CAT FH110 Face Haulage Operation and Maintenance Manual A6474X432 - PDF DOWNLOAD

BI001487 A6474X432 April 2015

Operation and Maintenance Manual FH110 Face Haulage

SAFETY.CAT.COM

BI001487

__________________________________________________________

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

This machine was manufactured under the guidelines, procedures and requirements of 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.

© Caterpillar 2015 ALL RIGHTS RESERVED

BI001487

________________________________________________ Table of contents

Table of contents 1. About this manual 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

2. Your 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

3. Storage and transport 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

________________________________________________________________ A6474X432

REV 3

BI001487

Table of contents _________________________________________________ 5. Operation 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 Operator’s compartment.................................................. 5.4 Hazard zone ....................................................................... 5.16 Starting procedure .............................................................. 5.17 Machine operation ......................................................... 5.18 Shutdown procedure .......................................................... 5.21 Battery change procedure .................................................. 5.23 Instructions on the maintenance ........................................ 5.29 Important notes ............................................................. 5.29 Before maintenance ...................................................... 5.29 Critical torque values ..................................................... 5.31 Lubricants, fluids and capacities ................................... 5.31 Specific lubrication and maintenance instructions ............. 5.35 Every shift ...................................................................... 5.35 Every third shift .............................................................. 5.36 First week of service ...................................................... 5.41 Weekly ........................................................................... 5.45 Every two weeks ........................................................... 5.50 Monthly .......................................................................... 5.51 Every six months ........................................................... 5.58 Optional wheel end motor maintenanceBBBBBB...5.60 Instructions on the adjustment procedures ........................ 5.65 Main hydraulic system pressure .................................... 5.65 Steering relief pressure ................................................ 5.66 Gearbox oil filter system circuit relief pressure ........... 5.67 False bottom/ejector blade sequence valve ................. 5.68 Gear case and planetary wheel end shim procedure Number 1 ....................................................................... 5.69 Gear case and planetary wheel end shim procedure Number 2 ....................................................................... 5.70 Major maintenance ............................................................. 5.73 Drive motor/gear case .................................................. 5.73 Gear case & brake module ........................................... 5.76 Planetary wheel end ..................................................... 5.79 Gear case/planetary wheel end shimming - Proc 1 ...... 5.81 Gear case/planetary wheel end shimming - Proc 2 ...... 5.82 Gear case/planetary wheel end shimming - Proc 3 ...... 5.84 False bottom/ejector cylinder replacement ................... 5.86 Accumulator operation and precharging ...................... 5.89 2-wheel assist pump ..................................................... 5.92 Rear wheel motor (hydraulic) ....................................... 5.93 Tire/wheel installation ................................................... 5.95 Recommended wheel mounting ................................... 5.97 Hydraulic pump & motor ............................................... 5.99 Battery lift assembly ..................................................... 5.101 Canopy ......................................................................... 5.103 Tailgate assembly ........................................................ 5.105 Adjustable pedal assembly (if equipped) ...................... 5.106

________________________________________________________________ FH110

BI001487

________________________________________________ Table of contents 6. Technical data Technical data ......................................................................... 6.3 Tightening torques ................................................................ 6.7 Permissible data ................................................................. 6.13 Lubrication fluids and greases ....................................... 6.13

________________________________________________________________ A6474X432

REV 3

BI001487

Table of contents _________________________________________________

________________________________________________________________ FH110

BI001487

_______________________________________________________________

1

About this manual

________________________________________________________________

BI001487

_______________________________________________________________

________________________________________________________________

BI001487

___________________________________________ Before starting to work

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 applicable operating manual

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

machine type

This operating manual is intended for the model FH110 and is only permitted to be used for equipment of this type.

new operation manual

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 prepare the rise heading 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.

______________________________________________________________ A6474X432 REV 3 1.3

BI001487

Before starting to work ____________________________________________ What is the purpose of this operating manual? cost-effectiveness

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

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

safety

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.

________________________________________________________________ 1.4 FH110

BI001487

___________________________________________ Before starting to work 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.

______________________________________________________________ A6474X432 REV 3 1.5

BI001487

Before starting to work ____________________________________________

________________________________________________________________ 1.6 FH110

BI001487

_______________________________________________________________

2

Your safety

________________________________________________________________

BI001487

_______________________________________________________________

________________________________________________________________

BI001487

______________________________________________________ Personnel

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. state of the art

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 Caterpillar.

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:

additional manuals

■

of the mine.

■

of the Mines Inspector and

■

of the mining supervisory authorities

Read 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.

______________________________________________________________ A6474X432 REV 3 2.3

BI001487

Personnel _______________________________________________________ Personnel Operation training

The machine may only be operated by qualified, trained personnel.

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.

________________________________________________________________ 2.4 FH110

BI001487

_____________________________________________ Operating conditions 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.

■

the transport of persons

Caterpillar accepts no liability for any damage resulting from any such unauthorized use.

______________________________________________________________ A6474X432 REV 3 2.5

BI001487

Operating conditions _____________________________________________

________________________________________________________________ 2.6 FH110

BI001487

_______________________________________________ Safety instructions Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 dB(A).

Inform your colleagues of:

safety equipment

■

your exact location.

■

the work you are performing.

■

the time that you will probably require.

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the machine.

symbol plates emergency stop (panic strip)

disconnect battery

cordon off working area moving parts

steering lockout

Observe the symbol plates on the machine.

Press the EMERGENCY STOP switch immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Disconnect the battery while performing: ■

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

Never allow parts of your body to come between parts which could move, such as e.g.: ■

false bottoms

■

pivot points

■

battery lifts

Connect the steering lockout device before performing maintenance or repairs on the machine.

______________________________________________________________ A6474X432 REV 3 2.7

BI001487

Safety instructions _______________________________________________ Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.

mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

Pre-start inspection operation

Read this entire guide before attempting to operate this machine.

inspection

Inspect the machine and have any malfunctioning, broken or missing parts corrected or replaced before use.

maintenance instruction and safety tags

operator’s compartment canopy

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

These are as important as any other equipment on the machine.

Clean any foreign material from the operator’s compartment.

This machine was shipped from the factory equipped with a protective canopy. The canopy must be securely in place before operating the unit.

________________________________________________________________ 2.8 FH110

BI001487

____________________________________ Overview of safety instructions Installation and start-up inclined face

environmental acceptability

On inclined faces secure all component parts by chains, e.g. to the support.

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

controls

When starting up machine, do not operate any controls located inside the operator’s compartment from outside the compartment.

starting procedures

Follow the starting procedure instructions in chapter 5 of this manual.

hazard zone

Do not operate any levers, pedals or controls if anyone is in the hazard zone. (See Hazard zone in Chapter 5 of this manual)

Operation training

Operate the machine only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective machine.

before start-up

Before start-up, ensure that there are no persons or obstructions in your line of travel or in the articulation area when steering the unit.

protective devices

Check that all protective devices are installed on the machine and function properly.

operator’s compartment

Clean the operator’s compartment at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

Never climb onto, or climb out of the machine while it is in motion.

Do not operate the machine with any part of your body outside of the operator’s compartment in order to prevent body parts from being crushed between the machine and outside objects .

traveling

Use extreme caution when traveling in close quarters or in congested or blind-travel areas. The warning gong should be sounded to alert personnel of your movement.

passengers

Never carry passengers to prevent the passengers from being thrown off or crushed between the machine and outside objects.

safety rules

Always follow all safety rules of each particular mine when operating the machine.

problems and malfunctions

If problems or malfunctions are encountered while operating the unit, it must be properly shutdown and the problem corrected immediately.

______________________________________________________________ A6474X432 REV 3 2.9

BI001487

Safety instructions _______________________________________________ Stopping operator’s compartment

Do not leave the operator’s compartment with the unit running. Always properly shutdown the unit before leaving the operator’s compartment.

parking

Always park the unit on solid, level ground. If this is not possible, park the unit at a right angle to the slope to prevent accidental movement of the machine.

Use proper flags, warnings or barriers when parking in areas of traffic.

Chock all four (4) wheels in both directions whenever possible.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration. securing

Secure your working area over a wide range, in order to avoid endangering other persons.

Disconnect the battery from the machine to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

replacing components

Disconnect the battery from machine to prevent from restarting before replacing any defective components.

Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

lifting

handling of hydraulic fluids

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original spare parts. Please refer to the spare parts lists for the order numbers.

For raising the machine use only: ■

crib blocks with adequate load-holding capacity.

■

hoists, jacks or cranes with adequate load-carrying capacity.

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

Never use hydraulic fluid for rinsing or cleaning. Hydraulic fluid represents a very serious danger to health.

________________________________________________________________ 2.10 FH110

BI001487

_______________________________________________ Safety instructions maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work on the hydraulic system.

Avoid, whenever possible, servicing, cleaning or examining the machine in congested areas.

Avoid, whenever possible, servicing or providing maintenance to the unit unless the wheels are chocked and steering lockout device is connected to prevent accidental movement of the unit.

Do not alter the electrical or hydraulic settings from that indicated in this manual or as set at the factory.

Always replace damaged or lost decals and metal instruction plates.

Disconnect the battery when working with the electrical system, or when welding on the unit to prevent electrical shock.

Be sure the battery area is well ventilated (clear of fumes) when it is necessary to connect battery charger. Fumes from the battery could ignite from a spark and explode.

Always follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: ■

the hoses are not pinched or trapped.

■

the hoses have no bubbles or blisters.

■

the hose or outer sheathes of the hose are not abnormally rigid or hard.

■

the outer sheath of the hoses is not damaged.

■

the connectors are securely inserted into the sockets.

■

the connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage in the whole system!

Flush out the hydraulic lines thoroughly before connecting.

______________________________________________________________ A6474X432 REV 3 2.11

BI001487

Safety instructions _______________________________________________ If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn orings.

Replace hydraulic hoses only with hoses of the same or a higher quality.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

________________________________________________________________ 2.12 FH110

BI001487

_______________________________________________ Safety instructions laying hydraulic hoses

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting Right

■

Wrong

are not bent directly behind the connections. (distance min. 1.5 x nominal diameter).

Fig. 3: Laying hydraulic hoses, bending Right

Wrong

______________________________________________________________ A6474X432 REV 3 2.13

BI001487

Safety instructions _______________________________________________ ■

always have a little slack.

Fig. 4: Laying hydraulic hoses, crossing Right

■ ■ ■ ■

Wrong

are not kinked. do not have to withstand tensile strains. are protected against thermal radiation. are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

When installing the hydraulic hoses, ensure that they cannot be: ■ ■ ■ ■ ■

torn out, kinked, crushed, driven over or twisted by movement of the machine.

Fig. 5: Laying hydraulic hoses, connections on moving parts Right

Wrong

________________________________________________________________ 2.14 FH110

BI001487

_______________________________________________________________

3

Storage and transport

________________________________________________________________

BI001487

_______________________________________________________________

________________________________________________________________

BI001487

____________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the machine. Observance of the instructions and tips will increase the service life and availability of the machine. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

Components coated with temporary corrosion inhibitor are protected for approximately six months.

Before delivery, the hydraulically operated equipment is operated and all gear boxes, hydraulic oil tank, etc. are filled to their maximum fill point.

Storage of the machine and spare parts no direct exposure to sunlight

dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic – such as seals and hoses – and hydraulic fluids only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).

Protect the equipment and all spare parts stored outdoors against moisture and dirt, e.g. using tarpaulins.

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.

short-term storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

long-term storage

If the equipment is to be stored more than six months, the hydraulic components must be completely filled with a corrosion inhibiting/frostproofing fluid such e.g. CV 50.

Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow.

Then seal the ports with plastic or steel plugs.

The equipment must be stored in a well ventilated, dry room. Do not store outdoors.

______________________________________________________________ A6474X432 REV 3 3.3

BI001487

Storage and transport _____________________________________________ plastic deformation

In order to prevent plastic deformation of the seal elements, cylinders must be stored in an upright position. Some cylinders must be removed so that they can be stored upright.

random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

On request, the inspection can be carried out by your Service Representative.

natural aging

Even with proper storage, seals and hoses are subject to natural ageing. Do not use these parts if they have been stored for more than two years.

HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

IMPORTANT! Take care to insure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

Transport Load units; dimensions and weights Observe the transport sheets for the machine and spare parts. They contain information on: ■

Dimensions

■

Weight

■

lifting points, etc.

Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

________________________________________________________________ 3.4 FH110

BI001487

____________________________________________ Storage and transport Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid (e.g. CV 50).

Transport of equipment at temperatures between -6° F (-21° C) and 40° F (-40° C) is only permissible when certain measures were taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport.

electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

______________________________________________________________ A6474X432 REV 3 3.5

BI001487

Storage and transport _____________________________________________

________________________________________________________________ 3.6 FH110

BI001487

_______________________________________________________________

4

Installation

________________________________________________________________

BI001487

_______________________________________________________________

________________________________________________________________

BI001487

_____________________________________________________ Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on: the safety components (pressure relief valves, fire extinguishing equipment etc.) the electrical equipment (control units, signaling devices, etc.)

And the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by service engineers or by specially trained personnel.

Which tools are required for installation? tool box

Standard tools are required to put the machine into service.

The battery plugs and receptacles come with a special wrench for connecting and disconnecting battery plugs and receptacles.

In addition, various items of auxiliary equipment and machines may be required at the point of installation.

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

______________________________________________________________ A6474X432 REV 3 4.3

BI001487

Installation ______________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the machine as a result of incorrect installation. The unit should therefore only be installed under the instruction of specialists. installation plan

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established

________________________________________________________________ 4.4 FH110

BI001487

_____________________________________________________ Installation Pre-installation check list NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: ■

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

clean any foreign material from the operator’s compartment

■

clean any foreign material from behind the ejector blade and false bottom

■

check safety provisions for operational condition on fire suppression system

■

start up the machine and check for correct operation of panic switch (s) which are located inside the operator’s compartment

■

check that all covers and guards are in place and secure

■

check that all tags and instruction labels are in place and secure

■

check that operator’s canopy is secure and in place

■

start the machine and allow the hydraulic system to warm up for five (5) to ten (10) minutes

■

check hydraulic system pressures (see spare parts manual for proper hydraulic schematic)

■

check all control handles and switches to ensure all machine functions are operating properly

______________________________________________________________ A6474X432 REV 3 4.5

BI001487

Installation ______________________________________________________ Safety features NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

Reference Fig. 6 panic strips

The machine is equipped with two (2) panic strips located inside the operator’s compartment. The panic strip is used to break the control circuit, stopping all motors. Striking with a small amount of force will actuate the panic strip.

emergency stop button

The machine is equipped with an emergency stop button, located on the control station in the operator’s compartment. Pushing the emergency stop button will break the control circuit, stopping all motors, and will turn off the main circuit breaker.

circuit breaker reset

The machine is equipped with a circuit breaker reset located inside the operator’s compartment. The circuit breaker reset may be used to shutdown the machine in emergency situations.

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators. One is located in the operator’s compartment and the other is located on the side of the machine opposite the operator. This system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

warning gong

The machine is equipped with a warning gong. Follow all applicable rules and regulations regarding the sounding of the warning gong.

canopy

The machine was shipped from the factory with a protective canopy.

Ensure that the canopy is in place and secure at all times to protect the operator from fall debris.

guards and covers

The machine is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.

DANGER! Do not operate the machine any of the guards or covers removed.

You or other personnel could be seriously injured from moving or rotating parts.

The machine is equipped with a steering lockout. The lockout should be connected and secure during shutdown and while performing ________________________________________________________________ maintenance on the machine.

