Technical Manual
© Bucyrus All Rights Reserved
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BI000857
BUCYRUS
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NOTICE
A6474X96 THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. BI000857
OPERATION, PREVENTIVE MAINTENANCE, TROUBLESHOOTING AND SERVICE GUIDE MODEL CH810
NOTICE
THIS GUIDE IS NOT INTENDED TO BE A COMPLETE OPERATING OR SERVICE MANUAL OR GUIDE. IT IS PREPARED ON THE BASIS THAT THE INDIVIDUAL OPERATING THIS UNIT IS TRAINED IN THE OPERATION OF UNITS OF THIS TYPE AND HAS HAD SPECIAL TRAINING TO OPERATE THIS UNIT. FURTHER, IT IS ASSUMED THAT THE INDIVIDUAL WILL TAKE NECESSARY PRECAUTIONS TO ENSURE SAFE OPERATION FOR HIMSELF AND FOR OTHERS.
THE TEXT IN NO WAY COVERS ALL POSSIBLE CONTINGENCIES OR OPERATING PROCEDURES.
THIS GUIDE IS DESIGNED TO BE OF GENERAL ASSISTANCE. IF PROCEDURES OR CONDITIONS ARE ENCOUNTERED WHICH ARE NOT INCLUDED IN THIS GUIDE, THE OPERATOR SHOULD GET EXPERT ASSISTANCE BEFORE ATTEMPTING TO OPERATE OR REPAIR THE MACHINE. FOR THE DBT AMERICA SERVICE DEPARTMENT, CALL (540) 9804530.
DBT AMERICA INC. ASSUMES NO RESPONSIBILITY FOR THE PERFORMANCE OR OPERATION OF THIS UNIT IF IT IS ALTERED IN ANY MANNER.
NOTICE
SOME ILLUSTRATIONS IN THIS GUIDE MAY SHOW GUARDS OR COVERS REMOVED FOR PURPOSES OF CLARITY. NEVER OPERATE UNIT WITHOUT ALL GUARDS AND COVERS IN PLACE.
SOME ILLUSTRATIONS IN THIS GUIDE MAY SHOW UNITS WITH OPTIONAL EQUIPMENT INSTALLED. THIS OPTIONAL EQUIPMENT MAY BE PURCHASED FROM YOUR LOCAL DBT AMERICA DEALER.
SOME ILLUSTRATIONS IN THIS MANUAL MAY BE OF PROTOTYPE MODELS. PRODUCTION MODELS MAY VARY IN SOME DETAIL.
CONTINUING IMPROVEMENT AND ADVANCEMENT OF PRODUCT DESIGN MAY CAUSE CHANGES TO YOUR MACHINE WHICH MAY NOT BE INCLUDED IN THIS PUBLICATION. EACH PUBLICATION IS REVIEWED AND REVISED, AS REQUIRED, TO UPDATE AND INCLUDE THE CHANGES IN LATER ADDITIONS. DBT AMERICA RESERVES THE RIGHT TO MODIFY OR MAKE CHANGES WITHIN A SPECIFIC MODEL GROUP WITHOUT NOTICE AND WITHOUT INCURRING ANY LIABILITY TO RETROFIT UNITS PREVIOUSLY SHIPPED FROM THE FACTORY. CONTACT YOUR DBT AMERICA DEALER FOR MAINTENANCE THAT IS NOT COVERED IN THIS PUBLICATION.
BI000857
OPERATION, PREVENTIVE MAINTENANCE, TROUBLESHOOTING AND SERVICE GUIDE
MODEL CH810
A6474X96
Revision 6
May 2004
THIS GUIDE IS TO BE USED ONLY WITH THE MODEL CH810 UN-A-HAULER. OTHER MODELS IN THIS SERIES MAY HAVE OPERATING FEATURES UNLIKE THE MODEL CH810.
