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Operation and Maintenance Manual

SH650 D Roof Support Carrier

SAFETY.CAT.COM

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This manual is intended to provide GENERAL product information. The illustrations, descriptions, and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

This machine was manufactured under the guidelines, procedures, and requirements of the appropriate government regulatory agencies.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit without the consent of Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to Caterpillar’s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

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1. 2. Your

_________________________________________________Table of contents ________________________________________________________________ A6474X279 REV 7 BI001883

Table of contents

About this manual................................................................... 1.3 Before starting to work.........................................................1.3 Who is this operating manual intended for?.........................1.3 What is the purpose of this operating manual?....................1.4 Characters and symbols ......................................................1.5

About this manual

safety Your safety............................................................................... 2.3 Personnel.............................................................................2.4 Operation.........................................................................2.4 Installation and repair......................................................2.4 Operating conditions............................................................2.5 Intended use....................................................................2.5 Unauthorized use............................................................2.5 Safety instructions................................................................2.7 General rules:..................................................................2.7 Storage and transport......................................................2.8 Pre-start inspection .........................................................2.8 Installation and start-up...................................................2.9 Operation.........................................................................2.9 Stopping........................................................................ 2.10 Maintenance and repair................................................. 2.10 Diesel emissions ........................................................... 2.11 Handling of hydraulic fluids........................................... 2.13

Storage and transport............................................................. 3.3 Storage.................................................................................3.3 Storage of the machine and spare parts.........................3.3 Transport..............................................................................3.4 Before transport...............................................................3.5 4. Installation Installation ............................................................................... 4.3 Points to observe prior to installation...................................4.3 Who is allowed to carry out installation?.........................4.3 Which tools are required for installation?........................4.3 Notes on installation........................................................4.4 Pre-installation check list.................................................4.5 Safety features................................................................4.6

3. Storage and transport

5. Operation

Table of contents_________________________________________________ ________________________________________________________________ SH650 D Roof Support Carrier BI001883

Pre-operation suggestions.....................................................5.3 Operation..................................................................................5.4 How to operate the machine ................................................5.4 Who is allowed to operate the machine ..........................5.4 When can operation be started?.....................................5.4 Controls and indicators.........................................................5.5 Operator’s compartment - left and center........................5.5 Operator’s compartment - right........................................5.6 Hazard zone.........................................................................5.18 Starting procedure................................................................5.19 Shutdown procedure ............................................................5.20 Towing a disabled machine..................................................5.21 Instructions on the maintenance ..........................................5.23 Important notes................................................................5.23 Before maintenance ........................................................5.23 Critical torque values.......................................................5.25 Lubricants, fluids and capacities......................................5.25 Specific lubrication and maintenance schedule ..............5.26 Specific lubrication and maintenance procedure..................5.30 Pre-shift ...........................................................................5.30 Every third shift................................................................5.33 Weekly.............................................................................5.40 First 50 hours of service..................................................5.60 Every three months .........................................................5.61 Every 100 hours ..............................................................5.66 Every 500 hours ..............................................................5.68 Every six months.............................................................5.70 Every twelve months .......................................................5.72 Servicing heavy duty air filter elements................................5.73 Diesel emissions maintenance..................................................5.77 Introduction (emissions).......................................................5.77 Diesel emissions...................................................................5.77 Diesel emissions stall test....................................................5.79 Operational issues................................................................5.81 Best practices.......................................................................5.82 Proactive attitudes................................................................5.85 Typical exhaust gas components.........................................5.87 Carbon dioxide ................................................................5.87 Carbon monoxide............................................................5.87 Oxides of nitrogen ...........................................................5.87 Hydrocarbons..................................................................5.87 Particulate matter ............................................................5.88 Oxides of sulfur................................................................5.88 Smoke..............................................................................5.88 Engine systems and conditions affecting diesel emissions..5.89 Combustion chamber design...........................................5.89 Intake manifold system....................................................5.91 Operating conditions that affect emissions......................5.92 Low turbocharger boost pressure....................................5.93 High exhaust backpressure.............................................5.93