4.6 FH110 steering lockout

BI001487

_____________________________________________________ Installation Fig. 6: Safety features

Fire suppression actuator

Canopy

Steering lock (stored location) Steering lock (installed location)

Panic strip

Fire suppression actuator

Warning gong

Emergency stop

Circuit beaker reset lever

Panic strip

______________________________________________________________ A6474X432 REV 3 4.7

BI001487

Installation ______________________________________________________ Fig. 7: Overview of the machine Battery Controller

Center section Ejector blade

False bottom

Operator’s compartment

Nose cone

Hydraulic oil tank

________________________________________________________________ 4.8 FH110

BI001487

_______________________________________________________________

5

Operation

________________________________________________________________

BI001487

_______________________________________________________________

________________________________________________________________

BI001487

______________________________________________________ Operation

Operation This chapter contains important information on the operation and maintenance of the machine. It also includes instructions on the replacement of wear parts.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

How to operate the machine DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the machine?

The machine is only allowed to be operated by persons with adequate knowledge of the complete machine.

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can operation be started?

Operation must not be started until the safe condition and proper function of the complete machine has been checked and the daily maintenance operations have been carried out.

______________________________________________________________ A6474X432 REV 3 5.3

BI001487

Operation _______________________________________________________ Controls and indicators Operator’s compartment The primary controls for the machine are located in the operator’s compartment (Fig. 8).

Fig. 8: Operator’s compartment 1

2

5

3

6

7

4

8

9

10

11

12

5

13

14

1. Control station 2. Assist light 3. Control system display 4. Breaker reset lever 5. Panic strip (2) 6. Fire suppression actuator 7. Warning gong 8. Control stick/left hand steering 9. Brake 10. Foot speed switch (accelerator) 11. Diverter valve, battery lift/lock 12. Valve bank 13. Gauge panel 14. Hand pump, emergency brake release

________________________________________________________________ 5.4 FH110

BI001487

______________________________________________________ Operation control station

The control station (Fig. 9) is located to the left of the operator. Table 1 describes the functions of control and indicators located on the control station.

Fig. 9: Control station

1

6

5

2

3

4

Table 1: Control station controls and indicators Component 1. EMERGENCY STOP

2. ASSIST LIGHT

3. SPEED

Function

Operation

Opens the machine circuit breaker, shutting down the machine, and applies the park brake.

1. To activate, strike with a small amount of force.

Turns the assist light (Fig. 8) on and off.

1. Push to turn the light on.

2. Push again to turn the light off.

Used to change tram speed.

1. Push to change speed from low to high.

2. To reset, reset the circuit breaker and run the HiPAC 10 diagnostics function.

2. Push again to change speed from high to low.

4. Counter

5. PLC LED Indicators

Used to count the number of payloads.

Used to monitor the control system inputs and outputs.

1. To count, press the button after each load.

2. To reset, press and hold the button for five (5) seconds.

Display only.

6. I/S Relay LED Indica- Provide a visual indication of 1. A red LED indicates a line fault. tors operator controls communica- 2. A green LED indicates power is on. tion with the control system.

3. A yellow LED indicates output is OK. For more information, see the machine’s electrical schematic.

______________________________________________________________ A6474X432 REV 3 5.5

BI001487

Operation _______________________________________________________ Fig. 10: Controls and indicators 1

4

2

5

6

3

7

8

9

4

10

________________________________________________________________ 5.6 FH110

BI001487

______________________________________________________ Operation Table 2: Controls and indicators

Component 1. Assist light

Function

Operation

Provides operator compartment lighting.

1. To position light, pull the spring loaded knob down and swivel the mounting plate until the light is pointed in the desired direction then release the spring loaded knob and lock in position.

2. To operate the light, please see Table 1.

2. HiPAC 10 display

Display unit for the machine control unit.

3. Circuit breaker lever

Used to turn off, on, and reset 1. Move the lever to the desired position as indicated on the tag. the machine circuit breaker.

WARNING! The machine circuit breaker de-energizes the electrical controller and motors. However, electrical power is still present inside the controller to the circuit breaker. If the circuit breaker inside the controller requires service, the battery plug should be disconnected from the machine.

Please see document A6474X328 for display information.

IMPORTANT! Do not use the circuit breaker lever as an on/off switch for normal operation.

Follow shutdown procedures outlined in this manual.

WARNING! Ensure all electrical switches are in the off position before the circuit breaker lever is moved to the on position.

Note: The circuit breaker cannot be turned on until diagnostics is run and the system okay message is displayed.

4. Panic strip

Used to break the control circuit, stopping all motors and applying the park brake.

5. Fire suppression actuator

1. Pull the safety pin and strike the plunger.

Activates the pneumatically actuated fire suppression sys- IMPORTANT! If the fire suppression system is tem. activated, it must be completely recharged with chemicals and expellants.

6. Warning gong

Used as an audible warning device.

1. Strike the panic strip with a small amount of force to activate.

1. Strike the knob in the center of the gong to sound.

IMPORTANT! Follow all applicable rules and regulations regarding sounding the warning gong.

7. Foot speed switch (accelerator)

Used to control tram speed.

1. To increase tram speed, press the pedal. The farther the pedal is pushed, the faster the machine will travel.

CAUTION! Do not depress the accelerator while braking, or when the park brake is applied.

Even though the machine is equipped with overload protection, tram motor overload may occur and tram motor life will be affected.

______________________________________________________________ A6474X432 REV 3 5.7

BI001487

Operation _______________________________________________________ Table 2, continued: Controls and indicators

Component 8. Brake pedal

Function

Operation

Used to apply the brakes, 1. When the machine is running, the brake circuit slowing or stopping tramming. pressure, as displayed by the ACCUMULATOR gauge, should read 1,400 psi.

WARNING! If the pressure is not 1,400 psi, do not operate the machine as the brakes will not be functional.

2. Depress the brake pedal to slow or stop the machine. The farther the pedal is pressed, the more speed should be reduced.

9. Diversion valve, battery lift/battery lock

Used to control the function of 1. Pull the button out for battery lift function. the “BATTERY” section of the 2. Push the button in for battery lock function. valve bank.

10. Hand pump, emergency brake release

1. To release the brakes, ensure that the hand Used to release the spring pump drain valve is completely closed (turned applied (on), pressure release clockwise). Using the handle, pump until the (off) emergency brakes durbrake pressure gauge indicates the minimum ing hydraulic system failure. required pressure of 1,500 psi.

2. To apply the brakes, turn the hand pump drain valve counterclockwise to drain the brake circuit. When the brake pressure gauge reads 0 psi, close the valve by turning the handle clockwise. Return the handle to the storage position.

WARNING! The hand pump drain valve must be returned to the normal (closed) position before continuing to operate the machine. Failure to do so may result in hydraulic system pressure spikes that could damage the hand pump.

________________________________________________________________ 5.8 FH110

BI001487

______________________________________________________ Operation control handle/ left hand steering lever

The control handle (Fig. 11) functions are listed in Table 3. For full operating procedures, see the Operating Procedures section of this manual.

Fig. 11: Control handle

4

5

6 3

7 2

8

1

9 10

______________________________________________________________ A6474X432 REV 3 5.9

BI001487

Operation _______________________________________________________ Table 3: Controls handle functions Component 1. TRAM (battery end)

Function Activates tramming toward the battery end of the machine.

Operation 1. To enable tramming (pump motor must be running and park brake must be released. a. Press the in-position button and hold. b. Depress the TRAM button and hold. c.

Hold both the TRAM and in-position buttons in until the display indicates tram selection.

d. Release the TRAM button. e. Release the in-position button.

2. To disable tramming, push the TRAM button.

Note: Tram speed is controlled by the foot speed switch (accelerator).

2. LIGHTS (battery end) Activates the lights on the battery end of the machine.

1. To activate the lights, press the LIGHT button.

2. To activate Auto Position lights (headlights follow the selected tram direction): a. Press the In-Position button and hold. b. Press the battery end LIGHTS button (LIGHTS ). c.

Release the In-Position button.

Lights will stay in the auto position until STOP or either LIGHT button is pushed.

3. TRACTION ASSIST

Engages traction assist.

1. To engage traction assist, press the button.

2. To disengage, release the button.

IMPORTANT! Traction assist can be used as necessary, however, battery life will be prolonged if traction assist is disengaged whenever possible.

4. PUMP START

Used to start the pump motor and to stop the pump motor and set the park brake.

1. To start the pump motor: a. Press the In-Position button and hold. b. Press the PUMP START button and hold until the pump motor starts. c.

Release the PUMP START button.

d. Release the In-Position button.

2. To stop the pump motor: a. Press the PUMP START button

________________________________________________________________ 5.10 FH110

BI001487

______________________________________________________ Operation Table 3, continued: Controls handle functions Component 5. PARK BRAKE

Function Used to set or release the park brake.

Operation 1. To set the park brake and leave the pump motor running: a. Press the PARK BRAKE button 2. To release the park brake (pump motor must be running): a. Press the In-Position button and hold. b. Press the PARK BRAKE button and hold until the display indicates “PARK BRAKE RELEASED”. c.

Release the In-Position button.

d. Release the PARK BRAKE button.

6. STOP

Used to shut down the machine—stops the pump motor, turns off the lights, and sets the park brake.

1. Press the STOP button

7. LIGHTS (trailer end)

Activates the lights on the trailer end of the machine.

1. To activate the lights, press the LIGHT button.

2. To activate All Position lights (headlights follow the selected tram direction): a. Press the In-Position button and hold. b. Press the battery end LIGHTS button (LIGHTS ). c.

Release the In-Position button.

Lights will stay in the auto position until STOP or either LIGHT button is pushed.

8. TRAM (trailer end)

Activates tramming toward 1. To enable tramming (pump motor must be runthe trailer end of the machine. ning and park brake must be released). a. Press the in-position button and hold. b. Depress the TRAM button and hold. c.

Hold both the TRAM and in-position buttons in until the display indicates tram selection.

d. Release the TRAM button. e. Release the in-position button.

2. To disable tramming, push the TRAM button.

Note: Tram speed is controlled by the foot speed switch (accelerator).

______________________________________________________________ A6474X432 REV 3 5.11

BI001487

Operation _______________________________________________________ Table 3, continued: Controls handle functions Component

Function

9. Diagnostics

Activates the HiPAC 10 machine diagnostics function.

10. In-Position

Used in conjunction with other buttons to activate a function.

Steering

The control handle is mounted to a steering control lever.

The control handle/steering lever is used to steer the machine.

Operation 1. Press the diagnostics button and hold until a message is given on the display.

1. To steer left while moving forward (or right when moving in reverse), slowly pull the steering control lever toward the operator.

2. To steer right while moving forward (or left when moving in reverse), slowly push the steering control lever away from the operator.

________________________________________________________________ 5.12 FH110

BI001487

______________________________________________________ Operation hydraulic valve bank

The hydraulic valve bank (Fig. 12) has handles used to operate the machine’s hydraulic functions (Table 4). The gauges (Fig. 12, Table 4) display the hydraulic pressure in specified hydraulic circuits.

Fig. 12: Hydraulic valve bank and gauge panel

1 5 2 6

3 7 4

1.

2.

3.

4.

5.

6.

7.

EJECTOR ARTICULATION BATTERY LIFT/BATTERY LOCK PTO ACCUMULATOR gauge SYSTEM PRESSURE gauge BRAKE PRESSURE gauge

______________________________________________________________ A6474X432 REV 3 5.13

BI001487

Operation _______________________________________________________ Table 4: Hydraulic valve bank and gauge panel Component 1. EJECTOR

Function Operates the ejector blade and false bottom.

Operation WARNING! Before operating the ejector blade/ false bottom, verify that no one has any part of his body between the ejector blade/false bottom and the front of the payload section. Failure to heed this warning may result in severe injury or death.

Verify that there are no foreign objects located in the area between the false bottom and the front of the payload area so that the ejector blade/false bottom can be positioned completely to the front of the trailer.

1. To extend the ejector cylinder, moving the false bottom and ejector blade to the rear of the trailer (emptying the trailer), push the handle forward (away from the operator).

2. To retract the ejector cylinder, ejector blade, and false bottom, pull the lever back (toward the operator).

2. ARTICULATION

Controls the vertical articulation of the machine.

WARNING! The vertical articulation control lever moves the center of the machine up or down, causing the ends of the machine to move in the opposite direction of the center of the machine.

Make sure all personnel are clear of the machine before operating the control. Failure to heed this warning could result in severe injury or death.

WARNING! Do not articulate the machine without a canopy securely in place. Failure to heed this warning could result in severe injury or death of the operator.

WARNING! Do not articulate the machine while tramming as the machine could jam into the top or bottom, resulting in damage to the passageway or to the machine. If vertical adjustment is desired, stop the machine, make the necessary adjustment, and then continue tramming.

1. To raise the center of the machine (causing the payload and battery ends of the machine to lower), pull the lever back.

2. To lower the center of the machine (causing the payload and battery ends of the machine to raise), push the lever forward.

________________________________________________________________ 5.14 FH110

BI001487

______________________________________________________ Operation Table 4: Hydraulic valve bank and gauge panel Component 3. BATTERY LIFT/ BATTERY LOCK

Function Depending on the position of the diversion valve (see Fig. 10 and Table 2), used to raise and lower the battery and to secure the battery during tramming operations.

Operation To raise or lower the battery: WARNING! The battery should only be raised or lowered at a battery change station. If the battery is raised in a low roof area, it may hit the roof, damaging the battery.

IMPORTANT! The battery cannot be changed if it is not level when in the raised position. See the battery change section for battery change procedures.

1. To raise the battery (retract the battery lift cylinders), pull the lever back.

2. To lower the battery (extend the battery lift cylinders), push the lever forward.

WARNING! Always make sure the battery lock is engaged after each battery change and disengaged prior to battery change. The batteries may be damaged if left unsecured during tramming.

WARNING! The battery should be in tramming position before engaging/disengaging the battery lock. The battery lock may not engage/ disengage if attempted while the battery is on ground level.

To engage the battery lock: 1. Lift the battery into tramming position and push the lever forward.

To disengage the battery lock: 1. Ensure the battery is in tramming position and pull the lever back. Lower the battery to the ground.

4. PTO

Used to engage the PTO function.

1. Move the lever forward or back to energize either PTO port, A or B.

5. ACCUMULATOR gauge

Used to monitor accumulator (brake) pressure.

Normal reading = 1,400 psi.

6. SYSTEM PRESSURE Used to monitor hydraulic gauge system pressure.

Reading depends on the active function.

7. BRAKE PRESSURE gauge

Normal reading = 1,250 psi.

Used to monitor the tractor brake circuit pressure.

______________________________________________________________ A6474X432 REV 3 5.15

BI001487

Operation _______________________________________________________ Hazard zone The hazard zone exists unless: •

The battery plug is disconnected from the battery, OR;

•

The machine circuit breaker is in the “OFF” or “TRIPPED” position.

Fig. 13: Hazard zone

________________________________________________________________ 5.16 FH110

BI001487

______________________________________________________ Operation Starting procedure After reading the previous descriptions and locating each control, the operator is ready to operate the machine. An experienced operator should monitor a new operator's indoctrination to the starting procedure.

WARNING! Check the battery connections and the battery covers. The battery covers must be in place and locked.

WARNING! Never operate any levers or pedals from outside the operator's compartment.

WARNING! This unit is equipped with a cab or canopy. Be careful not to hit your head when entering or leaving the operator's compartment.

This machine must not be operated without the canopy in place.

General (Refer to Fig. 14 for illustration of control handle) 1. Disconnect the steering lockout device (Fig. 15).

2. Sit in the operator's seat and adjust the seat position relative to the foot and hand controls.

WARNING! Be sure no one is in the hazard zone (Fig. 13) before operating any levers or pedals.

Never try to adjust the operator's seat while the machine is in motion.

Do not operate the machine with any part of your body outside the operator's compartment to prevent having body parts caught between the unit and outside objects.

3. The tape panic strips may be pressed at any time to stop, set the park brake, and to de-energize the tram and pump motors. Be prepared for a sudden stop when a panic bar or the stop switch is struck. Pressing the E-Stop button will trip the circuit breaker.

4. The “STOP” button may be pressed at any time to set the park brake, and to de-energize the tram and pump motors.

______________________________________________________________ A6474X432 REV 3 5.17

BI001487

Operation _______________________________________________________ Fig. 14: Control handle

Diagnostics

In-Position

Machine operation 1. Press and hold the diagnostics button to begin on board diagnostics. Continue to hold until a message is displayed on the HiPAC 10 display.

2. If the display indicates “SYSTEM OKAY” continue, if any other message is displayed, turn “OFF” the machine circuit breaker and contact your service representative.

3. Release the diagnostics button and set the machine circuit breaker.

4. Test each panic bar before beginning each shift. a. Press the left side panic bar. The tram and pump motor should shut down. b. Repeat steps 1 through 4 and press the right side panic bar.

The tram and pump motor should shut down.

Note: If motors fail to shut down from either panic bar, turn the machine circuit breaker off and contact your service representative. If both panic bars shut down the tram and pump motors, continue to step 6.

________________________________________________________________ 5.18 FH110

BI001487

______________________________________________________ Operation 5. Test the “EMERGENCY STOP” switch before beginning each shift. a.

Press the “EMERGENCY STOP” button: the machine circuit breaker should trip, shutting down the machine. If the machine circuit breaker fails to trip, shut down the machine and turn the machine circuit breaker to “OFF” and call your service representative. If the machine circuit breaker does trip, reset the circuit breaker, perform diagnostics, restart the machine, and proceed to step 7.

6. Test all control handle functions before beginning each shift. Follow steps 8 through 23. If any function does not operate correctly, turn “OFF” the circuit breaker and contact your service representative.

7. To start the pump motor, press and hold the in-position button (bottom button) . Then press and hold “PUMP START” until the pump motor starts. Release the “PUMP START” button and then release the in-position button. (Note: to turn off the pump motor, press “STOP” or “PUMP START”.)

8. Release the park brake (pump motor must be running) a. Press and hold the in-position button. b. Press and hold “PARK BRAKE” until the dashboard display indicates “PARK BRAKE RELEASED” c.

Release the “PARK BRAKE” button and then the in-position switch.

9. To set the park brake and leave the pump motor running, press “PARK BRAKE”.

10. To turn off the pump motor and set the park brake, press “STOP” or “PUMP START” 11. To activate a tramming direction (the pump motor must be running and the park brake must be released): a. Press and hold the in-position button and the press and hold either “TRAM ” or “TRAM " until the dashboard display indicates direction of travel. b. Release “TRAM ” or “TRAM " and then release the inposition button.

12. The accelerator may now be depressed to control machine travel.

WARNING! The machine is equipped with a solid state speed controller (accelerator). This means that the farther the accelerator pedal is depressed, the faster the machine will tram.

______________________________________________________________ A6474X432 REV 3 5.19

BI001487

Operation _______________________________________________________ 13. To change direction of travel, press and hold the in-position button and then press and hold the desired direction of travel (“TRAM ” or “TRAM ") until the dashboard display indicates direction of travel. Then release “TRAM ” or “TRAM " and then release the in-position button. Note: before the direction of travel will actually change, the accelerator pedal must be released and then reengaged (recycled through the off position).

14. To disable tramming, press “TRAM ” or “TRAM ".

15. To leave pump motor running, set park brake, and disable tramming, press “PARK BRAKE”.

16. To disable tramming, turn off the pump motor and set the park brake, press “STOP” or “PUMP START”.

17. To activate the traction assist function (if equipped), press “TRACTION ASSIT”.

IMPORTANT! The traction assist may be used as necessary. However, battery life will be prolonged if the traction assist is allowed to remain disengaged when possible.

18. Press “LIGHTS ” or “LIGHTS " to turn lights on in desired direction.

19. For auto position headlights, where the headlights follow the direction of the selected tram direction, press and hold the in-position button, press and release “LIGHTS ”, then release the in-position button. Lights will stay in auto position until “STOP”, “LIGHTS ”, or “LIGHTS " is pressed.

20. To turn off all lights, press “LIGHTS " and “LIGHTS ” simultaneously and then release both simultaneously.

________________________________________________________________ 5.20 FH110

BI001487

______________________________________________________ Operation Shutdown procedure 1. Tram the machine to its designated parking place.

2. Stop the machine by releasing the accelerator pedal and depressing the foot brake pedal. When the accelerator pedal is released, the tram (traveling) motors will deenergize but will continue to rotate. Applying the foot brake will stop forward (or reverse) motion.

The hydraulic pump's electric motor will still be running, making a whining sound.

WARNING! Always check before moving the ejector blade and false bottom control lever to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.

3. Return the ejector blade/false bottom to the front of the payload section. There should be no obstructions behind the ejector blade/ false bottom.

Note: Refer to Fig. 14 for illustration of control handle.

4. Before leaving the operator’s compartment, press “STOP” to turn the machine off.

5. Before leaving the operator’s compartment, turn off the machine circuit breaker by pressing the “EMERGENCY STOP” button.

6. Connect the steering lockout device (Fig. 15): a. remove the steering lockout device from its storage lugs b. remove the hitch pin from the end farthest from the center section c.

adjust turnbuckle until holes line up between the turnbuckle lug and the front section lug

d. insert the hitch pin into the front section lug through the turnbuckle WARNING! Never enter the articulation area while the machine is running.

Completely shutdown the machine as outlined before connecting the steering lockout device. Failure to observe this precaution may result in injury or death.

CAUTION! This unit is equipped with a canopy. Be careful not to hit your head when entering or leaving the operator's compartment.

______________________________________________________________ A6474X432 REV 3 5.21

BI001487

Operation _______________________________________________________ WARNING! In the event of an emergency, the machine may also be shutdown by striking the panic strip. When the panic strip is struck, the motors will shut down and the automatic emergency brakes will be applied. Be prepared for the sudden stop when the panic strips are struck.

Fig. 15: Steering lockout device

Steering lock - installed

Steering lock - stored

________________________________________________________________ 5.22 FH110

BI001487

______________________________________________________ Operation Battery change procedure Two people are needed to change the battery in the machine. Since one person may step into the Hazard Zone, the other person (operating the machine) must be very careful and look each time before moving any levers or pedals. Take time now to review the Hazard zone (Fig. 13).

1. Line up the battery end of the machine with the place where the battery is to be deposited (Fig. 16) (see Starting procedure in this chapter).

Fig. 16: Battery change procedure

Discharged battery

Charged battery

WARNING! The "BATTERY LIFT/LOCK" control lever should never be operated except at a battery change station or when it’s necessary to adjust the battery's terrain clearance. If the "BATTERY LIFT/ LOCK” control lever is operated in a low roof area, the battery may be damaged.

______________________________________________________________ A6474X432 REV 3 5.23

BI001487

Operation _______________________________________________________ 2. Unlock the battery before placing the battery on the ground (Fig. 17). a. Push in the battery lift/lock diversion valve to activate the battery lock circuit. b. Push the “BATTERY LIFT/LOCK” lever away from the operator and hold until the hooks are completely below the battery lift arms to unlock the battery.

Fig. 17: Battery change procedure

Battery hold down lever

Battery “LIFT” control lever

3. Pull out the battery lift/lock diversion valve to activate the battery lift circuit.

4. Lower the battery completely to the surface by pulling the battery hold down lever towards the operator and pushing the "BATTERY LIFT/LOCK” control lever away from the operator. The bottom of the battery should touch the surface (Fig. 18).

WARNING! Never attempt to disconnect a hydraulic hose from the battery lifting cylinders while the battery is in the up position. This could cause the battery to fall and could result in serious injury.

Fig. 18: Battery fully lowered

5. After the battery is fully lowered, shutdown the machine (see Shutdown procedure in this chapter).

________________________________________________________________ 5.24 FH110

BI001487

______________________________________________________ Operation 6. After shutting down the machine, disconnect the discharged battery (Figure 19): a.

Unlock and remove the padlock at the battery connector.

b.

Grasp the threaded lock ring and rotate it counterclockwise (CCW) until the threads are disengaged and it is free to slide away from the locking lug; the lock ring is designed to move freely but to not come off the plug.

c.

Grasp the plug and pull it out until the plug is completely disconnected from the receptacle; the plug is made to fit very tightly inside the battery receptacle and-should not be driven out of the receptacle, dropped, or handled roughly; if the plug (or receptacle) is damaged, it will not fit together properly.

d.

Install the cap which is secured to the receptacle on the battery by a small chain; this cap is placed over the threaded receptacle and rotated in a clockwise (CW) direction until hand tight and until a padlock will fit into the locking lug; the padlocks all use the same key.

Fig. 19: Battery plug and receptacle (typical) Receptacle

Locking lug

Threaded lock ring

Plug assembly

Wrench

______________________________________________________________ A6474X432 REV 3 5.25

BI001487

Operation _______________________________________________________ 7. Connect the jumper cable: a. Connect the receptacle end of the jumper cable to the plug coming out of the connection box on the machine (Fig. 20). b. Connect the plug end of the jumper cable to the fully charged battery. c.

Secure the jumper cable connections by using the threaded lock rings. These lock rings must be hand tight but do not have to be padlocked.

d. One person should hold the jumper cable so it will not be damaged or be run over when the machine is moved.

Fig. 20: Battery change procedure Discharged battery

Jumper cable

Charged battery

________________________________________________________________ 5.26 FH110

BI001487

______________________________________________________ Operation 8. Start the machine (see Starting procedure in this chapter). Gently pull away from the discharged battery while the second person holds the jumper cable away from possible damage.

9. Line the machine up with the fully charged battery. Move the machine forward until the lift arms are aligned with the slots in the battery (Fig. 21). Continue to slowly move the machine forward until the lift arms are in the correct position.

Fig. 21: Battery change procedure

Discharged battery

Charged battery

Jumper cable

______________________________________________________________ A6474X432 REV 3 5.27

BI001487

Operation _______________________________________________________ 10. Raise the battery to the carry position by pulling the "BATTERY" change control lever toward the operator (Fig. 22).

Fig. 22: Battery change procedure

Charged battery

11. Push the battery hold down lever away from the operator, pull battery “LIFT” control lever towards the operator and hold until battery hooks have completely locked the battery in position.

12. Shutdown the machine (see Shutdown procedure in this chapter).

13. Disconnect the jumper cable and connect the charged battery directly to the machine’s cable (Fig. 19). Remember to be careful with the plugs. After the plug is in the receptacle, the lock ring should be rotated clockwise (CW) until hand tight. The padlock must be in the locking lug and locked for this connection to be permissible.

14. Start the machine (see Starting procedure in this chapter).

15. This completes the ground level battery change procedure.

________________________________________________________________ 5.28 FH110

BI001487

____________________________________________________ Maintenance Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine.

In particular, observe the safety instructions in chapter 2 “Your safety”.

Important notes Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

■

Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original spare parts when replacing components.

■

All electrical work must be supervised and inspected by a certified electrician.

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this guide.

Before maintenance WARNING! 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.

WARNING! Do not move any hydraulic control lever 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.

WARNING! 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.

WARNING! 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.

______________________________________________________________ A6474X432 REV 3 5.29

BI001487

Maintenance _____________________________________________________ NOTICE! If any welding is to be done to machine, the circuit breakers must be in the “OFF” position and the batteries disconnected. Failure to do so may cause electrical component damage.

Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power and follow all applicable lockout/tagout procedures. Either the machine circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the battery should be disconnected. Also, make sure the capacitor discharge module indicates that the capacitors are discharged before working inside the controller.

■

Test the controls to ensure that the unit will not move.

■

Chock all four (4) wheels in each direction.

■

Connect steering lockout device.

■

During maintenance or servicing, if drive motors are to be run, the machine must be jacked clear of the ground and securely blocked. All four wheels must be free to rotate. The center section should also be blocked.

■

Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■

Cleanliness can not be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

________________________________________________________________ 5.30 FH110

BI001487

____________________________________________________ Maintenance Critical torque values Table 5: Critical torque values Location Steering cylinder pins Tire-Wheel mounting Planetary wheel end-to-frame mounting Gear case-to-frame mounting Drive motor-to-gear case mounting

Bolt size

Grade

Torque (ft-lb)

3/4-16X1-3/4 3/4-10X3-1/4

8 8

300 300

3/4-10X2-1/4 3/4-10X2-3/4

8 5

300 300

Approximate capacity 65 Gallons 4 Gallons Each As Required

Notes 1 2, 3 4

Lubricants, fluids and capacities Table 6: Lubricants, fluids and capacities Location Hydraulic oil Gear case Grease points

Lubricant Spec. 100-1 Spec. 100-8 Spec. 100-3

Notes: 1. With false bottom/ejector blade completely retracted.

2. 4 gallons of oil to completely fill dry system. Actual level should be checked after running unit to fill cooling system. Use dipsticks (one in each drive gear case) to check oil level. If not equipped with dipstick, use the plug approximately located at center on one end of the gearbox.

3. Drain gear case and wheel end separately. Fill gear case only to proper level on dipstick.

4. Pump grease into fitting until old grease can be observed coming out of component.

______________________________________________________________ A6474X432 REV 3 5.31

BI001487

Maintenance _____________________________________________________ Table 3: Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

Every shift 1 2

Panic strip (check) Emergency stop (check)

2 1

Every third shift 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Center section pivots Steering cylinders (rod and base end) Center section ball bearing Ejector hose carrier Battery change assembly Articulation cylinders Articulation pivot Tail gate cylinders (If equipped) Battery change cylinders Fasteners (nuts, bolts and screws) Electrical cables, conduits and glands Hydraulic hoses and connections Tires (inspect) Headlights (inspect) Reflectors and warning tags Hydraulic oil level (check)

4 4 9 2 8 4 2 4 4 Inspect Inspect Inspect 6 4 Inspect 1

Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3

2

Spec. 100-8

Spec. 100-1

First week of service 19 20 21 22

Gear cases and planetary wheel end oil (change) Gear case and planetary wheel end mounting bolts (inspect) Wheel mounting bolts (inspect) Wheel end spindle/wheel motor mounting bolts (inspect)

2 4 2

Weekly 23 24 25 26 27 28 29 30

Center section pins and nuts Fire suppression system Steering cylinder pins (inspect) Accelerator pedal pivot bearings Brake pedal Filter, main pump pressure (check) Filter, return (check) Brake fluid cooling filters (inspect/change as required)

Inspect Inspect 4 2 1 1 1 2

Spec. 100-3 Spec. 100-3

13

Spec. 100-3

2 1 2

Spec. 100-8

Every two weeks 31

Control handles and steering linkage

Monthly 32 33 34 35 36 37 38 39

Drive motors (inspect) Pump motor (inspect) Gear cases and planetary wheel end oil (change) Wheel mounting bolts (check) Hydraulic system pressure Steering relief pressure Gear box oil filter system relief pressure Ejector/false bottom valve or ejector/false bottom/ tailgate sequence valve

4 Check Check Check Check

________________________________________________________________ 5.32 FH110

BI001487

____________________________________________________ Maintenance Table 3 (continued): Lubrication and maintenance schedule Item

Description Every six months

Places

40 41

Hydraulic oil (change) Hydraulic oil suction strainer

1 1

Lubricant

Specification Spec. 100-1

______________________________________________________________ A6474X432 REV 3 5.33

BI001487

Maintenance _____________________________________________________ Fig. 23: Lubrication chart 22 6 33

5

3,23 8,9 7 19,34 32

15

4,25

18,40,41

1, 2,26,27,31

11

20

21,35

________________________________________________________________ 5.34 FH110

BI001487

____________________________________________________ Maintenance Specific lubrication and maintenance procedures Every shift panic strips

emergency stop switch

Check each panic strip (Fig. 24) for correct operation. Start the machine, but do not tram. Strike a panic strip and the machine should shut down. Restart the machine and check the second panic strip.

Check the emergency stop switch (Fig. 24) for correct operation. Start the machine, but do not tram. Strike the emergency stop switch; the machine circuit breaker should trip and the machine shut down.

Fig. 24: Panic strips and emergency stop switch

Panic strip

Emergency stop switch

Panic strip

______________________________________________________________ A6474X432 REV 3 5.35

BI001487

Maintenance _____________________________________________________ Every third shift center section pivots

Lubricate the center section pivot points (4 places) with Spec. 100-3 through the grease fittings located on the center section assembly (Fig. 25). Pump grease into the fittings until new grease can be observed coming out of the bearings.

steering cylinders

Lubricate the steering cylinders (4 places) with Spec. 100-3 through the grease fittings located on the rod and base end of each cylinder (Fig. 25). Pump grease into the fittings until new grease can be observed coming out of the pins.

center section bearing

Lubricate the center section bearing with Spec. 100-3 through the nine grease fittings located around the bearing (Fig. 25). Pump grease into the fittings until new grease can be observed coming out of the bearing.

Fig. 25: Center section and steering cylinders lubrication points Center section bearing (9 fittings)

Steering cylinder (2) (rod and base end)

Center section pivot (4 places)

________________________________________________________________ 5.36 FH110

BI001487

____________________________________________________ Maintenance ejector hose carrier

Lubricate the ejector hose carrier (2 places) with Spec. 100-3 through the grease fittings located at the two (2) pivot points (Fig. 26). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 26: Ejector hose carrier lubrication points Grease fitting (2)

battery change assembly

Lubricate the battery change assembly with Spec. 100-3 through the grease fittings located on the two (2) lubrication blocks (Fig. 27). Pump grease into each of the four fittings on each lubrication block until new grease can be observed coming out of the pins.

Fig. 27: Battery change assembly lubrication points Lubrication block (2) (4 grease fittings)

______________________________________________________________ A6474X432 REV 3 5.37

BI001487

Maintenance _____________________________________________________ articulation cylinders

Lubricate the articulation cylinders (4 places) with Spec. 100-3 through the grease fittings: two (2) cylinder eye fittings located under the nose cone center cover and two (2) rod eye fittings (Fig. 28). Pump grease into the fittings until new grease can be observed coming out of the bushings.

articulation pivot

Lubricate the articulation pivot pins (2 places) with Spec. 100-3 through the grease fittings located on the two (2) lubrication blocks (Fig. 28).

Pump grease into the fittings until new grease can be observed coming out of the bushings.

Fig. 28: Articulation cylinders lubrication points Vertical articulation main pivot pin lubrication

Articulation cylinder grease fittings (4)

Vertical articulation main pivot pin lubrication tailgate cylinders (if equipped)

Lubricate the tailgate cylinders (4 places) with Spec. 100-3 through the grease fittings located on the cylinder rod and base ends. Pump grease into the fittings until new grease can be observed coming out of the bushings.

________________________________________________________________ 5.38 FH110

BI001487

____________________________________________________ Maintenance battery change cylinders

Lubricate the battery change cylinders with Spec. 100-3 through the grease fittings located on the cylinder rod and base ends (Fig. 29).

Pump grease into the fittings until new grease can be observed coming out of the bushings.

Fig. 29: Battery change cylinders lubrication points Grease fitting

fasteners (nuts, bolts and screws)

Loose fasteners will cause premature wear and failure to machine and components. Visually inspect for loose fasteners and tighten as required.

electrical cables, conduits and glands

Visually inspect all electrical cables, conduits and glands for signs of wear or damage.

hydraulic hoses and connections

Visually inspect all hydraulic hoses and connections for signs of wear, damage or leakage.

tires

Visually inspect all tires for signs of wear or damage.

headlights

Turn on headlights and visually inspect for bulbs that need replaced or signs of damage.

reflectors and warning plates

Visually inspect the condition and readability of all warning tags, labels and reflectors for signs of wear or damage. Replace any found missing or damaged.

______________________________________________________________ A6474X432 REV 3 5.39

BI001487

Maintenance _____________________________________________________ hydraulic oil level

Check the hydraulic oil level by looking at the sight glass located on the oil tank (Fig. 30). If the oil level is low, add oil through the fill cap located on top of the tank until oil is visible in the sight glass.

Fig. 30: Hydraulic oil level

Sight glass

Fill cap

Sight glass

________________________________________________________________ 5.40 FH110

BI001487

____________________________________________________ Maintenance First week of service gear case and planetary wheel end

Change the oil in both gear cases and planetary wheel ends after the first week of service (Fig. 31).

1. Remove the drain plug (or hose connection if equipped with rear tractive assist) from the gear case and planetary wheel end (common drain plug) and allow the oil to completely drain .

2. Replace the drain plugs and refill with oil (Spec. 100-17) until oil begins to flow from check/level plug.

Fig. 31: Gear case and planetary wheel end oil Fill plug (optional)

Fill/check plug

Drain plug

______________________________________________________________ A6474X432 REV 3 5.41

BI001487

Maintenance _____________________________________________________ gear case and planetary wheel end mounting bolts

Inspect the gear case and planetary wheel end mounting bolts (Fig. 32). Bolts should be torqued to 300 ft-lbs. If necessary, remove bolts, coat with Loctite 242, and torque to 300 ft-lbs.

Fig. 32: Gear case and planetary wheel end mounting bolts

Gear case mounting bolts

________________________________________________________________ 5.42 FH110

BI001487

____________________________________________________ Maintenance wheel mounting bolts

Inspect the wheel mounting bolts (Fig. 33). If necessary, remove bolts, coat with Loctite 242, and torque to 300 ft-lbs. Always torque in a triangular pattern as shown.

Fig. 33: Wheel mounting bolts

Mounting bolts (9)

Torque Pattern

1

3

2

______________________________________________________________ A6474X432 REV 3 5.43

BI001487

Maintenance _____________________________________________________ wheel end spindle/wheel motor mounting bolts

Inspect the wheel end spindle/motor mounting bolts (Fig. 34). The mounting bolts should be torqued to 300 ft-lbs. If necessary, remove bolts, coat with Loctite 242, and torque to 300 ft-lbs.

Fig. 34: Wheel end spindle/wheel motor mounting bolts

Mounting bolts (9)

________________________________________________________________ 5.44 FH110

BI001487

____________________________________________________ Maintenance Weekly center section pins and nuts

Inspect the center section pins and nuts for looseness or wear (Fig. 35).

Tighten where necessary and replace any worn parts.

Fig. 35: Center section and pins and nuts Inspect center section pivot pins and nuts

______________________________________________________________ A6474X432 REV 3 5.45

BI001487

Maintenance _____________________________________________________ fire suppression system

Check the fire suppression system (Fig. 36).

1. Inspect the hoses, fittings, and nozzles and replace any found damaged.

2. Check the extinguisher tank for signs of damage or corrosion. The extinguisher tank is located in the rear section of the machine.

3. Check the nozzle openings. The slot should be packed with silicone grease. If the nozzles are open or need to be repacked, the lines should be checked for blockage and blown clear before repacking them with clean silicone grease.

4. Remove the fill cap.

5. Check that the extinguisher is filled with free flowing Ansul multipurpose A, B, C dry chemical to a level not more than 3 inches (75 mm) from the bottom of the fill opening.

6. Replace the fill cap, hand tight.

Fig. 36: Fire suppression system (typical) Chemical tank (optional location)

Nozzle (6 locations)

Actuator

Chemical tank

Actuator

Fill cap

Tank Nozzle opening

________________________________________________________________ 5.46 FH110

BI001487

____________________________________________________ Maintenance steering cylinder pins

Inspect the steering cylinder pins and nuts for looseness or wear (Fig. 37). Tighten where necessary and replace any worn parts.

Fig. 37: Steering cylinder pins

Steering cylinder pin

speed foot switch (accelerator) pedal pivot bearings

Lubricate the foot pedal pivot bearings (2 places) with Spec. 100-3 through the grease fittings located on each bearing (Fig. 8). Pump grease into the fittings until new grease can be observed coming out of the bearings.

brake pedal

Lubricate the brake pedal (1 places) with Spec. 100-3 through the grease fitting located on the pedal (Fig. 38). Pump grease into the fittings until new grease can be observed coming out of the bearing.

Fig. 38: Foot switch and brake pedal lubrication

Grease points

______________________________________________________________ A6474X432 REV 3 5.47

BI001487

Maintenance _____________________________________________________ main pressure filter

Inspect the hydraulic system filter dirt alarm (Fig. 39) located on the head of the filter. If the alarm indicates the filter element is dirty, replace element.

Fig. 39: Hydraulic system filter

return filter

Inspect the return filter dirt alarm (Fig. 40) located on the head of the filter. If the alarm indicates the filter element is dirty, replace element.

Fig. 40: Return filter

________________________________________________________________ 5.48 FH110

BI001487

____________________________________________________ Maintenance brake cooling fluid filters

Inspect the two (2) brake cooling spin on filter element dirt alarms (Fig. 41) located on the head of each filter. If the alarms indicate that the elements are dirty, replace elements.

Fig. 41: Brake fluid cooling filters

Brake cooling filters

______________________________________________________________ A6474X432 REV 3 5.49

BI001487

Maintenance _____________________________________________________ Every two weeks control handles and steering linkage

Lubricate the control handles and steering linkage with Spec. 100-3 through the grease (Fig. 42). Pump grease into the fittings until new grease can be observed coming out.

Fig. 42: Control handles and steering linkage lubrication

Steering linkage grease fitting

Grease fittings located on each handle

________________________________________________________________ 5.50 FH110

BI001487

____________________________________________________ Maintenance Monthly drive and pump motor (s)

Inspect the drive and pump motors (Fig. 43).

1. Be sure that the machine circuit breaker lever is in the "OFF" position.

2. Remove the inspection cover.

3. Inspect the windings, bearings, and motor connections. a. Windings should be dry and free of dust, grease, oil, and dirt. b. The leads and motor connections should be examined for corrosion, burn spots and for tightness.

4. Replace the inspection plate being sure it is securely tightened.

IMPORTANT! The drive and pump motors do not require periodic lubrication.

The pump motor bearings are sealed. The drive motors have one bearing sealed and the other bearing receives lubrication from the gear case oil.

Fig. 43: Drive and pump motors

Drive motors

Pump motor

______________________________________________________________ A6474X432 REV 3 5.51

BI001487

Maintenance _____________________________________________________ gear cases and planetary wheel ends

Change the oil in both gear cases and planetary wheel ends (Fig. 44).

1. Remove the drain plug (or hose connection if equipped with rear tractive assist) from the gear case and from the planetary wheel end and allow the oil to completely drain.

2. Replace the drain plug and fill with oil (Spec. 100-17) until oil begins to flow from check/level plug.

Fig. 44: Gear case and planetary wheel end lubrication Fill plug (optional)

Breather

Fill/check plug

Drain plug

________________________________________________________________ 5.52 FH110

BI001487

____________________________________________________ Maintenance wheel mounting bolts

Check the wheel mounting bolts (Fig. 45). The mounting bolts should be torqued to 300 ft-lbs. If necessary, remove the bolts, coat with Loctite 242, reinstall the bolts, and torque to 300 ft-lb.

Fig. 45: Wheel mounting bolts

Mounting bolts (typical all six wheels)

______________________________________________________________ A6474X432 REV 3 5.53

BI001487

Maintenance _____________________________________________________ hydraulic system pressure

Check the hydraulic system pressure (Fig. 46).

WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.

1. Pull the “EJECTOR” control lever toward the operator until the ejector blade/false bottom has completely returned to the front of the rear (payload) section.

2. Continue to hold the “EJECTOR” lever pulled toward the operator and read the pressure indicated on the “SYSTEM PRESSURE” gauge (located in the operator’s compartment).

3. Normal system pressure is set at the factory and should not be changed. If the pressure indicated on the “SYSTEM PRESSURE” gauge is not as specified on the hydraulic schematic supplied with your machine, see Main hydraulic system pressure adjustment in this chapter.

CAUTION! Do not adjust the hydraulic system pressure to more than specified on the hydraulic schematic supplied with your machine.

Damage to the hydraulic system may result.

Fig. 46: Check the hydraulic system pressure “EJECTOR” control lever

“SYSTEM PRESSURE” gauge

________________________________________________________________ 5.54 FH110

BI001487

____________________________________________________ Maintenance steering relief pressure

Check the steering system relief pressure (Fig. 47).

WARNING! In order to check and adjust the steering system relief pressure, it is necessary to steer the machine to the turning limit in both directions. Care must be taken to avoid having anyone or any part of your body in the articulation area while the unit is being steered.

All adjustments to the steering relief pressure must be made from inside the operator’s compartment and not from outside the unit.

1. Steer the unit to the turning limit in either direction and read the pressure indicated on the “SYSTEM PRESSURE” gauge.

2. Normal steering relief pressure is set at the factory and should not be changed. If the pressure indicated on the “SYSTEM PRESSURE” gauge (located in the operator’s compartment) is not as specified on the hydraulic schematic supplied with your machine in one or both directions, see Steering system relief pressure adjustment in this chapter.

Fig. 47: Check the steering relief pressure

“STEERING” control lever

“SYSTEM PRESSURE” gauge

______________________________________________________________ A6474X432 REV 3 5.55

BI001487

Maintenance _____________________________________________________ brake cooling relief pressure

Check the gearbox oil filter system circuit relief pressure (Fig. 48).

1. Raise and securely block the machine off the ground so that all four (4) wheels are free to rotate.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.

2. Remove the hose fittings going to the filter from the side of the relief valve.

3. With a gauge and suitable fittings, install the gauge onto the relief valve where the hose was disconnected.

4. Start the machine, release the automatic brakes and slowly depress the accelerator pedal.

5. As the drive wheels begin to turn, read the pressure indicated by the gauge. The pressure should be 50 psi. If the pressure is not 50 psi, see Brake cooling relief pressure adjustment in this chapter.

Fig. 48: Relief valve

Relief valve

________________________________________________________________ 5.56 FH110

BI001487

____________________________________________________ Maintenance ejector/false bottom sequence valve

Check the ejector/false bottom sequence valve (or, if equipped with tailgate, check the ejector/false bottom/tailgate sequence valve) during both the extend and the retract cycle.

Extend WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of his body between the ejector blade/false bottom and the front of the rear (payload) section.

1. When the ejector/false bottom is being retracted, the ejector blade should return to the back of the false bottom as the false bottom begins to move.

2. When the ejector/false bottom is being extended, the false bottom should extend before the ejector blade extends.

3. If the above sequence is incorrect, see ejector/false bottom sequence valve adjustment in this chapter.

Retract WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.

1. When the ejector/false bottom is being retracted, the ejector blade should return to the back of the false bottom as the false bottom begins to move.

2. When the ejector/false bottom is being extended, the false bottom should extend before the ejector blade extends.

3. If the above sequence is incorrect, see ejector/false/bottom sequence valve adjustment in this chapter.

______________________________________________________________ A6474X432 REV 3 5.57

BI001487

Maintenance _____________________________________________________ Every six months hydraulic oil, suction strainers, and breather

1. Change the oil and clean or replace the hydraulic suction strainers inside the hydraulic oil tank and the tank breather (Fig. 49).

