CAT SH640 D Roof Support Carrier Operation Manual SN 5003716 - PDF DOWNLOAD

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Revision No 0 10 September 2012

Operation Manual SH640 D Roof Support Carrier Serial Number 5003716

SAFETY.CAT.COM

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Operation Manual

TABLE OF CONTENTS Section 1

General Information Introduction ..................................................................................... 1 Description...................................................................................... 1 General Arrangement ..................................................................... 2 Specifications ................................................................................. 3

Section 2

General Safety and Precautions ................................................. 5

Section 3

Gauge Parameters and Colour Coding ...................................... 9

Section 4

Machine Orientation, Controls and Functions Machine Orientation Basic Machine Layout ......................................................... 13 Control Locations Compartment Door .............................................................. 14 Transmission Gear Control Lever ....................................... 15 Transmission Directional Control Lever .............................. 15 Park Brake Button ............................................................... 16 Four-Way Joystick Control Lever ........................................ 17 No 1—Two-Way Hydraulic Control Lever ........................... 17 No 2—Two-Way Hydraulic Control Lever ........................... 17 Operator’ Seat ..................................................................... 18 Accelerator Pedal ................................................................ 18 Brake Pedal ......................................................................... 18 Steering Wheel .................................................................... 19 Brake Head Pressure Gauge .............................................. 20 Brake Accumulator Pressure Gauge ................................... 20 Steering Accumulator Pressure Gauge ............................... 20 Engine Start Button ............................................................. 21 Air Pressure Gauge ............................................................. 21 On/Off Toggle Switch .......................................................... 21 Transmission Oil Temperature Gauge ................................ 22 Engine Coolant Temperature Gauge .................................. 22 Load Indicator Gauge .......................................................... 23 Horn Button ......................................................................... 24 Engine Service Hour Meter ................................................. 24 Air Cleaner Service Indicator............................................... 25 Shutdown System Test Valve ............................................. 25 Exhaust Back Pressure Gauge ........................................... 26 Exhaust Outlet Gas Temperature Gauge ............................ 26 Engine Oil Pressure Gauge................................................. 26 Engine Fuel Primer Pump ................................................... 27 Attachment Quick Connects Button .................................... 27 Emergency Intake Shut Off Valve ....................................... 28 Emergency Fuel Shut Off Valve .......................................... 29 Reversing Camera .............................................................. 30

Section 5

Machine Isolation Engine Isolation ............................................................................ 31 Pneumatic Isolation ...................................................................... 32 Hydraulic Isolation ........................................................................ 33 Engine Coolant Isolation............................................................... 34

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Section 5

Machine Isolation (cont.)

Electrical Isolation ......................................................................... 35 Articulation Isolation ...................................................................... 36 Lift Arm Isolation ........................................................................... 37 Exhaust Conditioner Isolation ....................................................... 38 Exhaust Conditioner Mark Up Tank Pressure Isolation ................ 39

Section 6

Pre-Start Procedure .................................................................... 41

Section 7

Engine Starting Procedure ........................................................ 51

Section 8

Post Start Checks ....................................................................... 53

Section 9

Stopping the Engine ................................................................... 57

Section 10

Tramming the Machine ............................................................... 59

Section 11

Stopping and Braking ................................................................ 61

Section 12

Driving on a Ramp ...................................................................... 63

Section 13

Parking on a Ramp ..................................................................... 65

Section 14

Loading ........................................................................................ 67

Section 15

Cookie Plate Use ......................................................................... 69

Section 16

Towing the Machine when Disabled ......................................... 71

Section 17

Towing with the Machine ........................................................... 73

Section 18

Air Venting the Fuel System ...................................................... 75

Section 19

Air Venting the Engine Cooling System ................................... 77

Section 20

Diesel Control System (DCS) ..................................................... 79

Section 21

Fluid Specification Table ........................................................... 83

This document is the property of Caterpillar SUBJECT MATTER HEREIN IS PRIVATE, CONFIDENTIAL AND RESTRICTED. Do not use, reproduce, copy, distribute or disclose except with, and only to the extent of, prior written consent of Caterpillar PERSONS RECEIVING THIS DOCUMENT ARE RESPONSIBLE FOR RESTRICTING DISCLOSURE, except as absolutely necessary consistent with the intended use. When such is completed, return immediately to Caterpillar.

Caterpillar recommends that all Safe Working procedures should be approved and checked by Mine Officials. Caterpillar declines all liability for direct or indirect consequences of printing errors.

This document is copyright. All intellectual property rights and copyright in the document (or any part of this document remains the property of Caterpillar. Except as provided for in the Copyright Act 1968 (Ctn) no part of this document may in any form or by any means (including without limitation electronic, mechanical, micro copying, photocopying, recording or otherwise) be reproduced, stored in a retrieval system or transmitted without the prior written permission of Caterpillar.

CATERPILLAR Australia Room & Pillar Division 20 Kullara Close, PO Box 373 Beresfield NSW 2322 Australia Phone: +61 2 49147000 Fax: +61 2 49147059

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Section

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General Information INTRODUCTION The operation of heavy mining machinery can be hazardous. To ensure safe operation, operators and personnel must be alert, competent, correctly trained, tested and licensed in the principles, capabilities and correct operating and isolation procedures of the machinery.

This manual is designed to provide the SH640 D Roof Support Carrier operator with the proper information regarding the machine’s instrumentation, operating controls and general safe working procedures. All operators of this machine must be conversant with the information contained within this manual before operating the machine.

To ensure safe and efficient operation, the SH640 D Roof Support Carrier must be adequately maintained by the operators and service personnel. To achieve this, the operator’s pre-start inspection procedure contained in Section 6 of this manual must be performed before any use of this machinery is undertaken.

Any abnormalities should be reported immediately to service personnel to avoid costly machine repairs, production downtime and unsafe operation of the machine.

DESCRIPTION The SH640 D is a 40000 kg high capacity Roof Support Carrier. It has been designed for lifting and carrying heavy pieces of equipment and machinery in underground coal mines.

Its main function is the carrying and placing of longwall equipment and shields. The machine comes standard with a set of fork tines and winch for this purpose.

The motive force is provided by a 172 kW CAT C7 turbocharged four-stroke inline six cylinder flameproof diesel engine package.

Flameproofing of the system includes an inlet flametrap, and a wet bath exhaust system, complete with exhaust purifier and dual particulate filtration.

The machine has a pneumatic starting and safety interlock system coupled to a Diesel Control System (DCS), which is an intrinsically safe electronic monitoring and shutdown system that prevents the engine running outside of the predetermined safe operating parameters.

The engine power output is connected to the constant four-wheel drive system via a transfer case (drop box) coupled to the engine flywheel, and a four speed Dana/Spicer 32000 Series transmission providing power to heavy duty Dana 53R outboard planetary drive axles through bevel gear and pinion.

A site specific Risk Assessment is recommended to be conducted before this machine is introduced into service.

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GENERAL ARRANGEMENT

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SPECIFICATIONS All specifications are subject to change without notice. Axles Outboard planetary Always consult the dealer to obtain current information Type Front axle make/model Dana 53R before applying critical loads.

Rear axle make/model Dana 53R Differential type Bevel gear and pinion Weight Differential lock type - front Posi-Torque Operating with full fuel and operator 39400 kg Differential lock type - rear Posi-Torque Tractive Effort (standard wheels) Tyres – Standard 1st gear 280 kN Size 1290 diameter x 534 mm 2nd gear 135 kN Inflation media Solid 3rd gear 78 kN 4th gear 45 kN Hydraulic Systems Steering Closed centre 17.30 MPa Vehicle Speeds (standard wheels) Brakes Closed centre 17.30 MPa Empty Carry plate lift and tilt Open centre 21.05 MPa PTO Open centre 21.05 MPa 1st gear 3.1 Tank type Sealed and pressurised Tank pressure 50 kPa 2nd gear 6.9 Hydraulic Filtration 3rd gear 11.9 Auxiliary system Type In tank return replaceable with bypass 4th gear 19.3 Rating 10 micron Grade Ability Front to rear Side to side (empty) Side to side (laden fully raised) Engine Make/model Displacement Maximum power

1:4 1:4 1:8

Caterpillar C7 7.2 litre 171.5 kW @ 2300 RPM

Engine Cooling System Cooling system Cooling fan Water pump Radiator and fan orientation Engine Speeds Low idle High idle

Fan Pump Type Nominal output @ 2300 RPM

Gear open centre 76 lpm

800 RPM 2300 RPM

Alternator/HEX Pump Type Nominal output @ 2300 RPM

Gear open centre 38 lpm

Turbine air start

Intake Air Cleaner Type/Make Elements Flame trap

Dry Dual (primary and safety) Intake between turbo and after cooler

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Inline return replaceable with bypass 25 micron

