CAT Bucyrus CH810B, CH816B, CH816LB & CH818 Operation Manual A6474X211 - PDF DOWNLOAD

Operation Manual Bucyrus - UN-A-HAULER ® Model - CH810B, CH816B, CH816LB, and CH818 Doc. No.:

A6474X211

Bucyrus America, Inc. ________________________________________ 4041 Wurno Road Pulaski, VA

Telephone: 540-980-4530 Fax: 540-994-3763

Internet: www.bucyrus.com

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__________________________________________________________

This manual is intended to provide GENERAL product information for the Models CH810B, CH816B, CH816LB, and CH818 UN-AHAULERS ® . The illustrations, descriptions and procedures contained in this publication apply only to these machines. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This UN-A-HAULER ® was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U.S. regulatory agency standards.

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 Bucyrus America, Inc., and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© BUCYRUS AMERICA , INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

Table of contents 1. About this manual About this manual .................................................................. 1.3 Before starting to work ......................................................... 1.3 Who is this operating manual intended for? ........................ 1.3 What is the purpose of this operating manual? ................... 1.4 Characters and symbols ...................................................... 1.5

2. Your safety

© BUCYRUS AMERICA, INC.

Your safety .............................................................................. 2.3 Personnel............................................................................. 2.4 Operation ........................................................................ 2.4 Installation and repair...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use ................................................................... 2.5 Unauthorized use............................................................ 2.5 Safety instructions................................................................ 2.7 General rules: ................................................................. 2.7 Storage and transport ..................................................... 2.8 Pre-start inspection ......................................................... 2.8 Installation and start-up................................................... 2.9 Operation ........................................................................ 2.9 Stopping .........................................................................2.10 Maintenance and repair .................................................2.10 Overview of the safety instructions .....................................2.15 Chapter 3: Storage and transport ..................................2.15 Chapter 4: Installation ....................................................2.15 Chapter 5: Operation .....................................................2.16 Chapter 6: Technical data..............................................2.21

3. Storage and transport Storage and transport ............................................................ 3.3 Storage ................................................................................ 3.3 Storage of the machine and spare parts......................... 3.3 Transport.............................................................................. 3.4 Before transport .............................................................. 3.5

4. Installation Installation ............................................................................... 4.3 Points to observe prior to installation................................... 4.3 Who is allowed to carry out installation?......................... 4.3 Which tools are required for installation?........................ 4.3 Notes on installation........................................................ 4.4 Pre-installation check list ................................................ 4.5 Safety features ................................................................ 4.6

________________________________________________________________ A6474X211

VTVI/05

Table of contents _________________________________________________

Operation ................................................................................. 5.3 How to operate the UN-A-HAULER ® .................................. 5.3 Who is allowed to operate the UN-A-HAULER ® ............ 5.3 When can operation be started?..................................... 5.3 Controls and indicators ........................................................ 5.4 Operator’s compartment ................................................. 5.4 General hydraulic control information ............................5.12 Hazard zone........................................................................5.16 Starting procedure ..............................................................5.17 Machine operation .........................................................5.18 Shutdown procedure...........................................................5.21 Battery change procedure (Vertical lift) ..............................5.23 Battery change procedure (CH818 ground level) ...............5.30 Battery change procedure (CH810B and CH816B ground level)..................................5.35 Instructions on the maintenance.........................................5.41 Important notes ..............................................................5.41 Before maintenance.......................................................5.41 Critical torque values .....................................................5.43 Lubricants, fluids and capacities ....................................5.43 Specific lubrication and maintenance instructions ..............5.46 Every third shift ..............................................................5.46 Weekly ...........................................................................5.51 Every two weeks ............................................................5.56 Monthly...........................................................................5.57 Every three months ........................................................5.59 Tire/wheel installation procedure ...................................5.67 Instructions on the adjustment procedures.........................5.71 Main hydraulic system pressure ....................................5.71 Steering relief pressure adjustment ...............................5.72 Brake cooling circuit relief pressure adjustment ............5.73 False bottom/ejector blade sequence valve adjustment 5.74 Tailgate sequence valve adjustment (P/N LUP01820) ..5.75 Tailgate sequence valve adjustment (P/N LUP00781) ..5.80 Tailgate sequence valve adjustment (P/N LUP02119) ..5.83 Gear case and planetary wheel end shim procedure Number 1 .......................................................................5.87 Gear case and planetary wheel end shim procedure Number 2 .......................................................................5.88 Brake pedal valve and HDC actuator adjustment..........5.90 Major maintenance .............................................................5.93 Drive motor/gear case removal/replacement.................5.93 Gear case and brake module assembly/disassembly ...5.95 Planetary wheel end removal/replacement....................5.97 Gear case/planetary wheel end shim procedure 1 ........5.98 Gear case/planetary wheel end shim procedure 2 ........5.99 Gear case/planetary wheel end shim procedure 3 ...... 5.101 False bottom/ejector cylinder replacement .................. 5.103 Accumulator operation and precharging...................... 5.105 2-wheel assist pump removal ...................................... 5.107 Rear wheel motor removal/replacement...................... 5.108