2. Remove the drain plug from the hydraulic oil tank to allow the oil to drain.

3. Remove the breather and inspect. Clean/replace as necessary.

4. Remove the suction strainer from the bottom of the tank as follows: a. Remove the oil tank cover and gasket. b. Reach through opening and unscrew the suction strainer from the fitting on the bottom of the tank.

5. Inspect and clean the suction strainer. If the strainer is not torn or damaged, it can be cleaned using kerosene and a soft brush and dried thoroughly. If the strainer is damaged, it must be replaced.

6. Replace the strainer in the tank and tighten hand-tight.

7. Inspect cover gasket for damage and replace if necessary.

8. Replace cover and gasket.

9. Install drain plug.

10. Install breather.

11. Add hydraulic oil (Spec. 100-1) until oil is visible in the sight glass.

If equipped with power fill function, fill as follows: a. Remove the fill cap and manually add oil to the tank until the suction strainers are completely submerged.

CAUTION! The suction strainer must be completely flooded with oil before operating the power fill function to avoid damaging the main pump. b. Replace the fill cap. c.

Open the power fill ball valve located to the right of the hydraulic oil tank.

d. Activate the power fill function by operating the lever located to the right of the hydraulic oil tank.

________________________________________________________________ 5.58 FH110

BI001487

____________________________________________________ Maintenance e. Add oil (Spec. 100-1) until oil is visible in the sight glass on the left side of the tank. f.

Return the power fill lever to the neutral position.

g. Close the power fill ball valve.

Fig. 49: Hydraulic oil tank Fill cap

Sight gauge

______________________________________________________________ A6474X432 REV 3 5.59

BI001487

Maintenance _____________________________________________________ (optional) hydraulic wheel end motors

Charge Pressure The minimum pressure required at the motor’s inlet port is called the charge pressure. It is needed to guarantee continuous contact between the cam ring and the cam rollers, especially in applications where an external force rotates the motor. For each motor size the charge pressure depends on the actual speed and case pressure. The performance curves show the charge pressure figure at minimum back pressure and with no casing pressure. With hydrostatic braking the charge pressure must increase 15-30 PSI (1-2 bar). Simultaneously, sufficient oil supply to the motor inlet port has to be assured. Especially for open circuits during hydrostatic braking using a relief valve, be sure to compensate for the drain flow and flushing of heated oil.

Back pressure In applications where the pressure in the return line is too low compared to the case pressure and actual speed, the motor may make extraneous noise in service. This is caused by the inertial force of the piston and the fact that the piston and cam rollers tend to lose contact with the cam ring. This problem can be eliminated by increasing pressure in the return line as high as required charge pressure at current speed, which guarantees continuous contact between the cam ring and cam rollers. This back pressure must not be present at the motor ports during freewheeling.

Case pressure The recommended case pressure for standard motors is 0-30 PSI (0-2 bar). The maximum intermittent pressure is 145 PSI (10 bar). If the motor is not rotating, a static case pressure up to 580 PSI (40 bar) is allowed. Requirements for charge and back pressure increase, if the case pressure rises. For freewheeling, case filling and for regulating the case pressure, a check valve with 15-30 PSI (1-2 bar) opening pressure is usually placed in the drain line. If freewheeling is never used and the motor is below the level of oil in the tank, the drain line is connected directly to the tank.

Freewheeling To disengage the motor, both working lines (i.e. inlet line and return line) are to be connected directly to the tank. To ensure that the lines are completely without pressure they should not be connected together with lines from other hydraulic circuits if this can lead to pressure disturbances, nor should any components causing pressure peaks or increases be connected to them. In order to produce the freewheeling pressure in the case, a fluid must be supplied to the motor through case drain line “C” (1-speed motor only). When 2-speed motor is needed to freewheel it is recommended to use motor with 2 case drain lines (6th digit in order code=1) and a fluid to produce free coupling pressure must be supplied to the motor cause through additional case drain line “C1”.

________________________________________________________________ 5.60 FH110

BI001487

____________________________________________________ Maintenance Freewheeling (continued) A check valve with an opening pressure of 30 PSI (2 bar) in the drain line regulates the pressure in the case. Limitation of pressure peaks in the case is accomplished by dimensioning the return line and check valve to correspond with the maximum intended speed of the motors at the moment of engaging/disengaging.

Under certain circumstances (e.g. with long length of pipe, high rotational speeds, or high viscosity oil) it is recommended to connect an accumulator (with at least 1/4 nominal capacity of the motor) to the drain line “C” (1-speed motor) of “C1” (2-speed motor with 2 drain lines). The accumulator should be as close to the motor as possible.

Hydraulic accumulators designed for storing low pressure are sufficient.

At the moment of engaging or disengaging the need for increased charge pressure must be taken into account.

Closed circuit For vehicles having special hydraulic motors, freewheeling can provide higher speed ranges, since the total pump output is divided between fewer working motors.

Disengaging the motor (shifting to higher speed range) 1. Motors to be freewheeled are detached to form an independent free circulation circuit.

2. A path from the motor circuit to the reservoir is rapidly opened, after which the constant small pressure in the casing disengages the motor.

3. The system charge pressure must be maintained in the pump circuit throughout the shifting procedure.

4. While shifting speed ranges, the sum of the displacement of the motors in operation changes gradually. The pump delivery is to be adjusted manually or automatically as required.

5. To avoid jerking during alteration of the pump delivery, the pump lines must be softly throttled.

Engaging the motor (shifting to lower speed range) 1. Disengaged motors are brought back into operation by connecting the “A” and “B” ports back into closed loop.

2. A charge pressure is rapidly applied to this circulation, forcing the pistons into motion. The charge pressure must be high enough to cover the pressure losses in the free circulation circuit as well.

3. The motors are connect to the same circuit as the pump.

4. The pump delivery is adjusted as required. Jerking can be avoided in the same way as when disengaging.

5. If the charge pump is too small, an accumulator is required to maintain the charge pressure

______________________________________________________________ A6474X432 REV 3 5.61

BI001487

Maintenance _____________________________________________________

Engaging the motor (shifting to lower speed range) (Continued) Accomplishment of the previous is made easier by motor manufacturer’s valves, which perform all the required operations except for modulating pump delivery. Some wheel end hydraulic motors are equipped with mechanical freewheeling springs. These motors are freewheeled automatically when the motor’s working lines become non-pressurized.

However, a rapid disengaging requires an increase in case pressure.

Short circuiting connection Short circuiting connection is used, if the motor is required to rotate by an external force faster than the circuit flow is capable to supply. In such case motor outlet oil must be connected to the motor inlet port.

Maximum allowed short circuit speed is 1.5 times maximum speed of the motor. The required charge pressure is easily regulated with back pressure in the return lines. Simultaneously flushing with fresh fluid must be insured for proper cooling Permissible external loads The figures given in the tables refer only to non-simultaneous radial and axial loads. If applications with high combined radial and axial loads exist, please consult motor manufacture or its representative to determine maximum permissible loading. The maximum permissible shaft loads depend on the loading point.

Wet multi-disc brake The wet multi-disc brake is basically a parking brake, but in certain cases it can also be used as an emergency brake. (Not recommended for use as a service brake. When used as a service brake consult motor manufacturer or its representatives.) The minimum pressure to release the spring operated brake is shown in the performance data page, however, the operating pressure used may be not higher than 435 PSI (30 bar). The brake has internal leakage (max. 0.5L/min) and this has to take into consideration, while designing the brake release system.

Notice that EP, HD and some anti-wear additives in oil can cause remarkable reduction of brake torque.

Operation temperature The maximum allowed continuous operating temperature is 160°F (70° C) and the maximum intermittent value is 185°F (85°C), if the oil viscosity does not fall below 15 cSt. The lowest permissible operating temperature for a standard motor is -31°F (-35°C).

When staring the motor the difference between the motor and oil temperatures must not exceed 140°F (60°C ). To avoid thermal shocks at low temperatures we recommend the following measures:

________________________________________________________________ 5.62 FH110

BI001487

____________________________________________________ Maintenance Operation temperature (continued) • •

Run the at first with a low speed, unloaded. Gradually increase the speed and loading.

Below 32°F (O°C) avoid disengaging and engaging of motors when the vehicle is moving and the drain line is cold.

Oil requirements The mineral oil used should meet the following requirements: • The viscosity index must be at least 100. If the oil contains additives improving the viscosity index, the effect of these ought to be as permanent as possible. The oil is to maintain the required viscosity throughout its service life.

• The minimum permissible viscosity is 15 cSt. • The maximum viscosity is determined by the specifications of the system pump.

• The recommended viscosity range at operating temperature is 2550 cSt. In slow use, a higher viscosity oil can be used.

• To obtain maximum service life of both oil and entire system, oil temperatures exceeding 160°F (70°C) are to be avoided.

• Oil additives must conform to the API - classification for SC motor oils. Hydraulic oils and SC. SD, SE and SF motor oils are recommended. Fire resistant fluids HFB and HFC or similar may be used under certain circumstances. Please always consult motor manufacturer or its representative before using these fluids.

Filtration Required cleanliness level: ISO 4406 (1987) Code 18/13 (NAS 1638 Code 8) or better. Filtration requirements for the pump and other system components must also be taken into consideration. In the event that other devices operated by the same hydraulic fluid are connected to the system and thus may allow impurities to pass into the system, the hydraulic motor circuit must be isolated from these. Where pressure in the main drive power transmission system is over 3,600 PSI (250 bar), absolute 10 µm main flow filtering is required. The filter should be equipped with cleanliness indicators.

Physical motor mounting Connection ports for working lines are marked with “A” and “B”. Connection port for drain line and case pressure is marked with “C”. NOTE: Motors with flushing line “C1” have connection port for case drain line marked with “C2”. Brake pressure connection is marked with “D”. 2speed pilot connection is marked with “Y”.

______________________________________________________________ A6474X432 REV 3 5.63

BI001487

Maintenance _____________________________________________________

Flushing Flushing should be performed at initial start-up, after system modifications or repairs. Before connecting the motor and pump to the system, THE CIRCUIT MUST ALWAYS BE FLUSHED, e.g. by circulating oil through a filter positioned in place of the motor. During flushing the oil is circulated with minimal pressure in the whole system, for at least one hour. After flushing, renew all filters. Always use plastic plugs to close off open ports and hoses. Do not use or add the tank with dirty oil.

Bleeding or filling DO NOT START MOTOR UNLESS THE CASE IS FILLED WITH OIL. Place the motor in a position in which the bleed screw is in its topmost position and unscrew it half a turn. Allow the case to be filled by system charge pressure. The bleed screw is closed after all air is out. If the motor is applied in a system that does not provide charge pressure, the case must be filled by pouring the oil in until all air is out.

Multi-speed motors Use 290-435 PSI (20-30 bar) control pressure in “Y” port to activate 2speed (partial displacement of a 2 speed motor) and de-pressurize to return to full displacement. Do not use work / high pressure in “Y” port to control 2-speed valve. Always use “C2” port as connection for case drain line Motor initial start-up After flushing and filling, the motor is first rotated unloaded. Increase the motor speed and load gradually, and check for leaks and extraneous noise.

________________________________________________________________ 5.64 FH110

BI001487

___________________________________________ Adjustment procedures Instructions on the adjustment procedures It is essential that adjustments be made periodically, as otherwise damage can be caused to other parts of the machine. Inspect the adjustments at regular intervals.

Main hydraulic system pressure To adjust the main hydraulic system pressure proceed as follows (Fig. 50).

IMPORTANT! This procedure requires two people: one to adjust the pressure and one to operate the valve bank and watch the pressure gauge.

The second person must remain in the operator’s compartment at all times, ready to strike the emergency stop button, if required.

1. Open swing out door at the pump motor to gain access to the relief valve.

2. Locate the relief valve attached to the pump.

3. Loosen the relief valve lock nut.

CAUTION! Do not adjust the hydraulic system pressure to more than specified on the hydraulic schematic supplied with your machine.

4. While another person holds the “EJECTOR” lever completely pulled toward the operator, turn the adjustment screw until the “SYSTEM PRESSURE” gauge indicates the specified pressure on the hydraulic schematic supplied with your machine.

5. Tighten locknut and secure swing out door.

Fig. 50: System pressure relief valve

Lock nut

Adjustment screw

______________________________________________________________ A6474X432 REV 3 5.65

BI001487

Adjustment procedures ___________________________________________ Steering relief pressure adjustment WARNING! In order to check and adjust the steering system relief pressure, it is necessary to steer the machine to the turning limit in both directions. Care must be taken to avoid having anyone or any part of your body in the articulation area while the unit is being steered.

All adjustments to the steering relief pressure must be made from inside the operator’s compartment and not from outside the unit.

To adjust the steering relief pressure proceed as follows (Fig. 51).

1. Remove the access cover inside the operator’s compartment.

2. For right turn, loosen the locknut on the end of the relief cartridge and hold the “STEERING” control lever completely pushed away from the operator. With an allen wrench, adjust the relief cartridge until the pressure indicated on the “SYSTEM PRESSURE” gauge indicates the pressure specified on the hydraulic schematic supplied with your machine. Once the gauge indicates the required pressure, tighten the locknut.

3. For left turn, loosen the locknut on the end of the relief cartridge and hold the “STEERING” control lever completely pulled toward the operator. With an allen wrench, adjust the relief cartridge until the pressure indicates the pressure specified on the hydraulic schematic supplied with your machine. Once the gauge indicates the required pressure, tighten the locknut.

4. Replace the access cover inside the operator’s compartment.

Fig. 51: Steering relief pressure adjustment

Steering relief (typical both sides of valve bank)

________________________________________________________________ 5.66 FH110

BI001487

___________________________________________ Adjustment procedures Gearbox oil filter system circuit relief pressure adjustment To adjust the steering relief pressure proceed as follows (Fig. 52).

1. Raise and securely block the machine off the ground so that all four (4) wheels are free to rotate.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.

2. Remove the hose fittings going to the filter from the side of the relief valve.

3. With a gauge and suitable fittings, install the gauge onto the relief valve where the hose was disconnected.

4. Start the machine, release the automatic brakes and slowly depress the accelerator pedal.

5. As the drive wheels begin to turn, read the pressure indicated by the gauge. The pressure should be 50 psi. If the pressure is not 50 psi, continue to next step.

6. Remove the cap that covers the pressure adjustment screw.

7. Using an allen wrench, turn the screw until the correct pressure of 50 psi is indicated on the pressure gauge.

8. Replace the cap on the relief valve.

9. Remove the gauge and replace the hose in the relief valve.

Fig. 52: Circuit relief pressure adjustment

Relief valve

______________________________________________________________ A6474X432 REV 3 5.67

BI001487

Adjustment procedures ___________________________________________ False bottom/ejector blade sequence valve adjustment To adjust the false bottom/ejector blade sequence valve proceed as follows (Fig. 53).

IMPORTANT! This procedure requires two people: one to adjust the pressure and one to operate the valve bank and watch the pressure gauge.

The second person must remain in the operator’s compartment at all times, ready to strike the emergency stop button, if required.

WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.

1. Extend the ejector blade/false bottom to the rear of the payload section and shutdown the machine.

2. Adjust the sequence valve extend and retract cartridges.

3. Start the machine the machine and cycle the ejector blade/ false bottom. When cycled the following sequence should be achieved: •

When the ejector/false bottom is being retracted, the ejector blade should return to the back of the false bottom as the false bottom begins to move. If the false bottom moves before the ejector blade is fully retracted, increase (turn clockwise) retract sequence cartridge pressure setting.

•

When the ejector/false bottom is being extended, the false bottom should extend before the ejector blade extends. If the ejector blade moves before the false bottom fully extends, increase (turn clockwise) extend sequence cartridge pressure setting.

