CAT Bucyrus CH810C, CH816C & CH816CL Operation Manual A6474X268 - PDF DOWNLOAD

Operation Manual BUCYRUS - UN-A-HAULER ® Model - CH810C, CH816C, and CH816CL Doc. No.:

A6474X268

Bucyrus America, Inc. ________________________________________ 4041 Wurno Road Pulaski, VA

Telephone: 540-980-4530 Fax: 540-994-3763

Internet: www.bucyrus.com

__________________________________________________________

This manual is intended to provide GENERAL product information for the Models CH810C, CH816C, and CH816CL UN-A-HAULER ® The illustrations, descriptions and procedures contained in this publication apply only to these machines. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This UN-A-HAULER ® was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U.S. regulatory agency standards.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Bucyrus America, Inc., and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© BUCYRUS AMERICA , INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

Table of contents 1. About this manual About this manual .................................................................. 1.3 Before starting to work ......................................................... 1.3 Who is this operating manual intended for? ........................ 1.3 What is the purpose of this operating manual? ................... 1.4 Characters and symbols ...................................................... 1.5

2. Your safety

© BUCYRUS AMERICA, INC.

Your safety .............................................................................. 2.3 Personnel............................................................................. 2.4 Operation ........................................................................ 2.4 Installation and repair...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use ................................................................... 2.5 Unauthorized use............................................................ 2.5 Safety instructions................................................................ 2.7 General rules: ................................................................. 2.7 Storage and transport ..................................................... 2.8 Pre-start inspection ......................................................... 2.8 Installation and start-up................................................... 2.9 Operation ........................................................................ 2.9 Stopping .........................................................................2.10 Maintenance and repair .................................................2.10 Overview of the safety instructions .....................................2.15 Chapter 3: Storage and transport ..................................2.15 Chapter 4: Installation ....................................................2.15 Chapter 5: Operation .....................................................2.16 Chapter 6: Technical data..............................................2.21

3. Storage and transport Storage and transport ............................................................ 3.3 Storage ................................................................................ 3.3 Storage of the machine and spare parts......................... 3.3 Transport.............................................................................. 3.4 Before transport .............................................................. 3.5

4. Installation Installation ............................................................................... 4.3 Points to observe prior to installation................................... 4.3 Who is allowed to carry out installation?......................... 4.3 Which tools are required for installation?........................ 4.3 Notes on installation........................................................ 4.4 Pre-installation check list ................................................ 4.5 Safety features ................................................................ 4.6

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Table of contents _________________________________________________

Operation ................................................................................. 5.3 How to operate the UN-A-HAULER ® .................................. 5.3 Who is allowed to operate the UN-A-HAULER ® ............ 5.3 When can operation be started?..................................... 5.3 Controls and indicators ........................................................ 5.4 Operator’s compartment ................................................. 5.4 General hydraulic control information ............................5.12 Hazard zone........................................................................5.16 Starting procedure ..............................................................5.17 Machine operation .........................................................5.18 Shutdown procedure...........................................................5.21 Battery change procedure ..................................................5.23 Instructions on the maintenance.........................................5.29 Important notes ..............................................................5.29 Before maintenance.......................................................5.29 Critical torque values .....................................................5.31 Lubricants, fluids and capacities ....................................5.31 Specific lubrication and maintenance instructions ..............5.34 Every third shift ..............................................................5.34 Weekly ...........................................................................5.39 Every two weeks ............................................................5.44 Monthly...........................................................................5.45 Tire/wheel installation procedure ...................................5.54 Instructions on the adjustment procedures.........................5.59 Main hydraulic system pressure ....................................5.59 Steering relief pressure adjustment ...............................5.60 Brake cooling circuit relief pressure adjustment ............5.61 False bottom/ejector blade sequence valve adjustment 5.62 Tailgate sequence valve adjustment (P/N LUP01820) ..5.63 Tailgate sequence valve adjustment (P/N LUP00781) ..5.68 Tailgate sequence valve adjustment (P/N LUP02119) ..5.71 Gear case and planetary wheel end shim procedure Number 1 .......................................................................5.75 Gear case and planetary wheel end shim procedure Number 2 .......................................................................5.76 Brake pedal valve and HDC actuator adjustment..........5.78 Linear pedal adjustment.................................................5.81

6. Technical data Technical data ......................................................................... 6.3 Components of the CH810C UN-A-HAULER ® ................... 6.3 Components of the CH816C UN-A-HAULER ® ................... 6.5 Components of the CH816CL UN-A-HAULER ® ................. 6.7 Tightening torques ............................................................... 6.9 Permissible data .................................................................6.15 Lubrication fluids and greases .......................................6.15

_________________________________________________________________ BUCYRUS– Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

5. Operation

________________________________________________ Table of contents 7. For your information

© BUCYRUS AMERICA, INC.

For your information .............................................................. 7.3 Our service........................................................................... 7.3 Service address .............................................................. 7.3 Rebuild facility address ................................................... 7.4

________________________________________________________________ A6474X268

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© BUCYRUS AMERICA, INC.

Table of contents _________________________________________________

_________________________________________________________________ BUCYRUS– Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

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1

About this manual

________________________________________________________________

________________________________________________________________

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_______________________________________ Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual

machine type

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

This operating manual is intended for: BUCYRUS – Model CH810C, CH816C, and CH816CL Serial No.: N/A and is only permitted to be used for equipment of this type.

© BUCYRUS AMERICA, INC.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine.

It should, if possible, always be available at the place of operation.

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine.

Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who: ■ ■ ■ ■ ■ ■ ■ ■

are in charge of transport prepare the rise heading perform assembly / disassembly work operate the machine eliminate faults perform daily routine work on the face or in the entry perform maintenance work perform repair work

supervisory personnel who: ■ ■

initiate and/or supervise the activities just indicated.

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Before starting to work ________________________________________ What is the purpose of this operating manual? cost-effectiveness

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

© BUCYRUS AMERICA, INC.

service

_________________________________________________________________ 1.4 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

_______________________________________ Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

© BUCYRUS AMERICA, INC.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

■

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

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© BUCYRUS AMERICA, INC.

Before starting to work ________________________________________

_________________________________________________________________ 1.6 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

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2

Your safety

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________________________________________________________________

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__________________________________________________ Personnel

Your safety This chapter provides vital information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by Bucyrus America, Inc.

© BUCYRUS AMERICA, INC.

Use only original spare parts from Bucyrus America, Inc. Note that the use of parts from other manufacturers will void the guarantee.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine.

■

of the Mines Inspector and

■

of the mining supervisory authorities

Please read also the operating manuals of the components required for operation, e.g. of gearboxes, electric motors, etc., carefully and thoroughly. Clarify any questions before starting work.

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Personnel ___________________________________________________ Personnel Operation training

The machine may only be operated by qualified, trained personnel.

The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit.

Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the ■

mechanics,

■

hydraulics and

■

control engineering

Installation and repair As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on: ■

safety components (pressure relief valves, extinguishers, etc.)

■

the electrics (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

may only be carried out by service engineers from Bucyrus America, Inc. or by specially qualified personnel of the mine.

_________________________________________________________________ 2.4 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

and must be able to prove this knowledge.

_________________________________________ Operating conditions Operating conditions Intended use The UN-A-HAULER ® has been designed and manufactured purely for transporting of mined material from a continuous miner to the main conveying system for transporting outside.

Intended uses include: ■

the transport of mined material between continuous miner and main conveying system.

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.

© BUCYRUS AMERICA, INC.

■

the transport of persons

Bucyrus America, Inc. accepts no liability for any damage resulting from any such unauthorized use.

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© BUCYRUS AMERICA, INC.

Operating conditions __________________________________________

_________________________________________________________________ 2.6 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

___________________________________________ Safety instructions Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 dB(A).

© BUCYRUS AMERICA, INC.

Inform your colleagues of:

safety equipment

■

your exact location.

■

the work you are performing.

■

the time that you will probably require.

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the machine.

symbol plates emergency stop (panic strip)

disconnect battery

cordon off working area moving parts

steering lockout

Observe the symbol plates on the machine.

Press the EMERGENCY STOP switch immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Disconnect the battery while performing: ■

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the machine.

Never allow parts of your body to come between parts which could move, such as e.g.: ■

false bottoms

■

pivot points

■

battery lifts

Connect the steering lockout device before performing maintenance or repairs on the machine.

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Safety instructions ____________________________________________ Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.

mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

Pre-start inspection operation

Read this entire guide before attempting to operate this machine.

inspection

Inspect the machine and have any malfunctioning, broken or missing parts corrected or replaced before use.

maintenance instruction and safety tags

operator’s compartment canopy

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

These are as important as any other equipment on the machine.

Clean any foreign material from the operator’s compartment.

This machine was shipped from the factory equipped with a protective canopy. The canopy must be securely in place before operating the unit.

_________________________________________________________________ 2.8 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

means of attachment

________________________________ Overview of safety instructions Installation and start-up inclined face

environmental acceptability

On inclined faces secure all component parts by chains, e.g. to the support.

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

controls

When starting up machine, do not operate any controls located inside the operator’s compartment from outside the compartment.

starting procedures

Follow the starting procedure instructions in chapter 5 of this manual.

hazard zone

Do not operate any levers, pedals or controls if anyone is in the hazard zone. (See Hazard zone in Chapter 5 of this manual)

© BUCYRUS AMERICA, INC.

Operation training

Operate the machine only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective UN-A-HAULER ©.

before start-up

Before start-up, ensure that there are no persons or obstructions in your line of travel or in the articulation area when steering the unit.

protective devices

Check that all protective devices are installed on the machine and function properly.

operator’s compartment

Clean the operator’s compartment at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

Never climb onto, or climb out of the machine while it is in motion.

Do not operate the machine with any part of your body outside of the operator’s compartment in order to prevent body parts from being crushed between the machine and outside objects .

traveling

Use extreme caution when traveling in close quarters or in congested or blind-travel areas. The warning gong should be sounded to alert personnel of your movement.

passengers

Never carry passengers to prevent the passengers from being thrown off or crushed between the machine and outside objects.

safety rules

Always follow all safety rules of each particular mine when operating the machine.

problems and malfunctions

If problems or malfunctions are encountered while operating the unit, it must be properly shutdown and the problem corrected immediately.

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Safety instructions ____________________________________________ Stopping operator’s compartment

Do not leave the operator’s compartment with the unit running. Always properly shutdown the unit before leaving the operator’s compartment.

parking

Always park the unit on solid, level ground. If this is not possible, park the unit at a right angle to the slope to prevent accidental movement of the machine.

Use proper flags, warnings or barriers when parking in areas of traffic.

Chock all four (4) wheels in both directions whenever possible.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

securing

Secure your working area over a wide range, in order to avoid endangering other persons.

Disconnect the battery from the machine to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

replacing components

Disconnect the battery from machine to prevent from restarting before replacing any defective components.

Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

lifting

handling of hydraulic fluids

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Bucyrus America, Inc. spare parts.

Please refer to the spare parts lists for the order numbers.

For raising the UN-A-HAULER ® use only: ■

crib blocks with adequate load-holding capacity.

■

hoists, jacks or cranes with adequate load-carrying capacity.

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

Never use hydraulic fluid for rinsing or cleaning. Hydraulic fluid represents a very serious danger to health.

_________________________________________________________________ 2.10 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration.

___________________________________________ Safety instructions maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work on the hydraulic system.

Avoid, whenever possible, servicing, cleaning or examining the machine in congested areas.

Avoid, whenever possible, servicing or providing maintenance to the unit unless the wheels are chocked and steering lockout device is connected to prevent accidental movement of the unit.

Do not alter the electrical or hydraulic settings from that indicated in this manual or as set at the factory.

Always replace damaged or lost decals and metal instruction plates.

© BUCYRUS AMERICA, INC.

Disconnect the battery when working with the electrical system, or when welding on the unit to prevent electrical shock.

Be sure the battery area is well ventilated (clear of fumes) when it is necessary to connect battery charger. Fumes from the battery could ignite from a spark and explode.

Always follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: ■

the hoses are not pinched or trapped.

■

the hoses have no bubbles or blisters.

■

the hose or outer sheathes of the hose are not abnormally rigid or hard.

■

the outer sheath of the hoses is not damaged.

■

the connectors are securely inserted into the sockets.

■

the connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage in the whole system!

Flush out the hydraulic lines thoroughly before connecting.

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Safety instructions ____________________________________________ If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn orings.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

_________________________________________________________________ 2.12 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Replace hydraulic hoses only with hoses of the same or a higher quality.

___________________________________________ Safety instructions laying hydraulic hoses

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

■

Wrong

are not twisted.

© BUCYRUS AMERICA, INC.

Fig. 2: Laying hydraulic hoses, twisting Right

■

Wrong

are not bent directly behind the connections. (distance min. 1.5 x nominal diameter).

Fig. 3: Laying hydraulic hoses, bending Right

Wrong

______________________________________________________________ A6474X268 SSVT/01 2.13

Safety instructions ____________________________________________ ■

always have a little slack.

Fig. 4: Laying hydraulic hoses, crossing Right

■ ■ ■ ■

Wrong

are not kinked. do not have to withstand tensile strains. are protected against thermal radiation. are accessible at all times.

When installing the hydraulic hoses, ensure that they cannot be: ■ ■ ■ ■ ■

torn out, kinked, crushed, driven over or twisted by movement of the machine.

Fig. 5: Laying hydraulic hoses, connections on moving parts Right

Wrong

_________________________________________________________________ 2.14 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

________________________________ Overview of safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and transport Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

IMPORTANT! Take care to insure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

© BUCYRUS AMERICA, INC.

Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

Chapter 4: Installation CAUTION! Serious damage can be caused to the UN-A-HAULER ® as a result of incorrect installation.

The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc. IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

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Overview of safety instructions _________________________________ WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

DANGER! Do not operate the machine any of the guards or covers removed.

You or other personnel could be seriously injured from moving or rotating parts.

Chapter 5: Operation

WARNING! Before operating any levers or pedals on the UN-A-HAULER ® always make sure no one is in the hazard zone. Do not operate any levers or pedals from outside the operator's compartment.

CAUTION! The speed switch foot pedal should not be depressed at the same time as the foot brake pedal or when the parking brakes are set.

To do so may overload the tram motors and could shorten their usefulness. The UN-A-HAULER ® is provided with overload protection, but continued abuse can shorten motor life.

IMPORTANT! For more detailed instructions on the LA2000 display, refer to the BUC 2000 Dual Motor Troubleshooting guide.

IMPORTANT! For more detailed control handle operating instructions, see Starting procedures in this chapter.

WARNING! The machine circuit breaker de-energizes the electrical controller and motors. However, electrical power is still present inside the controller to the circuit breaker. If the circuit breaker inside the controller requires service, the battery circuit breaker should be turned to the "OFF" position or the battery plug disconnected from the battery.

WARNING! All electrical switches in the operator's compartment must be in the "OFF" position before moving the battery circuit breaker lever to the "ON" position.

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© BUCYRUS AMERICA, INC.

DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

________________________________ Overview of safety instructions WARNING! Once the breaker has tripped, it will not stay in the “on” position without first being moved to the "RESET" position, and then to "ON".

WARNING! Always make sure the battery hold down is engaged after each battery change and disengaged prior to changing batteries. The batteries may be damaged if left unsecured during tramming operations.

© BUCYRUS AMERICA, INC.

WARNING! Make sure no one is in the hazard zone (see Hazard zone in this chapter) before operating any levers or pedals and never operate any levers or pedals from outside the operator's compartment.

WARNING! Before moving the ejector blade/false bottom control lever, verify that no one has any part of his body between the ejector blade/ false bottom and the front of the rear (payload) section. Also keep any obstructions from behind the ejector blade/false bottom so it can return completely to the front of the rear (payload) section.

CAUTION! The "BATTERY CHANGER" lever should only be operated at a battery change station. The battery may be damaged if accidentally raised in a low roof area.

WARNING! The battery cannot be changed if the battery is not level when in the raised position. For more information on how to change the battery see Battery change procedure in this chapter.

WARNING! Never attempt to disconnect a hydraulic hose from the battery lifting cylinders with the battery in the "UP" position. This would allow the battery to fall and could result in injury.

WARNING! The vertical articulation control moves the center of the machine up or down while each end of the machine moves up or down (opposite of the center). Make sure no one is on the machine or near the machine before operating this control. Failure to do so could result in the injury or death of a bystander or to the operator if the machine is used without a canopy.

WARNING! Do not actuate “ARTICULATION” function while tramming the machine as this could cause the machine to jam into the top or bottom causing damage to the passage and/or the machine. If vertical adjustment is desired, stop the machine, make the necessary adjustment, and then resume tramming.

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Overview of safety instructions _________________________________ CAUTION! Use caution when traveling down grade, exceeding 5 mph (8 kph) with this machine will result in tram motor failure.

WARNING! Check the battery connections and the battery covers. They must be in place and locked to be permissible.

WARNING! Never operate any levers or pedals from outside the operator's compartment.

WARNING! Be sure no one is in the hazard zone (Fig. 20) before operating any levers or pedals.

Never try to adjust the operator's seat while the UN-A-HAULER ® is in motion.

Do not operate the UN-A-HAULER ® with any part of your body outside the operator's compartment to prevent having body parts caught between the unit and outside objects.

WARNING! The UN-A-HAULER ® is equipped with a solid state speed controller. This means that the farther the speed switch foot pedal is depressed, the faster the UN-A-HAULER ® will tram.

IMPORTANT! The tractive assist can be used as necessary. However, battery life will be prolonged if the tractive assist is allowed to remain disengaged when possible.

WARNING! Always check before moving the ejector blade and false bottom control lever to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.

WARNING! Never enter the articulation area while the machine is running.

Completely shutdown the machine as outlined before connecting the steering lockout device. Failure to observe this precaution may result in injury or death.

CAUTION! This unit is equipped with a canopy. Be careful not to hit your head when entering or leaving the operator's compartment.

_________________________________________________________________ 2.18 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

WARNING! This unit is equipped with a cab or canopy. Be careful not to hit your head when entering or leaving the operator's compartment.

This machine must not be operated without the canopy in place.

________________________________ Overview of safety instructions WARNING! In the event of an emergency, the UN-A-HAULER ® may also be shutdown by striking the panic strip. When the panic strip is struck, the machine circuit breaker will trip. This disconnects the motors and applies the automatic emergency brake. Be prepared for the sudden stop when the panic strips are struck.

WARNING! The "battery" change control lever should never be operated except at a battery change station or when it’s necessary to adjust the battery's terrain clearance. If the "battery" change control lever is operated in a low roof area, the battery may be damaged.

© BUCYRUS AMERICA, INC.

WARNING! Never attempt to disconnect a hydraulic hose from the battery lifting cylinders while the battery is in the up position. This could cause the battery to fall and could result in serious injury.

WARNING! Before performing maintenance on the machine, disconnect the electrical power. Either the battery circuit breaker or the machine circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the battery should be disconnected. Also make sure the capacitor discharge module indicates that the capacitors are discharged before working inside the controller. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

NOTICE! If any welding is to be done to machine, the circuit breakers must be in the “OFF” position and the batteries disconnected. Failure to do so may cause electrical component damage.

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Overview of safety instructions _________________________________ IMPORTANT! The drive and pump motors do not require periodic lubrication.

The pump motor bearings are sealed. The drive motors have one bearing sealed and the other bearing receives lubrication from the gear case oil.

CAUTION! Do not adjust the hydraulic system pressure to more than the main system setting shown on the hydraulic schematic drawing located in the replacement parts manual for your particular machine.

WARNING! Mixing parts of different design or from a variety of sources for wheels with pneumatic tires could cause severe injury or death.

WARNING! When torquing any wheel bolt pattern, always torque in a triangular pattern.

IMPORTANT! Wheel bolts or nuts “seat in” during normal vehicle operation.

Therefore, it is necessary to repeat torquing procedures as necessary to seat the wheel to the hub. Planned periodic checks will help maintain correct torque values. All bolts and nuts, regardless of type, should be regularly checked for tightness.

WARNING! Do not install or remove tire/wheel assemblies from a machine without proper training.

WARNING! Check wheel components periodically for cracks or broken parts.

Replace all cracked, badly worn, damaged or severely rusted components. When in doubt replace.

WARNING! Do not, under any circumstances, attempt to rework, weld, heat or braze any wheel components that are cracked, broken or damaged. Replace such components with new OEM parts of the correct size and type.

WARNING! Mixing wheel parts of different design or from a variety of sources is potentially dangerous.

_________________________________________________________________ 2.20 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

WARNING! In order to check and adjust the steering system relief pressure, it is necessary to steer the machine to the turning limit in both directions. Care must be taken to avoid having anyone or any part of your body in the articulation area while the unit is being steered.

All adjustments to the steering relief pressure must be made from inside the operator’s compartment and not from outside the unit.

________________________________ Overview of safety instructions WARNING! Replace broken studs and each unbroken stud next to the broken one.

WARNING! Replace all damaged wheel studs or bolts.

IMPORTANT! It will save time to purposely manufacture a drifting sequence to accurately adjust the pilot operated sequence cartridge (1).

© BUCYRUS AMERICA, INC.

IMPORTANT! Remember that counterbalance cartridges adjust opposite of relief cartridges. Turning the stem clockwise will reduce pressure.

NOTICE! The following procedure is only for installing a new drive, wheel end or gear case only where stamped measurements are visible.

If the drive or wheel end have had parts replaced, refer to Gear case and planetary wheel end shim procedure number 2 in this chapter.

WARNING! Chock all wheels from both directions and install steering lock before proceeding with component replacement and/or adjustment procedures, to ensure the unintentional movement of the machine is inhibited. Failure to follow appropriate safety measures could result in personal injury or death.

CAUTION! Actuation of the brake pedal with the side plate or link bushing removed will result in damage to the link and could result in malfunction or failure of the brake. Always insure that the side plate or link bushing are fully installed on the link when actuating the brake pedal.

Chapter 6: Technical data IMPORTANT! The technical data listed in this chapter is for stock machines only. Customer specials may not be listed.

IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

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Overview of safety instructions _________________________________ NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc.! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! Bucyrus America, Inc. expressly point out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be disposed of per your local EPA standards.

_________________________________________________________________ 2.22 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

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3

Storage and transport

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________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the UN-A-HAULER ®.

Observance of the instructions and tips will increase the service life and availability of the machine. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

Components coated with temporary corrosion inhibitor are protected for approximately six months.

© BUCYRUS AMERICA, INC.

Before delivery, the hydraulically operated equipment is operated and all gear boxes, hydraulic oil tank, etc. are filled to their maximum fill point.

Storage of the machine and spare parts no direct exposure to sunlight

dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic – such as seals and hoses – and hydraulic fluids only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).

Protect the equipment and all spare parts stored outdoors against moisture and dirt, e.g. using tarpaulins.

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.

short-term storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

long-term storage

If the equipment is to be stored more than six months, the hydraulic components must be completely filled with a corrosion inhibiting/frostproofing fluid such e.g. CV 50.

Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow.

Then seal the ports with plastic or steel plugs.

The equipment must be stored in a well ventilated, dry room. Do not store outdoors.

______________________________________________________________ A6474X268 SSVT/01 3.3

Storage and transport _________________________________________ plastic deformation

In order to prevent plastic deformation of the seal elements, cylinders must be stored in an upright position. Some cylinders must be removed so that they can be stored upright.

random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

On request, the inspection can be carried out by Bucyrus America, Inc.

natural aging

Even with proper storage, seals and hoses are subject to natural ageing. Do not use these parts if they have been stored for more than two years.

HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

Transport Load units; dimensions and weights Observe the transport sheets for the machine and spare parts. They contain information on: ■

Dimensions

■

Weight

■

lifting points, etc.

Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

_________________________________________________________________ 3.4 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

IMPORTANT! Take care to insure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

________________________________________ Storage and transport Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid (e.g. CV 50).

Transport of equipment at temperatures between -6° F (-21° C) and 40° F (-40° C) is only permissible when certain measures were taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

© BUCYRUS AMERICA, INC.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport. electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

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© BUCYRUS AMERICA, INC.

Storage and transport _________________________________________

_________________________________________________________________ 3.6 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

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4

Installation

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__________________________________________________Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on: the safety components (pressure relief valves, fire extinguishing equipment etc.) the electrical equipment (control units, signaling devices, etc.)

And

© BUCYRUS AMERICA, INC.

the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by Bucyrus America, Inc. service engineers or by specially trained personnel.

Which tools are required for installation? tool box

No special tools are required to put the UN-A-HAULER ® into service.

The battery plugs and receptacles come with a special wrench for connecting and disconnecting battery plugs and receptacles.

In addition, various items of auxiliary equipment and machines may be required at the point of installation.

These include i.e.: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

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Installation___________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the UN-A-HAULER ® as a result of incorrect installation.

The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc. installation plan

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

© BUCYRUS AMERICA, INC.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established

_________________________________________________________________ 4.4 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

__________________________________________________Installation Pre-installation check list

© BUCYRUS AMERICA, INC.

NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: ■

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

clean any foreign material from the operator’s compartment

■

clean any foreign material from behind the ejector blade and false bottom

■

check safety provisions for operational condition on fire suppression system

■

start up the machine and check for correct operation of panic switch (s) which are located inside the operator’s compartment

■

check that all covers and guards are in place and secure

■

check that all tags and instruction labels are in place and secure

■

check that operator’s canopy is secure and in place

■

start the machine and allow the hydraulic system to warm up for five (5) to ten (10) minutes

■

check hydraulic system pressures (see spare parts manual for proper hydraulic schematic)

■

check all control handles and switches to ensure all machine functions are operating properly

______________________________________________________________ A6474X268 SSVT/01 4.5

Installation___________________________________________________ Safety features NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

panic strip (s)

The machine is equipped with two (2) panic strips located inside the operator’s compartment. One is located to the right and one is located to the left of the operator while sitting in the operator’s seat. The panic strip (s) are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate either panic strip.

canopy

The machine was shipped from the factory with a protective canopy.

Ensure that the canopy is in place and secure at all times to protect the operator from fall debris.

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators. One is located to the operator’s left inside the operator’s left and the other is located next to the battery on the side of the machine opposite the operator. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

guards and covers

The machine is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.

DANGER! Do not operate the machine any of the guards or covers removed.

You or other personnel could be seriously injured from moving or rotating parts.

steering lockout

The machine is equipped with a steering lockout. The lockout should be connected and secure during shutdown and while performing maintenance on the machine.

circuit breaker reset

The machine is equipped with a circuit breaker reset located inside the operator’s compartment. The circuit breaker reset may be used to shutdown the machine in emergency situations.

_________________________________________________________________ 4.6 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Safety features include: (Reference Fig. 6)

__________________________________________________Installation Fig. 6: Safety features on the UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Fire suppression actuator

Steering lock storage location

Canopy

Steering lock connections for shutdown and maintenance

Circuit breaker reset Panic strip

Fire suppression actuator Panic strip

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Installation___________________________________________________ Fig. 7: Overview of the UN-A-HAULER ®

Battery

Tractor end

Vertical articulation and center section

False bottom

Trailer end

Operator’s compartment

Tailgate

Hydraulic oil tank

_________________________________________________________________ 4.8 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Controller

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5

Operation

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___________________________________________________Operation

Operation This chapter contains important information on the operation and maintenance of the machine. It also includes instructions on the replacement of wear parts.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

How to operate the UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the machine and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the UN-A-HAULER ®?

The UN-A-HAULER ® is only allowed to be operated by persons with adequate knowledge of the complete machine.

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can operation be started?

Operation must not be started until the safe condition and proper function of the complete machine has been checked and the daily maintenance operations have been carried out.

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Operation____________________________________________________ Controls and indicators Operator’s compartment The primary controls for the machine are located in the operator’s compartment (Fig. 8).

Fig. 8: Operator’s compartment BUC 2000 display

Brake pedal

Control handle

Linear pedal adjustment (Model 816C only)

Warning gong

Panic strip

Panic strip

Fire suppression actuator

Seat

Emergency brake release hand pump

Note: Typical operator’s compartment shown, location of controls may vary.

Gauge panel

Battery hold down (Model 816 only)

Circuit breaker reset

Hydraulic control panel

_________________________________________________________________ 5.4 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Speed switch (accelerator)

___________________________________________________Operation WARNING! Before operating any levers or pedals on the UN-A-HAULER ® always make sure no one is in the hazard zone (page 20). Do not operate any levers or pedals from outside the operator's compartment. fire suppression actuators

The two fire suppression (remote) actuators (Fig. 9) are located to the operator's left in the operator's compartment and beside the battery on the side of the machine opposite the operator. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the fire suppression system from either of the two actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the tractor through six nozzles, located over each electric motor, behind the hydraulic control panel, and in the rear (payload) section.

© BUCYRUS AMERICA, INC.

Fig. 9: Fire suppression locator (typical)

ACTUATOR

PLUNGER

ACTUATOR PIN

CO2 CARTRIDGE (BOMB)

______________________________________________________________ A6474X268 SSVT/01 5.5

brake pedal (service)

The foot brake pedal (Fig. 10) is a foot-operated pedal located in front of, and to the left of the operator and is used to apply the service brakes. The foot brake pedal works similarly to an automobile brake pedal. The pedal is normally operated by the left foot. When the machine is first activated, the brake accumulator pressure should build up to 1500 PSI, and is shown on the "ACCUMULATOR" gauge . When the brakes have been applied enough times to drop the pressure to 1200 PSI, the accumulator charging valve should open, allowing pressure to build back up to 1500 PSI. The braking system of the UN-AHAULER ® uses one set (in each gear case) of spring-applied, pressure-released wet disc brakes for both the service and automatic (emergency) braking systems. When the machine is started, the accumulator is fully charged, and the Brake Release Button is depressed, hydraulic pressure compresses the mechanical brake springs, releasing the wet disc brakes, allowing the machine to move. As the foot brake pedal is depressed, the brake valve demodulates pressure in the brake circuit allowing the mechanical springs to engage the brake discs.

When the pedal is released, hydraulic pressure again compresses the springs. An accumulator in the system allows for a limited number of cycles should hydraulic pressure to the system fail. Once the accumulator pressure is exhausted, there will be no pressure to compress the springs and the brakes will be applied, stopping the machine.

accelerator pedal

This pedal (Fig. 10), operated by the right foot, is used to start the tram (traveling) motors and regulate the speed of the machine.