_________________________________________________Table of contents ________________________________________________________________ A6474X279 REV 7 BI001883 High crankcase pressure.................................................5.95 Overview of six engine systems..............................................5.96 Overview of engine introduction...........................................5.96 Intake system ......................................................................5.97 Dry type air cleaners .......................................................5.98 Air induction piping..........................................................5.99 Aftercoolers.....................................................................5.99 Air-to-air aftercoolers.......................................................5.100 Water aftercoolers...........................................................5.100 Intake system recommendations ....................................5.101 Servicing the intake system.............................................5.102 Job aid checklist (Intake System)....................................5.103 Exhaust system ...................................................................5.104 Exhaust system recommendations.................................5.105 Exhaust after treatment system maintenance.................5.106 Job aid checklist for exhaust system...............................5.108 Introduction to tools used for exhaust system analysis...5.109 ECOM AC+ gas analyzer...........................................5.109 UGAS software application ........................................5.111 Testing protocol..........................................................5.111 Pre-test conditions......................................................5.112 Emissions testing protocol..........................................5.112 Basic emission equipment operation ..............................5.113 Undiluted diesel particulate measurement.................5.113 Measurement interpretation .......................................5.115 Analysis of particulate samples..................................5.115 Thermal optical method..............................................5.116 Job aid checklist for exhaust system analysis tools...5.116 ECOM AC+ gas analyzer...........................................5.117 Particulate sampling - Gilian pump.............................5.117 Intake testing..............................................................5.118 Intake restrictions and exhaust backpressure............5.119 Fuel injection system............................................................5.120 Introduction (Fuel injection system)................................5.120 Injection pump or injector failure.....................................5.121 Inadequate fuel supply....................................................5.121 Incorrect injection pump or injector timing.......................5.122 Advanced timing..............................................................5.122 Retarded timing...............................................................5.122 Fuel system types ...........................................................5.122 Individual unit jerk pumps................................................5.124 Inline pump system .........................................................5.125 Distributor pump system..................................................5.126 Cummins PT fuel system ................................................5.126 Unit injectors....................................................................5.127 Electronically controlled fuel injection systems...............5.127 Fuel injection system recommendations.........................5.128 Job aid checklist for fuel systems....................................5.129 Cooling systems...................................................................5.130 Cooling system recommendations..................................5.130 Cooling system maintenance..........................................5.131 Coolant mixture...............................................................5.131 Conditioner and inhibitors................................................5.131 Cleaning and flushing......................................................5.132

Table of contents_________________________________________________ ________________________________________________________________ SH650 D Roof Support Carrier BI001883 Troubleshooting...............................................................5.132 Thermostats.....................................................................5.132 Aeration in coolant...........................................................5.132 Radiator cap relief valve..................................................5.133 Temperature probe..........................................................5.133 Job aid checklist for cooling system)...............................5.134 Diesel fuel and fuel supply systems ....................................5.135 Introduction (Diesel fuel and fuel supply systems)..........5.135 Best practice recommendations......................................5.135 Sulfur content..................................................................5.136 Cetane number................................................................5.136 Viscosity..........................................................................5.136 Flashpoint........................................................................5.136 Fuel quality and handling recommendations...................5.137 Lubrication............................................................................5.138 Lubrication recommendations.........................................5.138 Lubrication classification .................................................5.139 Combined service applications........................................5.140 Lubrication system checks..............................................5.140 Conclusion.......................................................................5.141 Diesel emissions – job aid check list....................................5.142 Hydraulic system..................................................................5.143 Adjustment procedures........................................................5.145 Pressure compensated (PC) control...............................5.145 Main relief valve ..............................................................5.146 Steering section port relief valves...................................5.147 Pressure limiter ...............................................................5.147 Pressure reducing valve..................................................5.148 Bell crank bi-directional valve..........................................5.148 Auxiliary relief valve.........................................................5.150 Dif-lok valve.....................................................................5.151 Hand pump relief valve....................................................5.152 Replacement of wear parts..................................................5.153 Tire/wheel installation......................................................5.153 Axle removal/installation..................................................5.157 Drive shaft removal/installation .......................................5.160 Accumulator operation/precharging................................5.161 Ejector blade and cylinder removal/installation...............5.163 Canopy/cab removal .......................................................5.165 Steering cylinder..............................................................5.166 Tilt cylinder......................................................................5.168 Lift cylinder......................................................................5.170 Brake bleeding procedure...............................................5.172 DST Dry System™ .............5.173 On-board Cleaning System™.........................................5.173 Background ................................................................5.173 Activating....................................................................5.173 Diagnosing high exhaust backpressure.....................5.175 Procedure to replace the particulate filter...................5.177 Replacement exhaust particulate filters .....................5.178 Pre-operating inspection .................................................5.179 MSHA requirements...................................................5.179 System requirements..................................................5.179 Pre-operating inspection checklist..............................5.180