4. Repeat the procedure until the procedure is complete.

Fig. 53: False bottom/ejector blade sequence valve adjustment

Sequence valve

________________________________________________________________ 5.68 FH110

BI001487

___________________________________________ Adjustment procedures Gear case and planetary wheel end shim procedure number 1 The purpose of the shim procedure is to set the axial end play between the gear case spacer (bronze) and the planet carrier/wheel end to from 0.005” to 0.030” (loose).

NOTICE! The following procedure is only for installing a new drive, wheel end or gear case only where stamped measurements are visible.

If the drive or wheel end have had parts replaced, refer to Gear case and planetary wheel end shim procedure number 2 in this chapter.

DANGER! You could be seriously injured or even killed by falling loads.

Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.

To calculate the required amount of shims for the gear case and planetary wheel end proceed as follows (Fig. 58).

1. Measure machined plate thickness of wheel well plate. Record figure on line “A”.

2. Locate the value stamped on machined mount face of drive unit (gear case). Record this value on line “B”.

3. Subtract line “B” from line “A” to get line “C”.

4. Locate the value stamped on machined mount face of wheel end.

Record this value on line “D”.

5. If “C” is larger then “D”, proceed to step 6. If “D” is larger than “C”, proceed to step 7.

6. Subtract “D” from “C” to get ”E”. Then divide “E” by .025 and round answer up to nearest whole number. This is the number of shims that must be added at location “X”.

7. Subtract “C” from “D” to get ”F”. Then divide “F” by .025 and round answer up to nearest whole number. This is the number of shims that must be removed from location “X”.

A.

If “C” is greater:

IF “D” is greater:

B. -

C.

D.

C.

D.-

C.-

D.

E.

F.

E / .025 = Number of shims to be added

F / .025 = number of shims to be added

______________________________________________________________ A6474X432 REV 3 5.69

BI001487

Adjustment procedures ___________________________________________ Gear case and planetary wheel end shim procedure number 2 The purpose of the shim procedure is to set the axial end play between the gear case spacer (bronze) and the planet carrier/wheel end to from 0.005” to 0.030” (loose).

NOTICE! The following procedure is to be used only for gear case and planetary wheel ends that have had parts replaced. For new gear case and planetary wheel end shim procedure, refer to Gear case and planetary wheel end shim procedure number 1 in this chapter.

DANGER! You could be seriously injured or even killed by falling loads.

Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.

To calculate the required amount of shims for the gear case and planetary wheel end proceed as follows (Fig. 54).

1. Install gear case assembly.

2. Remove all shims from behind the bronze bushing. Be sure to remove all axial clearance in the pinion shaft and bushing.

3. Place a straight edge across surface “G” and against the end of the bushing.

4. Stack shims on the pinion shaft at location “Y” until all clearance is taken out between the straight edge and bushing. Get as close as possible to no clearance but not go over. The remaining gap can be measured with a feeler gauge to ensure proper shimming.

5. Get the dimension “D” from the wheel end by the stamped value or by measuring.

6. Remove the quantity of shims from the pinion shaft necessary to be equal to or greater than the dimension “D”.

7. This procedure is designed to give axial clearance of 0.005” 0.030” using 0.025” shims. In some cases this procedure will be more than 0.030” due to the clearance at step 4, plus the clearance at step 6. If large clearances are present at steps 4 and 6, use a feeler gauge at step 4 and math at step 6 to quantify the clearance.

If the clearance is greater than 0.030”, remove one shim.

________________________________________________________________ 5.70 FH110

BI001487

___________________________________________ Adjustment procedures Fig. 54: Gear case and planetary wheel end shim procedure

______________________________________________________________ A6474X432 REV 3 5.71

BI001487

Adjustment procedures ___________________________________________

________________________________________________________________ 5.72 FH110

BI001487

_______________________________________________ Major maintenance Drive motor/ gear case removal and replacement WARNING! Power must be removed by unplugging the battery plug before servicing the motors. Follow all applicable rules and regulations regarding lockout/tagout procedures.

WARNING! Observe the safe working load limits of all lifting and blocking devices. Falling component or machines may result in serious injury, death, or machine damage.

To remove a drive motor (reference Fig. 55): 1. Remove the motor inspection cover and disconnect the power cables to the motor. Unpack the motor gland and completely remove the wiring and conduit from the motor.

2. Attach a crane or hoist, capable of lifting the motor, to the eyebolt on top of the motor and take up any slack in hoist chain.

3. Remove the four bolts that attach the motor to the gear case. Access holes are provided in the frame to the bottom motor bolts.

Cover the reducer opening to prevent foreign matter from entering the gear case.

4. Lift the motor out of the unit.

To remove a drive motor and gear case (reference Fig. 55): 1. Remove the motor inspection cover and disconnect the power cables to the motor. Unpack the motor gland and completely remove the wiring and conduit from the motor.

2. Attach a crane or hoist, capable of lifting the motor and gear case, and take up any slack in the hoist chain.

3. Remove the bolts that attach the gear case to the frame.

4. Lift the motor/gear case up just far enough to remove the brake hoses attached to the gear case.

5.

Lift the motor/gear case out of the unit.

______________________________________________________________ A6474X432 REV 3 5.73

BI001487

Major maintenance _______________________________________________ Fig. 55: Drive assembly component removal

Motor to frame mounting bolts

Motor to gear case mounting bolts

________________________________________________________________ 5.74 FH110

BI001487

_______________________________________________ Major maintenance To install a drive motor (reference Fig. 56): 1. Verify that the motor pinion gear is installed.

2. Clean all mating surfaces on the motor and the gear case.

3. Lower motor into unit and align bolt holes.

4. Apply Loctite 242 to bolt threads.

5. Bolt motor onto gear reducer, turning the pinion gear as necessary to align gears.

6. Torque bolts to 300 ft-lb.

7. Reconnect cable leads.

8. Replace inspection cover.

To install a drive motor and gear case (reference Fig. 59) WARNING! The correct number of shims to use in between the gear case and planetary wheel end must be determined before installing either (see shim procedure that follows).

1. Apply Loctite 242 to bolt threads.

2. Bolt the motor to gear case.

3. Torque bolts to 300 ft-lb.

4. Clean all mating surfaces on the gear case and frame.

5. Position the motor and gear case close to its location in the frame.

6. Align the gear case and mating flange and pull case squarely into the flange. Coat bolt threads with Loctite 242 and install. Torque the mounting bolts to 300 ft-lb. The gear case must be squarely against the frame and tight. Misalignment of the motor and gear case to the frame and wheel end will cause premature wear and failure.

7. Check all oil levels before operating the unit.

______________________________________________________________ A6474X432 REV 3 5.75

BI001487

Major maintenance _______________________________________________ Gear case and brake module disassembly and assembly WARNING! Failure to follow these procedures may result in bodily injury.

NOTICE! Replace the brake spring assembly each time the disc pack is replaced.

WARNING! Failure of a re-used brake spring will reduce brake effectiveness.

WARNING! The retainer plate is under spring force. Remove hydraulic pressure before disassembly and set the parking brake.

WARNING! Follow all rules and regulations regarding lockout/tagout. Failure to lockout the machine may result in severe injury or death.

Brake spring removal (reference Fig. 57): 1. Loosen the retaining screws consecutively rotating the screws two turns counterclockwise. Continue this procedure until the brake spring pressure has been released.

2. When the retaining screws have been rotated sufficiently to release spring pressure, the screws can be completely backed out by hand.

3. Remove the bolts from the spring clamp.

WARNING! The retainer plate is under spring force. Remove hydraulic pressure before disassembly. Set the parking brake.

4. Remove the spring clamp.

5. Remove the brake spring.

________________________________________________________________ 5.76 FH110

BI001487

_______________________________________________ Major maintenance Fig. 57: Brake pack disassembly and assembly

Gear case

“O” Ring

Shim (as required)

Spacer

Piston Spring Disc pack

Seal Spring clamp

Screw, self-locking

______________________________________________________________ A6474X432 REV 3 5.77

BI001487

Major maintenance _______________________________________________ Assembly procedure for installation of brake springs (Fig. 57): 1. Insert the brake spring assembly into the pilot diameter in the brake piston.

2. Lay the spring clamp over the spring assembly.

3. Insert all retaining screws into the holes in the spring clamp while aligning the screws with the tapped holes in the housing.

4. Tighten the screws by hand until all of the screw threads are hand tight.

5. Tighten the screws 2 turns consecutively until the spring clamp is snug against the housing.

6. Torque the screws in a crisscross pattern to 46 ft-lb .

________________________________________________________________ 5.78 FH110

BI001487

_______________________________________________ Major maintenance Planetary wheel end removal and replacement WARNING! Follow all rules and regulations regarding lockout/tagout. Failure to lockout the machine may result in severe injury or death.

WARNING! Observe the safe working load limits of all lifting and blocking devices. Failure to do so may result in severe injury or death or in machine damage.

To remove the planetary wheel end (reference Fig. 58): 1. Raise and securely block the machine's drive wheels off the ground.

2. Remove the tire-wheel assembly.

3. Attach a sling and hoist to the wheel end and take up any slack in the sling.

4. Remove the bolts that secure the wheel end to the frame.

Fig. 58: Planetary wheel end removal

Wheel end mounting bolts

______________________________________________________________ A6474X432 REV 3 5.79

BI001487

Major maintenance _______________________________________________ Planetary wheel end replacement WARNING! The correct number of shims to use in between the gear case and planetary wheel end must be determined before installing either the gear case or the planetary wheel end (see shim procedure that follows).

1. Clean the mating surfaces on the wheel end and the frame.

2. Place the correct number of shims (as determined in the shim procedure) on the gear case.

3. Using a sling and hoist, raise the wheel end to the frame.

4. Align the gearing.

5. Apply Loctite 242 to bolts and secure the wheel end to the frame.

Using the torque sequence shown in Fig. 59, torque bolts to 300 ftlb. (400 Nm).

6. Check all oil levels before operating the unit.

Fig. 59: Bolt torque sequence

________________________________________________________________ 5.80 FH110

BI001487

_______________________________________________ Major maintenance Gear case and planetary wheel end shim procedure number 1 (shimming procedure does not apply to Fairfield gearboxes) The purpose of the shim procedure is to set the axial end play between the gear case spacer (bronze) and the planet carrier/wheel end from 0.005” to 0.030” (loose).

NOTICE! The following procedure is only for installing a new drive, wheel end or gear case only where stamped measurements are visible. If the drive or wheel end have had parts replaced, refer to Gear case and planetary wheel end shim procedure number 2 in this chapter.

For an alternate, easier shimming procedure, refer to Gear case and planetary wheel end shim procedure number 3 in this chapter.

DANGER! You could be seriously injured or even killed by falling loads.

Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.

To calculate the required amount of shims for the gear case and planetary wheel end proceed as follows (Fig. 60).

1. Measure machined plate thickness of wheel well plate. Record figure on line “A”.

2. Locate the value stamped on machined mount face of drive unit (gear case). Record this value on line “B”.

3. Subtract line “B” from line “A” to get line “C”.

4. Locate the value stamped on machined mount face of wheel end.

Record this value on line “D”.

5. If “C” is larger then “D”, proceed to step 6. If “D” is larger than “C”, proceed to step 7.

6. Subtract “D” from “C” to get ”E”. Then divide “E” by .025 and round answer up to nearest whole number. This is the number of shims that must be added at location “X”.

7. Subtract “C” from “D” to get ”F”. Then divide “F” by .025 and round answer up to nearest whole number. This is the number of shims that must be removed from location “X”.

A.

If “C” is greater:

IF “D” is greater:

B. -

C.

D.

C.

D.-

C.-

D.

E.

F.

E / .025 = Number of shims to be added

F / .025 = number of shims to be added

______________________________________________________________ A6474X432 REV 3 5.81

BI001487

Major maintenance _______________________________________________ Gear case and planetary wheel end shim procedure number 2 (shimming procedure does not apply to Fairfield gearboxes) The purpose of the shim procedure is to set the axial end play between the gear case spacer (bronze) and the planet carrier/wheel end from 0.005” to 0.030” (loose).

NOTICE! The following procedure is to be used only for gear case and planetary wheel ends that have had parts replaced. For new gear case and planetary wheel end shim procedure, refer to Gear case and planetary wheel end shim procedure number 1 in this chapter. For an alternate, easier shimming procedure, refer to Gear case and planetary wheel end shim procedure number 3 in this chapter.

DANGER! You could be seriously injured or even killed by falling loads.

Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.

To calculate the required amount of shims for the gear case and planetary wheel end proceed as follows (Fig. 60).

1. Install gear case assembly.

2. Remove all shims from behind the bronze bushing. Be sure to remove all axial clearance in the pinion shaft and bushing.

3. Place a straight edge across surface “G” and against the end of the bushing.

4. Stack shims on the pinion shaft at location “Y” until all clearance is taken out between the straight edge and bushing. Get as close as possible to no clearance but not go over. The remaining gap can be measured with a feeler gauge to ensure proper shimming.

5. Get the dimension “D” from the wheel end by the stamped value or by measuring.

6. Remove the quantity of shims from the pinion shaft necessary to be equal to or greater than the dimension “D”.

7. This procedure is designed to give axial clearance of 0.005” 0.030” using 0.025” shims. In some cases this procedure will be more than 0.030” due to the clearance at step 4, plus the clearance at step 6. If large clearances are present at steps 4 and 6, use a feeler gauge at step 4 and math at step 6 to quantify the clearance.

If the clearance is greater than 0.030”, remove one shim.

________________________________________________________________ 5.82 FH110

BI001487

_______________________________________________ Major maintenance Fig. 60: Gear case and planetary wheel end shim procedure

______________________________________________________________ A6474X432 REV 3 5.83

BI001487

Major maintenance _______________________________________________ Alternate gear case and planetary wheel end shim procedure number 3 (shimming procedure does not apply to Fairfield gearbox) The purpose of the shim procedure is to set the axial end play between the gear case spacer (bronze) and the planet carrier/wheel end from 0.005” to 0.030” (loose).

NOTICE! The following procedure is an alternate, easier procedure that can be used instead of Procedure 1 or 2.

DANGER! You could be seriously injured or even killed by falling loads.

Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.

1. To determine the correct number of shims required to fill the gap between the wheel end mounting surface and the brass sleeve (reference Fig. 61): use a straight edge across the wheel end mounting surface on the wheel well plate on the machine tractor frame. Add the correct number of shims to fill gap between sleeve and appropriate straight edge being used.

2. Each shim is 0.025” thick. For example, if gap is 0.125” total, this will require five shims to fill this gap. Once you have determined the correct number of shims to fill gap, then remove the shims from the pinion shaft. Make certain during the process of determining the proper number of shims that the straight edge is resting against the mounting surface as you shim it outward. Do not have any gaps between the mounting surface and the straight edge during this process and make sure the sleeve is pushed back into the reducer until there is no slack present.

3. After removing the shims, record measurement. For example 0.125”, equates to five shims total as shown in the example above.

4. Document the measurement that is stamped on the mounting face of the wheel end. For example, a measurement of 0.083” could be a typical measurement.

5. Subtract stamped wheel end measurement from the total number of shims recorded from the above process. establishing the gap to be filled. For example 0.083” subtracted from 0.125” equals 0.042”. This means one shim needs to be added behind the sleeve. This will leave a clearance of 0.017”. Proper clearance of 0.005” to 0.030” must be maintained .

________________________________________________________________ 5.84 FH110

BI001487

_______________________________________________ Major maintenance Fig. 61: Gear case and planetary wheel end shim procedure 3

______________________________________________________________ A6474X432 REV 3 5.85

BI001487

Major maintenance _______________________________________________ False bottom cylinder replacement WARNING! Because you will be working in between the false bottom and the front of the rear (payload) section, you must completely shutdown the unit (see shutdown procedure) and disconnect the battery plug to prevent accidental movement of the false bottom.