CAUTION! The speed switch foot pedal should not be depressed at the same time as the foot brake pedal or when the parking brakes are set.

To do so may overload the tram motors and could shorten their usefulness. The UN-A-HAULER ® is provided with overload protection, but continued abuse can shorten motor life.

Fig. 10: Brake and accelerator pedal location Brake pedal

light switch

Accelerator pedal

The machine is equipped with a light switch (Fig. 11) that is used to deenergize all power to the front and rear headlights. Location may vary.

_________________________________________________________________ 5.6 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

___________________________________________________Operation

© BUCYRUS AMERICA, INC.

Fig. 11: Light switch.

warning gong

The warning gong (Fig. 12), is located to the operator's left. It is sounded by striking the knob in the center of the gong. This warning gong should be used in accordance with the safety standards at the mine where the UN-A-HAULER ® will be used.

panic strip (s)

The UN-A-HAULER ® is equipped with two (2) panic strips (Fig. 12) located in the operator’s compartment. One is located to the right and one is located to the left while sitting in the operator’s seat. The panic strips are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force can actuate either panic strip.

BUC 2000 display

The optional BUC 2000 display (Figure 12) is located in front of the operator’s seat. Features include: ■

battery discharge indicator

■

hour meter displaying tram-on hours

■

hour meter displaying pump-on hours

■

rotating display showing: 1.

2.

3.

4.

battery voltage pump motor current diagnostic fault status tram motor current

IMPORTANT! For more detailed instructions on the BUC 2000 display, refer to the BUC 2000 Dual Motor Troubleshooting guide.

Fig. 12: Panic strip, warning gong, and BUC 2000 display location

Warning gong BUC 2000 display

Panic strip Panic strip

______________________________________________________________ A6474X268 SSVT/01 5.7

Operation____________________________________________________ Control handle The control handle (Fig. 13), located to the left of the operator has a group of switches that control the following: IMPORTANT! For more detailed control handle operating instructions, see Starting procedures in this chapter.

The control handle (Figure 13) located to the left of the operator has a group of switches that control the following: Press down for Traction Assist.

“PUMP MOTOR”

To start the pump motor, press diagnostics trigger down and hold.

Then press “PUMP MOTOR” button and hold until the pump motor starts. Release “PUMP MOTOR” button and then release diagnostics trigger. To turn off the pump motor, press “STOP” button or “PUMP MOTOR” button.

“PARK BRAKE”

To release park brake, (pump motor must be running) press diagnostics trigger down and hold. Then press “PARK BRAKE” button until the dashboard display indicates “PARK BRAKE RELEASED”. Release trigger and “PARK BRAKE” button. To set “PARK BRAKE” and leave pump motor running, press “PARK BRAKE BUTTON”. To turn “OFF” the pump motor and set the park brake, press “STOP” button or “PUMP MOTOR” button.

“TRAM  or ”

To activate a tramming direction;  The pump motor must be running.  The park brake must be released.  Press in-position down and hold, press either “TRAM ” for tram direction or “TRAM ” for tram direction, hold until the dashboard display indicates direction of travel.  Release “TRAM ” or “TRAM ” depending on direction selected and then release in-position trigger.  To disable tramming, press either “TRAM” button and release.

“LIGHTS  or ”

To activate “LIGHTS” press either “LIGHTS ” for light direction or “LIGHTS ” for light direction. For auto position headlights, whereas the headlights follow the direction of the selected tram direction, press in-position trigger down and hold, press “LIGHTS ” release “LIGHTS ”, then release in-position trigger. Lights will stay in auto position until “STOP”, “LIGHTS ” or “LIGHTS ” is pressed.

“DIAGNOSTICS”

Press up for machine diagnostics.

_________________________________________________________________ 5.8 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

“TRACTION ASSIST”

___________________________________________________Operation Fig. 13: Control handle “PUMP MOTOR”

“PARK BRAKE”

“STOP” “TRACTION ASSIST”

“LIGHTS” (BATTERY END)

© BUCYRUS AMERICA, INC.

“TRAM” (BATTERY DIRECTION)

“LIGHTS” (TRAILER END)

“TRAM” (TRAILER DIRECTION)

DIAGNOSTICS

IN-POSITION

circuit breaker reset lever

Also used to turn unit off, this lever (Fig. 14), located to the right of the operator is used to reset the circuit breaker when it has tripped. This circuit breaker is located in the electrical controller enclosure.

The machine circuit breaker is not intended as an "ON-OFF" switch for normal operation. Except in an emergency, the UN-A-HAULER ® should be shutdown by first depressing the “STOP” button located on the control handle and then moving the machine circuit breaker to the "OFF" position.

WARNING! The machine circuit breaker de-energizes the electrical controller and motors. However, electrical power is still present inside the controller to the circuit breaker. If the circuit breaker inside the controller requires service, the battery circuit breaker should be turned to the "OFF" position or the battery plug disconnected from the battery.

WARNING! All electrical switches in the operator's compartment must be in the "OFF" position before moving the battery circuit breaker lever to the "ON" position.

______________________________________________________________ A6474X268 SSVT/01 5.9

Operation____________________________________________________ Fig. 14: Circuit breaker reset lever location

battery circuit breaker lever

The battery circuit breaker is located on the battery. This circuit breaker has 4 positions: "OFF," to de-energize the machine's electrical systems, "TRIPPED," when the circuit breaker is overloaded, "RESET," to reset the circuit breaker after it has tripped, and "ON," for normal operation (Fig. 15). The battery circuit breaker should be in the "OFF" or "TRIPPED" position before the UN-A-HAULER ® is serviced or when the battery plug is being connected or disconnected.

WARNING! Once the breaker has tripped, it will not stay in the “on” position without first being moved to the "RESET" position, and then to "ON".

Fig. 15: Typical battery circuit breaker reset lever “RESET” “OFF”

“TRIPPED” “ON”

Fig. 16: Optional battery circuit breaker reset lever “(PUSH)” “OFF”

“(PULL)” “ON”

_________________________________________________________________ 5.10 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Circuit breaker reset lever

___________________________________________________Operation battery hold down

The battery hold down (Fig. 17), available on Models CH816C and CH816CL, is located directly in front of the operator’s seat. It is used to secure the battery in position during tramming operations. To engage the hold down, push the handle away from the operator and to unlock, pull the handle towards the operator.

WARNING! Always make sure the battery hold down is engaged after each battery change and disengaged prior to changing batteries. The batteries may be damaged if left unsecured during tramming operations.

linear pedal adjustment

The linear pedal adjustment (Fig. 17), available on Model CH816C, is located directly in front of the operator’s seat. It is used to adjust the position of the pedals. See adjustment procedure in this chapter.

Fig. 17: Battery hold down lever and linear pedal adjustment lever location Battery hold down lever

© BUCYRUS AMERICA, INC.

Linear pedal adjustment

______________________________________________________________ A6474X268 SSVT/01 5.11

Operation____________________________________________________ General hydraulic control system information In the operator's compartment is a group of control levers (Fig. 18).

These levers control the steering, ejector blade/false bottom, battery changer, optional articulation, and P.T.O. by means of a hydraulic valve bank located behind the panel to the operator's right. To the left of the operator is the steering control lever. The hydraulic system pressure relief valve is set at the factory at, and should not be changed (Refer to the hydraulic schematic for your particular machine). Should the "SYSTEM PRESSURE" gauge (Fig. 18) read more than 1,800 PSI, shutdown the UN-A-HAULER ® and call a maintenance person (see Shutdown procedure in this chapter).

WARNING! Make sure no one is in the hazard zone (see Hazard zone in this chapter) before operating any levers or pedals and never operate any levers or pedals from outside the operator's compartment.

“EJECTOR”

“ACCUMULATOR”

“ARTICULATION” (OPTIONAL)

“BATTERY CHANGER”

“SYSTEM PRESSURE”

“BRAKE PRESSURE”

“P.T.O.”

Steering control lever

_________________________________________________________________ 5.12 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Fig. 18: Hydraulic control levers and gauges

© BUCYRUS AMERICA, INC.

___________________________________________________Operation “STEERING” control lever

The “STEERING” control lever to the left of the operator (Fig. 18) is used to steer the UN-A-HAULER ®. To steer left while moving forward (right while moving in reverse), pull the steering control lever slowly toward the operator. To turn right while moving forward (left while moving in reverse), push the steering control lever slowly away from the operator.

“EJECTOR” control lever

The "EJECTOR" lever (Fig. 18), operates the ejector blade/false bottom, located in the rear section. The ejector blade/false bottom pushes out everything in its path, emptying the rear section. When the "EJECTOR" lever is pushed by the operator, the ejector blade/false bottom should move toward the rear of the unit (extend). When the "EJECTOR" lever is pulled by the operator, the ejector blade/false bottom should move toward the operator (retract). When the ejector blade/false bottom is not being used, it should be resting in the retracted position.

WARNING! Before moving the ejector blade/false bottom control lever, verify that no one has any part of his body between the ejector blade/ false bottom and the front of the rear (payload) section. Also keep any obstructions from behind the ejector blade/false bottom so it can return completely to the front of the rear (payload) section.

“BATTERY CHANGER” control lever

The "BATTERY CHANGER" lever (Fig. 18) controls the battery changing system, which is made up of two hydraulic cylinders (battery lifting cylinders), one on each side of the battery. When the "BATTERY CHANGER" control lever is pulled by the operator, the battery-lifting cylinders will raise the battery. Pushing the handle away from the operator will lower the battery. On vertical lift battery change systems the battery lift cylinders are equipped with passive hold-down devices to prevent the battery from moving inside the machine. The hold-down pressure is regulated by a relief valve in the system (refer to the Maintenance section of this guide).

CAUTION! The "BATTERY CHANGER" lever should only be operated at a battery change station. The battery may be damaged if accidentally raised in a low roof area.

WARNING! The battery cannot be changed if the battery is not level when in the raised position. For more information on how to change the battery see Battery change procedure in this chapter.

WARNING! Never attempt to disconnect a hydraulic hose from the battery lifting cylinders with the battery in the "UP" position. This would allow the battery to fall and could result in injury.

______________________________________________________________ A6474X268 SSVT/01 5.13

Operation____________________________________________________ automatic emergency brakes

The automatic emergency brakes are spring-applied (on), pressure release (off) brakes located inside the gear reducers. Before the UN-AHAULER ® is moved, the automatic emergency brakes must be released. If they are not released, the brakes will drag and be damaged.

The drive train and the electrical system will also be damaged. Any of the following conditions will apply the automatic emergency brakes:  The panic bar is struck, tripping the machine circuit breaker.  The “STOP” button located on the control handle is depressed.  The battery circuit breaker is in the "OFF" or "TRIPPED" position.  The machine circuit breaker is in the "OFF" or "TRIPPED" position.

To release the automatic emergency brakes:

 The pump motor must be running.  Press the trigger on the control handle and hold and depress “PARK BRAKE” button and hold until the dashboard display indicates park brake released (Figure 13, page 5.9).  Release the trigger and “PARK BRAKE” button.

“ARTICULATION” control lever (optional)

The vertical articulation control (Fig. 18) actuates a cylinder in the center section that enables the operator to "bend" the machine to improve the ramp-up or hump-over abilities of the machine instantly as required by the conditions of the bottom at any given time. Pulling the lever towards the operator causes the center of the machine (and the operator) to rise upward while the battery and payload end both go down. Care must be taken not to drive the canopy into the top in low coal conditions. Pushing the lever away from the operator causes the center of the machine (and the operator) to move downward while the battery and payload end move up (Fig. 18).

WARNING! The vertical articulation control moves the center of the machine up or down while each end of the machine moves up or down (opposite of the center). Make sure no one is on the machine or near the machine before operating this control. Failure to do so could result in the injury or death of a bystander or to the operator if the machine is used without a canopy.

WARNING! Do not actuate “ARTICULATION” function while tramming the machine as this could cause the machine to jam into the top or bottom causing damage to the passage and/or the machine. If vertical adjustment is desired, stop the machine, make the necessary adjustment, and then resume tramming.

_________________________________________________________________ 5.14 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 The battery circuit breaker and machine circuit breaker levers must be in the “ON” position.

___________________________________________________Operation Fig. 18: UN-A-HAULER ® shown in “UP” articulated position

© BUCYRUS AMERICA, INC.

Note: Typical machine shown.

“TAILGATE” (optional)

The optional tailgate lowers automatically when the “EJECTOR” control lever is engaged and raises when the ejector blade and false bottom are retracted.

disconnect switch (optional)

An optional disconnect switch is available to disconnect power to the motors through a switch located in an enclosure near the controller. To disconnect power, push in the disconnect button. To reset the switch, pull the button back out.

rear tractive assist (optional)

An optional rear tractive assist package is available that provides ondemand, hydraulically-driven rear wheels to assist travel in areas of bad bottom conditions. To engage the rear wheels, press down the rear tractive assist button located on the control handle and release (Fig. 13). To disengage the rear wheels, press the button again and release.

brake release hand pump

The automatic emergency brakes are spring-applied (on), pressurerelease (off) brakes located inside the gear reducers. The automatic (park) brake is normally released using the "PARK BRAKE" release button located on the control handle (see "AUTOMATIC EMERGENCY BRAKES”, in this chapter). Should hydraulic system failure occur, the automatic (park) brake can be released using the manual brake release hand pump. To release the brakes using the hand pump, turn the hand pump selector valve to the set position. Pump the hand pump until the brake release valve indicates the required minimum 1,500 psi.

______________________________________________________________ A6474X268 SSVT/01 5.15

Operation____________________________________________________ Hazard zone The hazard zone exists unless:  The battery plug is disconnected from the battery, OR;  The machine circuit breaker is in the “OFF” or “TRIPPED” position, OR;  The battery circuit breaker is in the “OFF” or “TRIPPED” position.

© BUCYRUS AMERICA, INC.

Fig. 20: Hazard zone

_________________________________________________________________ 5.16 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

___________________________________________________Operation Starting procedure After reading the previous descriptions and locating each control, the operator is ready to operate the UN-A-HAULER ®. An experienced operator should monitor a new operator's indoctrination to the starting procedure.

CAUTION! Use caution when traveling down grade, exceeding 5 mph (8 kph) with this machine will result in tram motor failure.

WARNING! Check the battery connections and the battery covers. They must be in place and locked to be permissible.

© BUCYRUS AMERICA, INC.

WARNING! Never operate any levers or pedals from outside the operator's compartment.

WARNING! This unit is equipped with a cab or canopy. Be careful not to hit your head when entering or leaving the operator's compartment.

This machine must not be operated without the canopy in place.

General  1. Disconnect the steering lockout device (Fig. 22).  2. Sit in the operator's seat and adjust the seat position relative to the foot and hand controls.

WARNING! Be sure no one is in the hazard zone (Fig. 20) before operating any levers or pedals.

Never try to adjust the operator's seat while the UN-A-HAULER ® is in motion.

Do not operate the UN-A-HAULER ® with any part of your body outside the operator's compartment to prevent having body parts caught between the unit and outside objects.  3. The tape panic strips may be pressed at any time to trip the machine circuit breaker, set the park brake, and to de-energize the tram and pump motors.  4. Stop button “J3” may be pressed at any time to set the park brake, and to de-energize the tram and pump motors (Fig. 21).

Note: Refer to Fig. 21 for illustration of control handle.

______________________________________________________________ A6474X268 SSVT/01 5.17

Operation____________________________________________________ Fig. 21: Control handle “J7” PRESS “J2” AND “J7” TO START PUMP MOTOR. PRESS “J7” TO STOP PUMP MOTOR.

“J8” WITH PUMP MOTOR RUNNING PRESS “J2” AND “J8” TO RELEASE PARK BRAKE. PRESS “J8” TO SET PARK

“J12” PRESS DOWN FOR TRACTION ASSIST.

“J3” PUSH DOWN FOR STOP

“J10” WITH PUMP MOTOR RUNNING AND BRAKE RELEASED PRESS “J2” AND “J10” TO ACTIVATE  TRAM DIRECTION. PRESS “J10” TO DISABLE ð TRAM

“J9” WITH PUMP MOTOR RUNNING AND BRAKE RELEASED PRESS “J2” AND “J9” TO ACTIVATE  TRAM DIRECTION. PRESS “J9” TO DISABLE  TRAM DIRECTION.

“J11” PUSH UP FOR DIAGNOSTICS

“J2” PUSH DOWN FOR IN-POSITION

Machine operation  1. Turn the battery circuit breaker and/or disconnect switch (if equipped) to the “ON” position.  2. Press “J11” to begin on board diagnostics.  3. Hold “J11” until a message is displayed on the BUC 2000 display.  4. If the display indicates “SYSTEM OKAY” continue, if any other message is displayed, turn “OFF” battery circuit breaker and/or disconnect switch (if equipped) and contact Bucyrus America, Inc. service department.  5. Release “J11” and set machine circuit breaker.

_________________________________________________________________ 5.18 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

“J6” PUSH DOWN FOR  LIGHTS.

“J4” PRESS “J4” TO ACTIVATE  LIGHTS. PRESS “J2” AND “J4” FOR AUTO LIGHTS. AUTO LIGHTS FOLLOW DIRECTION OF TRAVEL.

___________________________________________________Operation  6. Test tape switch panic bars before beginning each shift, press left side tape switch and machine circuit breaker should trip.

Repeat steps 1 through 5 and press right side tape switch and machine circuit breaker should trip. If machine circuit breaker fails to trip, from either tape switch, turn “OFF” battery circuit breaker and/or disconnect switch (if equipped) and contact Bucyrus America, Inc. service department. If both tape switch panic bars trip machine circuit breaker, repeat steps 1 through 5 and proceed to step 7.  7. Test all control handle functions before beginning each shift.

Follow steps 8 through 24. If any function does not operate correctly, turn “OFF” circuit breaker (s) and disconnect switch (if equipped) and contact Bucyrus America, Inc. service department.

© BUCYRUS AMERICA, INC.

 8. To start the pump motor, press “J2” and hold. Then press “J7” and hold until the pump motor starts. Release “J7” and then release “J2”.  9. To turn off the pump motor, press “J3” or “J7”.  10. To release the park brake; ■

the pump motor must be running

■

press “J2” and hold, press “J8” and hold until the dashboard display indicates “PARK BRAKE RELEASED”

■

release “J8” and then “J2”

 11. To set the park brake and leave the pump motor running, press “J8 .  12. To turn “OFF” the pump motor and set the park brake, press “J3” or “J7”.  13. To activate a tramming direction; ■

the pump motor must be running

■

the park brake must be released

■

press “J2” and hold, press either “J9” for  tram direction or “J10” for  tram direction, hold until the dashboard display indicates direction of travel.

■

release “J9” or “J10” depending on direction selected and then release “J2.

 14. The foot pedal may now be depressed to control the machine.

______________________________________________________________ A6474X268 SSVT/01 5.19

Operation____________________________________________________ WARNING! The UN-A-HAULER ® is equipped with a solid state speed controller. This means that the farther the speed switch foot pedal is depressed, the faster the UN-A-HAULER ® will tram.  15. To change direction of travel, press “J2” and hold, then press either “J9” or “J10” and hold until the dashboard display indicates direction of travel. Then release “J9” or “J10” depending on direction selected and then release “J2”.  16. Each time the direction of travel is changed, the foot pedal will require recycling through the off position.  17. To disable tramming, press ”J9” or “J10”.  18. To leave pump motor running, set park brake, and disable tramming, press “J8”.

 20. If equipped, to activate the optional traction assist function, press “J12”.

IMPORTANT! The tractive assist can be used as necessary. However, battery life will be prolonged if the tractive assist is allowed to remain disengaged when possible.  21. Press “J4” then release “J4” for  direction lights.  22. Press “J6” then release “J6” for  direction lights.  23. For auto position headlights, whereas the headlights follow the direction of the selected tram direction, press “J2” and hold, press “J4” release “J4”, then release “J2”. Lights will stay in auto position until “J3”, “J4” or “J6” is pressed.  24. To turn off all lights, press “J4” and “J6” simultaneously and then release both “J4” and “J6” simultaneously.

_________________________________________________________________ 5.20 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 19. To disable tramming, turn off the pump motor and set the park brake, press “J3” or “J7”.

___________________________________________________Operation Shutdown procedure Tram the UN-A-HAULER ® to its designated parking place.

Stop the UN-A-HAULER ® by releasing the speed-switch foot pedal and depressing the foot brake pedal. When the speed-switch foot pedal is released, the tram (traveling) motors will stop. Applying the foot brake will stop forward (or reverse) motion. The hydraulic pump's electric motor will still be running, making a whining sound.

WARNING! Always check before moving the ejector blade and false bottom control lever to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.

© BUCYRUS AMERICA, INC.

 1. Pull the ejector blade/false bottom control lever toward the operator to move the ejector blade/false bottom to the front of the rear (payload) section. There should be no obstructions behind the ejector blade/false bottom.

Note: Refer to Fig. 21 for illustration of control handle.  2. Before leaving the operator’s compartment, press J3” to turn “OFF” the machine.  3. Turn “OFF” the machine circuit breaker.  4. Turn “OFF” battery circuit breaker and/or disconnect switch (if equipped) before leaving the machine area.  5. Connect the steering lockout device (Fig. 22): ■

remove the steering lockout device from its storage lugs

■

remove the hitch pin from the end farthest from the center section

■

adjust turnbuckle until holes line up between the turnbuckle lug and the front section lug

■

insert the hitch pin into the front section lug through the turnbuckle

WARNING! Never enter the articulation area while the machine is running.

Completely shutdown the machine as outlined before connecting the steering lockout device. Failure to observe this precaution may result in injury or death.

______________________________________________________________ A6474X268 SSVT/01 5.21

Operation____________________________________________________ CAUTION! This unit is equipped with a canopy. Be careful not to hit your head when entering or leaving the operator's compartment.

WARNING! In the event of an emergency, the UN-A-HAULER ® may also be shutdown by striking the panic strip. When the panic strip is struck, the machine circuit breaker will trip. This disconnects the motors and applies the automatic emergency brake. Be prepared for the sudden stop when the panic strips are struck.

Fig. 22: Steering lockout device

Steering lock (Installed location)

Note: Steering lock storage location may vary.

_________________________________________________________________ 5.22 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Steering lock (Storage location)

___________________________________________________Operation Battery change procedure Two people are needed to change the battery in the UN-A-HAULER ®.

Since one person may step into the Hazard Zone, the other person (operating the UN-A-HAULER ®) must be very careful and look each time before moving any levers or pedals. Take time now to refamiliarize yourself with the Hazard zone (Fig. 20).  Line up the battery end of the UN-A-HAULER ® with the place where the battery is to be deposited (Fig. 23) (see Starting procedure in this chapter).

Fig. 23: Battery change procedure

© BUCYRUS AMERICA, INC.

Discharged battery

Charged battery

WARNING! The "BATTERY CHANGE" control lever should never be operated except at a battery change station or when it’s necessary to adjust the battery's terrain clearance. If the "BATTERY CHANGE” control lever is operated in a low roof area, the battery may be damaged.

______________________________________________________________ A6474X268 SSVT/01 5.23

Operation____________________________________________________  Unlock the battery before placing the battery on the ground (Fig. 23). Push the battery hold down lever away from the operator, then push the battery “LIFT” control lever away from the operator and hold until the hooks are completely below the battery lift arms to unlock the battery.

Fig. 24: Battery change procedure

Battery hold down lever

 Lower the battery completely to the surface by pulling the battery hold down lever towards the operator and pushing the "BATTERY CHANGE” control lever away from the operator. The bottom of the battery should touch the surface (Figure 25).

WARNING! Never attempt to disconnect a hydraulic hose from the battery lifting cylinders while the battery is in the up position. This could cause the battery to fall and could result in serious injury.

Fig. 25: Battery change procedure (CH816)

Discharged battery

 After the battery is fully lowered, shutdown the UN-A-HAULER ® (see Shutdown procedure in this chapter).

_________________________________________________________________ 5.24 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Battery “LIFT” control

___________________________________________________Operation

© BUCYRUS AMERICA, INC.

 After shutting down the Un-A-Hauler®, disconnect the discharged battery (Figure 29): ■

Unlock and remove the padlock at the battery connector.

■

Grasp the threaded lock ring and rotate it counterclockwise (CCW) until the threads are disengaged and it is free to slide away from the locking lug; the lock ring is designed to move freely but to not come off the plug.

■

Grasp the plug and pull it out until the plug is completely disconnected from the receptacle; the plug is made to fit very tightly inside the battery receptacle and-should not be driven out of the receptacle, dropped, or handled roughly; if the plug (or receptacle) is damaged, it will not fit together properly.

■

Install the cap which is secured to the receptacle on the battery by a small chain; this cap is placed over the threaded receptacle and rotated in a clockwise (CW) direction until hand tight and until a padlock will fit into the locking lug; the padlocks all use the same key.

 Connect the jumper cable: ■

Connect the receptacle end of the jumper cable to the plug coming out of the connection box on the UN-A-HAULER ® (Fig. 26).

■

Connect the plug end of the jumper cable to the fully charged battery.

■

Secure the jumper cable connections by using the threaded lock rings. These lock rings must be hand tight but do not have to be padlocked.

■

One person should hold the jumper cable so it will not be damaged or be run over when the UN-A-HAULER ® is moved.

______________________________________________________________ A6474X268 SSVT/01 5.25

Operation____________________________________________________ Fig. 26: Battery change procedure

Discharged battery

Charged battery

 Start the UN-A-HAULER ® (see Starting procedure in this chapter).

Gently pull away from the discharged battery while the second person holds the jumper cable away from possible damage.  Line the UN-A-HAULER ® up with the fully charged battery. Move the machine forward until the lift arms are aligned with the slots in the battery (Fig. 27). Continue to slowly move the machine forward until the lift arms are in the correct position.

Fig. 27: Battery change procedure

Discharged battery

Charged battery

Jumper cable

_________________________________________________________________ 5.26 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Jumper cable

___________________________________________________Operation  Raise the battery to the carry position by pulling the "BATTERY" change control lever toward the operator (Fig. 28).

Fig. 28: Battery change procedure (CH816 ground level) Charged battery

© BUCYRUS AMERICA, INC.

 Push the battery hold down lever away from the operator, pull battery “LIFT” control lever towards the operator and hold until battery hooks have completely locked the battery in position.  Shutdown the UN-A-HAULER ® (see Shutdown procedure in this chapter).  Disconnect the jumper cable and connect the charged battery directly to the machine’s cable (Fig. 29). Remember to be careful with the plugs. After the plug is in the receptacle, the lock ring should be rotated clockwise (CW) until hand tight. The padlock must be in the locking lug and locked for this connection to be permissible.  Start the UN-A-HAULER ® (see Starting procedure in this chapter).  This completes the ground level battery change procedure.

______________________________________________________________ A6474X268 SSVT/01 5.27

Operation____________________________________________________ Fig. 29: Battery plug and receptacle (typical)

Threaded lock ring

Locking lug

Plug assembly

Wrench

_________________________________________________________________ 5.28 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Receptacle

________________________________________________ Maintenance Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine.

In particular, observe the safety instructions in chapter 2 “Your safety”.

Important notes

© BUCYRUS AMERICA, INC.

Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

■

Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus America, Inc. spare parts when replacing components.

■

All electrical work must be supervised and inspected by a certified electrician.

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this Bucyrus America, Inc. guide.

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power. Either the battery circuit breaker or the machine circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the battery should be disconnected. Also make sure the capacitor discharge module indicates that the capacitors are discharged before working inside the controller.

WARNING! Before performing maintenance on the machine, disconnect the electrical power. Either the battery circuit breaker or the machine circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the battery should be disconnected. Also make sure the capacitor discharge module indicates that the capacitors are discharged before working inside the controller. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

______________________________________________________________ A6474X268 SSVT/01 5.29

Maintenance _________________________________________________ ■

Test the controls to ensure that the unit will not move.

■

Chock all four (4) wheels in each direction.

■

Connect steering lockout device.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

During maintenance or servicing, if drive motors are to be run, the machine must be jacked clear of the ground and securely blocked. All four wheels must be free to rotate. The center section should also be blocked. The machine should be blocked at the points shown in Fig. 30.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

■

Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked if maintenance is to be performed with the boom in the raised position.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■

Cleanliness can not be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

NOTICE! If any welding is to be done to machine, the circuit breakers must be in the “OFF” position and the batteries disconnected. Failure to do so may cause electrical component damage.

_________________________________________________________________ 5.30 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

■

________________________________________________ Maintenance Critical torque values Torque values are expressed in lubricated and dry thread values. Lubricated thread torque values should be used any time the bolt threads are covered with oil, grease, anti-seize or thread-locking compounds.

Dry thread torque values should be used when threads are completely clean and dry.

Table 1: Critical torque values Location

Bolt size

Dry

Lubricated

400

240

Grade 8

420

250

Grade 8

420

250

Grade 8

380

230

Grade 8

380

230

Grade 5

380

230

Grade 8

650

N/A

Grade 8

1886

Grade

© BUCYRUS AMERICA, INC.

Steering cylinder pins Tire-Wheel mounting bolts (Front) Tire-Wheel mounting bolts (Rear) Planetary wheel end-to-frame mounting bolts Gear case-to-frame mounting bolts Drive motor-to-gear case mounting bolts Center section (Outer ring) (810 & 816) * See note 1 Center section (Inner ring) (810 & 816) * See note 1

3/4-16UNF X2-1/2 3/4-16UNF X2 3/4-NC 3-1/4 3/4-NC 2-1/4 3/4-NC 2-3/4 7/8-NC 9 1 1/4 NC 9

Notes: 1. Retorque of these bolts should not be required due to the use of prevailing torque locknuts. If bolts require to be retorqued, new bolts and locknuts must be installed.

Lubricants, fluids and capacities Table 2: Lubricants, fluids and capacities Location Hydraulic oil

Specification Spec. 100-1

Drive sump (Gear case)

Spec. 100-8

Multi-Purpose grease

Spec. 100-3

Approximate capacity 72 Gallons (816) 65 Gallons (810) 4 Gallons Each As Required

Notes 1 2, 3 4

Notes: 1. With false bottom/ejector blade completely retracted.

2. 4 gallons of oil to completely fill dry system. Actual level should be checked after running unit to fill cooling system. Use dipsticks (one in each drive gear case) to check oil level.

