CAT Operator Manual FBL-10 LHD Utility Vehicle SN 5001693

BI643687

BUCYRUS Australia 2008©

FBL-10 LHD/Utility Vehicle

Serial No. 5001693

Operator Manual BUCYRUS Australia Room & Pillar Division Phone: +61 2 49147000 Fax: +61 2 49147059

BI643687

FBL-10 Serial No. 5001693

Operator Manual

Index 1.

GENERAL INFORMATION

2.

GENERAL SAFETY AND PRECAUTION

3.

GAUGE PARAMETERS AND COLOUR CODING

4.

MACHINE ORIENTATION CONTROLS AND FUNCTIONS

5.

MACHINE ISOLATION

6.

PRE-START POCEDURE

7.

ENGINE STARTING PROCEDURE

8.

POST START CHECKS

9.

STOPPING THE ENGINE

BUCYRUS Australia 2008©

10. TRAMMING THE MACHINE 11. STOPPING AND BRAKING 12. DRIVING ON A RAMP 13. PARKING ON A RAMP 14. LOADING 15. DUMPING 16. TOWING THE VEHICLE WHEN DISABLED 17. TOWING WITH THE VEHICLE 18. AIR VENTING THE FUEL SYSTEM 19. AIR VENTING ENGINE COOLANT SYSTEM 20. ATTACHING IMPLEMENTS 21. DETACHING IMPLEMENTS 22. SAFETY SHUTDOWN SYSTEM 23. FLUID SPECIFICATION TABLE

BUCYRUS Australia recommends that all Safe Working procedures should be approved and checked by Mine Officials. BUCYRUS Australia declines all liability for direct or indirect consequences of printing errors.

This document is copyright. All intellectual property rights and copyright in the document (or any part of this document remains the property of BUCYRUS Australia. Except as provided for in the Copyright Act 1968 (Ctn) no part of this document may in any form or by any means (including without limitation electronic, mechanical, micro copying, photocopying, recording or otherwise) be reproduced, stored in a retrieval system or transmitted without the prior written permission of BUCYRUS Australia.

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1.

1.1

General Information

Introduction

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

This manual is designed to provide the 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.

BUCYRUS Australia 2008©

1.2

Description

The FBL-10 is a 10,000 kg Load Haul Dump/Utility vehicle. This allows it to be used for general purpose work through out the mine, which includes carrying heavy loads, materials and supplies.

The motive force is provided by a 172 kW Caterpillar 3216 six cylinder turbocharged 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 four speed bi-directional power shift transmission to heavy duty axles.

The FBL-10 utilises a dry exhaust system complete with a replaceable particulate filter, catalysed exhaust post treatment purifier and a exhaust outlet flame trap.

NOTE

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

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Dimensions

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1.3

General Information

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1.4

General Information

Specifications

All specifications are subject to change without notice.

Capacities Bucket Payload 8000 kg RAS Forks, Max Payload 10000 kg RAS Slewing Jib, Max Payload 7000 kg RAS Belt/Cable Reeler, Max Payload 7000 kg Maximum un-braked trailer mass 10000 kg Maximum braked trailer mass Consult BUCYRUS Australia Standard Ejector Bucket Heaped capacity (SAE) Struck capacity Break out force standard bucket tip (Hydraulic).

Tractive effort, Maximum

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

3

3.5 m 2.7 m3 15000 kg 21300 kg 7.0 sec 4.0 sec 7.0 sec 5.0 sec

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

19000 kg 29000 kg

Engine Type Diesel, Turbocharged, and 4 Cycle Cooling system Water based radiator Cooling fan Hydraulic driven fan Engine Make/model Caterpillar 3126 Displacement 7.2 litre Maximum power 172 kW @ 2200 RPM Maximum torque 720 Nm @ 1400 RP, Ventilation (NSW Requirement) 10.29 m3/s Engine Speeds Low idle High idle Governed

700 RPM 2600 RPM 2100 RPM

Stall Speeds Converter stall Full stall Hydraulic stall

2100 RPM 1700 RPM 2050 RPM

Fuel Consumption At full power Average mine duty

37.5 litre/hr 8-30 litre/hr

Exhaust Conditioner Type Make Exhaust Filter Exhaust Flame trap After treatment

Flameproof dry type BUCYRUS Australial Replaceable element Fitted Catalytic Exhaust purifier

Transmission Type Power shift with Fwd/Rev mod.

Make/model Dana/Spicer 32,000 series MHR Speeds, forward and reverse 4 Torque Converter Type Make/model

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Mounted in trans, Single element Dana/Spicer 13.1 integral

Axles Type Front axle make/model Rear axle make/model Differential type Differential lock type - Front Differential lock type - Rear Overall ratio

Outboard planetary Dana/Spicer 16D Dana/Spicer 16D Bevel gear and pinion POSI TORQ POSI TORQ 31.06:1

Wheels Make/model

3 piece (Heavy Duty)

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

Michelin X mine D2 17.5 x 25 Radial Air 110 PSI front, 110 PSI rear

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

L3 R Lug 20.5 x 25 24 Bias ply Air 110 PSI front, 110 PSI rear

Hydraulic Systems Steering Closed centre, Pressure Comp 2500 PSI Brakes Closed centre, Pressure Comp 2500 PSI Bucket/lift Open centre 3000 PSI PTO (2 on machine) Open centre 3000 PSI Tank type Sealed and pressurised Tank pressure 50 PSI Start System Starter motor type Intake Air Cleaner Type/Make Intake Dual element type

Air (Auststart) Dry/Donaldson Primary and Secondary

Main Hydraulic Pump Type Standard pump output @ 2000 RPM

Gear Open centre 150 lpm

Steering/Brake Pump Type Pressure compensated piston Standard pump output @ 2000 RPM 33 lpm Cylinders Type Double acting Rods Case hardened and hard chromed Counterbalance valves Lift and Tilt Cushion stops Steering and Tilt Steering System Control valve Actuation Pressure Compensated Cushion relief Accumulator Steering Type Quantity x capacity Operating Pre charge pressure