WARNING! Follow all rules and regulations regarding lockout/tagout procedures. Failure to do so may result in severe injury or death.

To remove the ejector and false bottom cylinders (reference Fig. 62): The ejector blade/false bottom assembly is operated by three hydraulic cylinders - one on the ejector blade and two on the false bottom.

1. Extend false bottom to within 152 mm to 304 mm from the end of the machine (manually if necessary).

2. Shutdown the machine, following all lockout/tagout procedures.

3. Remove false bottom cylinder covers.

4. Remove bolts (4 each) from false bottom cylinder clevis (2) located in outer end of false bottom.

5. Start-up machine and fully extend false bottom cylinders. (Note: Be sure all persons are away from the false bottom before start-up).

The cylinders will push out the clevises out from the false bottom exposing the pins.

6. Shutdown the machine, following all lockout/tagout procedures.

7. Remove pins from rod end clevis that are now exposed.

8. Start up machine and retract false bottom cylinders.

9. Shutdown machine.

10. Remove cylinder end pins and remove false bottom cylinders.

NOTICE! A "port-a-power" unit can be used to press the cylinder end pins out from the false bottom cylinders by inserting the unit between the rear section frame and the pin.

________________________________________________________________ 5.86 FH110

BI001487

_______________________________________________ Major maintenance Fig. 62: False bottom and ejector blade assembly

3

1

2

1.

2.

3.

4.

False bottom cylinder (2) False bottom Ejector blade False bottom cylinder covers and bolts

4

______________________________________________________________ A6474X432 REV 3 5.87

BI001487

Major maintenance _______________________________________________ To install the false bottom cylinders (reference Fig. 62): 1. Slide false bottom cylinders through the access holes in the rear of the false bottom.

2. Connect the base end of the cylinder to the cylinder clevis at the front of the false bottom using the false bottom cylinder pins.

3. Connect the hydraulic hoses to the false bottom cylinders.

4. Start the machine and very slowly extend the false bottom cylinders until the rod end of the cylinder extends out through the access hole in the false bottom.

5. Attach a rear false bottom cylinder clevis to each false bottom cylinder.

6. Slowly retract the false bottom cylinders, pulling the clevises back to their mounting holes in the false bottom.

7. Bolt the clevises to the false bottom.

________________________________________________________________ 5.88 FH110

BI001487

_______________________________________________ Major maintenance Accumulator operation and pre-charging procedure Operation The accumulator used in the machine’s braking system is a hydropneumatic bladder accumulator working essentially as a fluid pressure storage chamber. Incompressible fluid (hydraulic oil) is stored against a compressible force of gas (nitrogen) to act as a secondary source of pressure.

The flexible rubber bladder in the accumulator shell is pre-charged with nitrogen gas. Basic accumulator operation is: 1. Pre-charge with nitrogen gas to 1,000 psi.

2. When fluid pressure in the accumulator is less than 1,200 psi, the accumulator charging valve opens, allowing the hydraulic pump to force hydraulic oil into the fluid chamber of the accumulator.

3. As fluid is forced into the chamber, the nitrogen gas in the bladder compresses until the gas pressure becomes equal to the system pressure.

4. At 1,500 psi, the accumulator charging valve closes.

WARNING! Do not disconnect any hoses in the brake system until all pressure has been relieved and the “accumulator” gauge indicates "0” bar.

To pre-charge the bladder: WARNING! Always use dry inert gas (dry nitrogen - N2) for pre-charging.

NEVER USE AIR OR OXYGEN due to the danger of combustion/ explosion.

1. Connect the accumulator charging gauge and hose assembly.

2. Reduce the hydraulic pressure on the fluid end to zero. This can be accomplished by: a. Shutting down the system and bleeding system hydraulic pressure to zero; or b. By isolating the accumulator from the system with the use of a safety shutoff valve and manually bleeding off any hydraulic pressure remaining with the manual needle valve in the safety shutoff valve.

3. Insure all hydraulic fluid is drained from the accumulator.

4. Remove the gas guard (gas valve protection) and valve cap from the accumulator.

______________________________________________________________ A6474X432 REV 3 5.89

BI001487

Major maintenance _______________________________________________ 5. Insure the T-handle of the gas cock is retracted from the gas cock by turning counterclockwise and then attach the charging gauge and valve assembly to the accumulator gas valve, using the gas cock.

6. Insure the bleed valve on the gauge assembly is closed and then depress the gas valve core by turning the T-handle of the gas cock clockwise. Gas pressure can now be read on the gauge.

7. If pre-charge pressure needs to be reduced, a. Carefully open the bleed valve until the desired pre-charge pressure is obtained. Then close the bleed valve and close the valve core by turning the T-handle counterclockwise. b. Allow the accumulator to rest approximately 10—15 minutes to allow gas temperature to adjust and equalize then recheck the gas pressure.

8. If pre-charge pressure needs to be increased, a. Insure that the valve on the high pressure nitrogen supply is securely closed. b. Using a charging gauge and hose assembly, attach the hose assembly to the nitrogen supply and the tank valve on the charging gauge assembly. c.

Open the accumulator gas valve.

d. SLOWLY open the valve on the nitrogen supply and allow the gas to flow into the accumulator until the desired gas precharge pressure has been reached. e. Close the valve on the nitrogen supply. f.

Close the accumulator gas valve and turn the T-handle on the gas cock counterclockwise .

g. Open the bleed valve on the gauge assembly to relieve gas pressure in the hose assembly. h. Allow the accumulator to rest approximately 10—15 minutes to allow gas temperature to adjust and equalize then recheck the gas pressure.

9. Check the accumulator gas valve for leaks with soapy water. If none are observed, complete disconnection procedure and reassemble by re-installing the gas valve cap and protective gas guard.

________________________________________________________________ 5.90 FH110

BI001487

_______________________________________________ Major maintenance Fig. 63: Nitrogen charging assembly, typical

Gauge

Tank valve (to charging hose) Gas cock (to accumulator)

Gas chuck (to tank valve)

Gas connector (to dry Nitrogen)

Hose

______________________________________________________________ A6474X432 REV 3 5.91

BI001487

Major maintenance _______________________________________________ 2-Wheel assist pump removal procedure To remove the 2-wheel assist pump (reference Fig. 64): WARNING! Follow all rules and regulations regarding lockout/tagout. Failure to lockout the machine may result in severe injury or death.

WARNING! Observe the safe working load limits of all lifting and blocking devices. Failure to do so may result in severe injury or death or in machine damage.

1. Shut down the machine and disconnect power following all appropriate rules and regulations.

2. Attach a lifting device to the pump and take up any slack in the lifting device.

3. Remove the bolts that attach the pump assembly to the gear case.

4. Lift the pump assembly out of the unit.

To install the 2-wheel assist pump (reference Fig. 64): 1. Thoroughly clean all debris out of the pump compartment.

2. Attach a lifting device to the pump and position in the machine.

3. Apply Loctite 242 to and install the bolts that secure the pump to the gear case. Torque the bolts to 80 ft-lbs.

Fig. 64: 2-Wheel assist pump removal and installation

Assist pump mounting

________________________________________________________________ 5.92 FH110

BI001487

_______________________________________________ Major maintenance Rear wheel motor (hydraulic) removal and replacement WARNING! Follow all rules and regulations regarding lockout/tagout. Failure to lockout the machine may result in severe injury or death.

WARNING! Observe the safe working load limits of all lifting and blocking devices. Failure to do so may result in severe injury or death or in machine damage.

To remove a rear wheel motor (reference Fig. 65): 1. Remove the tire/wheel unit.

2. Remove, tag, and cap the hoses from the hydraulic motor. .

3. While the hoses are disconnected, verify proper operation of the hydraulic system connected to the motor. If problems are found in the hydraulic system, correct the problems and reconnect the motor.

4. Plug the working pressure and casing oil connections after detaching the hoses.

5. Attach a hoist and sling to the motor assembly and take up any slack in the sling.

6. Remove the bolts that hold the hydraulic wheel motor to the frame and lift the assembly away from the frame.

7. Drain the oil from the hydraulic motor.

8. Clean the motor externally and place the assembly on a clean working surface.

To install a rear wheel motor (reference Fig. 65): WARNING! Thoroughly cleaned mating surfaces, bolts, bolt holes and accurately torqued mounting bolts are essential for proper operation of the rear (hydraulic) wheel motors.

1. Thoroughly clean all mating surfaces and bolt holes, removing all dirt, oil, metal particles and paint.

2. Apply Loctite 242 to and install the bolts that secure the wheel hub to the motor. Torque to 300 ft-lb.

3. Attach a lifting device to the wheel motor assembly to the frame.

Bolt the motor assembly to the frame and tighten the bolts to 300 ftlb.

4. Fill the motor with clean hydraulic oil.

______________________________________________________________ A6474X432 REV 3 5.93

BI001487

Major maintenance _______________________________________________ Fig. 65: Rear hydraulic motor

Wheel assembly (ref.)

Wheel motor

Rear frame (ref.)

________________________________________________________________ 5.94 FH110

BI001487

_______________________________________________ Major maintenance Tire/wheel installation procedure The following installation procedures are for general guidance when installing a tire/ wheel assembly (Fig. 66) on most underground mining machines. Any use made of the advisory information contained herein is entirely within the control and discretion of the user and is wholly voluntary.

Fig. 66: Tire/ wheel assembly

WARNING! Mixing parts of different design or from a variety of sources for wheels with pneumatic tires could cause severe injury or death. tire/wheel stresses

Rubber tired underground mining machinery is routinely subject to severe abuse due to the conditions in which it is operated. Whether a primary haulage or utility/support vehicle, all are subject to extreme shock, vibration, temperature change and various other loads and stresses that cause maintenance problems. One such problem is found in tire/wheel assemblies.

Many maintenance personnel view installing a tire/wheel assembly on a machine as a relatively simple task. However, if a few simple rules on proper installation are not followed, unnecessary difficulties may be experienced. Tires act like shock absorbers on haulage and support vehicles, transferring cushioned loads to the wheels. Even after proper installation, periodic checks need to be made to insure that tire/wheel assemblies do not loosen, causing wheel studs to break or damaging the mounting bolt pattern.

wheel mounting arrangements

Various mounting arrangements between the wheel and hub or wheel end are used by manufacturers. One of the more common is the taperlock. This arrangement requires a taper on both wheel and hub where the mating surfaces of the taper carry the loads. Incomplete seating of the taper will allow the wheel to loosen, resulting in stud or bolt shear and possible tire/wheel damage.

______________________________________________________________ A6474X432 REV 3 5.95

BI001487

Major maintenance _______________________________________________ Another mounting arrangement is based on holding a very close pilot fit where the tolerance between the wheel and hub is very tight, requiring a clamp-load force to hold the wheel securely in place. If the wheel studs or bolts are allowed to loosen, the load will be transmitted to them, resulting in sheared studs or bolts. problem areas

Periodic wheel inspection is critical to the life cycle of a tire/wheel assembly. A fractured wheel, broken bolt pattern and missing or broken wheel studs are all contributors to tire/wheel failures. Problems in these areas occur as the result of repeated cyclical loading as the tire/wheel unit rotates during machine travel. Haulage vehicles loaded unevenly, downhill hauls with high speed turns, or operating a vehicle with one tire of a dual assembly damaged or flat are some examples of conditions that produce damaging high stresses in wheel assemblies. Also, the effects of corroding or poorly fitted mating parts can produce surface irregularities that result in cracks and ultimate failure of a wheel.

A most common problem with tire/wheel installations is the incorrect tightening of wheel bolts or studs. Threaded fasteners perform there function of holding things together better when torque control is used in their tightening. Using an accurate torque wrench correctly is the best and most practical way of securing fasteners, Although torque value charts are available as a reference guide to proper tightening, OEM specifications should always be followed when tightening fasteners.

However, proper torque values are of little benefit if certain other factors are not considered.

wheel mounting tips

All fasteners should be examined before use. Any fastener that is worn, bent or has damaged threads should be replaced. Fastener threads should also be lightly coated with a protective substance, such as residual oils, wax or loctite, because any oxidation or rust will upset the torque-to-tension relationship.

Mating surface conditions should also be considered. The tightening surface under the bolt or nut should be carefully inspected. A fastener, when tightened against a softer material, will gall under these conditions, and much of the applied torque may be lost through head friction.

It is very important when using higher strength fasteners to have a smooth, even surface under the bolt head. In some cases, hard flat washers and most lock washers will provide a good tightening surface.

An other area of concern is cleanliness. All mating surfaces should be free of rust, dirt, oil, paint, etc. Also no paint of any kind should exist between a fastener and wheel disc surface. Any form of contamination between these surfaces will most likely lead to serious wheel problems.

WARNING! When torquing any wheel bolt pattern, always torque in a triangular pattern.

________________________________________________________________ 5.96 FH110

BI001487

_______________________________________________ Major maintenance Fig. 67: Triangular bolt pattern

1

3

2

Recommended wheel mounting procedures:

All steel mating surfaces must be free and clean of any dirt, corrosion, paint, etc. These areas include wheel/hub tapers and disc faces. NO PAINT should be present under bolt heads or nuts.

Fasteners should be in proper condition. Any fastener with damage, such as corrosion, bending or worn threads, should be replaced. Replace all broken wheel studs.

After positioning the wheel on the hub, tighten nuts down evenly.

Triangulate the bolt pattern tightening sequence as shown in the diagrams.

After operating the machine for a short period of time, check the wheel-mounting bolts or nuts for proper torque.

IMPORTANT! Wheel bolts or nuts “seat in” during normal vehicle operation.

Therefore, it is necessary to repeat torquing procedures as necessary to seat the wheel to the hub. Planned periodic checks will help maintain correct torque values. All bolts and nuts, regardless of type, should be regularly checked for tightness.

______________________________________________________________ A6474X432 REV 3 5.97

BI001487

Major maintenance _______________________________________________ PRECAUTIONS: WARNING! Do not install or remove tire/wheel assemblies from a machine without proper training.

WARNING! Check wheel components periodically for cracks or broken parts.

Replace all cracked, badly worn, damaged or severely rusted components. When in doubt replace.

WARNING! Do not, under any circumstances, attempt to rework, weld, heat or braze any wheel components that are cracked, broken or damaged. Replace such components with new OEM parts of the correct size and type.

WARNING! Mixing wheel parts of different design or from a variety of sources is potentially dangerous.

WARNING! Replace broken studs and each unbroken stud next to the broken one.

WARNING! Replace all damaged wheel studs or bolts.

________________________________________________________________ 5.98 FH110

BI001487

_______________________________________________ Major maintenance Hydraulic pump and motor removal and replacement WARNING! Power must be removed by unplugging the battery plug before servicing the motors. Follow all rules and regulations regarding lockout/tagout. Failure to lockout the machine may result in severe injury or death.

WARNING! Observe the safe working load limits of all lifting and blocking devices. Failure to do so may result in severe injury or death or in machine damage.

To remove the hydraulic pump and motor (reference Fig. 68): 1. Remove power from the machine, following all lockout/tagout rules and regulations.

2. Remove access covers as needed.

3. Remove the pump motor strap (Fig. 72) and all hoses connected to the pump.

4. Disconnect the power cables to the motor. Unpack the motor gland and completely remove the wiring and conduit from the motor.

5. Attach a crane or hoist, capable of lifting the motor, to the eyebolt on top of the motor and take up any slack in hoist chain.

6. Remove the bolts that attach the motor assembly to the frame.

7. Lift the motor assembly out of the unit.

To install the hydraulic pump and motor (reference Fig. 68): 1. Clean all mating surfaces.

2. Lower motor into unit and align bolt holes.

3. Bolt motor onto frame.

4. Attach motor strap.

5. Connect hydraulic hoses to the pump.

6. Connect power cables to the motor.

7. Replace covers.

______________________________________________________________ A6474X432 REV 3 5.99

BI001487

Major maintenance _______________________________________________ Fig. 68: Hydraulic pump and motor removal and installation 1

2

3

4 5

1.

2.

3.

4.

5.

Access cover Motor strap Motor mounting bolts Access cover Motor strap bolt

________________________________________________________________ 5.100 FH110

BI001487

_______________________________________________ Major maintenance Battery lift assembly removal procedure WARNING! Because you will be working with the battery lift cylinders, you must completely shutdown the unit (see shutdown procedure) and disconnect the battery plug to prevent accidental movement of the cylinders. Follow all rules and regulations regarding lockout/ tagout. Failure to lockout the machine may result in severe injury or death.

WARNING! Observe the safe working load limits of all lifting and blocking devices. Failure to do so may result in severe injury or death or in machine damage.

To remove the battery lift assembly (reference Fig. 69): Note: The battery lift assembly is operated by two hydraulic cylinders.

1. Fully raise the battery assembly.

2. Shutdown the machine following all lockout/tagout regulations.

3. Attach a crane or hoist, capable of lifting the assembly, to the assembly and take up any slack in hoist chain.

4. Remove, tag, and cap the hydraulic hoses from the lift cylinders.

5. Remove the cylinder pins that attach the lift assembly to the cylinders.

6. Remove the lift pins from the assembly 7. Lift the assembly out of the unit.

To install the battery lift assembly (reference Fig. 69): 1. Attach a lifting device to the battery lift assembly and position the assembly in the machine.

2. Insert the two lift pins into the assembly, securing the assembly to the frame.

3. Insert the cylinder pins that attach the lift assembly to the cylinders.

4. Connect the hydraulic hoses to the cylinders.

______________________________________________________________ A6474X432 REV 3 5.101

BI001487

Major maintenance _______________________________________________ Fig. 69: Battery lift assembly (typical both sides)

4

3

2 1

1.

2.

3.

4.

Lift pins (2 per side) Cylinder pin (1 per cylinder) Lift cylinder (2 per assembly) Lift assembly

________________________________________________________________ 5.102 FH110

BI001487

_______________________________________________ Major maintenance Canopy removal procedure WARNING! Follow all rules and regulations regarding lockout/tagout. Failure to lockout the machine may result in severe injury or death.

WARNING! Observe the safe working load limits of all lifting and blocking devices. Failure to do so may result in severe injury or death or in machine damage.

WARNING! Do not operate the machine with the canopy removed. You or other personnel could be seriously injured.

To remove the canopy (reference Fig. 70): 1. Shut down the machine following all applicable lockout/tagout rules and regulations.

2. Attach a crane or hoist, capable of lifting the canopy, and take up any slack in hoist chain.

3. Remove the bolts that attach the canopy to the frame.

4. Remove the cotter pin and pins that secure the canopy legs to the canopy posts.

5. Lift the assembly out of the unit.

To install the canopy (reference Fig. 70): 1. Attach a lifting device to the canopy and position on the machine.

Note that there are multiple canopy heights available. Position the canopy so that it will be clear of all roof obstructions when the machine is in operation.

2. Insert the bolts that secure the canopy to the frame and tighten.

3. Insert the pins through the canopy post and leg and insert cotter pin to secure.

4. Restore power to the machine.

______________________________________________________________ A6474X432 REV 3 5.103

BI001487

Major maintenance _______________________________________________ Fig. 70: Canopy assembly removal and installation

1 2

1. Canopy 2. Mounting bolts

________________________________________________________________ 5.104 FH110

BI001487

_______________________________________________ Major maintenance Tailgate assembly removal and installation procedure (if equipped) WARNING! Because you will be working close to the false bottom, you must completely shutdown the unit (see shutdown procedure) and disconnect the battery plug to prevent accidental movement of the false bottom. Follow all rules and regulations regarding lockout/ tagout. Failure to lockout the machine may result in severe injury or death.

WARNING! Observe the safe working load limits of all lifting and blocking devices. Failure to do so may result in severe injury or death or in machine damage.

To remove the tailgate assembly Note: The tailgate assembly is operated by two hydraulic cylinders.

1. Fully extend the tailgate by pressing the ejector extend button on the right control handle until the tailgate lowers fully.

2. Shutdown the machine following all applicable lockout/tagout regulations.

3. Fully support the tailgate assembly.

4. Remove upper bolts and pin from tailgate cylinder clevis (2) located in outer end of tailgate.

5. Start-up machine and fully retract the tailgate cylinders. (Note: Be sure all persons are off of and away from the machine before startup). The cylinders will pull out the clevises out from the tailgate assembly.

6. Shutdown the machine following all applicable lockout/tagout regulations.

7. Remove lower pins and bolt from the tailgate assembly.

8. Remove tailgate.

______________________________________________________________ A6474X432 REV 3 5.105

BI001487

Major maintenance _______________________________________________ Adjustable pedal assembly removal and installation procedure (if equipped) WARNING! Follow all rules and regulations regarding lockout/tagout. Failure to lockout the machine may result in severe injury or death.

WARNING! Observe the safe working load limits of all lifting and blocking devices. Failure to do so may result in severe injury or death or in machine damage.

To remove the adjustable pedal assembly: 1. Shut down the machine following all applicable rules and regulations regarding lockout/tagout.

2. Attach a lifting device capable of lifting the assembly and take up any slack.

3. Disconnect the accelerator connections.

4. Disconnect, tag, and cap the hydraulic hoses from the brakes.

5. Remove adjustment bolts from the assembly.

6. Remove the bolts that attach the assembly to the frame.

7. Lift the assembly out of the unit.

To install the adjustable pedal assembly: 1. Using an appropriate lifting device, position the pedal assembly in the machine.

2. Secure the pedal assembly to the frame with bolts.

3. Insert the adjustment bolts into the assembly.

4. Connect the hydraulic hoses to the brakes.

5. Connect the accelerator connections.

6. Adjust the assembly to ensure correct function of the adjustment assembly.

________________________________________________________________ 5.106 FH110

BI001487

_______________________________________________________________

6

Technical data

________________________________________________________________

BI001487

_______________________________________________________________

________________________________________________________________

BI001487

___________________________________________________ Technical data

Technical data This chapter contains the most important technical data on the machine. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

The technical data listed in this chapter is for stock machines only. Customer specials may not be listed.

Technical data sheet general

Operating height ............................................ 1,117-1,575 mm (44-62 in) Frame height ................................................. 914-990 mm (36-39 in) Payload capacity ........................................... 9 tones (10 tons) Overall length ................................................ 11,684 mm (38 ft 4 in) With extended deck ....................................... 3,395 mm (11 ft 2 in) Trailer............................................................. 3,302 mm (10ft 8 in) Empty weights without battery ......................................... 23,995 kg (52,900 lbs) with 64-SS85-25 battery ......................... 30,844 kg (68,000 lbs) with 64-SS100-25 battery ....................... 31,524 kg (69,500 lbs) Capacity Heaped with no sideboards .................... 12.34 m3 (436 ft3) Struck capacity ........................................ 6.25 m3 (221 ft3) Ground clearance (with 35 in tires) ............... 194 mm (8 in) Minimum canopy height (with 35 in tires) ...... 1,092 mm (43 in) Trailer height at top of false bottom (with 35 in tires) .... 954mm (38 in) trailer frame height (with 35 in tires)........ 914 mm (36 in)

performance

Steering articulation ....................................... 120 degrees total Inside turning radius ...................................... 3.60 m (11 ft 10 in) Outside turning radius ................................... 7.51 m (24 ft 8 in) Minimum entry width ...................................... 4.62 m (15 ft 2 in) Tram speed* ................................................. 0 – 8.04 km/h (0 - 5 mph) *(varies depending on floor conditions) Discharge time ............................................... 30 seconds Terrain compensation articulation ................. +15 degrees - 10 degrees

______________________________________________________________ A6474X432 REV 3 6.3

BI001487

Technical data ___________________________________________________

________________________________________________________________ 6.4 FH110

BI001487

______________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Set screws Table 4: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8 #10

9 in-lbs 13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

Table 5: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

______________________________________________________________ A6474X432 REV 3 6.5

BI001487

Tightening torques _______________________________________________ Table 6: FSR hex bolts (SAE 5 and 325 steel) Nominal diameter

Recommended torque setting

¼”

9 ft-lbs

5/16”

18 ft-lbs

3/8”

31 ft-lbs

7/16”

50 ft-lbs

½”

75 ft-lbs

9/16”

110 ft-lbs

5/8”

150 ft-lbs

¾”

250 ft-lbs

7/8”

378 ft-lbs

1”

583 ft-lbs

1 1/8”

782 ft-lbs

1 ¼”

1,097 ft-lbs

1 3/8”

1,461 ft-lbs

1 ½”

1,748 ft-lbs

1 ¾”

3,114 ft-lbs

2” 2 ¼”

4,504 ft-lbs 6,497 ft-lbs

2 ½”

7,144 ft-lbs

2 ¾”

12,092 ft-lbs

3”

15,744 ft-lbs

Table 7: Socket, flat & button head cap screws (Steel only) Nominal diameter

Recommended torque setting

#6 #8 #10 ¼”

26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs

5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

________________________________________________________________ 6.6 FH110

BI001487

______________________________________________ Tightening torques Table 8: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Table 8: Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 8: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

______________________________________________________________ A6474X432 REV 3 6.7

BI001487

Tightening torques _______________________________________________ Table 9: Untreated screw, black finish (Fine thread) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25

Nm

27

52

95

Ft-lbs

19

38

70

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

Table 9: Untreated screw, black finish (Fine thread, continued) Proper- Torqu Recommended Nominal diameter ty e torque setting class Ma M14 X 1.5 M16 X 1.5 M18 X 1.5 8.8 10.9 12.9

Nm

150

225

325

Ft-lbs

110

165

239

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

Table 9: Untreated screw, black finish (Fine thread, continued) Property class

Torque Ma

8.8

Nm

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399

Ft-lbs 10.9 12.9

610

780

449

575

Nm

640

860

1100

Ft-lbs

472

634

811

Nm

770

1050

1300

Ft-lbs

567

774

958

________________________________________________________________ 6.8 FH110

BI001487

______________________________________________ Tightening torques Table 10: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M33 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

Table 10: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nm

36

58

88

Nominal diameter M18

M20

M22

121

171

230

Ft-lbs

26

42

54

89

126

169

Nm

83

132

200

275

390

530

Ft-lbs

61

97

147

202

287

390

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 10: Electrically zinc plated (Coarse thread, continued) Property class 5.6

8.8

10.9

12.9

Torque Ma

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

______________________________________________________________ A6474X432 REV 3 6.9

BI001487

Tightening torques _______________________________________________ Table 11: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

Torque Ma Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

Recommended torque setting M8 X 1 25 18 35 25 42 30

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 11: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 11: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

________________________________________________________________ 6.10 FH110

BI001487

_______________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Only use approved lubrication fluids and greases! These fluids and greases have been tested and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent. Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins. In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Caterpillar expressly points out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be disposed of per your local EPA standards.

______________________________________________________________ A6474X432 REV 3 6.11

BI001487

Permissible media ________________________________________________ Approved suppliers: Table 12: Anti-wear hydraulic oil (Spec 100-1) Supplier

Brand name

1

Amoco Oil Company

Amoco AW oil No.68

2

Gulf oil

Harmony 68 AW

3 4

Mobil Oil Corporation Chevron U.S.A.

5

Sun Oil Company

Mobil DTE-16 Chevron hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hyldraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers

Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

________________________________________________________________ 6.12 FH110

BI001487

_______________________________________________ Permissible media Table 13: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460

6

Unocal 76

7

Shell Oil company

8

Century Lubricating Oils, Inc.

9

Texaco Lubricants Company

Hulbest EP-7 Powergear 460 Meropa 680

10

Exxon

Spartan EP 460

11

Pennzoil

Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube

12

Lubricating Engineers

608 Almosal Vari-Purpose Gear Lubricant

13

Conoco Inc.

Gear oil 460

14

Hydrotex

933 Industrial Gear Lubricant

15

Phillips

16

Miners Oil

All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680

______________________________________________________________ A6474X432 REV 3 6.13

BI001487

Permissible media ________________________________________________ Table 14: Extreme pressure motor bearing grease (Spec. 100-3) Supplier

Brand name

1

Amoco Oil Company

2 3 4

Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil company Century Lubricating Oils, Inc.

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Amolith grease 2 EP Rykon Premium Grease 2 EP Gulfcrown grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Table 15: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century oils Limited Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

________________________________________________________________ 6.14 FH110

BI001487

_______________________________________________ Permissible media Table 16: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company

5 6

Cincinnati – Vulcon Company Cities Service Oil company

7 8

10 11

Century Oils limited Fiske Bros. Refining Company Getty Oil company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

12 13 14 15 16 17

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and chemical Co. Pennzoil Quaker Chemical Company

18

Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

9

19 20 21

22 23

Standard Oil Company of Ohio (Boron Sohio) Sun Oil company Tower Oil Company

24 25

Wynn Oil company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion fire resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR

Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant hydraulic Fluid HY-Guard

______________________________________________________________ A6474X432 REV 3 6.15

BI001487

Permissible media ________________________________________________ Table 17: Extreme pressure gear oil, SAE 90 (Spec. 100-6) Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

________________________________________________________________ 6.16 FH110

BI001487

_______________________________________________ Permissible media Table 18: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) Supplier Brand name 1

Amoco Oil Company

American Industrial Oil No. 68

2

Gulf oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy – Medium

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754

6

Unocal 76

7

Shell Oil Company

Unax RX68 or Turbine Oil 68 Turbo 68

8

Century Lubricating Oils, Inc.

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

______________________________________________________________ A6474X432 REV 3 6.17

BI001487

Permissible media ________________________________________________ Table 19: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name 1

Amoco Oil Company

American Industrial oil No. 150

2

Gulf Oil

Harmony 150

3 4

Mobil Oil Corporation Chevron U.S.A.

5

Sun Oil Company

DTE Oil EX. Heavy Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961

6

Unocal 76

7

Shell Oil company

Unax RX 700 or Turbine Oil 700 Turbo 150

8

Century Lubricating Oils, Inc.

Centraulic R&O 150

9

Atlantic Richfield Company

10

Texaco Lubricants Company

Duro 600 or S-700 Regal Oil R&O 150

11

Exxon

Teresstic 150

12

Pennzoil

Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15

Conoco Inc.

Dectol R&O 76

16

Hydrotex

System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Table 20: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier Brand name 1 Amoco Oil Company Cylinder oil No. 1000 2 Mobil Oil Corporation Extra Hecla Super Cylinder Oil 3 Chevron U.S.A. Chevron Cylinder Oil W ISO 1000 4 Sun Oil Company Sun Steam Cylinder Oil 5 Unocal 76 Worm gear Lube 250 or Stevalc 6 Century Lubricating Oils, Inc. Garwal 680 7 Atlantic Richfield Company Modoc 195 8 Texaco Lubricants Company 650 T Cylinder Oil 1000 9 Exxon Cylesstic TK-1000 10 Pennzoil Cylinder Oil #1000 11 Conoco Inc. Inca Oil 1000

________________________________________________________________ 6.18 FH110

BI001487

_______________________________________________ Permissible media Table 21: Light gear oil, SAE 40 motor oil (Spec. 100-10)

1 2 3 4

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 22: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

______________________________________________________________ A6474X432 REV 3 6.19