PDF Operation Manual Cat SH650D Shield Hauler - 3 MB
This operation manual provides detailed instructions for the safe and effective use of the Cat SH650D Shield Hauler.
It covers all aspects of operation, from pre-start checks to machine controls and basic maintenance.
Understanding this manual is key to maximizing productivity and ensuring safety in demanding mining environments.
A vital document for all operators and site supervisors.
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BI002302
A6474X413
November 2012
Operation Manual
SH650D Shield Hauler
SAFETY.CAT.COM
--- Page 3 ---
BI002302
________________________________________ Machine Mounted Controls
Table 1: Gauges
Gauge Function Operating Value
1. EXH TEMP Monitors the temperature of the exhaust
gas.
2. BRAKE PSI Monitors the pressure in the brake circuit. 0 psi when brakes are not engaged.
1,800 psi when brakes are engaged.
3. EXHAUST H2O Monitors the back pressure across the dry Maximum back pressure = 60 inches
filter. of water (read with engine in neutral
at high idle).
4. DIF-LOCK PSI Monitors the pressure in the differential 0 psi when dif-locks are not engaged.
lock circuit.
800 psi when dif-locks are engaged.
5. INTAKE H2O Monitors inlet vacuum pressure and pro- Maximum restriction = 26 inches of
vides a visual indication of when the air water.
inlet filter needs servicing.
6. PILOT PSI Monitors the hydraulic pilot circuit pres- 500 psi
sure.
7. AIR PSI Monitors the pressure in the pneumatic 120 - 150 psi
system.
8. TRANSMISSION TEMP Monitors the temperature of the transmis- Maximum temperature = 250 F.
sion oil.
9. SYSTEM PSI Monitors the hydraulic system pressure. 2,800 psi
If 3,000 psi or greater, shut down and
call for service.
10. ACCUM PSI Monitors the pressure in the accumulator 1,800 psi
circuit (should be the same as the system
pressure). The accumulator circuit pro-
vides the pressure necessary to release
the brakes.
11. TRANSMISSION PSI Monitors the oil pressure in the transmis- Greater than 160 psi.
sion.
12. ENGINE OIL PSI Monitors the pressure of the engine oil. If the pressure drops below 15 psi,
machine will shut down.
13. ENGINE COOLANT Monitors the temperature of the coolant in If the temperature exceeds 200° F,
TEMP the engine. the machine will shut down.
14. TACHOMETER Displays the engine rpms.
______________________________________________________________
A6474X413 REV 1 11
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_______________________________________________________________
Table of contents
Safety Instruction............................................................................... 4
General Description........................................................................... 5
Troubleshooting................................................................................. 10
________________________________________________________________
A6474X400 REV 1
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BI0016249
_________________________________________________ Troubleshooting
Table 1, continued: Engine troubleshooting
Symptom Probable Cause Test, Check, or Remedy
Oil in cooling system Leaking head gasket Install new head gasket
Mechanical noise Connecting rod bearing failure Call Caterpillar Service Representative
(knock) in engine
Timing gear damaged Call Caterpillar Service Representative
Crankshaft damaged Call Caterpillar Service Representative
Excessive fuel con- Fuel system leaks Inspect fuel system and make repairs as
sumption necessary
Fuel and combustion noise Small increases in fuel consumption may
be the result of defective fuel nozzles,
rough running, or factors causing loss of
power (see previous sections)
Incorrect fuel injection timing Call Caterpillar Service Representative
Loud valve noise or Valve spring damage Call Caterpillar Service Representative
valve drive compo-
nent noise Camshaft damage Call Caterpillar Service Representative
Valve lifter damage Call Caterpillar Service Representative
Valve damage Call Caterpillar Service Representative
Little movement of Excessive valve clearance Call Caterpillar Service Representative
rocker arm and exces-
sive valve clearance Insufficient lubrication Check lubrication in valve compartment.
There must be a strong flow of oil at high
engine rpm but only a small flow at low
engine rpm. Oil passages must be clean,
especially those sending oil to the cylinder
head.