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TABLE OF CONTENTS Page IMPORTANT SAFETY INSTRUCTIONS .....................................................................................1 MAJOR HAZARDS .................................................................................................................... 2 SAFETY PRECAUTIONS AND GUIDELINES .......................................................................... 5 OVERVIEW ................................................................................................................... 5 PRE-START INSPECTION ........................................................................................... 5 STARTING ..................................................................................................................... 5 OPERATION ................................................................................................................. 5 STOPPING .................................................................................................................... 6 MAINTAINANCE ........................................................................................................... 6 INTRODUCTION ........................................................................................................................ 7 CONTROLS AND INDICATORS ............................................................................................... 8 BRAKE RELEASE BUTTON ......................................................................................... 8 FIRE SUPPRESSION ACTUATORS ............................................................................ 8 FOOT BRAKE PEDAL ................................................................................................... 9 SPEED SWITCH (ACCELERATOR) FOOT PEDAL ..................................................... 9 LIGHT SWITCH LEVER ................................................................................................ 9 MASTER SWITCH LEVER .......................................................................................... 10 BREAKER RESET LEVER .......................................................................................... 11 BATTERY CIRCUIT BREAKER LEVER ..................................................................... 11 GENERAL HYDRAULIC CONTROL SYSTEM INFORMATION ................................ 12 “STEERING” CONTROL LEVER ................................................................................ 12 “EJECTOR” CONTROL LEVER .................................................................................. 14 “BATTERY” CHANGER CONTROL LEVER ............................................................... 14 AUTOMATIC EMERGENCY BRAKES ....................................................................... 14 OPTIONAL DISCONNECT SWITCH .......................................................................... 15 OPTIONAL REAR TRACTIVE ASSIST ....................................................................... 15 HAZARD ZONE ..................................................................................................................... 17 STARTING PROCEDURE ..................................................................................................... 18 SHUTDOWN PROCEDURE .................................................................................................. 21 BATTERY CHANGE PROCEDURE ..................................................................................... 23 GENERAL MAINTENANCE INSTRUCTIONS ..................................................................... 30 CRITICAL BOLT TORQUE VALUES .......................................................................... 31 LUBRICANTS, FLUIDS AND CAPACITIES ................................................................ 32 MAINTENANCE CHECK LIST .................................................................................... 33 MAINTENANCE CAPACITIES AND SPECIFICATIONS ............................................ 34 PERIODIC MAINTENANCE PROCEDURES........................................................................... 35 EVERY THIRD SHIFT ................................................................................................. 35 ONCE PER WEEK ..................................................................................................... 37 ONCE PER MONTH .................................................................................................... 44 EVERY THREE MONTHS .......................................................................................... 47 BI000857
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OF CONTENTS (Continued) Page LUBRICATION CHART ........................................................................................................... 52 TROUBLESHOOTING PROCEDURES .................................................................................. 54 HYDRAULIC SYSTEM ................................................................................................ 55 ACCUMULATOR CHARGING VALVE ........................................................................ 56 BRAKES ...................................................................................................................... 57 HYDRAULIC CYLINDERS .......................................................................................... 59 HYDRAULIC PUMP .................................................................................................... 60 RELIEF VALVES ......................................................................................................... 62 REAR TRACTIVE ASSIST .......................................................................................... 63 TRAM GEAR CASE .................................................................................................... 64 MAJOR MAINTENANCE PROCEDURES................................................................................65 VERTICAL ARTICULATION CYLINDER REMOVAL...................................................65 CONTACTOR TIP REPLACEMENT.............................................................................67 DRIVE MOTOR/GEAR CASE REMOVAL AND REPLACEMENT...............................68 GEAR CASE AND BRAKE MODULE DISASSEMBLY AND ASSEMBLY...................70 PLANETARY WHEEL END REMOVAL AND REPLACEMENT...................................71 GEAR CASE/PLANETARY WHEEL END SHIM PROCEDURE .................................72 FALSE BOTTOM/EJECTOR CYLINDER REPLACEMENT ........................................74 ACCUMULATOR OPERATION AND PRECHARGING PROCEDURE ......................76 REAR HUB ASSEMBLY INSPECTION AND LUBRICATION .....................................78 REAR (HYDRAULIC) WHEEL MOTOR REMOVAL AND REPLACEMENT ...............79 TIRE/WHEEL INSTALLATION PROCEDURE ......................................................................... 81 TIRE AND WHEEL STRESSES .................................................................................. 81 WHEEL MOUNTING ARRANGEMENTS .................................................................... 81 PROBLEM AREAS ...................................................................................................... 81 WHEEL MOUNTING TIPS .......................................................................................... 82 RECOMMENDED WHEEL MOUNTING PROCEDURES .......................................... 83 PRECAUTIONS ........................................................................................................... 83 BI000857
TABLE
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IMPORTANT SAFETY INSTRUCTIONS
This guide provides important information to familiarize you with safe operating and maintenance procedures for the CH810 UN-A-HAULER. Even though you may be familiar with similar equipment, you MUST read and understand this guide before operating this unit.
