CAT SH640 D Roof Support Carrier Service Manual SN 5004086 – PDF DOWNLOAD

Description

CAT SH640 D Roof Support Carrier Service Manual SN 5004086 – PDF DOWNLOAD

FILE DETAILS:

CAT SH640 D Roof Support Carrier Service Manual SN 5004086 – PDF DOWNLOAD

Language : English
Pages : 346
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT SH640 D Roof Support Carrier Service Manual SN 5004086 – PDF DOWNLOAD

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 and service personnel
  with the proper information regarding the machine’s instrumentation, operating controls and general
  safe working procedures. All operators and service personnel of this machine must be conversant
  with the information contained within this manual before operating the machine or performing
  services tasks on the machine.
• To ensure safe and efficient operation, the SH640 D Roof Support Carrier must be
  adequately maintained by the operators and service personnel. The operator’s pre-start
  inspection procedure contained in Section 6 of the Operator’s Manual must be performed before the
  machine is returned to active service.

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 SH640 D is powered by a 172 kW (230 HP) 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.

DESCRIPTION:

CAT SH640 D Roof Support Carrier Service Manual SN 5004086 – PDF DOWNLOAD

Section 1 General Information
Introduction 1
Description 1
Safety Labels and Instructions 2
Gauge Colour Code 3
Gauge Alarm Parameters 3
General Arrangement 6
Specifications 7
Lubrication and Fuel Specifications
General 9
Fuels 9
Fuel Specification Table 9
Fuel Additives 10
Diesel Fuel Relevant Information 11
Engine Oil 12
Torque Converter/Transmission Fluid 12
Hydraulic Oil 12
Gear Oil 12
Multi Purpose EP Grease 12
Exhaust Conditioner Make Up Tanks 12
Fluid Specification Table 13
Grease Point Reference Drawing 14
Machine Isolation
Engine Isolation 15
Pneumatic Isolation 16
Hydraulic Isolation 17
Engine Coolant Isolation 18
Electrical Isolation 18
Articulation Isolation 19
Lift Arm Isolation 20
Exhaust Conditioner Isolation 21
Exhaust Conditioner Make Up Tank Pressure Isolation 22
General Safety and Precaution
General 23
Packing and Supporting the Machine 26
Maintenance Schedules 27
10 Hours—Daily Off Line Mechanical Inspection 29
50 Hours—Weekly Off Line Mechanical Inspection 39
250 Hours—3 Months Off Line Mechanical Inspection 49
500 Hours—6 Months Off Line Mechanical Inspection 59
1000 Hours—12 Months Off Line Mechanical Inspection 69
2000 Hours—2 Yearly Off Line Mechanical Inspection 79
5000 Hours—5 Yearly Off Line Mechanical Inspection 91
10000 Hours—10 Yearly Off Line Mechanical Inspection 101
Recommended Bolt Torque 112
Section 2 Engine System
General Description 113
Electronic Control System Components 115
Fuel System
General Description 117
Component Description 118
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Section 2 Engine System (cont )
Fuel System
Lower Pressure Fuel System 121
Injection Actuation System 122
Pump Control Valve Operation 126
HEUI Injector (Components) 128
Safety Precautions 129
Fuel Tank 130
Checking and Cleaning Filler Neck Screen 130
Fuel Lines 131
Primary Fuel Filter/Water Separator 132
Secondary Fuel Filter 134
Fuel System – Priming 135
Lubrication System 136
General Description 137
Safety Precautions 139
Oil Filter 140
Checking/Filling Engine Oil 141
Changing Engine Oil 141
Flushing the Lubrication System 142
Air Inlet System
General Description 143
Air Cleaner/Indicator Assembly 144
Emergency Intake Shutoff Valve 145
Inlet Flame Trap/Flameproof Joints 146
Servicing Air Inlet System 146
Cooling System
General Description 148
Safety Precautions 148
Expansion Tank 150
Header Tank 151
Fan Assembly 151
Water Pump Belt Tension 153
Radiator 154
Checking/Filling and Flushing Coolant System 155
Flushing a Contaminated Cooling System 156
Exhaust System
General Description 157
Safety Precautions 158
Exhaust Downpipe/Purifier 158
