CATERPILLAR SH660 D Roof Support Carrier Operation & Maintenance Manual SN JE300564 – PDF DOWNLOAD

Operation and Maintenance Manual

Serial Number JE300564

• 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.

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.

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.

Maintenance Section

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. Items without specific intervals are listed under the “When Required” service interval. The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance.

Maintenance Intervals

Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and correlate with the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first.

Certified Engine Maintenance

Proper maintenance and repair is essential to keep the engine and machine systems operating correctly. As the heavy duty off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual.

Caterpillar Production Identification Number

Each Caterpillar machines has a unique identification number. This number can be found on the front frame of the machine in the articulation area and will follow the format below: JE3XXXXX

Illustration 1

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 SH660 D. 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.

Illustration 2

Illustration 3

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

Exhaust

Use caution. Exhaust fumes can be hazardous to your health. Do not work on the machine 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 machine’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

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 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 machine 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.

Illustration 4

Illustration 5

 The transmission is in neutral.

 All water, coolant, fuel, and oil levels have been checked.

 All job site specific checks have been completed.

NOTICE

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

Always ensure that the operator’s compartment door is securely closed.

Always familiarize yourself with the size and width of the machine relative to the space constraints within the job site.

Operation

During operation of the machine:

 Do not tie down or tow equipment with chains or slings that are not rated for the capacity of the machine and equipment.

 Always travel at low speeds in congested areas.

 Always slow down while traveling around corners and sound the horn frequently in areas of limited visibility.

 Always drive carefully, observing all traffic rules and regulations at your job site. Be in full control of the machine at all times.

 Always be aware of the impact of the payload to operator visibility.

 The recommended maximum speed when loaded is 10 km/h. The operator should use responsible judgement to drive to the conditions considering payload, visibility, and the design of the mine.

 Always take special care when traveling up or down grades.

Travelling at high speeds, on cross grades or articulating the machine with raised loads may cause the machine to become unstable. Always exercise caution, follow job site regulations, and consider variables such as payload, visibility, and mine configuration when operating the machine. Refer to job site JSA and SOP’s prior to towing with the machine. It is recommended that holes and ruts should be rectified as they may cause serious injury or damage to the equipment.

Always ensure that the area around the machine is clear of personnel when performing machine functional tests, including lift arm functions, steering, brake release and functional testing of any attachments that may be attached to the machines’s Power Take-Off (PTO) couplings.

Engine Stopping

Do not exit the machine unless:

 The machine is parked in a safe place.

 The transmission is in neutral.

 The park brake is applied and the brake head pressure gauge reads zero.

 The park brake is applied and the steer accumulator pressure reads zero.

 The lift arms are lowered.

 The engine is stopped.

Always allow the engine to idle prior to shutdown. Allow all systems, especially the engine, to cool sufficiently prior to commencing any maintenance or service.

Crushing Prevention and Cutting Prevention

Support the equipment properly before you perform any work or maintenance beneath that equipment. Beware that equipment can fall if a control is moved, or if a hydraulic line breaks.

Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running.

Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement such as articulation areas.

Stay clear of all rotating and moving parts. Always be aware of your surroundings.

If it is necessary to remove guards in order to perform maintenance, always install the guards after the maintenance is performed.

Use appropriate Personal Protective Equipment (PPE) when working on the machine.

Burn Prevention

Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the air system, in the oil system, in the lubrication system, in the fuel system, or in the cooling system before any lines, fittings, or related items are disconnected.

Coolant

When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all coolant lines to and from the engine contain hot coolant.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

Check the coolant level only after the engine has been stopped.

Ensure that the filler car is cool before removing the filler cap. Remove the filler cap slowly in order to relieve pressure.

Oils

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Remove the hydraulic tank filler cap only after the engine has been stopped. The filler cap must be cool to touch prior to removal. Follow the procedure outlined in the manual to remove the hydraulic tank filler cap.

Fire Prevention and Explosion Prevention

Illustration 6

General

All fuels, most lubricants, and some coolant mixtures are flammable.

To minimize the risk of fire or explosion, Caterpillar recommends the following actions:

Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a machine when a fire hazard exists. Contact your Cat dealer for service.

Do not operate a machine with a fluid leak. Repair leaks and clean up fluids before resuming machine operation. Fluids that are leaking or spilled onto hot surfaces or into electrical components can cause a fire. A fire may cause personal injury or death.

Remove flammable material such as leaves, twigs, papers, trash, and so on. These items may accumulate in the engine compartment or around other hot areas and hot parts on the machine.

