PDF Operation and Maintenance Manual CAT FH110 FH120 Face Haulage - 1 MB
Ensure the safe and efficient use of your CAT FH110 and FH120 Face Haulage systems with this official Operation and Maintenance Manual.
This document provides operators with essential knowledge on controls, safety features, and daily checks.
It also outlines the recommended maintenance schedules and procedures to maximize machine life and performance.
This manual is a critical resource for all personnel working with this specialized mining equipment.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
A6474X268
August 2012
Operation and
Maintenance
Manual
Face Haulage
FH110 (CH810C)
FH120 (CH816C)
FH120 (CH816CL)
--- Page 3 ---
___________________________________________ 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. Possi-
ble 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 ma-
chine damage.
NOTICE!
Points in the text marked with this symbol draw attention to harm-
ful situations. Possible consequences are: damage to the ma-
chine 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.
______________________________________________________________
A6474X268 REV 04 1.5
--- Page 4 ---
____________________________________ Overview of safety instructions
Installation and start-up
inclined face On inclined faces secure all component parts by chains, e.g. to the sup-
port.
environmental acceptability When working with oils, greases and other chemical substances, ob-
serve 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 con-
trol 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 func-
tion 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 per-
sonnel 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.
______________________________________________________________
A6474X268 REV 04 2.9
--- Page 5 ---
____________________________________________ 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/frost-
proofing 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. Never-
theless, 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 trans-
port.
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.
______________________________________________________________
A6474X268 REV 04 3.5
--- Page 6 ---
_______________________________________________________________
5 Operation
________________________________________________________________
--- Page 7 ---
______________________________________________________ Operation
battery hold down The battery hold down (Fig. 17), available on Models CH816C and
CH816CL, is located directly in front of the operator’
s seat. It is used to
secure the battery in position during tramming operations. To engage
the hold down, push the handle away from the operator and to unlock,
pull the handle towards the operator.
WARNING!
Always make sure the battery hold down is engaged after each
battery change and disengaged prior to changing batteries. The
batteries may be damaged if left unsecured during tramming op-
erations.
linear pedal adjustment The linear pedal adjustment (Fig. 17), available on Model CH816C, is
located directly in front of the operator’
s seat. It is used to adjust the
position of the pedals. See adjustment procedure in this chapter.
Fig. 17: Battery hold down lever and linear pedal adjustment lever
location
Linear pedal adjustment Battery hold down lever
______________________________________________________________
A6474X268 REV 04 5.11
--- Page 8 ---
______________________________________________________ Operation
Shutdown procedure
Tram the machine to its designated parking place.
Stop the machine by releasing the speed-switch foot pedal and de-
pressing the foot brake pedal. When the speed-switch foot pedal is re-
leased, the tram (traveling) motors will stop. 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 be-
tween the ejector blade/false bottom and the front of the rear
(payload) section.
1. Pull the ejector blade/false bottom control lever toward the operator
to move the ejector blade/false bottom to the front of the rear
(payload) section. There should be no obstructions behind the
ejector blade/false bottom.
Note: Refer to Fig. 21 for illustration of control handle.
2. Before leaving the operator’
s compartment, press J3”to turn “OFF”
the machine.
3. Turn “OFF”the machine circuit breaker.
4. Turn “OFF”battery circuit breaker and/or disconnect switch (if
equipped) before leaving the machine area.
5. Connect the steering lockout device (Fig. 22):
■ remove the steering lockout device from its storage lugs
■ remove the hitch pin from the end farthest from the center sec-
tion
■ adjust turnbuckle until holes line up between the turnbuckle lug
and the front section lug
■ insert the hitch pin into the front section lug through the turn-
buckle
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.
______________________________________________________________
A6474X268 REV 04 5.21
--- Page 9 ---
____________________________________________________ Maintenance
Critical torque values
Torque values are expressed in lubricated and dry thread values. Lu-
bricated thread torque values should be used any time the bolt threads
are covered with oil, grease, anti-seize or thread-locking compounds.
Dry thread torque values should be used when threads are completely
clean and dry.
Table 1: Critical torque values
Location Bolt size Grade Dry Lubricated
Steering cylinder pins 400 240
Tire-Wheel mounting bolts 3/4-16UNF Grade 8 420 250
(Front) X2-1/2
Tire-Wheel mounting bolts 3/4-16UNF Grade 8 420 250
(Rear) X2
Planetary wheel end-to-frame 3/4-NC Grade 8 380 230
mounting bolts 3-1/4
Gear case-to-frame mounting 3/4-NC Grade 8 380 230
bolts 2-1/4
Drive motor-to-gear case 3/4-NC Grade 5 380 230
mounting bolts 2-3/4
Center section (Outer ring) 7/8-NC Grade 8 650 N/A
(810 & 816) * See note 1 9
Center section (Inner ring) 1 1/4 NC Grade 8 1886
(810 & 816) * See note 1 9
Notes:
1. Retorque of these bolts should not be required due to the use of
prevailing torque locknuts. If bolts require to be retorqued, new
bolts and locknuts must be installed.
Lubricants, fluids and capacities
Table 2: Lubricants, fluids and capacities
Location Specification Approximate capacity Notes
Hydraulic oil Spec. 100-1 72 Gallons (816) 1
65 Gallons (810)
Drive sump (Gear case) Spec. 100-8 4 Gallons Each 2, 3
Multi-Purpose grease Spec. 100-3 As Required 4
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.
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.
______________________________________________________________
A6474X268 REV 04 5.31
--- Page 10 ---
____________________________________________________ Maintenance
gear cases and Change the oil in both gear cases and planetary wheel ends after the
planetary wheel ends first week of service (Fig. 42).
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.
Replace the drain plugs and refill with oil to full level on dipstick or
until oil begins to flow from check/level plug.
Fig. 42: Gear case and planetary wheel end lubrication
Oil level dip stick
Fill plug
Breather and
Drain plug optional oil
level plug
Cooling oil outlet
Wheel end
drain plug
wheel mounting bolts Check the wheel mounting bolts (Fig. 43). The mounting bolts should
be torqued to 300 ft-lbs on Models CH810C, CH816CL and to 380 ft-
lbs on Model CH816C. Use Loctite 242 on wheel mounting bolts.
Fig. 43: Wheel mounting bolts
Check torque of wheel
mounting bolts on all 4 tire
and wheel assemblies
______________________________________________________________
A6474X268 REV 04 5.41
--- Page 11 ---
____________________________________________________ Maintenance
hydraulic oil suction strainer Clean or replace the hydraulic suction strainer inside the hydraulic oil
tank (Fig. 56).
Remove the drain plug from the hydraulic oil tank to allow the oil to
drain.
Remove the oil tank cover and gasket.
Reach through opening in tank and unscrew strainer from fitting.
Replace the strainer with a new one or thoroughly clean the old
one with kerosene and a soft brush. Dry the cleaned strainer with
air before replacing in the tank.
Replace the strainer in the tank and tighten hand-tight.
Inspect cover gasket for damage and replace if necessary.
Replace cover and gasket,
Install drain plug.
Refill tank to proper level with hydraulic oil (Spec. 100-1).
Purge hydraulic system of air.
Fig. 56: Hydraulic oil suction strainer maintenance
Hydraulic
oil tank
Sight glass
______________________________________________________________
A6474X268 REV 04 5.51
--- Page 12 ---
__________________________________________ Adjustment procedures
Brake cooling circuit relief pressure adjustment
To adjust the steering relief pressure proceed as follows (Fig. 65).
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. Ob-
serve the safe working load of the lifting and blocking devices and
keep a safe distance away from suspended loads.
Remove the hose fittings from the top of the relief valve.
With a gauge and suitable fittings, install the gauge onto the relief
valve where the hose was disconnected.
Start the machine, release the automatic brakes and slowly de-
press the accelerator pedal.
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.
Remove the cap that covers the pressure adjustment screw.
Using an allen wrench, turn the screw until the correct pressure of
50 psi is indicated on the pressure gauge.
Replace the cap on the relief valve.
Remove the gauge and replace the hose in the relief valve.
Fig. 65: Brake cooling circuit relief pressure adjustment
Pressure adjustment
Brake cooling Pressure gauge
relief valve connection
______________________________________________________________
A6474X268 REV 04 5.61
--- Page 13 ---
__________________________________________ Adjustment procedures
Tailgate sequence valve adjustment (P/N LUP02119)
To adjust the tailgate sequence valve proceed as follows (Fig. 69 and
70).
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.
IMPORTANT!
Remember that counterbalance cartridges adjust opposite of relief
cartridges. Turning the stem clockwise will reduce pressure.
The cartridges on the sequence valve are identified with numbers sten-
ciled on the valve body beside the location of the respective cartridge.
Ensure that the “SYSTEM PRESSURE”is set as specified on the
hydraulic schematic supplied with your machine before beginning
this procedure.
Extend cycle
Cartridges #3 and #4 should be minimized (Turn adjustment stem out
in a counter-clockwise direction), prior to operating the Extend Cycle.
These two cartridges control the sequential operation of the extend
function and should prevent any movement of the false bottom or ejec-
tor, until the tailgate is fully open. Cartridge #3 controls oil flow to the
false bottom cylinders extend ports and Cartridge #4 controls oil flow to
the ejector extend port. If adjustment is required, proceed as follows:
If the false bottom or ejector cylinders are extending while the tail-
gate is being opened, increase the setting of Cartridge #3 first, in
full turn increments (Turn adjustment stem in clockwise), to inhibit
any movement of the false bottom and ejector cylinders until the
tailgate is fully opened. Once this is achieved, you may optimize
the cartridge setting by decreasing the adjustment (Counter-
clockwise direction) in fractional increments (e.g. 1/2hf; 1/4tr;
1/8th turns) to insure that the transition between functions is as
smooth as possible. At this point, you may have to increase the
adjustment of Cartridge #4 in like fashion to insure that the false
bottom reaches full extension before the ejector will move. Again,
you should optimize the cartridge setting for the ejector control to
insure that the transition between functions is as smooth as possi-
ble.
IMPORTANT!
Insure that all the jam nuts have been locked down securely be-
fore returning the machine to service, to insure that the cartridge
settings will be maintained.
______________________________________________________________
A6474X268 REV 04 5.71
--- Page 14 ---
__________________________________________ Adjustment procedures
Linear pedal adjustment (if equipped)
To adjust the linear position of the pedals proceed as follows (Fig. 73).
Turn the handle counterclockwise to move the pedals away from
the operator.
Turn the handle clockwise to move the pedals toward the operator.
Fig. 73: Linear pedal adjustment
Linear pedal adjustment
______________________________________________________________
A6474X268 REV 04 5.81
--- Page 15 ---
______________________________________________ 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: 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 cer-
tain during the process of determining the proper num-
ber 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 pre-
sent.
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 meas-
urement 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 .
______________________________________________________________
A6474X268 REV 04 5.91
--- Page 16 ---
______________________________________________ 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 as-
sembly. 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 condi-
tions, 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 lockwashers 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.
______________________________________________________________
A6474X268 REV 04 5.101
--- Page 17 ---
__________________________________________________ Technical data
Technical data