Exhaust Conditioner Make Up Tanks 160
Exhaust Conditioner 160
Exhaust Particulate Filter 170
Exhaust Outlet Flame Trap 172
Flame Paths or Fixed Connections 173
Exhaust Emission Testing Procedure 173
Throttle Control
General Description 175
Safety Precautions 175
Section 3 Transmission and Drive Train
Engine Drive Coupling
General Description 177
Safety Precautions 177
Checking and Lubrication of Drop Box Drive Coupling 178
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Section 3 Transmission and Drive Train (cont )
Engine Drive Coupling
Removal and Installation of Drop Box Drive Coupling
Arrangement 180
Transmission and Torque Converter
General Description 182
Safety Precautions 184
Checking/Filling the Transmission Oil 185
Changing the Transmission Oil Filter Element 186
Changing the Transmission Oil 188
Troubleshooting Guide 189
Service Data 191
Front and Rear Axle
General Description 194
Safety Precautions 194
Checking/Filling the Planetary Wheel End Oil Level 195
Checking/Filling the Axle Centre Oil Level 196
Changing the Oil In Axle Centres, Wheel Ends, and Liquid
Cooled Brakes 197
Checking Wear of the Brake Assemblies 198
Drive Lines
General Description 199
Safety Precautions 200
Greasing and Inspecting Drive Lines 201
Removing and Installing the Rear Drive Line 201
Removing and Installing the Front Drive Line 202
Removing and Installing the Upper Drive Line 203
Wheel and Tyre Assemblies
General Description 204
Safety Precautions 204
Removal 204
Installation 206
Section 4 Hydraulic System
General Description 207
Safety Precautions 208
Hydraulic Isolation 209
Pumps and Mountings
Steering/Brake Pump 210
Main Hydraulic Pump 212
Auxiliary Hydraulic Pumps 214
Hydraulic Tank
Checking and Filling Hydraulic Oil 215
Changing Hydraulic Oil 216
Checking and Replacing Return Filter 217
Steering and Brake Hydraulic Manifold 218
Steering/Brake Pump Pressure Filter 222
Steering Circuit
Steering Accumulator 224
Steering Control Valve 225
Brake Circuit
Brake Accumulator 226
Brake Valve 227
Park Brake 231
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Section 4 Hydraulic System (cont )
Brake Circuit
Brake Heads 233
Control Levers 234
Main Control Valve Bank 236
Tilt and Lift Circuits 238
Winch and PTO Circuits 239
Alternator Circuit and Cooling Fan Circuit 241
Hydraulic Schematic 243
Section 5 Electrics System
General Description 245
Safety Precautions 245
Electrical Components General Arrangement 246
System Layout 247
Electric Lighting Components 248
Electrical Troubleshooting 249
IS Junction Enclosure 251
Flameproof Electrical Enclosures 252
Power Supply
System Overview 255
Power-Up Sequence and Troubleshooting Guide 255
24VDC Battery 256
Alternator 259
Power Interface Board 264
Diesel Control System (DCS)
General Description 265
Control Unit 267
Power Supply 268
DCS Looms 269
DCS Sensors 270
DCS Display Unit 276
Display Illustrations 278
DCS Display Menu 282
System Operation 288
Instructions for Diesel Control System Head 290
Engine Electronics
System Overview 296
Engine Control Unit (ECU) 297
Engine Conditioning Module 298
Electronic Engine Sensors 299
Sensor Location 300
Siren 304
Section 6 Frame Components
General Description 305
Safety Precautions 305
Front Frame
Chassis 306
Lift Arm
General 308
Lift Arm Isolation 309
Fork Cradle Assembly 310
Winch Assembly 311
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Section 6 Frame Components (cont )
Rear Frame
Chassis 316
Operator’s Compartment 317
Compartment Door Assembly 317
Canopy Assembly 318
Operator’s Seating 320
Articulation Joint 321
Covers 323
Section 7 Pneumatic System
General Description 325
Pneumatic Schematic 326
Safety Precautions 328
Air Compressor
Compressor Mounting 329
Compressor 329
Air Receiver 330
Starter Motor 332
Safety Circuit
Diesel Control System 334
Make Up Head Tank Pressure 334
Safe Start System 335
Brake and Transmission Interlock System 336
Operator’s Horn 337
Pneumatic System Troubleshooting 338

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