Cat Seneca FBL-15 LHD UTILITY VEHICLE Operators Manual SN 9004 - PDF DOWNLOAD

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Technical Manual

BI643641

FBL-15 LHD / UTILITY VEHICLE

OPERATOR’S MANUAL UGM ENGINEERS PTY LTD Serial No.: 9004 Plant No.: UGM004

PRINT DATE: 22ND SEPTEMBER 2000 REVISION: 0 DOC NUMBER OM008/1-9004

SENECA AUSTRALIA PTY LTD PHONE: (02) 8796 7580 – SYDNEY PHONE: (02) 4964 8383 – TOMAGO

BI643641 SENECA FBL-15 SERIAL NO.: 9004 PLANT NO.: UGM004

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

INDEX 1.

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

INTRODUCTION……………………………………………………… 3

1.2

FBL-15 DESCRIPTION……………………………………………….. 3

1.3

FBL-15 DIMENSIONS………………………………………………… 4

1.4

FBL-15 SPECIFICATIONS…………………………………………... 8

2.

GENERAL SAFETY AND PRECAUTIONS…………………………………….. 15

3.

CONTROLS AND CONTROLS…………………………………………………. 17

4.

MACHINE ISOLATION….………………………………………………….…... 29

5.

PRE-START PROCEDURE………………………………………………….…... 34

6.

ENGINE STARTING PROCEDURE…………………………………………….. 37

7.

FUNCTIONAL TEST AFTER STARTING THE ENGINE…………………… 39

8.

SHUTTING DOWN THE ENGINE……………………………………………… 41

9.

TRAMMING THE MACHINE…………………………………………………… 42

10.

STOPPING AND BRAKING……………………………………………………… 43

11.

DRIVING ON A RAMP…………………………………………………………… 44

12.

PARKING ON A RAMP…………………………………………………………... 44

13.

LOADING…………………………………………………………………………... 45

14.

DUMPING………………………………………………………………………….. 46

15.

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

16.

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

17.

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

18.

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

19.

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

20.

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

21.

SAFETY SHUTDOWN SYSTEM…………………………………………………. 52

22.

PREVENTIVE MAINTENANCE SCHEDULE AND CHECKLISTS……….

23.

FBL-15 FLUID SPECIFICATION TABLE………………………………………. 59

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BI643641 SENECA FBL-15 SERIAL NO.: 9004 PLANT NO.: UGM004

UGM ENGINEERS PTY LTD

1.

GENERAL INFORMATION

1.1

Introduction

OPERATOR’S MANUAL

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-15 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-15 utility vehicle must be adequately maintained by the operators and service personnel. To achieve this, the Operator’s pre-start inspection procedure contained at the rear of this manual must be performed.

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

1.2

FBL-15 Description

The FBL-15 is a 15,000-kg capacity Load Haul Dump and utility vehicle that can be fitted with a number of attachments to allow it to load, carry and tow heavy loads, materials and supplies.

The attachments are fitted with the Rapid Attach System (RAS) to allow the quick and easy connection and disconnection to the FBL-15.

The motive force is provided by a 229 kW Detroit 6V92 six cylinder pre-combustion, turbo charged and supercharged 2-stroke “V6” FLAMEPROOF diesel engine package. Flame proofing of the system includes a “dry” exhaust conditioning system complete with exhaust and intake flame traps. The start and safety shutdown system is pneumatic. The engine power output is connected to the constant four wheel drive system via a drop box and drive coupling through a Clark 36000 model 4 speed bidirectional power shift transmission to Clark 19D heavy duty axles with liquid cooled POSI STOP brakes.

The FBL-15 utilises a dry exhaust system complete with a replaceable particulate filter and a catalytic exhaust post treatment purifier. The machine may be operated with or without the filter fitted. However to protect personnel in areas of limited ventilation, the replaceable exhaust filter should be fitted.

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1.3

FBL-15 Dimensions

1.3.1

FBL-15 General Arrangement

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1.3.2

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

FBL-15 10,000 kg Fixed Jib - General Arrangement

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1.3.3

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

FBL-15 15,000 kg Side Shift Forks - General Arrangement

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1.3.4

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

FBL-15 5 Cubic Metre Bucket - General Arrangement

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BI643641 SENECA FBL-15 SERIAL NO.: 9004 PLANT NO.: UGM004

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

1.4 FBL-15 Specifications Capacities Bucket Payload................................................................................................................12,000 kg RAS forks max, Payload .................................................................................................15,000 kg RAS Fixed Jib max Payload............................................................................................10,000 kg RAS Slewing Jib max Payload..........................................................................................8,000 kg RAS Belt reeler ...............................................................................................................12,000 kg Standard Ejector Bucket Heaped capacity (SAE) .......................................................................................................... 5 m3 Struck capacity ....................................................................................................................... 4 m3 Break out force std bucket tip (Hydraulic)......................................................................15,000 kg Tractive effort, Maximum ..............................................................................................27, 145 kg

Bucket Motion Times Lift to full raised position...................................................................................................7.0 secs Lower fully to floor ............................................................................................................4.0 secs Roll bucket fully back ........................................................................................................7.0 secs Roll bucket fully forward ...................................................................................................5.0 secs Weight Operating with bucket only .............................................................................................29,000 kg Operating without bucket ................................................................................................26,500 kg

Engine Type.......................................................................................Diesel, Turbo/super charged,2 cycle Cooling system .............................................................................................. Water based radiator Cooling fan ..................................................................................................Engine belt driven fan Engine Make/model .................................................................................................. Detroit 6V92 Displacement .................................................................................................................... 9.05 litre Maximum power. ..........................................................................................227 kW @ 2100 rpm Maximum torque .........................................................................................1200 Nm @ 1500 rpm Ventilation (NSW Req) ...................................................................................................... 14 m3/s

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Engine Speeds Low idle............................................................................................................................. 650 rpm High idle .......................................................................................................................... 2200 rpm Governed ......................................................................................................................... 2100 rpm Stall Speeds Converter stall ................................................................................................................. 2100 rpm Full stall........................................................................................................................... 1700 rpm Hydraulic stall ................................................................................................................. 2050 rpm Fuel Consumption At full power ................................................................................................................65 Litres/hr Average mine duty ................................................................................................. 35-55 Litres/hr Start System Starting control .............................................................. Neutral start interlock pneumatic control Starter motor type................................................................................................ Air (Startmaster) Intake System Type / Make........................................... Dry single element (standard) – dual element (optional) Intake flame trap.................................................................................... Replaceable crimp ribbon Exhaust System Type................................................................................................................Flameproof dry type Make.....................................................................................................................Seneca Australia Exhaust filter ...................................................................................... Seneca replaceable element Exhaust flame trap / after treatment ......... Single element water cooled catalytic exhaust purifier Transmission Type.................................................................................. Power shift with Fwd/Rev modulation.