_________________________________________________Table of contents ________________________________________________________________ A6474X279 REV 7 BI001883 Operating instructions..........................................................5.181 Background....................................................................5.181 Starting the engine.........................................................5.181 Starting a cold engine (after extended parking) ............5.182 Automatic safety shutdown features..............................5.183 Manual shutdown features ............................................5.184 Excessive idling.............................................................5.184 Operating recommendations.........................................5.184 Stopping the engine and parking the machine..............5.185 Carbon Monoxide (CO) sampling procedure.......................5.186 Background....................................................................5.186 Reasons for monitoring engine-out CO emissions........5.187 Reasons for monitoring treated CO emissions (opt).....5.187 Permanently installed CO sampling ports.....................5.188 CO sampling procedure.................................................5.189 CO sampling instruments..............................................5.190 Maintenance for flameproof ports..................................5.191 CO sampling recordkeeping (sample form)...................5.192 Cooling system filling procedure..........................................5.193 Safety shutdown system......................................................5.194 System description (pneumatic system)........................5.194 Starting the system........................................................5.195 Manual system shutdown..............................................5.195 Manual emergency shutdown........................................5.195 Automatic temperature shutdown feature......................5.195 Automatic low oil pressure shutdown feature................5.196 MSHA documentation.................................................................5.197 Machine permissibility (drawing 624309).............................5.197 Power package permissibility (drawing M255-001-01)........5.205 Electric package permissibility (drawing M261-008-01).......5.217 General arrangement (drawing 624312)..............................5.222 Electrical schematic (drawing M261-003-01).......................5.224 Electrical installation (drawing M261-010-01)......................5.225 Alternator installation (drawing M250-107-01).....................5.226 Starting circuit - Cummins 8.3 (drawing M250-012-01) .......5.227 Cooling system (drawing M250-008-01)..............................5.228 Water injection system, pneumatic (drawing M265-006-01)5.229 CO monitoring ports (drawing M250-006-01) ......................5.230 Shutdown system (drawing M250-007-01)..........................5.231 Fuel system, C8.3 (drawing 624310)...................................5.232 Operator’s compartment (drawing 624311).........................5.233 Troubleshooting procedures.......................................................5.235 Hydraulic system (general) ..................................................5.236 Brakes..................................................................................5.239 Hydraulic cylinders...............................................................5.240 Hydraulic pump....................................................................5.242 Valves...................................................................................5.244 Engine..................................................................................5.245 Converter..............................................................................5.256 Transmission........................................................................5.258 Fuel injector..........................................................................5.259 Compressor..........................................................................5.259 Leaking intake system..........................................................5.261 Air intake system restriction and fuel flow............................5.261 Catalyst failure......................................................................5.261 Exhaust particulate filter failure............................................5.261

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BI001883

About this manual

_______________________________________________________________ ________________________________________________________________ BI001883

applicable operating manual machine type operation manual

About this manual

This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

This operating manual is intended for SH650 D roof support carrier and is only permitted to be used for equipment of this type.

The operating manual must be accessible at all times to all persons working on or with the machine. It should, if possible, always be available at the place of operation.

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine. Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who:

■ are in charge of transport

■ perform assembly/disassembly work

■ operate the machine

■ eliminate faults

■ perform daily routine work on the face or in the entry

■ perform maintenance work

■ perform repair work and supervisory personnel who:

■ initiate and/or

■ supervise the activities just indicated.

____________________________________________Before starting to work ______________________________________________________________ A6474X279 REV 7 1.3 BI001883

cost-effectiveness service safety

What is the purpose of this operating manual?

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

Read the chapter “Your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

Before

to work ____________________________________________ ________________________________________________________________ 1.4 SH650 D

BI001883

starting

Roof Support Carrier

Characters and symbols used

The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER!

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

WARNING!

These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

CAUTION!

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

NOTICE!

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

IMPORTANT!

Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

____________________________________________Before starting to work ______________________________________________________________ A6474X279 REV 7 1.5 BI001883

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL