CAT Face Haulage FH125 D Operation & Maintenance Manual SN 5004121 - PDF DOWNLOAD

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Revision No 0 1 October 2013

Operation Manual FH125 D Face Haulage Serial Number 5004121

SAFETY.CAT.COM

BI014569

Operation Manual

TABLE OF CONTENTS Section 1

General Information Introduction ..................................................................................... 1 Description...................................................................................... 1 General Arrangement ..................................................................... 2 Dimensions ..................................................................................... 4 Specifications ................................................................................. 5

Section 2

General Safety and Precautions ................................................. 7

Section 3

Gauge Parameters and Colour Coding .................................... 13

Section 4

Machine Orientation, Controls and Functions Machine Orientation Basic Machine Layout ......................................................... 17 Control Locations Compartment Door .............................................................. 18 Transmission Gear Control Lever ....................................... 19 Transmission Directional Control Lever .............................. 19 Park Brake Button ............................................................... 20 No 1—Two-Way Hydraulic Control Lever ........................... 21 No 2—Two-Way Hydraulic Control Lever ........................... 21 Operator’ Seat ..................................................................... 22 Accelerator Pedal ................................................................ 22 Brake Pedal ......................................................................... 22 Steering Wheel .................................................................... 23 Primary Park Brake Valve Gauge ....................................... 24 Brake Head Pressure Gauge .............................................. 24 Brake Accumulator Pressure Gauge ................................... 24 Steering Accumulator Pressure Gauge ............................... 24 Engine Start Button ............................................................. 25 Air Pressure Gauge ............................................................. 25 On/Off Toggle Switch .......................................................... 25 Transmission Oil Temperature Gauge ................................ 26 Engine Coolant Temperature Gauge .................................. 26 Exhaust Outlet Gas Temperature Gauge ............................ 26 Horn Button ......................................................................... 27 Engine Service Hour Meter ................................................. 28 Air Cleaner Service Indicator............................................... 28 Engine Fuel Primer Pump ................................................... 29 Shutdown System Test Valve ............................................. 29 Exhaust Back Pressure Gauge ........................................... 30 Engine Oil Pressure Gauge................................................. 30 Emergency Intake Shut Off Valve ....................................... 31 Emergency Fuel Shut Off Valve .......................................... 32

Section 5

Machine Isolation Engine Isolation ............................................................................ 33 Pneumatic Isolation ...................................................................... 34 Hydraulic Isolation ........................................................................ 35 Engine Coolant Isolation............................................................... 36 Electrical Isolation......................................................................... 37 Articulation Isolation ..................................................................... 38

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Section 5

Machine Isolation (cont’d) Tailgate Isolation ........................................................................... 39 Engine Isolation ............................................................................ 33 Exhaust Conditioner Isolation ....................................................... 40 Exhaust Conditioner Make Up Tank Pressure Isolation ............... 41

Section 6

Pre-Start Procedure .................................................................... 43

Section 7

Engine Starting Procedure ........................................................ 55

Section 8

Post Start Checks ....................................................................... 57

Section 9

Stopping the Engine ................................................................... 61

Section 10

Tramming the Machine ............................................................... 63

Section 11

Stopping and Braking ................................................................ 65

Section 12

Driving on a Ramp ...................................................................... 67

Section 13

Parking on a Ramp ..................................................................... 69

Section 14

Loading ........................................................................................ 71

Section 15

Ejecting ........................................................................................ 73

Section 16

Towing the Machine when Disabled ......................................... 75

Section 17

Air Venting the Fuel and Engine Cooling System ................... 77

Section 18

Diesel Control System (DCS) ..................................................... 79

Section 19

Fluid Specification Table ........................................................... 83

This document is the property of Caterpillar SUBJECT MATTER HEREIN IS PRIVATE, CONFIDENTIAL AND RESTRICTED. Do not use, reproduce, copy, distribute or disclose except with, and only to the extent of, prior written consent of Caterpillar PERSONS RECEIVING THIS DOCUMENT ARE RESPONSIBLE FOR RESTRICTING DISCLOSURE, except as absolutely necessary consistent with the intended use. When such is completed, return immediately to Caterpillar.

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

Caterpillar Australia Room & Pillar Division 20 Kullara Close, PO Box 373 Beresfield NSW 2322 Australia Phone: +61 2 49147000 Fax: +61 2 49147059

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

This manual is designed to provide the FH125 D Face Haulage machine operator with the proper information regarding the machine’s instrumentation, operating controls and general safe working procedures. All operators of this machine must be conversant with the information contained within this manual before operating the machine.

To ensure safe and efficient operation, the FH125 D must be adequately maintained by the operators and service personnel. To achieve this, the operator’s pre-start inspection procedure contained in Section 6 of this manual must be performed before any use of this machinery is undertaken.

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

DESCRIPTION The FH125 D is a 15m³ capacity Face Haulage machine. This allows it to be used for carrying coal from the continuous miner to the feeder breaker station.

The FH125 D is powered by a 172 kW (230HP) CAT 3126 turbocharged four-stroke inline six cylinder diesel engine package. Flameproofing of the system includes a wet exhaust conditioning system. The start system is pneumatic. The diesel control system is an intrinsically safe electronic monitoring system. The engine power output is connected to the four speed bidirectional power shift transmission via a drive coupling on the rear of the engine, the power is then transmitted to heavy duty axles. The trailer axle drives the trailer wheels via 90° bevel gear boxes to the trailer planetary hub complete with liquid-cooled Posi-Stop brakes.

The FH125 D utilises a wet exhaust system complete with a replaceable particulate filter.

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

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GENERAL ARRANGEMENT

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11103

3258

35° ANGLE OF REPOSE

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5 Y

X

1000

3

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DIMENSIONS Table 1 Tyre Brand

Tyre Size

Tyre Type

Dimension 1 mm Canopy Down

Dimension 2 mm Canopy Raised

Dimension 3 mm Ground Clearance

Dimension 4 mm Width Trailer End

Michelin

20.5R25

XKA Air Filled

1870

2060

454

3330

Michelin

17.5R25

XKA Air Filled

1753

2006

400

3292

Table 2 Load Capacities and Size Code 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

* No Tailgate Fitted

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

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SPECIFICATIONS All specifications are subject to change without notice. Always Articulation consult the Dealer to obtain current information before Bearing type applying critical loads.

Pin and spherical bearing (top and bottom) fully sealed

Degrees of turn either side

+/- 42°

Capacities Payload (nominal with hungry boards) Other capacities available: Payload (maximum weight all material) Consult the dealer for weight over

20000 kg 15000 kg

Oscillation Type Centre articulation bearing Bearing type Ball type slewing roller bearing Degrees up and down from horizontal +/- 30°

Weight Unladen with full tanks Laden with 15T load

27000 kg 42000 kg

Seating (Operator) Type Cross-seated Suspension Adjust spring/shock absorber (standard)

15 m³

Engine Type Diesel, turbocharged, after cooled, 4 cycle Cooling system Water based radiator Cooling fan Hydraulic driven fan Engine make/model Cat 3126 Displacement 7.6 litre Maximum power 172 kW @ 2200 RPM Maximum torque 720 Nm @ 1400 RPM

Canopy Type Electrical System Type Voltage Polarity Shutdown system

Engine Speeds Low idle High idle Governed

800 RPM 2700 RPM 2600 RPM

Lights Number /location Type

Fuel Consumption At full power Average mine duty

37.5 litre/hr 8-30 litre/hr

Alternator Drive Type

Start System Starter motor type Intake Air Cleaner Type/make Intake flame trap Exhaust Conditioner Type Make Exhaust filter After treatment

Air turbine type

Dry duel element/Caterpillar Intake flame trap Spiral wound type

Flameproof wet Caterpillar Replaceable Catalytic exhaust purifier

Transmission Type Power shift with forward/reverse mod Speeds, forward and reverse 4 Torque Converter Type Mounted in transmission, single element Axles Axles Standard Type Front axle Rear axle Differential type

Outboard planetary Fixed Bolster mount Bevel gear and pinion

Wheels Make/model

5 piece (heavy duty)

Tyres - Standard Type Size Ply rating Inflation media Inflation pressure

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

Adjustable protective device MDG1 Approved flameproof 12 V Negative ground Electronic Intrinsically Safe approved

2 front, 2 rear High performance Approved flameproof

Hydraulic Approved flameproof

Piston engine gear driven 0.340 m³/mm @ 1500 RPM 800 kPa 830 kPa 80 litre

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

300 litre 300 litre 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 7.8 kph 13.6 kph 23.4 kph

XKA Tyres 17.5 x 25 Radial Air 800 kPa

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210 kN 96 kN 55 kN 32 kN

Grade Ability Front to rear Side to side (empty)

1:4 1:8

Overloading equipment could cause personal injury, death or equipment damage. Due to configuration or options these weights can vary up to 20%. Caterpillar recommends that relevant standards and safety procedures should always be used when operating this machine. Removal of protective canopies, doors, interlocks and structures etc., could cause serious injury or death. Replacement with correctly torqued fasteners is mandatory.

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General Safety and Precautions This section contains specific safety precautions that shall be followed whilst the machine is being used by suitably qualified operators. This list is NOT all inclusive and a measure of commonsense should always be applied together with established and ongoing site specific risk assessment and safety procedures.

ONLY TRAINED AND AUTHORISED OPERATORS SHALL OPERATE THIS MACHINE DO NOT

use the machine for any purpose other than its intended use.

DO NOT

for any reason exceed the indicated capacity of the machine.

DO NOT

operate the machine unless all operator checks and scheduled servicing have been performed. Report any damage or faulty operation immediately and do not operate the machine until the fault has been corrected.

DO NOT

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

DO NOT

operate the machine unless:   

DO NOT

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

DO NOT

There are no tags attached stating otherwise.

All covers and guards are correctly installed.

Personal protective equipment is worn.

There are no tags attached stating otherwise.

The area around the machine is clear.

The park brake is applied.

Transmission is in neutral.

All water and oil levels are checked.

All site specific checks are completed.

leave the machine unless:    

The machine is parked in a safe place.

The transmission is in neutral.

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

The engine is stopped.

DO NOT

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

ALWAYS

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

ALWAYS

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

ALWAYS

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

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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 servicing or accessing beneath or on the machine.

ALWAYS

operate carefully and in a responsible manner and observe all Manager’s Transport Rules.

ALWAYS

refer to site JSA and SOPs prior to towing with the machine.

ALWAYS

ensure sufficient ventilation is available to dilute exhaust gases, as stated on the machine’s compliance plate.

ALWAYS

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

ALWAYS

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

ALWAYS

Engine coolant pressure (see Section 5).

Engine coolant temperature (see Section 5).

Engine exhaust temperature (see Section 5).

Rotating radiator fan.

Stored hydraulic pressure (see Section 5).

Stored air pressure (air receiver) (see Section 5).

Engine oil pressure and temperature.

Transmission oil temperature.

Articulation area (see Section 5).

Tailgate area (see Section 5).

Machine mass.

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

Check floor.

Hold on, step down.

Three points of contact at all times.

Board using hand holds only, and not the steering wheel.

ALWAYS

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

ALWAYS

ensure the area around the machine is clear of personnel when performing machine functional test. These include tailgate functions, steering, brake release and functional testing of any attachments that may be attached to the machine’s PTO couplings.

ALWAYS

allow the engine or machine systems to cool sufficiently prior to commencing any maintenance or service on hot machine components.