Safety is everyone's business and must be one of your primary concerns. Knowing the guidelines covered in the following paragraphs will help provide for your safety, for the safety of those around you, and for the machine's proper operation.
LOOK FOR THESE SYMBOLS WHICH POINT OUT ITEMS OF EXTREME IMPORTANCE TO YOU AND YOUR CO-WORKERS’ SAFETY. READ AND UNDERSTAND THOROUGHLY. HEED THE WARNING AND FOLLOW THE INSTRUCTIONS.
WARNING CAUTION
WARNING SAFETY NOTES MUST BE FOLLOWED. YOUR MISTAKE MIGHT RESULT IN SERIOUS INJURY OR DEATH TO YOURSELF OR OTHERS.
CAUTION SAFETY NOTES ARE ALSO VERY IMPORTANT. THEY POINT OUT TO YOU WHERE YOUR MISTAKES COULD CAUSE PHYSICAL HARM TO YOU OR OTHERS, OR DAMAGE TO THE MACHINE.
NOTICE
NOTICE IS USED TO NOTIFY PEOPLE OF INSTALLATION, OPERATION, OR MAINTENANCE INFORMATION WHICH IS IMPORTANT BUT NOT HAZARDRELATED.
MODEL CH810 UN-A-HAULER DBT AMERICA INC. 1
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MAJOR HAZARDS
AREA HAZARD SAFEGUARDS WHERE HAZARD CAN OCCUR WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED
HOW TO AVOID THE HAZARD
ENTIRE MACHINE
Movement of machine can run over or crush body parts between machine and other objects and cause irreparable injury or death.
Keep alI people out of Hazard Zone (page 17). Use extreme caution when moving machine. The machine should be properly shutdown (see page 21) before the operator leaves the operator's compartment.
OPERATOR'S AREA
Operation of machine with head, arms, or hands outside of operator's compartment could cause irreparable injury or death if body parts strike or are crushed between machine and outside objects.
Keep head, arms, hands, inside operator's compartment at alI times.
REAR SECTION
Ejector blade or false bottom being returned could cause irreparable injury or death if body parts or persons are crushed between ejector blade/false bottom and the the rear (payload) section frame.
Keep alI hands, arms, legs, feet and persons out from between the front of the rear (payload) section and the ejector blade/false bottom. The machine must be properly shutdown for service (see page 21).
CENTER SECTION (ARTICULATION POINT)
Machine could be steered crushing persons, hands, feet, or legs in the articulation area.
Keep alI persons, hands, feet, legs, out of articulation area and off the top and out from under the machine. Machine should be properly shutdown (page 21) before servicing. The machine must also be blocked under the battery, payload end, and center section.
UNDERNEATH DURING SERVICE
Machine raised for service could falland crush persons or body parts underneath.
If machine must be raised for service, it must be securely blocked so that all wheels may safely turn (see maintenance page 30). The machine must also be blocked under the battery, payload end, and center section..
DBT AMERICA INC. MODEL CH810 UN-A-HAULER 2
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MAJOR HAZARDS
AREA HAZARD SAFEGUARDS WHERE HAZARD CAN OCCUR WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED
HOW TO AVOID THE HAZARD
ELECTRICAL (BATTERY, CONTROLLER, MOTORS, ETC.)
Electrical shock could cause irreparable injury or death.
The electrical system should be maintained by certified electricians. The battery should be disconnected before servicing the motors or controller. When the controller cover is removed, the capacitor discharge indicator should show that the capacitors have been discharged.
BATTERY The battery produces lethal amounts of power whether connected to the machine or not.
The battery should be maintained by qualified personnel. (Refer to DBT America "INSTALLATION, USE, MAINTENANCE, AND REPAIR OF MINE POWER STORAGE BATTERIES,” PART NUMBER A6474X26, for complete instructions).
Battery covers could fall crushing hands or arms.
Battery hold-down clamps could crush fingers.
Batteries produce explosive gases that could be ignited causing burns or explosions. Batteries contain strong acid that could cause severe burns if spilled or splashed on body parts or in the eyes.
Be sure cover supports are in place when working on battery.
Keep fingers away fromholddown clamps.
Batteries should be well vented before servicing particulary if welding or burning on the battery. Batteries should be maintained by qualified personnel.
Protective clothing, gloves, and eyeware must be worn when working on batteries. Batteries should be maintained by qualified personnel.
MODEL CH810 UN-A-HAULER DBT AMERICA INC. 3
BI000857
• 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
