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BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationManual Bucyrus - UN-A-HAULER ® Model - CH816CAC Doc.No.: A6474X257 BI620982

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ThismanualisintendedtoprovideGENERALproductinformationfor theModelCH816CAC UN-A-HAULER® .Theillustrations,descriptionsandprocedurescontainedinthispublicationapplyonlytothismachine.BucyrusAmerica,Inc.reservestherighttorevisemodelsand designswithoutpriornotice.

This UN-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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BI620982

© BUCYRUSAMERICA,INC. ALLRIGHTSRESERVED

________________________________________________ Tableofcontents A6474X257 VTVI/04 ©BUCYRUSAMERICA,INC. 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 2.22

Storageandtransport Storageandtransport............................................................ 3.3 Storage 3.3 Storageofthemachineandspareparts 3.3 Transport.............................................................................. 3.4 Beforetransport 3.5

Installation Installation............................................................................... 4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation? 4.3 Whichtoolsarerequiredforinstallation?........................ 4.3 Notesoninstallation 4.4 Pre-installationchecklist 4.5 Safetyfeatures 4.6 BI620982

5. Operation

Tableofcontents _________________________________________________ BucyrusAmerica,Inc. – ModelCH816CACUN-A-HAULER® ©BUCYRUSAMERICA,INC.

Operation................................................................................. 5.3 HowtooperatetheUN-A-HAULER ® 5.3 WhoisallowedtooperatetheUN-A-HAULER ®............ 5.3 Whencanoperationbestarted? 5.3 Controlsandindicators 5.4 Operator’scompartment 5.4 Operator’scompartmentright......................................... 5.5 Lefthandcontrollever 5.9 Righthandcontrollever 5.13 Hazardzone 5.18 Startingprocedure 5.19 Machineoperation 5.20 Shutdownprocedure 5.23 Batterychangeprocedure 5.25 Instructionsonthemaintenance 5.35 Importantnotes..............................................................5.35 Beforemaintenance 5.35 Criticaltorquevalues 5.37 Lubricants,fluidsandcapacities 5.37 Specificlubricationandmaintenanceinstructions..............5.38 Everyshift 5.40 Everythirdshift ..............................................................5.40 Weekly 5.44 Everytwoweeks............................................................5.50 Monthly 5.51 HydraulicSystemOverview.....................................................5.61 MainHydraulicSystem 5.61 WhatisLoadSensing?...................................................5.61 MainPump 5.62 ControlValves.................................................................5.63 LoadEject 5.65 TankPowerFill 5.66 BatteryLiftSuspension 5.67 BrakeSystem 5.68 AuxiliaryPump 5.68 UnloadingValve 5.68 Accumulator 5.69 BrakeValves 5.69 Brakes 5.70 TwoWheelAssistHydraulicSystem 5.72 Pumps 5.72 CircuitValves 5.74 WheelMotors 5.74 OperatingtheTwoWheelAssist 5.75 Filtration ..............................................................................5.76 HydraulicOilFilters 5.76 GearOilFilters................................................................5.77 BI620982

