Operation Manual
SH620RoofSupportCarrier SAFETY.CAT.COM A6474X271 May2012
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ThismanualisintendedtoprovideGENERALproductinformationfor theModelSH620RoodSupportCarrier.Theillustrations,descriptions andprocedurescontainedinthispublicationapplyonlytoTHISmachine.Caterpillarreservestherighttorevisemodelsanddesignswithoutpriornotice.
ThisRoofSupportCarrierwasmanufacturedundertheguidelines,proceduresandrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart0, Part75forundergroundcoalmines,andotherapplicablenon-U.S. regulatoryagencystandards.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofCaterpillarand theseregulatoryagencies,oranyrepairorreplacementofpartscontrarytotheinstructions,mayinvalidatetheseapprovalsandrenderthis unitunsafetooperate.
StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourservicerepresentative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
__________________________________________________________
© CATERPILLAR2012 ALLRIGHTSRESERVED
_________________________________________________ Tableofcontents A6474X271 Rev2 Tableofcontents
Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual?....................1.4 Charactersandsymbols 1.5
1.
Yoursafety Yoursafety 2.3 Personnel 2.4 Operation 2.4 Installationandrepair......................................................2.4 Operatingconditions 2.5 Intendeduse 2.5 Unauthorizeduse 2.5 Safetyinstructions 2.7 Generalrules: 2.7 Storageandtransport 2.8 Pre-startinspection 2.8 Installationandstart-up 2.9 Operation 2.9 Stopping 2.10 Maintenanceandrepair 2.10 Overviewofthesafetyinstructions 2.15 Chapter3:Storageandtransport.................................. 2.15 Chapter4:Installation 2.15 Chapter5:Operation..................................................... 2.16 Chapter6:Technicaldata 2.23
2.
Storageandtransport Storageandtransport.............................................................3.3 Storage 3.3 Storageofthemachineandspareparts 3.3 Transport..............................................................................3.4 Beforetransport 3.5
3.
Installation Installation ...............................................................................4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation? 4.3 Whichtoolsarerequiredforinstallation?........................4.3 Notesoninstallation 4.4 Pre-installationchecklist 4.5 Safetyfeatures 4.6
4.
5. Operation
Tableofcontents _________________________________________________ ModelSH620RoofSupportCarrier
Operation..................................................................................5.3 HowtooperatetheSH620 5.3 WhoisallowedtooperatetheSH620.............................5.3 Whencanoperationbestarted? 5.3 Controlsandindicators 5.4 Operator’scompartment 5.4 Controlhandle .................................................................5.8 Hazardzone 5.16 Startingprocedure 5.17 General 5.17 Machineoperation 5.18 Shutdownprocedure 5.21 Proceduresforloadingandunloading TheLongwallroofsupport 5.23 Loadingfromthelongaxisoftheshield 5.23 Unloadingfromthelongaxisoftheshield ....................5.23 Loadingfromthesideoftheshield 5.24 Unloadingfromthesideoftheshield 5.25 Towingadisabledmachine 5.26 Batterychangeprocedure..................................................5.27 Instructionsonthemaintenance 5.33 Importantnotes..............................................................5.33 Beforemaintenance 5.33 Criticaltorquevalues.....................................................5.35 Lubricants,fluidsandcapacities 5.35 Specificlubricationandmaintenanceinstructions .............5.39 Everythirdshift 5.39 Weekly...........................................................................5.45 Monthly 5.51 Everythreemonths .......................................................5.52 Replacementofwearparts 5.57 Tire/wheelinstallation 5.57 Wheelmountingprocedure 5.59 Drivemotor/gearboxremoval/installation 5.61 Axleremoval/installation 5.65 Driveshaftremoval/installation 5.68 Pumpandmotorremoval/installation 5.70 Accumulatoroperationandprecharging 5.72 Bucketinstallation/removal 5.74 Ejectorbladeandcylinderremoval/installation 5.76 Canopy/cabremoval 5.78 Steeringcylinderremoval/installation 5.79 Tiltcylinderremoval/installation 5.81 Liftcylinderremoval/installation 5.83 Batteryliftcylinderremoval/installation .........................5.85 Liftplateinstallation/removal 5.87 Brakebleedingprocedure .............................................5.88 Adjustmentprocedures 5.89 Mainrelief - primary(mainimplement)pumpsection ...5.89 Unloadingvalve 5.90 Reliefvalve - brakecoolingmanifold.............................5.92