Make/model...................................................................................................................Clark 3600 Speeds, forward and reverse..........................................................................................................4 Gear ratios .............................................................................................5.325, 2.219, 1.263, 0.718

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OPERATOR’S MANUAL

Torque Converter Type............................................................................................. Mounted in trans single element Make/model...................................................................................................... Clark 14.1 integral Stall ratio ............................................................................................................................ 2.715:1 Offset ratio.......................................................................................................................... 1.000:1 Axles Type..................................................................................................................Outboard planetary Front axle make/model ...................................................................................................Clark 19D Rear axle make/model ....................................................................................................Clark 19D Diff. type ..................................................................................................... Bevel gear and pinion Diff. lock type Front..............................................................................................POSI TORQUE Diff. lock type Rear ...............................................................................................POSI TORQUE Overall ratio.................................................................................................................... 25.8692:1 Wheels Make/model....................................................................................5 piece split rim (Heavy Duty) Tyres – Standard Type..................................................................................................... Michelin X mine D2 radial Size ...................................................................................................................................20.5 x 25 Inflation media .......................................................................................................................... Air Inflation pressure...........................................................................120 P.S.I. front / 120 P.S.I rear Tyres - Optional Option 1

Type..........................................................................................................Setco solid Size........................................................................................... 1220 diam x 510mm

Option 2

Type................................................................................ Michelin X mine D2 radial Size..............................................................................................................23.5 x 25 Inflation media ..................................................................................................... Air Inflation pressure......................................................120 P.S.I. front / 120 P.S.I rear

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BI643641 SENECA FBL-15 SERIAL NO.: 9004 PLANT NO.: UGM004

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Hydraulic System Circuits Steering / Brakes ....................................................................................... Closed centre 17.2MPa Bucket / Lift..................................................................................................Open centre 20.7MPa PTO ..............................................................................................................Open centre 20.7MPa Tank................................................................................................. Sealed and pressurised 50kPa Filtration Steering / brakes ...................... Pressure type, in line, 5 micron, replaceable with 350kPa bypass Bucket / lift............................... Return type, in line, 10 micron, replaceable with 172kPa bypass PTO ...............................................................................................In line 10 micron (return filter) Tank suction ..................................................................................................... Filler neck strainer Bucket/Lift System Pump Type..................................................................................................Fixed displacement gear type Output at 2100rpm................................................................................. 176 lpm @ 1:1 drive ratio Steering/Brake System Pump Type.......................................................................................... Pressure compensated piston type Output at 2100rpm................................................................................. 104 lpm @ 1:1 drive ratio Cylinders Type.......................................................................................................................... Double acting Rods........................................................................................... Case hardened and hard chromed Steering – 2 off .................................... 89 mm bore, 708 mm stroke, 44 mm rod with cushioning Lift – 2 off ...................152 mm bore, 564 mm stroke, 76 mm rod with load lock and cushioning Dump – 2 off ........................................ 152 mm bore, 900 mm stroke, 76 mm rod with load lock RAS lock tongue – 1 off................90mm bore, 145mm stroke, 45mm rod with check valve lock Steering / Brake System Accumulators Type.......................................................................................................................................Piston Quantity ............................................................................................... 1off brakes & 1off steering Capacity........................................................................................ 2 litre brake and 5 litre steering Pre-charge pressure ............................................................................................................ 6.2MPa Steering System Type.......................................................................................................Closed Centre, articulated Actuation ............................................................................................................................. Orbital Cross over relief ............................................................................................................... 17.2MPa

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Hydraulic System Main Valve Bank Type............................................................................................................. Closed centre / in line Actuation ....................................................................................................Remote hydraulic pilot Main relief ........................................................................................................................ 20.7MPa Port reliefs ........................................................................................................................ 22.1MPa Service Brake Type....................................4 × Totally enclosed, liquid cooled POSI-STOP (at each wheel end) Application .......................................................... Spring applied, hydraulic release front and rear Actuation .......................................................................................Foot pedal, reverse modulating Park and Emergency Brake Type....................................4 × Totally enclosed, liquid cooled POSI-STOP (at each wheel end) Application .......................................................... Spring applied, hydraulic release front and rear Actuation .............Loss of pneumatic or hydraulic pressure / hand control / cab door interlocked Articulation Bearing type and size ........................ Pin and spherical bearing (top), bush (bottom) fully sealed Bush material...........................................................................................................Hardened steel Pin material..............................................................................................................Hardened steel Articulation range...............................................................................................................+ / - 450 Oscillation Type............................................................................................. Clark rear axle mounted trunion Bush material...........................................................................................................Hardened steel Pin material..............................................................................................................Hardened steel Oscillation range..................................................................................................................+ / - 90 Seating Type................................................................................. Cross seated driver / forward passenger Suspension....................................................Adjustable spring with shock absorber (driver only) Seat belts........................................................................................................Driver and passenger Canopy Type..................................Adjustable class 2 protective device to MDG1 (driver and passenger)

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Electrical System Type...........................................................................Approved explosion protected (flameproof) Voltage ..................................................................................................................12V dc nominal Polarity .............................................................................................................................. Floating Lights Type......................................................................................................................................... ATF Number / location.............................................................................2 forward / 2 rearward facing Alternator Type...........................................................................................................Mining Repairs 32 amp Drive / ratio .....................................................................................................................Belt / 2: 1 Hourmeter Type.............................................................................................................................. ATF / NHP Pneumatic System Compressor type............................................................................................. Water cooled piston Drive........................................................................................................ Gear driven from engine Air flow ...................................................................................................0.034m3/min @1500rpm Governed pressure...............................................................................................................793kPa Relief pressure.....................................................................................................................827kPa Air receiver volume..........................................................................................................150 litres Service Capacities Hydraulic tank ................................................................................................................... 300 litre Fuel tank ............................................................................................................................ 300 litre Transmission / converter oil ................................................................................................ 40 litre Drop box oil......................................................................................................................... 10 litre Engine crankcase oil............................................................................................................ 22 litre Engine coolant..................................................................................................................... 72 litre Axle oil (each) ..................................................................................................................... 60 litre Vehicle Speeds (with 20.5 × 25 tyres) 1st gear ................................................................................................................................ 3km/hr 2nd gear ............................................................................................................................. 11km/hr 3rd gear.............................................................................................................................. 17km/hr 4th gear .............................................................................................................................. 26km/hr

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Tractive Effort (with 20.5 × 25 tyres) 1st gear .............................................................................................................................27,145kg 2nd gear ............................................................................................................................11,311kg 3rd gear...............................................................................................................................6,438kg 4th gear ...............................................................................................................................3,660kg

Grade Ability Front to rear ........................................................................................................................... 1 in 4 Side to side (empty)............................................................................................................... 1 in 4 Side to side (laden bucket fully raised) ................................................................................. 1 in 8 Side to side (with load handling attachments) ...........................................Refer Seneca Australia

WARNING Overloading or misuse of equipment can cause personal injury, death or equipment damage. Due to the machines configuration or options the stated load capacities can vary up to 20%. Seneca Australia recommends that relevant community safety standards, practices and government regulations are observed when operating this equipment.

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

Only trained, authorised and competent personnel should operate and / or service this equipment.

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BI643641 SENECA FBL-15 SERIAL NO.: 9004 PLANT NO.: UGM004

2.

