Issuu

Technical Manual

BUCYRUS

• 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

OPERATION, PREVENTIVEMAINTENANCE, TROUBLESHOOTING ANDSERVICEGUIDE

MODELCH818

A6474X80

NOTICE

BI000858-00

THISGUIDECONTAINSIMPORTANTOPERATIONANDSAFETYINFORMATIONANDSHOULDBE KEPTAVAILABLETOTHOSEPERSONNELINSTALLINGANDOPERATINGTHISEQUIPMENT.

NOTICE

THISGUIDEISNOTINTENDEDTOBEACOMPLETEOPERATINGORSERVICEMANUALOR GUIDE.ITISPREPAREDONTHEBASISTHATTHEINDIVIDUALOPERATINGTHISUNITIS TRAINEDINTHEOPERATIONOFUNITSOFTHISTYPEANDHASHADSPECIALTRAINING TOOPERATETHISUNIT.FURTHER,ITISASSUMEDTHATTHEINDIVIDUALWILLTAKE NECESSARYPRECAUTIONSTOENSURESAFEOPERATIONFORHIMSELFANDFOR OTHERS.

THE TEXTINNOWAYCOVERSALLPOSSIBLECONTINGENCIESOROPERATING PROCEDURES.

THISGUIDEISDESIGNEDTOBEOFGENERALASSISTANCE.IFPROCEDURESOR CONDITIONSAREENCOUNTEREDWHICHARENOTINCLUDEDINTHISGUIDE,THE OPERATORSHOULDGETEXPERTASSISTANCEBEFOREATTEMPTINGTOOPERATEOR REPAIRTHEMACHINE.FORTHE BUCYRUS AMERICA,INC. SERVICEDEPARTMENT,CALL (540)980-4530.

BUCYRUS AMERICA,INC. ASSUMESNORESPONSIBILITYFORTHEPERFORMANCEOR OPERATIONOFTHISUNITIFITISALTEREDINANYMANNER.

NOTICE

SOMEILLUSTRATIONSINTHISGUIDEMAYSHOWGUARDSORCOVERSREMOVEDFOR PURPOSESOFCLARITY.NEVEROPERATEUNITWITHOUTALLGUARDSAND COVERSIN PLACE.

SOMEILLUSTRATIONSINTHISGUIDEMAYSHOWUNITSWITHOPTIONALEQUIPMENT INSTALLED.THISOPTIONALEQUIPMENTMAYBEPURCHASEDFROMYOURLOCALDBT AMERICADEALER.

SOMEILLUSTRATIONSINTHISMANUALMAYBEOFPROTOTYPEMODELS.PRODUCTION MODELSMAYVARYINSOMEDETAIL.

CONTINUINGIMPROVEMENTANDADVANCEMENTOFPRODUCTDESIGNMAYCAUSE CHANGESTOYOURMACHINEWHICHMAYNOTBEINCLUDEDINTHISPUBLICATION. EACHPUBLICATIONISREVIEWEDANDREVISED,ASREQUIRED,TOUPDATEAND INCLUDETHECHANGESINLATERADDITIONS. BUCYRUSAMERICA,INC. RESERVESTHE RIGHTTOMODIFY ORMAKECHANGESWITHINASPECIFICMODELGROUPWITHOUT NOTICEANDWITHOUTINCURRINGANYLIABILITYTORETROFITUNITSPREVIOUSLY SHIPPEDFROMTHEFACTORY.CONTACTYOUR BUCYRUSAMERICA,INC. DEALERFOR MAINTENANCETHATISNOTCOVEREDINTHISPUBLICATION.

BI000858-00

OPERATION, PREVENTIVEMAINTENANCE, TROUBLESHOOTING ANDSERVICEGUIDE MODELCH818

A6474X80

REVISION9

October2009

THISGUIDEISTOBEUSEDONLYWITHTHEMODELCH818UN-A-HAULER. OTHERMODELSINTHISSERIESMAYHAVEOPERATINGFEATURESUNLIKE THEMODELCH818.