Keep the operator’s compartment door closed and in working condition. Identify the location of the fire extinguisher and all available fire suppression equipment.

Clean all accumulations of flammable materials such as fuel, oil, and debris from the machine.

Keep shields in place. Do not modify any of the wet exhaust cooling jackets on the exhaust manifold and downpipe. The purpose of the wet exhaust system is reduce the surface temperatures of exhaust components.

Do not weld or flame cut on tanks or lines that contain flammable fluids or flammable material.

Inspect all lines and hoses for wear or deterioration. Replace damaged lines and hoses. The lines and the hoses should have adequate support and secure clamps. Tighten all connections to the recommended torque.

Store fuels and lubricants in properly marked containers away from unauthorized personnel. Store oily rags and flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials.

Wiring

Check electrical wires daily. If any of the following conditions exist, replace parts before you operate the machine.

 Fraying

 Signs of abrasion or wear

 Cracking

 Discoloration

 Cuts on insulation

 Other damage

Make sure that all clamps, guards, clips, and straps are reinstalled correctly. This will help to prevent vibration, rubbing against other parts, and excessive heat during machine operation.

Attaching electrical wiring to hoses and tubes that contain flammable fluids or combustible fluids should be avoided.

Use caution when you are fueling a machine. Do not smoke while you are fueling a machine. Do not fuel a machine near open flames or sparks. Always stop the engine before fueling. Fill the fuel tank outdoors. Properly clean areas of spillage.

Never store flammable fluids in the operator compartment of the machine.

Fire Extinguisher

Know the location of your fire extinguisher. Be familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and service the fire extinguisher regularly. Follow the recommendations on the instruction plate.

Fire on a machine can result in personal injury or death. Exposed battery cables that come into contact with a grounded connection can result in fires. Replaces cables and related parts that show signs of wear or damage. Contact your Cat dealer.

Fire Safety

The underground operation of this machine in a coal mine is a potentially hazardous situation. Methane gas that is expelled by mining coal can be extremely deadly if an open flame is present.

If you find that you are involved in a machine fire, your safety and that of others on site is the top priority. Remember, if you are unable to do anything else, shut off the machine before exiting the operator’s compartment and engage the parking brake.

In the event where emergency shutdown is required, this machine is equipped with an emergency shutdown button that actuates a valve to cut off the air intake to the engine. There is also a manual valve that cuts off the fuel supply to the engine. This manual will cover the locations of these safety features.

Illustration 7

Electrical Storm Injury Prevention

If the machine is above ground and lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures:

Mount the machine.

Dismount the machine.

If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

Hazard Sources

Always be aware of the hazard sources:

 Engine coolant temperature.

 Engine coolant pressure.

 Engine exhaust temperature.

 Rotating radiator fan.

 Spinning engine auxilary drives and belts (ex: drive belt for the water pump).

 Stored hydraulic pressure.

 Stored air pressure in the air receiver.

 Engine oil temperature.

 Engine oil pressure.

 Transmission oil temperature.

 Articulation areas.

 Lift arm area.

 Machine size and mass.

 Unplanned trailer movements.

Product Information Section

General Information

This manual contains product information for the Caterpillar SH660 D Roof Support Carrier. The operation of heavy mining machinery can be hazardous. To ensure safe operation, operators, personnel must be alert, competent, correctly trained, tested and licensed in the principles, capabilities and correct operating and isolation procedures of the machinery.

The SH660 D is a 60000 kg high capacity Roof Support Carrier. It has been designed for lifting and carrying heavy pieces of equipment and machinery in the underground coal mines. Its main function is carrying and placing of longwall equipment and shields. The machine comes standard with a set of fork tines and winch for this purpose.

The SH660 D is powered by a 172 kW (230 HP) Caterpillar 3126 turbocharged four-stroke inline six cylinder flameproof diesel engine package. Flameproofing of the system includes a wet exhaust conditioning system complete with intake flame trapand dual particulate filtration. The start system is pneumatic. The Diesel Control System (DCS) is an intrinsically safe electronic monitoring system. The engine power output is connected to the constant four-wheel drive system via a drive coupling through a four-speed bidirectional power shift transmission to heavy duty axles.

The SH660 D Roof Support Carrier utilises a wet bath exhaust system complete with an exhaust purifier and replaceable particulate filters.

NOTICE

A site specific Risk Assessment is recommended before introducing this machine into service.

Machine Specifications

All specifications are subject to change without notice. Always consult the Dealer to obtain current information before applying critical loads.

• 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.