Important Safety Information
The operation of heavy mining machinery can be hazardous. Accidental machine starting can cause injury or death to personnel working on the machine.
Only trained and authorized operators should operate this machine. A site specific Risk Assessment is recommended to be conducted before this machine is introduced into service.
Never enter the articulation area while the machine is running. Failure to observe this precaution may result in injury or death.
In the event of an emergency, the machine may also be shutdown by pressing the engine emergency shutdown button located beneath the Diesel Control System (DCS) display box. When the emergency shutdown button is pressed, air will be cut-off from the engine. Ensure that the machine has come to a full stop and the parking brake has been engaged before exiting the operator’s compartment.
Follow all applicable rules and regulations regarding lockout/tagout of equipment before performing maintenance work. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.
Do not move the lift forks unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.
You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.
Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.
Overloading equipment can cause personal injury, death, or equipment damage. Relevant standards and safety procedures should always be followed when operating this machine.
Removal of protective canopies, doors, interlocks, or any other safety measure can cause serious injury or death.
EM008801-0 (en-us)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product until you have read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows: Attention! Become Alert Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or death.
EM008801-0 (en-us)
5 Table of Contents Table of Contents Foreword .............................................................. 6 Safety Section Overview .............................................................. 7 Personal Protective Equipment ............................ 7 Trapped Pressure ................................................ 7 Containing Fluid Spillage ..................................... 8 Inhalation .............................................................. 8 Responsible Operation ......................................... 8 Before Starting Engine ......................................... 8 Operation.............................................................. 9 Engine Stopping ................................................... 9 Crushing and Cutting Prevention ......................... 9 Burn Prevention.................................................. 10 Coolant ............................................................... 10 Oils ..................................................................... 10 Fire and Explosion Prevention ........................... 10 General............................................................... 10 Fire Extinguisher ................................................ 11 Fire Safety .......................................................... 11 Electrical Storm Injury Prevention ...................... 11 Hazard Sources.................................................. 11 General Operational Safety Precautions ........... 11 Product Information Section General Information ........................................... 13 Machine Specifications ...................................... 13 General Arrangement ......................................... 14 Articulation Angle Drive Guides ......................... 22 Operation Section Trailer Connection ............................................. 24 Trailer Controls .................................................. 33 Trailer Function Test .......................................... 37 Power Assist (Option) ........................................ 39 Loading the Trailer ............................................. 43 Travelling with the Trailer Loaded ..................... 45 Unloading the Trailer ......................................... 46 Trailer Disconnection ......................................... 48 Maintenance Section Fifth Wheel Maintenance ................................... 49 Bolt Torque ........................................................ 50 Lubricant Viscosities (Fluids Recommendations) ................................ 52 Grease and Oil Locations .................................. 53 Mechanical Components ................................... 54 Winch ................................................................. 60 Hydraulics .......................................................... 62 Maintenance Interval Schedule ......................... 68 EM008801-0 (en-us)
Foreword
Literature Information
This manual contains safety information, operation instructions, transportation information, lubrication information and maintenance information.
This manual should be stored in a location that is readily available to operations and service personnel.
Some photographs or illustrations in this publication show details or attachments that can be different from your machine. Guards and covers might have been removed for illustrative purposes.
Whenever a question arises regarding your machine, or this publication, please consult your Caterpillar dealer for the latest available information.
Safety
The safety section lists basic safety precautions. Study the safety section in conjunction with job site safety rules and regulations to promote a safe working environment.
Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this machine.
Operation
The operation section is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, machine controls, attachment controls, transportation and towing information.
Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the machine.
Operating techniques outlined in the publication are basic. Skill and techniques develop as the operator gains knowledge of the machine.
Maintenance
The maintenance section is a guide to equipment care. The Maintenance Interval Schedule (MIS) lists the items to be maintained at a specific service interval.
Caterpillar Production Identification Number
Each Caterpillar machines has a unique identification number. SH150 shield trailers have the following part number sequence: JESXXXXX
6 Foreword
EM008801-0 (en-us)
Safety Section Overview
This section contains safety precautions that should be followed in conjunction with the operation of this machine. There are several potential safety hazards on the SH150. The hazards are reviewed in this section to help raise awareness, educate new operators, and serve as a reminder to experienced operators. Always follow specific job site safety procedures and refer to site specific risk assessments.
Make sure that all protective guards and all covers are secured in place on the equipment.
Keep the equipment free from foreign material that could pose a trip or slip hazard. Remove debris, oil, tools, and other items from the operator’s compartment, operator’s controls and pedals. Clean all contact surfaces that will be used for accessing service areas of the machine. This includes foot holds that are used to access the top of the machine. A clean machine is a safer machine.
NOTICE
Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the machine if it is being serviced, repaired, or is malfunctioning. Do not operate the machine unless all operator checks and scheduled servicing have been performed. Report damage or machine malfunctions immediately and do not operate the machine until the fault has been corrected by trained and authorized service personnel.
Always maintain three points of contact on the machine when mounting, dismounting, and accessing the top of the machine to avoid injury.
Always follow correct boarding and dismounting procedures:
Board using hand holds, not the steering wheel.
Check floor before dismounting.
Hold on while dismounting.
Maintain three points of contact at all times.
Only trained and authorized operators should operate this machine. Do not use the machine for any purpose other than its intended use. Do not exceed the indicated capacity of the machine.
Personal Protective Equipment (PPE)
Wear a hard hat, protective glasses, and other protective equipment as required. Always keep head, body, and arms inside the operator’s compartment at all times.
Trapped Pressure
Pressure can be trapped in a hydraulic system. Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings. High pressure oil that is released can cause a hose to whip. Fluid penetration can cause serious injury and possible death. Always make sure that the lift arms are lowered, the transmission is in neutral, the parking brake is applied, and the engine is stopped prior to working on hydraulics.
7 Safety Section
Illustration 1
Illustration 2
EM008801-0 (en-us)
Containing Fluid Spillage
Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluid. Always refer to specific job site requirements for handling and disposal of fluids.
Inhalation
Use caution. Exhaust fumes can be hazardous to your health. Do not work on the prime mover in poorly ventilated areas while the engine is running. The engine should not be operated underground if it is smoky, running unevenly, or if the exhaust system is leaking or deteriorating. Ensure sufficient ventilation is available to dilute exhaust gases. The minimum ventilation air quality rate (m3/sec) is listed on the prime mover’s serialization plate in the operator’s compartment. In areas where auxiliary ventilation is used, the operator should make sure fans are operating before starting the machine. Never leave the engine running unattended.
NOTICE
Never shutdown the engine when load is applied. Always allow the engine to idle for a few minutes before stopping the engine.
Never operate a machine that you feel is mechanically unsafe.
Dispose of Waste Property
Illustration 4
Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to job site and local regulations.
Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.
Responsible Operation
Only trained and authorized operators should operate this machine. Do not operate the machine if:
The machine is locked out/tagged out.
Covers and guards are missing or incorrectly installed.
The operator’s compartment roof on the prime mover is unsecure.
Appropriate Personal Protective Equipment (PPE) is not provided or worn.
The operator’s compartment door will not close securely.
Before Starting Engine
Do not start the prime mover unless:
The machine is free of any lockout tags, do not operate tags, or any other indicators of a potential lockout/tagout.
The area around the machine is clear. Make sure that no one is on the machine, underneath the machine, or around the machine.
The parking brake is applied.
8 Safety Section
Illustration 3 Exhaust
EM008801-0 (en-us)
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