Closed centre Orbital 2500 PSI 3000 PSI Piston 1 x 5.9 litre 900 PSI Nitrogen

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Specifications

Accumulator Brakes Type Quantity x capacity Operating Pre charge pressure Bucket System Control valve Actuation Main relief

Open centre Remote Hydraulic pilot 3000 PSI

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

3050 PSI 3050 PSI 3050 PSI 3050 PSI

RAS in port relief RAS out port relief

3050 PSI 3050 PSI

Hydraulic Filtration Suction Bucket system BUCYRUS Australia 2008©

Piston 1 x 2 litre 900 PSI Nitrogen

Steer/brake system Optional return PTO

In line, strainer Return 25 micron replaceable with bypass Pressure 10 micron replaceable with bypass In line, 25 micron

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

Centre articulated, hydraulic

Service Brake Type Totally enclosed, liquid cooled POSI STOP Make/model Dana/Spicer 16150 Application Spring Applied Hydraulic Release Location Each wheel end Park Brake Type Make/ model Application Location

Totally enclosed, liquid cooled POSI STOP Dana/Spicer 16150 Spring Applied Hydraulic Released Each wheel end

Articulation Bearing type and size

Pin and Spherical bearing (top), bush (bottom) Fully sealed Bush material Hardened steel Pin material Hardened steel Degrees of turn either side 43-degree Oscillation Type Bush material Pin material Degrees up and down from horizon

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Seating (Operator) Type Make Suspension

Cross-seated BUCYRUS Australia Adjust spring/shock absorption

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

Adjustable Protective device MDG1 and MDG17 Approved flameproof 12 V Floating 2 front, 2 rear SETCO High performance approved flameproof Hydraulic Customer preference approved flameproof

Vehicle Speeds 1st gear 2nd gear 3rd gear 4th gear Pneumatic System Compressor type Air flow Governed pressure Relief pressure Air receiver volume

4.2 kph 8.5 kph 14.4 kph 23.8 kph 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)

250 litre 200 litre 40 litre 22 litre 72 litre 60 litre

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

22545 kg 10852 kg 6264 kg 3627 kg

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

1:4 1:4 1:8

Rear Bolster Hardened steel Hardened steel 7.5 degree

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General Information

Specifications

The FBL-10 comes standard with the Rapid Attachment System (RAS) for rapid pick up and release of attachments.

Optional attachments available: 10000 kg Forks with Side Shift 7000 kg Slewing Jib Crane 3.5 m3 Bucket – spade or straight lip 5m³ Bucket (Direct Mount) General Purpose Trailer Pipe trailer

7000 kg Belt/Cable Reeler 10000kg Manual Side Shift Forks Work Platform Fuel Pod Concrete Kibble

BUCYRUS Australia 2008©

Contact your local BUCYRUS Australia representative for further information on any of the above listed attachments. If you have a specific job task requirement or an attachment that is not listed let BUCYRUS Australia assist by developing a solution for and with you.

BUCYRUS Australia Room and Pillar Division 20 Kullara Close PO Box 373, Beresfield, NSW 2322 Telephone: 02 4914 7000 Facsimile: 02 4914 7059

WARNING

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

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

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Operator Manual

General Safety and Precautions

This section contains specific safety precautions that shall be followed whilst the machine is being used by suitably qualified operators.

ONLY TRAINED AND AUTHORISED OPERATORS SHALL OPERATE THIS MACHINE. DO NOT

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

DO NOT

for any reason exceed the indicated capacity of the machine.

DO NOT

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

DO NOT

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

DO NOT

operate the machine unless:

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a. b.

All covers and guards are correctly installed.

Personal protective equipment is worn.

• • • • •

DO NOT

start the machine unless: a. b. c. d.

DO NOT

Eye protection Hearing protection Hard hat Appropriate protective clothing Dust mask and gloves as required

The area around the machine is clear.

The park brake is applied.

Transmission is in NEUTRAL. All water and oil levels are checked.

leave the machine unless: a. b. c. d.

The vehicle is parked in a safe place.

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

The engine is stopped.

ALWAYS

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

ALWAYS

ensure that the operator’s compartment door is CLOSED and made secure before operating the vehicle.

ALWAYS

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.

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General Safety and Precautions

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 or accessing beneath or on the machine.

ALWAYS

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

ALWAYS

refer to site JSA and SOP’s prior to towing with the machine.

ALWAYS

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

ALWAYS

be aware of the hazard sources on the machine:

BUCYRUS Australia 2008©

a. b. c. d. e. f. g. h. i. j. k. l.

Engine coolant pressure (see Section 4) Engine coolant temperature Engine Exhaust temperature Exhaust coolant temperature (see Section 4) Rotating radiator fan Stored Hydraulic pressure (see Section 4) Stored air pressure (Air receiver) Engine oil pressure/temperature Transmission oil temperature Articulation Area (see Section 4) Lift arm area (see Section 4) Machine mass

ALWAYS

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

ALWAYS

use correct boarding and dismounting procedures: a. b. c. d.

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 that may cause injury or damage the equipment.

NEVER

operate the machine under unsecured roof.

NEVER

operate the machine near unsecured ribs.

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Operator Manual

General Safety and Precautions

•

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

•

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

•

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

•

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

•

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

•

Never operate a machine that you feel is mechanically unsafe.

Notes, Cautions and Warnings

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

NOTE

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

CAUTION

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

WARNING

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

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3.

Gauge Information

3.1 Gauge Colour Code The gauges in the operator’s compartment are colour coded to assist the operators to recognise if the temperatures and pressures are within the correct operating parameters.

During normal operation some gauges may, at times, read outside of the indicated “normal” operating range e.g. during normal operation, when the operator applies the service brake the brake head pressure gauge will drop below the minimum pressure and indicate that the pressure is to low.

This is because the pressure is being released from the brakes to allow the springs to apply the brakes. When the operator releases the service brake the gauge should then return to the green zone.

RED:

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

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

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YELLOW:

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

GREEN:

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

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3.2

Gauge Information

Gauge Alarm Parameters

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

Yellow Green Orange

107-120°C

Red

Coolant temperature to low.

Normal operating temperature range.

Above normal operating temperature. E n g i n e shutdown imminent.

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

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

Green Orange

107-120°C

Red

Normal operating temperature range.

Above normal operating temperature. Engine shutdown imminent.

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

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

Green Orange

150-200°C

Red

Normal operating temperature range.

Above normal operating temperature. Engine shutdown imminent.

Above normal operating temperature. Engine should have shutdown.

Exhaust Pressure 0-10 kPa 10-12 kPa

Green Orange

12-25kPa

Red

Normal operating pressure.

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

Exhaust pressure to high. Exhaust filter needs to be replaced.

Continued long periods of operation will result in damage to engine.

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

Red Green Red

Engine oil pressure to low. Engine should have shutdown.

Normal operating pressure range.

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

Orange Green Red

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

Normal operating pressure range.

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

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

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Gauge Information

Gauge Alarm Parameters

Brake Accumulator Pressure Gauge 0-13790 kPa 13790-18616 kPa 18616-25000 kPa

Red Green Red

Pressure to low. Brakes may not fully release. Premature brake wear may result if operated for prolonged periods. Needle may drop into this area for a short period when brakes are operating.

Normal operating pressure range.

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

Brake Head Pressure Gauge 0-11377 kPa

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11377-12756 kPa 12756-16000 kPa

Red

Green Red

Pressure below normal operating range. During normal operation needle will register in this area during normal operation of brakes and when park brake is applied. Gauge must return to normal operating range when brakes are released. Premature brake wear may result if operation continued.

Normal operating pressure range.

Pressure to high. Damage to brake units may occur.

Steering Accumulator Pressure Gauge 0-13790 kPa 13790-18616 kPa 18616-25000 kPa

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Red Green Red

Pressure to low. Steering may become heavy to operate. Needle will drop into this area for a short period when steering is operating.

Normal operating pressure range.

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

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Operator Manual

Machine Orientation Controls and Functions

4.1

Machine Orientation

4.1.1

Basic Machine Layout

The FBL-10 consists of two main sections a front and rear frame, housed in the front frame is the lift arm assembly, axle and main hydraulic control valve bank. The rear frame houses the transmission and hydraulic pumps, both cooling system radiators, flame proof engine package which utilises a dry exhaust conditioner the operator’s compartment and all the storage reservoirs, (Hydraulic, Pneumatic and Fuel tanks).

Lift Arm Assembly

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Front Axle

Main Hydraulic Control Valve Bank

Hydraulic Tank

Operator’s Compartment

Transmission and Hydraulic Pumps

Rear Axle Air Receiver

Fuel Tank Dry Exhaust Conditioner Cooling System Radiators

Flameproof Engine

Figure 4.1.1.1 - Basic Machine Layout

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Machine Orientation Controls and Functions

4.2

Control Locations

4.2.1

Operator’s Compartment Door

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

WARNING

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

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

NOTE

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

Figure 4.2.1.1 - Door Assembly

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Figure 4.2.1.2 - Door Interlock Valve

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4.2

Control Locations

4.2.2

Transmission Gear Control Lever

The gear control lever has four positions, FIRST, SECOND, THIRD, and FOURTH. Shifting to a higher or lower speed may be made at full engine RPM.

NOTE

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

4.2.3

Transmission Directional Control Lever

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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 4.2.2.1 - Transmission Controls

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Machine Orientation Controls and Functions

4.2

Control Locations

4.2.4

Operator’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).

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If the engine shutdown 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.

Figure 4.2.4.1 - Park Brake Valve

Figure 4.2.4.2 - Brake Head Pressure

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.

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4.2

Control Locations

4.2.5

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.

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4.2.6

No. 1 - 2 Way Hydraulic RAS Control Lever

There are two hydraulic RAS (Rapid Attach System) control levers fitted to the machine. The first lever closest to the operator 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) 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.

4.2.7

No. 2 - 2 Way Hydraulic RAS Control Lever

The second lever, furthest from the operator, 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. 1 - 2 Way Hydraulic RAS Control Lever

No. 2 - 2 Way Hydraulic RAS Control Lever

Figure 4.2.5.1 - Four Way Bucket Control Lever

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Figure 4.2.6.1 - RAS Controls

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Control Locations

4.2.8

Operator’s Seat

On the operator’s seat the height, backrest tilt and seat suspension are all adjustable. The controls for these functions are beside the seat.

4.2.9

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

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

4.2.10 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 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.

CAUTION

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.

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4.2

Operator Manual

Machine Orientation Controls and Functions

Control Locations

4.2.11 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 operator. 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

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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 4.2.11.1 - Orbital Control Steering Wheel

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4.2

Operator Manual

Machine Orientation Controls and Functions

Control Locations

4.2.12 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 (1600 PSI). If the pressure is below this it is likely that the brakes are dragging. The machine shall not be operated with dragging brakes as fire or brake failure may result. Immediately report the problem to service personnel.

CAUTION

BUCYRUS Australia 2008©

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

4.2.13 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).

CAUTION

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

4.2.14 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 4.2.12.1 - Right Hand Side Operator’s Panel

Rev 0

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Operator Manual

Machine Orientation Controls and Functions

Control Locations

4.2.15 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.

2.

3.

4.

The transmission is in neutral.

The park brake is applied.

The engine safety shutdown circuit shows no fault.

The ON/OFF valve is “ON”.

NOTE

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.

BUCYRUS Australia 2008©

4.2.16 Air Starting Pressure Gauge This gauge indicates the air starting pressure in the air receiver. Normal air pressure is set at 760860 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.