_________________________________________________________________ BUCYRUS– Models CH810B, CH816B, CH816LB, and CH818 UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

5. Operation

________________________________________________ Table of contents BBC06 w/ brakes mechanical disconnect procedure .. 5.109 Tire/wheel installation procedure ................................. 5.110 Recommended wheel mounting procedure ................. 5.112 Hydraulic pump & motor removal/replacement............ 5.114 Tailgate assembly removal .......................................... 5.115 Battery lift assembly removal ....................................... 5.116 Pedal assembly removal.............................................. 5.117 Canopy removal........................................................... 5.118

6. Technical data

© BUCYRUS AMERICA, INC.

Technical data......................................................................... 6.3 Components of the CH810 UN-A-HAULER ® ..................... 6.3 Components of the CH816B UN-A-HAULER ® ................... 6.6 Components of the CH816LB UN-A-HAULER ® ................. 6.9 Components of the CH816B UN-A-HAULER ® ................... 6.6 Components of the CH818 UN-A-HAULER ® ....................6.12 Tightening torques ..............................................................6.15 Permissible data .................................................................6.21 Lubrication fluids and greases ............................................6.21

7. For your information For your information .............................................................. 7.3 Our service........................................................................... 7.3 Service address .............................................................. 7.3 Rebuild facility address ................................................... 7.4

________________________________________________________________ A6474X211

VTVI/05

© BUCYRUS AMERICA, INC.

Table of contents _________________________________________________

_________________________________________________________________ BUCYRUS– Models CH810B, CH816B, CH816LB, and CH818 UN-A-HAULER ®

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1

About this manual

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_______________________________________ Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

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

This operating manual is intended for: BUCYRUS – Model, CH810B, CH816B, CH816LB and CH818 Serial No.: N/A and is only permitted to be used for equipment of this type.

© BUCYRUS AMERICA, INC.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine.

It should, if possible, always be available at the place of operation.

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine.

Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who: ■ ■ ■ ■ ■ ■ ■ ■

are in charge of transport prepare the rise heading perform assembly / disassembly work operate the machine eliminate faults perform daily routine work on the face or in the entry perform maintenance work perform repair work

supervisory personnel who: ■ ■

initiate and/or supervise the activities just indicated.

______________________________________________________________ A6474X211 VTVI/05 1.3

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

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

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

safety

Read the chapter “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

© BUCYRUS AMERICA, INC.

service

_________________________________________________________________ 1.4 BUCYRUS – Models CH810B, CH816B, CH816LB, and CH818 UN-A-HAULER ®

_______________________________________ Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

© BUCYRUS AMERICA, INC.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

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

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

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Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

______________________________________________________________ A6474X211 VTVI/05 1.5

© BUCYRUS AMERICA, INC.

Before starting to work ________________________________________

_________________________________________________________________ 1.6 BUCYRUS – Models CH810B, CH816B, CH816LB, and CH818 UN-A-HAULER ®

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2

Your safety

________________________________________________________________

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DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL