Operation and Maintenance Manual
FH120 Face Haulage
SAFETY.CAT.COM
BI002283
A6474X322 May 2015
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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 machines. 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 Federal and State Mining 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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Caterpillar 2015 ALL RIGHTS RESERVED
Table of contents
1. About this manual
2. Your safety
3. Storage and transport
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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
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
Storage and transport ............................................................. 3.3 Storage ................................................................................. 3.3 Storage of the machine and spare parts ......................... 3.3 Transport .............................................................................. 3.4 Before transport ............................................................... 3.5
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
4.
5. Operation
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Operation ................................................................................. 5.3 How to operate the machine ................................................ 5.3 Who is allowed to operate the machine .......................... 5.3 When can operation be started? ..................................... 5.3 Controls and indicators......................................................... 5.4 Hazard zone ....................................................................... 5.21 Starting procedure .............................................................. 5.23 Machine operation ......................................................... 5.23 Shutdown procedure .......................................................... 5.26 Battery change procedure .................................................. 5.28 Hydraulic system overview ................................................. 5.35 Instructions on the maintenance ........................................ 5.56 Important notes ............................................................. 5.56 Before maintenance ...................................................... 5.56 Critical torque values ..................................................... 5.58 Lubricants, fluids and capacities ................................... 5.58 Specific lubrication and maintenance instructions ............. 5.59 Every shift ...................................................................... 5.62 Every third shift .............................................................. 5.62 First week of service ...................................................... 5.67 Weekly ........................................................................... 5.70 Every two weeks ........................................................... 5.74 Monthly .......................................................................... 5.75 Every six months ........................................................... 5.80 Hydraulic adjustment procedures ....................................... 5.82 Main pump settings ....................................................... 5.82 Control valve.................................................................. 5.85 Cylinders........................................................................ 5.86 Motor cutback pressure switch ...................................... 5.87 Sequence valve adjustment .......................................... 5.88 Auto retract pressure reducing valve ............................ 5.92 Auto retract pressure switch .......................................... 5.94 Battery lift suspension ................................................... 5.95 Brake system ................................................................. 5.96 Manual brake release hand pump relief valve .............. 5.98 Two wheel assist ........................................................... 5.99 Power fill flow control valve ........................................... 5.103 Hydraulic wheel end motors……………………………...5.104 Major maintenance ............................................................. 5.108 False bottom/ejector cylinder replacement ................... 5.108 Two wheel assist pump removal procedure .................. 5.110 Rear wheel motor removal/replacement ....................... 5.112 BBC06 series with brakes mechanical disconnect procedure ...................................................................... 5.113 Tire/wheel installation procedure .................................. 5.114 Hydraulic pump & motor removal/replacement ............. 5.118 Tailgate assembly removal procedure .......................... 5.121 Battery lift assembly removal procedure ....................... 5.122 Pedal assembly removal procedure .............................. 5.123 Canopy removal procedure ........................................... 5.124
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Technical
Technical data ......................................................................... 6.3 Components ......................................................................... 6.3 Tightening torques ................................................................ 6.4 Permissible data ................................................................. 6.10
6.
data
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About this manual
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applicable operating manual
machine type new 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 the model FH120 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
supervisory personnel who:
■ initiate and/or
■ supervise the activities just indicated.
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cost-effectiveness
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.
service safety
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 “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.
Before
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starting to
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. you carry out your work faster and more importantly, safer.
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Your safety
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further operating manuals
Your safety
This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible.
The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations. You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.
Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by the manufacturer.
Use only original spare parts. Note that the use of parts from other manufacturers will void the guarantee.
In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.
Observe the safety and accident prevention regulations:
■ of the mine,
■ of the mine inspector, and
■ of the mining supervisory authorities.
Please read also the operating manuals of the components required for operation, e.g. of gearboxes, electric motors, etc., carefully and thoroughly. Clarify any questions before starting work.
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state of the art
Personnel Operation
The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit. Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.
You must have adequate knowledge of the
■ mechanics,
■ hydraulics, and
■ control engineering and must be able to prove this knowledge.
Installation and repair
As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements. Installation and repair work on:
■ safety components (pressure relief valves, extinguishers, etc.)
■ the electrics (motors, controllers, etc.)
■ the hydraulics (controls, cylinders, etc.)
may only be carried out by service engineers or by specially qualified personnel of the mine.
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Hauler BI002283
FH120
training
Operating conditions
Intended use
The machine has been designed and manufactured purely for transporting of mined material from a continuous miner to the main conveying system for transporting outside.
Intended uses include:
■ the transport of mined material between continuous miner and main conveying system.
Unauthorized use
Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine including but not limited to:
■ the transport of persons
The manufacturer accepts no liability for any damage resulting from any such unauthorized use.
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Operating conditions
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• 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
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