4.2.17 On/Off Toggle Switch The ON/OFF switch controls the supply of pilot air pressure to the air pressure switch on the Electronic Safety System, which allows air to pilot the starter motor.

1.

2.

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

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

Air Starting Pressure Gauge Engine Start Button

On/Off Toggle Switch

Figure 4.2.15.1 - Right Hand Side Operator’s Panel

Rev 0

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Machine Orientation Controls and Functions

Control Locations

4.2.18 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: 1.

2.

Bring the machine to a halt, lower the RAS attachments to the ground and apply the park brake.

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

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

BUCYRUS Australia 2008©

CAUTION

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

4.2.19 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 five minutes. The engine must also be shut off and cooled when the coolant level is to be topped up.

WARNING

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

Transmission Oil Temperature Gauge

Engine Coolant Temperature Gauge

Figure 4.2.18.1 - Left Hand Side Operator’s Panel

Rev 0

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Machine Orientation Controls and Functions

Control Locations

4.2.20 Exhaust Coolant Temperature Gauge This shows the coolant temperature circulating through the engine, exhaust cooling system. Normal operating temperature is between 70ºC-85ºC. The engine should not be operated under heavy load until it has time to warm up approximately five minutes.

WARNING

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

4.2.21 Operator’s Horn Button Pushing this button sounds the air horns.

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Horn Button

NOTE

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

4.2.22 Emergency Fuel Shut-off Valve This valve is located after the fuel filter/water separator. Closing this valve will stop the flow of fuel to the engine. This provides a second means of shutting down the engine should the ON/OFF toggle switch fail.

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Machine Orientation Controls and Functions

Control Locations

4.2.23 Engine Service Hour Meter This electric meter is mounted on the off operator’s side at the rear of the FBL-10. Use the hour meter to determine servicing intervals.

BUCYRUS Australia 2008©

Figure 4.2.23.1 - Engine Hour Meter

Air Cleaner

Air Cleaner Service Indicator

Figure 4.2.24.1 - Air Cleaner and Indicator

4.2.24 Air Cleaner Service Indicator The air cleaner service indicator is located at the air cleaner and indicates the condition of the air cleaner element. When the service indicator is in the RED zone, the air cleaner elements should be removed and serviced.

Rev 0

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Machine Orientation Controls and Functions

Control Locations

4.2.25 Exhaust Back Pressure Gauge The exhaust back pressure gauge located in the operator’s compartment indicates the condition of the filter element. When the back pressure is above 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 back pressure gauge reads above 10 KPa and clean the flame trap.

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NOTE

Dirty filters should be disposed of correctly. Appropriate Personal Protective Equipment should be worn. Operators should minimise skin contact with dirty filters. The dirty element should be placed in the plastic bag that is supplied with the new filter, completely seal. The contaminated element must be removed from the underground environment and disposed of safely.

4.2.26 Engine Oil Pressure Gauge This gauge indicates the engine lubricating oil pressure. Normal pressure is between 207 kPa-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.

CAUTION

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

Immediately report the problem to service personnel.

Engine Oil Pressure Gauge

Rev 0

Exhaust Back Pressure Gauge

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Machine Orientation Controls and Functions

Control Locations

4.2.27 Engine Hand Fuel Primer Pump

BUCYRUS Australia 2008©

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 4.2.28.1. -Engine Hand Fuel Primer Pump

4.2.28 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.

4.2.29 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 two seconds.

RAS Pressure Release Valve

Rev 0

RAS Pilot Lock Cylinder Release Valve

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Machine Orientation Controls and Functions

Control Locations

4.2.30 Emergency Intake Shut Off Valve

BUCYRUS Australia 2008©

This valve is used in the event that the machine fails to shutdown under normal circumstances as stated in Section 8. Closing this valve will stop the flow of air to the engine. This provides a second means of shutting down the engine should the ON/OFF toggle valve fail.

Figure 4.2.31.1 - Emergency Intake Shut Off Valve Activation Button

Figure 4.2.31.2 - Emergency Intake Shut Off Valve Reset Lever

The valve is activated from the operator’s compartment by a button which is pushed, once activated and the engine shuts down the valve will need to be reset before restarting. Ensure that the button in the operator’s compartment has been pulled out and there is a lever down on the main body of the valve that will rotate and latch into the operating position. If the valve has not been reset the engine will not start. When valve has been reset the engine can be started.

WARNING

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

Rev 0

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Machine Orientation Controls and Functions

Control Locations

4.2.31 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 machine with a second means of shutting down the engine should the ON/OFF toggle switch fail.

BUCYRUS Australia 2008©

Emergency Fuel Shut Off Valve

Figure 4.2.28.1—Fuel Shut Off Valve

4.2.32 Engine Service Hour Meter This electric meter is mounted on the off operator side at the rear of the machine. Use the hour meter to determine servicing intervals.

Figure 4.2.29.1 - Engine Hour Meter

4.2.33 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 Service

Figure 4.2.30.1 - Air Cleaner and Indicator

Rev 0

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5.

Machine Isolation

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

5.1

Engine Isolation

To isolate the engine perform the following procedure:

BUCYRUS Australia 2008©

1.

2.

3.

4.

5.

6.

Select “NEUTRAL” on transmission directional control lever.

Apply the “Park Brake”.

Shutdown the diesel engine.

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

Connect the steering lock and chock the wheels.

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

Figure 5.1.1 - Air Pressure Isolation and Indication in Operator’s Compartment

Main Isolation Valve

Main Drain Valve

Figure 5.1.2 - Main Air Manifold

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5.

5.2

Machine Isolation

Pneumatic Isolation

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

2.

3.

4.

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.

Locate the pneumatic air receiver at the rear of the engine bay on the operator’s side of the machine.

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

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

NOTE

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

BUCYRUS Australia 2008©

WARNING

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

Main Isolation Valve

Main Drain Valve

Figure 5.2.1 - Main Air Manifold

Rev 0

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5.

5.3

Machine Isolation

Hydraulic Isolation

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

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

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.