Water cooled Hydraulic driven fan Engine driven Vertical

Start System Starter motor type

Torque Converter Make/model

Optional PTO Type Rating

Gear open centre 156 lpm

52.9 litres/hr 20-40 litres/hr

Transmission Make/Model Speeds, forward/reverse

Inline return replaceable with bypass 10 micron

Implement Pump Type Nominal output @ 2500 RPM

Fuel Consumption At full power Average mine duty

Exhaust Conditioner Type Make Exhaust filter Exhaust flame trap After treatment

Steer/brake system Type Rating

Wet Scrubber Caterpillar Replaceable element Wet MA Catalytic exhaust purifier

Dana 32000 4

Steering and Brake Pump Type Pressure compensated piston Nominal output @ 2300 RPM 96 lpm Cylinders Type Rods Counterbalance valves Cushion stops Steering Type Steering System Control valve Actuation Pressure compensated Crossover relief Accumulator – Brakes Type Quantity x capacity Operating pre-charge pressure

Double acting Hard Chromed Lift and tilt Steering and tilt

Centre articulated, hydraulic

Closed centre Orbital 17.30 MPa 19.30 MPa

Piston 1 x 2 litre 6.2 MPa

Dana

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Service Brake Type

Totally enclosed, liquid cooled Posi-Stop Dana Spring applied hydraulic release Each wheel end

Make Application Location Park Brake Type

Totally enclosed, liquid cooled Posi-Stop Dana Spring applied hydraulic release Each wheel end

Make Application Location Articulation Bearing type and size

Pin and spherical bearing (top) bush, (bottom) fully sealed Bush material Hardened steel Pin material Hardened steel Degrees of turn either side 45 degree Oscillation Type Dana rear axle mounted trunnion Bush material Hardened steel Pin material Hardened steel Up and down from horizontal 6 degree Seating (Operator) Type Make Suspension Canopy Type

Cross-seated Caterpillar Shock absorption

Electrical System Type Voltage Lights Number/location Type Alternator Drive Type Pneumatic System Compressor type Air flow Governed pressure Relief pressure Air receiver volume Shutdown System System type

Service Capacities Hydraulic tank Fuel tank Transmission/converter oil Engine crankcase oil (with filter) Engine cooling system water Axle oil (each) Wet scrubber water reserve

Flameproof 24 V

STD 2 front, 2 rear Approved flameproof

Hydraulic Flameproof

Piston engine gear driven 0.50 m³/min @ 1500 RPM 800 kPa 830 kPa 80 litres

DCS electronic Intrinsically safe approved

450 litre 350 litre 40 litre 25 litre 72 litre 60 litre 468 litre

Protective device MDG1

Overloading equipment could cause personal injury, death or equipment damage. Due to configuration or options these weights can vary up to 20%. Caterpillar recommends that relevant standards and safety procedures should always be used when operating this machine. Removal of protective canopies, doors, interlocks and structures etc., could cause serious injury or death. Replacement with correctly torqued fasteners is mandatory.

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General Safety and Precautions This section contains specific safety precautions that shall be followed whilst the machine is being used by suitably qualified operators. This list is NOT all inclusive and a measure of commonsense should always be applied together with established site specific risk assessment and safety procedures.

ONLY TRAINED AND AUTHORISED OPERATORS SHALL OPERATE THIS MACHINE DO NOT

use the machine for any purpose other than its intended use.

DO NOT

for any reason exceed the indicated capacity of the machine.

DO NOT

operate the machine unless all operator checks and scheduled servicing have been performed. Report any damage or faulty operation immediately and do not operate the machine until the fault has been corrected.

DO NOT

tie down or tow equipment such that the chains or slings are not rated for the capacity of the machine and equipment.

DO NOT

operate the machine unless:   

DO NOT

start the machine unless:      

DO NOT

There are no tags attached stating otherwise.

All covers and guards are correctly installed.

Personal protective equipment is worn.

There are no tags attached stating otherwise.

The area around the machine is clear.

The park brake is applied.

Transmission is in neutral.

All water and oil levels are checked.

All site specific checks are completed.

leave the machine unless:      

The machine is parked in a safe place.

The transmission is in neutral.

The park brake is applied and brake head pressure is zero.

The park brake is applied and the steer accumulator pressure is zero The lift arms are lowered.

The engine is stopped.

DO NOT

work on the machine in low ventilated areas while the engine is running.

ALWAYS

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

ALWAYS

ensure that the operator’s compartment door is closed and made secure before operating the machine.

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ALWAYS

keep head, body and arms inside the operator’s compartment at all times.

ALWAYS

travel at low speeds in congested areas. Slow down while travelling around corners and sound the horn frequently in areas of limited visibility.

ALWAYS

drive carefully, observing all traffic rules and regulations at your colliery and be in full control of the machine at all times.

Travelling at high speeds, on cross grades or articulating the machine with raised loads may cause the machine to become unstable.

ALWAYS

follow the correct isolation and tag out procedure before performing any servicing or accessing beneath or on the machine.

ALWAYS

operate carefully and in a responsible manner and observe all Manager’s Transport Rules.

ALWAYS

refer to site JSA and SOP’s prior to towing with the machine.

ALWAYS

ensure sufficient ventilation is available to dilute exhaust gases, as stated on the machine’ compliance plate.

ALWAYS

be aware of the hazard sources on the SH640 D:           

ALWAYS

Engine coolant pressure (see Section 5).

Engine coolant temperature (see Section 5).

Engine exhaust temperature (see Section 5).

Rotating radiator fan.

Stored hydraulic pressure (see Section 5).

Stored air pressure (Air receiver) (see Section 5).

Engine oil pressure and temperature.

Transmission oil temperature.

Articulation area (see Section 5).

Lift arm area (see Section 5).

Machine mass.

use correct boarding and dismounting procedures:    

Check floor.

Hold on, step down.

Three points of contact at all times.

Board using hand holds only, and not the steering wheel.

ALWAYS

drive the machine to suit the conditions, report or rectify any holes and ruts, that may cause injury or damage to the equipment.

ALWAYS

ensure the area around the machine is clear of personnel when performing machine functional tests. These include lift arm functions, steering, brake release and functional testing of any attachments that may be attached to the machine’s PTO couplings.

ALWAYS

allow the engine or machine systems to cool sufficiently prior to commencing any maintenance or service on hot machine components.

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ALWAYS

be aware of the impact of the payload on the visibility available to the operator. The recommended maximum speed when loaded is 10 km/h, however, the impact of the payload on the operator’s field of vision must be considered when operating the machine with payload. Drive to the conditions.

NEVER

operate the machine under unsecured roof.



Keep your machine clean. A clean machine makes for a safer machine.



No diesel engine should be operated underground if it is smoky, running unevenly, or if the exhaust system is not in good condition.



In areas where auxiliary ventilation is used, the operator should make sure fans are operating before starting the machine.



The engine shall not for any reason be left running unattended underground.



The engine should not be shutdown from full load and must be allowed to idle for a few minutes before stopping.



Never operate a machine that you feel is mechanically unsafe.

GRAB HANDLE FOR MACHINE TOP ACCESS On the off driver’s side of the machine, a grab handle and three foot holds have been installed to aid in safe access to the top of the machine.

Prior to accessing the top of the machine ensure the top surfaces are free of any material that could pose a trip or slip hazard. Use grab handle and keep footing on three points of access to avoid injury.

Foot Holds

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SAFETY LABELS AND INSTRUCTIONS This manual contains important information affecting the safety of personnel and the equipment being used.

The safety instructions and behavioural rules are intended to protect operators from potentially dangerous situations and assist in the safe operation of the trailer and associated equipment.

The following symbols are used with safety instructions and identify varying degrees of hazardous conditions.

The safety instructions associated with these symbols are to be considered the minimum requirements for effective hazard and operational control.

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

These points contain information on potentially dangerous situations.

Possible consequences are very serious or fatal injury.

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

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

Text marked with this symbol contains useful information associated with the machine and its application.

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Gauge Parameters and Colour Coding GAUGE COLOUR CODE The gauges in the operator’s compartment are colour coded to assist the operator to recognise if the temperatures and pressures are within the correct operating parameters.

During normal operation some gauges may, at times, read outside of the indicated normal operating range e.g. during normal operation, when the operator applies the brake the brake head pressure gauge will drop below the minimum pressure and indicate that the pressure is too low. This is because the pressure is being released from the brakes to allow the springs to apply the brakes. When the operator releases the brake the gauge should then return to the green zone.

RED:

The gauge is indicating an unsafe condition. When this occurs the operator should stop the machine and rectify the problem or have service personnel rectify the problem before placing the machine back in service.

ORANGE: The gauge is indicating a temperature or pressure outside of the normal operating range. The operator should closely monitor the gauge and report the problem to service personnel for rectification.

YELLOW: The gauge is indicating a temperature or pressure below the normal operating range. This will not cause immediate damage if operated for short periods. Report to service personnel for rectification if machine continually operates in this area.

GREEN:

The gauge is indicating that the temperature or pressure being monitored is within the normal operating range.

GAUGE ALARM PARAMETERS Engine Coolant Temperature

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Exhaust Gas Temperature

Brake Accumulator Pressure

Brake Head Pressure

Engine Oil Pressure

Air Pressure

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Steering Accumulator Pressure

Transmission Oil Temperature

Exhaust Back Pressure

Primary Park Brake

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Section

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Machine Orientation, Controls and Functions MACHINE ORIENTATION BASIC MACHINE LAYOUT The SH640 D consists of two main sections: a front and rear frame. Housed in the front frame is the lift arm assembly, axle and main hydraulic control valve bank. The rear frame houses the transmission and hydraulic pumps, cooling system radiator, flameproof engine package (which utilises a wet bath exhaust conditioner), the operator’s compartment and all the storage reservoirs (hydraulic, pneumatic, exhaust conditioner make up and fuel tanks).

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CONTROL LOCATIONS COMPARTMENT DOOR The compartment door must be closed and locked after entering the compartment before the park brake button can be released and the declutch cylinder deactivated.

Never use the door to apply the park brake. Always manually apply the park brake by pressing the park brake button and ensure the brake head pressure gauge reads zero before exiting the Operator’s compartment.

On both opening the operators door and manual operation of the park brake valve, the steering pressure will automatically begin to bleed down upon engine shutdown, never assume the steering pressure has bled down unless the steering pressure gauge reads zero.

When the door is open the machine cannot be operated, as the park brake will be on and the transmission will be declutched. There is a roller cam valve in the door lock that needs to be activated to release the park brake. Also the brake system pressure is dumped with the door open. The engine will run with the door open.

DOOR INTERLOCK VALVE

COMPARTMENT DOOR ASSEMBLY

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TRANSMISSION GEAR CONTROL LEVER The transmission gear control lever has four positions, first, second, third and fourth.

Shifting from one range to another can be made at any time conditions permitting.

Momentarily decrease engine revs when selecting a higher gear.

The transmission in the machine is modulated. This prevents severe shocks being transmitted through the drive train when the transmission is shifted between gears.

TRANSMISSION DIRECTIONAL CONTROL LEVER A directional control lever controls the transmission. This lever has three positions, forward, neutral and reverse. The engine should be at low idle when the transmission is shifted from the neutral position to either forward or reverse direction.

The transmission must be placed in the neutral position for the starter motor to engage when starting the engine.

If the engine starts when the transmission is not in neutral, the machine should be tagged out of service until the problem is rectified.

Transmission Gear Control Lever

Transmission Directional Control Lever

TRANSMISSION CONTROLS

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PARK BRAKE BUTTON The park brake button has two positions and it is held in the release position by pilot air pressure. By pushing the button inwards, the park brake is applied, and by pulling the button out the park brake will be released. The park brake cannot be released until the system pressure is sufficient to overcome the spring force of the brake control, it also will not release unless the door is closed (there is an interlock valve inside the door lock which needs to be activated to release the park brake).

If the engine shuts down the park brake will automatically apply itself by dumping the pilot air pressure via the brake interlock pilot valve. The brake head pressure gauge must read zero when the brake is applied.

Never use the door interlock to actuate the park brake when exiting the machine. If there is a malfunction on the door interlock system, the park brake could possibly not apply when exiting the machine and the machine could run away resulting in serious damage or injury.

The park brake must be applied for the starter motor to engage whenever an engine start is required.

PARK BRAKE BUTTON

BRAKE HEAD PRESSURE GAUGE

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FOUR-WAY JOYSTICK CONTROL LEVER This lever has five positions, tilt back, tilt forward, lift, lower and hold. Pushing the lever to the right tilts the lift arms back for loading and tramming. Pulling the lever to the left tilts the lift arms down for unloading. Pushing the lever forward lowers the lift arms. Pulling the lever back raises the lift arms. The lever is spring centred to the hold position.

Two functions may be engaged at the same time by pushing the fourway joystick control lever at 45° in the direction of the two required functions.

NO. 1 - TWO-WAY HYDRAULIC CONTROL LEVER There are two hydraulic two-way control levers fitted to the machine. The first lever closest to the operator is used to operate auxiliary hydraulic power take off fitted to the rear of the machine. This lever has three positions, up, down and hold. The lever is spring centred to the hold position.

NO. 2 - TWO-WAY HYDRAULIC CONTROL LEVER The second lever, furthest from the operator, is used to control the winch. This lever has three positions, up, down and hold. When operating the winch, the down position winches the rope in and pulling the lever up winds the winch rope out. The lever is spring centred to the hold position.

No. 1 - Two-Way Hydraulic Control Lever

No. 2 - Two-Way Hydraulic Control Lever

TWO-WAY CONTROL LEVERS

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OPERATOR’S SEAT On the operator’s seat the height, backrest tilt and seat suspension are all adjustable. The controls for these functions are at the base of the seat.

ACCELERATOR PEDAL The accelerator pedal is connected via a mechanical cable to the engine throttle position sensor. When the accelerator pedal is depressed the engine speed increases. The accelerator pedal is spring returned so that when pedal pressure is removed, the engine returns to low idle.

Always keep the operator’s compartment clean. Dirt, etc. can build up under the accelerator pedal restricting its movement.

BRAKE PEDAL The brake pedal when depressed applies the brakes on the front and rear axles. There are four liquid-cooled Posi-Stop brakes located internally in each axle wheel end. Whenever possible use the engine compression to slow the machine on a grade or decline by selecting a lower gear and driving the machine using engine revs.

Do not ride the brakes while tramming the machine.

If the engine should stall, the machine is fitted with fail-safe brake system that will fully apply the brakes. The operator can apply the brakes at any time following an engine stall to immediately bring the machine to a controlled stop.

Always keep the operator’s compartment clean. Dirt, etc. can build up under the brake pedal restricting its movement.

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STEERING WHEEL The steering wheel controls the flow of hydraulic oil to the steering cylinder via an orbital steering valve. As the cylinder strokes, the machine articulates to the left or to the right.

Turning the wheel anti-clockwise articulates the machine towards the operator. This effectively turns the machine to the left in the forward direction (lift arms end).

Turning the wheel clockwise articulates the machine away from the operator. This effectively turns the machine to the right in the forward direction (lift arms end).

The machine will turn in the opposite directions when travelling in forward and reverse. Operator training and familiarity with Roof Support Carrier operation is important to ensure that collisions are avoided.

If the engine should stall, the machine is fitted with a system that will begin to dump the steering pressure. This allows the operator time to steer the machine via a 6 litre back up accumulator following an engine stall to bring the machine to a safe controlled stop.

If the door is opened or the park brake is applied, the machine is fitted with fail-safe steering system that will immediately begin to dump the steering system pressure. This is to protect the operator or personnel from being crushed in the articulation area. Steering cannot be used until the door is shut and latched and the park brake button pulled out to the released position.

STEERING WHEEL

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BRAKE HEAD PRESSURE GAUGE This gauge shows the service and park brake system’s brake head pressure. Operators should periodically check this gauge. The gauge will read zero pressure when the brakes are fully applied via the service and/or park brake controls.

If the operator’s foot is off the brake pedal and the park brake is released, the indicated pressure shall be a minimum of 12000 kPa (1750 psi). If the pressure is below this it is likely that the brakes are dragging. The machine shall not be operated with dragging brakes as fire or brake failure may result. Immediately report the problem to service personnel.

Observe that the brake head pressure is on zero after applying the park brake.

BRAKE ACCUMULATOR PRESSURE GAUGE This gauge indicates the service and park brake system’s accumulated pressure. Normal operating system pressure is 17200 kPa (2500 psi).

Do not operate the machine if the brake accumulator pressure gauge is less than 17200 kPa (2500 psi). Immediately report the problem to service personnel.

STEERING ACCUMULATOR PRESSURE GAUGE This gauge indicates the steering system’s accumulated pressure. Normal operating system pressure is 17200 kPa (2500 psi).

If the pressure constantly drops below or will not hold 17200 kPa (2500 psi), steering may become difficult. The machine should not be operated and the problem shall be reported immediately to service personnel.

Steering Accumulator Pressure

Brake Accumulator Pressure

Brake Head Pressure

RIGHT HAND SIDE OPERATOR’S PANEL

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ENGINE START BUTTON Depressing the engine start button engages the starter motor to start the engine. The engine start button will not activate the starter motor unless: 1.

2.

3.

4.

5.

6.

The transmission is in neutral.

The park brake is applied.

The diesel control system shows no fault.

The on/off toggle switch is on.

The audible warning has been heard.

Sufficient air is in the receiver and air valve is turned on.

Do not apply throttle when starting the engine. Immediately remove finger from the engine start button when the engine fires.

AIR PRESSURE GAUGE This gauge indicates the air pressure in the air receiver. Normal air pressure is set at 760 kPa-860 kPa (110 psi -125 psi).

The main air isolation valve is mounted in the engine compartment.

Turn this valve on before entering the machine. The gauge will read zero when the valve is shut.

ON/OFF TOGGLE SWITCH The on/off toggle switch controls the supply of pilot air pressure to the air pressure switch on the diesel control system, which allows air to pilot the start motor.

1.

2.

To start the engine, place the on/off toggle switch in the on position.

To shutdown the engine place the on/off toggle switch in the off position.

Air Pressure Gauge Engine Start Button

On/Off Toggle Switch

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TRANSMISSION OIL TEMPERATURE GAUGE This gauge indicates the oil temperature in the transmission and torque converter. Normal oil temperature is between 82 °C-93 °C. If the temperature should rise above 121 °C, carry out the following procedure: 1.

