

(as required)

Multi-purpose EP Grease

4

Hydraulics

300 litres

Hydraulic

5

Axles

32 litres ( Each )

6

Cooling system

72 litres

Mineral gear oil with limited slip additive Water & inhibitor

7

Fuel

300 litres

8

Lube points - Pins & bushes - Drive train - Door hinges - Tow point

(as required)

5/12/2004

CAPACITY

LUBRICANT

22 litres (as required)

Engine oil

Distillate “diesel” fuel Multi-purpose EP grease

TEMP. BELOW 0ºC SAE 15W-40 API CD-II (Shell Rimula X 15W-40 or equiv.)

SAE 10W Cat TO-4

TEMP, 0-32ºC SAE 40 API CD-II (Shell Rimula DD 40 or equiv.)

SAE 30 Cat TO-4 (Shell Donax TC30 or equivalent) NLGI no. 2 (Shell Alvania EP (LF) 2 or equivalent)

NLGI no. 1 or no.

0 (Shell Alvania EP (LF) 0/1 or equivalent) SAE 68 (Shell Tellus 68 or equivalent)

TEMP. ABOVE 32ºC SAE 50 API CD-II (Shell Rimula DD 50 or equiv.)

SAE 40 Cat TO-4

NLGI no. 2 (Shell Alvania EP (LF) 2 or equivalent)

SAE 90LS (Shell DIFFOIL 90LS or equivalent) Ethylene glycol antifreeze inhibitor (low silicate formulation) to GM 6038-m or ASTM d4985 (Shell Coolguard HD50) to ASTM D975 (grades D-1 & D-2) and to Detroit and AS3584.2 specifications NLGI no. 1 or no. 0 NLGI no. 2 NLGI no. 2 (Shell Alvania EP (LF) (Shell Alva(Shell Alvania EP (LF) 2 0/1 or equivalent) nia EP (LF) or equiva2 or equivalent) lent)

Operators manual

55