5. Operation(continued)

________________________________________________ Tableofcontents A6474X257 VTVI/04 ©BUCYRUSAMERICA,INC.

HydraulicsAdjustmentsandSettings......................................5.79 MainSystem 5.79 MarginPressure.............................................................5.80 MainReliefValve 5.81 LoadSenseReliefValve 5.82 PressureSwitch 5.82 PressureLimiters...........................................................5.83 SequenceValve 5.84 BatteryLiftSuspension 5.85 BatteryLiftReliefValve 5.86 SteeringCylinderReliefValves 5.86 Auxiliary/BrakeSystem 5.88 AuxiliaryReliefValve 5.88 UnloadingValve 5.90 TwoWheelAssistSystem 5.90 ChargeReliefValve.......................................................5.90 AssistReliefValve 5.91 PumpDisplacementAdjustments 5.91 SpoolStrokeLimiters 5.93 LimitingSteeringSpool.......................................................5.93 TailgateGoSwitchAdjustment 5.94 Troubleshootingprocedures...............................................5.95 Hydraulicsystem(general) 5.96 Brakes............................................................................5.99 Hydrauliccylinders 5.101 Hydraulicpump............................................................5.102 Valves 5.105 Majormaintenance ...........................................................5.107 Drivemotor/gearcaseremovalandreplacement 5.107 Gearcaseandbrakemoduledisassemblyandassy..5.109 Planetarywheelendremovalandreplacement 5.111 Gearcaseandplanetarywheelendshimprocedure Number1 5.112 Gearcaseandplanetarywheelendshimprocedure Number2 5.113 Gearcaseandplanetarywheelendshimprocedure Number3(alternateprocedure) 5.115 Falsebottom/ejectorcylinderreplacement 5.117 Accumulatoroperationandprechargingprocedure 5.119 2-Wheelassistremovalprocedure 5.121 Rear(hydraulic)wheelmotorremovalandreplacement 5.122 BBC06Serieswithbrakesmechanicaldisconnect procedure 5.123 Tire/wheelinstallationprocedure.................................5.124 Recommendedwheelmountingprocedures 5.127 Hydraulicpumpandmotorremovalandreplacement.5.128 Tailgateassemblyremovalprocedure 5.129 Batteryliftassemblyremovalprocedure......................5.130 Pedalassemblyremovalprocedure 5.131 Canopyremovalprocedure..........................................5.132 BI620982

________________________________________________ Tableofcontents A6474X257 VTVI/04 ©BUCYRUSAMERICA,INC. 6. Technicaldata Technicaldata........................................................................6.3 ComponentsoftheCH816CACUN-A-HAULER ® 6.3 GaugeChart .......................................................................6.4 Tighteningtorques 6.5 Permissibledata 6.11 Lubricationfluidsandgreases 6.11 7. Foryourinformation Foryourinformation .............................................................7.3 Ourservice 7.3 Serviceaddress .............................................................7.3 Rebuildfacilityaddress 7.4 BI620982

_______________________________________________________________ 1 Aboutthismanual BI620982

________________________________________________________________ BI620982

applicableoperatingmanual machinetype

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.

Beforestartingtowork

Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.

Thisoperatingmanualisintendedfor:

BucyrusAmerica,Inc. – ModelCH816CACUN-A-HAULER® 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 A6474X257 VTVI/04 1.3 ©BUCYRUSAMERICA,INC.

newoperationmanual BI620982

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 BucyrusAmerica,Inc. – ModelCH816CACUN-A-HAULER® ©BUCYRUSAMERICA,INC.

BI620982

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 A6474X257 VTVI/04 1.5 ©BUCYRUSAMERICA,INC.

BI620982

Beforestartingtowork ________________________________________ 1.6 BucyrusAmerica,Inc. – ModelCH816CACUN-A-HAULER® ©BUCYRUSAMERICA,INC. BI620982

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BI620982

2 Yoursafety

________________________________________________________________ BI620982

furtheroperatingmanuals

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

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

stateoftheart

BI620982

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

BucyrusAmerica,Inc. – ModelCH816CACUN-A-HAULER®

training BI620982

Operatingconditions

Intendeduse

TheUN-A-HAULER ® hasbeendesignedandmanufacturedpurelyfor transportingofminedmaterialfromacontinuousminertothemain conveyingsystemfortransportingoutside.

Intendedusesinclude:

■ thetransportofminedmaterialbetweencontinuousminerand mainconveyingsystem.

Unauthorizeduse

Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.

■ thetransportofpersons

BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.

BI620982

Operatingconditions __________________________________________ 2.6 BucyrusAmerica,Inc. – ModelCH816CACUN-A-HAULER® ©BUCYRUSAMERICA,INC. BI620982

• 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