2.

Bring the machine to a halt, lower the lift arms to the ground and apply the park brake.

Put the transmission in neutral and rev the engine to about ½ speed.

Observe the temperature gauge for about two minutes. If the temperature does not begin to fall within two minutes, shutdown the machine and do not attempt to operate it until corrective action has been taken. Immediately report the problem to service personnel.

Do not operate the machine if the oil temperature is above 121 °C.

Transmission temperature can be affected by incorrect gear selection for the load being carried and or the road conditions.

ENGINE COOLANT TEMPERATURE GAUGE This shows the coolant temperature circulating through the engine, exhaust and radiator systems. Normal operating temperature is between 89 °C-97 °C. The engine should not be operated under heavy load until it has time to warm up approximately five minutes. The engine must also be shut off and cooled when the coolant level is to be topped up.

Shut off the engine immediately if the coolant temperature gauge goes above 105 °C. The diesel control system will give an alarm at 100 °C and should shutdown the engine at 105 °C.

Transmission Oil Temperature Gauge

Engine Coolant Temperature Gauge

LEFT HAND SIDE OPERATOR’S PANEL

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LOAD INDICATOR GAUGE This gauge indicates the load pressure at the cap end of the lift cylinders. Refer to the load indicator table below for the procedure to determine the load/ pressure relationship.

LOAD INDICATOR

Do not operate the machine with a load greater than its rated capacity of 40T (156 Bar load gauge pressure).

Overloading the machine beyond its rated load capacity could cause catastrophic machine failure, injury and even death.

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HORN BUTTON Pushing this button sounds the air horn.

It is good operating procedure to sound the horn 2-3 seconds before an engine start or whenever approaching blind intersection.

Horn Button

RIGHT HAND SIDE OPERATOR’S PANEL

ENGINE SERVICE HOUR METER The electric hour meter is mounted inside an enclosure window on the off driver’s side in the rear frame of the machine.

Use the hour meter to determine servicing intervals.

ENGINE HOUR METER

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AIR CLEANER SERVICE INDICATOR The air cleaner service indicator is located at the back of the air cleaner and indicates the condition of the air cleaner element. When the service indicator is in the red zone, the air cleaner elements should be removed and serviced.

AIR CLEANER AND INDICATOR

SHUTDOWN SYSTEM TEST VALVE The test valve is used to check the integrity of the Fail-Safe Shutdown System. This test should be carried out on a daily basis as part of the10 Hour Daily Off Line Mechanical Inspection. (Refer to Section 8 - Post Start Checks).

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EXHAUST BACK PRESSURE GAUGE The exhaust back pressure gauge located in the operator’s compartment indicates the condition of the filter element. When the back pressure is above 12 kPa on the green area on the back pressure gauge, the elements should be removed and replaced.

Dirty filters should be disposed of correctly. Appropriate personal protective equipment should be worn. Operators should minimise skin contact with dirty filters. The dirty element should be placed in the plastic bag that is supplied with the new filter and completely sealed.

The contaminated element must be removed from the underground environment and disposed of safely.

EXHAUST OUTLET GAS TEMPERATURE GAUGE This shows the exhaust gas temperature upon exiting the wet exhaust conditioner. The machine will shutdown if this temperature exceeds 77 °C. ENGINE OIL PRESSURE GAUGE This gauge indicates the engine lubricating oil pressure. Normal pressure is between 210 kPa-550 kPa (30 psi-80 psi) at rated RPM. Shut off the engine if the oil pressure drops and stays below 70 kPa (10 psi). The diesel control system should shutdown the engine at 70 kPa (10psi).

Do not run the engine with low oil pressure, as engine damage will result. Immediately report the problem to service personnel.

Engine Oil Pressure Gauge

Exhaust Outlet Gas Temperature Gauge

Exhaust Filter Back Pressure Gauge

RIGHT HAND SIDE OPERATOR’S PANEL

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ENGINE FUEL PRIMER PUMP If the engine fuel system has been run dry or serviced, the fuel system should be primed via manual activation of the hand fuel primer pump. The pump is located adjacent to the fuel water separator in the engine compartment. Normally no priming is required to start the engine.

Fuel shut off valve must be set in the position shown for the engine to run.

ATTACHMENT QUICK CONNECTS BUTTON This button releases all of the pressure in the PTO lines to allow the couplings to be easily released. To release the pressure, release both of the two-way control levers to the hold position and press in the pressure release button for two seconds.

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EMERGENCY INTAKE SHUT OFF VALVE This valve is used in the event that the machine fails to shutdown under normal circumstances as stated in Section 8. Closing this valve will stop the flow of air to the engine. This provides a second means of shutting down the engine should the on/off toggle switch fail to stop the engine in a hazardous zone.

EMERGENCY INTAKE SHUT OFF VALVE STOP BUTTON EMERGENCY INTAKE SHUT OFF VALVE RESET LEVER

The valve is activated from the operator’s compartment by a stop button which is pushed, once activated and the engine shuts down the valve will need to be reset before restarting.

Ensure that the stop button has been pulled out (approx 25mm) and there is a reset lever down on the main body of the valve that will rotate and latch into the operating position. If the valve has not been reset the engine will not start. When the valve has been reset the engine can be started.

If the emergency intake shutoff valve has been activated, the restarting of the engine should be done in compliance with the relevant regulations and Manager’s Rules.

This engine system is fitted with a wet exhaust conditioner. Operation of the Emergency Intake Shut Off Valve while the engine is running may result in exhaust conditioner water being drawn back into the engine. This may result in catastrophic damage to the engine.

Only restart the engine after verifying that there has been no ingress of water from exhaust conditioner into the engine. This is to be verified by Service Personnel prior to attempting to engine start

If the emergency intake valve has been accidentally activated then the engine will not start until the stop button has been pulled out and the valve lever reset to the run position as shown above.

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EMERGENCY FUEL SHUT OFF VALVE This valve is located after the fuel filter/water separator. Closing this valve will stop the flow of fuel to the engine. This provides a another means of shutting down the engine should the on/off toggle switch fail.

The Emergency Intake Shut Off Valve Button in the Operator’s compartment should be activated first in any emergency situation.

Restarting of the engine should be done in compliance with the Manager’s Rules.

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REVERSING CAMERA (OPTIONAL) The machine is fitted with a reversing camera. The camera is located at the engine end of the machine and offers improved visibility when reverse gear is selected. The screen is located in the Operator’s compartment, to the right of the four-way joystick control lever.

The camera requires reverse to be selected on the transmission controls, and the park brake to be released before it becomes active.

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Section

5

Machine Isolation Before commencing work on the machine, it is imperative to ensure the system to be worked on is correctly isolated. This may also require the isolation of other systems that affect the safe completion of the job.

Any site/mine specific isolation procedures override those listed on the following pages. The procedures presented here are the minimum required to perform any work on the machine. Before commencing check with the relevant people regarding any site/mine specific isolation procedures.

ENGINE ISOLATION To isolate the engine perform the following procedure: 1.

2.

3.

4.

5.

6.

7.

8.

9.

Ensure the area is clear of any obstructions and area is fit for carrying out safe operation and maintenance.

Ensure the machine is in a straight line (not articulated).

Lower the lift arms to the ground.

Select neutral on transmission directional control lever.

Apply the park brake.

Shutdown the engine.

Fit a personal danger tag to the on/off toggle switch.

Connect the articulation lock and chock the wheels.

Close the main air isolation valve and fit a personal danger tag (see Pneumatic Isolation). This valve provides for personal isolation locks to be fitted.

Be careful of hot surfaces, when working on or around the machine, allow time for them to cool down.

Air Pressure Gauge On/Off Toggle Switch

RIGHT HAND SIDE OPERATOR’S DISPLAY PANEL

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PNEUMATIC ISOLATION To isolate the pneumatic system perform the following procedure: 1.

2.

3.

4.

5.

Ensure the area is clear of any obstructions and area if fit for carrying out safe operation and maintenance.

Lower the lift arms to the ground, shutdown the engine, fit a personal danger tag to the on/off toggle switch, connect the articulation lock and chock the wheels.

Locate the main air isolation valve at the driver’s side rear of the engine compartment and rotate to the off position and install a personal danger tag. This valve provides for personal isolation locks to be fitted.

Push the horn valve until the air pressure gauge indicates zero pressure.

Check the system for dead by observing the air pressure gauge reads zero when the on/off toggle switch is in the on position.

If work is required on the air receiver it will be necessary to remove air pressure from the air receiver by actuating the main air drain valve located next to the fill point. Stored air pressure will be safely released to the atmosphere. Ensure that the three-way ball valve is not connected to an external pressure source.

Compressed air can be hazardous. Wear suitable equipment such as safety glasses and hearing protection.

protective

MAIN AIR ISOLATION VALVE

MAIN AIR DRAIN VALVE AND MAIN AIR CHARGE VALVE

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HYDRAULIC ISOLATION To isolate the hydraulic system perform the following procedure: 1.

2.

3.

4.

5.

Ensure the area is clear of any obstruction and area is fit for carrying out safe operation and maintenance.

