PDF Operation Manual CAT BUCYRUS FBL 15 LHD - 1 MB
This operation manual is the essential guide for the CAT BUCYRUS FBL 15 LHD (Load Haul Dump) utility vehicle.
It provides operators with critical information on controls, safety procedures, and daily maintenance checks.
Following the manufacturer's guidelines is key to ensuring a safe and productive underground mining environment.
This document is a must-have for all personnel operating this machine.
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BI014627
Reliability at work
Operator’s Manual
FBL-15 LHD/Utility
Serial No: 5003707
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BI014627
Operator’s Manual
SPECIFICATIONS
All specifications are subject to change without notice. Steer/brake system Pressure10 micron
Always consult BUCYRUS to obtain current information replaceable with bypass
before applying critical loads.
Bucket Pump
Capacities Type Gear open centre
Bucket Payload 12000 kg Standard pump output @ 2100 RPM 228 lpm
RAS forks maximum payload 15000 kg
RAS fixed jib maximum payload 10000 kg Steer and Brake Pump
RAS slewing jib maximum payload 8000 kg Type Pressure compensated piston closed centre
RAS belt reeler 12000 kg Standard pump output @ 2100 RPM 106 lpm
Maximum unbraked trailer mass 15000 kg
Maximum braked trailer mass Consult Bucyrus Cooling Fan Pump
Type Gear open centre
Standard Ejector Bucket
Heaped capacity (SAE) 4.5 mÂł Alternator Drive Pump
Struck capacity 3.5 mÂł Type Gear open centre
Weight Cylinders
With bucket only 29000 kg Type Double acting
Without bucket 26500 kg Rods Hard chromed
Counterbalance valves Lift and tilt
Engine Cushion stops Steering and tilt
Type Diesel, turbocharged, 4 cycle
Cooling system Water based radiator Steering System
Cooling fan Hydraulic driven fan Control valve Closed centre
Engine make/model Caterpillar 3126 Actuation Orbital
Displacement 7.2 litre
Maximum power 153 kW @ 2300 RPM Bucket System
Control valve Open centre
Engine Speeds Actuation Remote hydraulic pilot
Low idle 800 RPM
High idle 2600 RPM Service/Brake Hydraulic System
Type Reverse modulating
Fuel Consumption Control valve Closed centre
At full power 45 litre/hr Actuation Foot pedal
Average mine duty 12-40 litre/hr Operating pressure 0 to 17.10 MPa
Start System Accumulator - Brakes
Starter motor type Air turbine type Type Piston
Quantity x capacity 1 x 2 litre
Intake Air Cleaner
Type Dry dual element Service Brake
Intake flame trap Bucyrus spiral wound type Type Totally enclosed, liquid cooled Posi-Stop
Application Spring applied hydraulic release
Exhaust Conditioner Location Each wheel end built into axle
Type Flameproof wet type
Make Bucyrus Park Brake
Exhaust Filter Replaceable element Type Totally enclosed, liquid cooled Posi-Stop
Exhaust flame trap Wet Application Spring applied hydraulic release
After treatment Catalytic exhaust purifier Location Each wheel end built into axle
Transmission Steering
Type Power shift with forward/reverse modulation Type Centre articulated, hydraulic
Speeds, forward and reverse 4
Articulation
Axles Bearing type and size Pin and spherical bearing
Type Outboard planetary (top), bush (bottom) fully sealed
Differential type Bevel gear and pinion Bush material Hardened steel
Differential lock type - front Posi-Torque Pin material Hardened steel
Differential lock type - rear Posi-Torque Degrees of turn either side 45 degree
Wheels Oscillation
Make/model 5 piece (heavy duty) Type Rear axle mounted trunnion
Bush material Hardened steel
Tyres - Standard Pin material Hardened steel
Size 20.5 x 25 Degrees up and down from horizon 7.5 degree
Ply rating Radial
Inflation media Air Seating (Operator)
Inflation pressure 110 psi front, 110 psi rear Type Cross-seated
Make Bucyrus
Hydraulic Filtration Suspension Adjustable spring/shock absorption
Bucket system Return 10 micron
replaceable with bypass
Rev. 0 FBL-15 LHD/Utility Serial No. 5003707 3
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Operator’s Manual
Section 4
Machine Orientation, Controls and Functions
MACHINE ORIENTATION
BASIC MACHINE LAYOUT
The FBL-15 consists of two main sections a front and rear frame. Housed in the front frame
is the lift arm assembly, axle and main hydraulic control valve bank. The rear frame houses
the transmission and hydraulic pumps, cooling system radiator, flameproof engine package
(which utilises a wet bath exhaust conditioner), the operator’s compartment and all the
storage reservoirs, (hydraulic, pneumatic, exhaust conditioner make up and fuel tanks).
Lift Arm Assembly
Front Axle
Main Hydraulic Control
Valve Bank
Hydraulic Tank
Operator’s Compartment
Transmission and
Hydraulic Pumps
Rear Axle
Fuel Tank
Air Receiver
Wet Bath Exhaust
Conditioner
Makeup Tank
Flameproof Engine
Cooling System
Radiators
Rev. 0 FBL-15 LHD/Utility Serial No. 5003707 13
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Operator’s Manual
HORN BUTTON
Pushing this button sounds the air horns.
It is good operating procedure to sound the horn 2-3 seconds before
an engine start or whenever approaching blind intersection.