_________________________________________________ Tableofcontents A6474X271 Rev2 Troubleshootingprocedures 5.93 Hydraulicsystem(general) 5.94 Brakes 5.97 Hydrauliccylinders 5.99 Hydraulicpump 5.100 Valves...........................................................................5.102 6. Technicaldata Technicaldata .........................................................................6.3 Tighteningtorques................................................................6.5 Permissibledata 6.11 Lubricationfluidsandgreases ...................................... 6.11 7. Foryourinformation Foryourinformation...............................................................7.3 Ourservice 7.3 Serviceaddress...............................................................7.3 Rebuildfacilityaddress 7.4
_______________________________________________________________ 1 Aboutthismanual
applicableoperatingmanual
machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
ModelSH620RoofSupportCarrier SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
newoperationmanual
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingontheface,intheintersection betweenfaceandentry,orintheentrymustreadthisoperatingmanual.
Thisincludespersonswho:
■ areinchargeoftransport
■ performassembly/disassemblywork
■ operatethemachine
■ eliminatefaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/or
■ supervisetheactivitiesjustindicated.
________________________________________Beforestartingtowork A6474X271 Rev2 1.3
cost-effectiveness
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
service safety
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Yoursafety”withspecialattention.Thechaptercontainsimportantinformationindicatingpossiblehazards.Observethe informationgivenandfollowtheproceduralinstructions.
Beforestartingtowork ________________________________________ 1.4 ModelSH620RoofSupportCarrier
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER!
Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING!
Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE!
Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.
IMPORTANT!
Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterand,moreimportantly,safer.
________________________________________Beforestartingtowork A6474X271 Rev2 1.5
_______________________________________________________________
2 Yoursafety
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stateoftheart
Yoursafety
Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Themachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. Youandotherscanneverthelessbeexposedtodangeroussituations asaresultofenvironmentalinfluences,machinedamage,oroperator errors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.Allmodificationsandchangesmustbeapproved.
Useonlyoriginalspareparts.Notethattheuseofpartsfromother manufacturerswillvoidtheguarantee.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations
■ ofthemine,
■ oftheminesinspector,and
■ oftheminingsupervisoryauthorities
furtheroperatingmanuals
Pleasereadalsotheoperatingmanualsofthecomponentsrequiredfor operation,e.g.ofgearboxes,electricmotors,etc.,carefullyandthoroughly.Clarifyanyquestions before startingwork.
___________________________________________________ Personnel A6474X271 Rev2 2.3
Personnel
Operation
Themachinemayonlybeoperatedbyqualified,trainedpersonnel. Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit.Readingofthe operationmanual,especiallythechapteronsafety,shallconstitutea partofthistraining.
Youmusthaveadequateknowledgeofthe
■ mechanics,
■ hydraulics,and
■ controlengineering andmustbeabletoprovethisknowledge.
Installationandrepair
Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.
Installationandrepairworkon
■ safetycomponents(pressurereliefvalves,extinguishers,etc.),
■ theelectrics(motors,controllers,etc.),
■ thehydraulics(controls,cylinders,etc.),and mayonlybecarriedoutbyserviceengineersorbyspeciallyqualified personnelofthemine.
Personnel ___________________________________________________ 2.4 ModelSH620RoodSupportCarrier
training
Operatingconditions
Intendeduse
Themachinehasbeendesignedandmanufacturedpurelyfortransportingoflongwallsupportshieldsandforutilitywork.
Intendedusesinclude:
■ thetransportoflongwallsupportshields.