Lower the lift arms to the ground, shutdown the engine, fit a danger tag to the on/off toggle switch, connect the articulation lock and chock the wheels.

Depress the attachment quick connects button located in the operator's compartment.

This will remove any residual pressure stored in the PTO lines.

Observe both steering and brake pressure gauges located in the operator's compartment. The hydraulic system features a steering and brake accumulator. The brake/steer control manifold bleeds accumulator pressure over time, once the machine has been shutdown. To aid in the removal of residual pressure, prior to exiting the operator’s compartment and with the door closed turn the steering wheel from side to side and observe the steering accumulator pressure gauge return to zero.

Remove hydraulic tank pre-charge pressure (50 kPa) by cracking hydraulic tank filler cap.

Serious injuries can occur from hydraulic oil under pressure. Ensure all loads are mechanically supported before removal of any hydraulic lines. Always assume there is hydraulic pressure in hydraulic lines or components unless it has been isolated by yourself. Hydraulic fluid may be hot. Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves.

Crack hose end fitting (if pressure is present in line tighten fitting and remove pressure as above) but do not remove till any residual pressure is removed.

Ensure the machine is clear of pedestrians and equipment when undertaking these procedures.

Steering Accumulator Pressure Gauge

Brake Accumulator Pressure Gauge

RIGHT HAND SIDE OPERATOR’S DISPLAY PANEL

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ENGINE COOLANT ISOLATION To isolate the engine cooling system perform the following procedure: 1.

2.

3.

4.

5.

6.

Ensure the area is clear of any obstructions and area if fit for carrying out safe operation and maintenance Lower the lift arms to the ground, shutdown the engine, fit a personal danger tag to the on/off toggle switch, connect the articulation lock and chock the wheels.

Isolate the pneumatic circuit by turning of the main air isolator and fitting personal danger lock.

Locate the header tank relief cap located at the rear of the machine.

Remove coolant circuit pressure (105 kPa) by slowly lifting up the red relief lever on the relief cap and hold up until pressure is released.

Slowly remove relief cap with relief lever held in the up position.

The coolant fluid will be under pressure and hot (up to 100 °C). Always relieve pressure by lifting the relief lever on relief cap before removal.

Wear personal protective equipment such as safety glasses, long sleeve shirt and gloves to avoid scalds and burns from hot coolant.

Engine Coolant Relief Cap

Coolant Header Tank and Relief Valve

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ELECTRICAL ISOLATION 1.

2.

Ensure the area is clear of any obstructions and area is fit for carrying out safe operation and maintenance.

Lower the lift arms to the ground, shutdown the engine, connect the articulation lock and chock the wheels.

The electrical system installed on this machine is approved/certified as explosion protected for use in Australian underground coal mines and may cause an atmospheric explosion if not maintained and used in its approved state. Such equipment is to be inspected and maintained in accordance with the relevant regulatory authorities rules and regulations and the conditions for which the apparatus has been approved.

If any fault or damage is detected to the electrical system it should be reported to the service personnel.

Do not bypass shutdown conditions or devices.

Isolating the main air isolation valve or completely draining the pneumatic system of air will render the machine unable to be started until it is re-energised.

The C7 engine has a battery in the electrical enclosure for start up.

This battery is isolated by the DCS System, once the DCS display is off the battery will be isolated. This takes 60-90 seconds after engine shutdown.

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ARTICULATION ISOLATION To fit the articulation lock: 1.

2.

3.

4.

5.

Ensure the area is clear of any obstructions and area is fit for carrying out safe operation and maintenance.

Bring the machine to a stop and manually apply the park brake by pressing the red park brake button located in the operator’s compartment and isolate the engine.

Locate the articulation lock at the articulation area on the off driver’s side of the machine and remove the locking clamp on the bottom location.

Line the articulation lock up with the pin location on the front and rear half of the machine.

Install the lynch pin through the retaining hole in the locating pins.

To remove the articulation lock: 1.

2.

With the park brake applied, remove the lynch pins from the locating pins.

Install articulation lock on the storage location pins and secure it with the lynch pins.

The articulation area of this machine can cause fatal crush injuries if extreme caution is not observed. Always ensure that the park brake is applied and the operator’s compartment is vacant when accessing the articulation area to fit or remove the articulation lock. NEVER work in the vicinity of the articulation joint unless the articulation lock has been correctly installed.

ARTICULATION LOCK IN LOCKED POSITION

ARTICULATION LOCK IN STORED POSITION

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LIFT ARM ISOLATION To install the lift arm lock: 1.

2.

3.

4.

5.

6.

7.

8.

Ensure the area is clear of any obstructions and area if fit for carrying out safe operation and maintenance.

Remove any load from the fork tines.

Park the machine on flat level ground. Ensure the ground is stable.

Fit the articulation lock.

Raise the lift arms until the locking pin holes on the rear of the lift arm line up with the locking pin hole mounted on the front frame.

Remove the lock pin from storage location and install through the aligned holes on the lift arms and front frame.

Note that the pin is to be fully inserted into the holes.

It is now safe to work under the lift arms.

To remove the lift arm lock: 1.

2.

Remove the lock pin from the locating holes and secure in their respective storage locations.

Lower the lift arm to the ground.

The lift arms on this machine can cause fatal crush injuries if extreme caution is not observed. Never access or perform work under the lift arms unless the engine has been shutdown, the articulation lock fitted, the park brake applied, and the lift arms have been supported in the raised position.

STORAGE POSITION ON FRONT GUARD

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EXHAUST CONDITIONER ISOLATION To isolate the exhaust conditioner perform the following procedure: 1.

2.

3.

Ensure the area is clear of any obstruction and area is fit for carrying out safe operation and maintenance.

Isolate the machine.

Isolation of the wet bath exhaust conditioner is carried out via a valve located between the water inlet hose and the conditioner shutdown float chamber. The main isolation valve has two positions closed and open, this regulates the water flow from the make up tanks.

If the exhaust conditioner remains isolated after testing or maintenance to the system and the machine is returned to service it will be purged of water causing the machine to shutdown via the safety system.

Main Isolation Valve

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EXHAUST CONDITIONER MAKE UP TANK PRESSURE ISOLATION To isolate the pressurised make up tank, perform the following procedure: 1.

2.

3.

4.

5.

Ensure the area is clear of any obstruction and area is fit for carrying out safe operation and maintenance.

Lower the lift arm to the ground, shutdown the engine and isolate the machine in accordance with the site isolation procedure.

Locate the make up tank filler cap located at the rear of the machine on the off driver’s side.

Remove the make up tank air pressure by slowly rotating the filler cap and hold until the air pressure is released.

Slowly remove filler cap.

The make up tank is pressurised via the pneumatic system to provide a positive head feed to the exhaust conditioner. Always relieve pressure first by slowly rotating the filler cap before removal. Wear personal protective equipment such as safety glasses.

Exhaust Conditioner Make Up tank Filler Cap

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PAGE LEFT BLANK INTENTIONALLY

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Section

6

Pre-Start Procedure Walk around the machine: 1.

Ensure the area is clear of any obstructions and the area is fit for carrying out safe operation and maintenance.

Check condition of all tyres. Inspect for sidewall cuts, tread cuts and separation.

Look for damaged or missing wheel nuts and studs.

Check for loose wheel nuts.

Guards and covers are in place and secure.

Missing or loose bolts.

Oil leaks.

Hose damage.

2.

3.

4.

5.

6.

7.

8.

Never start or operate the machine if the diesel control system has been bypassed, report to service personnel.

Always ensure the machine is correctly isolated before undertaking any tasks.

Check the hydraulic tank oil level: 1.

2.

Be sure the machine is on a level surface when checking oil level.

Ensure the lift arms are in the lower position, the engine is turned off and the machine is isolated as per Section 5 Pneumatic Isolation.

Check the level at normal operating temperature.

When the oil level has dropped below the mark shown below, add hydraulic oil to restore the correct operating level.

The tank fill cap is located on the off driver’s side of the machine on the top of the hydraulic tank.

3.

4.

5.

Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 21).

Breather Cap

Fill Cap

HYDRAULIC LEVEL SIGHT GAUGE Rev. 0

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Check the engine oil level: 1.

2.

3.

4.

Stop the engine and allow the oil time to settle before checking via the dipstick.

If required the engine should be filled to the full mark on the engine dipstick. The oil fill plug is a screw type fitted to the rocker cover of the engine.

Ensure the correct engine oil is used. Oil specifications are listed in the Section 21 Fluid Specifications Table.

Do not over fill.

Always ensure the machine is correctly isolated before undertaking any tasks.

Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 21).

The oil level should only be checked with the engine stopped, the engine should be allowed to sit for five minutes before checking.

Engine Oil Filler Cap

Engine Oil Dipstick

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Check the fuel level: 1.

2.

3.

Gauge fitted to the fuel tank.

Check the filler cap is secure, not damaged and seal is in place.

Ensure the filler cap seal is in place.

To fill the fuel tank: 1.

2.

3.

4.

Ensure the area is clear of any obstruction and the area is fit for carrying out safe operation and maintenance.

Locate the fuel tank filler cap on the driver’s side of the machine.

Release the filler cap lock by pulling the Lock away from the centre of the cap.

Lift the filler cap and insert the fuel filler/nozzle and fill the tank.

Do not allow the fuel tank to overflow as diesel fuel is a fire hazard.

Clean any excess fuel away immediately and dispose of in an appropriate manner.

5.

6.

Once the tank is full, close the fuel tank filler cap and allow the filler cap lock to spring into position over the cap.

The fuel level gauge will indicate the tank is full.

Always ensure the machine is correctly isolated before undertaking any tasks.

Do not operate the machine with the fuel level below empty level on the fuel tank. It is recommended procedure to fill the fuel tanks at the end of each shift

Always use quality fuel to the specification shown in Section 21.

FUEL LEVEL GAUGE AND FILLER CAP

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Check the condition and tension of the water pump drive belt: 1.

2.

Located at the rear of the machine, on the driver’s side of the engine.

Damaged or loose belts should be reported to service personnel.

Running the machine with loose or damaged belts will cause the machine to overheat.

WATER PUMP DRIVE BELT

Check the condition of the fuel water separator: 1.

2.

3.

Located in the engine compartment on the driver’s side of machine.

Replace filter and drain if any sign of water or cloudy fuel.

Check fuel lines for leaks or damage.

Check the articulation lock (see Section 5): 1.

2.

For proper storage and loose fasteners.

For damage.

Check the lift arm lock (see Section 5): 1.

2.

For proper storage and loose fasteners.

For damage.

Check the expansion tank coolant level: 1.

2.

3.

4.

Ensure coolant is to correct level on sight gauge.

Check for coolant leaks.

Ensure the correct coolant mix is being added (if required).

Report to service personnel if coolant is low.

Check the radiator: 1.

2.

44

For coolant leaks.

For build up of dirt (Clean if radiator fins are blocked or dirty).

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Check the headlights: 1.

2.

Are securely mounted and operational.

For cables and glands for damage.

Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 21).

FUEL WATER TRAP

Filler Cap

COOLANT EXPANSION TANK

Coolant Expansion Tank Sight Gauge

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Check the air cleaner (see Section 4): 1.

2.

3.

4.

Filter condition indicator.

Replace filter element if indicator is in the red area.

Check intake pipes and hoses for loose or damaged connections.

Check joints are secured.

Do not operate the machine with loose intake pipe connection, this will allow particles of dust into engine and cause serious damage.

Check air receiver: 1.

2.

For damage.

Drain condensate from main air drain valve.

It is important to drain the condensate from the air receiver on a daily basis to stop it contaminating the air circuit and the starter motor.

Personal Protective Equipment must be worn when operating main air drain valve.

MAIN AIR DRAIN VALVE

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Check the fire extinguisher: 1.

2.

3.

4.

5.

Located on front driver’s side mudguard.

Check inspection date.

Check contents indicator is reading in the green area.

If fire suppression system fitted check actuation points.

Check safety pins are in place.

Fire Extinguisher

Fire Suppression

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The wet bath exhaust conditioning system on the SH640 D carries out the following major functions:    

To cool and dilute exhaust gases.

To act as an approved flame trap.

To prevent hot gases from entering the mine atmosphere.

To reduce air borne exhaust particulates and hydrocarbons that enter the mine atmosphere.

Flameproof diesel engine maintenance must be carried out by a qualified and authorised person.

Inlet

Ins pe

ctio n

Ho les

Outlet

Shutdown Float Chamber

WET BATH EXHAUST CONDITIONER

Check exhaust system: 1.

2.

3.

4.

5.

6.

For damage.

Check joints for signs of leakage.

Check cooling hoses for security and condition.

Check exhaust filter back pressure and change filters as required i.e. >10kPa. Check the valves are in the correct position.

Check the make up tanks are full of water.

Do not operate the machine with loose or damaged exhaust components, report to service personnel immediately. Using the machine in an unsafe condition may cause serious damage or loss of life.

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Flameproof diesel engine maintenance must be carried out by a qualified and authorised person.

WET BATH EXHAUST CONDITIONER

Make Up Tank Breather, Fill Point and Level Gauge

MAKE UP TANK

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Inlet Valve

Wear suitable eye protection, gloves and dust mask when performing maintenance tasks as particulate may be harmful to the respiratory system. Immediately wash any particulate matter from skin with warm, soapy water.

Emergency Intake Shut Off Valve: The emergency intake shutoff valve (strangler valve) should be inspected before attempting to start the engine. The stop button should be pulled out (approx 25mm) and the reset lever latch into the operating position (see Section 4).

The engine will not start if the emergency shut off valve is activated, continued attempts to start the engine may result in damaged components.

If the emergency intake shut off valve has been activated, the restarting of the engine should be done in compliance with the relevant regulations and Manager’s Rules.

EMERGENCY INTAKE SHUT OFF VALVE STOP BUTTON EMERGENCY INTAKE SHUT OFF VALVE RESET LEVER

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Section

7

Engine Starting Procedure Always sound the horn and make sure the area around the machine, especially between the front and rear frames, is clear before starting the engine. Never attempt to start an engine without first knowing how to shut it off.

Do not start the engine if machine is tagged out of service or Personal Danger Tag/Lock is affixed.

If the machine is to be put into operation, make certain that the articulation lock is disconnected.

1.

2.

3.

4.

5.

Turn the main air isolation valve, located in the engine compartment to the on position.

Enter the operator’s compartment and close and latch the door.

Place the transmission directional control lever in the neutral position.

Make sure the park brake is applied. Check the air pressure gauge. If the start pressure is below 700 kPa (100 psi) the engine may not start. If the air pressure is below 700 kPa (100 psi), recharge the air receiver up to maximum 827 kPa (120 psi).

Turn the on/off toggle switch to the on position.

The diesel control system display will not activate if the air pressure is below 275 kPa (39 psi).

6.

7.

8.

9.

10.

11.

12.

Wait for the display to indicate waiting for start (showing three green LEDS).

Do not press start button until the siren sounds.

Do not apply throttle when starting the engine.

Press the engine start button and release it when the engine has fired.

Check the display indicates Engine Running.

If the alternator becomes faulty do not continue to use the machine as this will discharge the battery.

Carry out post start checks and operate machine normally.

See Section 20 - Operating Diesel Control System As soon as the engine starts, check all gauges and indicators to ensure that all systems are functioning correctly. Always let the engine warm up slowly. Never load up a cold engine.

Do not engage the starter motor when the flywheel is moving.

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Excessive use of starting fluid can cause serious backfire and violent explosions within the engine. Serious engine damage may occur.

Avoid the use of starting aids and DO NOT use starting fluid (Aerostart) underground

The steering and brake pressure gauges register in the normal operating range only when the park brake is released.

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Section

8

Post Start Checks The following tests are required to be performed with the engine running: Check all gauges are on correct operational pressure: 1.

Gauges are colour coded (should read in green area).

Check steering function.

Check park brake operation: 1.

2.

Ensure brake head pressure gauge reads 10342 kPa-11032 kPa when brake is released.

Ensure brake head pressure gauge and primary park brake valve gauge read zero when park brake is applied.

The machine must not be used under any circumstance if gauges do not indicate zero pressure.

The primary park brake valve gauge maybe located undercover within the machine adjacent to the operator’s compartment.

Check that all of the lights are working: 1.

2.

There are two forward and rear facing headlights.

Control switch is operational, (manual or auto directional).

Check the transmission oil level: 1.

2.

3.

4.

5.

6.

7.

8.

Always check when the transmission is warm.

Once the correct transmission oil temperature has been reached park the machine on flat, level ground and leave it running.

Place the machine in neutral and apply the park brake.

Access the dipstick from the operator’s compartment through the cover over the top of the transmission.

The engine should be idling at 800 RPM. Remove the dipstick by pulling upwards and wipe with a clean, lint free cloth.

Reinsert the dipstick into the spout, push it all the way home.

Withdraw the dipstick and check the oil level. The level is to be maintained at the full mark.

Always use the specified lubricant for the application and the region’s seasonal temperatures. (See Section 21).

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Transmission Dipstick

Check the particulate filter back pressure indicator: 1.

2.

3.

Locate the indicator in the operator's compartment.

Run the engine at high idle and observe the indicator position.

If the indicator is above 10 kPa the filter requires replacement.

Ensure that the filter element is cool enough to handle otherwise the garbage bag will melt causing skin burns.

To replace the particulate filters (if fitted): 1.

2.

3.

4.

5.

6.

7.

8.

Ensure that the engine has had sufficient time to cool and is isolated and tagged as described in Section 5 - Engine Isolation.

Put on protective gloves and dust mask (protective gloves and mask should be worn throughout the entire change out operation to protect the operator from corrosive agents (combustion by-products and particulates) as well as elevated surface temperatures and sharp edges.

Remove the filter housing lid.

Undo filter retaining nuts if fitted.

Remove the disposable bag from the new replacement filter packaging and place it over exposed filter.

Partially pull the filter out of the housing to “unseat” the filter at the base of the housing .

Continue to remove the filter ensuring the bag covers the filter during the remainder of the process. With filter in the bag , tie the open end to secure it.

Discard the used filter elements in the appropriate manner.

Wear suitable eye protection, gloves and dust mask when performing filter replacement as particulate caught by the filter may be harmful to the respiratory system. Immediately wash any particulate matter from skin with warm, soapy water.

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Check the diesel control system operation: 1.

2.

3.

4.

Run the engine at high idle.

Press the shutdown test button and hold for ten seconds.

Machine should shutdown and the low oil pressure display should be on.

The engine should not restart until the on/off toggle switch is reset.

If the engine does not shutdown do not use the machine. Report it to the service personnel for repairs.

Perform low exhaust water shutdown test: 1.

Start DES and ensure all shutdown systems are operational, allow engine to warm up and run for several minutes.

2.

Shut make up tank ball valve and open the lower water shutdown test ball valve.

Main Isolation Valve

Low Water Shut Down Test Point

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3.

Observe machine taking note of water flow out of the low water shutdown test point when DES shuts down. Ensure the display on the DCS shutdown system indicates both proximity switches/magnetic reed switches are open.

The machine must not be used under any circumstance if it fails the low water shutdown test.

If the machine does not shutdown on a test it must be reported to service personnel for immediate rectification.

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9

Stopping the Engine 1.

2.

3.

4.

5.

6.

Ensure the area is clear of any obstructions and area is fit for carrying out safe operation and maintenance.

Lower the lift arms completely to the ground and remove any load from the engine.

Put the transmission directional control lever into the neutral position.

Remove any hydraulic load from the engine.

Apply the park brake. Observe that the brake head pressure gauge and primary park brake valve gauge are on zero.

Allow the engine to run at idle speed for five minutes. This will allow internal temperatures to reduce gradually.

As the engine is turbocharged, shutting down the engine when the engine’s operating temperature is high may cause damage to the turbocharger and the lubrication system.

The primary park brake valve gauge maybe located undercover within the machine adjacent to the operator’s compartment.

7.

8.

9.

Turn the on/off toggle switch to the off position and the engine will shutdown.

Allow the steering accumulator pressure to bleed down the steering pressure accumulator gauge reads zero.

Open the door, check floor, hold on and step down using three points of contact at all times.

Any problems with the normal engine shut off mechanism must be corrected before the engine is restarted.

If the engine fails to shutdown under the normal procedure the Emergency Intake Shut Off Valve should be used (see Section 4).

9.

Close the main air isolation valve on the main air manifold after the engine has stopped.

Ensure the lift arms are flat on the ground before leaving the operator’s compartment.

Ensure the machine is parked in an area that will not block traffic or in a blind intersection that may result in a collision.

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10

Tramming the Machine 1.

2.

3.

4.

5.

The machine is designed to travel in both forward or reverse direction with equal ease and performance.

The transmission is controlled by a directional control lever and a gear control lever.

The machine has the same gear ratios in forward and reverse. This is to provide equal speeds and performance in each direction.

The engine should be at idle and the machine stationary when either forward or reverse gears are selected.

Always start in the low speed and shift into the next higher speed as the machine accelerates and as conditions permit.

Do not coast the machine in neutral. Excessive speed may result in an uncontrollable runaway.

6.

Use the transmission to slow the machine whenever possible, as this avoids excessive brake wear.

Do not downshift the transmission unless the machine is travelling at a speed suitable for the lower range.

Always ensure that the transmission control levers are fully shifted.

7.

8.

Shifting from one range to another can be made at any time, conditions permitting.

Momentarily decrease engine revs when selecting a higher gear.

If the transmission should overheat: a. b. c.

Stop machine in a suitable place and apply park brake.

Select neutral and run the engine at ½ speed until the oil temperature has returned to a safe operating level.

If this does not work follow the shutdown procedure and advise the service personnel.

Hearing and eye protection shall be worn by the operator of this machine at all times whilst the engine is running.

The machine speed can be regulated by using the brakes, the accelerator pedal or by changing up and down gear ratios.

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Always be aware of the impact of the payload on the visibility available to the operator. The recommended maximum speed when loaded is 10 km/h, however, the impact of the payload on the operator’s field of vision must be considered when operating the machine with payload.

Drive to the conditions.

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11

Stopping and Braking 1.

2.

3.

4.

5.

6.

7.

Use the transmission to help slow down the machine, by shifting down gears and utilising engine braking.

Apply the brakes and bring the machine to a halt at the side of the roadway, turn the machine toward the rib and lower the lift arms to the ground.

Apply the park brake.

Observe brake head pressure gauge and primary park brake valve gauge within the operator’s compartment reads zero pressure.

The engine should not be shutdown from full load. To stabilise temperatures allow it to idle for a few minutes before stopping.

Shut off the engine by turning the on/off toggle switch to the off position.

After stepping off the machine, switch off the main air isolation valve.

The brakes fitted to the machine are extremely effective to cope with towing large loads. Operators should be prepared for rapid deceleration when the brakes are applied.

In an emergency immediately apply the brake. If this fails to activate the brakes, immediately apply the park brake.

The machine must not be used under any circumstance if gauges do not indicate zero pressure.

The primary park brake valve gauge maybe located undercover within the machine adjacent to the operator’s compartment.

The seat belt should be worn whilst operating the machine at all times.

If the brakes fail on the machine you should:     

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Use the gears to help slow the machine.

Lower the lift arms.

Gradually turn machine to the rib.

Apply the park brake.

Shutdown the engine.

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12

Driving on a Ramp 1.

2.

3.

4.

Stop and shift into first gear, and check the brakes before travelling up or down a ramp.

Always use a low gear when travelling down a ramp.

Avoid changing gears while travelling on a steep ramp.

If you have a mechanical or brake failure: a. b. c.

Immediately apply the brakes.

If they don’t function, apply park brake.

If the machine does not stop, turn the machine into the rib.

The machine should not be operated on more than the recommended grades (Section 1).

Operators must be competent in Emergency Stop Procedure (Section 11).

Always be aware of the impact of the payload on the visibility available to the operator. The recommended maximum speed when loaded is 10 km/h, however, the impact of the payload on the operator’s field of vision must be considered when operating the machine with payload.

Drive to the conditions.

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13

Parking on a Ramp

Do not park on a ramp unless absolutely necessary.

1.

2.

3.

4.

5.

6.

7.

Use the engine braking to help slow down the machine by letting up on the accelerator pedal.

Apply the brakes and bring the machine to a halt at the side of the road.

Turn the machine toward the rib.

If possible remove the load from the forks.

Apply the park brake. Observe that the brake head pressure gauge and primary park brake valve gauge is on zero.

Always chock the wheels.

Inform mine management of the position of machine.

When on steep grades (more than 1:4). Do not rely on the park brake to hold the machine.

Always park with forks into the rib and chock the wheels when on grades of more than 1:4.

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14

Loading The SH640 D has been primarily designed for carrying and placing heavy loads. To pick up a load drive the fork tynes underneath the load then pull the load onto the fork tynes using the winch. The load must be secured to the back plate by using the RUD links fitted and suitably rated chains. When preparing to carry a heavy load ensure it is within the capacity of the machine.

USING THE WINCH Before using the winch the following should be inspected: 1.

2.

3.

4.

The rope should be inspected for damage such as broken strands, yielding or kinking as it is wound out.

Inspect the eye and joint between the rope and eye for damage.

Inspect any other attachments on the winch rope.

Inspect the mounting bolts on the winch assembly.

If 20% of the rope strands for the total cross section of the rope are damaged the rope would be considered unsafe for use.

Always use gloves when handling the winch rope.

When winching a heavy load onto the fork tines the following procedure should be used: 1.

2.

3.

4.

5.

6.

7.

Connect the winch rope onto the load and ensure all connections are secure.

Engage machine into low forward gear.

Release park brake.

Engage winch and pull load with the winch while machine slowly drives forward.

When load is fully winched onto fork tynes, apply park brake.

Secure load by chaining load to RUD links fitted to the backing plate with suitably rated chains.

When load is secure and area clear engage machine in low gear and carry load to the area where it is to be unloaded.

Never stand between the winched load and the operator’s compartment when winching a load onto the machine. When using the winch a minimum of three wraps of rope shall be left on the spool.

The winch shall only be used with the winch rope in a straight line between the load and the winch drum. It should never be allowed to be dragged against the rib at an intersection or over a stationary object as this will damage the rope.

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Do not exceed the machine’s carry capacity.

Always be aware of the impact of the payload on the visibility available to the operator. The recommended maximum speed when loaded is 10 km/h, however, the impact of the payload on the operator’s field of vision must be considered when operating the machine with payload.

Drive to the conditions.

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15

Cookie Plate Use A cookie plate is available to be used with the fork tynes on the SH640 D. The following outlines the use of the cookie plate.

ATTACHING AND REMOVING THE COOKIE PLATE To attach the cookie plate: 1.

2.

3.

Lift out the retaining pins on either side of the cookie plate.

Align the fork tynes with the slots in the cookie plate and drive the machine forward until the holes for the retaining pins are aligned between the back plate and the cookie plate.

Insert the pins through the cookie plate and into the locating holes in the back plate.

To remove the cookie plate: 1.

2.

The method for removing the cookie plate is the opposite sequence to attaching.

Ensure the cookie plate retaining pins and the keeper chain are clear before driving the machine away from the cookie plate.

SECURING A LOAD TO THE COOKIE PLATE All loads for the cookie plate should be within the capacity of the machine and properly secured. There are a series of holes around the circumference of the cookie plate for securing the load. The load should be secured using suitably rated chains.

Always check that the cookie plate retaining pins are secure and properly installed before using the machine. Failure to confirm that the pins are installed may result in the cookie plate sliding of the fork tynes for use.

All site transport rules should be observed when securing and transporting equipment with this machine.

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16

Towing the Machine when Disabled Apply the park brake, lower the lift arms to the carry position and stop the engine. The towing machine must have sufficient braking capacity to stop and hold both machines.

1.

2.

The machine should be secured by 2 x 16000 kg safety chains in addition to a 30 tonne capacity draw bar.

If the machine must be towed and the distance is less than 1000 metres: a. b. c.

Connect the machine to the towing machine.

Place the transmission in neutral.

Release the spring applied brake by hydraulically overcoming the brake spring pressure by use of a Porta-Power and tow at low speed.

The brakes can be released with a Porta-Power (maximum 12756 kPa [1850 psi]) connected into the pressure port on the secondary brake valve. The operator is to stay in the operator’s compartment to apply the brake or park brake if necessary. If these are applied the PortaPower needs to be pumped to (minimum 11376 kPa [1650 psi]) to release the brakes again.

Brake Valve Pressure Port

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Do not over pressurise the brake system or serious damage will be done to the seals in the brake heads.

The transmission will not hold the machine when the spring applied park brakes are bypassed by the hydraulic hand pump pressure.

Always connect the disabled machine to the towing machine before releasing the SH640 D park brake. Make sure the park brake is reapplied before the towing machine is disconnected.

Maximum towing speed is 3 kph.

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17

Towing with the Machine The transmission will not hold the machine when the spring applied park brakes are bypassed by the Porta-Power pressure.

Maximum towing speed is 3 kph.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Ensure the machine is parked and isolated prior to connecting the trailer or load, park brake on.

Attach the load to the rear tow hitch, ensure tow pin is secure.

The trailer or load should be secured by 2 x 16000 kg safety chains in a straight line pull in addition to a rated draw bar for the task.

Both chains must be used and adjusted to ensure an even pull.

Both chains have a combined loading of 32000 kg in a straight line.

Both chains must be used for maximum tractive effort pull.

Ensure all connections on the towed piece are in good condition and rated for the maximum pull.

Ensure all holding devices and hitches are in good condition and rated for the maximum pull before connecting the machine.

Always ensure that the trailer and load are secure before towing, and prior to releasing the park brake.

Travel at a speed that is suitable to conditions and load.

Ensure trailer or load has wheels chocked prior to removal from the machine.

Always connect the trailer or load before releasing the park brakes.

Make sure the park brake is reapplied before the towing machine is disconnected

For towing braked trailer masses consult the dealer.

Failure to comply to these procedures may result in serious personal injury or damage to the equipment.

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18

Air Venting the Fuel System If the engine misfires or fails to start due to air in the fuel line, the system must be bled as follows.

1.

2.

3.

4.

Ensure the governor control lever is in the shut off position.

Unscrew the knob on the priming pump sufficiently to release it, then pump in and out until positive pressure is observed.

Tighten and secure the priming pump.

Start the engine. If it misfires or smokes with the engine running repeat the above.

Check the fuel tank contents gauge before air venting the system.

Check the fuel water separation bowl before venting the system.

ENGINE FUEL PRIMER PUMP

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19

Air Venting the Engine Cooling System To prevent an air lock in the engine coolant system, the cooling system automatically bleeds back to the expansion tank. Fill the coolant system expansion tank only with the correct mix of potable water and inhibitor as required in Section 21 - Fluid Specification Table.

Add water conditioner as necessary.

Refer to Section 5 for isolation of the cooling system and Section 6 for checking and filling of the cooling system.

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20

Diesel Control System (DCS) DIESEL SHUTDOWN

The purpose of the electronic shutdown system is to prevent the engine running outside of the predetermined safe operating parameters.

The following sensors are fitted to the machine: Hi Methane Shutdown (1.25%) Shuts engine down Lo Methane Warning (1%) Warning message Charge Failure Warning message/shutdown after 30 minutes Engine Oil Pressure Shuts engine down Engine Coolant Level Shuts engine down Hydraulic Oil Level Warning message Engine Coolant Temperature Shuts engine down Exhaust Scrubber Temperature Shuts engine down Exhaust Outlet Temperature Shuts engine down Power Up Pressure Switch (PUPS) System start up Wet Scrubber Water Level 1 Shuts engine down Wet Scrubber Water Level 2 Shuts engine down Fire Suppression Shuts engine down Exhaust Scrubber Temperature Shuts engine down

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SYSTEM OPERATION 1.

Position the on/off toggle switch to the on position: This will activate the DCS electronics. The system will display “Waiting for methane sensor warm up” and the methane LED will be illuminated. After approximately 15 seconds the screen display will read “Pre run checks” while the DCS checks that the system is ready to start.

Once this is completed the screen will display “Waiting for start”. The engine can now be started. If the engine is not started within 30 seconds the DCS will shut itself down.

To restart the system toggle the on/off toggle switch to off, wait a couple of seconds then back to on.

ON/OFF TOGGLE SWITCH ON THE OPERATOR’S DISPLAY PANEL

2.

Start engine: Activate the engine start button. After the engine has started, the display will read “Engine running”.

3.

After starting the engine if the alternator is not charging the engine will run for a predetermined period of time before shutting down.

4.

Drive machine normally.

5.

Shutdown: When finished with the machine, toggle the on/off toggle switch to the off position. This will deactivate the DCS electronics, thus cutting power to the solenoid and shutting off pilot air pressure to the fuel shut off cylinder and the engine will stop.

6.

After a shutdown whether by the operator or an engine trip, if the up or down arrows are pressed the system will return to “Waiting for start” providing no trip conditions are still active.

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If methane concentration is over 1.25%, it should be reported immediately!

Bypassing of the electrical safety system is not allowed under any circumstance!

If the air pressure is below 240 kPa (35 psi), the power up pressure switch will not close, and the DCS will not activate.

The start sequence is the same if the methane monitor is not fitted

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21

Fluid Specification Table SPEC.

1

COMPONENT

Engine

2

Transmission

CAPACITY (Litres)

LUBRICANT

TEMPERATURE BELOW 0ºC

0-32ºC

ABOVE 32ºC

Engine Oil

SAE15W-40 API CD-II (Valvoline - Super Diesel 15W -40 or Equivalent)

SAE40 API CD-II (Valvoline - All Fleet Premium 40 or Equivalent)

SAE50 API CD-II (Valvoline - All Fleet Premium 40 or Equivalent)

Mineral Gear Oil

SAE10W CAT TO-4 (Valvoline Valtorque C4 10W or Equivalent)

SAE30 CAT TO-4 (Valvoline -Valtorque C4 30 or Equivalent)

SAE50 CAT TO-4 (Valvoline Valtorque C4 50 or Equivalent)

450

Hydraulic

ISO68 (Valvoline Ultramax HVI 46 or Equivalent)

ISO68 (Valvoline - Ultramax 68 or Equivalent)

ISO68 (Valvoline Ultramax 68 or Equivalent)

25

40

3

Hydraulic

4

Axle / Wheel Ends

60 (Each Axle)

Mineral Gear Oil with Limited Slip Additive

SAE90LS (Valvoline - HP Gear Oil LS SAE90 or Equivalent)

5

Cooling System

72

Pre-mixed Coolant Conditioner

Ethylene Glycol Antifreeze Inhibitor to GM 6038-M (Valvoline - Heavy Duty Coolant 50 or Equivalent)

6

Fuel

350

Distillate “Diesel” Fuel

To ASTM D975 (Grades D-1 and D-2) and (AS3584.2 Specifications in Australia)

7

Lube Points - Drive Line - Pins / Bushes - Door Hinges - Tow Pin - Diff Pinion Oil Seal

As required

8

Winch Gearbox

5

Gear Oil

API-GLZ Spec (Valvoline - EPG 220 Gear Lubricant)

9

Winch Planetary

2.5

Gear Oil

API-GLZ Spec (Valvoline - EPG 220 Gear Lubricant)

10

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Drop Box

Multi-purpose EP Grease

8

Mineral Gear Oil

NLGI No. 0 or 1 (Shell - Alvania EP 0/1 or equivalent)

SAE10W CAT TO-4 (Valvoline Valtorque C4 10W or Equivalent)

NLGI No. 2 (Valvoline - Valplex EP 2 or equivalent)

SAE30 CAT TO-4 (Valvoline -Valtorque C4 30 or Equivalent)

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NLGI No. 2 (Valvoline Valplex EP 2 or equivalent)

SAE50 CAT TO-4 (Valvoline Valtorque C4 50 or Equivalent)

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© 2003

CATERPILLAR ALL RIGHTS RESERVED

CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, “CATERPILLAR YELLOW” AND THE “POWER EDGE” TRADE DRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.