3. Drain gear case and wheel end separately. Fill gear case only to proper level on dipstick.

4.

Pump grease into fitting until old grease can be observed coming out of component.

______________________________________________________________ A6474X268 SSVT/01 5.31

Maintenance _________________________________________________ Table 3: Lubrication and maintenance schedule Description Every third shift

Places

Lubricant

Specification

1

Center section pivots

4

Century Replex 2

Spec. 100-3

2

Steering cylinders (rod and base end)

4

Century Replex 2

Spec. 100-3

3

Center section ball bearing

9

Century Replex 2

Spec. 100-3

4

Ejector hose carrier

2

Century Replex 2

Spec. 100-3

5

Battery change assembly

8

Century Replex 2

Spec. 100-3

6

Articulation cylinders

4

Century Replex 2

Spec. 100-3

7

Articulation pivot

2

Century Replex 2

Spec. 100-3

8

Tail gate cylinders (If equipped)

4

Century Replex 2

Spec. 100-3

9

Battery change cylinders

4

Century Replex 2

Spec. 100-3

10

Fasteners (Nuts, bolts and screws)

Inspect

11

Electrical cables, conduits and glands

Inspect

12

Hydraulic hoses and connections

Inspect

13

Tires (Inspect)

4

14

Headlights (Inspect)

4

15

Reflectors and warning tags

Inspect

16

Hydraulic oil level (Check)

1

Century Hydraulic AW 68

Spec. 100-1

17

Panic strips (Check)

2

Century Centraulic R&O 150

Spec. 100-8

Century Replex 2 Century Replex 2

Spec. 100-3 Spec. 100-3

Century Replex 2

Spec. 100-3

Weekly 18

Center section pins and nuts

Inspect

19

Fire suppression system

Inspect

20

Hydraulic system filter (Check)

1

21

Gear cases and planetary wheel ends (first week of service) (Change) Steering cylinder pins and nuts (Inspect) Wheel mounting bolts (first week of service) (Inspect) Wheel end spindle bolts (first week of service) (Inspect) Foot pedal pivot bearings Brake pedal

2

Return filter (Inspect/change as required) Hydraulic system filter (Inspect/change as required) Brake fluid cooling filters (Inspect/change as required)

1 1

22 23 24 25 26 27 28 29

4 4 2 2 1

2

Every two weeks 30

Control handles and steering linkage

13

_________________________________________________________________ 5.32 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Item

________________________________________________ Maintenance Table 3 (continued): Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

© BUCYRUS AMERICA, INC.

Monthly 31

Drive motors (Inspect)

2

32

Pump motor (Inspect)

1

33

2

34

Gear cases and planetary wheel end oil (Change) Wheel mounting bolts (Check)

35

Hydraulic system pressure

Check

36

Steering relief pressure

Check

37

Brake cooling relief pressure

Check

38

Check

39

Ejector/false bottom/tailgate sequence valve Hydraulic oil suction strainer

40

Rear wheel bearings (if equipped)

2

41

Hydraulic system filter (Change)

1

42

Return filter (Change)

1

43

Brake cooling fluid filters (Change)

2

Century Centraulic R&O 150

Spec. 100-8

4

Check Bearing grease

Fig. 30: Lubrication chart 3

1, 18 6 7

4

2, 22

20, 32, 39, 41 17, 25, 26, 30, 35 5

31

29, 43

14 9

8 21, 33

16, 27, 28, 39, 42

24, 40

13, 23, 34

______________________________________________________________ A6474X268 SSVT/01 5.33

Maintenance _________________________________________________ Specific lubrication and maintenance procedures Every third shift center section pivots

Lubricate the center section pivot points (4 places) with Spec. 100-3 through the grease fittings located on the center section assembly (Fig. 31). Pump grease into the fittings until new grease can be observed coming out of the bearings.

steering cylinders

Lubricate the steering cylinders (4 places) with Spec. 100-3 through the grease fittings located on the rod and base end of each cylinder (Fig. 31). Pump grease into the fittings until new grease can be observed coming out of the pins.

center section ball bearing

Lubricate the center section ball bearing (9 places) with Spec. 100-3 through the grease fittings located around the ball bearing (Fig. 31).

Pump grease into the fittings until new grease can be observed coming out of the bearings.

© BUCYRUS AMERICA, INC.

Fig. 31: Center section and steering cylinders lubrication points Center section pivots (4 places)

Steering cylinders (2) (rod and base end) (4 places)

Center section ball bearing (9 places)

_________________________________________________________________ 5.34 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

________________________________________________ Maintenance ejector hose carrier

Lubricate the ejector hose carrier (2 places) with Spec. 100-3 through the grease fittings located at the two (2) pivot points (Fig. 32). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 32: Ejector hose carrier lubrication points Grease fitting

© BUCYRUS AMERICA, INC.

Grease fitting

battery change assembly

Lubricate the battery change assembly (8 places) with Spec. 100-3 through the grease fittings located on the two (2) lubrication blocks (Fig. 33). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 33: Battery change assembly lubrication points Lubrication block (4 grease fittings) Lubrication block (4 grease fittings)

______________________________________________________________ A6474X268 SSVT/01 5.35

Maintenance _________________________________________________ articulation cylinders

Lubricate the articulation cylinders (4 places) with Spec. 100-3 through the grease fittings: two (2) cylinder eye fittings located under the nose cone center cover and two (2) rod eye fittings (Fig. 34). Pump grease into the fittings until new grease can be observed coming out of the bushings.

articulation pivot

Lubricate the articulation pivot pins (2 places) with Spec. 100-3 through the grease fittings located on the two (2) lubrication blocks (Fig. 34).

Pump grease into the fittings until new grease can be observed coming out of the bushings.

Fig. 34: Articulation cylinders lubrication points

Vertical articulation main pivot pin lubrication block (2 places)

Articulation cylinder grease fitting

Articulation cylinder grease fitting (2 places)

Articulation cylinder grease fitting

tailgate cylinders (if equipped)

Lubricate the tailgate cylinders (4 places) with Spec. 100-3 through the grease fittings located on the cylinder rod and base ends (Fig. 35).

Pump grease into the fittings until new grease can be observed coming out of the bushings.

Fig. 35: Tailgate cylinders lubrication points

Grease fitting

Grease fitting

_________________________________________________________________ 5.36 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Nose cone center cover

________________________________________________ Maintenance battery change cylinders

Lubricate the battery change cylinders (4 places) with Spec. 100-3 through the grease fittings located on the cylinder rod and base ends (Fig. 36). Pump grease into the fittings until new grease can be observed coming out of the bushings.

Fig. 36: Battery change cylinders lubrication points Grease fitting located on rod and base end of cylinder

© BUCYRUS AMERICA, INC.

Grease fitting located on rod and base end of cylinder

Fasteners (nuts, bolts and screws)

Loose fasteners will cause premature wear and failure to machine and components. Visually inspect for loose fasteners and tighten as required.

Electrical cables, conduits and glands

Visually inspect all electrical cables, conduits and glands for signs of wear or damage.

hydraulic hoses and connections

Visually inspect all hydraulic hoses and connections for signs of wear, damage or leakage.

tires

Visually inspect all tires for signs of wear or damage.

headlights

Turn on headlights and visually inspect for bulbs that need replaced or signs of damage.

reflectors and warning plates

Visually inspect the condition and readability of all warning tags, labels and reflectors for signs of wear or damage. Replace any found missing or damaged.

______________________________________________________________ A6474X268 SSVT/01 5.37

Maintenance _________________________________________________ hydraulic oil level

Check the hydraulic oil level by looking at the sight glass located on the oil tank (Fig. 37). If the oil level is low, add oil through the fill cap located on top of the tank until oil is visible in the sight glass.

Fig. 37: Hydraulic oil level

panic strips

Check the panic strips located inside the operator’s compartment (Fig. 38). Start the machine, but do not tram. Strike the panic strips to be certain that they are operating properly, tripping the machine circuit breaker and shutting down the machine.

Fig. 38: Panic strips Panic strip

Panic strip

_________________________________________________________________ 5.38 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Sight glass

________________________________________________ Maintenance Weekly center section pins and nuts

Inspect the center section pins and nuts for looseness or wear (Fig. 39).

Tighten where necessary and replace any worn parts.

steering cylinder pins and nuts

Inspect the steering cylinder pins and nuts for looseness or wear (Fig. 39). Tighten where necessary and replace any worn parts.

Fig. 39: Center section and steering cylinder pins and nuts Inspect center section pivot pins and nuts

© BUCYRUS AMERICA, INC.

Inspect steering cylinder (s) fasteners (rod and base end)

Inspect center section ball bearing fasteners (Torque to 650 ft-lb)

hydraulic system filter

Check the hydraulic system filter dirt alarm (Fig. 40) on the base of the filter. If the alarm indicates the filter element is dirty, replace element.

Fig. 40: Hydraulic system filter

Dirt alarm

______________________________________________________________ A6474X268 SSVT/01 5.39

Maintenance _________________________________________________ fire suppression system

Check the fire suppression system (Fig. 41).  Inspect the hoses, fittings, and nozzles and replace any found damaged.  Check the extinguisher tank for signs of damage or corrosion. The extinguisher tank is located in the rear section of the machine.  Check the nozzle openings. The slot should be packed with silicone grease. If the nozzles are open or need to be repacked, the lines should be checked for blockage and blown clear before repacking them with clean silicone grease.  Remove the fill cap.  Check that the extinguisher is filled with free flowing Ansul multipurpose A, B, C dry chemical to a level not more than 3" (.75 mm) from the bottom of the fill opening.

© BUCYRUS AMERICA, INC.

 Replace the fill cap, hand tight.

Fig. 41: Fire suppression system Actuator

Nozzle (6 locations)

Chemical tanks (2)

Actuator

Fill cap

Tank Nozzle opening

_________________________________________________________________ 5.40 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

________________________________________________ Maintenance gear cases and planetary wheel ends

Change the oil in both gear cases and planetary wheel ends after the first week of service (Fig. 42).  Remove the drain plug (or hose connection if equipped with rear tractive assist) from the gear case and from the planetary wheel end and allow the oil to completely drain.  Replace the drain plugs and refill with oil to full level on dipstick or until oil begins to flow from check/level plug.

Fig. 42: Gear case and planetary wheel end lubrication Oil level dip stick

Fill plug Breather and optional oil level plug

© BUCYRUS AMERICA, INC.

Drain plug

Cooling oil outlet

Wheel end drain plug

wheel mounting bolts

Check the wheel mounting bolts (Fig. 43). The mounting bolts should be torqued to 300 ft-lbs on Models CH810C, CH816CL and to 380 ftlbs on Model CH816C. Use Loctite 242 on wheel mounting bolts.

Fig. 43: Wheel mounting bolts

Check torque of wheel mounting bolts on all 4 tire and wheel assemblies

______________________________________________________________ A6474X268 SSVT/01 5.41

Maintenance _________________________________________________ wheel end spindle bolts (optional)

Check the wheel end spindle mounting bolts (Fig. 44). The mounting bolts should be torqued to 400 ft-lbs .

Fig. 44: Wheel end spindle bolts Frame

Spindle

foot pedal pivot bearings

Lubricate the foot pedal pivot bearings (2 places) with Spec. 100-3 through the grease fittings located on each bearing (Fig. 45). Pump grease into the fittings until new grease can be observed coming out of the bearings.

brake pedal

Lubricate the brake pedal (1 places) with Spec. 100-3 through the grease fitting located on the pedal (Fig. 45). Pump grease into the fittings until new grease can be observed coming.

Fig. 45: Foot and brake pedal lubrication Grease fitting

Grease fitting

Grease fitting

_________________________________________________________________ 5.42 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Mounting bolts

________________________________________________ Maintenance return filter

Inspect the return filter dirt alarm (Fig. 46) located on the head of the filter. If the alarm indicates the filter element is dirty, replace element.

Fig. 46: Return filter Dirt alarm

hydraulic system filter

Inspect the hydraulic system filter dirt alarm (Fig. 47) located on the head of the filter. If the alarm indicates the filter element is dirty, replace element.

© BUCYRUS AMERICA, INC.

Fig. 47: Hydraulic system filter

Dirt alarm

brake cooling fluid filters

Inspect the two (2) brake cooling spin on filter element dirt alarms (Fig. 48) located on the head of each filter. If the alarms indicate that the elements are dirty, replace elements.

Fig. 48: Brake fluid cooling filters

Dirt alarms located on each filter head

______________________________________________________________ A6474X268 SSVT/01 5.43

Maintenance _________________________________________________ Every two weeks control handles and steering linkage

Lubricate the control handles and steering linkage (13 places) with Spec. 100-3 through the grease (Fig. 49). Pump grease into the fittings until new grease can be observed coming out.

Fig. 49: Control handles and steering linkage lubrication Control handle (s) grease fitting access area location

© BUCYRUS AMERICA, INC.

Grease fitting

_________________________________________________________________ 5.44 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

________________________________________________ Maintenance Monthly drive and pump motor (s)

Inspect the drive and pump motors (Fig. 50).  Be sure that the machine circuit breaker lever is in the "OFF" position.  Remove the inspection cover.

© BUCYRUS AMERICA, INC.

 Inspect the windings, commutators, brushes, armature, and terminal leads.

–

Windings should be dry and free of dust, grease, oil, and dirt.

–

The commutator should be clean and smooth with a medium polish and a light brown color.

–

Brushes and brush holders should be clean so that the brushes are free to move in the holders and are properly seated.

Brushes should be replaced before wear permits the rivets to score the commutator. (See replacement procedure in this chapter)

–

The armature and field leads should be undamaged.

–

Terminal leads should be tight.

 Replace the inspection plate being sure it is securely tightened.

IMPORTANT! The drive and pump motors do not require periodic lubrication.

The pump motor bearings are sealed. The drive motors have one bearing sealed and the other bearing receives lubrication from the gear case oil.

Fig. 50: Rocker ring and brushes

Inspection cover Rocker ring Rocker ring lock screws Brushes and brush holders

______________________________________________________________ A6474X268 SSVT/01 5.45

Maintenance _________________________________________________ gear cases and planetary wheel ends

Change the oil in both gear cases and planetary wheel ends (Fig. 51).  Remove the drain plug (or hose connection if equipped with rear tractive assist) from the gear case and from the planetary wheel end and allow the oil to completely drain.  Replace the drain plugs and refill with oil to full level on dipstick or until oil begins to flow from check/level plug.

Fig. 51: Gear case and planetary wheel end lubrication Oil level dip stick

Fill plug

Cooling oil outlet

Wheel end drain plug

wheel mounting bolts

Check the wheel mounting bolts (Fig. 52). The mounting bolts should be torqued to 300 ft-lbs on the Model 810C and to 380 ft-lbs on Models 816C and 816CL . Use Loctite 242 on wheel mounting bolts.

Fig. 52: Wheel mounting bolts

Check torque of wheel mounting bolts on all 4 tire and wheel assemblies

_________________________________________________________________ 5.46 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Breather and optional oil level plug

Drain plug

________________________________________________ Maintenance hydraulic system pressure

Check the hydraulic system pressure (Fig. 53).

WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.   Pull the “EJECTOR” control lever toward the operator until the ejector blade/false bottom has completely returned to the front of the rear (payload) section.  Continue to hold the “EJECTOR” lever pulled toward the operator and read the pressure indicated on the “SYSTEM PRESSURE” gauge (located in the operator’s compartment).

© BUCYRUS AMERICA, INC.

 Normal system pressure is set at the factory and should not be changed. If the pressure indicated on the “SYSTEM PRESSURE” gauge is not as specified on the hydraulic schematic supplied with your machine, see Main hydraulic system pressure adjustment in this chapter.

CAUTION! Do not adjust the hydraulic system pressure to more than specified on the hydraulic schematic supplied with your machine.

Fig. 53: Check the hydraulic system pressure

“EJECTOR” control lever

“SYSTEM PRESSURE” gauge

______________________________________________________________ A6474X268 SSVT/01 5.47

Maintenance _________________________________________________ steering relief pressure

Check the steering system relief pressure (Fig. 54).

WARNING! In order to check and adjust the steering system relief pressure, it is necessary to steer the machine to the turning limit in both directions. Care must be taken to avoid having anyone or any part of your body in the articulation area while the unit is being steered.

All adjustments to the steering relief pressure must be made from inside the operator’s compartment and not from outside the unit.   Steer the unit to the turning limit in either direction and read the pressure indicated on the “SYSTEM PRESSURE” gauge.

Fig. 54: Check the hydraulic system pressure

“STEERING” control lever

“SYSTEM PRESSURE” gauge

_________________________________________________________________ 5.48 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 Normal steering relief pressure is set at the factory and should not be changed. If the pressure indicated on the “SYSTEM PRESSURE” gauge (located in the operator’s compartment) is not as specified on the hydraulic schematic supplied with your machine in one or both directions, see Steering system relief pressure adjustment in this chapter.

________________________________________________ Maintenance brake cooling relief pressure

Check the brake cooling relief pressure (Fig. 55).  Raise and securely block the machine off the ground so that all four (4) wheels are free to rotate.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.  Remove the hose fittings from the top of the relief valve.  With a gauge and suitable fittings, install the gauge onto the relief valve where the hose was disconnected.

© BUCYRUS AMERICA, INC.

 Start the machine, release the automatic brakes and slowly depress the accelerator pedal.  As the drive wheels begin to turn, read the pressure indicated by the gauge. The pressure should be 50 psi. If the pressure is not 50 psi, see Brake cooling relief pressure adjustment in this chapter.

Fig. 55: Brake cooling relief pressure

Pressure gauge connection

Brake cooling relief valve

______________________________________________________________ A6474X268 SSVT/01 5.49

Maintenance _________________________________________________ ejector/false bottom sequence valve

Check the ejector/false bottom sequence valve.

WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.  When the ejector/false bottom is being retracted, the ejector blade should return to the back of the false bottom as the false bottom begins to move.  When the ejector/false bottom is being extended, the false bottom should extend before the ejector blade extends.  If the above sequence is incorrect, see ejector/false bottom sequence valve adjustment in this chapter.

Check the ejector/false bottom/tailgate sequence valve.

WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.  When the ejector/false bottom is being retracted, the ejector blade should return to the back of the false bottom as the false bottom begins to move and the tailgate should raise after the false bottom has cleared the end of the frame.  When the ejector/false bottom is being extended, the tailgate should lower first and the false bottom should extend before the ejector blade extends.  If the above sequence is incorrect, see ejector/false/bottom/tailgate sequence valve adjustment in this chapter.

_________________________________________________________________ 5.50 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

ejector/false bottom/tailgate sequence valve

________________________________________________ Maintenance hydraulic oil suction strainer

Clean or replace the hydraulic suction strainer inside the hydraulic oil tank (Fig. 56).  Remove the drain plug from the hydraulic oil tank to allow the oil to drain.  Remove the oil tank cover and gasket.  Reach through opening in tank and unscrew strainer from fitting.  Replace the strainer with a new one or thoroughly clean the old one with kerosene and a soft brush. Dry the cleaned strainer with air before replacing in the tank.  Replace the strainer in the tank and tighten hand-tight.  Inspect cover gasket for damage and replace if necessary.  Replace cover and gasket,

© BUCYRUS AMERICA, INC.

 Install drain plug.  Refill tank to proper level with hydraulic oil (Spec. 100-1).  Purge hydraulic system of air.

Fig. 56: Hydraulic oil suction strainer maintenance

Hydraulic oil tank

Sight glass

______________________________________________________________ A6474X268 SSVT/01 5.51

Maintenance _________________________________________________ rear wheel bearings (if equipped)

Clean , inspect and grease the rear (payload) section hubs (Fig. 57).  Raise and securely block both rear (payload) wheels off the ground.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.  Remove the cover from the hub.  Wipe out all old grease.  Visually inspect bearings for wear and correct pre-loading. The retaining nut should be tight enough to remove all slack in the bearings, but not tight enough to cause binding.

© BUCYRUS AMERICA, INC.

 Pump clean grease into the fitting just until the grease begins to come through the outside bearing. DO NOT over grease by filling the entire cavity.  Clean up all excess grease and replace cover.  Repeat procedure for the other side.

Fig. 57: Rear wheel bearings lubrication Spindle Seal Bearing cone Bearing cup Hub Flat washer Cotter pin Retaining nut

Grease fitting Bearing cup Bearing cone Cover

_________________________________________________________________ 5.52 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

________________________________________________ Maintenance hydraulic system filter

Change the hydraulic system filter element (Fig. 58) . If the element is extremely dirty, a more frequent interval may be required.

Fig. 58: Hydraulic system filter

Dirt alarm

return filter

Change the return filter element (Fig. 59) . If the element is extremely dirty, a more frequent interval may be required.

© BUCYRUS AMERICA, INC.

Fig. 59: Return filter Dirt alarm

brake cooling fluid filters

Change the two (2) brake cooling spin on filter elements (Fig. 60) . If the elements are extremely dirty, a more frequent interval may be required.

Fig. 60: Brake fluid cooling filters Dirt alarms located on each filter head

______________________________________________________________ A6474X268 SSVT/01 5.53

Maintenance _________________________________________________ Tire/wheel installation procedure The following installation procedures are for general guidance when installing a tire/ wheel assembly (Fig. 61) on most underground mining machines. Any use made of the advisory information contained herein is entirely within the control and discretion of the user and is wholly voluntary.

WARNING! Mixing parts of different design or from a variety of sources for wheels with pneumatic tires could cause severe injury or death. tire/wheel stresses

Rubber tired underground mining machinery is routinely subject to severe abuse due to the conditions in which it is operated. Whether a primary haulage or utility/support vehicle, all are subject to extreme shock, vibration, temperature change and various other loads and stresses that cause maintenance problems. One such problem is found in tire/wheel assemblies.

Many maintenance personnel view installing a tire/wheel assembly on a machine as a relatively simple task. However, if a few simple rules on proper installation are not followed, unnecessary difficulties may be experienced. Tires act like shock absorbers on haulage and support vehicles, transferring cushioned loads to the wheels. Even after proper installation, periodic checks need to be made to insure that tire/wheel assemblies do not loosen, causing wheel studs to break or damaging the mounting bolt pattern.

wheel mounting arrangements

Various mounting arrangements between the wheel and hub or wheel end are used by manufacturers. One of the more common is the taperlock. This arrangement requires a taper on both wheel and hub where the mating surfaces of the taper carry the loads. Incomplete seating of the taper will allow the wheel to loosen, resulting in stud or bolt shear and possible tire/wheel damage.

_________________________________________________________________ 5.54 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Fig. 61: Tire/ wheel assembly

________________________________________________ Maintenance Another mounting arrangement is based on holding a very close pilot fit where the tolerance between the wheel and hub is very tight, requiring a clamp-load force to hold the wheel securely in place. If the wheel studs or bolts are allowed to loosen, the load will be transmitted to them, resulting in sheared studs or bolts.

© BUCYRUS AMERICA, INC.

problem areas

Periodic wheel inspection is critical to the life cycle of a tire/wheel assembly. A fractured wheel, broken bolt pattern and missing or broken wheel studs are all contributors to tire/wheel failures. Problems in these areas occur as the result of repeated cyclical loading as the tire/wheel unit rotates during machine travel. Haulage vehicles loaded unevenly, downhill hauls with high speed turns, or operating a vehicle with one tire of a dual assembly damaged or flat are some examples of conditions that produce damaging high stresses in wheel assemblies. Also, the effects of corroding or poorly fitted mating parts can produce surface irregularities that result in cracks and ultimate failure of a wheel.

A most common problem with tire/wheel installations is the incorrect tightening of wheel bolts or studs. Threaded fasteners perform there function of holding things together better when torque control is used in their tightening. Using an accurate torque wrench correctly is the best and most practical way of securing fasteners, Although torque value charts are available as a reference guide to proper tightening, OEM specifications should always be followed when tightening fasteners.

However, proper torque values are of little benefit if certain other factors are not considered.

wheel mounting tips

All fasteners should be examined before use. Any fastener that is worn, bent or has damaged threads should be replaced. Fastener threads should also be lightly coated with a protective substance, such as residual oils, wax or loctite, because any oxidation or rust will upset the torque-to-tension relationship.

Mating surface conditions should also be considered. The tightening surface under the bolt or nut should be carefully inspected. A fastener, when tightened against a softer material, will gall under these conditions, and much of the applied torque may be lost through head friction.

It is very important when using higher strength fasteners to have a smooth, even surface under the bolt head. In some cases, hard flat washers and most lockwashers will provide a good tightening surface.

An other area of concern is cleanliness. All mating surfaces should be free of rust, dirt, oil, paint, etc. Also no paint of any kind should exist between a fastener and wheel disc surface. Any form of contamination between these surfaces will most likely lead to serious wheel problems.

WARNING! When torquing any wheel bolt pattern, always torque in a triangular pattern.

______________________________________________________________ A6474X268 SSVT/01 5.55

Maintenance _________________________________________________ Fig. 62: Triangular bolt pattern

Recommended wheel mounting procedures:  All steel mating surfaces must be free and clean of any dirt, corrosion, paint, etc. These areas include wheel/hub tapers and disc faces. NO PAINT should be present under bolt heads or nuts.  Fasteners should be in proper condition. Any fastener with damage, such as corrosion, bending or worn threads, should be replaced. Replace all broken wheel studs.  After positioning the wheel on the hub, tighten nuts down evenly.

Triangulate the bolt pattern tightening sequence as shown in the diagrams.  After operating the machine for a short period of time, check the wheel-mounting bolts or nuts for proper torque.

IMPORTANT! Wheel bolts or nuts “seat in” during normal vehicle operation.

Therefore, it is necessary to repeat torquing procedures as necessary to seat the wheel to the hub. Planned periodic checks will help maintain correct torque values. All bolts and nuts, regardless of type, should be regularly checked for tightness.

_________________________________________________________________ 5.56 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Fig. 62: Torque patterns

________________________________________________ Maintenance PRECAUTIONS: WARNING! Do not install or remove tire/wheel assemblies from a machine without proper training.

WARNING! Check wheel components periodically for cracks or broken parts.

Replace all cracked, badly worn, damaged or severely rusted components. When in doubt replace.

WARNING! Do not, under any circumstances, attempt to rework, weld, heat or braze any wheel components that are cracked, broken or damaged. Replace such components with new OEM parts of the correct size and type.

© BUCYRUS AMERICA, INC.

WARNING! Mixing wheel parts of different design or from a variety of sources is potentially dangerous.

WARNING! Replace broken studs and each unbroken stud next to the broken one.

WARNING! Replace all damaged wheel studs or bolts.

______________________________________________________________ A6474X268 SSVT/01 5.57

© BUCYRUS AMERICA, INC.

Maintenance _________________________________________________

_________________________________________________________________ 5.58 BUCYRUS – Models CH810C, CH816C,and CH816CL UN-A-HAULER ®

_______________________________________ Adjustment procedures Instructions on the adjustment procedures It is essential that adjustments be made periodically, as otherwise damage can be caused to other parts of the machine. Inspect the adjustments at regular intervals.

Main hydraulic system pressure To adjust the main hydraulic system pressure proceed as follows (Fig. 63).  Open swing out door on rear (payload) section to gain access to the relief valve.  Locate the relief valve attached to the pressure filter.

© BUCYRUS AMERICA, INC.

 Loosen the relief valve locknut.

CAUTION! Do not adjust the hydraulic system pressure to more than specified on the hydraulic schematic supplied with your machine.  While another person holds the “EJECTOR” lever completely pulled toward the operator, turn the adjustment screw until the “SYSTEM PRESSURE” gauge indicates the specified pressure on the hydraulic schematic supplied with your machine.  Tighten locknut and secure swing out door.

Fig. 63: Main hydraulic system pressure adjustment

Relief valve

“EJECTOR” control lever

“SYSTEM PRESSURE” gauge

______________________________________________________________ A6474X268 SSVT/01 5.59

Adjustment procedures ________________________________________ Steering relief pressure adjustment WARNING! In order to check and adjust the steering system relief pressure, it is necessary to steer the machine to the turning limit in both directions. Care must be taken to avoid having anyone or any part of your body in the articulation area while the unit is being steered.

All adjustments to the steering relief pressure must be made from inside the operator’s compartment and not from outside the unit.

To adjust the steering relief pressure proceed as follows (Fig. 64).

 For right turn, loosen the locknut on the end of the relief cartridge and hold the “STEERING” control lever completely pushed away from the operator. With an allen wrench, adjust the relief cartridge until the pressure indicated on the “SYSTEM PRESSURE” gauge indicates the pressure specified on the hydraulic schematic supplied with your machine. Once the gauge indicates the required pressure, tighten the locknut.  For left turn, loosen the locknut on the end of the relief cartridge and hold the “STEERING” control lever completely pulled toward the operator. With an allen wrench, adjust the relief cartridge until the pressure indicates the pressure specified on the hydraulic schematic supplied with your machine. Once the gauge indicates the required pressure, tighten the locknut.  Replace the access cover inside the operator’s compartment.

Fig. 64: Steering relief pressure adjustment

Right steering pressure relief valve

“STEERING” control lever

Left steering pressure relief valve

Valve bank

“SYSTEM PRESSURE” gauge

_________________________________________________________________ 5.60 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 Remove the access cover inside the operator’s compartment.

_______________________________________ Adjustment procedures Brake cooling circuit relief pressure adjustment To adjust the steering relief pressure proceed as follows (Fig. 65).  Raise and securely block the machine off the ground so that all four (4) wheels are free to rotate.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.  Remove the hose fittings from the top of the relief valve.  With a gauge and suitable fittings, install the gauge onto the relief valve where the hose was disconnected.

© BUCYRUS AMERICA, INC.

 Start the machine, release the automatic brakes and slowly depress the accelerator pedal.  As the drive wheels begin to turn, read the pressure indicated by the gauge. The pressure should be 50 psi. If the pressure is not 50 psi, continue to next step.  Remove the cap that covers the pressure adjustment screw.  Using an allen wrench, turn the screw until the correct pressure of 50 psi is indicated on the pressure gauge.  Replace the cap on the relief valve.  Remove the gauge and replace the hose in the relief valve.