■ useduringcleanupandutilitywork.
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
Themanufactureracceptsnoliabilityforanydamageresultingfrom anysuchunauthorizeduse.
_________________________________________ Operatingconditions A6474X271 Rev2 2.5
general noiseemissions
Safetyinstructions
Generalrules:
Alwaysworkwithfullconcentration.
Familiarizeyourselfwithyourworkingenvironment.
Alwayswearyourpersonalprotectiveequipment.Thisincludesear protectorsasthenoiseemittedbyotherequipmentintheareamayat timesexceed85db(A).
Informyourcolleaguesof:
■ yourexactlocation,
■ theworkyouareperforming,and
■ thetimethatyouwillprobablyrequire.
safetyequipment
Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.emergencystopdevices,coverplates, etc.arecorrectlyinstalled.
Observetheacousticandopticalstart-upwarningsofthemachine.
symbolplates
emergencystop(panicstrip)
disconnectbattery
Observethesymbolplatesonthemachine.
Pressthe“POWERDISCONNECT”switchimmediatelyintheeventof faultorirregularitiesinoperation.Reportanypeculiaritytoyoursuperiorsothatnecessarymeasurescanbetakenimmediately.
Disconnectthebatterywhileperforming:
■ maintenancework
■ inspectionwork
■ repairwork
cordonoffworkingarea
movingparts
Cordonoffyourworkingareawidelyforthemachine.
Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchas:
■ forklifts
■ pivotpoints
■ batterylifts
steeringlockout
Connectthesteeringlockoutdevicebeforeperformingmaintenanceor repairsonthemachine.
___________________________________________
A6474X271 Rev2 2.7
Safetyinstructions
Storageandtransport
Maintaintheprescribedstorageperiodsandobservetheinstructions forstorage.
Donotstorematerialsorpartsinthetravelwayorinyourworking area.
Informthepersonsinvolvedabouttheintendedtransportrouteandthe anticipateddurationofthetransport.
Ensurethatthetransportsafetydevicesarecorrectlyfitted.
Fixallmovingpartswithtransportlocks.
Neverstandunderunsupportedpartsorsuspendedloads.
Connecttheliftingequipmentonlytothepointsofattachmentprovided forthatpurpose.Observethedifferentloadlimitsoftheattachment points.Also,observetheinstructionsonthetransportsheet.
Onlyusemeansofattachmentwhichareingoodconditionandhave beendesignedfortheloadstobehandled.
Forroundcomponents,usetransportstrapsonly.Neverusechainsor steelcablesforthispurpose.
Donotdamagethetreatedorpolishedsurfacesofshafts,sealingsurfaces,etc.
Whenusingmobilehandlingsystemsfortransport,makesurethatthe centerofgravityisaslowaspossible.
Pre-startinspection
Readthisentireguidebeforeattemptingtooperatethismachine. Inspectthemachineandhaveanymalfunctioning,broken,ormissing partscorrectedorreplacedbeforeuse.
Verifythatallmaintenancehasbeenperformed.
Verifythatallinstructionandsafetytagsareinplaceandreadable. Theseareasimportantasanyotherequipmentonthemachine.
Cleananyforeignmaterialfromtheoperator’scompartment.
Thismachinewasshippedfromthefactoryequippedwithaprotective cab/canopy.Thecab/canopymustbesecurelyinplacebeforeoperatingtheunit.
2.8
Safetyinstructions____________________________________________
ModelSH620RoofSupportCarrier
transportsafetydevice meansofattachment mobilehandlingequipment operation inspection maintenance instructionandsafetytags operator’scompartment cab/canopy
Installationandstart-up
Oninclinedfaces,secureallcomponentpartsbychains,e.g.tothe support.
Whenworkingwithoils,greases,andotherchemicalsubstances,observethesafetyregulationsapplicabletotheproduct.
Disposeofcleaningrags,etc.whichhavebeensoiledwithoil,grease, orotherchemicalsubstancesinanenvironmentallysafemanner.