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ALWAYS

be aware of the impact of the payload on the visibility available to the operator. The recommended maximum speed when loaded is 10 km/h however, the impact of the payload on the operator’s field of vision must be considered when operating the machine with payload. Drive to the conditions.

NEVER

operate the machine under unsecured roof.



Keep the machine clean. A clean machine makes for a safer machine.



No diesel engine should be operated underground if it is smoky, running unevenly, or if the exhaust system is not in good condition.



In areas where auxiliary ventilation is used, the operator should make sure fans are operating before starting the machine.



The engine shall not for any reason be left running unattended underground.



The engine should not be shutdown from full load and must be allowed to idle for a few minutes before stopping.



Never operate a machine that you feel is mechanically or electrically unsafe.

Potential Crush Point Articulation

One Metre No Go Zone When Trailer in Ejected or Retracted

Potential Crush Point Against Rib When Articulating

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GRAB HANDLE FOR MACHINE TOP ACCESS On the driver’s side of the machine, there are two location points with grab handles and three points of access that have been installed to aid in safe access to the top of the machine.

Prior to accessing the top of the machine ensure the top surfaces are free of any material that could pose a trip or slip hazard. Use grab handle and keep footing on three points of access to avoid injury.

Three Points of Access

Grab Handles

Three Points of Access

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SAFETY LABELS AND INSTRUCTIONS This manual contains important information affecting the safety of personnel and the equipment being used.

The safety instructions and behavioural rules are intended to protect operators from potentially dangerous situations and assist in the safe operation of the trailer and associated equipment.

The following symbols are used with safety instructions and identify varying degrees of hazardous conditions.

The safety instructions associated with these symbols are to be considered the minimum requirements for effective hazard and operational control.

Points in the text marked with this symbol draw attention to immediately impending danger. Possible consequences are very serious or fatal injury.

These points contain information on potentially dangerous situations.

Possible consequences are very serious or fatal injury.

This symbol draws attention to potentially dangerous situations. Possible consequences are light to moderately serious injury and machine damage.

Points in the text marked with this symbol draw attention to potentially harmful situations. Possible consequences are damage to machine or equipment in immediate vicinity

Text marked with this symbol contains useful information associated with the machine and its application.

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3

Gauge Parameters and Colour Coding GAUGE COLOUR CODE The gauges in the operator’s compartment are colour coded to assist the operator to recognise if the temperatures and pressures are within the correct operating parameters.

During normal operation some gauges may, at times, read outside of the indicated normal operating range e.g. during normal operation, when the operator applies the brake the brake head pressure gauge will drop below the minimum pressure and indicate that the pressure is too low. This is because the pressure is being released from the brakes to allow the springs to apply the brakes. When the operator releases the brake the gauge should then return to the green zone.

RED:

The gauge is indicating an unsafe condition. When this occurs the operator should stop the machine and rectify the problem or have service personnel rectify the problem before placing the machine back in service.

ORANGE: The gauge is indicating a temperature or pressure outside of the normal operating range. The operator should closely monitor the gauge and report the problem to service personnel for rectification.

YELLOW: The gauge is indicating a temperature or pressure below the normal operating range. This will not cause immediate damage if operated for short periods. Report to service personnel for rectification if machine continually operates in this area.

GREEN:

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

GAUGE ALARM PARAMETERS Engine Coolant Temperature

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Exhaust Gas Temperature

Brake Accumulator Pressure

Brake Head Pressure

Engine Oil Pressure

Air Pressure

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Steering Accumulator Pressure

Transmission Oil Temperature

Exhaust Back Pressure

Primary Park Brake

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Machine Orientation, Controls and Functions MACHINE ORIENTATION BASIC MACHINE LAYOUT The FH125 D 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, the cooling system radiator, explosion-protected engine package (which utilises a wet exhaust conditioner), the operator’s compartment and all the storage reservoirs (hydraulic, pneumatic, brake flushing and fuel tanks).

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

Never use the door to apply the park brake. Always manually apply the park brake by pressing the park brake button and ensure the brake head pressure gauge reads zero before exiting the Operator’s compartment.

On both opening the operator’s door and manual operation of the park brake valve, the steering pressure will automatically begin to bleed down upon engine shutdown, never assume the steering pressure has bled down unless the steering pressure gauge reads zero.

When the door is open the machine cannot be operated, as the park brake will be on and the transmission will be declutched. There is a roller cam valve in the door lock that needs to be activated to release the park brake. Also the brake system pressure is dumped with the door open. The engine will run with the door open.

Door Latch

DOOR INTERLOCK VALVE

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

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

Momentarily decrease engine revs when selecting a higher gear. Momentarily increase engine revs when selecting a lower gear.

The transmission in the machine is modulated. This prevents severe shocks being transmitted through the drive train when the transmission direction is changed.

TRANSMISSION DIRECTIONAL CONTROL LEVER A directional control lever controls the transmission and direction of travel. This lever has three positions, forward, neutral and reverse. The engine should be at low idle when the transmission is shifted from the neutral position to either forward or reverse direction.

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

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

Transmission Directional Control Lever

Transmission Speed Control Lever

TRANSMISSION CONTROLS

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

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

Never use the door interlock to actuate the park brake when exiting the machine. If there is a malfunction on the door interlock system, the park brake could possibly not apply when exiting the machine and the machine could run away resulting in serious damage or injury.

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

BRAKE HEAD PRESSURE GAUGE

PARK BRAKE VALVE

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NO. 1 - TWO-WAY HYDRAULIC 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.

NO. 2 - TWO-WAY HYDRAULIC CONTROL LEVER This lever has three positions, PTO, PTO, and hold: 1.

2.

3.

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.

No. 1 - Two-Way Hydraulic Control Lever

No. 2 - Two-Way Hydraulic Control Lever

TWO-WAY CONTROL LEVERS

Eject Pilot Control Lever

Operator’s Door

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OPERATOR’S SEAT On the operator’s seat the height, backrest tilt and seat suspension are all adjustable. The controls for these functions are beside and in front of the seat base.

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

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

BRAKE PEDAL The brake pedal when depressed applies the brakes on the front and rear axles. There are four liquid-cooled Posi-Stop brakes located internally in each axle wheel end. Whenever possible select a lower gear on a grade or decline to slow the machine

Do not ride the brakes while tramming the machine.

If the engine should stall, the machine is fitted with fail-safe brake system that will fully apply the brakes. The operator can apply the brakes at any time following an engine stall to immediately bring the machine to a controlled stop.

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

Brake Pedal

Accelerator Pedal

PEDAL ASSEMBLIES

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STEERING WHEEL The steering wheel controls the flow of hydraulic oil to the steering cylinder via an orbital steering valve. As the cylinder strokes, the machine articulates to the left or to the right.

Turning the wheel anti-clockwise articulates the trailer away from the operator. This effectively turns the machine to the left in the forward direction (tailgate end).

Turning the wheel clockwise articulates the trailer towards the operator. This effectively turns the machine to the right in the forward direction (tailgate end).

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

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

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

STEERING WHEEL

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PRIMARY PARK BRAKE VALVE GAUGE This gauge indicates the pressure in the primary park brake valve system. Normal operating system pressure is 17237 kPa (2500 psi).

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

If the operator’s foot is off the brake pedal and the park brake is released, the indicated pressure shall be a minimum of 12000 kPa (1740 psi). If the pressure is below this it is likely that the brakes are dragging. The machine shall not be operated with dragging brakes as fire or brake failure may result. Immediately report the problem to service personnel.

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

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

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

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

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

Brake Accumulator Pressure Steering Accumulator Pressure

Brake Accumulator Pressure

Brake Head Pressure

LEFT HAND SIDE OPERATOR’S PANEL

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

2.

3.

4.

5.

The transmission is in neutral.

The park brake is applied.

The diesel control system shows no fault.

The on/off toggle switch is on.

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

Depress the accelerator pedal ⅓ before a start to ensure sufficient fuel is available. Immediately remove finger from the engine start button when the engine fires.

AIR PRESSURE GAUGE This gauge indicates the air pressure in the air receiver. Normal air pressure is set at 760 kPa-860 kPa (110 psi -125 psi).

The main air isolation valve is mounted near the operator’s compartment. Turn this valve on once entering the machine. The gauge will read zero when the valve is shut.

ON/OFF TOGGLE SWITCH The on/off toggle switch controls the supply of pilot air pressure to the air pressure switch on the diesel control system, which allows air to pilot the start motor.

1.

2.

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

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

Engine Start Button Air Pressure Gauge

On/Off Toggle Switch

LEFT HAND SIDE OPERATOR’S PANEL

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TRANSMISSION OIL TEMPERATURE GAUGE This gauge indicates the oil temperature in the transmission and torque converter. Normal operating oil temperature is between 82 °C-93 °C. If the temperature should rise above 121 °C, carry out the following procedure: 1.

2.

Bring the machine to a halt, retract the telebody and ejector plate as required and apply the park brake.

Put the transmission in neutral and rev the engine to about ½ speed.

Observe the temperature gauge for about two minutes. If the temperature does not begin to fall within two minutes, shutdown the machine and do not attempt to operate it until corrective action has been taken. Immediately report the problem to service personnel.

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

Transmission temperature can be affected by incorrect gear selection for the load being carried and/or the road conditions.

ENGINE COOLANT TEMPERATURE GAUGE This shows the coolant temperature circulating through the engine, exhaust and radiator systems. Normal operating temperature is between 82 °C-95 °C. The engine should not be operated under heavy load until it has time to warm up approximately five minutes. The engine must also be shut off and cooled when the coolant level is to be topped up.

Shut off the engine immediately if the coolant temperature gauge goes above 105 °C. The diesel control system will give an alarm at 100 °C and should shutdown the engine at 105 °C. EXHAUST OUTLET GAS TEMPERATURE GAUGE This shows the exhaust gas temperature upon exiting the wet exhaust conditioner. The machine will shutdown if this temperature exceeds 77 °C. Observe the temperature gauge for approximately 2-5 minutes. If the temperature does not begin to fall within this period, shutdown the machine and do not attempt to operate it until corrective action has been taken. Immediately report the problem to service personnel.

Do not operate the machine if the oil temperature is beyond 80 °C. Operation continuously above this range may result in damage to hydraulic components, and excessively high oil temperatures could result in a fire.

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RIGHT HAND SIDE OPERATOR’S PANEL

HORN BUTTON Pushing this button sounds the air horn.

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

LEFT HAND SIDE OPERATOR’S PANEL

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ENGINE SERVICE HOUR METER This electric meter is mounted on the driver’s side in the articulation area of the machine.

Use the hour meter to determine servicing intervals.

ENGINE HOUR METER

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

AIR CLEANER AND SERVICE INDICATOR

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ENGINE FUEL PRIMER PUMP If the engine fuel system has been run dry or serviced, the fuel system should be primed via manual activation of the hand fuel primer pump. The pump is located adjacent to the fuel water separator next to the hydraulic tank on the driver’s offside.

Normally no priming is required to start the engine.

Manual Fuel Primer

ENGINE HAND FUEL PRIMER PUMP

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

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EXHAUST BACK PRESSURE GAUGE The exhaust back pressure gauge located in the operator’s compartment indicates the condition of the two exhaust filter elements. When the back pressure is above 12 kPa on the green area on the back pressure gauge, the elements should be removed and replaced.

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 is supplied with the new filter and completely sealed.

The contaminated element must be removed from the underground environment and disposed of safely.

Running the engine with high exhaust back pressure affects the performance of the engine and may risk internal component damage.

ENGINE OIL PRESSURE GAUGE This gauge indicates the engine lubricating oil pressure. Normal pressure is between 210 kPa-550 kPa (30 psi-80 psi).

Shut off the engine if the oil pressure drops and stays below 70 kPa (10 psi). The diesel control system should shutdown the engine at 70 kPa (10 psi).

Do not run the engine with low oil pressure, as engine damage will result. Low oil pressure can indicate low oil sump level, debris blockage in the oil pump feed tube or oil filter, or other serious complications. Immediately report the problem to service personnel.

Exhaust Back Pressure Gauge Engine Oil Pressure Gauge

LEFT HAND SIDE OPERATOR’S DISPLAY PANEL

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

EMERGENCY INTAKE SHUT OFF VALVE STOP BUTTON

EMERGENCY INTAKE SHUT OFF VALVE RESET LEVER

The valve is activated from the operator’s compartment by a stop button which is pushed, once activated and the engine shuts down the valve will need to be reset before restarting.

Ensure that the stop button has been pulled out (approx 25mm) and there is a reset lever down on the main body of the valve that will rotate and latch into the operating position. If the valve has not been reset the engine will not start. When the valve has been reset the engine can be started.

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

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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 another means of shutting down the engine should the on/off toggle switch fail.

FUEL SHUT OFF VALVE

The Emergency Intake Shut Off Valve Button in the Operator’s compartment should be activated first in any emergency situation.

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

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Section

5

Machine Isolation Before commencing work on the machine, it is imperative to ensure the system to be worked on is correctly isolated. This may also require the isolation of other systems that affect the safe completion of the job.

Any site/mine specific isolation procedures override those listed on the following pages. The procedures presented here are the minimum required to perform any work on the machine. Before commencing check with the relevant people regarding any site/mine specific isolation procedures.

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

2.

3.

4.

5.

6.

7.

8.

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

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

Select neutral on the transmission directional control lever.

Apply the park brake.

Shutdown the engine.

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

Connect the articulation lock and chock the wheels.

Close the main air isolation valve and fit a personal danger tag (see Pneumatic Isolation). This valve provides for personal isolation locks to be fitted.

Be careful of hot surfaces, when working on or around the machine , allow time for them to cool down.

On/Off Toggle Switch

Air Pressure Gauge

LEFT HAND SIDE OPERATOR’S PANEL

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

2.

3.

4.

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

Shutdown the engine, fit a personal danger tag to the on/off toggle switch, connect the articulation lock and chock the wheels.

Locate the main air isolation valve in front of the operator above the two-way hydraulic control levers and rotate to the off position and install a personal danger tag.

Check the system for dead by observing the air pressure gauge reads zero when the on/off toggle switch is in the on position.

If work is required on the air receiver it will be necessary to remove air pressure from the air receiver by actuating the main air drain valve.

Stored air pressure will be safely released to the atmosphere. Ensure that the three-way ball valve is not connected to an external pressure source.

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

MAIN AIR CHARGE VALVE MAIN AIR ISOLATION VALVE

MAIN AIR DRAIN VALVE

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

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

Shutdown the engine, fit a personal danger tag to the on/off toggle switch, connect the articulation lock and chock the wheels.

Move the No 2 two-way hydraulic control lever located in the operator's compartment up and down. This will remove any residual pressure stored in the PTO lines.

Observe both steering and brake pressure gauges located in the operator's compartment. The hydraulic system features a steering and brake accumulator. The brake/steer control manifold bleeds accumulator pressure over time, once the machine has been shutdown. To aid in the removal of residual pressure, prior to exiting the operator’s compartment and with the door closed turn the steering wheel from side to side and observe the steering accumulator pressure gauge return to zero.

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

2.

3.

4.

5.

Serious injuries can occur from hydraulic oil under pressure. Ensure all loads are mechanically supported before removal of any hydraulic lines. Always assume there is hydraulic pressure in hydraulic lines or components unless it has been isolated by yourself. Hydraulic fluid may be hot. Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves.

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

Ensure the machine is clear of pedestrians and equipment when undertaking this procedures.

Steering Accumulator Pressure Gauge

Brake Accumulator Pressure Gauge

LEFT HAND SIDE OPERATOR’S PANEL

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

2.

3.

4.

5.

6.

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

Shutdown the engine, fit a personal danger tag to the on/off toggle switch, connect the articulation lock and chock the wheels.

Isolate the pneumatic circuit by turning off the main air isolator and fitting a personal danger lock.

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

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

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

The coolant fluid will be under pressure and hot (up to 100 °C). Always relieve pressure by lifting the relief lever on relief cap before removal.

Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves to avoid scalds and burns from hot coolant.

Engine Coolant Relief Cap

COOLANT HEADER TANK AND RELIEF VALVE

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ELECTRICAL ISOLATION 1.

2.

3.

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

Shutdown the engine, connect the articulation lock and chock the wheels.

All electrical energy is isolated once the engine has stopped.

The electrical system installed on this machine is approved/certified as explosion protected for use in 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.

Isolate at the circuit breaker before performing welding on the machine.

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

Do not bypass shutdown conditions or devices.

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

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ARTICULATION ISOLATION To fit the articulation lock: 1.

2.

3.

4.

5.

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

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

Locate the articulation lock at the articulation area on the driver’s side of the machine and remove the lynch pin.

Swing the articulation lock across until it lines up with the pin location on the tractor side of the machine.

Install the locking pin through the retaining hole and secure with the lynch pin.

To remove the articulation lock: 1.

2.

With the park brake applied, remove the lynch pin and locking pin and swing the bar across to locate on the support bracket.

Ensure the locking pin is installed and secured with the lynch pin.

The articulation area of this machine can cause fatal crush injuries if extreme caution is not observed. Always ensure that the park brake is applied and the operator’s compartment is vacant when accessing the articulation area to fit or remove the articulation lock. Never work in the vicinity of the articulation joint unless the articulation lock has been correctly installed.