Fig. 65: Brake cooling circuit relief pressure adjustment Pressure adjustment

Brake cooling relief valve

Pressure gauge connection

______________________________________________________________ A6474X268 SSVT/01 5.61

Adjustment procedures ________________________________________ False bottom/ejector blade sequence valve adjustment To adjust the false bottom/ejector blade sequence valve proceed as follows (Fig. 66).

WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.  Extend the ejector blade/false bottom to the rear of the payload section and shutdown the machine.  Adjust the sequence valve extend and retract cartridges.

–

When the ejector/false bottom is being retracted, the ejector blade should return to the back of the false bottom as the false bottom begins to move.

–

When the ejector/false bottom is being extended, the false bottom should extend before the ejector blade extends.

 Repeat the procedure until the procedure is complete.

Fig. 66: False bottom/ejector blade sequence valve adjustment

Retract adjustment

Extend adjustment

_________________________________________________________________ 5.62 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 Start the machine the machine and cycle the ejector blade/ false bottom. When cycled the following sequence should be achieved:

_______________________________________ Adjustment procedures Tailgate sequence valve adjustment (P/N LUP01820) To adjust the tailgate sequence valve proceed as follows (Fig. 67).

WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.

© BUCYRUS AMERICA, INC.

The following cartridges on the sequence valve are identified with numbers stenciled on the valve body beside the location of the respective cartridge. The cartridges are represented as follows: ■

kick down sequence cartridge (3)

■

ejector cylinder sequence cartridge (5 - 3)

■

false bottom sequence cartridge (5 - 2)

■

tailgate adjustment, vented counterbalance cartridge (2)

■

pilot opened sequence cartridge (1)

■

internal pilot 3-way sequence cartridge (5 - 1)

■

vented counterbalance cartridge (1)

IMPORTANT! Remember that counterbalance cartridges adjust opposite of relief cartridges. Turning the stem clockwise will reduce pressure.  Ensure that the “SYSTEM PRESSURE” is set as specified on the hydraulic schematic supplied with your machine before beginning this procedure.  Increase pressure fully on cartridge (5 -1) by turning the stem clockwise until it is bottomed out.  Reduce the pressure fully on cartridge (1) by turning the stem counterclockwise all the way out.  Increase the pressure fully on cartridges (5 - 2)and (5 - 3) by turning clockwise until they are bottomed out. Increase pressure on cartridge (2) by turning counterclockwise to increase pressure to the fullest extent.  Adjust cartridge (7) by turning the stem clockwise until bottomed out and then turning counterclockwise one (1) full turn. This cartridge should not need to be adjusted again in this procedure.

The above cartridges will be adjusted later in this procedure. Retract cylinders fully before continuing.

______________________________________________________________ A6474X268 SSVT/01 5.63

Adjustment procedures ________________________________________ The kick down sequence cartridge (3) controls the extend feature of the circuit.  Loosen locknut and back the allen head stem of the cartridge all the way out (counterclockwise) and proceed to extend the cylinders. If the false bottom and ejector cylinders move while the tailgate drops, stop the extend sequence and increase the pressure by turning the stem clockwise. Continue this sequence of events until the tailgate drops without the false bottom or ejector cylinders moving. Once this is accomplished, tighten locknut to prevent setting from drifting. The extend sequence is now complete. Retract cylinders fully before beginning next phase of procedure.

 Operate extend sequence until the tailgate drops, then operate the retract sequence. If the tailgate comes up, increase the pressure by turning the counterbalance cartridge counterclockwise in increments of 1/4” to 1/2” turns. Continue this sequence until the tailgate fails to raise in the retract mode. Once setting is satisfied, tighten locknut. Retract cylinders fully before beginning next phase of procedure.

Refer to pilot operated sequence cartridge (1).

IMPORTANT! It will save time to purposely manufacture a drifting sequence to accurately adjust the pilot operated sequence cartridge (1).  It will save time to purposely manufacture a drifting sequence to accurately adjust the pilot operated sequence cartridge (1). This can be done by insuring the stem of the cartridge is backed out far enough to induce drifting. Operate the extend sequence of the circuit until separation of the ejector blade and false bottom occurs.

Once this occurs, operate the retract sequence of the circuit. If during this sequence, the false bottom drifts (retracts slowly) while the ejector blade is coming back, stop the retract sequence and increase pressure by turning the stem clockwise. Continue this sequence until the drifting is eliminated. .

_________________________________________________________________ 5.64 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Refer to counterbalance cartridge (2) located on the tailgate sequence valve.

_______________________________________ Adjustment procedures

© BUCYRUS AMERICA, INC.

Refer to false bottom sequence cartridge (5 – 2).  Adjust the false bottom sequence cartridge (5 – 2). This is labeled ejector cylinder sequence cartridge, but it needs to plumb to the false bottom cylinder. First obtain a multi-gauge or simply install a 3,000 psi pressure gauge on port (G2). Operate the extend sequence of the circuit until the false bottom is fully extended. Stop and turn the cartridge counterclockwise until a pressure reading is seen on the gauge (low pressure, 100 - 200 psi). Once this pressure is seen, turn the stem one complete turn clockwise. Operate the extend sequence until the false bottom is extended fully. Operate the retract sequence. If you witness pressure on the gauge during this sequence, stop and increase the pressure setting of the cartridge by turning the stem clockwise. Extend the false bottom blade fully and then operate the retract sequence. If you continue to see pressure, stop and adjust the pressure again. Continue this process until no pressure is seen on the gauge. Once this is complete, operate the extend sequence until the false bottom is fully extended. Operate the retract mode and monitor the gauge during this process. You should not see pressure on the gauge until the rod of the cylinder retracts back to the pilot port of the jack which is located 18” (26.62” on Model 818”s) from the rod end, or roughly 1” past the tailgate. If you witness pressure prior to this, adjust the cartridge as described above.

Refer to ejector cylinder sequence cartridge (5 – 3).  Move gauge to port (G1). This gauge port will measure the pressure coming out of the ejector sequence cartridge. First obtain a multi-gauge or simply install a 3,000 psi pressure gauge on port (G2). Operate the extend sequence of the circuit until the ejector blade is fully extended. Stop and turn the cartridge counterclockwise until a pressure reading is seen on the gauge (low pressure, 100 - 200 psi). Once this pressure is seen, turn the stem one complete turn clockwise. Operate the extend sequence until the ejector blade is extended fully. Operate the retract sequence. If you witness pressure on the gauge during this sequence, stop and increase the pressure setting of the cartridge by turning the stem clockwise. Extend the ejector blade fully and then operate the retract sequence. If you continue to see pressure, stop and adjust the pressure again. Continue this process until no pressure is seen on the gauge. Once this is complete, operate the extend sequence until the ejector blade is fully extended. Operate the retract mode and monitor the gauge during this process. You should not see pressure on the gauge until the rod of the cylinder retracts back to the pilot port of the jack which is located 70” from the rod end of the cylinder. If you witness pressure prior to this, adjust the cartridge as described above.

______________________________________________________________ A6474X268 SSVT/01 5.65

Adjustment procedures ________________________________________ Refer to internal pilot 3-way sequence cartridge (5 – 1) located on the false bottom control valve.  Ensure that this cartridge is turned all the way in. Operate the circuit in the extend mode until the tailgate drops and the false bottom is extended 2 - 3 feet. Operate the circuit in the retract mode. If the false bottom retracts in a jerky mode while the tailgate cylinders are retracting, stop the retract sequence and decrease the pressure by turning the stem counterclockwise. Continue this sequence of events until the false bottom doesn’t jerk while retracting.

As an option, you can operate the extend sequence of the circuit all the way out and then operate the retract sequence. Monitor the false bottom as the tailgate comes up. If any movement of the false bottom is seen, stop and adjust the cartridge as described above.

Sequence of operation after all cartridges have been adjusted.

When operating the extend mode of the circuit, the tailgate cylinders will extend and allow the tailgate to drop. The false bottom or ejector blade should not move during this sequence. Once the tailgate, the false bottom and ejector blade will begin to extend to their full stroke.  Retract: When operating the retract mode of the circuit, the ejector blade will retract first. When it passes the pilot port located 70” from the rod end, the sequence cartridge (5 - 3) will open up. The ejector will continue retracting until it is bottomed out. Once this occurs the false bottom will begin retracting in a slower mode until it reaches the pilot port of the cylinder located 18” from the end of the rod. It will stop retracting. The false bottom should be located roughly 1” past the tailgate at this time. The tailgate cylinders will then begin to retract and raise the tailgate. Once the tailgate is fully up, the false bottom will begin to retract again to the desired position.

_________________________________________________________________ 5.66 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 Extend:

_______________________________________ Adjustment procedures Fig. 67: Tailgate sequence valve adjustment (P/N LUP01820) 5 2

5

7 5 3 6

1

© BUCYRUS AMERICA, INC.

4

______________________________________________________________ A6474X268 SSVT/01 5.67

Adjustment procedures ________________________________________ Tailgate sequence valve adjustment (P/N LUP00781) To adjust the tailgate sequence valve proceed as follows (Fig. 68).

WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.

■

relief cartridge (10)

■

kick down sequence cartridge (3)

■

ejector cylinder sequence cartridge (5)

■

false bottom sequence cartridge (8)

■

tailgate adjustment, vented counterbalance cartridge (2)

IMPORTANT! Remember that counterbalance cartridges adjust opposite of relief cartridges. Turning the stem clockwise will reduce pressure.  Ensure that the “SYSTEM PRESSURE” is set as specified on the hydraulic schematic supplied with your machine before beginning this procedure.  Refer to relief cartridge (10). This is located to the left, perpendicular to the ejector and false bottom sequence cartridges. Increase the pressure setting of the cartridge by turning the stem clockwise after loosening the locknut.  Refer to ejector (5) and false bottom (8) sequence cartridges.

Loosen locknuts and turn stems on both cartridges clockwise until bottomed out.

These three cartridges will be adjusted later in the procedure. Retract cylinders fully before continuing.

The kick down sequence cartridge (3) controls the extend feature of the circuit.  Loosen locknut and back the allen head stem of the cartridge all the way out (counterclockwise) and proceed to extend the cylinders. If the false bottom and ejector cylinders move while the tailgate drops, stop the extend sequence and increase the pressure by turning the stem clockwise. Continue this sequence of events until the tailgate drops without the false bottom or ejector cylinders moving. Once this is accomplished, tighten locknut to prevent setting from drifting. The extend sequence is now complete. Retract cylinders fully before beginning next phase of procedure.

_________________________________________________________________ 5.68 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

The following cartridges on the sequence valve are identified with numbers stenciled on the valve body beside the location of the respective cartridge. The cartridges are represented as follows:

_______________________________________ Adjustment procedures Refer to counterbalance cartridge (2).  Operate extend sequence until the tailgate drops, then operate the retract sequence. If the tailgate comes up, increase the pressure by turning the counterbalance cartridge counterclockwise. Continue this sequence until the tailgate fails to raise in the retract mode. Once setting is satisfied, tighten locknut. Retract cylinders fully before beginning next phase of procedure.

Refer to ejector cylinder sequence cartridge (5).

© BUCYRUS AMERICA, INC.

 First obtain a multi-gauge or simply install a 3000 psi pressure gauge on port (G2). This port will measure the pressure on the backside of the ejector sequence cartridge after it receives the pilot signal from the cylinder. Turn the stem counterclockwise until pressure is witnessed. Next turn the stem clockwise until the pressure goes away, then turn an additional 1/4 turn. Next extend the cylinder 2 - 3 feet.

Then retract the cylinder. During this retract sequence, if you don’t witness a pressure reading on the gauge, reduce the pressure setting on the cartridge by turning the stem counterclockwise until you witness a pressure reading. Once a pressure reading is seen (1000 - 1700 psi), extend the cylinder to it’s full stroke. Begin the retract mode again. If you see a pressure reading on the gauge, before it reaches the pilot of the cylinder, (70” from the end of the stroke) the cartridge is set too low. Increase if necessary by turning the stem clockwise. Continue to adjust until the pressure reading is not seen on the tailgate side of the pilot port. Once setting is satisfied, tighten locknut of cartridge. Remove gauge and re-install plug.

Refer to false bottom sequence cartridge (8).  Move gauge to port (G1). This gauge port will measure the pressure coming out of the false bottom sequence cartridge (8). This phase of the procedure is the same as the ejector cylinder. Turn the stem counterclockwise until pressure is witnessed. Next turn the stem clockwise until the pressure goes away, then turn an additional 1/4 turn. Next extend the false bottom cylinders 2 - 3 feet.

Then retract the cylinders. During this retract sequence, if you don’t witness a pressure reading on the gauge, reduce the pressure setting on the cartridge by turning the stem counterclockwise until you witness a pressure reading. Once a pressure reading is seen (1,000 - 1,700 psi), extend the cylinders to their full stroke.

Begin the retract mode again. If you see a pressure reading on the gauge, before it reaches the pilot of the cylinder, (26” from the end of the stroke) the cartridge is set too low. Increase if necessary by turning the stem clockwise. Continue to adjust until the pressure reading is not seen on the tailgate side of the pilot port. Once setting is satisfied, tighten locknut of cartridge. Remove gauge and re-install plug.

______________________________________________________________ A6474X268 SSVT/01 5.69

Adjustment procedures ________________________________________ Refer to relief cartridge (10).  Relief cartridge (10) is located perpendicular to the ejector and false bottom sequence cartridges. Extend the cylinders until ONLY the false bottom cylinder is extended fully. Then retract the cylinders until ONLY the ejector blade is bottomed out. The flow divider spool is now locked up. If the cylinders cease to move in tandem, where only the false bottom cylinders are moving in this mode, the flow divider cartridge will develop a high pressure on the side of the cartridge of which the cylinder has bottomed out and locked up.

This is the nature of a flow divider spool. To relieve the locked pressure, reduce the pressure setting of the relief cartridge by turning it counterclockwise. Begin retracting again. As the locked pressure is relieved, the false bottom cylinders will begin to drift in the retract mode when operating. Continue to reduce the pressure until the speed of the retract mode is normal. This will generally be around 1,700 psi. You can read this pressure on the “SYSTEM PRESSURE” gauge.

© BUCYRUS AMERICA, INC.

Fig. 68: Tailgate sequence valve adjustment (P/N LUP00781)

_________________________________________________________________ 5.70 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

_______________________________________ Adjustment procedures Tailgate sequence valve adjustment (P/N LUP02119) To adjust the tailgate sequence valve proceed as follows (Fig. 69 and 70).

WARNING! Before moving the “EJECTOR” control lever, always check to make sure no one has any part of their body between the ejector blade/false bottom and the front of the rear (payload) section.

IMPORTANT! Remember that counterbalance cartridges adjust opposite of relief cartridges. Turning the stem clockwise will reduce pressure.

The cartridges on the sequence valve are identified with numbers stenciled on the valve body beside the location of the respective cartridge.

© BUCYRUS AMERICA, INC.

 Ensure that the “SYSTEM PRESSURE” is set as specified on the hydraulic schematic supplied with your machine before beginning this procedure.

Extend cycle Cartridges #3 and #4 should be minimized (Turn adjustment stem out in a counter-clockwise direction), prior to operating the Extend Cycle.

These two cartridges control the sequential operation of the extend function and should prevent any movement of the false bottom or ejector, until the tailgate is fully open. Cartridge #3 controls oil flow to the false bottom cylinders extend ports and Cartridge #4 controls oil flow to the ejector extend port. If adjustment is required, proceed as follows:  If the false bottom or ejector cylinders are extending while the tailgate is being opened, increase the setting of Cartridge #3 first, in full turn increments (Turn adjustment stem in clockwise), to inhibit any movement of the false bottom and ejector cylinders until the tailgate is fully opened. Once this is achieved, you may optimize the cartridge setting by decreasing the adjustment (Counterclockwise direction) in fractional increments (e.g. 1/2hf; 1/4tr; 1/8th turns) to insure that the transition between functions is as smooth as possible. At this point, you may have to increase the adjustment of Cartridge #4 in like fashion to insure that the false bottom reaches full extension before the ejector will move. Again, you should optimize the cartridge setting for the ejector control to insure that the transition between functions is as smooth as possible.

IMPORTANT! Insure that all the jam nuts have been locked down securely before returning the machine to service, to insure that the cartridge settings will be maintained.

______________________________________________________________ A6474X268 SSVT/01 5.71

Adjustment procedures ________________________________________

The sequential operation of the Retract Cycle is controlled by Cartridges #7, #9 and #11. Prior to operating the Retract Cycle, Cartridge #11 should be maximized (Turned in fully in a clockwise direction) to inhibit the retraction of the tailgate and Cartridge #9 should be maximized (Turned in fully in a clockwise direction) to prevent conflict between the false bottom and tailgate operations until other conditions are satisfied. If Cartridge #12 exists (Re: Initial production units), it should always be adjusted to the maximum setting, with the adjustment stem turned in completely, in a clockwise direction. The desired operation will insure that the ejector is the first and only segment of the circuit to be energized and the adjustment of Cartridge #7 must insure that the false bottom will not move until the ejector blade has retracted fully.

Operate the Retract Cycle and note whether or not the false bottom moves while the ejector is retracting. If it does, the adjustment of Cartridge #7 must be increased (Turned in clockwise in fractional increments) until the false bottom remains stationary while the ejector fully retracts. Fractional adjustment of the cartridge stem will allow you to precisely adjust this setting which optimizes the performance of the circuit and allows for a smooth transition between these stages of the operation. If the false bottom does not move during this step, or does not retract once the ejector cycle has been satisfied, Cartridge #7 must be decreased (Turned out counter-clockwise) to a point that induces movement of the false bottom. From that point, fractional increment adjustment of Cartridge #7 must be increased to the minimum setting required to prevent the false bottom from moving. Once this is achieved, the false bottom will retract clear of the tailgate, after the ejector fully retracts. At that point, a signal from a false bottom cylinder pilot port should override Cartridge #11, which will signal Cartridge #5 to shift and divert the oil flow to the tailgate cylinders. This will cause the false bottom to stop/hesitate at that point, until the tailgate closes fully. To optimize the performance of the tailgate retraction, Cartridge #11 may be reduced at this point (Turn stem counter-clockwise in full turn increments).

CAUTION! Limited phases of the retract cycle will be repeated several times at this point and will ultimately result in raising the tailgate up against the false bottom before the final adjustment is reached.

Take care to monitor this process as closely as possible to prevent any excessive mechanical interference between the false bottom and tailgate. Once premature retraction of the tailgate is induced, adjustment of Cartridge #11 must be reversed to increase the setting to a point that prevents the tailgate from binding up against the false bottom as it retracts and is accurately achieved in fractional increments.

_________________________________________________________________ 5.72 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Retract cycle

_______________________________________ Adjustment procedures  The final control to be adjusted is Cartridge #9, which must now be reduced to a setting slightly higher than the system pressure required to close the tailgate. Reduce the adjustment in full turn increments until the false bottom tries to move while the tailgate closes. Once movement of the false bottom has been induced, reverse the adjustment procedure of Cartridge #9 and increase the setting in fractional increments, to a point that will hold the false bottom stationary while the tailgate closes .

IMPORTANT! Insure that all the jam nuts have been locked down securely before returning the machine to service, to insure that the cartridge settings will be maintained.

Fig. 69: Tailgate sequence valve adjustment (P/N LUP02119) 9 4 9 © BUCYRUS AMERICA, INC.

3

11

______________________________________________________________ A6474X268 SSVT/01 5.73

Adjustment procedures ________________________________________

© BUCYRUS AMERICA, INC.

Fig. 70: Tailgate sequence valve adjustment schematic (P/N LUP02119)

_________________________________________________________________ 5.74 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

_______________________________________ Adjustment procedures Gear case and planetary wheel end shim procedure number 1 The purpose of the shim procedure is to set the axial end play between the gear case spacer (bronze) and the planet carrier/wheel end to from 0.005” to 0.030” (loose).

NOTICE! The following procedure is only for installing a new drive, wheel end or gear case only where stamped measurements are visible.

If the drive or wheel end have had parts replaced, refer to Gear case and planetary wheel end shim procedure number 2 in this chapter.

© BUCYRUS AMERICA, INC.

DANGER! You could be seriously injured or even killed by falling loads.

Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.

To calculate the required amount of shims for the gear case and planetary wheel end proceed as follows (Fig. 71).  1. Measure machined plate thickness of wheel well plate. Record figure on line “A”.  2. Locate the value stamped on machined mount face of drive unit (gear case). Record this value on line “B”.  3. Subtract line “B” from line “A” to get line “C”.  4. Locate the value stamped on machined mount face of wheel end. Record this value on line “D”.  5. If “C” is larger then “D”, proceed to step 6. If “D” is larger than “C”, proceed to step 7.  6. Subtract “D” from “C” to get ”E”. Then divide “E” by .025 and round answer up to nearest whole number. This is the number of shims that must be added at location “X”.  7. Subtract “C” from “D” to get ”F”. Then divide “F” by .025 and round answer up to nearest whole number. This is the number of shims that must be removed from location “X”.

A.

If “C” is greater:

IF “D” is greater:

B. -

C.

D.

C.

D.-

C.-

D.

E.

F.

E / .025 = Number of shims to be added

F / .025 = number of shims to be added

______________________________________________________________ A6474X268 SSVT/01 5.75

Adjustment procedures ________________________________________ Gear case and planetary wheel end shim procedure number 2 The purpose of the shim procedure is to set the axial end play between the gear case spacer (bronze) and the planet carrier/wheel end to from 0.005” to 0.030” (loose).

NOTICE! The following procedure is to be used only for gear case and planetary wheel ends that have had parts replaced. For new gear case and planetary wheel end shim procedure, refer to Gear case and planetary wheel end shim procedure number 1 in this chapter.

DANGER! You could be seriously injured or even killed by falling loads.

Observe the safe working load of the lifting and blocking devices and keep a safe distance away from suspended loads.

 1. Install gear case assembly.  2. Remove all shims from behind the bronze bushing. Be sure to remove all axial clearance in the pinion shaft and bushing.  3. Place a straight edge across surface “G” and against the end of the bushing.  4. Stack shims on the pinion shaft at location “Y” until all clearance is taken out between the straight edge and bushing. Get as close as possible to no clearance but not go over. The remaining gap can be measured with a feeler gauge to ensure proper shimming.  5. Get the dimension “D” from the wheel end by the stamped value or by measuring.  6. Remove the quantity of shims from the pinion shaft necessary to be equal to or greater than the dimension “D”.  7. This procedure is designed to give axial clearance of 0.005” 0.030” using 0.025” shims. In some cases this procedure will be more than 0.030” due to the clearance at step 4, plus the clearance at step 6. If large clearances are present at steps 4 and 6, use a feeler gauge at step 4 and math at step 6 to quantify the clearance. If the clearance is greater than 0.030”, remove one shim.

_________________________________________________________________ 5.76 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

To calculate the required amount of shims for the gear case and planetary wheel end proceed as follows (Fig. 71).

_______________________________________ Adjustment procedures

© BUCYRUS AMERICA, INC.

Fig. 71: Gear case and planetary wheel end shim procedure

______________________________________________________________ A6474X268 SSVT/01 5.77

Adjustment procedures ________________________________________ Brake pedal valve and HDC actuator adjustment (if equipped) To adjust the brake pedal valve and HDC actuator proceed as follows (Fig. 72).

WARNING! Chock all wheels from both directions and install steering lock before proceeding with component replacement and/or adjustment procedures, to ensure the unintentional movement of the machine is inhibited. Failure to follow appropriate safety measures could result in personal injury or death.

Preparation:  Insure that the hydraulic and brake systems are completely installed and fully functional.

 Adjust the stop bolt so it does not contact the pedal.  Install multi-gauges or 0 - 1,500 psi test gauges in the actuator line (“A” port) of the brake de-modulating valve and the actuator line (“A” port) of the HDC actuator valve.

Testing:  Start the pump motor and note the system pressure of the accumulator circuit (normal range is 1,200 - 1,500 psi). If pressure is outside the normal range or the accumulator charging circuit fails to operate properly, follow corrective actions to resolve the issue before proceeding with brake valve and HDC actuator adjustment.  Release brakes and note the test gauge reading of the brake circuit (normal range is 900 - 1,100 psi). If pressure is outside the normal range, follow corrective actions to resolve the issue before proceeding with brake valve and HDC actuator adjustment.

_________________________________________________________________ 5.78 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 Footboard must be in place and secured.

_______________________________________ Adjustment procedures Adjustment: CAUTION! Actuation of the brake pedal with the side plate or link bushing removed will result in damage to the link and could result in malfunction or failure of the brake. Always insure that the side plate or link bushing are fully installed on the link when actuating the brake pedal.

© BUCYRUS AMERICA, INC.

 Slowly depress the brake pedal and note the brake circuit test gauge pressure. If the pressure falls to zero (0) psi before the pedal contacts the footboard, the connector must be disconnected from the pedal and turned out (CCW). If the pressure fails to fall to zero (0) psi when the pedal contacts the footboard, the connector must be turned in (CW) until this is achieved. Brake link must be removed each time an adjustment is made to the connector and must be fully installed prior to next step.   After proper adjustment of the activated pedal travel has been achieved, depress the pedal fully and lock the jam nut against the connector to hold it securely in place.  With the pedal de-activated, adjust stop bolt out (CCW) against the brake pedal until the brake circuit pressure on the test gauge begins to fall. This will remove all free travel from the brake pedal actuation. At that point, lock jam nut down to prevent the stop bolt from getting out of adjustment.  Move now to the HDC actuator. Loosen the jam nut on the adjustment bolt and loosen the two (2) anchor bolts that secure the HDC actuator mounting bracket. The desired pressure reading on the HDC actuator test gauge is zero (0) psi, while the machine is running and the brake pedal is in rest (deactivated) position. If pressure is present on the HDC actuator test gauge, back the adjustment bolt out (CCW) until this is achieved. At that point, tighten the two (2) anchor bolts down and confirm that the pressure remains at zero (0) psi once they are torqued down. The jam nut may now be tightened to secure the adjustment bolt in place. If pressure is not present while the machine is running and the brake pedal is in at rest (deactivated) position, the adjustment bolt must be turned in (CW) until pressure becomes visible on the test gauge of the HDC actuator circuit. Once pressure is noted here, back the adjustment bolt out (CCW) just to the point that the pressure has been exhausted. At this point, tighten the two (2) anchor bolts down and confirm that the zero (0) psi setting has been maintained. The jam nut for the adjustment bolt should be tightened to secure it in place.  The wheel chocks and steering lock may now be removed to allow for controlled performance tests to be performed. Prior to putting the machine into service, tram the machine in an area away from others and confirm that proper brake performance has been successfully achieved.

______________________________________________________________ A6474X268 SSVT/01 5.79

Adjustment procedures ________________________________________ Fig. 72: Brake pedal valve and HDC actuator adjustment

Brake pedal link

Connector

Link bushing

Jam nut

Brake pedal actuator

Footboard

“A” Port Brake de-modulating valve

Section E-E

Brake pedal “A” Port HDC actuator

Section A-A

Section B-B HDC valve mounting bolts

HDC valve cover plate

HDC valve

Section C-C

Section D-D

_________________________________________________________________ 5.80 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Stop bolt

_______________________________________ Adjustment procedures Linear pedal adjustment (if equipped) To adjust the linear position of the pedals proceed as follows (Fig. 73).  Turn the handle counterclockwise to move the pedals away from the operator.  Turn the handle clockwise to move the pedals toward the operator.

Fig. 73: Linear pedal adjustment

© BUCYRUS AMERICA, INC.

Linear pedal adjustment

______________________________________________________________ A6474X268 SSVT/01 5.81

© BUCYRUS AMERICA, INC.

Adjustment procedures ________________________________________

_________________________________________________________________ 5.82 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

_______________________________________________________________

6

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the UN-AHAULER ®. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

The technical data listed in this chapter is for stock machines only.

Customer specials may not be listed.

Components of the CH810C UN-A-HAULER ® Technical data sheet

© BUCYRUS AMERICA, INC.

general

performance

Overall length: Overall width tractor (extended deck option): Overall width w/ 10.00 dual tires on tractor and 14.50XR15 tires on trailer: Overall width trailer: Wheelbase: Weight (empty less battery): Weight (w/ 64-SS100-25 battery): Weight (w/ 64-SS85-25 battery): Design gross vehicle weight: Material capacity (max.): Component load capacity (max.): Cubic feet capacity (max. payload—calculated) (w/no sideboards or tailgate) (heaped): (struck): Ground clearance (w/ 10.00R15 dual tires on tractor and 14.50XR15 tires on trailer): Ground clearance (w/ 400/80R15 tires): Min. canopy height (w/ 10.00R15 dual tires on tractor and 14.50XR15 tires on trailer): Min. canopy height (w/ 400/80R15 tires): Trailer height (w/ 10.00R15 dual tires on tractor and 14.50XR15 tires on trailer): Trailer height (w/ 400/80R15 tires): Trailer frame height (w/ 10.00R15 dual tires on tractor and 14.50XR15 tires on trailer): Trailer frame height (w/ 400/80R15 tires):

approx. 38’ 4” approx. 11’ 1”

Inside turning radius: Outside turning radius: Minimum entry width: Steering articulation: Tram speed: (speed will vary depending gear box ratios): Discharge time: Terrain compensation articulation:

approx. 11’ 6 approx. 24’ 4” approx. 15’ 6” 120° total

approx. 11’ 3” approx. 10’ 8” approx. 19’ 9” approx. 52,900 lbs approx. 71,000 lbs approx. 69,500 lbs approx. 91,000 lbs approx. 20,000 lbs approx. 24,000 lbs approx. 436 cu ft approx. 221 cu ft approx. 8” approx. 10” approx. 40” approx. 41 approx. 38” approx. 41” approx. 36” approx. 39”

approx: 0-5 mph approx: 30 seconds approx: (+) 15° approx: (-) 10°

______________________________________________________________ A6474X268 SSVT/01 6.3

Technical data ________________________________________________ drive train

brakes (service)

Two (2) proprietary design, double reduction parallel primary reducers equipped with integral multiple wet disc brakes and axle shaft mounted to proprietary design planetary wheel end.

Two (2) hydraulically actuated, multiple wet disc brakes.

brakes (automatic)

Spring applied, hydraulic released braking system controlled by electrical/hydraulic solenoid and equipped with totally enclosed multiple wet disc brake in each drive unit, manual hand pump release, and glycerin filled pressure monitoring system.

hydraulic

Pump motor: Mine duty laminated frame, direct current motor rated at 16 hp at 1,630 rpm and 110 volts for 1 hour; MSHA totally enclosed explosion proof; non-ventilated cooling; foot mounted.

Reservoir: 51 gallon capacity reservoir equipped with breather and removable suction strainer.

Valve bank: Five-section parallel type equipped with glycerin filled pressure monitoring gauge for following the machine functions; steering, false bottom/ ejector blade, battery changer, terrain compensation and battery lock.

Hydraulic PTO: Two (2) quick coupler connections and a 1,200 psi recommended operating pressure.

Steering cylinder: Two (2) double acting cylinders with 2.5” forged rods. Shock absorbing HIC suspension system.

Battery changer cylinder: Two (2) double acting cylinders with 2.5” forged rods and internal load checks. frame

Heavy duty with bends utilized where applicable to reduce the number of indeterminate stresses introduced in welding.

center section

Heavy duty, dual articulating joint, welded steel construction with steel pivot pins, complete with horizontal self-aligning pivot thrust bearings on the primary articulation and ball bearing on secondary articulation with an axial load rating of 576,000 lbs.

battery changer

Hydraulically operated integral system including flow divider for level operation. The machine is equipped with a ground base change system.

No battery stands are required.

_________________________________________________________________ 6.4 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Pump: Main hydraulic system, 1.5” gear type pump directly splined to pump motor rated at 26 gpm at 2,300 psi and monitored by a glycerin filled main system pressure gauge.

_______________________________________________ Technical data Components of the CH816C UN-A-HAULER ® Technical data sheet

© BUCYRUS AMERICA, INC.

general

performance

drive train

brakes (service)

Overall length: approx. 39’ 9” Overall width tractor (extended deck option): approx. 11’ 2” Overall width tractor (w/o extended deck option): approx. 10’ 8” Overall width trailer: approx. 10’ 8” Wheelbase: approx. 19’ 10” Weight (empty less battery): approx. 56,300 lbs Weight (w/ 64-SS100-25 battery): approx. 75,700 lbs Weight (w/ 64-SS125-25 battery): approx. 76,300 lbs Design gross vehicle weight: approx. 112,300 lbs Component load capacity (max.): approx. 36,000 lbs Cubic feet capacity (max. payload—calculated) heaped with no sideboards approx. 609 ft³ heaped with 6” sideboards approx. 679 ft³ heaped with 12” sideboards approx. 747 ft³ Ground clearance (with 44” tires): approx. 12” Canopy height (min) (with 44” tires): approx. 52” Trailer height (w/ 44” tires at top of false bottom):approx. 48” Frame height (with 44” tires): approx. 46” Inside turning radius: Outside turning radius: Minimum entry width: Steering articulation: Tram speed: (speed will vary depending gear box ratios): Discharge time: Terrain compensation articulation:

approx. 11’ 4” approx. 24’ 11” approx. 16’ 4” 120° total approx: 0-5 mph approx: 30 seconds approx: (+) 15° approx: (-) 10°

Two (2) proprietary design, double reduction parallel primary reducers equipped with integral multiple wet disc brakes and axle shaft mounted to proprietary design planetary wheel end.

Two (2) hydraulically actuated, multiple wet disc brakes.

brakes (automatic)

Spring applied, hydraulic released braking system controlled by electrical/hydraulic solenoid and equipped with totally enclosed multiple wet disc brake in each drive unit, manual hand pump release, and glycerin filled pressure monitoring system.

frame

Heavy duty with bends utilized where applicable to reduce the number of indeterminate stresses introduced in welding.

center section

Heavy duty, dual articulating joint, welded steel construction with steel pivot pins, complete with horizontal self-aligning pivot thrust bearings on the primary articulation and ball bearing on secondary articulation with an axial load rating of 576,000 lbs.

battery changer

Hydraulically operated integral system including flow divider for level operation. The machine is equipped with a ground base change system. No battery stands are required. ______________________________________________________________ A6474X268

SSVT/01

6.5

Technical data ________________________________________________ hydraulic

Pump Motor: Mine duty laminated frame, direct current motor rated at 16 hp at 1,630 rpm and 110 volts for 1 hour; MSHA totally enclosed explosion proof; non-ventilated cooling; foot mounted.

Pump: Main hydraulic system, 1.5” gear type pump directly splined to pump motor rated at 26 gpm at 2,300 psi and monitored by a glycerin filled main system pressure gauge.

Reservoir: 54 gallon capacity reservoir equipped with a wire screen cap, dipstick, breather and removable suction strainer.

Hydraulic PTO: Two (2) quick coupler connections and a 1,200 psi recommended operating pressure.

Steering cylinder: Two (2) double acting cylinders with 2.5” forged rods and a shock absorbing HIC suspension system.

Battery changer cylinder: Two (2) double acting cylinders with 2.5” forged rods and internal load checks.

_________________________________________________________________ 6.6 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Valve bank: Five-section parallel type equipped with glycerin filled pressure monitoring gauge for following the machine functions; steering, false bottom/ ejector blade, battery changer, terrain compensation and hydraulic power take off (detented).

_______________________________________________ Technical data Components of the CH816CL UN-A-HAULER ® Technical data sheet general

© BUCYRUS AMERICA, INC.

performance

drive train

brakes (service)

Overall length: approx. 39’ 3” Overall width tractor (w/ extended deck): approx. 11’ 2” Overall width tractor (w/out extended deck): approx. 10’ 8” Overall width trailer: approx. 10’ 8” Wheelbase: approx. 19’ 7” Weight (empty less battery): approx. 56,820 lbs Weight (w/64-SS100-25 battery): approx. 75,000 lbs Design gross vehicle weight: approx. 99,000 lbs Component load capacity (max.): approx. 24,000 lbs Cubic feet capacity (heaped w/no sideboards): approx. 590 ft³ Ground clearance (with 38” tires): approx. 9” Canopy height (min) (with 38” tires): approx. 42.”

Trailer height (w/ 38” tires at top of false bottom):approx. 44” Frame height (with 38” tires): approx. 34” Turning radius: Inside turning radius: Outside turning radius: Minimum entry width: Steering articulation: Tram speed: (speed will vary depending on floor conditions): Discharge time: Terrain compensation articulation:

approx. 11’ 4” approx. 24’ 11” approx. 16’ 4” 120° total approx: 0-5 mph approx: 30 seconds approx: (+) 15° approx: (-) 10°

Two (2) proprietary design, double reduction parallel primary reducers equipped with integral multiple wet disc brakes and axle shaft mounted to proprietary design planetary wheel end.

Two (2) hydraulically actuated, multiple wet disc brakes.

brakes (automatic)

Spring applied, hydraulic released braking system controlled by electrical/hydraulic solenoid and equipped with totally enclosed multiple wet disc brake in each drive unit, manual hand pump release, and glycerin filled pressure monitoring system.

frame

Heavy duty with bends utilized where applicable to reduce the number of indeterminate stresses introduced in welding.

center section

Heavy duty, dual articulating joint, welded steel construction with steel pivot pins, complete with horizontal self-aligning pivot thrust bearings on the primary articulation and ball bearing on secondary articulation with an axial load rating of 576,000 lbs.

battery changer

Hydraulically operated integral system including flow divider for level operation. The machine is equipped with a ground base change system. No battery stands are required.

______________________________________________________________ A6474X268 SSVT/01 6.7

Technical data ________________________________________________ hydraulic

Pump: Main hydraulic system, 1.5” gear type pump directly splined to pump motor rated at 26 gpm at 2,300 psi and monitored by a glycerin filled main system pressure gauge.

Reservoir: 56 gallon capacity reservoir equipped breather and removable suction strainer.

Valve bank: Five-section parallel type equipped with glycerin filled pressure monitoring gauge for the following machine functions; steering, false bottom/ ejector blade, battery changer, terrain compensation, and hydraulic power take off (detented).

Steering cylinder: Two (2) double acting cylinders with 2.5” forged rods and shock absorbing HIC suspension system.

Battery changer cylinder: Two (2) double acting cylinders with 2.5” forged rods and internal load checks.

_________________________________________________________________ 6.8 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Hydraulic PTO: Two (2) quick coupler connections and a 1,200 psi recommended operating pressure.

___________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Set screws

© BUCYRUS AMERICA, INC.

Table 4: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8 #10

9 in-lbs 13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

Table 5: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

______________________________________________________________ A6474X268 SSVT/01 6.9

Tightening torques ____________________________________________

Nominal diameter

Recommended torque setting

¼”

9 ft-lbs

5/16”

18 ft-lbs

3/8”

31 ft-lbs

7/16”

50 ft-lbs

½”

75 ft-lbs

9/16”

110 ft-lbs

5/8”

150 ft-lbs

¾”

250 ft-lbs

7/8”

378 ft-lbs

1”

583 ft-lbs

1 1/8”

782 ft-lbs

1 ¼”

1,097 ft-lbs

1 3/8”

1,461 ft-lbs

1 ½”

1,748 ft-lbs

1 ¾”

3,114 ft-lbs

2” 2 ¼”

4,504 ft-lbs 6,497 ft-lbs

2 ½”

7,144 ft-lbs

2 ¾”

12,092 ft-lbs

3”

15,744 ft-lbs

Table 7: Socket, flat & button head cap screws (Steel only) Nominal diameter

Recommended torque setting

#6 #8 #10 ¼”

26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs

5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

_________________________________________________________________ 6.10 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Table 6: FSR hex bolts (SAE 5 and 325 steel)

___________________________________________ Tightening torques Table 8: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

© BUCYRUS AMERICA, INC.

Table 9: Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 10: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

______________________________________________________________ A6474X268 SSVT/01 6.11

Tightening torques ____________________________________________ Table 11: Untreated screw, black finish (Fine thread) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25

Nm

27

52

95

Ft-lbs

19

38

70

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

8.8 10.9 12.9

Nm

150

225

325

Ft-lbs

110

165

239

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

© BUCYRUS AMERICA, INC.

Table 12: Untreated screw, black finish (Fine thread, continued) PropTorqu Recommended Nominal diameter erty e torque setting class Ma M14 X 1.5 M16 X 1.5 M18 X 1.5

Table 13: Untreated screw, black finish (Fine thread, continued) Property class

Torque Ma

8.8

Nm

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399

Ft-lbs 10.9 12.9

610

780

449

575

Nm

640

860

1100

Ft-lbs

472

634

811

Nm

770

1050

1300

Ft-lbs

567

774

958

_________________________________________________________________ 6.12 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

___________________________________________ Tightening torques Table 14: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M33 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

© BUCYRUS AMERICA, INC.

Table 15: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nm

36

Ft-lbs

26

42

Nm

83

132

Ft-lbs

61

97

58

Nominal diameter M18

M20

M22

121

171

230

54

89

126

169

200

275

390

530

147

202

287

390

88

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 16: Electrically zinc plated (Coarse thread, continued) Property class 5.6

8.8

10.9

12.9

Torque Ma

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

______________________________________________________________ A6474X268 SSVT/01 6.13

Tightening torques ____________________________________________ Table 17: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

Torque Ma Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

Recommended torque setting M8 X 1 25 18 35 25 42 30

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 18: Electrically zinc plated (Fine thread, continued)

8.8 10.9 12.9

Torque Ma

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 19: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

_________________________________________________________________ 6.14 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Property class

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© BUCYRUS AMERICA, INC.

NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc.! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Bucyrus America, Inc. expressly point out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be disposed of per your local EPA standards.

______________________________________________________________ A6474X268 SSVT/01 6.15

Permissible media ____________________________________________ Approved suppliers:

Supplier

Brand name

1

Amoco Oil Company

Amoco AW oil No.68

2

Gulf oil

Harmony 68 AW

3 4

Mobil Oil Corporation Chevron U.S.A.

5

Sun Oil Company

Mobil DTE-16 Chevron hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hyldraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers

Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

_________________________________________________________________ 6.16 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Table 20: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 21: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460

6

Unocal 76

7

Shell Oil company

8

Century Lubricating Oils, Inc.

9

Texaco Lubricants Company

Hulbest EP-7 Powergear 460 Meropa 680

10

Exxon

Spartan EP 460

11

Pennzoil

Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube

12

Lubricating Engineers

608 Almosal Vari-Purpose Gear Lubricant

13

Conoco Inc.

Gear oil 460

14

Hydrotex

933 Industrial Gear Lubricant

15

Phillips

16

Miners Oil

All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680

______________________________________________________________ A6474X268 SSVT/01 6.17

Permissible media ____________________________________________

Supplier

Brand name

1

Amoco Oil Company

2 3 4

Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil company Century Lubricating Oils, Inc.

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Amolith grease 2 EP Rykon Premium Grease 2 EP Gulfcrown grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Table 23: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century oils Limited Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

_________________________________________________________________ 6.18 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Table 22: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ Permissible media Table 24: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company

5 6

Cincinnati – Vulcon Company Cities Service Oil company

7 8

10 11

Century Oils limited Fiske Bros. Refining Company Getty Oil company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

12 13 14 15 16 17

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and chemical Co. Pennzoil Quaker Chemical Company

18

Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

© BUCYRUS AMERICA, INC.

9

19 20 21

22 23

Standard Oil Company of Ohio (Boron Sohio) Sun Oil company Tower Oil Company

24 25

Wynn Oil company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion fire resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR

Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant hydraulic Fluid HY-Guard

______________________________________________________________ A6474X268 SSVT/01 6.19

Permissible media ____________________________________________

Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

_________________________________________________________________ 6.20 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Table 25: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 26: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) Supplier Brand name 1

Amoco Oil Company

American Industrial Oil No. 68

2

Gulf oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy – Medium

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754

6

Unocal 76

7

Shell Oil Company

Unax RX68 or Turbine Oil 68 Turbo 68

8

Century Lubricating Oils, Inc.

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

______________________________________________________________ A6474X268 SSVT/01 6.21

Permissible media ____________________________________________

1

Amoco Oil Company

American Industrial oil No. 150

2

Gulf Oil

Harmony 150

3 4

Mobil Oil Corporation Chevron U.S.A.

5

Sun Oil Company

DTE Oil EX. Heavy Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961

6

Unocal 76

7

Shell Oil company

Unax RX 700 or Turbine Oil 700 Turbo 150

8

Century Lubricating Oils, Inc.

Centraulic R&O 150

9

Atlantic Richfield Company

10

Texaco Lubricants Company

Duro 600 or S-700 Regal Oil R&O 150

11

Exxon

Teresstic 150

12

Pennzoil

Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15

Conoco Inc.

Dectol R&O 76

16

Hydrotex

System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Table 28: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier Brand name 1 Amoco Oil Company Cylinder oil No. 1000 2 Mobil Oil Corporation Extra Hecla Super Cylinder Oil 3 Chevron U.S.A. Chevron Cylinder Oil W ISO 1000 4 Sun Oil Company Sun Steam Cylinder Oil 5 Unocal 76 Worm gear Lube 250 or Stevalc 6 Century Lubricating Oils, Inc. Garwal 680 7 Atlantic Richfield Company Modoc 195 8 Texaco Lubricants Company 650 T Cylinder Oil 1000 9 Exxon Cylesstic TK-1000 10 Pennzoil Cylinder Oil #1000 11 Conoco Inc. Inca Oil 1000

_________________________________________________________________ 6.22 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Table 27: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 29: Light gear oil, SAE 40 motor oil (Spec. 100-10)

1 2 3 4

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 30: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

______________________________________________________________ A6474X268 SSVT/01 6.23

© BUCYRUS AMERICA, INC.

Permissible media ____________________________________________

_________________________________________________________________ 6.24 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

_______________________________________________________________

7

For your information

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

© BUCYRUS AMERICA, INC.

Service address Beckley, WV 200 George Street, Suite 4 Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA (Corporate Headquarters) 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 Oak Hill, WV 25901

Paonia, CO P.O. Box 566 Paonia, CO 81428

Price, UT 1814 North 1500 West P.O. Box 1016 Price, UT 84501 Phone: (435) 637-3930 Fax: (435) 637-9754

719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846 Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

______________________________________________________________ A6474X268 SSVT/01 7.3

Our service __________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

© BUCYRUS AMERICA, INC.

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

_________________________________________________________________ 7.4 BUCYRUS – Models CH810C, CH816C, and CH816CL UN-A-HAULER ®

OPERATION, PREVENTIVE MAINTENANCE, TROUBLESHOOTING AND GUIDE MODELS BUCYRUS 5, 6, 8, 10, 12 AND 14 BATTERY CHARGERS WITH DIGITAL DISPLAY

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. P/N A6474X230 Revision 1, December / 07  BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED

Bucyrus America, Inc. ________________________________________________________________ 4041 Wurno Road Telephone: 540-980-4530 Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.bucyrus.com

Bucyrus America, Inc.

TABLE OF CONTENTS Page PREFACE ............................................................................................................................................... 1 SYMBOLS AND SPECIAL NOTATIONS ................................................................................................ 2 MAJOR HAZARDS ................................................................................................................................. 4 SAFETY PRECAUTIONS AND GUIDELINES ......................................................................................... 5 OVERVIEW............................................................................................................................................. 5 LOCATION ............................................................................................................................................. 5 PRE-START ........................................................................................................................................... 5 MAINTENANCE ....................................................................................................................................... 6 THEORY OF OPERATION FERRORESONANT DESIGN....................................................................... 8 INTRODUCTION ..................................................................................................................................... 9 GENERAL .............................................................................................................................................. 9 GENERAL INFORMATION ................................................................................................................... 10 RECEIVING INSTRUCTIONS ............................................................................................................... 10 HANDLING ........................................................................................................................................... 10 NOMENCLATURE PLATES ................................................................................................................. 10 ADJUSTMENTS ................................................................................................................................... 10 SPARE PARTS..................................................................................................................................... 10 RATINGS AND SPECIFICATIONS ....................................................................................................... 11 OUTPUT RATINGS ................................................................................................................................ 11 INPUT RATINGS .................................................................................................................................... 11 TYPICAL ELECTRICAL SPECIFICATIONS ................................................................................................... 11 STANDARD FEATURES .......................................................................................................................... 12 OPTIONAL GROUND INTEGRITY .............................................................................................................. 12 ENVIRONMENTAL RATINGS .................................................................................................................... 13 INSTALLATION INFORMATION........................................................................................................... 14 MINIMUM W IRE SIZES ........................................................................................................................... 14 ELECTRICAL CONNECTIONS & FIELD W IRING ........................................................................................... 14 OPERATION ......................................................................................................................................... 16 START UP (ELECTRONIC TIMER) ............................................................................................................ 16 ADJUSTMENTS ..................................................................................................................................... 17 CIRCUIT OPERATION............................................................................................................................. 17 TROUBLESHOOTING .......................................................................................................................... 18 GENERAL INSPECTION .......................................................................................................................... 18 SERVICE INFORMATION ......................................................................................................................... 18 I

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Bucyrus America, Inc.

SYMPTOMS AND CAUSES ...................................................................................................................... 19 GROUND AND SHORT CIRCUIT TEST ....................................................................................................... 19 TROUBLESHOOTING AND REPLACING POWER SILICON DIODES .................................................................. 20 CHECKING CAPACITORS........................................................................................................................ 20

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

PREFACE This manual is intended to provide GENERAL product information for Bucyrus Series Battery Chargers.

The illustrations, descriptions and procedures contained in this publication apply only to Bucyrus Series Battery Chargers.

Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Bucyrus Series Battery Charger was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U. S. regulatory agency standards.

At the completion of the manufacturing process, the charger was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of the charger, without the consent of Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render the charger unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this charger.

While this manual attempts to anticipate the most important operations and maintenance needs for this charger, unforeseen circumstances may arise that have not been

addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is nontransferable. Distribution and access is limited only to authorized personnel.

Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

 Bucyrus America, Inc. All rights reserved.

Bucyrus America, Inc.

SYMBOLS AND SPECIAL NOTATIONS Throughout this manual there are specific notations that are either UPPERCASE BOLD, UNDERLINED or ITALICIZED for the primary purpose of emphasis. Please pay special attention to such statements as they regard safety or critical maintenance installation information.

You will also see the following:

NOTICE: THIS NOTATION DENOTES A REFERENCE TO PREVIOUSLY STATED INSTRUCTIONS.

IMPORTANT: THIS SYMBOL DENOTES THAT SPECIAL ATTENTION MUST BE ADHERED TO IN THE ATTACHED STATEMENT.

CAUTION: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A CUT, BRUISE OR ABRASION.

WARNING: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A LOST TIME ACCIDENT.

DANGER: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A SERIOUS INJURY OR FATALITY.

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

DANGER ONLY TRAINED AUTHORIZED PERSONNEL SHOULD OPERATE OR PERFORM MAINTENANCE ON THE CHARGER. FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH. FAILURE TO OPERATE OR MAINTAIN THIS CHARGER IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

3

Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

ELECTRICAL (A.C. Input, Charger, Battery)

Electrical shock could cause irreparable injury or death.

All electrical systems should be maintained by certified electricians.

The a.c. input and charger plug should be disconnected before servicing the charger.

Charging a battery of a size different than that shown on the charger nameplate could cause the battery to burst, or cause damage to the battery or charger.

Chargers should be matched to the size batteries in use at each particular mine.

The battery produces lethal amounts of power whether connected to the machine or charger, or not.

The battery should be maintained by qualified personnel. (Refer to Bucyrus America, Inc. "INSTALLATION, USE, MAINTENANCE, AND REPAIR OF MINE POWER STORAGE BATTERIES,” PART NUMBER A6474X26, for complete instructions).

Battery covers could fall crushing hands or arms.

Be sure cover supports are in place when working on battery.

Battery hold-down clamps could crush fingers.

Keep fingers away from hold-down clamps.

Batteries produce explosive gases that could be ignited causing burns or explosions.

Batteries should be well vented before servicing particularly if welding or burning on the battery.

Batteries should be maintained by qualified personnel.

Batteries contain strong acid that could cause severe burns if spilled or splashed on body parts or in the eyes.

Protective clothing, gloves, and eyewear must be worn when working on batteries. Batteries should be maintained by qualified personnel.

BATTERY

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

SAFETY PRECAUTIONS AND GUIDELINES Overview Before using this equipment, read all instructions and cautionary markings on (1) unit, (2) battery, and (3) product using the battery.

READ and STUDY this guide. KNOW how to safely use the unit's controls and what you must do for safe operation and maintenance.

ALWAYS wear or use the proper safety items required for your personal protection.

If you have ANY QUESTIONS about the safe use or maintenance of this unit: ASK YOUR SUPERVISOR - NEVER GUESS - ALWAYS CHECK

Location LOCATE the charging station away from rain, snow, wet conditions or areas of high traffic when possible.

NEVER place this unit directly above a battery. equipment.

Gases from the battery will corrode and damage

NEVER allow the battery electrolyte to drop on this unit when reading the specific gravity or filling the battery.

DO NOT operate this unit in a closed in area or restrict ventilation in anyway.

DO NOT set a battery on top of this unit

Pre-Start Read this entire guide BEFORE attempting to operate this unit. You should be familiar with the controls and their functions before the unit is energized.

DO NOT operate this equipment if it has received a sharp blow been dropped, or otherwise damaged in any way; take it to a qualified service technician.

INSPECT the charger by doing a pre-operational inspection. Have any broken or missing parts corrected or replaced before use.

VERIFY that all maintenance has been performed.

VERIFY that all the instruction and safety labels are in place and readable. These are as important as any other equipment on the machine.

CLEAN any foreign material from inside the charger cabinet.

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

Starting ALWAYS follow all safety rules of each particular mine when operating the charger.

If problems or equipment malfunctions are encountered while operating the unit, it must be properly shutdown and the problem repaired. Continuing to use malfunctioning equipment can not only be unsafe for the operator and other personnel but can lead to further damage to the unit as well.

Before using this equipment, read all instructions and cautionary markings on the charger and the battery.

Maintenance AVOID, whenever possible, servicing, cleaning or examining the charger in congested areas.

DO NOT alter the electrical settings from that indicated in this operation guide or as set at the factory.

DO NOT disassemble this unit; take it to a qualified service technician if service or repair is required.

Incorrect reassemble may result in a risk of electric shock or fire.

ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Section for the proper location and part number of decals and plates.

DISCONNECT the battery when working with electrical systems, or when welding on the unit to prevent electrical shock.

To help reduce risk of electric shock, disconnect this unit from the AC power supply and batteries before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

BE SURE the battery area is well ventilated (clear of fumes) when it is connected to the battery charger or when working on or around the battery with sparks or flames. Fumes from the battery could ignite by a spark and explode.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

USE ONLY THE NUMBER AND TYPE OF BATTERIES SPECIFIED ON NAMEPLATE. ATTEMPTING TO CHARGE OTHER TYPES OF BATTERIES COULD CAUSE THE BATTERY TO BURST, CAUSING PERSONAL INJURY OR DAMAGE. BATTERIES PRODUCE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF THE UTMOST IMPORTANCE THAT EACH TIME BEFORE USING THIS UNIT, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY. To reduce risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of any other equipment you intend to use in the vicinity of the battery.

Review cautionary marking on all products.

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

Personal Precautions Have someone within range of your voice or close enough to come to your aid when you work near a battery.

Have plenty of fresh water and soap nearby in case the battery electrolyte contacts skin, clothing, or eyes.

Wear complete eye protection and clothing protection. Avoid touching eyes while working near a battery.

If the battery electrolyte contacts skin or clothing, wash immediately with soap and water. If the electrolyte enters the eye, immediately flood the eye with running cold water for at least ten (10) minutes and get medical attention immediately.

NEVER smoke or allow a spark or flame in vicinity of a battery.

Avoid dropping metal tools onto a battery. It might spark or short circuit the battery or other electric parts that could cause an explosion.

REMOVE personal metal items such as rings, bracelets, necklaces, and watches when working with a battery. A battery can produce a short circuit current high enough to weld a ring or the like to metal, causing a severe burn.

NEVER charge a frozen battery.

If it is necessary to remove the battery connections, always remove the grounded terminal from the battery first. Make sure all loads are disconnected and unit is off, so as not to cause an arc.

Be sure the area around the battery is well ventilated while the battery is being charged.

When cleaning battery terminals, be careful to keep corrosion from coming in contact with the eyes.

Study all the battery manufacturer's specific precautions such as do not remove cell caps while charging, recommended rates of charge, and maintenance procedures.

7

Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

THEORY OF OPERATION FERRORESONANT DESIGN The transformer in a ferroresonant design is non-linear. Its secondary is operated in saturation while the primary is operated in the linear region of the B-H curve.

A magnetic shunt is used to separate the primary and secondary fluxes, which are at different levels.

This non-linear operation means that the transformer no longer obeys the turn’s ratio laws of the linear transformer. That is, the secondary voltage is no longer a function of the turns ratio times the primary voltage. This means that changes in the primary voltage do not directly affect the secondary voltage value.

The secondary voltage is proportional to the voltage across the resonating winding only. The voltage of the resonating winding is affected by the amount of magnetic coupling to the primary, and by careful selection of magnetic shunts and capacitor values. Thus a battery charging curve can be established.

The charging curve is essentially fixed and can only be altered by changes in the transformer design.

Under short circuit conditions, the amount of primary to secondary magnetic coupling determines the value of the output current limit.

Rectifiers are added to convert the output of this A.C. regulator into D.C. The ferroresonant circuit requires a good grade of capacitor in the resonating circuit to improve reliability and a careful design of the transformer. That is the principle of the ferroresonant design.

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

INTRODUCTION The Bucyrus America, Inc. Series Charger can be one of the most useful and safe machines found underground today, IF IT IS OPERATED CORRECTLY BY A PROPERLY TRAINED OPERATOR. Before operating the Bucyrus Series Charger, study the illustrations to become familiar with the controls and read the description of each control.

General The Bucyrus Series Mine Battery Charger combines reliable, rugged components with unmatched circuit simplicity.

The ferroresonant design of the Bucyrus Series Charger eliminates the need for complicated control circuits and lowers the parts count.

Three major components make up the circuit of the Bucyrus Series Charger; a ferroresonant step down transformer; silicon rectifiers, and timer.

The magnetics are designed with an extra margin of capacity and have a Class H (180 degrees C) rating.

Cores and windings are insulated with Class H Nomex material. The DuPont Nomex system uses a modified polyester baking varnish for further protection. This assures continued operation under the most severe, damp and dirty conditions present in the mine.

The full wave rectifier includes conservatively rated silicon diodes and surge suppressers to provide a reliable d. c. output.

The Bucyrus Series Charger regulates the d. c. output voltage to produce the proper charging curves for the battery. Its charge rate is dependent on the state of charge of your battery. A.C. line voltage compensation prevents any drift from the d. c. charging curve because of surges or drops in voltage.

Basic design eliminates the need for voltage sensitive relays.

The Bucyrus Series a Charger automatically limits the output of the charger to approximately 125% of its rating. This prevents battery overheating, fuse blowing and assures long life for both battery and charger.

The Bucyrus Series Charger is a completely automatic constant voltage charger. Each Bucyrus Series Charger is designed to operate on a specific type of battery with a specified number of cells.

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

GENERAL INFORMATION TO ENSURE SAFE INSTALLATION AND OPERATION, THE INFORMATION GIVEN IN THIS INSTRUCTION MANUAL SHOULD BE READ AND UNDERSTOOD BEFORE INSTALLING OR USING THE EQUIPMENT.

RECEIVING INSTRUCTIONS Unpacking and Inspection: Examine the shipping crate upon arrival. If there is obvious damage, describe on the receiving documents. Within a few days after delivery, the equipment should be uncrated and carefully inspected for hidden damages. When removing packaging material, be careful not to discard any equipment, parts, or manuals

HANDLING EQUIPMENT CAN BE VERY HEAVY, AND TOP HEAVY. USE ADEQUATE MANPOWER OR EQUIPMENT FOR HANDLING. UNTIL THE EQUIPMENT IS SECURELY MOUNTED, CARE MUST BE USED TO PREVENT THE EQUIPMENT FROM BEING ACCIDENTALLY TIPPED OVER.

NOMENCLATURE PLATES Each Bucyrus Series Charger shipped is identified by part number on the nomenclature plate.

ADJUSTMENTS All equipment is shipped from the factory fully checked and adjusted. Do not make any adjustments unless the equipment has been powered-up and the settings have been determined to be incorrect.