Rocker arm worn at face that contacts Call Caterpillar Service Representative
valve
End of valve stem worn Call Caterpillar Service Representative
Worn push rods Call Caterpillar Service Representative
Worn valve lifters Call Caterpillar Service Representative
Damaged valve lifters Call Caterpillar Service Representative
Worn cams on camshaft Call Caterpillar Service Representative
Oil at the exhaust Excessive oil in the valve compartment Call Caterpillar Service Representative
Worn valve guides Call Caterpillar Service Representative
Worn piston rings Call Caterpillar Service Representative
______________________________________________________________
A6474X400 REV 1 13
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BI0016248
A6474X385
November 2012
Operation Manual
SEMS 2 Electronic Monitoring System
SAFETY.CAT.COM
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BI0016248
______________________________________________ General Description
Run solenoid sensor
The run solenoid sensor is located in the center bay of the machine with the
engine monitoring system (Fig. 5). This sensor monitors the run solenoid. If the
solenoid is not working, the solenoid valve will open, exhausting air pressure
from the system causing the fuel shutdown cylinder to close the fuel rack.
When the fuel rack closes, no fuel is sent to the engine and the engine shuts
down.
Fig. 5: Run solenoid sensor
Run solenoid
sensor
Engine coolant temperature sensor
The engine coolant temperature sensor is located in the engine compartment
(Fig. 6). This sensor monitors the engine coolant temperature and is set at 205°
F (96° C). When the engine coolant temperature exceeds this value, the sensor
will stop power to the solenoid valve. This valve will open exhausting air pres-
sure from the system causing the fuel shutdown cylinder to close the fuel rack.
When the fuel rack closes, no fuel is sent to the engine and the engine shuts
down.
Fig. 6: Engine coolant temperature sensor
Engine coolant
temperature
sensor/probe
(shutdown at ap-
proximately 205° F)
______________________________________________________________
A6474X385 REV 3 11
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BI016255
__________________________________________________________
This manual is intended to provide GENERAL product information. The
illustrations, descriptions and procedures contained in this publication
apply only to THIS machine. Caterpillar reserves the right to revise
models and designs without prior notice.
This machine was manufactured under the guidelines, procedures and
requirements of the appropriate government regulatory agencies.
At the completion of the manufacturing process, this unit was issued the
appropriate approval numbers and nameplates indicating it met the
technical requirements of these regulatory agencies. Any change to the
design or structure of this unit, without the consent of Caterpillar and
these regulatory agencies, or any repair or replacement of parts con-
trary to Caterpillar’
s instructions, may invalidate these approvals and
render this unit unsafe to operate.
Strict compliance with all laws, regulations and practices regarding the
safe operation and maintenance of underground mining equipment and
strict adherence to the instructions in this manual is necessary for the
personal safety of those working on or around this unit.
While this manual attempts to anticipate the most important operations
and maintenance needs for this unit, unforeseen circumstances may
arise that have not been addressed in this manual. If any concerns or
questions arise, please contact your Service Representative immedi-
ately.
This work contains information protected under trade secret and other
intellectual property laws, and is protected under the U. S. Copyright
Act of 1976, as amended. This work is provided under license and the
license is non-transferable. Distribution and access is limited only to
authorized personnel. Disclosure, reproduction, distribution or unau-
thorized use may be a violation of federal and state laws and may sub-
ject the unauthorized user to criminal liability.
© Caterpillar 2012
ALL RIGHTS RESERVED
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BI016255
Maintenance Schedule ____________________________________________
Table 5, continued: Lubrication and maintenance schedule
Item Description Places Lubricant Specification
39 Axle oil level (Check) 2 Hypoid gear oil
SAE 90W
40 Planetary wheel end oil level (Check) 4 Hypoid gear oil
SAE 90W
41 Carbon monoxide (CO) sampling
Every 100 hours
42* Engine oil and filter Change 10W40 API CF/ 4
43 Primary fuel filter (change) 1
44 Secondary fuel filter (change) 2
Every three months
45 Axle oil (Change) 2 Hypoid gear oil
SAE 90W
46 Planetary wheel end oil (Change) 4 Hypoid gear oil
SAE 90W
47 Wet disc brake wear (Check) 4
48 Hydraulic oil (Change) 1 Spec. 100-12
49 Tank suction strainer (Clean/change) 1
50 Winch oil (Change) (if equipped) 1 API GL4 (140) Gear oil
Peragma Grade 8
Every 500 hours
51 Transmission fluid and filter Clean
52 Radiator coolant Change Avia Antifreeze Extra
Glysantin G 48
DEA radiator anti-
freeze
Shell GlycoShell
53 Exhaust heat exchanger Inspect
Every 1000 hours
54 Scrubber heat exchanger Clean
Every 6 months
55 Power system permissibility: intake sys-
tem
56 Power system permissibility: shutdown
circuit testing
* Change engine oil and filter after the first 50 hours of operation and then every 100 hours of operation.