Observe both steering and brake pressure gauges located in the operator' s compartment. The hydraulic system features a steering and brake accumulator automatic bleed circuit which will remove hydraulic pressure from both accumulators once the diesel engine has stopped. This normally takes around 30 seconds. The steering and brake accumulators can also be bled via rotation of the steering wheel and actuation of the service brake pedal, once the engine has been shutdown.

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

2.

3.

4.

WARNING

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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 5.3.1 - Steering and Brake Accumulator Pressure Indication Gauges

Rev 0

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5.

5.4

Machine Isolation

Engine and Heat Exchanger Coolant Isolation

To isolate the engine and heat exchanger cooling systems 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.

Isolate the pneumatic circuit as described in Section 5.2.

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

Remove coolant circuit pressure (105 kPa) by slowly lifting up the RED relief lever on the filler cap and hold up till pressure is released Slowly remove filler cap with relief vale held in the up position.

2.

3.

4.

5.

WARNING

BUCYRUS Australia 2008©

The coolant fluid will be under pressure and hot (up to 100oC). Always relieve pressure by lifting the relief valve on pressure cap before removal. Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves to avoid scalds and burns from hot coolant.

Engine Coolant Relief Cap

Exhaust Coolant Relief Cap

Figure 5.4.1 - Coolant Header Tank and Pressure Relief Valves

Rev 0

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5.

5.5 1.

2.

Machine Isolation

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

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

WARNING

The electrical system installed on this machine is approved/certified as explosion protected for use in Australian underground coal mines and may cause an atmospheric explosion if not maintained and used in its approved state. Such equipment is to be inspected and maintained in accordance with the relevant regulatory authorities rules and regulations and the conditions for which the apparatus has been approved.

NOTE

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

BUCYRUS Australia 2008©

NOTE

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

Rev 0

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5.

Machine Isolation

5.6

Articulation Isolation or Steering Lock

5.6.1

Fitting and Removal of Steering Lock

To fit the steering lock: 1.

2.

3.

4.

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

Locate the steering lock at the articulation area on the off operator’s side of the machine and remove the locking clamp on the bottom location Swing the steering lock up until it lines up with the pin location on the rear half of the machine.

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

To remove the steering lock: 1.

2.

With the park brake applied, remove the lynch pins from the locating pins and swing the bar down to locate on the lower locating pin.

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

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WARNING

The articulation area of this machine can cause fatal crush injuries if extreme caution is not observed. Always ensure that the park brake is applied and the operator’s compartment is vacant when accessing the articulation area to fit or remove the steering lock.

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

Figure 5.6.1.1 - Articulation Lock in Locked Position

Rev 0

Figure 5.6.1.2 - Articulation Lock in Stored Position

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5.

Machine Isolation

5.7

Lift Arm Isolation or Lift Arm Lock

5.7.1

Fitting and Removal of Lift Arm Lock

To fit the lift arm lock: 1.

2.

3.

4.

5.

6.

7.

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

Chock the wheels Fit the articulation lock (see 5.6.1) Raise the lift arm until the locking pin holes are in line with holes in the front frame and the pins can be placed through the lift arm on both sides in the location points as shown in Figure 5.7.1.1.

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

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

It is now safe to work under the lift arm

To remove the lift arm lock:

BUCYRUS Australia 2008©

1.

2.

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

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 shutdown, 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

! " #%$ $ &

Rev 0

Figure 5.7.1.2 - Storage Position on Both Front Guards

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6.

Pre Start Procedure

Walk around the machine: a. b. c. d. e. f.

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

Look for damaged or missing wheel nuts and studs.

Check for loose wheel nuts.

Guards and covers are in place and secure.

Missing or loose fasteners.

Oil leaks.

Check the hydraulic reservoir oil level: a. b. c. d. e.

Be sure the machine is on level surface when checking fluid level.

Ensure the lift arm is in the lowered position, the engine is turned off and the machine is isolated as per Section 5.2 - Pneumatic Isolation.

Check the level at normal operating temperature.

When the fluid level has dropped below the mark shown in Figure 6.1, add hydraulic oil to restore the correct operating level.

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

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CAUTION

ALWAYS Use the specified lubricant for the application and the regions seasonal temperatures. (See Section 23).

Figure 6.2 - Hydraulic Tank Fill Point Figure 6.1 - Hydraulic Level Sight Gauge

Rev 0

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6.

Pre Start Procedure

Check the engine oil level: 1.

2.

3.

4.

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

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

Ensure the correct engine oil is used. Oil specifications are listed in the Section 23 - Fluid Specifications Table.

Do not over fill.

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

CAUTION

BUCYRUS Australia 2008©

ALWAYS Use the specified lubricant for the application and the regions seasonal temperatures. (See Section 23).

Figure 6.4 - Engine Oil Dipstick

Figure 6.3 - Engine Oil Filler Cap

Rev 0

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6.

Pre Start Procedure

Check the fuel level: 1.

2.

3.

Gauge fitted to the fuel tank.

Check the filler cap is secure and not damaged.

Ensure the filler cap seal is in place.

CAUTION

Do not operate the loader with the fuel level below empty level on the fuel tank.

It is recommended procedure to fill the fuel tanks at the end of each shift.

CAUTION

ALWAYS Use the specified lubricant for the application and the regions seasonal temperatures. (See Section 23).

Check the condition and tension of the water pump drive belts: Located at the rear of the machine behind the rear hinged door.

Damaged or loose belts should be reported to maintenance personnel.

BUCYRUS Australia 2008©

1.

2.

Level Gauge and Filler Cap

Figure 6.5 - Fuel Sight Gauge

Figure 6.6 - Water Pump Drive Belt

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

Check the condition of the fuel water separator: a. b.

Located at rear operator’s side of machine.

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

Figure 6.7 - Fuel Water Trap Rev 0

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6.

Pre Start Procedure

Check the articulation safety lock bar (see Section 5.6): 1.

2.

For proper storage and loose fasteners.

