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BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA Fax:540-994-3763 Internet:www.bucyrus.com OperationManual Bucyrus - UN-A-HAULER ® Model - CH810C,CH816C,and CH816CL Doc.No.: A6474X268

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ThismanualisintendedtoprovideGENERALproductinformationfor theModelsCH810C,CH816C,andCH816CLUN-A-HAULER ® The illustrations,descriptionsandprocedurescontainedinthispublication applyonlytothesemachines.BucyrusAmerica,Inc.reservestheright torevisemodelsanddesignswithoutpriornotice.

ThisUN-A-HAULER ® wasmanufacturedundertheguidelines,proceduresandrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart0, Part75forundergroundcoalmines,andotherapplicablenon-U.S. regulatoryagencystandards.

Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofBucyrusAmerica, Inc.,andtheseregulatoryagencies,oranyrepairorreplacementof partscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidate theseapprovalsandrenderthisunitunsafetooperate.

StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.

Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusAmerica,Inc.Service Representative immediately

Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.

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© BUCYRUSAMERICA,INC. ALLRIGHTSRESERVED

________________________________________________ Tableofcontents A6474X268 VRVI/02 © B U C Y R U S A M E R I C A , I N C Tableofcontents

Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual? ................... 1.4 Charactersandsymbols 1.5

Yoursafety Yoursafety 2.3 Personnel 2.4 Operation 2.4 Installationandrepair...................................................... 2.4 Operatingconditions 2.5 Intendeduse 2.5 Unauthorizeduse 2.5 Safetyinstructions 2.7 Generalrules: 2.7 Storageandtransport 2.8 Pre-startinspection 2.8 Installationandstart-up 2.9 Operation 2.9 Stopping 2.10 Maintenanceandrepair 2.10 Overviewofthesafetyinstructions 2.15 Chapter3:Storageandtransport ..................................2.15 Chapter4:Installation 2.15 Chapter5:Operation .....................................................2.16 Chapter6:Technicaldata 2.24

Storageandtransport Storageandtransport............................................................ 3.3 Storage 3.3 Storageofthemachineandspareparts 3.3 Transport.............................................................................. 3.4 Beforetransport 3.5 4. Installation Installation............................................................................... 4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation? 4.3 Whichtoolsarerequiredforinstallation?........................ 4.3 Notesoninstallation 4.4 Pre-installationchecklist 4.5 Safetyfeatures 4.6

5. Operation

Tableofcontents _________________________________________________ BUCYRUS– ModelsCH810C,CH816C,andCH816CLUN-A-HAULER® © B U C Y R U S A M E R I C A , I N C

Operation................................................................................. 5.3 HowtooperatetheUN-A-HAULER ® 5.3 WhoisallowedtooperatetheUN-A-HAULER ®............ 5.3 Whencanoperationbestarted? 5.3 Controlsandindicators 5.4 Operator’scompartment 5.4 Generalhydrauliccontrolinformation............................5.12 Hazardzone 5.16 Startingprocedure 5.17 Machineoperation 5.18 Shutdownprocedure 5.21 Batterychangeprocedure 5.23 Instructionsonthemaintenance 5.29 Importantnotes 5.29 Beforemaintenance 5.29 Criticaltorquevalues .....................................................5.31 Lubricants,fluidsandcapacities 5.31 Specificlubricationandmaintenanceinstructions 5.34 Everythirdshift 5.34 Weekly ...........................................................................5.39 Everytwoweeks 5.44 Monthly...........................................................................5.45 Tire/wheelinstallationprocedure 5.54 Instructionsontheadjustmentprocedures.........................5.59 Mainhydraulicsystempressure 5.59 Steeringreliefpressureadjustment...............................5.60 Brakecoolingcircuitreliefpressureadjustment 5.61 Falsebottom/ejectorbladesequencevalveadjustment5.62 Tailgatesequencevalveadjustment(P/NLUP01820) 5.63 Tailgatesequencevalveadjustment(P/NLUP00781)..5.68 Tailgatesequencevalveadjustment(P/NLUP02119) 5.71 Gearcaseandplanetarywheelendshimprocedure Number1 5.75 Gearcaseandplanetarywheelendshimprocedure Number2 5.76 BrakepedalvalveandHDCactuatoradjustment 5.78 Linearpedaladjustment 5.81 Majormaintenance 5.83 Drivemotor/gearcaseremovalandreplacement 5.83 Gearcase&brakemoduledisassembly/assembly 5.85 Planetarywheelendremoval/replacement 5.87 Gearcaseandplanetarywheelendshimming procedure1 5.88 Gearcaseandplanetarywheelendshimming procedure2....................................................................5.89 Gearcaseandplanetarywheelendshimming procedure3....................................................................5.91 Falsebottom/ejectorcylinderreplacement 5.93 Accumulatoroperationandprechargingprocedure ......5.95 2-wheelassistpumpremovalprocedure 5.97 Rearwheelmotorremoval/replacement........................5.98