Whenstartingupmachine,donotoperateanycontrolslocatedinside theoperator’scompartmentfromoutsidethecompartment.
FollowthestartingprocedureinstructionsinChapter5ofthismanual.
Donotoperateanylevers,pedals,orcontrolsifanyoneisinthehazard zone.(SeeHazardzoneinChapter5ofthismanual.)
Operation
Operatethemachineonlyifyouhaveaprofoundknowledgeofthecontrolelementsandtheirfunctions.Itisnecessarythatyouhavebeen tasktrainedontherespectivemachine.
Beforestart-up,ensurethattherearenopersonsorobstructionsinyour lineoftravelorinthearticulationareawhensteeringtheunit.
Checkthatallprotectivedevicesareinstalledonthemachineandfunctionproperly.
Cleantheoperator’scompartmentatregularintervals.Ensurethatthe operatingsymbolsarelegibleinordertoavoidanyoperatorerrorsand resultingaccidents.
Neverclimbontooroutofthemachinewhileitisinmotion.
Donotoperatethemachinewithanypartofyourbodyoutsideofthe operator’scompartmentinordertopreventbodypartsfrombeing crushedbetweenthemachineandoutsideobjects.
Useextremecautionwhentravelinginclosequartersorincongestedor blind-travelareas.Thewarninggongshouldbesoundedtoalertpersonnelofyourmovement.
Nevercarrypassengerstopreventthepassengersfrombeingthrown offorcrushedbetweenthemachineandoutsideobjects.
Alwaysfollowallsafetyrulesofeachparticularminewhenoperating themachine.
Ifproblemsormalfunctionsareencounteredwhileoperatingtheunit,it mustbeproperlyshutdownandtheproblemcorrectedimmediately.
_________________________________Overviewofsafetyinstructions A6474X271 Rev2 2.9
inclinedface environmentalacceptability
hazardzone controls training beforestart-up protectivedevices operator’scompartment traveling passengers
startingprocedures
safetyrules problemsandmalfunctions
Safetyinstructions____________________________________________
Stopping
Donotleavetheoperator’scompartmentwiththeunitrunning.Always properlyshutdowntheunitbeforeleavingtheoperator’scompartment. Alwaysparktheunitonsolid,levelground.Ifthisisnotpossible,park theunitatarightangletotheslopetopreventaccidentalmovementof themachine.
Useproperflags,warnings,orbarrierswhenparkinginareasoftraffic. Chockallfour(4)wheelsinbothdirectionswheneverpossible.
Maintenanceandrepair
Besuretoobservetheprescribedmaintenanceandinspectionintervals.
Informthesupervisorypersonnelandthefacecrewofanymaintenanceandrepairoperations.Givetheminformationontheintended operationsandtheanticipatedduration.
Secureyourworkingareaoverawiderangetoavoidendangering otherpersons.
Disconnectthebatteryfromthemachinetopreventunauthorizedand unintentionalrestarting.
Protectyourworkareaagainstfallingrocks.
Disconnectthebatteryfrommachinetopreventrestartingbeforereplacinganydefectivecomponents.
Passondefectivecomponentsremovedforservicingwithoutdelayto preventthesepartsfrombeingreinstalledelsewhere.
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. Thisisonlyensuredwithoriginalspareparts. Pleaserefertothesparepartslistsfortheordernumbers.
Forraisingthemachine,useonly:
■ cribblockswithadequateload-holdingcapacity,and
■ hoists,jacks,orcraneswithadequateload-carryingcapacity.
Avoiddirectcontactbetweentheskinandhydraulicfluids.Hydraulic fluidcanpenetratetheskinandcauseseriousinfection.
Neverusehydraulicfluidforrinsingorcleaning.Hydraulicfluidrepresentsaveryseriousdangertohealth.
2.10
ModelSH620RoofSupportCarrier
operator’scompartment parking securing replacingcomponents originalparts lifting handlingofhydraulicfluids
• 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
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