For damage.

Check the lift arm safety lock bars (see Section 5.7): 1.

2.

For proper storage and loose fasteners.

For damage.

Filler Cap

Check the expansion tank coolant level: a. b. c. d.

Ensure coolant is to correct level on sight gauge (2/3rds).

Check for coolant leaks.

Ensure to correct coolant mix is being added if required.

Sight Gauge Report to maintenance if coolant is low.

BUCYRUS Australia 2008©

Check the radiator: 1.

2.

For coolant leaks.

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

Figure 6.8 - Coolant Expansion Tank

Check the headlights: 1.

2.

Check lights are securely mounted.

Check cables and glands for damage.

CAUTION

ALWAYS Use the specified lubricant for the application and the regions seasonal temperatures. (See Section 23).

Check the air cleaner (see Section 4.2.24): 1.

2.

3.

Filter condition indicator.

Replace filter element if indicator is in the red area.

Intake pipes and hoses for loose or damaged connections.

Figure 6.9 Air Cleaner and Indicator

WARNING

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

Rev 0

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6.

Pre Start Procedure

Check air receiver: 1.

2.

For damage.

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.

BUCYRUS Australia 2008©

Main Drain Valve Figure 6.10 - Main Air Manifold

Check the fire extinguisher: 1.

2.

3.

4.

Located on front operator’s side mudguard.

Check inspection date.

Check contents indicator is reading in the green area.

If fire suppression system fitted check actuation points.

Fire Extinguisher

Fire Suppression

Rev 0

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6.

Pre Start Procedure

The dry exhaust conditioning system on the FBL-10 carries out four major functions: • • • •

To cool and dilute exhaust gases.

To act as an approved flame trap.

To prevent hot gases from entering the mine atmosphere.

To filter out particulates to prevent them entering the mine atmosphere.

CAUTION

BUCYRUS Australia 2008©

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

Figure 6.11 - Exhaust Gas Flow

Check Exhaust System • • • • • •

Check for damage.

Check Joints for signs of leakage.

Check cooling hoses for security and condition.

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

Check the drain and flushing plugs are fitted.

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

WARNING

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

Rev 0

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6.

Pre Start Procedure CAUTION

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

Plug

Plug

Heat Exchanger drain plug

BUCYRUS Australia 2008©

Flushing Plug

Filter Lid Lock Pin in Position

Filter Lock Pin

WARNING

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

Rev 0

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6.

Pre Start Procedure CAUTION

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

Safety clip fitted

BUCYRUS Australia 2008©

Flame trap nut handle below the spring returned safety pin

Figure 6.12 - Flame Trap in Location on Machine

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

Rev 0

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6.

Pre Start Procedure

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

CAUTION

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

WARNING

BUCYRUS Australia 2008©

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

Figure 6.14

Emergency Intake Shut Off Valve Reset Lever

Figure 6.13 Emergency Intake Shut Off Valve Activation Button

Rev 0

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7.

Operator Manual

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.

BUCYRUS Australia 2008©

5.

Turn the air system isolation valve, located at the main air manifold 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 207 kPa (30 PSI) the engine may not start. If the air pressure is below 207 kPa, recharge the air receiver up to max 890 kPa (120 PSI).

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

NOTE

The SEMs display lights will not activate if the air pressure is below 207 KPa.

6.

7.

8.

9.

10.

Wait for the shutdown system display RUN SOLENOID LED to go off (approximately 30 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 fired.

Check the CHARGE FAILURE, EXHAUST COOLANT FLOW and ENGINE OIL PRESSURE display LEDS has gone out.

Carry out Post Start checks and operate machine normally.

SEE SECTION 22.1 OPERATING SEMs 02

CAUTION

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

Rev 0

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Operator Manual

Engine Starting Procedure 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.

WARNING

BUCYRUS Australia 2008©

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

Rev 0

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8. Post Start Checks The following test are required to be performed with the engine running: 1.

Check all gauges are on correct operational pressure: a.

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

2.

Check Function of Lift Arm Assembly Hydraulic system:

3.

Check steering function.

4.

Check park brake operation, gauge must read 11377 KPa (1650 PSI) with brake off: a.

5.

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

BUCYRUS Australia 2008©

6.

To test move off slowly and apply the park brake.

There are two forward and rear facing headlights.

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

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

Always check when the transmission is warm.

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

Place the machine in neutral and apply the park brake Access the dipstick from the operator’s compartment through the 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.

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

Re-insert 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.

CAUTION

ALWAYS Use the specified lubricant for the application and the regions seasonal temperatures. (See Section 23).

Dipstick Access

Figure 8.1 - Transmission Oil Level Rev 0

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8. Post Start Checks 7.

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

Locate the indicator in the operator’s compartment.

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

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

WARNING

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

8.

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

BUCYRUS Australia 2008©

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

Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 5.1 - Engine Isolation.

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

Place a large garbage bag over the filter housing until the base of the bag is at the top of the housing Grasp the filter element through the garbage bag base and raise the filter element clear of the housing, ensuring that the garbage bag covers the filter element as it is raised.

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

Discard the used element in the appropriate manner.

Place the new filter element inside the housing.

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

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

WARNING

Wear suitable eye protection, gloves and dust mask when performing filter replacement as particulate caught by the filter may be harmful to the respiratory system.

Immediately wash any particulate matter from skin with warm, soapy water.

NOTE

The filter has a bypass system that allows the exhaust to bypass the filter for pressures over 80 KPa (11 PSI). Extended operations with the filter in bypass should be avoided.

Remove the filter if the back pressure gauge reads above 10 KPa.

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

If exhaust shutdowns occur regularly, check the exhaust filter back pressure and replace if necessary. The machine may require the heat exchanger to be cleaned if the exhaust shutdowns continue.

NOTE

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

WARNING

BUCYRUS Australia 2008©

Wear suitable personal protective equipment when servicing heat exchanger including dust masks, gloves and safety glasses.