________________________________________________ Tableofcontents A6474X268 VRVI/02 © B U C Y R U S A M E R I C A , I N C BBC06serieswithbrakesmechanicaldisconnect procedure 5.99 Tire/wheelinstallationprocedure 5.100 Recommendedwheelmountingprocedure 5.102 Hydraulicpump&motorremoval/replacement 5.104 Tailgateassemblyremovalprocedure.........................5.105 Batteryliftassemblyremovalprocedure 5.106 Pedalassemblyremovalprocedure 5.107 Canopyremovalprocedure 5.108 6. Technicaldata Technicaldata......................................................................... 6.3 ComponentsoftheCH810CUN-A-HAULER ® 6.3 ComponentsoftheCH816CUN-A-HAULER ® 6.4 ComponentsoftheCH816CLUN-A-HAULER ® 6.5 Tighteningtorques 6.7 Permissibledata .................................................................6.13 Lubricationfluidsandgreases 6.13 7. Foryourinformation Foryourinformation 7.3 Ourservice 7.3 Serviceaddress .............................................................. 7.3 Rebuildfacilityaddress 7.4

Tableofcontents _________________________________________________

ModelsCH810C,CH816C,andCH816CLUN-A-HAULER® © B U C Y R U S A M E R I C A , I N C

BUCYRUS–

_______________________________________________________________ 1 Aboutthismanual

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applicableoperatingmanual machinetype

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.

Beforestartingtowork

Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.

Thisoperatingmanualisintendedfor:

BUCYRUS – ModelCH810C,CH816C,andCH816CL SerialNo.:N/A

andisonlypermittedtobeusedforequipmentofthistype.

Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine. Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.

Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.

Whoisthisoperatingmanualintendedfor?

Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.

Everypersonworkingonthefaceorintheintersectionbetweenface andentryorintheentrymustreadthisoperatingmanual.

Thisincludespersonswho:

■ areinchargeoftransport

■ preparetheriseheading

■ performassembly/disassemblywork

■ operatethemachine

■ eliminatefaults

■ performdailyroutineworkonthefaceorintheentry

■ performmaintenancework

■ performrepairwork

supervisorypersonnelwho:

■ initiateand/or

■ supervisetheactivitiesjustindicated.

_______________________________________ Beforestartingtowork A6474X268 VRVI/02 1.3 © B U C Y R U S A M E R I C A , I N C

newoperationmanual

cost-effectiveness

Whatisthepurposeofthisoperatingmanual?

Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.

Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.

service safety

Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.

Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.

Beforestartingtowork ________________________________________ 1.4 BUCYRUS – ModelsCH810C,CH816C,andCH816CLUN-A-HAULER® © B U C Y R U S A M E R I C A , I N C

Charactersandsymbolsused

Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.

Trytomemorizethesymbolsandtheirmeanings.

DANGER!

Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.

WARNING!

Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.

CAUTION!

Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.

NOTICE!

Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.

IMPORTANT!

Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.

■ Itemsinlistsaremarkedwithbullets.

– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.

 Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.

_______________________________________ Beforestartingtowork A6474X268 VRVI/02 1.5 © B U C Y R U S A M E R I C A , I N C

Beforestartingtowork ________________________________________ 1.6 BUCYRUS – ModelsCH810C,CH816C,andCH816CLUN-A-HAULER® © B U C Y R U S A M E R I C A , I N C

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2 Yoursafety

________________________________________________________________

stateoftheart

Yoursafety

Thischapterprovidesvitalinformationforyoursafety. Payspecialattentiontothischapter.Thesafetyinstructionsandrules ofprocedurewillhelpyoutoavoidhazardoussituationsandtoperform thenecessaryworkassafelyaspossible.

Themachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. Youandotherscanneverthelessbeexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.

Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.AllmodificationsandchangesmustbeapprovedbyBucyrusAmerica,Inc.

UseonlyoriginalsparepartsfromBucyrusAmerica,Inc.Notethatthe useofpartsfromothermanufacturerswillvoidtheguarantee.

Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.

Observethesafetyandaccidentpreventionregulations:

■ ofthemine.

■ oftheMinesInspectorand

■ oftheminingsupervisoryauthorities

furtheroperatingmanuals

Pleasereadalsotheoperatingmanualsofthecomponentsrequiredfor operation,e.g.ofgearboxes,electricmotors,etc.,carefullyandthoroughly.Clarifyanyquestions before startingwork.

training

Personnel

Operation

Themachinemayonlybeoperatedbyqualified,trainedpersonnel.

Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit. Readingoftheoperationmanual,especiallythechapteronsafety,shall constituteapartofthistraining.

Youmusthaveadequateknowledgeofthe

■ mechanics,

■ hydraulicsand

■ controlengineering andmustbeabletoprovethisknowledge.

Installationandrepair

Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.

Installationandrepairworkon:

■ safetycomponents(pressurereliefvalves,extinguishers,etc.)

■ theelectrics(motors,controllers,etc.)

■ thehydraulics(controls,cylinders,etc.) mayonlybecarriedoutbyserviceengineersfromBucyrusAmerica, Inc.orbyspeciallyqualifiedpersonnelofthemine.

Personnel ___________________________________________________

2.4 BUCYRUS –

ModelsCH810C,CH816C,andCH816CLUN-A-HAULER®

Operatingconditions

Intendeduse

TheUN-A-HAULER ® hasbeendesignedandmanufacturedpurelyfor transportingofminedmaterialfromacontinuousminertothemain conveyingsystemfortransportingoutside.

Intendedusesinclude:

■ thetransportofminedmaterialbetweencontinuousminerand mainconveyingsystem.

Unauthorizeduse

Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.

■ thetransportofpersons

BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.

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Operatingconditions

Operatingconditions __________________________________________

2.6 BUCYRUS – ModelsCH810C,CH816C,andCH816CLUN-A-HAULER®

• 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