Technical Manual
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BI620963
BUCYRUS
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NOTICE OPERATION, PREVENTIVEMAINTENANCE, TROUBLESHOOTING ANDSERVICEGUIDE MODELCH818 W/LA2000 CHINA A6474X241 THISGUIDECONTAINSIMPORTANTOPERATIONANDSAFETYINFORMATIONANDSHOULDBE KEPTAVAILABLETOTHOSEPERSONNELINSTALLINGANDOPERATINGTHISEQUIPMENT. BI620963
NOTICE
THISGUIDEISNOTINTENDEDTOBEACOMPLETEOPERATINGORSERVICE MANUALORGUIDE.ITISPREPAREDONTHEBASISTHATTHEINDIVIDUAL OPERATINGTHISUNITISTRAINEDIN THEOPERATIONOFUNITSOFTHISTYPE ANDHASHADSPECIALTRAININGTOOPERATETHISUNIT.FURTHER,ITIS ASSUMEDTHATTHEINDIVIDUALWILLTAKENECESSARYPRECAUTIONSTO ENSURESAFEOPERATIONFORHIMSELFANDFOROTHERS.
THETEXTINNOWAYCOVERSALLPOSSIBLE CONTINGENCIESOROPERATING PROCEDURES.
THISGUIDEISDESIGNEDTOBEOFGENERALASSISTANCE.IFPROCEDURESOR CONDITIONSAREENCOUNTEREDWHICHARENOTINCLUDEDINTHISGUIDE,THE OPERATORSHOULDGETEXPERTASSISTANCEBEFOREATTEMPTINGTO OPERATEORREPAIR THEMACHINE.FORTHEDBTAMERICAINC.SERVICE DEPARTMENT,CALL(540)980-4530.
DBTAMERICAINC.ASSUMESNORESPONSIBILITYFORTHEPERFORMANCEOR OPERATIONOFTHISUNITIFITISALTEREDINANYMANNER.
NOTICE
SOMEILLUSTRATIONSINTHISGUIDEMAYSHOWGUARDSORCOVERS REMOVEDFORPURPOSESOFCLARITY.NEVEROPERATEUNITWITHOUTALL GUARDSANDCOVERSINPLACE.
SOMEILLUSTRATIONSINTHISGUIDEMAYSHOWUNITSWITHOPTIONAL EQUIPMENTINSTALLED.THISOPTIONALEQUIPMENTMAYBEPURCHASED FROMYOURLOCAL DBTAMERICAINC.DEALER.
SOMEILLUSTRATIONSINTHISMANUALMAYBEOFPROTOTYPEMODELS. PRODUCTIONMODELSMAYVARYINSOMEDETAIL.
CONTINUINGIMPROVEMENTANDADVANCEMENTOFPRODUCTDESIGNMAY CAUSECHANGESTOYOURMACHINEWHICHMAYNOTBEINCLUDEDINTHIS PUBLICATION.EACHPUBLICATIONISREVIEWEDANDREVISED,ASREQUIRED, TOUPDATEANDINCLUDETHECHANGESINLATERADDITIONS.DBTAMERICA INC.RESERVESTHERIGHTTOMODIFYORMAKECHANGESWITHINASPECIFIC MODELGROUPWITHOUTNOTICEANDWITHOUTINCURRINGANYLIABILITYTO RETROFITUNITSPREVIOUSLYSHIPPEDFROMTHEFACTORY.CONTACTYOUR DBTAMERICAINC.DEALERFORMAINTENANCETHATISNOTCOVEREDINTHIS PUBLICATION.
BI620963
OPERATION, PREVENTIVEMAINTENANCE, TROUBLESHOOTING ANDSERVICEGUIDE MODELCH818 W/LA2000 CHINA
A6474X241 REVISION0
JULY,2004 DBTAMERICAINC. 4041WURNOROAD PULASKI,VA24301
THISGUIDEISTOBEUSEDONLYWITHTHEMODELCH818UN-A-HAULER. OTHERMODELSINTHISSERIESMAYHAVEOPERATINGFEATURESUNLIKE THEMODELCH818.