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

GENERAL SAFETY AND PRECAUTIONS

This section contains specific safety precautions that shall be followed whilst FBL-15 is being operated. This list is NOT all-inclusive and a measure of common sense should always be applied.

ONLY TRAINED AND AUTHORISED OPERATOR’S SHALL OPERATE THIS MACHINE. DO NOT

use the FBL-15 for any purpose other than its intended use.

DO NOT

for any reason exceed the indicated capacity of the FBL-15

DO NOT

operate the FBL-15 unless all operator checks and scheduled maintenance have been performed. Report any damage or faulty operation immediately and DO NOT operate the FBL-15 until the fault has been corrected.

DO NOT

operate the FBL-15 unless all operator checks and scheduled maintenance have been performed. Report any damage or faulty operation immediately and DO NOT operate the FBL-15 until the fault has been corrected.

DO NOT

use tie down or tow equipment such as chains or slings that are not rated for the capacity of the FBL-15.

DO NOT

operate the machine unless: (a) All covers and guards are correctly installed. (b) Personnel protective equipment is worn.

DO NOT

start the machine unless: (a) The area around the machine is clear. (b) The park brake is applied. (c) Transmission is in NEUTRAL. (d) All water and oil levels are checked.

DO NOT

leave the machine unless: (a) The vehicle is parked in a safe place. (b) The transmission is in NEUTRAL. (c) The park brake is applied. (d) The bucket is flat on the ground. (e) The engine is stopped.

ALWAYS

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

ALWAYS

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

ALWAYS

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

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

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 the machine.

ALWAYS

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

ALWAYS

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

ALWAYS

drive carefully and observe all managers transport rules.

ALWAYS

Ensure sufficient ventilation is available to dilute exhaust gases. A nominal 14m3/sec is recommended.

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BI643641 SENECA FBL-15 SERIAL NO.: 9004 PLANT NO.: UGM004

3.

3.1

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

CONTROLS AND FUNCTIONS Control Locations

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BI643641 SENECA FBL-15 SERIAL NO.: 9004 PLANT NO.: UGM004

3.2.1

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Driver’s Cabin Door

The operator’s cab door must be closed and locked after entering the cab and before the engine is started.

NOTE:

3.2.2

The machine will not start with the door open as there is a roller cam valve in the door lock, that needs to be activated, to release the park brake. The engine will continue to run after the door has opened.

Passenger’s Cabin Door

The operator’s cab door must be closed and locked after entering the cab and before the engine is started.

NOTE:

The machine will not start with the door opened as there is a roller cam valve in the door lock, that needs to be activated, to release the park brake. The engine will continue to run after the door has been opened.

Transmission directional control lever

Park/emergency brake

RAS release button

Transmission Gear Control lever

2 way hydraulic RAS control levers

4 way bucket control lever

Figure 3.2.1 Operator’s Console Layout

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BI643641 SENECA FBL-15 SERIAL NO.: 9004 PLANT NO.: UGM004

3.2.3

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Transmission Gear Control Lever

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

NOTE:

3.2.4

The transmission in the FBL-15 is modulated. This prevents severe shocks being transmitted through the drive train when the transmission is shifted between gears.

Transmission Directional Control Lever

A directional control lever controls the transmission. 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:

3.2.5

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

Driver’s Park Brake / Emergency Brake Control

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

NOTE:

3.2.6

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

Passenger’s Park Brake / Emergency Brake Control

The park brake valve is detented and has two positions, by pushing the button inwards, the park and emergency brake is applied, and by pulling the button out the will allow the operator to release the park/emergency brake.

NOTE:

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The park brake control in the drivers cabin cannot be released until the passenger’s cabin control is reset.

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Horn

OPERATOR’S MANUAL

Emergency brake

Figure 3.2.2 Passenger’s Cabin Layout 22 - 9 - 2000

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3.2.7

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Four Way Bucket Control Lever

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

NOTE:

3.2.8

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

No. 1 - 2 Way Hydraulic RAS Control Lever

There are 2 (two) hydraulic RAS (Rapid Attach System) control levers fitted to the machine.

The first lever closest to the driver is used to control attachments and engage and disengage the RAS attachment. This lever has three positions, UP, DOWN, and HOLD. Pulling the lever DOWN 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:

3.2.9

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.

No. 2 - 2 Way Hydraulic RAS Control Lever

The second lever, furthest from the driver, is used to control RAS attachments. This lever has three positions, UP, DOWN, and HOLD. 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.

3.2.10 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.

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

3.2.11 Accelerator Pedal The accelerator pedal is connected to the diesel engine fuel pump governor via a hydraulic slave and master cylinder system. When the accelerator pedal is depressed the engine speed increases. The throttle pedal is spring returned so that when pedal pressure is removed, the engine returns to low idle.

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

3.2.12 Brake Pedal The brake pedal when depressed applies the service brakes on the front and rear axles. There are four liquid cooled POSI STOP service brakes on the FBL-15 located internally in each axle.

Whenever possible use the engine compression to slow the vehicle on a grade or decline by revving the engine to speed after selecting a lower gear.

DO NOT:

Ride the service brakes while tramming the vehicle.

NOTE:

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

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

3.2.13 Orbital Steering Control Wheel The steering wheel controls the flow of hydraulic oil to the steering cylinders. As the cylinders stroke, the vehicle articulates to the LEFT or to the RIGHT. Turning the wheel ANTI-CLOCKWISE articulates the vehicle away from the driver. This effectively turns the vehicle to the LEFT in the forward direction (bucket end).

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

NOTE:

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

NOTE:

If the engine should stall, the machine is fitted with a system that will dump the steering pressure in under 10 seconds. The operator can steer the machine via a 6 litre back up accumulator at any time following an engine stall to immediately bring the vehicle to a safe controlled stop.

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NOTE:

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

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. It is also used to protect operators working on or near the RAS system with the engine running. Steering cannot be used until the doors are shut and latched and the park brake control reset to the OFF position.

3.2.14 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 9000 kPa (1300 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.

3.2.15 Brake Gauge Pressure This gauge indicates the service, park and emergency brake system oil and accumulator pressure. Normal operating system pressure is 17.2 MPa (2500 psi).

DO NOT:

Operate the vehicle if the brake pressure gauge is less than 17.2 MPa (2500 psi).

Immediately report the problem to service personnel.

3.2.16 Driver’s Horn Button Pushing this button sounds the air horns.

NOTE:

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

3.2.17 Passenger’s Horn Button Pushing this button sounds the air horns.

NOTE:

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The button is provided to warn the driver.

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

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

NOTE:

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

The transmission is in neutral 2.

The park brake is applied 3.

Both doors are closed and latched 4.

The engine safety shutdown circuit shows no fault 5.

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.

On/Off toggle switch

Engine start button

RAS pressure release button Figure 3.2.3 Right hand side of Driver’s Cabin Layout 22 - 9 - 2000

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3.2.19 Steering Pressure Gauge This gauge indicates the steering system oil and accumulator pressure. system hydraulic oil pressure is 17200 kPa (2500 psi).

NOTE:

The normal steering

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 immediately reported to service personnel.

3.2.20 Air Starting Pressure Gauge This gauge indicates the air starting pressure in the air receiver. Normal air pressure is set at 760 - 860 kPa (110-125 psi).

NOTE:

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

3.2.21 On / Off Toggle Switch The ON / OFF switch controls the supply of pilot air pressure to the safety shutdown circuit. To start the engine, place the switch in the ON position.

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

3.2.22 Transmission Oil Pressure Gauge This gauge indicates the transmission oil clutch pressure. Normal clutch pressure is between 1680 - 1930 kPa (240-275 psi).

3.2.23 Transmission Oil Temperature Gauge This gauge indicates the oil temperature in the transmission and torque converter Normal oil temperature is between 82ºC - 93ºC. If the temperature should rise above 121ºC, carry out the following procedure; (a) (b) (a)

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.

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

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

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

DO NOT:

Run the engine with low oil pressure as engine damage will result. Immediately report the problem to service personnel.

3.2.25 Engine Water Temperature Gauge This shows the coolant temperature circulating through the engine, exhaust and radiator systems. Normal operating temperature is between 82ºC - 95ºC. The engine should not be operated under heavy load until it has time to warm-up approximately 5 minutes.

WARNING: Shut off the engine immediately if the engine water temperature gauge goes above 105 ºC. The engine safety shutdown system should shutdown the engine at 100 ºC. The engine must also be shut off and cooled when the coolant level is to be topped up. Lift the pressure release lever on the second radiator cap on the make-up tank. After the pressure has been released open the main filler cap on the make-up tank slowly.

CAUTION:

HOT WATER UNDER PRESSURE, may spray out when releasing the cap.

3.2.26 Emergency Fuel Shut-off Valve This valve is located after the fuel filter / water separator. Closing this valve will stop the flow of fuel to the engine. This provides the FBL-15 with a second means of shutting down the engine should the ON - OFF toggle switch fail.

3.2.27 Engine Service Hour Meter This electric meter is mounted near the transmission. Use the hour meter to determine servicing intervals.

3.2.28 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.

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3.2.29 Exhaust Filter Service Indicator The filter service indicator is located on top of the exhaust filter housing and indicates the condition of the filter element. When the service indicator is up, the elements should be removed and serviced.

NOTE:

The FBL-15 complies with emission requirements with and without the filter fitted. It is recommended that for areas of minimal ventilation the machine should be operated with a filter fitted.

NOTE:

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

NOTE:

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

NOTE:

The diesel aerosol particulates can be safely handled when wet.

3.2.30 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 first RAS hydraulic PTO control lever to engage and disengage the RAS lock cylinder.

NOTE:

The button need not be depressed to lock (extend) the RAS lock cylinder.

3.2.31 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 and press in the release button for 2 seconds.

3.2.32 Engine Hand Fuel Primer Pump If the diesel engine fuel system has been run dry or serviced the fuel system should be primed via manual activation of the hand fuel primer pump. The pump is located adjacent to the fuel water separator in the engine compartment. Normally no priming is required to start the motor.

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Engine hand fuel primer pump

Figure 3.2.4 Engine Hand Fuel Primer

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4.

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Machine Isolation

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

4.1

Engine Isolation

To isolate the engine perform the following procedure: 1.

Lower the bucket / attachment to the floor.

2.

Shutdown the diesel engine.

3.

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

4.

Connect the steering lock and chock the wheels.

4.2

Pneumatics

1.

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

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

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.

2.

3.

4.

ON/OFF toggle valve

Air pressure gauge

Air pressure isolation and indication in drivers compartment

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CUSTOMER

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If work is required on the air receiver it will be necessary to remove air pressure from the receiver by actuating the drain valve located at the bottom of the air receiver. Stored air pressure will be safely released to the atmosphere. Ensure that the three way ball valve is not connected to an external pressure source.

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

3 way ball valve

Isolation valve

Isolation valves at the air receiver (drain valve located underneath)

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4.3

Hydraulics

1.

Completely lower / support 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.

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 thirty seconds. The steering and brake accumulators can also be bled via rotation of the steering wheel and actuation of the service brake pedal, once the engine has been shut down.

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

2.

3.

4.

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

Brake accumulator pressure

Steering accumulator pressure

Steering and brake pressure indication gauges

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4.4

Engine Coolant

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 4.2.

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

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

2.

3.

4.

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

Coolant fill point

4.5

Electrical

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.

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

2.

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.

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4.6

CUSTOMER

OPERATOR’S MANUAL

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 driver's compartment. Fit a danger tag to the ON/OFF toggle valve.

Locate the steering lock at the articulation area off-driver's side of the machine and remove it from its mounting by removing the clamp bar.

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

Install the two lynch pins through the retaining holes in the locating pins.

To remove the steering lock:1.

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

2.

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

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

FBL15 Steering lock in position

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5.

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

PRE-START PROCEDURE

Refer to preventive maintenance check list in Section 22.

5.1

Walk around the machine and check condition of all tyres. Inspect for sidewall cuts, tread cuts and separation. Check also for proper inflation pressures. Look for damaged or missing wheel nuts and studs.

5.2

Check the hydraulic reservoir oil level. a) Be sure the machine is level and the bucket and boom are fully lowered when checking fluid level. b) Check the level at normal operating temperature. c) Locate the fluid level gauge on the hydraulic tank side wall adjacent to the engine intake air cleaner. d) Observe the fluid level indicated in the sight glass. The level should be adjusted if the oil level is below the red line marked on the sight glass. To perform this function refer to the Service Manual for the FBL-15 and the fluid specification section in this manual.

Hydraulic Tank Sight Glass

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Check the fuel level on the gauge fitted to the fuel tank.

DO NOT:

OPERATE THE LOADER WITH THE FUEL LEVEL BELOW THE EMPTY LEVEL ON THE FUEL TANK. It is recommended procedure to fill the fuel tanks at the end of each shift.

Fuel Tank Fill Point

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5.4

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Check the engine oil level. a) Park the FBL-15 on flat, level ground b) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in section 4. c) Allow twenty minutes for the engine oil to return to the sump. d) Locate the remote fill gallery at the front of the engine bay on the off drivers side. e) Remove the dip stick by pulling upward and wipe with a clean, lint free, cloth f) Re insert dipstick into the spout, remove and check oil level. g) If necessary top up the oil level to the full mark via the dipstick tube. DO NOT OVER FILL. Engine oil specifications listed in the fluid specification section of this manual.

CAUTION: If the oil level is constantly above the FULL mark on the dipstick, and there has been no oil added to the crank case, this may indicate that either fuel or coolant dilution has occurred. This can result in serious engine damage and should be investigated and rectified immediately.

5.5

Check the oil level in the transmission drop box. a) Park the FBL-15 on flat, level ground b) Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in section 4. c) Allow twenty minutes for the drop box oil to settle. d) Locate the remote fill gallery at the front of the engine bay on the Off-driver's side. e) Remove the dip stick by pulling upward and wipe with a clean, lint free, cloth f) Re insert dipstick into the spout, remove and check oil level. g) If additional oil is required fill via the dip stick tube. Allow time to settle then recheck the level with the dip stick. DO NOT OVERFILL. Dropbox oil specifications are listed in the fluid specification section of this manual.

5.6

Check the condition and tension of the alternator drive belt. Damaged or loose belts should be reported to maintenance personnel.

5.7

While walking around the machine, check for damaged or loose hydraulic hoses and fluid leaks, and look for any loose, disconnected and frayed wiring.

5.8

Check the articulation safety lock bar for proper storage and loose fasteners.

5.9

Be aware of equipment, structures, or other obstacles near the machine that could present a potential hazard when the loader is moved.

5.10

Prior to boarding the machine, be sure the air receiver isolate valve is in the “OPEN” position.

See Section 7 for the "Functional Test After Starting".

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6.

UGM ENGINEERS PTY LTD

OPERATOR’S 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.

6.1

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

6.2

Enter the cabin close and latch the door.

NOTE:

The engine will not start if either the passenger or driver’s door is open.

6.3

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

6.4

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

6.5

Make sure the PARKING BRAKE is applied. Check the AIR PRESSURE GAUGE. If the start pressure is below 500 kPa (75 psi) the engine may not start. If the air pressure is below 500 kPa, recharge the air receiver to 890 kPa (120 psi).

6.6

Hold the THROTTLE PEDAL approximately one third to halfway open.

6.7

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

CAUTION:

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

WARNING:

Excessive use of starting fluid can cause serious backfire and violent explosions within the engine. Serious engine damage may occur. Avoid the use of starting aids and DO NOT use starting fluid (Aerostart) underground.

6.8

As soon as the engine starts, check all gauges and indicators to ensure that all systems are functioning correctly.

NOTE:

Always let the engine warm up slowly. NEVER load up a cold engine.

NOTE:

Check the gauges frequently during operation.

WARNING:

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

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6.9

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

Pre-charging the Air System

A three-way ball valve is fitted to enable the air system receiver filling from an external air supply. If the system air pressure is below 500kPa (75psi) the engine may not start and the air receiver will need to be pre-charged to 890 kPa (120 psi).

The valve has three positions:- IN-OFF-TANK To fill the receiver via an external air hose:1.

Connect an external air supply to the MINSUP coupling.

2.

Rotate the three-way ball valve from the TANK to the OFF position and apply air pressure from the supply hose.

3.

Rotate the ball valve from the OFF to the IN position. This allows air to be delivered into the receiver.

4.

Once the correct air pressure has been obtained (observed at the air pressure gauge in the Driver's compartment), rotate the three-way ball valve to the TANK position. This opens the supply hose to the drain line and closes the inlet to the tank. Pressure in the hose is relieved to enable easy disconnection of the MINSUP coupling.

WARNING: Compressed air can be hazardous. Follow the correct isolation procedures and wear suitable eye protection when pre-charging the air receiver.

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7.

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

FUNCTIONAL TEST AFTER STARTING THE ENGINE

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

7.1

Check the transmission oil level. a) The oil temperature must be between 82.2 and 93.3oC. This can be read from the transmission temperature gauge in the Driver's compartment. DO NOT CHECK THE LEVEL OF THE TRANSMISSION WITH COLD OIL. To raise the transmission oil temperature to the desired level it is necessary to work the machine or "stall" out the torque converter. To stall out the machine, apply the brakes and engage the shift levers in the forward and high speed positions.

Accelerate the engine to half throttle. Hold the engine at stall until the desired transmission oil temperature is reached.

CAUTION: Excessive transmission stall will overheat and damage the torque converter.

b) c) d) e) f) g) h) i)

Once the correct transmission fluid temperature has been reached park the FBL-15 on flat, level ground and leave it running.

Place the FBL-15 in neutral, apply the park brake and install the articulation lock.

Remove the cover over the top of the transmission. This panel is located between the Driver's compartment and the hydraulic tank.

The engine should be idling at 500-600 rpm.

Remove the dip stick by pulling upwards and wipe with a clean, lint free cloth.

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

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

If necessary top up the oil level via the dipstick tube with the transmission lubricant specified in the fluid specification section of this manual.

Transmission Oil Level Dip Stick

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7.2

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

To check the condition of the exhaust particulate filter: a) Locate the indicator on the particulate filter lid. b) Ensure the park brake is applied and vehicle is in neutral. c) Run the engine at high idle and observe the indicator position. d) If the indicator is showing the filter requires replacement. Refer the machine to maintenance personnel for filter replacement. e) When the service indicator is up, the elements should be removed and serviced.

NOTE:

The FBL-15 complies with emission requirements with and without the filter fitted. It is recommended that for areas of minimal ventilation the machine should be operated with a filter fitted.

NOTE:

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

WARNING: Do handle the exhaust filter element without wearing suitable eye protection, gloves and dust mask as the particulate caught by the filter may be harmful to the respiratory system. Immediately wash any particulate matter from the skin with warm, soapy water. Refer to FBL-15 service manual for the replacing the element.

WARNING: Do NOT replace the exhaust filter element underground within two hours shutting the unit down.

NOTE:

The diesel aerosol particulates can be safely handled when wet.

NOTE:

If the particulate filter usage or engine smoke emissions are excessive the engine will require servicing. Contact Seneca Australia.

7.3

Perform the engine coolant loss pressure sensor test.

The engine coolant loss valve is located in the off-driver's side of the engine bay.

Operation is verified by activating the coolant loss test lever when the engine is running at high idle. As the coolant pressure is diverted to atmosphere when the test lever is rotated to the test position the diesel engine will stop within five seconds.

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

After the test simply rotate the valve back to the run position and restart the machine.

7.4

Check that all of the lights are working. There are two forward and rear facing headlights.

7.5

Visually inspect the exhaust system for any leaks.

7.6

The functional test are normally completed by testing the function of the emergency and service brakes however at first time start up these functions have not been detailed.

See section 3 - "Controls and Functions".

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8.

SHUTTING DOWN THE ENGINE

8.1

Lower the bucket or RAS attachment completely to the ground and remove any load from the engine.

8.2

Put the transmission FORWARD / NEUTRAL / REVERSE control lever into the NEUTRAL position.

8.3

Remove any hydraulic load from the engine.

8.4

Apply the PARKING BRAKE.

8.5

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

NOTE:

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

8.6

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

8.7

Open the door and exit the machine.

WARNING:

8.8

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

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

WARNING:

Ensure the bucket is flat on the ground before leaving the operator’s compartment.

WARNING:

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

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9.

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

TRAMMING THE MACHINE

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

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

9.1

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

9.2

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

DANGER:

9.3

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

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

DO NOT:

Down shift the transmission unless the machine is travelling at a speed suitable for the lower range.

ALWAYS:

Ensure that the transmission control levers are fully shifted.

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

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

If the transmission should overheat, 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 protection shall be worn by both the driver and the passenger of this machine at all times whilst the engine is running.

WARNING: Eye protection shall be worn by both the driver and the passenger of this machine at all times whilst the machine is moving in forward or reverse.