________________________________________________________________
12 SH650D Shield Hauler
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BI016255
Maintenance Instructions __________________________________________
Lubricate the oscillating bearing (9 places) with Spec. 100-3 through the grease
Oscillating Bearing fittings located around the bearing (Fig. 9). Pump grease into the fittings until
new grease can be observed coming out of the bearing.
Fig. 9: Oscillating bearing lubrication
Oscillating bearing
grease fitting (9 places)
________________________________________________________________
22 SH650D Shield Hauler
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BI016255
Maintenance Instructions __________________________________________
Steering Cylinder Pins and Inspect the steering cylinder pins and nuts for looseness or wear (Fig. 19).
Nuts Tighten ( 1480 - 1500 ft. lbs.) where necessary and replace any worn parts.
Center Section Pins and Inspect the center section pins and nuts for looseness or wear (Fig. 19).
Nuts Tighten ( 680 - 720 ft. lbs.) where necessary and replace any worn parts.
Fig. 19: Steering cylinder and center section pins and nuts
Center section
pin and nut
Steering cylinder
pin and nut
Wheel Mounting Nuts Check the wheel mounting nuts (Fig. 20) on all four wheels and torque (217 ft-
lbs) as required.
Fig. 20: Wheel mounting nuts
Wheel mounting
nuts
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32 SH650D Shield Hauler
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BI016255
Maintenance Instructions __________________________________________
Every 3 months
The purpose of this section is to describe the maintenance procedures that are
required every 3 months:
1. Change the axle oil
2. Change the planetary wheel end oil
3. Check the wet disc brakes for wear
4. Change the hydraulic oil and tank suction strainer
5. Change the winch oil (if equipped with winch)
________________________________________________________________
42 SH650D Shield Hauler
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BI016255
Maintenance Instructions __________________________________________
Exhaust Heat Exchanger The exhaust inlet and outlet ports should be visually examined to insure:
There is no green fluid in the exhaust outlet indicating a leaking tube bundle
or cracked housing
The cooling fins do not contain any appreciable accumulation of soot. The
definition of appreciable would be indicated by a pressure drop of greater
than 8 inches across the exchanger.
________________________________________________________________
52 SH650D Shield Hauler
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BI016252
Air Filters _______________________________________________________
Servicing heavy duty air filter elements
When to Service?
The element in any air cleaner should be serviced when the maximum allow-
able restriction, established by the engine manufacturer, has been reached. The
element should not be serviced on the basis of visual observation because this
will generally lead to over-servicing. Over-servicing will cause increased ser-
vice cost, both time and material, and may cause dust contamination of the en-
gine due to element damage from excessive handling, increased chance of im-
proper installation of element, and increased initial inefficiencies.
Achieving Maximum Air Filter Efficiency
The efficiency of an air filter increases as it is used. As soon as the air filter is
put into operation, it begins to remove dust particles. As these particles accu-
mulate throughout the filter, the microscopic openings in the filter medium be-
come obstructed, causing the filter to trap increasingly finer dust particles, re-
sulting in a more efficient medium. As the filter continues to plug with contami-
nation, the restriction to air flow will increase. Most engine manufacturers estab-
lish a maximum degree of vacuum in the air induction system that the engine
can tolerate and still operate efficiently.
What instruments are used to measure restriction?
Restriction is best recorded by a water manometer, an air cleaner service indi-
cator, or a dial gauge calibrated in inches of water or Kpa (other units may also
be used). Since some users will not have a water manometer or dial gauge
available, the use of permanently mounted service indicators should be consid-
ered. The indicator should be mounted in an area where the operator can moni-
tor the condition of the element constantly.