ARTICULATION LOCK IN LOCKED POSITION

ARTICULATION LOCK IN STORAGE POSITION

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TAILGATE ISOLATION To install the tailgate lock: 1.

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

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

Raise tailgate to the fully open position.

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

Install the lock pins through the retaining holes.

2.

3.

4.

5.

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.

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 unless the tailgate lock has been correctly installed.

Retaining Hole for Tailgate Lock Driver’s Side

Tailgate Lock on Driver’s Side

Retaining Hole for Tailgate Lock Off Driver’s Side

TAILGATE IN CLOSED POSITION ON DRIVERS’S SIDE

Tailgate Lock Off Driver’s Side

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

2.

3.

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

Isolate the machine.

Isolation of the wet bath exhaust conditioner is carried out via a valve located between the water inlet hose and the conditioner float chamber. The main isolation valve has two positions closed and open, this regulates the water flow from the make up tanks.

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

Main Supply/Isolation Valve

WET BATH EXHAUST CONDITIONER

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EXHAUST CONDITIONER MAKE UP TANK PRESSURE ISOLATION To isolate the pressurised make up tank, perform the following procedure: 1.

2.

3.

4.

5.

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

Retract the telebody and ejector plate as required. Shutdown the engine and isolate the machine in accordance with the site isolation procedure.

Locate the make up tank filler cap located at the rear of the machine on the driver’s side.

Remove the make up tank air pressure by slowly rotating the filler cap and hold until the air pressure is released.

Slowly remove filler cap.

The make up tank is pressurised via the pneumatic system to provide a positive head feed to the exhaust conditioner. Always relieve pressure first by slowly rotating the filler cap before removal. Wear personal protective equipment such as safety glasses.

Exhaust Conditioner Make Up tank Filler Cap

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Section

6

Pre-Start Procedure Walk around the machine: 1.

2.

3.

4.

5.

6.

7.

8.

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

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

Check for damaged or missing wheel nuts and studs.

Check for loose wheel nuts.

Guards and covers are in place and secure.

Check for missing or loose bolts.

Check for oil leaks.

Check for visible hose damage.

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

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

Check the hydraulic tank oil level: 1.

2.

3.

4.

5.

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

Ensure the tailgate is in the lowered position, the engine is turned off and the machine is isolated as per Section 5 - Pneumatic Isolation.

Check the level at normal operating temperature.

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

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

Always use the specified fuel for the application and the region’s seasonal temperatures. (See Section 19).

Hydraulic Tank Fill Point

Breather

Hydraulic Level Sight Gauges

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Check the engine oil level: 1.

2.

3.

4.

Stop the engine and allow the oil time to settle before checking via the dipstick.

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

Ensure the correct engine oil is used. Oil specifications are listed in Section 19 - Fluid Specifications Table.

Do not over fill.

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

Always use the specified oil for the application and the region’s seasonal temperatures. (See Section 19).

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

ENGINE FILL POINT

ENGINE OIL DIPSTICK

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Check the fuel level: 1.

2.

3.

4.

Gauge fitted to the fuel tank.

Check the filler cap is secure and not damaged and seal is in place.

Check for leaks.

Always fill machine completely.

To fill the fuel tank: 1.

2.

3.

4.

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

Locate the fuel tank filler cap on the driver’s side of the machine.

Release the filler cap lock by pulling the Lock away from the centre of the cap.

Lift the filler cap and insert the fuel filler/nozzle and fill the tank.

Do not allow the fuel tank to overflow as diesel fuel is a fire hazard.

Clean any excess fuel away immediately and dispose of in an appropriate manner.

5.

6.

Once the tank is full, close the fuel tank filler cap and allow the filler cap lock to spring into position over the cap.

The fuel level gauge will indicate the tank is full.

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

Do not operate the machine with the fuel level below empty level on the fuel tank. It is a recommended procedure to fill the fuel tanks at the end of each shift to drive out moisture laden air and to prevent condensation. Do not overfill the tank. Use caution when refuelling an engine. Ensure appropriate PPE is worn.

Always use quality fuel to the specification shown in Section 19.

Fuel Filler Cap and Fuel Level Sight Gauges

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

2.

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

Damaged or loose belts should be reported to service personnel.

The water pump is belt driven. Running the machine with loose or damaged belts will cause the machine to overheat and can seize the engine..

Check the condition of the fuel water separator: 1.

2.

3.

Located off driver’s side of machine near brake flushing and hydraulic tanks.

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

Check fuel lines for leaks or damage.

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

2.

For proper storage and loose fasteners.

For damage.

Check the tailgate locks (see Section 5): 1.

2.

For proper storage and loose fasteners.

For damage.

Check the expansion tank coolant level: 1.

2.

3.

4.

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

Check for coolant leaks.

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

Report to service personnel if coolant is low.

Check the radiator: 1.

2.

For coolant leaks.

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

Check the headlights: 1.

2.

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Are securely mounted and operational.

For cables and glands for damage.

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Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 19).

Filler Cap

Overflow Sight Level Indicators

FUEL WATER TRAP COOLANT EXPANSION TANK

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

2.

3.

4.

Filter condition indicator.

Replace filter element if indicator is in the red area.

Check intake pipes and hoses for loose or damaged connections.

Check joints are secured.

AIR CLEANER AND SERVICE INDICATOR

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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Check air receiver: 1.

2.

For damage.

Drain condensate from main air drain valve.

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

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

MAIN AIR DRAIN VALVE

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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: 1.

2.

Check sight gauge on the off driver’s side of the machine.

Fill as required.

BRAKE FLUSHING SIGHT GAUGES

Filter Housing Assembly Filler Cap Relief Check Valve

BRAKE FLUSHING TANK

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Check the fire extinguisher: 1.

2.

3.

4.

5.

Located on each side of the machine.

Check inspection date.

Check contents indicator is reading in the green area.

If fire suppression system fitted check actuation points.

Check safety pins are in place.

FIRE EXTINGUISHER

FIRE SUPPRESSION

REMOTE ACTIVATOR FOR FIRE SUPPRESSION

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The wet bath exhaust conditioning system on the FH125 D carries out the following major functions:   

To cool and dilute exhaust gases.

To prevent hot gases from entering the mine atmosphere.

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

Explosion-protected diesel engine maintenance must be carried out by a qualified and authorised person.

Inlet

Ins pe

ctio n

Ho les

Outlet

Shutdown Float Chamber

WET BATH EXHAUST CONDITIONER

Check exhaust system: 1.

2.

3.

4.

5.

6.

7.

For damage.

Check joints for signs of leakage.

Check cooling hoses for security and condition.

Check exhaust filter back pressure and change filters as required i.e. >10 kPa. Drain and flush conditioner regularly. Refer to the Service Manual.

Check the valves are in the correct position.

Check the make up tanks are full of water.

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

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Explosion-protected diesel engine maintenance must be carried out by a qualified and authorised person.

WET BATH EXHAUST CONDITIONER

MAKE UP TANK

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

INLET VALVE

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

Emergency Intake Shut Off Valve: The emergency intake shutoff valve (strangler valve) should be inspected before attempting to start the engine. The stop button should be pulled out (approx 25mm) and the reset lever latch into the operating position (see Section 4).

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

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

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

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Section

7

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

Do not start the engine if machine is tagged out of service or Personal Danger Tag/Lock is affixed.

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

ONLY RESTART THE ENGINE AFTER VERIFYING THAT THERE HAS BEEN NO INGRESS OF WATER FROM EXHAUST CONDITIONER INTO THE ENGINE. THIS IS TO BE VERIFIED BY SERVICE PERSONNEL PRIOR TO ATTEMPTING ENGINE START. 1.

2.

3.

4.

5.

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

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

Place the transmission directional control lever in the neutral position.

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

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

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

6.

7.

8.

9.

10.

Wait for the display to indicate waiting for start (showing three green LEDS).

Hold the accelerator pedal approximately ⅓ to ½ open.

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

Check the display indicates Engine Running.

Carry out post start checks and operate machine normally.

See Section 18 - Operating Diesel Control System As soon as the engine starts, check all gauges and indicators to ensure that all systems are functioning correctly. Always let the engine warm up before applying load. Never apply load to a cold engine.

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

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

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

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

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

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

Check function of ejector system.

Check steering function.

Check park brake operation: 1.

2.

Ensure brake head pressure gauge reads 11377 kPa-12756 kPa when brake is released.

Ensure brake head pressure gauge and primary park brake valve gauge read zero when brake is on.

The machine must not be used under any circumstance if gauge does not indicate zero pressure.

The primary park brake valve gauge maybe located undercover within the machine adjacent to the operator’s compartment.

Check that all of the lights are working: 1.

2.

There are two forward and rear facing headlights.

Control switch is operational, (manual or auto directional).

Check the transmission oil level: 1.

2.

3.

4.

5.

6.

7.

8.

Always check when the transmission is warm.

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

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

Access the transmission dipstick from the operator’s compartment through the cover over the top of the transmission (to the off driver's side)..

The engine should be idling at 750 RPM-850 RPM. Remove the dipstick by pulling upwards and wipe with a clean, lint free cloth.

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

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

Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 19).

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Dipstick and Fill Point

Check the particulate filter back pressure indicator: 1.

2.

3.

Locate the indicator in the operator's compartment.

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

If the indicator is above 10 kPa the filter requires replacement.

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

To replace the particulate filters (if fitted): 1.

2.

3.

4.

5.

6.

7.

8.

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

Put on protective gloves (protective gloves should be worn throughout the entire change out operation to protect the operator from corrosive agents (combustion byproducts) as well as elevated surface temperatures and sharp edges.

Remove the filter housing lid.

Undo filter retaining nuts if fitted.

Partially pull the filter out of the housing to unseat the filter at the base of the housing.

Take a disposable bag and place it over exposed filter.

Continue to remove the filter ensuring the bag covers the filter during the remainder of the process. With filter in the bag, tie the open end to secure it.

Discard the used filter elements in the appropriate manner.

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.

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Check the diesel control system operation: 1.

2.

3.

4.

Run the engine at high idle.

Press the shutdown test button and hold for ten seconds.

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

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

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

Perform low exhaust water shutdown test: 1.

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

DCS DISPLAY DIGITAL INPUT SCREEN

2.

Shut make up tank ball valve and remove blanking plug from low water shutdown test point and open ball valve.

Main Supply/Isolation Valve Low Water Shutdown Test Ball Valve

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3.

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

The machine must not be used under any circumstance if it fails the low water shutdown test. If the engine fails to stop or the water stops flowing out the test valve before the engine stops. DO NOT use the machine until the fault is rectified.

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

4.

60

When the test is complete, close the low water shutdown test point, reinsert blanking plug and open main isolation valve to allow water to refill the exhaust conditioner.

Check the make up tank level and fill accordingly.

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9

Stopping the Engine 1.

2.

3.

4.

5.

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

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 and primary park brake valve gauge are on zero.

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

This engine is turbocharged. Shutting down the engine stops the oil lubrication circuit to the turbocharger. Shutting down the engine at high operating temperatures or load risks damage to the turbocharger and the lubrication system.

The primary park brake valve gauge maybe located undercover within the machine adjacent to the operator’s compartment.

6.

7.

7.

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

Allow the steering accumulator pressure to bleed down until the steering pressure accumulator gauge reads zero.

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

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

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

9.

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

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

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

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10

Tramming the Machine 1.

2.

3.

4.

5.

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

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

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

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

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

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

6.

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

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

Always ensure that the transmission control levers are fully shifted.

7.

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

Momentarily decrease engine revs when selecting a lower gear.