Horn Button
RIGHT HAND SIDE OPERATOR’S PANEL
EMERGENCY FUEL SHUT OFF VALVE
This valve is located after the fuel filter/water separator. Closing this valve will stop the flow
of fuel to the engine.
This provides a second means of shutting down the engine should the on/off toggle switch
fail.
EMERGENCY FUEL SHUT OFF VALVE
Rev. 0 FBL-15 LHD/Utility Serial No. 5003707 23
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Operator’s Manual
HYDRAULIC ISOLATION
To isolate the hydraulic system perform the following procedure:
1. Ensure the area is clear of any obstruction and area is fit for carrying out safe
operation and maintenance.
2. Lower the lift arms or any attachment to the ground, shutdown the engine, fit a danger
tag to the on/off toggle switch, connect the articulation lock and chock the wheels.
3. Depress the attachment quick connects button located in the operator's compartment.
This will remove any residual pressure stored in the PTO lines.
4. Observe both steering and brake pressure gauges located in the operator's
compartment. The hydraulic system features a steering and brake accumulator
automatic dump off which removes hydraulic pressure from both accumulators once
the engine and main air has been stopped. This is immediate. This is done by an air
pilot from the air circuit.
5. Remove hydraulic tank pre-charge pressure (50 kPa) by cracking hydraulic tank filler
cap.
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.
Always assume there is hydraulic pressure in hydraulic lines or
components unless it has been isolated by yourself.
Crack hose end fitting (if pressure is present in line tighten fitting and
remove pressure as above) but do not remove till any residual
pressure is removed.
Steering Accumulator Pressure Gauge Brake Accumulator Pressure Gauge
RIGHT HAND SIDE OPERATOR’S DISPLAY PANEL
Rev. 0 FBL-15 LHD/Utility Serial No. 5003707 33
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Operator’s Manual
Check the air cleaner (see Section 4):
1. Filter condition indicator.
2. Replace filter element if indicator is in the red area.
3. Check intake pipes and hoses for loose or damaged connections.
AIR CLEANER AIR CLEANER
INDICATOR
Do not operate the machine with loose intake pipe connection, this
will allow particles of dust into engine and cause serious damage.
Check air receiver:
1. For damage.
2. Drain condensate from main air drain valve.
It is important to drain the condensate from the air receiver on a daily
basis to stop it contaminating the air circuit and the starter motor.
Personal Protective Equipment must be worn when operating main air
drain valve.
Main Air Drain
Valve
MAIN AIR MANIFOLD
Rev. 0 FBL-15 LHD/Utility Serial No. 5003707 43
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Operator’s Manual
Main Supply/Isolation Valve
Low Water Shutdown Test Ball Valve
3. Observe machine taking note of water flow out of the low water shutdown test point
when DES shuts down. Ensure the display on the DCS shutdown system indicates
both proximity switches/magnetic reed switches are open.
4. Shut low water shutdown ball valve as soon as the DES shuts down and remove top
cover from the float chamber
5. Measure the water level from the bottom of the float chamber (this is required to be
between 100mm and 110mm) and water must still be coming from low water
shutdown test valve when the DES shuts down.
6. Once shutdown water level is achieved refit top cover to float chamber.
Rev. 0 FBL-15 LHD/Utility Serial No. 5003707 53
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Operator’s Manual
Section 12
Driving on a Ramp
1. Stop and shift into first gear, and check the brakes before travelling up or down a
ramp.
2. Always use a low gear when travelling down a ramp.
3. Avoid changing gears while travelling on a steep ramp
4. If you have a mechanical or brake failure:
a. Immediately apply the brakes.
b. If the brakes do not function, apply park brake.
c. If the machine does not stop, turn the machine into the rib.
The machine should not be operated on more than the recommended
grades (Section 1).
Operators must be competent in Emergency Stop Procedure.
Rev. 0 FBL-15 LHD/Utility Serial No. 5003707 63
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Operator’s Manual
Section 17
Towing with the Machine
The transmission will not hold the machine when the spring applied
park brakes are bypassed by the Porta-Power pressure.
Maximum towing speed is 3 kph.
1. Ensure the machine is parked and isolated prior to connecting the trailer or load, park
brake on.
2. Attach the load to the rear tow hitch, ensure tow pin is secure.
3. The trailer or load should be secured by 2 x 15 Tonne safety chains in a straight line
pull in addition to a rated draw bar for the task.
4. Both chains must be used and adjusted to ensure an even pull.
5. Both chains have a combined loading of 20000 kg in a straight line.
6. Both chains must be used for maximum tractive effort pull.
7. Ensure all connections on the towed piece are in good condition and rated for the
maximum pull.
8. Ensure all holding devices and hitches are in good condition and rated for the
maximum pull before connecting the machine.
9. Always ensure that the trailer and load are secure before towing, and prior to
releasing the park brake.
10. Travel at a speed that is suitable to conditions and load.
11. Ensure trailer or load has wheels chocked prior to removal from the machine.
Always connect the trailer or load before releasing the park brakes.
Make sure the park brake is reapplied before the towing machine is
disconnected.
For towing of loads greater than 15000 kg the mass must be braked.
Prior to towing loads in excess of 15000 kg consult Bucyrus.
Failure to comply to these procedures may result in serious personal
injury or damage to the equipment.
Rev. 0 FBL-15 LHD/Utility Serial No. 5003707 73