BI000858-00

TABLEOFCONTENTS Page IMPORTANTSAFETYINSTRUCTIONS 1 MAJORHAZARDS ..................................................................................................................... 2 SAFETYPRECAUTIONSANDGUIDELINES ........................................................................... 5 OVERVIEW 5 PRE-STARTINSPECTION 5 STARTING 5 OPERATION .................................................................................................................. 5 STOPPING 6 MAINTAINANCE 6 INTRODUCTION ........................................................................................................................ 7 CONTROLSANDINDICATORS ............................................................................................... 8 BRAKERELEASEBUTTON ......................................................................................... 8 FIRESUPPRESSIONACTUATORS 8 FOOTBRAKE PEDAL 9 SPEEDSWITCH(ACCELERATOR)FOOTPEDAL 9 LIGHTSWITCHLEVER 9 MASTERSWITCHLEVER .......................................................................................... 10 BREAKERRESETLEVER 10 BATTERYCIRCUITBREAKERLEVER 11 GENERALHYDRAULICCONTROLSYSTEMINFORMATION ................................. 11 “STEERING”CONTROLLEVER 12 “EJECTOR”CONTROLLEVER .................................................................................. 12 “BATTERY”CHANGERCONTROLLEVER 14 AUTOMATICEMERGENCYBRAKES 14 OPTIONALDISCONNECTSWITCH .......................................................................... 14 OPTIONALREARTRACTIVEASSIST 14 HAZARDZONE ..................................................................................................................... 15 STARTINGPROCEDURE 16 SHUTDOWNPROCEDURE .................................................................................................. 19 BATTERYCHANGEPROCEDURE ...................................................................................... 21 GENERALMAINTENANCEINSTRUCTIONS 29 CRITICALBOLTTORQUEVALUES 30 LUBRICANTS,FLUIDSANDCAPACITIES 30 MAINTENANCECHECKLIST .................................................................................... 31 MAINTENANCECAPACITIESANDSPECIFICATIONS 32 PERIODICMAINTENANCEPROCEDURES............................................................................ 33 EVERYTHIRDSHIFT 33 ONCEPERWEEK 35 ONCEPERMONTH 42 EVERYTHREEMONTHS .......................................................................................... 45 BI000858-00

BI000858-00

TABLEOFCONTENTS(Continued) Page LUBRICATIONCHART ............................................................................................................ 50 TROUBLESHOOTINGPROCEDURES ................................................................................... 53 HYDRAULICSYSTEM ................................................................................................ 54 ACCUMULATORCHARGINGVALVE 55 BRAKES 56 HYDRAULICCYLINDERS 58 HYDRAULICPUMP 59 RELIEFVALVES ......................................................................................................... 61 REARTRACTIVEASSIST 62 TRAMGEARCASE 63 MAJORMAINTENANCEPROCEDURES CONTACTORTIPREPLACEMENT 64 DRIVEMOTOR/GEARCASEREMOVALANDREPLACEMENT................................ 65 GEARCASEANDBRAKEMODULEDISASSEMBLYANDASSEMBLY 67 PLANETARYWHEELENDREMOVALANDREPLACEMENT 68 GEARCASE/PLANETARYWHEELENDSHIMPROCEDURE .................................. 69 FALSEBOTTOM/EJECTORCYLINDERREPLACEMENT 70 ACCUMULATOROPERATIONANDPRECHARGINGPROCEDURE ....................... 72 REARHUBASSEMBLYINSPECTIONANDLUBRICATION 74 REAR(HYDRAULIC)WHEELMOTORREMOVALANDREPLACEMENT 75 TIRE/WHEELINSTALLATIONPROCEDURE......................................................................... 77 TIREANDWHEELSTRESSES 77 WHEELMOUNTINGARRANGEMENTS .................................................................... 77 PROBLEMAREAS 77 WHEELMOUNTINGTIPS 78 RECOMMENDEDWHEELMOUNTINGPROCEDURES ........................................... 79 PRECAUTIONS 79 BI000858-00

BI000858-00

IMPORTANTSAFETYINSTRUCTIONS

Thisguideprovidesimportantinformationtofamiliarizeyouwithsafeoperatingand maintenanceproceduresfortheCH818UN-A-HAULER.Eventhoughyoumaybefamiliarwith similarequipment,youMUSTreadandunderstandthis guidebeforeoperatingthisunit.

Safetyiseveryone'sbusinessandmustbeoneofyourprimaryconcerns.Knowingthe guidelinescoveredinthefollowingparagraphswillhelpprovideforyoursafety,forthesafetyof thosearoundyou,andforthemachine'sproperoperation.

LOOKFORTHESESYMBOLSWHICHPOINTOUTITEMSOFEXTREME IMPORTANCETOYOUANDYOURCO-WORKERS’SAFETY.READAND UNDERSTANDTHOROUGHLY.HEEDTHEWARNINGANDFOLLOWTHE INSTRUCTIONS.

WARNINGSAFETYNOTESMUSTBEFOLLOWED.YOURMISTAKEMIGHT RESULTINSERIOUSINJURYORDEATHTOYOURSELFOROTHERS.

CAUTIONSAFETYNOTESAREALSOVERYIMPORTANT.THEYPOINTOUTTO YOUWHEREYOURMISTAKESCOULDCAUSEPHYSICALHARMTOYOUOR OTHERS,ORDAMAGETOTHEMACHINE.

WARNING CAUTION NOTICE

NOTICEISUSEDTONOTIFYPEOPLEOFINSTALLATION,OPERATION,OR MAINTENANCEINFORMATIONWHICHISIMPORTANT BUTNOTHAZARDRELATED.

MODELCH818UN-A-HAULER BUCYRUSAMERICA, INC. 1

BI000858-00

MAJORHAZARDS

AREA HAZARD SAFEGUARDS WHEREHAZARDCAN OCCUR

WHATCANHAPPENIF PRECAUTIONSAND SAFEGUARDSARENOT OBEYED

HOWTOAVOID THEHAZARD

ENTIREMACHINE

Movementofmachinecanrun overorcrushbodyparts betweenmachineandother objectsandcauseirreparable injuryordeath.

KeepalIpeopleoutofHazard Zone(page15).Useextreme cautionwhenmovingmachine. Themachineshouldbe properlyshutdown(seepage 19)beforetheoperatorleaves theoperator'scompartment.

OPERATOR'SAREA

Operationofmachinewith head,arms,orhandsoutside ofoperator'scompartment couldcauseirreparableinjury ordeathifbodypartsstrikeor arecrushedbetweenmachine andoutsideobjects.

Keephead,arms,hands, insideoperator'scompartment atalItimes.

REARSECTION

Ejectorbladeorfalsebottom beingreturnedcouldcause irreparableinjuryordeathif bodypartsorpersonsare crushedbetweenejector blade/falsebottomandthethe rear(payload)sectionframe.

KeepalIhands,arms,legs, feetandpersonsoutfrom betweenthefrontoftherear (payload)sectionandthe ejectorblade/falsebottom. Themachinemustbeproperly shutdownforservice(seepage 19).

CENTERSECTION (ARTICULATIONPOINT)

Machinecouldbesteered crushingpersons,hands,feet, orlegsinthearticulationarea.

KeepalIpersons,hands,feet, legs,outofarticulationarea andoffthetopandoutfrom underthemachine.Machine shouldbeproperlyshutdown (page19)beforeservicing. Themachinemustalsobe blockedunderthebattery, payloadend,andcenter section.

UNDERNEATHDURING SERVICE

Machineraisedforservice couldfallandcrushpersonsor bodypartsunderneath.

Ifmachinemustberaisedfor service,itmustbesecurely blockedsothatallwheelsmay safelyturn(seemaintenance page29).Themachinemust alsobeblockedunderthe battery,payloadend,and centersection..

BUCYRUS AMERICA, INC. MODELCH818UN-A-HAULER 2

BI000858-00

MAJORHAZARDS

AREA HAZARD SAFEGUARDS WHEREHAZARDCAN OCCUR WHATCANHAPPENIF PRECAUTIONSAND SAFEGUARDSARENOT OBEYED

HOWTOAVOID THEHAZARD

ELECTRICAL (BATTERY,CONTROLLER, MOTORS,ETC.)

Electricalshockcouldcause irreparableinjuryordeath.

Theelectricalsystemshould bemaintainedbycertified electricians.Thebatteryshould bedisconnectedbefore servicingthemotorsor controller.Whenthecontroller coverisremoved,the capacitordischargeindicator shouldshowthatthe capacitorshavebeen discharged.

BATTERY

Thebatteryproduceslethal amountsofpowerwhether connectedtothemachineor not.

Thebatteryshouldbe maintainedbyqualified personnel.(Referto DBTAmerica "INSTALLATION,USE, MAINTENANCE,AND REPAIROF MINEPOWERSTORAGE BATTERIES,”PARTNUMBER A6474X26,forcomplete instructions).

Batterycoverscouldfall crushinghandsorarms. Batteryhold-downclamps couldcrushfingers.

Batteriesproduceexplosive gasesthatcouldbeignited causingburnsorexplosions. Batteriescontainstrongacid thatcouldcausesevereburns ifspilledorsplashedonbody partsorintheeyes.

Besurecoversupportsarein placewhenworkingonbattery. Keepfingersawayfromholddownclamps.

Batteriesshouldbewellvented beforeservicingparticularyif weldingorburningonthe battery.Batteriesshouldbe maintainedbyqualified personnel.

Protectiveclothing,gloves,and eyewaremustbewornwhen workingonbatteries.Batteries shouldbemaintainedby qualifiedpersonnel.

MODELCH818UN-A-HAULER BUCYRUSAMERICA, INC. 3

BI000858-00

MAJORHAZARDS

AREA HAZARD SAFEGUARDS WHEREHAZARDCAN OCCUR

WHATCANHAPPENIF PRECAUTIONSAND SAFEGUARDSARENOT OBEYED

HOWTOAVOID THEHAZARD

HYDRAULIC

IfpartofahydrauIiccircuitis removedwhilethereisaload onacylinderinthecircuit,the cylindercoulddroptheload.

Securelyblockorremoveany loadfromthecylinderbefore disconnecting.

BUCYRUS AMERICA, INC. MODELCH818UN-A-HAULER 4

BI000858-00

• 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