How is restriction measured?
Restriction is measured in the air cleaner outlet tap (if provided), at a tap in the
air transfer tube, or within the engine intake manifold. Accurate restrictions can
only be measured at maximum airflow. On naturally aspirated or supercharged
(not turbocharged) diesels, the maximum airflow occurs at maximum RPM (high
idle) without regard for engine power. On gasoline, LP, or turbocharged diesel
engines, the maximum airflow occurs only at maximum engine horsepower at
governed RPM. Most engine manufacturers suggest a maximum allowable re-
striction between 15 and 20 inches of water (3.75 - 5.00 Kpa) for gas and LP
engines, and from 20 to 30 inches of water (5.00 - 7.50 Kpa) for diesel engines.
Exceeding these maximums will affect engine performance.
The operator should not be alarmed when the signal on the restriction indicator
begins to appear. The air filter manufacturer furnished designed the element to
withstand several times these recommended maximums without collapsing or
leaking dirt into the engine.
________________________________________________________________
4 Diesel Equipment Reference Information
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BI016252
Operational Issues _______________________________________________
Maintenance scheduling
Utilize an oil analysis program to determine optimum intervals for engine
service. An excellent program to use is the CAT SOS oil analysis program
available from your local Caterpillar dealer.
Examine the possibility of splitting the preventive maintenance intervals
between engine systems and vehicle systems. For example, the engine
could be serviced at 100 hour intervals while the remaining vehicle systems
might only be serviced at 250 hours. This could be a method of achieving
better attention to detail as well as optimized intervals.
Examine the fleet profile and optimize the preventive maintenance schedule
to ensure utility equipment doesn't become over-serviced at the expense of
production equipment being under serviced.
The service interval for the intake system is probably the most critical point,
directly affecting engine performance and emissions. Specified intervals for
intake systems only go part way to solving this. Vehicle operators must be
made part of this process and educated as to it’ s importance. They must
become stakeholders in the process and become responsible for engine
operation and service. When an operator suspects the need for intake
service, he should be able to take the necessary action himself. For a
detailed explanation of how to properly service an air intake system, refer to
Section II (six engine systems).
Engine tune-ups
Intervals for engine tuneups should be determined by engine performance
and exhaust emissions . The UGAS tool is an excellent method of achieving
this. In many case, scheduling tuneup intervals on the basis of hours lapsed
since the last tuneup leads to poorer engine performance. An engine that
may be performing optimally may be scheduled for a tuneup by hours and
end up performing more poorly afterwards.
Have engine manufacturer service representatives train the mechanics
hands on in proper tuneup techniques.
Mechanics should be encouraged to use a diagnostic before starting
tuneups. Before opening up the engine, the mechanic should be trained to
look for clues using basic diagnostics such as turboboost pressure, air/fuel
ratio, timing advance, etc.
________________________________________________________________
14 Diesel Equipment Reference Information
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BI016252
System Specific Information _______________________________________
Low turbocharger boost pressure
Turbo boost pressures are similar for two-and four-stroke-cycle engines. Strate-
gically placed small pipe plugs on the engine can be accessed to isolate the
turbocharger boost pressure from the air box pressure on two-cycle engines
such as the Detroit Diesel 2 stroke models.
There are many causes for low turbocharger boost pressure, which include:
A high exhaust back pressure condition. (Check for plugged or restricted
after treatment devices or exhaust deflectors.)
Exhaust gas leaks feeding to the turbo from the engine. (Check for telltale
signs of black soot around turbo exhaust connections.)
Leaking fittings, connections, or intake manifold gasket from outlet side of
turbo (usually accompanied by a high-pitched whistle under load due to
pressurized air leaks).
Plugged turbocharger safety screen if used on the inlet or outlet side.
Plugged or damaged air system after cooler. (Check the temperature drop
across the aftercooler. Refer to manufacturer’
s specifications for your
particular application.)
Possible turbocharger internal damage (check the condition of the turbine
and compressor vanes for damage with the engine stopped)
Leaking gasket between direct-mounted Turbocharger and the blower
housing on a Detroit Diesel two-cycle engine
Low air box pressure on a two-cycle Detroit Diesel engine caused by any of
the following conditions: leaking inspection covers on the block, leaking
cylinder block-to-end-plate gaskets, a plugged blower inlet screen, or a
partially stuck closed emergency air system shutdown valve.