SPARE PARTS To minimize downtime during installation or normal service, it is advisable to purchase spare fuses, circuit boards and other recommended components. Please refer to the parts manual for parts numbers. It is recommended that spare fuses be ordered for all systems.

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

RATINGS AND SPECIFICATIONS Output Ratings D.C. Voltage The Bucyrus Series Mine Chargers are factory set to finish at approximately 2.5 volts/per cell for lead acid batteries. The chargers are available in 32 cell (64 volt) or 64 cell (128 volt) output.

Output Current (Refer to table 1).

Regulation The charge rate is dependent on the state of charge of the battery. Automatic a.c. line voltage compensation regulates the d.c. output and maintains the charging curve.

INPUT CURRENT AND BATTERY CAPACITIES

CHARGER MODEL 5 6 8 10 12 14

APPROX. AC CURRENT DRAW (3-PHASE) 480VAC / 575VAC 26 - 22 32 - 27 41 - 34 52 - 44 61 - 51 70 - 59

BATTERY AMPEREHOUR CHARGING CAPACITY 495 550 - 680 750 - 850 1000 - 1050 1200 - 1210 1375 - 1500

OUTPUT RATING 90 AMPS 110 AMPS 140 AMPS 180 AMPS 210 AMPS 240 AMPS

TABLE 1 Input Ratings A.C. VOLTAGE Taps are provided for various three phase a. c. input voltages with an a. c. input voltage range of +/10% of nominal. (See unit schematic for details) Input Frequency Range 57 to 63 Hz. (60 HZ nominal)

Typical Electrical Specifications (Refer to TABLE 1)

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

Standard Features Input Protection A. A.C. fuses on each input leg.

B. A.C. contactor to disconnect the unit from the a.c. line.

C. A.C. fuse in one leg of control transformer.

Meters Digital Volt/Amp Meter – Standard (See OPERATION section) Output Protection A. D.C. output fuse.

B. Current limiting automatically limits the d. c. output current of the charger to approximately 125% of its rating..

Electronic Timer 8 hour timer with auto start/stop feature on battery connection. (See OPERATION section) Mounting Low profile mine case with skids.

Optional Ground Integrity The Automatic Mine Recharger is designed to operate on a specific type of battery with a specified number of cells. The nameplate on the charger indicates the type of battery, number of cells, and the a.c. input voltage.

To energize the unit with optional ground integrity, the following procedure should be used: 1. Check a. c. input voltage with that specified on the nameplate. i.e.: chargers furnished with 480 volt and 575 volt power lines, are dual input units. Taps within the unit must be set on the 480 volt setting for 480 volt power lines, and 575 volt taps for 575 volt power systems. A schematic is provided with the unit which indicates how the a.c. power connections must be wired. Connect the power lines to the a.c. input terminals, the ground wire to the ground terminal bonded to the case near the input terminals.

2. A ground check wire supplied from the power center must be connected to terminal 3R, near the input terminals.

3. The battery, with a 4 wire plug, must be connected to the unit’s output in order to energize the unit.

4. Ground integrity must be made on all systems to energize the unit. If the case ground is more than 5 ohms, the unit will not energize.

5. The emergency stop switch must be pulled out.

6. Push in the green button. The unit should energize, and the charger will automatically start to charge the battery at some rate up to its maximum capacity, depending upon the state of charge of the battery, and charge the battery to full charge, then shutdown to a trickle charge-preserving-charge.

The charger will continue the trickle rate until the timer turns the unit completely off.

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Bucyrus America, Inc.

THIS UNIT IS EQUIPED WITH TWO (2) DOOR DISCONNECT SWITCHES AND ONE (1) COVER DISCONNECT SWITCH. THE TWO ACCESS DOORS AND THE TOP COVER OF THE UNIT MUST BE CLOSED FOR THE UNIT TO OPERATE. If the unit fails to energize: 1. Check a. c. power on all three phases.

2. Check to make sure voltage taps are wired properly.

3. Check a. c. and d. c. fuses.

4. Make sure battery is connected to unit’s output.

5. Check for ground integrity. This can be done by putting a jumper from ground bus #2 to terminal 1R or 2R on two circuit chargers. If unit starts when jumpered, ground integrity is the problem. (Disconnect the jumper after check) 6. Check emergency stop switch. It must be pulled out.

7. Check all ground connections.

8. Start button must be depressed to energize the unit. (Listen for click of control relay) If a second battery is added on two circuit chargers, the start button, again must be depressed.

9. Check all disconnect switches - doors and top must be closed.

Environmental Ratings Operating Ambient Temperatures Operation - 0 - 50 C (32 - 122 F)

Storage - -40 to +85 C (-40 to + 185 F)

Humidity This rectifier is capable of operating in an ambient relative humidity range of 0-95% (non-condensing).

Ventilation The unit should be placed so that the ventilating openings are not blocked and air entering the cabinet does not exceed 50 C (122 F).

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

INSTALLATION INFORMATION Minimum Wire Sizes Table 2 lists the a.c. input and the d.c. output minimum wire size requirements. At distances exceeding 10 ft., the d.c. wire size should be chosen to keep the voltage difference between the units d.c. output terminals and the battery at less than 1/2 volt when the unit is fully loaded.

FUSE SIZE 1 3 4 5 6 10 15 20 25 30 35 40 45 50 60 70 80 90 100 110 125 130

WIRE SIZE REQUIREMENT CUSTOMER CONNECTION #14 #14 #14 #14 #14 #14 #12 #12 #10 #10 #8 #8 #8 #8 #6 #6 #4 #4 #4 #2 #2 #2

EQUIPMENT GROUNDING CONDUCTOR MINIMUM #14 #14 #14 #14 #14 #14 #12 #12 #12 #10 #10 #10 #10 #10 #10 #8 #8 #8 #8 #6 #6 #6

FUSE SIZE 150 175 200 225 250 300 350 400 450 500 600 700 800 1000 1200 1600 2000 2500 3000 4000 5000 6000

WIRE SIZE REQUIREMENT CUSTOMER CONNECTION #1 #1/0 #2/0 #2/0 #4/0 250-MCM 350-MCM 400-MCM 500-MCM 600-MCM 900-MCM 1500-MCM 2/500-MCM 2/800-MCM 2/1000-MCM 2/2000-MCM

EQUIPMENT GROUNDING CONDUCTOR MINIMUM #6 #6 #6 #4 #4 #4 #2 #2 #2 #2 #1 1/0 1/0 4/0 4/0 4/0 250-MCM 350-MCM 400-MCM 500-MCM 700-MCM 800-MCM

TABLE 2 Electrical Connections & Field Wiring Terminal blocks are provided for connecting the a.c. input and d.c. output. A ground wire must be connected to the unit's case ground.

A.C. Input Make sure that the input source is the same voltage and frequency as that which is marked on the nameplate of the rectifier.

The a.c. input current, specified on the nameplate, is for (nominal) output. A.C. line fuses or breakers must be sized for the overload or current limit point of the charger which is 130% of the nameplate value.

An adequate earth ground lead should be connected to the terminal marked "GROUND" or "GND" on the rectifier terminal board or case.

Be sure the transformer taps are set for the correct a.c. input. (see Figure 1, page 15).

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

FIGURE 1 – TRANSFORMER TAP CONNECTIONS

D.C. Output Make sure that the battery which is being connected to the rectifier matches the cell type and number of cells that is marked on the rectifier nameplate.

OBSERVE PROPER POLARITY! The negative wire from the battery must be connected to the terminal marked "NEGATIVE" or "NEG" and the positive wire from the battery must be connected, to the terminal marked "POSITIVE" or "POS" on the rectifier.

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

OPERATION Start Up (Electronic Timer) A. With the a.c. input connected to the charger, turn the ON/OFF switch to the "ON" position.

B. Connect the battery to the charger. After a 20 second delay, which assures proper battery connection, the input contactor will close. The battery charger will start to charge and the "ON CHARGE" light will turn on. This completes the "Auto start" sequence.

The display will read, OUTPUT AMPS, push the select switch down once and the display will read D.C. VOLTAGE, a second push the display will read AMP/HOURS RETURNED and a third push the display will read ELAPSED TIME. Push the select switch UP and the unit will equalize the battery.

C. When the "80% CHARGE" point is reached in the charge cycle, the "80%" light will turn on and a three (3) hour timer will start. (If in the equalize mode, the unit will operate for six (6) hours after 80% light turns on.)

D. When the charge cycle is complete, normally 6 to 8 hours, the charge "COMPLETE" light will turn on.

E. If for some reason the a. c. input voltage fails, the battery charger will turn off. During this interval the time registers in the auto timer is held at the present count. When the a. c. has returned to normal, the charge cycle resumes where it left off.

TURN THE ON/OFF SWITCH TO THE "OFF" POSITION WHEN DISCONNECTING THE BATTERY DURING THE CHARGE CYCLE TO PREVENT ARCING AT THE D. C. CONNECTOR. FAILURE TO COMPLY WITH THE ABOVE WILL RESULT IN DAMAGE TO THE BATTERY AND CHARGER CONNECTORS. F. Fault Codes *Code 1 - Low or no a.c. input voltage *Code 2 - N/A *Code 3 - Wrong size battery/deeply discharged battery, open terminal voltage below 1.4pc

TO DISABLE THIS FEATURE, PUSH THE EQUALIZE BUTTON. THE UNIT WILL START.

MAKE SURE A BATTERY WITH THE CORRECT NUMBER OF CELLS IS CONNECTED TO THE CHARGER. *Code 4 - 12 Hour overrides timer, unit will automatically turn off in 12 hours after being connected to a battery *Code 5 - N/A *Code 6 - Possible shorted cells – Battery voltage decreases while battery is charging *Code 7 - Unit will turn OFF within 15 minutes if a fully charged battery is connected to charger

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Bucyrus America, Inc.

Adjustments The Bucyrus Series is a completely automatic constant voltage charger. Each is designed to operate on a specific type of battery with a specified number of cells. THE UNIT IS FACTORY SET AT 2.5 VOLTS PER CELL (V.P.C.).

Circuit Operation The Bucyrus Series Ferroresonant Mine battery charger has three basic components; a ferroresonant step down transformer, silicon rectifiers (diodes) and electronic timer.

The regulating action of the unit is caused by the current developed in the resonant winding of the power transformer. The resonating capacitor along with the resonant winding of the transformer form a tuned circuit which establishes the correct core saturation point and in turn regulates the unit's output.

The transformer also steps down the a.c. input voltage to the proper voltage to charge the battery. It also provides isolation from the input to the output.

The silicon diodes convert the a.c. output from the secondary of the transformer to the d.c. voltage needed to charge the battery.

The automatic timer senses the connection of the battery and turns the unit on, the timer will allow the charger to charge the battery for a period of time (maximum 12 hours), then turns the charger off. It will also turn the charger off when the battery is disconnected.

FIGURE 2 – CHARGER CONTROLS

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

TROUBLESHOOTING Troubleshooting should be performed only by trained service personnel or experienced electricians.

HAZARDOUS A.C. AND D.C. VOLTAGES ARE PRESENT WITHIN THE CHARGER’S CABINET. Equipment: The only equipment required is a multimeter (volt-ohm meter).

General Inspection On servicing new equipment, before setting up any complicated testing or jumping to any conclusions, give the unit a general inspection. Check the following: 1. Check d.c. output cables, connections, battery type, and number of battery cells with rectifier rating.

2. Check unit specifications with customer order.

3. Check input connections, input voltage and a.c. line breaker size.

4. Check for shipping damage, loose connections, broken wires, etc.

5. Certain failures can be caused by defective batteries and customer loads; make sure batteries and loads are free from defects.

6. Check all safety switches.

IF THE PROBLEM IS FOUND TO BE LOCATED IN THE PRINTED CIRCUIT BOARDS, THE BOARD SHOULD BE REPLACED. NO ATTEMPT SHOULD BE MADE TO REPAIR CIRCUIT BOARDS IN THE FIELD.

Service Information Information you should have when calling in for troubleshooting assistance: 1. Equipment model number and serial number.

2. The actual a.c. input voltage.

3. The d.c. output voltage with and without the battery.

4. Result of the check of a.c. input fuse and d.c. output fuse.

5. The actual d.c. output current and voltage when measured with battery connected to rectifier.

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

Bucyrus America, Inc.

Symptoms and Causes SYMPTOM

POSSIBLE CAUSE

REMEDY

OPEN A.C. FUSE

1. Wrong a.c. input voltage.

1. Correct input voltage.

2.The a.c. input taps on power transformer set incorrectly. (See schematic wiring diagram)

2. Set input taps correctly.

3. An a.c. to d. c. short or a.c. to d.c. short to ground. (See Ground Short Circuit Test, below).

3. Correct shorts.

4. Shorted power transformer.

4. Replace transformer.

5. Check for shorted power diodes (SD1). (See page 20)

5. Replace defective diodes.

6. Check for shorted coil on d.c. contactor or defective control transformer.

6. Replace contactor or transformer.

1. Shorted power diode.

1. Replace as required.

2. Shorted battery cells.

2. Repair battery.

3. Shorted output cables.

3. Repair or replace cables.

4. Shorted capacitors.

(See page 20)

4. Replace capacitors.

1. Shorted power diode.

1. Replace as required.

2. Shorted capacitor.

2. Replace capacitor.

1.Check a.c. input fuses.

1. Replace fuse(s).

2. Check power diodes.

(See diode troubleshooting procedure, page 20)

2. Replace diode(s).

OPEN D.C. FUSE

OPEN SECONDARY FUSE

CHARGER OPERATES BUT OUTPUT VOLTAGE IS LOW

Ground and Short Circuit Test A simple ohmmeter check can be performed to check the unit for a short to ground, primary to secondary breakdown, a.c.-d.c. short, or d.c. ground. Before installation of a new unit, the above checks should be made before installing. If a short of this type is suspected on a unit in service, check as follows: 1. Disconnect a.c. input power to the unit. Disconnect the d.c. battery and loads from the rectifier.

2. Set ohmmeter scale on ohms scale RX100.

3. Measure from one terminal of the input to one terminal of the output. Meter should not indicate. If the meter reads full scale deflection, this indicates an ac-dc short.

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Bucyrus America, Inc.

During shipping, an a.c. wire may rub against the d.c. lugs, terminals, etc. and cause a short.

These problems may be eliminated by very carefully inspecting the wiring to make certain the a.c. wires are not touching the d.c. wiring. If no wires are touching, then it is possible that the primary and secondary of the transformer is shorted. Disconnect the secondary of the transformer from the diodes. Measure with ohmmeter from input terminal to one of the isolated secondary leads. If there is an ohmmeter indication, there is an insulation breakdown between primary and secondary windings. The transformer should be replaced.

4. Check the input terminals to ground and check the output terminals ground. If the meter indicates full scale deflection, a wire is touching a metal part of the unit. Look for wires that are near any metal part and inspect for possible breakdown caused by shipping. The heatsink of the diodes and the control unit are insulated from ground through the mounting legs.

Troubleshooting and Replacing Power Silicon Diodes If a portable multimeter is used, set the switches on "ohms", "d.c.", and " Rx1 " scale.

1. Isolate one end of the diode by disconnecting the wires attached to the nipple (or pigtail) end of the diode (only one end of the diode must be disconnected).

2. Clip one lead of the ohmmeter to the anode lead of the diode. Clip the other ohmmeter lead to the cathode.

3. Note the ohmmeter reading. Then reverse the leads to the diode. Again, note the ohmmeter reading. If the diode is good, the meter will indicate a high resistance in one direction, and a low resistance with the leads reversed. If the diode is shorted, the meter will read full scale, or zero ("O") resistance with the leads in either direction. If the diode is "open", the ohmmeter needle will not indicate or it will show infinite resistance in either direction, indicating an open circuit.

4 All diodes must be checked in the event that more than one diode is defective.

5. If the diode is defective, remove it from the heatsink. Clean and smooth the heatsink surface, then using an electrically conductive grease, apply to the new diode and replace it in the heatsink.

Checking Capacitors When checking capacitors, be sure all power is turned off and the battery is disconnected.

Momentarily short circuit the capacitor leads to assure complete discharge. Connect the meter test leads to the capacitor leads or terminals and observe indicated resistance.

A good capacitor will indicate an initial low resistance and gradually increase as the capacitor charges.

The final resistance of a good capacitor is usually several hundred thousand ohms approaching a megohm.

Initial high resistance approaching infinity indicates an open capacitor.

Initial and continued low resistance readings indicate a shorted capacitor.

When ordering replacement parts, drawings, or schematics, always give model number, serial number and a.c. input voltage.

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Revised 12 – 07 BUCYRUS DIGITAL DISPLAY CHARGERS

OPERATION AND TROUBLESHOOTING GUIDE MODEL BUCYRUS 2000 DUAL AND SINGLE MOTOR SOLID STATE CONTROLLERS

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. P/N A6474X226 Revision 1, December / 07  BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED

Bucyrus America, Inc. ________________________________________________________________ 4041 Wurno Road Telephone: 540-980-4530 Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.bucyrus.com

Bucyrus America, Inc.

TABLE OF CONTENTS DESCRIPTION

PAGE #

PREFACE ..............................................................................................................................................2 SYMBOLS AND SPECIAL NOTATIONS ..............................................................................................3 MAJOR HAZARDS................................................................................................................................5 SAFETY PRECAUTIONS AND GUIDELINES ......................................................................................6 OVERVIEW ........................................................................................................................................6 MAINTENANCE .................................................................................................................................6 INTRODUCTION ....................................................................................................................................7 BUCYRUS 2000: INNOVATIVE SPEED CONTROL BY BUCYRUS AMERICA, INC........................7 GENERAL SPECIFICATIONS.............................................................................................................12 FAIL-SAFE OPERATION WILL INCLUDE THE FOLLOWING:......................................................12 DESCRIPTION OF FEATURES ..........................................................................................................13 BUCYRUS 2000 MOTOR CONTROLLER CONSIST OF:...............................................................13 BUCYRUS 2000 MOTOR IGBT PANEL (POWER CONNECTIONS) .............................................13 MICROPROCESSOR BASED LOGIC CARD (CONTROL INPUTS) ..............................................13 CONFIGURATION JUMPER TABLE...............................................................................................15 OPTIONAL DASHBOARD DISPLAY FEATURES (SEE FIGURE 9)...............................................15 FAULT MESSAGE CHART..............................................................................................................16 OPTIONAL HAND HELD DIAGNOSTICS/CALIBRATOR UNIT......................................................18 PERSONALITY ADJUSTMENT PROCEDURE ...............................................................................19 TRACTION PERSONALITIES (CONTROLLER ADJUSTMENTS) .................................................19 TRACTION STATUS DISPLAY .......................................................................................................21 TRACTION TEST DISPLAY.............................................................................................................23 TRACTION BDI DISPLAY................................................................................................................24 ERROR CODE LEGEND (STATUS DISPLAY)................................................................................25 TROUBLESHOOTING.........................................................................................................................26 IGBT MEASUREMENTS..................................................................................................................27 INDIVIDUAL IGBT MEASUREMENTS ............................................................................................28 DIODE MEASUREMENTS ...............................................................................................................29 DIODE MEASUREMENTS ...............................................................................................................30 PANEL MEASUREMENTS ..............................................................................................................31 DRIVER MEASUREMENTS.............................................................................................................32 IGBT DUAL MOTOR PANEL, FIGURE 16 .......................................................................................34 IGBT SINGLE MOTOR PANEL,FIGURE 17 ....................................................................................35 IGBT HEAT SINK ASSEMBLY, FIGURE 18 ....................................................................................36 SINGLE MOTOR PANEL HARNESS ASSEMBLY, FIGURE 19......................................................37 DUAL MOTOR PANEL HARNESS ASSEMBLY, FIGURE 20 .........................................................38 DASHBOARD DISPLAY, FIGURE 21..............................................................................................39 DUAL "Y" HARNESS, FIGURE 22...................................................................................................40 HARNESS FOR DASHBOARD DISPLAY, FIGURE 23 ...................................................................41 CALIBRATOR UNIT, FIGURE 24.....................................................................................................42 BUCYRUS 2000 PUMP MOTOR SHUNT, FIGURE 25 ....................................................................42 BUCYRUS 2000 PANEL WIRING HARNESS, FIGURE 26 .............................................................43

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

PREFACE This manual is intended to provide GENERAL operating and service procedures for the Bucyrus 2000 motor vehicle solid-state controller. The illustrations, descriptions and procedures contained in this publication apply only to Bucyrus 2000 motor vehicle solid-state controllers. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Bucyrus 2000 motor vehicles solid-state controller was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U. S. regulatory agency standards.

At the completion of the manufacturing process, the Bucyrus 2000 motor vehicles solid-state controller was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of the controller, without the consent of Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render the controller unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this controller.

While this manual attempts to anticipate the most important operations and maintenance needs for this controller, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is nontransferable. Distribution and access is limited only to authorized personnel.

Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

 Bucyrus America, Inc. All rights reserved.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

SYMBOLS AND SPECIAL NOTATIONS Throughout this manual there are specific notations that are either UPPERCASE BOLD, UNDERLINED or ITALICIZED for the primary purpose of emphasis. Please pay special attention to such statements as they regard safety or critical maintenance installation information.

You will also see the following:

NOTICE: THIS NOTATION DENOTES A REFERENCE TO PREVIOUSLY STATED INSTRUCTIONS.

IMPORTANT: THIS SYMBOL DENOTES THAT SPECIAL ATTENTION MUST BE ADHERED TO IN THE ATTACHED STATEMENT.

CAUTION: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A CUT, BRUISE OR ABRASION.

WARNING: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A LOST TIME ACCIDENT.

DANGER: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE POINTS IN THE TEXT MARKED WITH THIS SYMBOL DRAW YOUR ATTENTION TO IMMEDIATELY IMPENDING DANGER INCLUDING ELECTRICAL DANGERS. POSSIBLE CONSEQUENCES ARE: VERY SERIOUS INJURY, DEATH OR DEATH BY ELECTROCUTION.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

DANGER ONLY TRAINED AND/OR AUTHORIZED PERSONNEL SHOULD PERFORM MAINTENANCE ON THE CONTROLLER. FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH. FAILURE TO MAINTAIN THIS CONTROLLER IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

MOTORS AND CONTROLLER

Electrical shock could cause irreparable injury or death.

All electrical systems should be maintained by certified electricians.

The battery should be disconnected before servicing the motors or controller. When the controller cover is removed, wait for one minute for the capacitors to discharge.

BATTERY

The battery produces lethal amounts of power whether connected to the machine or charger, or not.

The battery should be maintained by qualified personnel. (Refer to Bucyrus America, Inc. "INSTALLATION, USE, MAINTENANCE, AND REPAIR OF MINE POWER STORAGE BATTERIES,” PART NUMBER A6474X26, for complete instructions).

Battery covers could fall crushing hands or arms.

Be sure cover supports are in place when working on battery.

Battery hold-down clamps could crush fingers or hands.

Keep fingers and hands away from hold-down clamps.

Batteries produce explosive gases that could be ignited causing burns or explosions.

Batteries should be well vented before servicing particularly if welding or burning on the battery.

Batteries should be maintained by qualified personnel.

Batteries contain strong acid that could cause severe burns if spilled or splashed on body parts or in the eyes.

Protective clothing, gloves, and eyewear must be worn when working on batteries. Batteries should be maintained by qualified personnel.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

SAFETY PRECAUTIONS AND GUIDELINES Overview Before you test, troubleshoot, service or in any other way, use this unit READ and STUDY this guide. KNOW what you must do for safe maintenance.

ALWAYS wear or use the proper safety items required for your personal protection.

If you have ANY QUESTIONS about the safe use or maintenance of this unit: ASK YOUR SUPERVISOR - NEVER GUESS - ALWAYS CHECK Maintenance AVOID, whenever possible, servicing, cleaning or examining the unit in congested areas.

AVOID, whenever possible, servicing or providing maintenance to the unit unless the wheels are adequately choked. If the drive motor (s) is to be run, the unit must be jacked clear of the ground and all four (4) wheels must be free to turn.

DO NOT alter the electrical settings from that indicated in this guide or as set at the factory.

ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Manual for the proper location and part number of decals and plates.

DISCONNECT the battery when working with electrical systems, or when welding on the unit to prevent electrical shock.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Some photographs and 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 PHOTOGRAPHS OR ILLUSTRATIONS IN THIS GUIDE MAY SHOW PROTOTYPE UNITS OR UNITS WITH OPTIONAL EQUIPMENT INSTALLED THAT MAY OR MAY NOT BE ON YOUR PARTICULAR MACHINE. PRODUCTION MODELS MAY VARY IN SOME DETAIL. OPTIONAL EQUIPMENT MAY BE PURCHASED FROM BUCYRUS AMERICA, INC. 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. BUCYRUS AMERICA, INC. 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 BUCYRUS DEALER FOR MAINTENANCE THAT IS NOT COVERED IN THIS PUBLICATION. 6

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

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INTRODUCTION BUCYRUS 2000: Innovative Speed Control by Bucyrus America, Inc. FIGURE 1 – SIMPLIFIED BUCYRUS 2000 CIRCUIT

In the early 1970's, S&S Corporation lead the way in mining innovation with the introduction of Solid State speed controls for battery-powered underground mining equipment. Solid State controls increased the range and reliability of the battery powered vehicles along with providing smooth, stepless acceleration. Even with solid state speed control, direction change was achieved with the use of electromechanical contactors. These contactors provided an endless source of maintenance problems and consumed excessive amounts of valuable controller-box space. Also, most solid state controllers of the past utilize an electromechanical "bypass" contactor to connect the motor directly to the batteries which caused more contactor problems.

In the 1980’s Bucyrus America, Inc., in conjunction with Sevcon, developed a contactorless motor controller (X90) to be used exclusively on Bucyrus equipment. The X90 system used a dual-field motor in combination with SCR's (Silicone Controlled Rectifier) to achieve solid state direction change.

Now Bucyrus America, Inc., in conjunction with Sevcon, has developed the Bucyrus 2000 motor controller. The Bucyrus 2000 system uses IGBT’s (Insulated Gate Bipolar Transistors) to achieve motor control and direction change. Unlike an SCR, an IGBT is turned ON and OFF via a gating electronic signal. This eliminated commutating capacitor banks and coils. The microprocessor based Bucyrus 2000 Logic Card provides complete motor control, and drives both a Diagnostic Dashboard Display along with a hand held Calibrator/Diagnostic Unit.

The IGBT switch operates so fast that it can connect and disconnect the motor in less than 1/1700 second. This is such a short time period that the dual-field motor does not have time to move. Each time the IGBT switch closes and reopens the full battery voltage is applied to the motor terminals for about 1/1700 second. This is commonly referred to as a "pulse."

The IGBT speed control works by feeding to the motor a rapid series of pulses. The number of pulses per second determines the average voltage at the motor terminals 7

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

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Since the windings of the motor are inductive, the current in the motor cannot change quickly.

When the IGBT switch is closed, the current builds up slowly and when the switch opens, the inductance wants to keep the current flowing. For this reason, the "flywheel" diode is provided.

Figures 3 and 4 illustrate the current paths with the switch closed in both forward (Figure 3) and reverse (Figure 4) modes.

FIGURE 2

FIGURE 3

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Bucyrus America, Inc.

FIGURE 4

As seen in Figure 5, the direction of the current through the motor does not change. More important, when the switch opens, although the battery current stops, the motor current continues to flow via the "flywheel" diode. The motor current is therefore made up of two components: 1. The battery current when the IGBT switch is closed.

2. The "flywheel" current when the IGBT switch is open.

FIGURE 5

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

The amount of the motor current supplied from the battery varies with the pulse frequency.

Figure 6 illustrates a typical situation at low speed. It can be seen from the illustration that the "flywheel" current, because it is flowing for a longer period, forms a larger part of the motor current than does the battery current. However, at high speeds (Figure 7), the motor current is made up of almost all battery current.

FIGURE 6

To summarize, the motor current is made up of a combination of battery current and "flywheel" current so that under all conditions the average motor current is always greater than the average battery current.

At low speeds the motor current can be several times greater than the battery current.

At high speeds, when the IGBT switch is open only for short periods before closing, the motor current is made up almost entirely of battery current.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

FIGURE 7

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

GENERAL SPECIFICATIONS The Bucyrus 2000 Motor Controller is designed to operate at 128 volts DC, 1200 Amps maximum current limit per motor and controls one or two dual-field electric motors. 

The maximum current default settings are: 800A, 1100A and 1200A



Traction functions operate at a speed that is directly proportional to the accelerator (FS1) demand. (See Figure 8)



Traction motor current will be continuously monitored in the motor. Current limit is preset and is adjustable via the optional hand held diagnostics/calibrator unit and is password protected.

FIGURE 8 – ACCELERATOR VOLTAGE

Fail-safe operation will include the following: 

In the event of a shorted IGBT, the circuit breaker will be opened, disconnecting power from the traction motors.



Operation of the circuit breaker will always be sensed, and if faulty, drive will be inhibited.



Whenever the vehicle is power-cycled, power-up diagnostics will be executed to test the tram drive circuitry. If faulty, drive will be inhibited.

The temperature of the Bucyrus 2000 Motor Controller will be continuously monitored and if it rises above 95C the motor current will be limited to a maximum of 300 amps of motor current will be allowed.

The Bucyrus 2000 Motor Controller features a data logging capability that stores critical data into non-volatile data RAM. The stored data is displayed in the traction status display of the optional hand held diagnostics/calibrator unit.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

DESCRIPTION OF FEATURES The Bucyrus 2000 Solid State Controller incorporates a variety of independent protection systems. These improve reliability, shield the motors and controller from overload, protect the machine from inadvertent abuse by the operator, and help to protect workers from potential harm from malfunctioning equipment.

Bucyrus 2000 Motor Controller Consist of: 

Dual Motor IGBT Panel or single motor IGBT Panel or 2-single motor IGBT panels



Microprocessor Based Logic Card



Optional Dashboard Display



Optional Hand held Diagnostics/Calibrator Unit



“Y” connecting harness (used only with 2-single motor panel systems)

Bucyrus 2000 Motor IGBT Panel (Power Connections)   

Battery positive Battery negative 4 motor connections for each motor (S1, S2, A1 and A2)

(For Power Circuit Layout see Machine Wiring diagram and schematic)

Microprocessor Based Logic Card (Control Inputs)            

Input applies battery voltage to logic card (Pin 16) Proportional control accelerator, 5000 OHMS (Pins 1 and 2) Tram direction select (Pin 7) Tram direction select (Pin 8) Park brake condition (set / release) (Pin 14) Circuit breaker driver (Pin 6) Circuit breaker condition (Pin 11) Current limit default setting (Pin 12) Accelerator (FS1) input switch (Pin 4) CAN Communication Input Port for optional hand held diagnostics/calibrator unit CAN Communication Input Port for optional dashboard display Analog Input for connection to pump motor shunt to allow pump motor current measurement

The Bucyrus 2000 Microprocessor-Based Logic Card will control dual two-quadrant IGBT devices, controlled by PWM (PULSE WIDTH MODULATED) switching, providing forward and reverse direction control.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

There is an LED on the logic card which serves as an indicator of the status of the controller. The following diagnostics shall apply:   

LED on LED off 1 Flash



2 Flash



3 Flash



4 Flash



5 Flash



6 Flash



7 Flash



8 Flash

Controller operational Power-up fault – check display or calibrator. If all is blank, then replace logic.

Personality CRC EEPROM Error.

Using the hand-held calibrator, change a password to any number then recycle power – should clear, otherwise replace logic.

Procedure FAULT FS1 closed before power on ,2 Directional Fault or Current imbalance fault.

Recycle through NEUTRAL to clear.

IGBT permanently low (IGBT Short Circuit FAULT).

This includes IGBT short circuit or IGBT open circuit. This fault shuts down all modes. Recycle through NEUTRAL to clear.

Motor neither low nor high (Breaker Open FAULT).

This includes breaker open circuit or IGBT open circuit. This fault shuts down all modes. Recycle through NEUTRAL to clear.

Motor permanently high.

This includes breaker welded. This fault shuts down all modes. Recycle “KEY” to clear.

Faulty TRACTION accelerator.

This includes the accelerator greater than 15% at power on and wire-off. If wireoff occurs during active function then the motor speed will set to zero. This fault auto-clears.

Battery voltage FAULT. This includes battery below a predetermined value. Recycle through NEUTRAL to clear.

Thermal cut-back (Over-Temperature FAULT).

This includes Heatsink temperature above 95 centigrade.

AS TEMPERATURE RISES CONTROLLER WILL LIMIT REGARDLESS OF DEMAND. 

9 Flash



10 Flash



15 Flash

ABOVE 95 CENTIGRADE, THE THE CURRENT TO 300 AMPS

UVR coil over-current FAULT (Coil short circuit FAULT).

Cleared with “KEY” recycled.

Brake on FAULT Will trip Directional and FS1 are energized without releasing brake. Recycle through NEUTRAL to clear.

Current Transducer FAULT. Occurs when current output is read during power-up or if no current is read during drive above 50% demand. “KEY” recycle to clear.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Configuration Jumper Table MAX. CURRENT CONFIG. LOGIC PIN 12 OPEN GROUND (CLOSED) OPEN

VEHICLE TYPE SINGLE MOTOR – 1200 AMP SINGLE MOTOR – 1100 AMP DUAL MOTORS 1100 AMP PER MOTOR – ADJUSTABLE TO 1200 AMP DUAL MOTORS 800 AMP PER MOTOR

GROUND (CLOSED)

OPTIONAL DASHBOARD DISPLAY FEATURES (See Figure 9)    

A battery discharge indicator An hour meter displaying tram-on hours An hour meter displaying pump-on hours A rotating display showing: 1. Battery voltage 2. Pump motor current 3. Diagnostic fault status, when applicable. Rotating display will lock on one of the following fault messages: (See Fault Message Chart, page 19)

FIGURE 9 – OPTIONAL DASHBOARD DISPLAY

BATTERY DISCHARGE FUNCTION

ROTATING DISPLAY

TRAM – ON PUMP – ON HOURS

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Fault Message Chart DASHBOARD DISPLAY “Rotating Disp.”

“Testing”

CALIBRATOR DISPLAY “OK” “Testing”

“System OK”

“System Okay”

“Over Temp.”

“Brkr Open”

“Thermal Cutback” “Breaker Open”

“Brkr Weld”

“Breaker Weld”

“UVR Coil” “Cap Fault” “Accel Flt.”

“UVR Coil” “Capacitor Fault” “Accel Flt.”

“Seq. Fault”

“Sequence Fault”

“2 Dir Fault” “Tram Fault” “Bat Low” “CRC Error”

“2 Dir Fault” “Tram Fault” “Bat Low” “CRC Error”

“IGBT s/c” “IGBT s/c” “Brake on”

“IGBT s/c” “IGBT s/c” “Brake on”

“Cur Xducer”

“Cur Xducer Flt”

“Bad Logic”

“Bad Logic”

“Bad Logic”

“Bad Logic”

“Cap Fault” “PTA Short”

“Cap Fault” “P. Up PTA Short”

“RPTA Short”

“P. Up R. PTA Short”

DESCRIPTION No fault Only visible when power-up diagnostics is running. Check connections if not clearing.

Power-up check completed, waiting to closure of Circuit Breaker Controller in thermal cut-back.

Circuit breaker failed to close. Faulty Circuit breaker, UVR, CB Auxiliary or faulty logic board.

Circuit breaker welded close. Faulty CB auxiliary switch or faulty logic will give this fault also.

UVR coil driver over-current sensed.

Caps failed to charge after power-up.

Accelerator fault sensed. Faulty accelerator (accelerator voltage 4.0v; accelerator voltage below 1.2v in NEUTRAL).

Faulty FS1 or logic board.

FS1 closed at power-up. Possible circuit breaker auxiliary switch not closing Both directional switches active.

Motor current imbalance sensed.

Battery fell below personality level.

During power-up a personality CRC error occurred. Try adjusting one of the passwords (1 or 2) then power recycle.

If not cleared replace logic board.

An IGBT short has been detected – SM. A left or right IGBT short has been detected – DM. The vehicle BRAKES are on while there is a direction and demand selected.

The controller reads current when it is first powered-up or does not read any current when demand for drive over 50%.

An internal errors has occurred in the software state machine. Faulty logic board.

Invalid status state encountered (internal error). Faulty logic board. * * * * POWER UP TEST STATUS * * * * Caps failed to change after power-up.

Single motor Block 0 point “A” short Motor short to ground or IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

Dual motor Block 0 point “A” short Motor shorted to ground or RIGHT IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Fault Message Chart (Continued) “LPTA Short”

“P. Up L. PTA Short”

“I. D. Fault” “Bad Logic”

“Vehicle ID Flt” “Bad Logic”

“R FWD ON”

“Tract R. FWD on”

“FWD ON”

“Tract FWD on”

“R REV ON”

“Tract R. REV on”

“REV ON”

“Tract REV on

“L FWD ON”

“Tract L. FWD on”

“L REV ON”

“Tract L. REV on”

“Drive off”

Drive 0 off Flt”:

“R FWD OFF”

“Tract R. FWD off”

“FWD OFF”

“Tract FWD off”

“R REV OFF”

“Tract R. REV off”

“REV OFF”

“Tract REV off”

“L FWD OFF”

“Tract L. FWD off”

“L REV OFF”

“Tract L. Rev off”

“BAD LOGIC”

“BAD LOGIC”

Dual motor Block 1 point “A” short Motor shorted to ground or LEFT IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

Vehicle Configuration ID invalid Diagnostic point “A” trip failed to disable UVR coil. Faulty logic board.

Diagnostic RIGHT FWD point “A” trip failed to be disabled. .

Faulty logic board, shorted motor to ground or shorted IGBT. Single motor Point “A” trip failed to disable FWD IGBT. Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic RIGHT REV point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Single motor Diagnostic REV point “A” trip failed to be disabled. Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic LEFT FWD point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic LEFT REV point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic test to enable UVR coil driver failed. Faulty logic board.

Diagnostic RIGHT FWD point “A” trip failed to disable PWMO. Faulty logic board.

Single motor Diagnostic FWD point “A” trip failed to disable PWMO. Faulty logic board.

Diagnostic RIGHT REV point “A” trip failed to disable PWMO. Faulty logic board.

Single motor Diagnostic REV point “A” trip failed to disable PWMO. Faulty logic board.

Diagnostic LEFT FWD point “A” trip failed to disable PWM1.

Faulty logic board.

Diagnostic LEFT REV point “A” trip failed to disable PWM1.

Faulty logic board.

Internal error (Software Only) Faulty logic board.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Optional Hand Held Diagnostics/Calibrator Unit Security Levels: 1.

2.

3.

4.

Customer level Service Level Advanced Level Engineering Level

SECURITY LEVELS 2-4 ARE ONLY ACCESSIBLE BY ENTERING THE APPROPRIATE PASSWORDS.

FIGURE 10 – OPTIONAL HAND HELD DIAGNOSTICS/CALIBRATOR UNIT RIGHT BUTTON

LEFT BUTTON

DOWN BUTTON

UP BUTTON

Connecting for Operation: 1. Turn the machine “OFF”.

2. Turn the main circuit breaker to the “OFF” position to de-energize power on machine.

3. Remove the main controller cover.

4. Connect the hand held diagnostics/calibrator unit to the CAN Communication Input Port of the logic card.

5. Turn the main circuit breaker to the “ON” position.

6. Leave the “Park Brake Set”.

The hand held diagnostics/calibrator unit is now operational.

Operation: Upon power-up of the hand held diagnostics/calibrator unit, before pressing any buttons, a top level display is visible to provide diagnostic information as follows: See list on page # 19 and 20 18

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Personality Adjustment Procedure 1. Power-up calibrator.

2. If the top level display indicates “OK”, go to step (4). If not “OK”, go to step (3).

3. Consult above diagnostic information table to determine cause of fault.

4. Press the “DOWN” button two times to access the personalities table.

5. Use the “LEFT” or “RIGHT” buttons to locate the desired personality.

6. After locating the personality, use the “+” or “-” buttons to adjust the values accordingly.

7. To go back to the top level display, press the “UP” button two times.

The following features shall be customer adjustable personalities, accessible using the Calibrator

Traction Personalities (Controller Adjustments) DISPLAY NAME

MAX CONTROLLER CURRENT

RANGE / NOTES

SECURITY LEVELS DISPLAYED

50 amps to maximum controller capacity.

ALL

ACCELERATOR DELAY

0.5 seconds to 5.0 seconds

DECELERATION DELAY

(1.0 seconds ALL VEHICLES) 1.0 seconds to 5.0 seconds

CREEP SPEED

(1.0 seconds ALL VEHICLES) 0% to 25%

MAXIMUM SPEED

(5%) 0% to 100%

PASSWORD ONE PASSWORD 2 PWM FREQUENCY ADJUST PLUG CONFIGURATION NOTE: REQUIRES POWER RECYCLE

BATTERY PROTECTION CUTOUT BATTERY PROTECTION DELAY MOTOR CURRENT LOG LEVEL

(100%) 0 – 255 characters 0 – 255 characters 0 – 255 characters (17) 0 – 1 (Internal factor) 0. RFU 1. Auto plug breaking 2. Selective plug breaking (Normal plug) (2) 50 v – 255 v

SERVICE ADVANCED ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING ALL ALL ALL ALL ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

ALL

(50v) 0.1 – 5.0 seconds

ALL

(5.0 seconds) 50 – 1200 Amps

ALL

19

SECURITY LEVELS ADJUSTABLE

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Personalities (Controller Adjustments) (Continued) PLUG CURRENT LOG LEVEL TEMPERATURE ADJUSTMENT

CLEAR DATA LOG

CLOSE CB DELAY ALLOWED

50 – 1200 Amps Compensates temperature look-up tables.

0-20 = Positive additives 21 – 40 = Negative additives 95 default (ALL VEHICLES) OFF – ON NOTE: THIS PERSONALITY CLEARS ALL OF THE DATALOG LOCATIONS IN NON-VOLATILE MEMORY. TO ENABLE THIS PERSONALITY PRESS THE “-” BUTTON. IT DISABLES ITSELF ONCE IT COMPLETES THE CLEARING TASK. FS1 MUST BE OPEN. 0 seconds (disables) to 90 seconds 45 seconds (ALL VEHICLES)

NO ACTIVITY DELAY TIMER

0 seconds (disables) to 40 minutes 0 minutes (ALL VEHICLES)

CURRENT IMBALANCE TIMER

0 seconds (disables) to 90 seconds

20

ALL

SERVICE ADVANCED ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING

ALL

SERVICE ADVANCED ENGINEERING

SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Status Display DISPLAY NAME

RANGE / NOTES

Battery Voltage Motor Voltage (S. M.) Right Motor Voltage Left Motor Voltage Motor Current (S. M.) Right Motor Current Left Motor Current S. M. Rev. IGBT Block Temp.

S. M. Fwd IGBT Block Temp.

DM Right IGBT Block Temp.

DM Left IGBT Block Temp.

IGBT Voltage (S. M.) Right IGBT Voltage Left IGBT Voltage Error Code (see error code sec.)

Number of “Key On” Hours Number of “Driving” Hours Current Calibration Factor (S. M.) Right Channel Zero Current Calibration Factor Left Channel Zero Current Calibration Factor Peak Motor Current (S. M.) Right Channel Peak Motor Current Motor Current Stored Duration High Bytes (S. M.) Right Channel Motor Current Stored Duration High Bytes (S. M.) Motor Current Stored Duration Mid Bytes (S. M.) Right Channel Motor Current Stored Duration Mid Bytes (S. M.) Motor Current Stored Duration Low Bytes (S. M.) Right Channel Motor Current Stored Duration Low Bytes (S. M.) Motor Current Stored Duration Low Bytes (S. M.) Right Channel Motor Current Stored Duration Low Bytes (S. M.)

21

SECURITY LEVELS DISPLAYED ALL ALL

SECURITY LEVELS ADJUSTABLE N/A N/A

ALL ALL

N/A N/A

ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Status Display (Continued) Peak Plugging Current (S. M.) Right Channel Peak Plugging Current Selected Plugging Current Recording Level

NOTE: CONVERT AS FOLLOWS 1. CONVERT EACH BYTE TO ITS HEX EQUIVALENT. 2. CONVERT THE (3) BTYE FIELD TO A DECIMAL AND MULTIPLY BY 3.0 MSECONDS TO OBTAIN REAL TIME.

Plugging Current Stored Duration High Bytes (S. M.) Right Channel Plugging Current Stored Duration High Bytes (S. M.) Plugging Current Stored Duration Mid Bytes (S. M.) Right Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Right Channel Plugging Current Stored Duration Low Bytes (S. M.) Peak Motor Current (S. M.) Left / Right Motor Peak Plugging Current Stored Duration High Bytes (S. M.) Left Channel Plugging Current Stored Duration High Bytes (S. M.) Plugging Current Stored Duration Mid Bytes (S. M.) Left Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Left Channel Plugging Current Stored Duration Low Bytes (S. M.) Peak Plugging Current (S. M.) Left Channel Peak Plugging Current Plugging Current Stored Duration High Bytes (S. M.) Left Channel Plugging Current Stored Duration High Bytes (S. M.) 22

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Status Display (Continued) Plugging Current Stored Duration Mid Bytes (S. M.) Left Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Left Channel Plugging Current Stored Duration Low Bytes (S. M.) SM FWD IGBT High Temperature SM REV IGBT High Temperature DM RIGHT IGBT High Temp.

DM LEFT IGBT High Temp.

SM FWD IGBT Low Temperature SM REV IGBT Low Temperature DM RIGHT IGBT Low Temp.

DM LEFT IGBT Low Temp.

Battery Voltage High Battery Voltage Low

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL ALL ALL

N/A N/A N/A

ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A

Security Level Displayed

Security Level Adjustable

ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Traction Test Display Display Name Accel. Voltage Accel. Percent Demand Forward Switch Reverse Switch FS1 Switch Configuration Jumper 1 Configuration Jumper 2 Brake Input Circuit Breaker Input Oil Temperature Oil Level Software Version

Range / Notes 0.0 V - 5.0 V 0 - 100% OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OK / HOT OK / LOW VX.XXX

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction BDI Display Display Name % CHANGE LEFT BDI CELLS

Range / Notes

RESET CELL LEVEL

0 - 100% 35 - 80 (64) 1.85V - 2.50V

EMPTY CELL LEVEL

(2.04V) 1.00V - 1.99V

WARNING LEVEL

(1.70V) 0% - 90%

CUTOUT LEVEL

(20%) 0% - 90%

BATTERY CALLIBRATION VOLTAGE BDI SAMPLE TIMER DISPLAY WORKING DISPLAY STATUS SELECT DASHBOARD DISPLAY STATUS

DISPLAY CONTRAST

(0%) 1.00V – 10.0V (5-VOLTS) 1.0 - 255 SECONDS 2.0 (20 SECONDS) OK LOCK / ROTATE (ROTATE) 0 - 4 (BATTERY VOLTAGE, PUMP CURRENT AND MOTOR CURRENT) BATTERY VOLTAGE (1) 0 - 127 1 (33)

24

Security Level Displayed ENGINEERING ENGINEERING

Security Level Adjustable ENGINEERING ENGINEERING

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

ENGINEERING

ENGINEERING

ENGINEERING

ENGINEERING

ADVANCED ENGINEERING ALL

ADVANCED ENGINEERING ALL

ALL

ALL

ALL

ALL

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Error Code Legend (Status Display) ERROR CODE 0 1 2

3

4

5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21

DESCRIPTION No Fault Caps failed to change after power-up Check for shorted cap Single Motor Block “0” Point “A” short Shorted IGBT or short between motor and ground Dual Motor Block “0” Point “A” short Shorted Right IGBT or short between motor and ground Dual Motor Block “0” Point “A” short Shorted Left IGBT or short between motor and ground Vehicle configuration ID invalid Diagnostic Point “A” trip failed to disable UVR Coil Replace logic assembly Diagnostic Right FWD Point “A” trip failed to disable Replace logic assembly Single Motor Point “A” trip failed to disable FWD IGBT Replace logic assembly Diagnostic Right REV Point “A” trip failed to disable Replace logic assembly Single Motor Diagnostic REV Point “A” trip failed to disable Replace logic assembly Diagnostic Left FWD Point “A” trip failed to disable Replace logic assembly Diagnostic Left REV Point “A” trip failed to disable Replace logic assembly Diagnostic test to enable UVR Coil driver failed Fault in logic assembly or faulty UVR Coil Diagnostic Right FWD Point “A” trip failed Replace logic assembly Single motor diagnostic FWD Point “A” trip failed Replace logic assembly Diagnostic Right REV Point “A” trip failed Replace logic assembly Single motor diagnostic FWD Point “A” trip failed Replace logic assembly Diagnostic Left FWD Point “A” trip failed Replace logic assembly Diagnostic Left REV Point “A” trip failed Replace logic assembly Breaker welded fault Internal error (Software Only) Replace logic assembly

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

TROUBLESHOOTING This section provides troubleshooting information. This guide assumes you have a working knowledge of IGBT controller servicing and that you have the following equipment.

1. Volt/Ohm Meter with Leads 2. Insulated Basic Hand Tools

WHEN WORKING INSIDE THE CONTROLLER, USE INSULATED GLOVES AND TOOLS WHERE POSSIBLE. ALL CONNECTIONS MUST BE TIGHT AND CARE MUST BE TAKEN TO PREVENT BOLTS, NUTS, WASHERS AND OTHER SMALL METAL FASTENERS FROM BEING DROPPED OR LOST INSIDE THE CONTROLLER. BEFORE STARTING ANY POWER-RELATED PERFORMANCE TESTS, THE MACHINE MUST BE JACKED AND SECURELY BLOCKED CLEAR OF THE GROUND WITH ALL FOUR (4) WHEELS FREE TO TURN.

REFER TO THE PARTS MANUAL FOR YOUR PARTICULAR MACHINE WIRING DIAGRAMS AND SCHEMATICS.

THE LOGIC UNIT CONTAINS NO USER-SERVICEABLE PARTS. OPENING THIS SEALED DEVICE WILL VOID THE WARRANTY.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT and Diode Measurements Before taking readings, the following system conditions must be met: 1. Master switch or control handle in the “OFF” position.

2. Panel disconnected from and isolated from the battery (via main circuit breaker) and battery plugs being disconnected.

3. Motor leads disconnected from panel 4. After power is removed, wait for one (1) minute before making measurements to allow voltage to bleed down

IGBT Measurements (See Figure 11) If reading is 0, IGBT is shorted.

There are two IGBT’s wired in parallel; therefore, if one IGBT indicates short, it may be one or both.

FIGURE 11

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Individual IGBT Measurements FIGURE 12

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Diode Measurements FIGURE 13

29

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Diode Measurements FIGURE 14

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Before taking readings, the following system conditions must be met: 1. Panel mounted in vehicle 2. Main circuit breaker in the “OFF” position 3. Power “OFF” at master switch or control handle (must be off at least one minute before taking measurement)

Panel Measurements FIGURE 15

Panel Measurements Before taking readings, the following system conditions must be met: 1.

2.

3.

4.

5.

All connections attached, and power applied Main circuit breaker on Master switch or control handle in the “PARK” or “PARK BRAKE APPLIED” position Accelerator NOT depressed (FS1 open) Main line contactor open   

B+ to B-: Battery Voltage B- to AA: 50V B- to S1L, S4L, S1R, & S4R: 50V

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Driver Measurements The measurement of the driver on the Bucyrus America, Inc. Bucyrus 2000 Motor Controller cannot be done with a volt-ohm-meter. In order to determine whether the driver is faulty, a process of elimination is required. The LED indicates if there is “look ahead” voltage on the IGBT’s and as such does not fully indicate whether the driver is working properly or not.

The steps to follow to determine if the driver is faulty are as follows: 1. Determine if any of the IGBT’s or diodes are faulty by performing the previously illustrated tests.

2. With power applied, the master switch or control handle to the “PARK” PARK BRAKE APPLIED” position, and all motor leads connected, measure the voltage with a volt-ohm meter from “B-” to the motor connection leads, each in turn (“S1” to “B-”, “S4” to “B-”, and so on). The main line contactor must be open.

3. The reading should be less than the battery voltage, but higher than “B-” (in the range of approximately 70 volts). This voltage may vary panel to panel as there is leakage voltage through the IGBT’s and diodes.

4. If the voltage is at the same potential as “B+”, then most likely a diode is shorted.

5. If the voltage is at “B-”, then most likely an IGBT is shorted.

6. The calibrator should indicate which channel is faulty.

7. If the calibrator does not indicate which channel is faulty, the faulty component can be determined in the following manner:  Remove power from the panel, remove the motor connection leads from the panel and follow the measurements as indicated in the previous sections, or determine which channel is faulty.

8. If all the IGBT’s and diodes measure okay, the problem may be with the driver or the logic board.

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IGBT PANELS

FOR REPLACEMENT PARTS AND MACHINE WIRING DIAGRAMS, PLEASE REFER TO YOUR SPARE PARTS MANUAL.

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IGBT Dual Motor Panel FIGURE 16 RESISTOR ASSEMBLY BUSS BAR, B -

THERMAL STRIP AND THERMISTOR

WIRING HARNESS

BUSS BAR, B +

BUSS BAR AND CURRENT TRANSDUCER

RESISTOR ASSEMBLY HEAT SINK ASSEMBLY

BUSS BAR SHUNT ASSEMBLY

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IGBT Single Motor Panel FIGURE 17 BUSS BAR CURRENT TRANSDUCER DIODE KIT

HARNESS ASSEMBLY

RESISTOR ASSEMBLY KIT

BUSS BAR ASSEMBLY KIT

BUSS BAR ASSEMBLY

DRIVER BOARD ASSEMBLY

THERMAL STRIP CAPACITOR ASSEMBLY

INSULATOR PLATE

HARNESS ASSEMBLY

COLLECTOR PLATE ASSEMBLY

DIODE KIT IGBT KIT

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IGBT Heat Sink Assembly FIGURE 18

CAPACITOR ASSEMBLY

INSULATOR PLATE

IGBT KIT

COLLECTOR PLATE ASSEMBLY

COPPER SPACER DRIVER BOARD

DIODE KIT HEAT SINK

WIRING HARNESS

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Single Motor Panel Harness Assembly FIGURE 19

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Dual Motor Panel Harness Assembly FIGURE 20

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Dashboard Display FIGURE 21

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Dual “Y” Harness FIGURE 22

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Harness for Dashboard Display FIGURE 23

RJ11 PLUG CABLE

RJ11 PLUG CABLE

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Calibrator Unit FIGURE 24

Bucyrus 2000 Pump Motor Shunt FIGURE 25

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Bucyrus 2000 Panel Wiring Harness FIGURE 26

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INSTALLATION, USE, MAINTENANCE AND REPAIR OF MINE POWER STORAGE BATTERIES

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. P/N A6474X26 Revision 11, January 09  BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED

Bucyrus America, Inc.

TABLE OF CONTENTS Page PREFACE ..................................................................................................................................................... 1 SYMBOLS AND SPECIAL NOTATIONS..................................................................................................... 3 MAJOR HAZARDS....................................................................................................................................... 5 SAFETY PRECAUTIONS AND GUIDELINES............................................................................................. 7 OVERVIEW ............................................................................................................................................... 7 MAINTENANCE ........................................................................................................................................ 7 CHAPTER 1 - INTRODUCTION ................................................................................................................... 8 SECTION I. GENERAL ................................................................................................................................... 8 SECTION II. DEFINITIONS ............................................................................................................................. 9 SECTION III. DESCRIPTION AND CONSTRUCTION ........................................................................................... 9 SECTION IV. PRINCIPLES OF OPERATION.................................................................................................... 13 CHAPTER 2 – INSTALLATION, USE, AND MAINTENANCE .................................................................. 16 SECTION I. PREPARATION FOR USE ............................................................................................................ 16 SECTION II. ROUTINE MAINTENANCE ........................................................................................................... 20 CHAPTER 3 – FIELD SERVICING AND REPAIR ..................................................................................... 25 SECTION I. TROUBLESHOOTING .................................................................................................................. 25 SECTION II. REPAIRING BATTERIES ............................................................................................................ 26 CHAPTER 4 – HEALTH AND SAFETY ..................................................................................................... 35 SECTION I. BATTERY HAZARDS ................................................................................................................... 35 SECTION II. SAFETY PROCEDURES ............................................................................................................. 35 CHAPTER 5 – STORAGE AND SHIPMEMT ............................................................................................. 39

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PREFACE This manual is intended to provide GENERAL product information for Bucyrus America, Inc. mine power storage batteries. The illustrations, descriptions and procedures contained in this publication apply only to Bucyrus America, Inc. mine power storage batteries. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Bucyrus America, Inc. mine power storage battery was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U. S. regulatory agency standards.

At the completion of the manufacturing process, the battery was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of the battery, without the consent of Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render the battery unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this battery.

While this manual attempts to anticipate the most important operations and maintenance needs for this battery, unforeseen circumstances may arise that have not been

addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is nontransferable. Distribution and access is limited only to authorized personnel.

Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

 Bucyrus America, Inc. All rights reserved.

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SYMBOLS AND SPECIAL NOTATIONS Throughout this manual there are specific notations that are either UPPERCASE BOLD, UNDERLINED or ITALICIZED for the primary purpose of emphasis. Please pay special attention to such statements as they regard safety or critical maintenance installation information.

You will also see the following:

NOTICE: THIS NOTATION DENOTES A REFERENCE TO PREVIOUSLY STATED INSTRUCTIONS.

IMPORTANT: THIS SYMBOL DENOTES THAT SPECIAL ATTENTION MUST BE ADHERED TO IN THE ATTACHED STATEMENT.

CAUTION: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A CUT, BRUISE OR ABRASION.

WARNING: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A LOST TIME ACCIDENT.

DANGER: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A SERIOUS INJURY OR FATALITY.

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DANGER ONLY TRAINED AUTHORIZED PERSONNEL SHOULD OPERATE OR PERFORM MAINTENANCE ON THE BATTERY. FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH. FAILURE TO OPERATE OR MAINTAIN THIS BATTERY IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

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MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

ENTIRE BATTERY

Mine service batteries can weigh several thousand pounds and could cause severe injury or death should the battery fall on persons or body parts

Batteries must be resting securely in a machine, on battery tables, or platforms capable of supporting the weight while performing maintenance or service on battery.

ELECTRICAL

Electrical shock could cause death or serious injury. The battery produces lethal amounts of current whether connected to a machine or not.

Batteries should be maintained and serviced by qualified personnel.

The battery should be disconnected before servicing.

EXPLOSIVE GASES

Batteries produce explosive gases that could be ignited causing burns or explosions.

Batteries should be well vented before servicing, particularly if welding or burning on the battery.

Batteries should be maintained by qualified personnel.

CORROSIVE ACIDS

Batteries contain strong acid that could cause severe burns if spilled or splashed on body parts or in the eyes.

Protective clothing, gloves, and eyewear must be worn when working on batteries. Batteries should be maintained by qualified personnel.

COVERS

Battery covers could fall, crushing hands, arms, or fingers.

Battery covers must be secured with the cover supported when working under the covers.

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SAFETY PRECAUTIONS AND GUIDELINES OVERVIEW Before you install, maintain or repair a mine service battery READ and STUDY this guide. KNOW how to safely use the battery and what you must do for safe maintenance.

ALWAYS wear or use the proper safety items required for your personal protection.

If you have ANY QUESTIONS about the safe use or maintenance of this unit: ASK YOUR SUPERVISOR - NEVER GUESS - ALWAYS CHECK

MAINTENANCE AVOID, whenever possible, servicing, cleaning or examining the battery in congested areas.

ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Manual for the proper location and part number of decals and plates.

DISCONNECT the battery when servicing or when welding on the battery.

BE SURE the battery area is well ventilated (clear of fumes) when it is necessary to connect battery charger. Fumes from the battery could ignite by a spark and explode.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Chapter 4 of this guide is dedicated to safety procedures that MUST be followed when using or servicing lead-acid batteries. It is important that you read and understand the procedures outlined in this guide, particularly those in Chapter 4.

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CHAPTER 1 - INTRODUCTION Section I. General 1-1. Scope This guide contains information concerning the theory, construction, installation, use, maintenance, repair, and hazards of lead-acid storage batteries used to power mine tractors, scoops, locomotives, and coal haulers.