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TABLEOFCONTENTS Page IMPORTANTSAFETYINSTRUCTIONS 1 MAJORHAZARDS ..................................................................................................................... 2 SAFETYPRECAUTIONSANDGUIDELINES ........................................................................... 5 OVERVIEW 5 PRE-STARTINSPECTION 5 STARTING 5 OPERATION .................................................................................................................. 5 STOPPING 6 MAINTAINANCE 6 INTRODUCTION ........................................................................................................................ 7 CONTROLSANDINDICATORS ............................................................................................... 9 BRAKERELEASEBUTTON ......................................................................................... 9 FIRESUPPRESSIONACTUATORS 9 FOOTBRAKEPEDAL 10 SPEEDSWITCH(ACCELERATOR)FOOTPEDAL 10 PUMPSTARTBUTTON 10 LIGHTSWITCHLEVER ............................................................................................... 10 MASTERSWITCHLEVER 11 BREAKERRESETLEVER 11 BATTERYCIRCUITBREAKERLEVER ...................................................................... 12 GENERALHYDRAULICCONTROLSYSTEMINFORMATION 12 “STEERING”CONTROLLEVER ................................................................................ 13 “EJECTOR”CONTROLLEVER 13 “BATTERY”CHANGERCONTROLLEVER 15 AUTOMATICEMERGENCYBRAKES ........................................................................ 15 OPTIONALDISCONNECTSWITCH 15 OPTIONALREARTRACTIVEASSIST ........................................................................ 15 HAZARDZONE 16 STARTINGPROCEDURE ..................................................................................................... 17 SHUTDOWNPROCEDURE ................................................................................................... 21 BATTERYCHANGEPROCEDURE(VERTICALLIFT) ........................................................ 23 BATTERYCHANGEPROCEDURE(GROUNDLEVEL) ...................................................... 31 GENERALMAINTENANCEINSTRUCTIONS 35 CRITICALBOLTTORQUEVALUES 36 LUBRICANTS,FLUIDSANDCAPACITIES 36 MAINTENANCECHECKLIST .................................................................................... 37 MAINTENANCECAPACITIESANDSPECIFICATIONS 36 BI620963
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Page PERIODICMAINTENANCEPROCEDURES............................................................................ 39 EVERYTHIRDSHIFT 39 ONCEPERWEEK ..................................................................................................... 41 ONCEPERMONTH 46 EVERYTHREEMONTHS 49 LUBRICATIONCHART ............................................................................................................ 55 TROUBLESHOOTINGPROCEDURES ................................................................................... 57 HYDRAULICSYSTEM ................................................................................................ 58 ACCUMULATORCHARGINGVALVE 59 BRAKES 60 HYDRAULICCYLINDERS 62 HYDRAULICPUMP 63 RELIEFVALVES ......................................................................................................... 65 REARTRACTIVEASSIST 66 TRAMGEARCASE 67 MAJORMAINTENANCEPROCEDURES................................................................................. 69 DRIVEMOTOR/GEAR CASEREMOVALANDREPLACEMENT 69 GEARCASEANDBRAKEMODULEDISASSEMBLYANDASSEMBLY .................... 71 PLANETARYWHEELENDREMOVALANDREPLACEMENT 72 GEARCASE/PLANETARYWHEELENDSHIMPROCEDURE 73 FALSEBOTTOM/EJECTORCYLINDERREPLACEMENT ......................................... 74 ACCUMULATOROPERATIONANDPRECHARGINGPROCEDURE 76 REARHUBASSEMBLYINSPECTIONANDLUBRICATION ...................................... 78 REAR(HYDRAULIC)WHEELMOTORREMOVALANDREPLACEMENT 79 TIRE/WHEELINSTALLATIONPROCEDURE......................................................................... 81 TIREANDWHEELSTRESSES .................................................................................. 81 WHEELMOUNTINGARRANGEMENTS 81 PROBLEMAREAS 81 WHEELMOUNTINGTIPS 82 RECOMMENDEDWHEELMOUNTINGPROCEDURES 83 PRECAUTIONS ............................................................................................................ 83 BI620963
TABLEOFCONTENTS(Continued)
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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 MAINTENANCEINFORMATIONWHICHISIMPORTANTBUTNOTHAZARDRELATED.