High exhaust back pressure
The exhaust system (Fig. 5) must be laid out in such a manner that the maxi-
mum permissible exhaust backpressure, as prescribed by the engine manufac-
turer, is not exceeded. A slight backpressure (refer to manufacturer’ s recom-
mendations for maximums, generally no more than 25 inches of water) in the
exhaust system is normal, but excessive exhaust backpressure will affect the
operation of the diesel engine. The use of after treatment devices, such as cata-
lytic converters, flame arrestors, water scrubbers, or particulate traps, will in-
crease the engine exhaust backpressure. Excessive exhaust backpressure has
a similar effect on engine performance and emissions as an intake restriction.
Power output reduction and increased exhaust temperature will become a prob-
lem. Carbon monoxide, black smoke, and particulate emissions will also in-
crease, counteracting the effect of the after treatment device. Improper mainte-
nance could lead to plugging of the after treatment device and could create a
flow restriction in excess of the manufacturer's recommended limits.
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24 Diesel Equipment Reference Information
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BI016252
System Specific Information _______________________________________
Intake system recommendations
In a mining applications, the intake system becomes the most critical engine
system affecting exhaust emissions. Problems associated with intake air are
magnified in every other engine system's performance.
Some points worth considering in maintaining intake systems:
The ducting and piping for the intake system should utilize two spring
loaded band clamps at each rubber hose connection.
The entire system (ducting, filter housing, gaskets, etc.) should be tested
every 100 hours for integrity and leaks. The use of ether spray is not
recommended under any circumstances due to danger of fire and explosion
and possible engine damage. The best test method is a compressed air
charge system described in the next section.
The location and installation of intake filter housings should be evaluated.
Ideally, they should be situated away from heat sources (exhaust) and dust
sources (tires). They should also be installed to facilitate easy service.
Every underground diesel engine should be equipped with a two-stage
intake filter system with a radial type seal at the back of the filter for failsafe
protection.
Inspect intake filter system and verify that it is sized correctly to meet
engine requirements. Refer to filter manufacturer’ s recommendations.
Verify that ducting is of sufficient size without unnecessary restrictions.
Ensure that intake filter housing is installed as close to the engine intake
manifold as possible.
On engines equipped with dual intake filters, ensure that there is a common
connection to both housings to prevent balance problems, such as turbo
overspeed.
Do not rely solely on intake restriction indicators located at the filter
housing. Proper gauges should be installed at the operator dash. It is
imperative that operators be educated on the use and importance of these
gauges.
The mechanics should service intake systems at minimum intervals. This
would be at least a weekly inspection and filter service, if required. Once
again, it is imperative that operators be educated and empowered to
monitor the intake system and perform necessary service immediately upon
detection of a problem.
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34 Diesel Equipment Reference Information
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BI016252
System Specific Information _______________________________________
Emissions testing protocol
Start the analyzer and log on to UGAS software 3-minute calibration
Perform a steady state engine stall against the converter and hydraulics
system (brakes on, wheels chocked, unit in second gear, maximum throttle,
along with hydraulic stall). Maximum stall time 60 seconds. Perform
Baccarat Smoke Test 60 Seconds Read RPM.
Enter Bacharach Smoke Value - RPM - Test ID Proceed to Gas Sampling.
Perform a steady state engine stall against the converter and hydraulics
system. Brakes on, wheels chocked, unit in second gear, maximum throttle,
along with hydraulic stall. Maximum stall time 60 seconds. Start gas
sampling within 60 seconds.
Print and save the results and repeat the test on the opposite exhaust bank
on "V" engines.
Exceeding a 60 second stall condition can potentially cause damage to
transmission and hydraulic systems. Use of caution and careful monitor-
ing of all temperatures is advised.
________________________________________________________________
44 Diesel Equipment Reference Information
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BI016252
System Specific Information _______________________________________
Fuel system types
Although new diesel engines employ electronic fuel injection and governing sys-
tems to reduce exhaust emissions, there are still many diesel engines in opera-