8.

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

Stop machine in a suitable place and apply park brake.

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

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

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

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

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Always be aware of the impact of the payload on the visibility available to the operator. The recommended maximum speed when loaded is 10 km/h, however, the impact of the payload on the operator’s field of vision must be considered when operating the machine with payload.

Drive to the conditions.

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11

Stopping and Braking 1.

2.

3.

4.

5.

6.

7.

Use the transmission to help slow down the machine, by shifting down when possible.

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

Observe brake head pressure gauge and primary park brake valve gauge within the operator’s compartment reads zero pressure.

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

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

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

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

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

The machine must not be used under any circumstance if the primary park valve gauge and brake head pressure gauge do not indicate zero pressure.

The primary park brake valve gauge maybe located undercover within the machine adjacent to the operator’s compartment.

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

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

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Use the gears to help slow the machine.

Gradually turn machine to the rib.

Apply the park brake.

Shutdown the engine.

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12

Driving on a Ramp 1.

2.

3.

4.

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

Always use a low gear when travelling down a ramp.

Avoid changing gears while travelling on a steep ramp.

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

Immediately apply the brakes.

If the brakes do not function, apply park brake.

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

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

Operators must be competent in Emergency Stop Procedure (Section 11).

Always be aware of the impact of the payload on the visibility available to the operator. The recommended maximum speed when loaded is 10 km/h, however, the impact of the payload on the operator’s field of vision must be considered when operating the machine with payload.

Drive to the conditions.

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13

Parking on a Ramp

Do not park on a ramp unless absolutely necessary.

1.

2.

3.

4.

5.

6.

7.

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

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

Turn the machine toward the rib.

If possible remove the load from the attachment.

Apply the park brake. Observe that the brake head pressure gauge and primary park brake valve gauge are on zero.

Always chock the wheels.

Inform mine management of the position of machine.

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

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

The machine must not be used under any circumstance if the primary park valve gauge and brake head pressure gauge do not indicate zero pressure.

The primary park brake valve gauge may be located undercover within the machine adjacent to the operator’s compartment.

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14

Loading To load the machine: 1.

2.

3.

4.

5.

6.

7.

8.

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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.

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Always be aware of the impact of the payload on the visibility available to the operator. The recommended maximum speed when loaded is 10 km/h, however, the impact of the payload on the operator’s field of vision must be considered when operating the machine with payload.

Drive to the conditions.

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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 No. 2 two-way hydraulic control lever to the up position.

Empty trailer by continuing to hold the control lever in the up position, 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.

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 Machine when Disabled Set the park brake and stop the engine. The towing machine must have sufficient braking capacity to stop and hold both machines.

1.

2.

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

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

3.

4.

5.

Connect the machine to the towing machine.

Place the transmission in neutral.

Release the spring applied brake by hydraulically overcoming the brake spring pressure by use of a hydraulic hand pump and tow at low speed.

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

If the machine 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.

The transmission will not hold the machine when the spring applied park brakes are bypassed by the hydraulic hand pump pressure.

Pressure P Active A Tank T

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

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

Maximum towing speed is 3 kph.

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17

Air Venting the Fuel and Engine Cooling System 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 until positive pressure is observed.

Tighten and secure the priming pump.

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

Check the fuel tank contents gauge before venting the system.

Check the fuel water separation bowl before venting the system.

Manual Fuel Primer

ENGINE HAND FUEL PRIMER PUMP

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AIR VENTING THE ENGINE COOLING SYSTEM To prevent an air lock in the engine coolant system, the cooling system automatically bleeds back to the expansion tank. Fill the coolant system expansion tank only with the fluid specified in Section 19—Fluid Specification Table.

Add water conditioner as necessary.

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

Diesel Control System (DCS) DIESEL SHUTDOWN The purpose of the diesel control system is to prevent the engine running outside of the predetermined safe operating parameters.

The following sensors are fitted to the machine: Hi Methane Shutdown (1.25%) Shuts engine down Lo Methane Warning (1%) Warning message Charge Failure Warning message/shutdown after 30 minutes Engine Oil Pressure Shuts engine down Engine Coolant Level Shuts engine down Engine Coolant Temperature Shuts engine down Engine Turbo Temperature Shuts engine down Exhaust Outlet Temperature Shuts engine down Power Up Pressure Switch (PUPS) System start up Wet Scrubber Water Level 1 Shuts engine down Wet Scrubber Water Level 2 Shuts engine down Exhaust Scrubber Temperature Shuts engine down Scrubber Make Up Water Level Warning message Fire Suppression Activation Shuts engine down

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SYSTEM OPERATION 1.

Position the on/off toggle switch to the on position: This will activate the DCS electronics. The system will display Waiting for methane sensor warm up and the methane LED will be illuminated. After approximately 15 seconds the screen display will read Pre run checks while the DCS checks that the system is ready to start. Once this is completed the screen will display Waiting for start. The engine can now be started. If the engine is not started within 30 seconds the DCS will shut itself down.

To restart the system toggle the on/off toggle switch to off then back to on.

ON/OFFTOGGLE SWITCH

2.

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

3.

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

4.

Drive machine normally.

5.

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

6.

After a shutdown whether by the operator or an engine trip, if the up or down arrows are pressed the system will return to Waiting for start providing no trip conditions are still active.

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

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

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

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

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19

Fluid Specification Table SPEC.

1

2

COMPONENT

Engine

Transmission

CAPACITY (Litres)

FLUID

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)

22

80

3

Hydraulic

4

Axle / Wheel Ends / 90º Drives

60 (each)

Mineral Gear Oil with Limited Slip Additive

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

5

Cooling System

72

Pre-mixed Coolant

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

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

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© 2003

CATERPILLAR ALL RIGHTS RESERVED

CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, “CATERPILLAR YELLOW” AND THE “POWER EDGE” TRADE DRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.