MODELCH818UN-A-HAULER DBTAMERICAINC. 1
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MAJORHAZARDS
AREA HAZARD SAFEGUARDS WHEREHAZARDCAN OCCUR
WHATCANHAPPENIF PRECAUTIONSAND SAFEGUARDSARENOT OBEYED
HOWTOAVOID THEHAZARD
ENTIREMACHINE
Movementofmachinecanrun overorcrushbodyparts betweenmachineandother objectsandcauseirreparable injuryordeath.
KeepalIpeopleoutofHazard Zone(page16).Useextreme cautionwhenmovingmachine. Themachineshouldbe properlyshutdown(seepage 21)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/falsebottomandtherear (payload)sectionframe.
KeepalIhands,arms,legs, feetandpersonsoutfrom betweenthefrontoftherear (payload)sectionandthe ejectorblade/falsebottom. Themachinemustbeproperly shutdownforservice(see page21).
CENTERSECTION (ARTICULATIONPOINT)
Machinecouldbesteered crushingpersons,hands,feet, orlegsinthearticulationarea.
KeepalIpersons,hands,feet, legs,outofarticulationarea andoffthetopandoutfrom underthemachine.Machine shouldbeproperlyshutdown (page21)beforeservicing. Themachinemustalsobe blockedunderthebattery, payloadend,andcenter section.
UNDERNEATHDURING SERVICE
Machineraisedforservice couldfallandcrushpersonsor bodypartsunderneath.
Ifmachinemustberaisedfor service,itmustbesecurely blockedsothatallwheelsmay safelyturn(seemaintenance page35).Themachinemust alsobeblockedunderthe battery,payloadend,and centersection.
DBTAMERICAINC. MODELCH818UN-A-HAULER 2
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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,allowa minimumofoneminutefor capacitorstodischarge.
BATTERY
Thebatteryproduceslethal amountsofpowerwhether connectedtothemachineor not.
Thebatteryshould be maintainedbyqualified personnel.(Referto DBTAmericaInc. "INSTALLATION,USE, MAINTENANCE,AND REPAIROF MINEPOWERSTORAGE BATTERIES,”PARTNUMBER A6474X26MC,forcomplete instructions).
Batterycoverscouldfall crushinghandsorarms.
Batteryhold-downclamps couldcrushfingers.
Batteriesproduceexplosive gasesthatcouldbeignited causingburnsorexplosions.
Besurecoversupportsarein placewhenworkingonbattery. Keepfingersaway fromholddownclamps.
Batteriesshouldbewellvented beforeservicingparticularlyif weldingorburningonthe battery.Batteriesshouldbe maintainedbyqualified personnel.
Batteriescontainstrongacid thatcouldcausesevereburns ifspilledorsplashedonbody partsorintheeyes.
Protectiveclothing,gloves,and eyewearmustbewornwhen workingonbatteries.Batteries shouldbemaintainedby qualifiedpersonnel.
MODELCH818UN-A-HAULER DBTAMERICAINC. 3
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MAJORHAZARDS
AREA HAZARD SAFEGUARDS WHEREHAZARDCAN OCCUR
WHATCANHAPPENIF PRECAUTIONSAND SAFEGUARDSARENOT OBEYED
HOWTOAVOID THEHAZARD
HYDRAULIC
Ifpartofa hydrauliccircuitis removedwhilethereisaload onacylinderinthecircuit,the cylindercoulddroptheload.
Securelyblockorremoveany loadfromthecylinderbefore disconnecting.
DBTAMERICAINC. MODELCH818UN-A-HAULER 4
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• 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
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