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10. STOPPING AND BRAKING NOTE:

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

10.1

Use the transmission to help slow down the vehicle, by shifting down gears and utilising engine braking.

10.2

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.

10.3

Set the park brake.

10.4

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

10.5

Shut off the engine by turning OFF the ON / OFF switch.

10.6

After stepping off the machine, switch off the air isolate at the air receiver.

NOTE:

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

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

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11. DRIVING ON A RAMP 11.1

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

11.2

Whenever possible travelling up or down a ramp, keep the bucket facing downhill.

11.3

Avoid changing gears while travelling on a steep ramp.

11.4

When driving down a ramp apply full throttle in first gear to enable the engine to act as a retarder. ie DRIVE THE MACHINE.

11.5

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

NOTE:

All operators must be competent in Emergency Stop Procedure.

NOTE:

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

12. PARKING ON A RAMP WARNING: Do not park on a ramp unless absolutely necessary.

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

12.2

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

12.3

Turn the vehicle toward the rib.

12.4

Lower the bucket or RAS attachment to the ground.

12.5

Set the park / emergency brake.

12.6

Chock the wheels.

12.7

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.

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ALWAYS:

03-01-01

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

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

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OPERATOR’S MANUAL

13. LOADING The LHD method of loading is called “crowd loading” which combines the tractive effort of the machine with the break out force of the bucket. With the 229 kW of power from the FBL-15 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 a similar to a limited NO-SPIN arrangement. At the bucket lip there is maximum break out force in excess of 15,000 kg. Maximum loading efficiency is obtained by adjusting the loading cycle to the operating conditions. The proper use of traction and break out force makes it possible for a single-pass load without spinning the tyres or ramming the muck pile. The following cycle includes operations common to all load haul - dump situations, it should be modified to suit other operating conditions.

ALWAYS:

When mucking from a pile, work from both sides towards the centre. Keep it trimmed at all times.

DO NOT:

Ram the muck pile or spin your tyres.

DO NOT:

Go under a hung up draw point or under any unsupported roof.

DO NOT:

Use your machine to bar down a hang up.

ALWAYS:

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

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

Very quickly raise the lift arm about 200 mm and at the same time, push the bucket control joystick to the right. By doing this your bucket will be brought back to the angle you originally had when it was sitting on the ground. Repeat the procedure as in the first part of the cycle at full speed. If the tyres start to spin, let up on the accelerator pedal slightly as you move the bucket control joystick away from you DO NOT:

Exceed the machines carry capacity

DO NOT:

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

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.

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OPERATOR’S MANUAL

14. DUMPING 14.1

Standard Dumping

ALWAYS:

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

As you approach the dump, release your foot from the throttle pedal and reduce speed (Apply service brakes). Raise your boom to clear the dump guard. When you are in dumping position the boom should be fully raised. Push the bucket control joystick to the left - the bucket will fully dump. When dumping into a boot, care should be taken to avoid damaging the structure of the boot. Approach the boot with the lift arm raised sufficiently to clear the tailgate. Move in as far as possible without damaging either machine and dump the bucket. In most cases it will be necessary to roll back the bucket before moving the machine away from the boot.

14.2

Ejecting

For limited height application raise the bucket as high as possible and roll it forward until the bottom of the bucket is level with the floor or tilted slightly downward. Push the RAS ejector bucket control lever (Lever closest to the driver) forward to eject the load.

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OPERATOR’S MANUAL

15. TOWING THE VEHICLE WHEN DISABLED WARNING:

Set the park brake, lower the bucket to the carry position and stop the engine.

The towing vehicle must have sufficient braking capacity to stop and hold both vehicles.

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

The brake can be released with a Porta Power (Maximum 13,800 kPa (2000 psi)) connected into the port provided in the Driver’s cabin. The operator is to stay in the operator’s station to apply the park brake if necessary.

If the vehicle must be towed around sharp bends or corners, disconnect the hydraulic hoses on the steering cylinders. Follow the hydraulic isolation procedure. Be sure to cap the ends of the hoses and cylinders to prevent contamination of the hydraulic circuit.

If the distance is more than 1000 meters, it will be necessary to disconnect the front and rear drivelines from the axle assemblies. Refer to the FBL-15 service manuals for details.

CAUTION:

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

WARNING:

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

ALWAYS:

Connect the disabled FBL-15 to the towing vehicle before releasing the FBL15 park brakes. Make sure the FBL-15 park brake is re-applied before the towing vehicle is disconnected.

NOTE:

Maximum Towing speed is 3 kph.

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OPERATOR’S MANUAL

16. AIR VENTING THE FUEL SYSTEM If the engine misfires, runs dry of fuel or fails to start due to air in the fuel line, the air must bled from the system as follows: 16.1

Ensure the engine has been isolated and tagged as described in section 4.

16.2

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

16.3

Fill the fuel tank with the recommended grade of fuel. If it not possible to completely fill the tank then add a minimum of 50 litres to the tank.

16.4

Remove the secondary spin on fuel filter after allowing sufficient time for the engine to cool down. Fill the filter with clean fuel via the outer ring of small holes (inlet) and coat the sealing gasket with clean fuel. Re-install the filter and tighten until the sealing gasket just touches the mounting adaptor head. Tighten the filter a further three quarters of a turn, HAND TIGHT ONLY.

16.5

Remove the lid on top of the primary fuel filter / water separator by undoing the brass tee handle on top of the filter unit. Fill with clean fuel. Re-install the lid and snugly tighten the T handle to HAND TIGHT ONLY.

16.6

Locate the bleed plug on top of the secondary spin on filter. Crack the plug and locate the hand primary adjacent to the primary fuel filter / water separator. Pump the primer until a continuous flow of fuel is evident at the secondary filter bleed plug. Tighten the plug and apply an additional six pumps to prime the fuel system.

16.7

Start the engine and check for any fuel leaks.

NOTE:

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

CAUTION: Do not use the starter motor and fuel pump to prime the fuel filters. Prolonged use of the fuel pump can result in damage to the starter, fuel pump and injectors and cause erratic running of the engine due to the volume of air in the lines and filters.

17. AIR VENTING THE ENGINE COOLING SYSTEM To prevent an air lock in the engine coolant system, the cooling system automatically bleeds back to the header tank. If the system has just been flushed the engine must be run for at least ten minutes at high idle with the fill cap removed to ensure de-aeration. Check the level of the system after running and adjust if necessary. Only fill with the top up fluid listed in the lubrication specification section of this manual

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OPERATOR’S MANUAL

18. GENERAL INFORMATION Keep your FBL-15 clean. A clean machine makes for a safer machine.

No diesel engine should be operated underground if it is smoky, running unevenly, or if the exhaust system is not in good condition In areas where auxiliary ventilation is used, the operator should make sure fans are operating before starting the machine.

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

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

Never operate a machine that you feel is mechanically unsafe.

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OPERATOR’S MANUAL

19. ATTACHING RAS IMPLEMENTS 19.1

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

19.2

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

19.3

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

19.4

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

19.5

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

WARNING:

NEVER walk under the bucket or lift arm.

19.6

Enter the cab and fully lower the lift arm. Press the RAS pressure release button to release the pressure in the hydraulic lines

19.7

Exit the cabin and disconnect the lock cylinder lines. These can now either be; a) Connected to the hydraulic system of the attachment. (eg. Push plate bucket). b) Connected into the provided dummy blocks to prevent the hoses from dragging on the ground and being damaged.

19.8

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

ALWAYS:

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

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20. DETACHING IMPLEMENTS 20.1

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

20.2

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

20.3

Connect the implement hydraulic lines to the RAS lock cylinder.

20.4

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.

20.5

Enter the cabin.

20.6

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

20.7

Select Reverse, first gear and release the park brake.

20.8

Drive away from the attachment whilst rolling the bucket forward.

DO NOT:

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Leave the attachment unsecured. An unstable implement may roll and crush personnel.

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OPERATOR’S MANUAL

21. SAFETY SYSTEM SHUTDOWN The pneumatic Safety Shutdown System on the FBL-15 has been designed and tested to comply with AS3584.2 (Flameproof Diesel engine systems for under ground coalmines) and will protect an engine from fire and explosion. To prevent accidental or purposeful override of the safety shut down circuit, there are NO mechanical over ride levers or linkages. All faults are to be repaired before the machine is restarted.

The system prevents the engine from starting should any of the following conditions apply: a) b) c) d) e) f) g)

Engine coolant overheating (100˚C) Exhaust coolant overheating (100˚C) Exhaust gas cooling overheating (150˚C) Low coolant level Transmission not in neutral Parking brake not applied Door/s open

The engine will shutdown for the following conditions; a) b) c) d) e) f) g) h) DO NOT:

Low engine oil pressure (less tan 70 kPa (10 psi)).

Excessive exhaust temperature (over 150˚C).

Engine coolant over temperature (over 100˚C).

Exhaust coolant over temperature (over 100˚C).

No coolant pressure.

Broken safety system airline.

Manual shutdown.

Loss of air pressure. bypass any safety shutdown device always rectify the problem before restarting the engine.

If the engine shuts down, check and rectify the following as required; a) b) c) d)

Check radiator coolant level.

Check engine temperature gauge. If over 100˚C allow engine to cool.

Check air pressure if less that 300 kPa (40 psi), check for air leaks.

Check engine oil level on dipstick, fill as required.

If the above tests and checks do not allow the machine to restart - Contact Maintenance personnel

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22.1

UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

PREVENTIVE MAINTENANCE SCHEDULE AND CHECKLIST EVERY 10 SERVICE HOURS OR DAILY

MACHINE NO.________________DATE_________________________________ HOUR METER________________SHIFT_________________________________ SIGNATURE_________________________________ ITEM ENGINE OIL TRANSMISSION OIL TRANSMISSION DROP BOX OIL HYDRAULIC OIL COOLING SYSTEM FUEL TANK INDICATORS AND GAUGES AIR FILTER

EXHAUST FILTER (IF REQURIED) WALK AROUND INSPECTION

ENGINE SHUTDOWN TEST SAFETY EQUIPMENT

EMERGENCY BRAKES SERVICE BRAKES LIGHTS CANOPYS DOORS EXHAUST SYSTEM

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SERVICE Check level and fill as required.

Check the level and fill as required.

Check the level and fill as required.

Check the level and fill as required.

Check the level and fill as required.

Check the level and fill as required.

Check operation

LUBE TICK

COMMENTS

Spec 1 Spec 2 Spec 3 Spec 4 Spec 6 Spec 7

Check indicator and replace if required(Air Cleaner Element Seneca # 501639) Check indicator and replace if required(Exhaust Particulate Element Seneca # 500677) Inspect for: - Loose or damaged components - Oil and air leaks - RAS condition, - Tyre wear & damage - Wheel nuts.

Coolant loss test at maximum RPM Check: - Fire extinguisher, - Seat belts Test function.

Test function Test for damage and operation Check for damage, & correct fasteners Check for damage, & operation Check for leaks, Physical Damage, Loose or missing fasteners

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

PREVENTIVE MAINTENANCE SCHEDULE AND CHECKLIST EVERY 100 SERVICE HOURS OR 2 WEEKS

MACHINE NO.________________DATE_________________________________ HOUR METER________________SHIFT_________________________________ SIGNATURE_________________________________ ITEM

ALL PINS, BUSHINGS, AND BEARINGS ENGINE OIL AND FILTERS

SERVICE LUBE TICK PERFORM PREVIOUS SERVICE HOUR ITEMS AS REQUIRED Grease Spec 8

COMMENTS

Change Spec 1 (Engine Oil Filter Element – Seneca # 502121) Steam / pressure clean ENGINE & BAY Steam / pressure clean RADIATOR Spec 5 AXLES & PLANETARIES Check the level and fill as required.

Check for play and tighten DRIVE LINES loose bolts Grease Spec 8 UNIVERSAL JOINTS Check tension FAN & ALTERNATOR BELTS Brake test EMERGENCY BRAKE Brake test SERVICE BRAKE Check and clean filler neck HYDRAULIC & FUEL screens TANKS Check and clean ALL BREATHERS Clean out cabins & wash MACHINE machine Drain AIR RECEIVER Check auto lube is full Spec 8 AUTO LUBE Check pressures TYRES Drain water separator FUEL SYSTEM Test ENGINE SHUTDOWN - Engine oil pressure TESTS - Manual shutdown Door(s) operation and DOOR(S) interlock(s) Test NEUTRAL & PARK BRAKE START INTERLOCKS Inspect hoses, cylinders & lift FRONT FRAME arm are clear Check blades for damage and Spec 8 FAN clearance. Grease Service Kit, 100 hour – Seneca Part Number 502222 Includes – 501639 qty-1, 500677 qty-1, 502121 qty-1

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

PREVENTIVE MAINTENANCE SCHEDULE AND CHECKLIST EVERY 200 SERVICE HOURS OR MONTHLY

MACHINE NO.________________DATE_________________________________ HOUR METER________________SHIFT_________________________________ SIGNATURE_________________________________ ITEM

SERVICE

LUBE TICK

COMMENTS

PERFORM PREVIOUS SERVICE HOUR ITEMS AS REQUIRED Clean filter housing AIR FILTER HOUSING, internally, check piping for PIPING leaks, loose clamps & damaged rubber couplings.

ENGINE FUEL FILTER(S) Change filter element(s) (Fuel filter – primary Seneca # 502080) (Fuel filter – secondary Seneca # 502110) Drain and clean.

ENGINE FUEL WATER SEPERATOR Check governor setting PNUEMATIC SYSTEM Remove exhaust purifier INTAKE SYSTEM flame trap, clean and inspect for cracked element. Replace if damaged Clean the inside of the EXHAUST SYSTEM exhaust heat exchanger with recommended solution (Seneca Part Number #502254) Check condition and replace MAIN HYDRAULIC if required FILTER (Hydraulic return filter – Seneca # 502126) Check condition and replace STEER & BRAKE if required HYDRAULIC FILTER (Steering pressure filter – Seneca # 501800) Test and record, CO, NOx EXHAUST EMISSIONS and smoke.

Service Kit, 200 hour – Seneca Part Number 502223 Includes – 501639 qty-1, 500677 qty-1, 502121 qty-1, 502080 qty-1, 502110 qty-1, 502126 qty-1 501800 qty-1

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

PREVENTIVE MAINTENANCE SCHEDULE AND CHECKLIST EVERY 400 SERVICE HOURS OR 3 MONTHLY

MACHINE NO.________________DATE_________________________________ HOUR METER________________SHIFT_________________________________ SIGNATURE_________________________________ ITEM

ENGINE MOUNTS RADIATOR MOUNTS ENGINE - EXHAUST SYSTEM TRANSMISSION AND AXLE MOUNTS AIR COMPRESSOR

PORTABLE FIRE EXTINGUISHER(S) BOLSTER PIVOT PIN RETAINING CAP BOLTS TRANSMISSION OIL FILTER DROP BOX

SERVICE

LUBE TICK

COMMENTS

PERFORM PREVIOUS SERVICE HOUR ITEMS AS REQUIRED Check condition Re-torque as required Check condition. Re-torque as required Check for loose flanges, fasteners, clamps, leaks, etc.

Check condition, tightness.

Re-torque as required Service / change filter (Air compressor filter element – Seneca #501523) Charge condition to be inspected by qualified individual Re-torque as required Change filter element (Transmission oil filter – Seneca #501471) Replace oil

Spec 3

Service Kit, 400 hour – Seneca Part Number 502224 Includes – 501639 qty-1, 500677 qty-1, 502121 qty-1, 502080 qty-1, 502110 qty-1, 502126 qty-1 501800 qty-1, 501523 qty-1, 501471 qty-2.

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

PREVENTIVE MAINTENANCE SCHEDULE AND CHECKLIST EVERY 800 SERVICE HOURS OR 6 MONTHLY

MACHINE NO.________________DATE_________________________________ HOUR METER________________SHIFT_________________________________ SIGNATURE_________________________________ ITEM

TRANSMISSION OIL EXHAUST GAS AND COOLANT OVER TEMPERATURE SENSORS*

SERVICE LUBE TICK PERFORM PREVIOUS SERVICE HOUR ITEMS AS REQUIRED Change oil, clean suction Spec 2 strainer Change out : - the two exhaust gas over temperature sensors (Seneca #502113) - the two coolant over temperature sensors (Seneca #501526)

COMMENTS

Drain and flush the cooling system.

Check all hoses for leakage, HYDRAULIC SYSTEM rubbing or damage to cover HOSES Change lubricant Spec 5 AXLE ASSEMBLIES Check CONTROL LINKAGES AND CABLE CONDITION 1. Engine throttle 2. Shutdown cylinder / OPERATION 3. Transmission shift 4. Brake controls 5. Hydraulic controls Check for proper lubrication, AXLE OSCILLATION possible wear BUSHS Check for damage or cracks, WHEEL RIMS re-torque all wheel nuts Remove exhaust purifier EXHAUST SYSTEM flame trap and inspect for cracked element. Replace if damaged Check service brake release BRAKE HYDRAULIC pressure settings reset as SYSTEM required Check for wear & damage TOW COUPLINGS COOLING SYSTEM

* keep the old two exhaust gas and coolant over temperature sensors for an available exchange program offered

by SENECA Australia.

Service Kit, 800 hour – Seneca Part Number 502225 Includes – 501639 qty-1, 500677 qty-1, 502121 qty-1, 502080 qty-1, 502110 qty-1, 502126 qty-1 501800 qty-1, 501523 qty-1, 501471 qty-2.

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UGM ENGINEERS PTY LTD

OPERATOR’S MANUAL

PREVENTIVE MAINTENANCE SCHEDULE AND CHECKLIST EVERY 1600 SERVICE HOURS OR YEARLY

MACHINE NO.________________DATE_________________________________ HOUR METER________________SHIFT_________________________________ SIGNATURE_________________________________ ITEM

WATER COOLED COOLING SYSTEM ENGINE COMPRESSION ENGINE –STARTER MOTOR ALTERNATOR BUCKET HYDRAULIC SYSTEM STEERING HYDRAULIC SYSTEM BOOM, BUCKET, STEERING STOP BLOCKS HYDRAULIC SYSTEM

SERVICE

Check condition and operation Check condition and operation Check all relief settings reset as required Check all relief & control settings.

Reset as required Check for proper contact.

Repair or replace as required Change hydraulic fluid Check relief valve setting

ENGINE

Check and record boost pressure Drain and clean out

EXHAUST HEAT EXCHANGER

ENGINE & TRANSMISSION OIL COOLERS ELECTRICAL SYSTEM

COMMENTS

PERFORM PREVIOUS SERVICE HOUR ITEMS AS REQUIRED Drain flush and change Spec 6 coolant Test and record compression

PNUMEATIC SYSTEM

FUEL TANK

LUBE TICK

Spec 4

Remove.

- De-coke gas fins - De-scale water tubes.

- Pressure test Remove and clean

Relevant code inspections

Service Kit, 800 hour – Seneca Part Number 502225 Includes – 501639 qty-1, 500677 qty-1, 502121 qty-1, 502080 qty-1, 502110 qty-1, 502126 qty-1 501800 qty-1, 501523 qty-1, 501471 qty-2.

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23.

FBL-15 FLUID SPECIFICATION TABLE

SPEC

COMPONENT

1

Engine

2

3

CAPACIT Y 22 litres (as required)

LUBRICANT

Transmission

40 litres (as required)

Mineral gear oil

SAE10W Cat TO-4

4

Transmission Drop Box Hydraulics

8 litres (as required) 300 litres

Synthetic gear oil Hydraulic

5

Axles

HD 220 (Shell Omala HD 220 or equivalent) SAE68 (Shell Tellus 68 or equivalent) SAE90LS (Shell DIFFOIL 90LS or equivalent)

6

Cooling System

72 litres

7

Fuel

300 litres

8

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

_s required

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Engine oil

Mineral gear oil with limited slip additive Water & inhibitor

Distillate “diesel” fuel Multi-purpose EP grease

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TEMP. BELOW 0ºC SAE15W-40 API CD-II (Shell Rimula X 15W-40 or equiv.)

OPERATOR’S MANUAL

TEMP, 0-32ºC SAE40 API CD-II (Shell Rotella DD 40 or equiv.)

SAE30 Cat TO-4 (Shell Donax TC30 or equivalent)

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

SAE40 Cat TO-4

Ethylene glycol antifreeze inhibitor (low silicate formulation) to GM 6038-m or ASTM d4985 (Shell Coolguard HD50) Recommended 50% coolant / water solution _o ASTM D975 (grades D-1 & D-2) and to Detroit and AS3584.2 specifications NLGI no. 1 or NLGI no. 2 NLGI no. 2 no. 0 (Shell Alvania (Shell Alvania (Shell Alvania EP EP (LF) 2 or EP (LF) 2 or (LF) 0/1 or equivalent) equivalent) equivalent)

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