WARNING

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

Check the shutdown system operation: a. b. c. d.

Run the engine at high idle.

Press the shutdown test button and hold for ten seconds.

Machine should shutdown and the low oil pressure LED light should be on.

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

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

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9.

1.

2.

3.

4.

5.

Operator Manual

Stopping the Engine

Lower the lift arm assembly and 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 idle speed for five minutes. This will allow internal temperatures to reduce gradually.

NOTE

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

6.

7.

Turn the ON/OFF toggle valve located on the instrument panel to the OFF position and the engine will shutdown.

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

BUCYRUS Australia 2008©

WARNING

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

NOTE

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

8.

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

WARNING

Ensure the attachment 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.

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10. Tramming the Vehicle 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 DIRECTION CONTROL LEVER and a SPEED CONTROL LEVER. The machine has the same gear ratios in forward and reverse. This is to provide equal speeds and performance in each direction.

The engine should be at idle and the vehicle stationary when either FORWARD or REVERSE gears are selected.

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

WARNING

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

6.

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

BUCYRUS Australia 2008©

NOTE

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

CAUTION

ALWAYS ensure that the transmission control levers are fully shifted.

7.

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

Momentarily decrease engine revs when selecting a lower gear.

8.

If the transmission should over heat: a. b. c.

Stop machine in a suitable place and apply park brake.

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

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

WARNING

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

NOTE

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

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11. Stopping and Braking 1.

2.

3.

4.

5.

6.

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 shutdown from full load. To stabilise temperatures allow it to idle for a few minutes before stopping.

Shut off the engine by turning OFF the ON/OFF toggle valve.

After stepping off the machine, switch off the main 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

BUCYRUS Australia 2008©

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

NOTE

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

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

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Use the gears to help slow the machine.

Lower the implement/attachment.

Gradually turn machine to the rib.

Apply the park/emergency brake.

Shutdown the engine.

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12. Driving on a Ramp 1.

2.

3.

4.

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

Always use a low gear when travelling down a ramp.

Avoid changing gears while travelling on a steep ramp.

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

Immediately apply the service brakes.

If they do not function, apply park/emergency brake.

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

NOTE

Operators must be competent in Emergency Stop Procedure.

WARNING

BUCYRUS Australia 2008©

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

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13. Parking on a Ramp WARNING

Do not park on a ramp unless absolutely necessary.

1.

2.

3.

4.

5.

6.

7.

Use the engine braking to help slow down the vehicle by letting up on the throttle pedal.

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

Turn the vehicle toward the rib.

If possible remove the load from the attachment.

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

Inform mine management of the position of vehicle.

WARNING

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

WARNING

BUCYRUS Australia 2008©

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

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14. Loading The LHD method of loading is called “crowd loading” which combines the tractive effort of the machine with the 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 15000 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.

NOTE

ALWAYS when mucking from a pile, work from both sides towards the centre.

Keep it trimmed at all times.

BUCYRUS Australia 2008©

NOTE

DO NOT ram the muck pile or spin the tyres.

WARNING

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

WARNING

DO NOT use the machine to bar down a hang up.

NOTE

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

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14. Loading Loading a Bucket: 1.

2.

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

Slowly crowd the bucket back as the machine pushes into the muck pile until the bucket is full and is in the carry position. If the tyres start to spin, let up on the accelerator pedal slightly as you move the bucket crowd control slightly faster.

WARNING

DO NOT exceed the machine’s carry capacity.

NOTE

Undercut a muck pile. A sudden flow of muck can trap the machine in a draw point and lift the rear of the machine violently against the roof or may swamp the operator.

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.

BUCYRUS Australia 2008©

3.

Figure 14. - FBL-10 Fully Loaded with Bucket in the “Carry” Position

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15. Dumping CAUTION

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

15.1 Standard Dumping 1.

2.

3.

4.

5.

6.

7.

As you approach to dump a load, remove 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 lift arm 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 load.

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

WARNING

BUCYRUS Australia 2008©

DO NOT carry load with the boom in a raised position.

15.2 Ejecting 1.

2.

3.

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

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

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

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16. Towing the Vehicle when Disabled WARNING

Set the park brake, lower the attachment 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 metres: a. b. c.

Connect the machine to the towing vehicle.

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

NOTE

BUCYRUS Australia 2008©

The brakes can be released with a Porta Power maximum 12756 kPa (1850 PSI) connected into the pressure port on the brake valve. The operator is to stay in the operator’s compartment to apply the service brake or park brake if necessary.

If these are applied the Porta Power needs to be pumped to (minimum 1650 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.

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16. 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.

CAUTION

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

NOTE

BUCYRUS Australia 2008©

Maximum towing speed is 3 kph.

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17. Towing with the Vehicle WARNING

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

NOTE

Maximum towing speed is 3 kph.

1.

2.

3.

BUCYRUS Australia 2008©

4.

5.

6.

7.

8.

9.

10.

11.

Ensure the machine is parked and isolated prior to connecting the trailer or load, park brake ON. Attach the load to the rear tow hitch, ensure tow pin is secure.

The trailer or load should be secured by 2 x 10 Tonne safety chains in a straight line pull in addition to a rated draw bar for the task.

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

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

Both chains must be used for maximum tractive effort pull.

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

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

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

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

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

CAUTION

ALWAYS connect the trailer or load before releasing the park brakes. Make sure the park brake is re-applied before the towing vehicle is disconnected.

WARNING

For towing of loads greater than 10,000kg the mass must be braked. Prior to towing loads in excess of 10,000kg consult BUCYRUS Australia Pty Ltd.

CAUTION

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

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

2.

3.

4.

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

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

Tighten and secure the priming pump.

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

NOTE

BUCYRUS Australia 2008©

Check the fuel tank contents gauge before venting the system.

Figure 18.1 - Fuel Priming Pump

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19. Air Venting the Engine Cooling System To prevent an air lock in the engine coolant system, the cooling systems automatically bleed 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 Table.

NOTE

Add water conditioner as necessary.

NOTE

BUCYRUS Australia 2008©

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

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20. Attaching Implements 1.

2.

3.

4.

5.

6.

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

Check that the RAS locking tongue is retracted.

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 mm-1500 mm above the ground.

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

WARNING

Do not stand underneath the raised lift arm.

WARNING

BUCYRUS Australia 2008©

NEVER walk under the attachment or lift arm

Implement Upper Cradle

Top Lip of RAS Cradle

Figure 20.1 - Attachment Cradle

Figure 20.2 - RAS Attach Hoses

NOTE

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

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20. Attaching Implements 7.

8.

9.

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 be connected to the hydraulic system of the attachment. (e.g. Push plate bucket).

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

NOTE

BUCYRUS Australia 2008©

If a man riding basket has been fitted an operational test on the emergency stop valve inside the basket must be performed before the attachment can be put into service.

Figure 20.4 - Man Basket E-Stop Connection Point

20.3 - Man Basket E-Stop

Figure20.5 - E-Stop Connection Point on RAS Cradle

The Emergency Stop valve on the man riding basket is connected to the machine via a hose from the basket to the RAS cradle as shown in Figures 20.4 and 20.5, ensure the hose has free movement through the hydraulic function tests.

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21. Detaching Implements 1.

2.

3.

4.

Ensure the area that the implement is to be stowed 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.

Enter the cabin.

Release park brake Depress the RAS unlock valve and at the same time pull the RAS lock release lever (Hydraulic PTO closest to the operator).

Select reverse and first gear .

Drive away from the attachment whilst rolling the RAS cradle forward.

8.

9.

WARNING

BUCYRUS Australia 2008©

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

Figure 21.2 - Fuel Pod Disconnected Figure 21.1 - Belt Reeler Attached to FBL-10

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22 Safety System 22.1 Safety Shutdown The intrinsically safe electronic monitoring system monitors the atmosphere for methane and controls the engine shutdown and will light the appropriate indicator on the LEDs on the display panel.

BUCYRUS Australia 2008©

The following sensors are fitted to the machine: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Hi Methane Shutdown (1.25%) Lo Methane Warning (1%) Charge Failure Engine Oil Pressure Exhaust Coolant Flow Engine Coolant/Hydraulic Oil Level Exhaust Coolant Temperature Engine Coolant Temperature Heat Exchanger Gas Temperature Flame Trap Gas Temperature Exhaust Outlet Temperature Run Solenoid Start Fault

Shuts engine down Warning light Warning light Shuts engine down Shuts engine down Shuts engine down Shuts engine down Shuts engine down Shuts engine down Shuts engine down Shuts engine down Warning light Warning light

Figure 22.1.1 - Operator Display Panel

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22 Safety System 22.2 System Operation 1.

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

This will activate the SEMs electronics.

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

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

• • • • • •

2.

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

BUCYRUS Australia 2008©

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

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

WARNING

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

b. c.

3.

Start Engine: a. b. c.

Rev 0

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

With the machine in neutral it can now be started.

Activate the operators start valve and start engine.

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

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22 Safety System 22.2 System Operation WARNING

If any of the LEDs remain illuminated after starting they should be reported to the maintenance staff.

NOTE

The SEMs Display lights will not activate if the air pressure is below 250 kPa.

NOTE

BUCYRUS Australia 2008©

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

Figure 22.2.1 - SEMS 11 Operator Display Panel

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22 Safety System 22.2 System Operation 4.

To shutdown machine: a.

BUCYRUS Australia 2008©

b.

When shutting down the machine, turn off the ON/OFF valve (Toggle Switch). This will unpower the SEMs and the start solenoid and stop the machine.

Turn the main isolating air valve off.

Figure 22.3 - Start/Reset Valve (Toggle Switch)

Figure 22.4 - Main Air Isolating Valve

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23. FBL-10 Fluid Specification Table SPEC.

1

COMPONENT

Engine

CAPACITY (Litres)

26

LUBRICANT

TEMPERATURE BELOW 0ºC

Engine Oil

BUCYRUS Australia 2008©

3

Transmission

Hydraulic

40

250

35

Mineral Gear Oil

Hydraulic

Mineral Gear Oil with Limited Slip Additive

4

Axle / Wheel Ends

5

Cooling System

72

Pre-mixed Coolant Conditioner

6

Fuel

200

Distillate “Diesel” Fuel

(Each Axle)

ABOVE 32ºC

SAE40

SAE50

API CD-II

API CD-II

API CD-II

(Valvoline - Super Diesel 15W -40 or Equivalent)

(Valvoline - All Fleet Premium 40 or Equivalent) SAE30

(Valvoline - All Fleet Premium 40 or Equivalent)

SAE10W

2

0-32ºC

SAE15W-40

CAT TO-4

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

(Valvoline Valtorque C4 30

ISO68

or Equivalent) ISO68

(Valvoline Ultramax HVI 46 or Equivalent)

(Valvoline Ultramax 68 or Equivalent)

SAE50 CAT TO-4 (Valvoline Valtorque C4 50 or Equivalent) ISO68 (Valvoline Ultramax 68 or Equivalent)

SAE90LS (Valvoline - HP Gear Oil LS SAE90 or Equivalent) Ethylene Glycol Antifreeze Inhibitor to GM 6038-M (Valvoline - Heavy Duty Coolant 50 or Equivalent) To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

Lube Points - Drive Line 7

- Pins / Bushes - Door Hinges

As required

Multi-purpose EP Grease

NLGI No. 0 or 1

NLGI No. 2

NLGI No. 2

(Shell - Alvania EP 0/1 or equivalent)

(Valvoline - Valplex EP 2 or equivalent)

(Valvoline - Valplex EP 2 or equivalent)

- Tow Pin - Diff Pinion Oil 8

Rev 0

Engine Drive Coupling

Refer Service Manual

High Temperature

NLGI no. 2 (Shell Stamina RL2)

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