1-2. Forms, Records and Reports The following form will be used by personnel responsible for the receipt, storage, operation, charging, and maintenance of lead-acid storage batteries. a. Monthly Storage Battery Record - The Monthly Storage Battery Record is to be used to record the services performed on motive power batteries. This record should be prepared and maintained by the using operator and should accompany the battery at all times. (See Figure 1 for a typical "Monthly Storage Battery Report" form.)

FIGURE 1 – MONTHLY STORAGE BATTERY RECORD

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Section II. Definitions 1-3. Standards Those definitions referenced throughout this manual generally agree with accepted industry standards.

For a more complete listing of "Definitions for Lead-Acid Industrial Storage Batteries" see NEMA Standards publication No. 1B 1-1971.

Copies of NEMA standards may be obtained at nominal cost by writing to: National Electrical Manufacturers Association, Department of Engineering and Safety Regulations, 2101 L Street, N.W. Washington, D.C. 20037.

Section III. Description and Construction 1-4. Battery Mine power lead-acid batteries for electric vehicles typically consist of of: (1) a steel tray into which the cells are assembled; (2) a battery terminal connector; and (3) other components necessary to secure and protect the cells and provide the necessary electrical interconnections. a. Battery Identification and Data - The essential information necessary for proper care of an industrial motive power battery appears on the battery, either stamped into one of the intercell connectors or on a name plate affixed to the tray. This information usually includes the manufacturer's name and model, number of plates per cell, battery capacity, battery voltage, serial number, suggested charging rate, and fully charged specific gravity of electrolyte.

If vital information is missing, or is no longer legible, such information can be obtained by contacting your nearest BUCYRUS AMERICA, INC. representative.

Some manufacturers list, as a part of the model or type designation, the rated ampere-hour capacity of a single positive plate, such as "SS75". As an alternate means of determining rated battery capacity, this number should be multiplied by the total number of positive plates in one cell. To find the number of positive plates in a cell, subtract one from the total number of plates and divide by two. To find the capacity of a battery designated "SS75-19," therefore: 19 - 1 = 18; 18 divided by 2 = 9; 9 x 75 = 675 Ah battery capacity. b. Cell Arrangement - The individual cells, which contain the energy generating components of the battery, may be arranged slightly differently for various types of equipment. The cells of all motive power batteries are, however, always connected in series to produce the required voltage. Cell and battery capacity, which is the available ampere-hours or watt-hours, is a function of the total number and size of plates within each cell. Voltage, though, is the same for all cells regardless of size. Each lead-acid cell yields a nominal 2 volts. c. Connector Arrangement - Connections between cells are made by intercell connectors which may be lead-coated copper straps or be cast of solid lead. These connections are always welded, in proper sequence, by the application of heat to the terminals of the cells. Energy from the battery is drawn off by terminal cables which extend beyond the steel tray wall and are in turn permanently joined to the battery terminal connector.

1-5. Cell

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This is the basic unit of any battery. It is a galvanic cell which produces electrical energy when connected to an electrical load and, after being discharged, may be restored to its original fully charged condition. It has a nominal voltage of 2 volts and consists of an element, from which the energy is derived, and the electrolyte; both are contained by an impact resistant, molded plastic jar. The element is prevented from contacting the bottom of the jar by means of a high impact bridge, which consists of a series of support ribs. These ribs provide sediment space below the bottom of the element to accommodate particles of active material, shed by the positive plates during normal operation of the battery. (See Figure 2.)

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FIGURE 2 – TYPICAL BUCYRUS AMERICA, INC. CELL

Cover - With lead insert bushing prevents leakage and voltage to ground.

Vent Cap – Quarter turn bayonet type simplifies watering and inspection.

Post - Special alloy for increased strength and conductivity.

Separator Guard – White in color to increase visibility for fast electrolyte check.

Post Plate Strap - Extra heavy to insure a permanent connection between post and plates.

Negative Plate – Designed to compliment positive plate performance.

Positive Grid - A non-porous lead alloy casting, designed for maximum current carrying capacity, capable of many years of service.

Vertical Mat - Laminated construction compromised of uniformly spaced fine glass tape that imbed into the active material and an interwoven glass fiber mat wrapped vertically around the positive plate insuring optimum active material retention.

Horizontal Mat - Made of glass fibers with an insoluble binder.

Breaks up gas bubbles and increases positive plate insulation.

Active Material - Specially formulated and uniformly applied under rigid laboratory control to insure maximum efficiency throughout long battery life.

Retainer and Bottom Shield - A high porosity perforated envelop that encases positive plate and glass mats to prevent shorts and insure maximum performance and life.

Jar - Molded of high-impact material to remain leak free under rough treatment.

Separator - Deep channeled, microporous, impervious to heat, acid and corrosion: provides insulation between positive and negative plates while allowing the free flow of electrolyte throughout the cell.

Bridge - Provides firm element support and ample sediment space.

Bucyrus America, Inc. mine batteries incorporate every feature required by today’s mines. They are designed by engineering technology and built by master battery craftsmen according to strict quality control guidelines. DBT America Inc. batteries are the finest available to meet today’s mining requirements, and our precision construction provides new equipment performance throughout a long life.

The top of each cell is fitted with a molded rubber plastic cover sealed to the jar at the edges. A vent or filler cap is located in the center of the cover. This vent permits the escape of hydrogen and oxygen while the cells are gassing and, when removed, provides an opening through which water may be added 11

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to the cell. The positive and negative terminal posts, which are part of the element, fit through openings in the cover. Prior to being connected together, cells are placed so that the positive terminal of one cell is adjacent to the negative terminal of the next. This arrangement permits a conveniently made series connection. a. Element - The element of the cell consists of one group each of positive and negative plates meshed together. The plates are insulated from each other by separators which are inserted between all plates. A plastic element protector is positioned on top of the separators. This prevents mechanical damage to the element and aids in preventing electrical shorts which occur when particles of active material bridge the space between plates. Terminal posts are welded to each group and are used to electrically connect one cell to another. b. Group - This is an assembly of plates of like polarity connected in parallel by welding to a common strap or busbar. A cell must contain one positive and one negative group. The negative group always has one more plate than the positive group. One or more terminal posts are welded to each. c. Plates - The plates (also called "electrodes") are either positive or negative and consist of a cast lead alloy grid and active material. The grid provides support to the active material and becomes the primary electrical conductor. The active materials result from the addition of chemicals to lead oxides which are converted, by electrochemical processing, to lead dioxide in the positive and to sponge lead in the negative.

(1) Pasted type - The grid of the pasted plate consists of horizontal and vertical or diagonal cast lead conducting members within a rectangular cast frame. A slurry of active material is pasted or squeezed into the voids, and the surfaces are then covered by porous glass and plastic retainers to prevent the loss of active material. d. Electrolyte - The element within the jar is immersed in an electrolyte, which is a solution of sulfuric acid and "pure" water. This permits the necessary chemical reaction to occur and provides a conducting medium in which the flow of electric current takes place. The electrolyte in a fully charged cell normally has a specific gravity of between 1.280 and 1.295 at 77 degrees F. As a cell discharges, the specific gravity decreases. Measurement of this specific gravity, by means of a hydrometer, indicates the state of charge of a cell. To save time in determining- this state of charge for the battery, a pilot cell or cells may be chosen; a pilot cell is a selected cell(s) whose condition is assumed to be representative of the condition of the entire battery. e. Separators - Separators are made from microporous plastic, which is resistant to heat and acid.

Separators provide mechanical and electrical insulation between positive and negative plates, but are porous enough to permit passage of electrolyte. The grooved or ribbed side of the separator is placed toward the positive plate to allow a free flow of electrolyte to the active material. The flat side faces the negative plate to contain the sponge lead. f. Positive Plate Retainers - Pasted type plate retainers are added, after pasting, typically by wrapping the plate first with fibrous-type glass tape or mats and then by a perforated plastic envelope complete with bottom boot or by other suitable filtering systems. All types of retainers act to prevent the escape of positive active material during normal use. Retainers are not needed on negative plates.

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Section IV. Principles of Operation 1-6. Fundamentals of Cycling A cycle is a discharge followed by a charge. During the charge, the electrical energy supplied by the charger causes an electromechanical reaction within the battery. This restores the active materials to a fully charged condition. a. The Fully Charged Cell or Battery - The positive and negative plates (electrodes) are separated from each other and immersed in electrolyte. In the fully charged condition, the active material of the positive plate is lead dioxide and that of the negative plate is sponge lead. The electrolyte is a solution of sulfuric acid and water that normally varies in a specific gravity from 1.280 to 1.295. The combination produces a voltage of approximately 2 volts on open circuit. This voltage potential results from the fundamental characteristic of a storage battery which dictates that when two electrodes of dissimilar metals are immersed in suitable electrolyte, and a circuit is closed between the two, electrons begin to flow. A fully charged cell should normally have an on-charge voltage of from 2.45 to 2.70 volts when charging at the finish rate. b. The Discharging Cell or Battery - While a battery is being discharged or used, lead dioxide and sponge lead combine with sulfuric acid to form lead sulfate within both plates. This action causes the specific gravity of the electrolyte to decrease. As the discharge progresses, individual cell and battery voltages decline, generally in direct proportion to the rate of discharge. c. The Discharged Cell or Battery - As the depth of discharge increases, more sulphuric acid is removed from the electrolyte so the specific gravity decreases and may drop below 1.100 as it approaches the specific gravity of water. Almost all of the active material of both positive and negative plates is converted to lead sulfate, and an effective electromechanical reaction is no longer possible.

At this point the battery has reached its discharge limit. d. The Charging Cell or Battery - The charging action begins when the terminals of the battery are connected to an external source of direct current. The electromechanical reaction is reversed and the positive plates, negative plates, and electrolyte start returning to their original charged condition.

Charging causes the battery voltage to rise as active materials are restored. A cell being charged may have a voltage of from 2.12 to 2.70 volts depending upon charging rate and time. e. General - Storage batteries do not actually store electrical energy; instead, they accept the electrical energy delivered to them during charging and convert it into chemical energy. During discharging, this chemical energy is reconverted into electrical energy to be used as needed.

To obtain the best performance and life from a mine power storage battery, it should usually be charged after each shift of use or whenever the specific gravity of the electrolyte falls below 1.240. It is very important that proper ventilation be provided during charging to make certain that (1) the hydrogen gas, given off toward the end of the charging process is dissipated (see Chapter 4), and (2) that individual cell electrolyte temperatures, during normal operations, do not exceed 110 degrees F. 1-7. Ampere-Hour Capacity The electrical capability of a storage battery is usually expressed in ampere-hours. The ampere-hour capacity is the number of ampere-hours which can be delivered under specified conditions of temperature, rate of discharge, and final voltage. Basically, ampere-hours are determined by multiplying the number of amperes which the battery will deliver by the number of hours during which the current is flowing. Total cell or battery capacity then is determined by the size and number of plates which make up

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the element. Due to the variety of job requirements, batteries are produced with many different sizes of cells.

1-8. Voltage With reference specifically to storage batteries, many "voltage" conditions have been recognized. The most important of these are: a. Open Circuit Voltage - This is the voltage of a cell or battery at the terminals, when no current is flowing. The nominal open circuit voltage of an individual fully charged cell is 2 volts. This is true regardless of cell size. The voltage of a 64 cell lead-acid battery is stated, therefore, as 128 volts. b. Initial Voltage - The initial voltage of a cell or battery is the closed circuit voltage at the beginning of a discharge. It is usually taken after current has been flowing for a sufficient period of time for the rate of change of the voltage to become practically constant, usually a matter of minutes. c. Average Voltage - The average voltage of the cell or battery is the average value of the voltage during the period of charge or discharge. d. Final Voltage - The final or cut-off voltage of a cell or battery is the prescribed voltage at which the discharge is considered complete. It is usually chosen so that the useful capacity of the battery is realized without subjecting it to harmful overdischarging. Final voltage will vary with the rate of discharge, cell temperature, and the type of service, but for mine power applications it is considered to be 1.70 volts per cell.

Inital voltage, average voltage, and final voltage are monitored when conducting test discharges.

1-9. Rated Capacity The rated capacity of a storage battery is the number of ampere-hours or watt-hours which it is capable of delivering when fully charged and under specified conditions of temperature, rate of discharge, final voltage, and specific gravity. United States industry standards for mine power batteries always specify this to be at the 6 hour rate of discharge. The total capacity available from a battery is greatest at low rates of discharge over a long period of time. Discharging at high current rates reduces the total ampere-hours available.

1-10. Sulfation Sulfation occurs when conditions within the cell cause sufficient accumulation of abnormal lead sulfate at both the positive and negative plates, permanently affecting the normal chemical reactions. Habitual overdischarging below final voltage, prolonged operation in an undercharged condition, and extended stand periods while in a discharged state are major causes of sulfation. A servicing schedule should be followed to provide frequent monitoring and adequate charging. See Chapter 3, Section 1, for methods of restoring a sulfated battery.

1-11. Operating Cycle An operating cycle of a storage battery is the discharge during use and subsequent charge to restore its initial condition.

1-12. Service Life The service life of a storage battery is the period during which it provides useful power while being discharged. It is usually expressed as the time period, or number of cycles, which elapses before the ampere-hour capacity falls below 80% of its rated value. To obtain maximum service life, it is 14

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recommended that a battery be restricted to one full cycle per 24 hour day or fewer than 300 cycles per year. Other factors which most often adversely influence service life are: 1. Abnormally high or low electrolyte temperatures.

2. Frequent overdischarging.

3. Failure to add water regularly.

4. Frequent overcharging.

5. Poor, or high, resistance, connections or contacts.

6. Adding too much water.

1-13. Effect of Temperature The normal operating characteristics of a storage battery are modified by unusually low or high cell temperatures. a. Low Temperature - Available battery power is reduced by low temperature because electrolyte viscosity and resistance is increased and diffusion throughout the pores of the active material is retarded. For example, a fully charged battery (1.280 to 1.295 specific gravity at 77 degrees F.), when its electrolyte temperature is about 32 degrees F., will deliver only 75% of the capacity which would be available at normal room temperature. This drops to 40% at 0 degrees F. The electrolyte could freeze if a discharged battery were exposed to very cold temperatures for several hours. (See Table 1 for freezing points of various electrolyte concentrations.)

In addition to the discharge-related problems, the charge acceptance of a lead-acid battery is impaired when electrolyte temperatures drop below 60 degrees F. As a result, batteries should always be kept fully charged, especially in cold weather. They should be heated, even during operation or storage, if exposure is severe enough to cause the temperature of the electrolyte to approach 32 degrees F. b. High Temperatures - Although high temperatures (up to 110 degrees F.) do not cause a reduction in available capacity, battery operation is adversely affected. Because most chemical reactions are accelerated at high temperatures, the rate of corrosion of the positive grid is increased and the active material is shed more rapidly. Even electrolyte temperatures above 90 degrees F. will cause some reduction in service life and should be avoided whenever possible. Cell temperatures should never be allowed to exceed 110 degrees F.

TABLE 1 FREEZING POINTS OF VARIOUS ELECTROLYTE CONCENTRATIONS State of Charge-Approximate (Percent)

Specific Gravity

Freezing Point (Degrees Fahrenheit)

100 75 50 25 10

1.280 1.250 1.220 1.160 1.130

-95 -62 -31 +1 +10

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CHAPTER 2 – INSTALLATION, USE, AND MAINTENANCE Section I. Preparation for Use 2-1. Establishing Requirements The number of batteries required for service depends primarily upon the number of 8-hour shifts in effect. Normally, for operation on a single-shift basis, the minimum number of batteries required will be the same as the number of items of operating equipment and the batteries need not be removed from the unit for charging. For operation on a 2- or 3-shift basis, the minimum number of batteries required will be twice the number of items of operating equipment and it will, therefore, be necessary to exchange discharged batteries for charged batteries at the end of each work shift. Whenever possible, it is recommended that more than the minimum number of batteries be available for multiple-shift operation, providing at least an 8-hour cooling period after charging. In an emergency, any one battery can be used for two 8-hour shifts during a 24-hour period, but this procedure, repeated regularly, will probably cause high electrolyte temperatures and could seriously affect service life. Therefore, where 3-shift operation is normal, 3 batteries will be required per item of equipment.

2-2. Unpacking Upon Receipt 1. It is important first to examine the exterior of the packing for wet spots on bottom or sides which may indicate leaking jars. Inspect also for physical damage to battery package because the battery could be affected as well. Report any damage to your supervisor.

2. Make certain that the package is right side up, with skid mounts resting firmly on floor.

3. Use a forklift truck or crane of sufficient capacity to remove the packaged battery from the truck or freight car. If a crane is employed, be sure the sling is secured against the bottom of the skid and not around the skid mounts.

LIFTING DEVICES USED TO MOVE BATTERIES MUST BE CAPABLE OF CARRYING THE WEIGHT STAMPED ON THE BATTERY CASE. KEEP ALL PERSONS AND BODY PARTS FROM UNDER THE BATTERIES WHEN THEY ARE LIFTED. 4. Move the crated battery to the uncrating area and remove packaging, including any wrapping or other protection provided to the battery terminal cable connectors.

5. Inspect battery and report any damage to your supervisor.

6. Use a properly insulated lifting beam of adequate capacity to lift the battery, by means of an overhead hoist, from the battery skid.

2-3. Handling Batteries When lifting batteries, always use a device which exerts a vertical pull on the lifting eye or tab. If a chain must be used, it should be in combination with a lifting beam with provision for adjusting lifting hook centers to the exact length of the tray. Any method of lifting which tends to "squeeze" or "stretch" the battery tray may distort it and could damage jars or disturb cell seals. A piece of rubber sheet or other insulating material, temporarily laid on the battery while lifting, will prevent any possible short circuits from chains or hooks. As an additional precaution against accidental shorting, the lifting beam hooks should be electrically insulated from each other.

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2-4. Preparing Batteries for Use a. See Table 2 for proportions of sulfuric acid and water to make electrolyte.

TABLE 2 Note: Sulfuric Acid of 1.400 Specific Gravity Specific Gravity Required

Parts Water Required

1.375 1.365 1.355 1.350 1.340 1.330 1.325 1.315 1.310 1.300 1.290 1.285 1.280 1.275 1.270 1.260 1.255 1.250 1.245 1.240 1.230 1.225 1.220 1.215 1.210 1.205 1.200

.075 .11 .14 .16 .20 .24 .27 .31 .33 .38 .43 .46 .49 .53 .56 .63 .67 .70 .74 .78 .85 .905 .96 1.00 1.05 1.11 1.16

Parts Acid Required 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

b. Charged and Wet Batteries - Charged and wet batteries are shipped with cells filled and fully charged. Prepare these batteries for use as follows:

PROPER EYE AND BODY PROTECTION MUST BE WORN AT ALL TIMES WHEN SERVICING THE BATTERIES TO PREVENT ELECTRICAL SHOCK AND CONTACT WITH THE BATTERY ACID. CLEAN AND NEUTRALIZE ANY ACID SPILLS IMMEDIATELY. 1. Examine battery to see if electrolyte has been accidentally spilled. If so, clean and neutralize any spillage with a cloth that has been dipped in a soda solution. Rinse area with clear water.

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2. Remove vent caps and check the electrolyte level in each cell. Take and record the specific gravity reading, electrolyte temperature, and individual open circuit voltage of each cell. Note any irregularities.

3. Check to make sure that all cells are properly connected and that terminal connections are tight. If there are irregularities in the electrolyte levels or specific gravity readings, or if the battery has been in storage for more than 30 days, it should be given a freshening charge (see Paragraph 2-10d).

4. Recheck electrolyte levels after charging and after gassing has stopped. Again take and record specific gravity readings and electrolyte temperatures. If irregularities in electrolyte specific gravity readings still exist, they should be adjusted as described in Paragraph 3-12.

2-5. General Economical and dependable performance from a storage battery depends, to a great extent, upon proper charging. Faulty charging causes a decrease in battery service life and dissatisfaction with its performance. The selection of suitable charging equipment and methods is as important as the application of the correct battery. A mine battery installation is completely satisfactory only when the unit, battery, and charger operate as a smoothly functioning team. This text on chargers is for general information and guidance only. If specific data is required on a particular type of charger, contact the nearest sales representative.

When preparing a battery to be charged, make certain that all points of contact between the charger and the battery are clean to assure good conductivity. Also make certain that the positive terminal of the battery is connected to the positive terminal of the charger and, correspondingly, negative of battery to negative of charger.

PERMANENT DAMAGE TO THE BATTERY OR CHARGER MAY RESULT IF THE BATTERY IS CONNECTED INCORRECTLY. 2-6. Charging Principles Charging, as applied to a storage battery, is the conversion of electrical energy into chemical energy within the cell or battery. This restores the active materials and is accomplished by maintaining a unidirectional current to the battery in the opposite direction to that during discharge. When a cell or battery is said to be charged it is understood to mean fully charged. The type of battery, service condition, time available for charging, and the variation in battery voltages will strongly influence which charging method is best for a particular situation. Normally lead-acid batteries are recharged in 8 hours following a full discharge. However, they can be recharged within other time periods when desirable. A deeply discharged battery will absorb high current rates when the voltage is low. As the charge progresses, the voltage steadily increases until it reaches gassing voltage, approximately 2.37 volts per cell at 77 degrees F. At this point, battery chargers normally reduce charging rates automatically and taper to finishing rates which are used to complete the charge. The battery is fully charged when nearly all of the active material has been converted and when the specific gravity of the electrolyte and cell voltage have reached their maximum or constant values (corrected for temperature), as indicated by similar readings over a two or three hour period.

Batteries used in mine power applications are cycled - they are either being charged or discharged. In most circumstances, batteries are charged after each shift of use, so they are cycled many times during their lifetime. Incorrect charging for only a few cycles will do little harm, but if repeated day after day, the battery's service life will be seriously shortened.

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2-7. Charging Rates Proper charging means charging the battery sufficiently without overcharging, overheating, or excessive gassing. The charge is usually started at high amperage which is known as the starting rate.

Later during the charge, this rate of current flow is reduced to what is called the finishing rate. It is suggested that this finishing rate should not exceed 5 amperes per 100 ampere-hours of rated battery capacity. The starting rate may be as much as four to five times higher than the finishing rate.

Lead-acid batteries should be charged for a sufficient length of time and at a rate which will put back into the battery the same number of ampere-hours removed on discharge, plus approximately 10% additional which is an acceptable, and in fact desirable, overcharge. The specific amount of overcharge depends upon the temperature, age, and history of the battery. In general, it is more harmful to excessively overcharge an older battery, or one which is operating at high temperature, than a new battery or one operating consistently at room temperature. Any charge rate is permissible which does not produce excessive gassing or cell temperatures greater than 110 degrees F. 2-8. Control of Gassing Gassing is the evolution of gases from one or more of the electrodes during electrolysis. It is a natural phenomenon which takes place when a battery on charge can no longer accept all of the current being applied to it. Gassing is evidenced by bubbling of the electrolyte. The gases liberated are oxygen (evolved at the positive plates) and hydrogen (evolved at the negatives).

The point at which significant gassing begins is determined by voltage, but the amount of gas depends upon the portion of the charging current that is not being absorbed by the battery. Normally, noticeable gassing will begin when the voltage exceeds 2.30 volts per cell. At 2.40 volts per cell, gassing will be normal; at 2.50, it will be rapid. The amperage at which gassing becomes excessive depends primarily upon the state of charge and electrolyte temperatures. As the battery approaches full charge, it is necessary to reduce the charging rate to a point at which excessive gassing is prevented. This safe rate is the finishing rate or below. When proper charging equipment is used, the tapering of the charging current to the finishing rate is achieved automatically.

2-9. Charging Methods and Equipment The modern storage battery, used with a properly designed, modern, automatic charger, needs only normal water additions, occasional cleaning, and regular checking of both charger adjustment and battery condition to provide long, dependable service.

There are two recommended methods for the normal charging of motive power batteries: a. Modified Constant Voltage (potential) Method - The modified constant voltage method, in which the tapering of the charging rate is accomplished gradually, requires a source of direct current with a constant bus voltage of approximately 2.63 volts for each cell. This is for an 8-hour charge. Proper series resistance in the output circuit inherently provides the correct starting rate and assures that the rate will automatically be reduced, as the charge progresses, to the recommended finish rate. The constant voltage source may be either a motor-driven generator or rectifier. b. Taper Method - The taper method can be used with either generator or rectifier type equipment. The charger is designed to provide the correct charge rate during a constantly tapering charge. This is accomplished by coordinating the rising battery voltage with the design characteristics of the charger.

The shape of the current-taper curve will vary with different types of equipment, but the result is essentially the same. Solid state chargers are available which deliver as much current as the battery can accept, up to maximum charger output, and then taper the input sharply, when cells begin to gas, to keep finish rates low. These chargers do not require adjustment.

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2-10. Types of Charge a. Normal Charge - The two generally recommended types of normal or routine charges, following a deep discharge, are: (1) modified constant voltage charge, and (2) taper charge. b. Boost Charge (Quick Charge) - A boost charge of a storage battery is a partial charge, usuallly at a high rate for a short period. Such a charge is given in an emergency when it is believed that the amperehour capacity of the battery may be less than normal and insufficient to complete a planned period of work. A boost charge may also be used when it is not possible to give a battery one of the recommended types of normal charge. c. Equalizing Charge - An equalizing charge of a storage battery is a prolonged charge, usually at the finishing rate or less, to correct any inequalities of voltage or specific gravity which may have developed between cells during service. It consists of following a normal charge with an extended charge of 4 hours at a rate no higher than the finishing rate. In mine power applications, a battery should receive an equalizing charge weekly. d. Freshening Charge - A freshening charge of a storage battery is a charge given to batteries in storage or during inactive periods to replace losses due to self-discharge and to assure that every cell is periodically brought to a fully charged state.

2-11. Charging Precautions 1. When connecting the battery to the charger always connect positive (+) to positive and negative (-) to negative terminals.

2. Always recharge the battery as soon as possible after discharging.

3. Keep vent caps tightly in place while the battery is being charged, except when servicing the cell or when taking specific gravity or temperature readings.

4. Make sure that battery and charger voltages and ampere-hour ratings match when preparing to charge batteries.

5. Make certain that charging area is well ventilated.

6. Prohibit smoking and open flames in charging area.

7. Do not allow tools or other metal objects to contact intercell connectors.

8. Observe safety and health practices defined in Chapter 4, Section 11. It is especially important, while preparing for charging, to take the following precautions: (1) Wear protective gear provided and know the location of fresh water for emergency purposes.

(2) Use proper mechanical equipment to move or lift batteries.

(3) Provide acceptable fire extinguishing equipment.

Section II. Routine Maintenance 2-12. General

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The modern industrial battery is designed and built to give an average of 1500 cycles of charge and discharge during its life, depending upon the application and the operating environment. The exact length of the service life will depend, to a great extent, upon the care the battery receives. The following maintenance procedures, carried out at the proper time, will do much to prolong the life of the battery and provide efficient, satisfactory service.

PROPER PROTECTIVE CLOTHING AND EQUIPMENT MUST BE USED WHEN SERVICING BATTERIES TO PROTECT AGAINST ELECTRICAL SHOCK AND BATTERY ACID. BATTERIES, CHARGERS AND RELATED ELECTRICAL EQUIPMENT SHOULD ONLY BE SERVICED BY QUALIFIED, PROPERLY TRAINED PERSONNEL. 2-13. Charger Adjustment Make sure that the charger adjustment, for control of charging rates and cut-off, are correct. This will ensure that the batteries are properly charged with no excessive overcharge. Batteries that are overcharged regularly will need water more often, and cell temperatures usually will be higher than normal. If either condition is evident, adjust the charge rate downward, in those chargers which have provision for adjustment, so it is between a normal finish rate and one-half normal finish rate.

2-14. Cleaning a Battery Inspect the battery at least once each month to make certain the terminal connections are tight.

Remove dirt or electrolyte accumulation from the tops of the cells. Wash weekly with clean water. Using a solution of baking soda and water (one pound of baking soda to one gallon of water), neutralize any acid which may be collected at cell or battery terminals to keep them free from corrosion.

Use the solution until all fizzing stops. Work the solution under the connectors. To remove all traces of soda solution and loose dirt, rinse the battery down with clear water from a low pressure hose.

Whenever the battery top is being cleaned or rinsed, vent caps must be tightly in place.

2-15. Adding Water A certain amount of water loss in cells is normal and it should be replaced with "pure" tap water or distilled water. In some geographical areas, tap water may contain chemicals or other impurities harmful to batteries. The NEMA recommendation for battery replacement water lists the following maximum allowable impurities (parts per million): Total Solids Chlorides as CI Nitrates as NO 3 Iron as Fe

350 PPM 25 PPM 10 PPM 4 PPM

DBT AMERICA INC. PROVIDES WATER ANALYSIS SERVICE. A MINIMUM OF ONE QUART IS REQUIRED. CONSULT YOUR SALES REPRESENTATIVE.

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Check the height of the electrolyte at least weekly and if water is needed, add just enough to bring the electrolyte to proper level. Do not overfill. Water should only be added to batteries while the batteries are on charge and gassing, or as soon after recharge as possible.

Add water often enough to prevent the electrolyte level from dropping below the perforated separator protector. Ideally, a watering schedule should be established. This schedule should assure adequate watering while taking into consideration those factors which control water consumption, such as (1) frequency of charging, (2) water storage capacity of the specific cell type, and (3) age and condition of the battery.

2-16. Taking Hydrometer Readings 1. With the tip of the hydrometer immersed in the electrolyte, squeeze the syringe bulb and then slowly release it, drawing into the cylinder or barrel just enough electrolyte to permit the hydrometer float to ride free. The float stem must not touch the side of the cylinder nor the top of the syringe. If the float stem touches the upper area of the syringe, too much electrolyte has been drawn up; if the float still rests on the bottom, too little electrolyte has been drawn up. (See Figure 3.)

2. Read the hydrometer float scale with your eye at the same level as the electrolyte. The reading should be taken at the surface of the liquid, disregarding any slight curvature. This reading will be the specific gravity uncorrected for temperature. (See Table 3 for correction factors.)

3. Return all electrolyte to cell.

2-17. Record Keeping Facilities with more than just a few batteries will find that records of battery cycles, maintenance, and repair are indispensable for an effective battery maintenance program. In addition to those monthly records which require the posting of data each time a battery is charged, the following procedure will be helpful: 1. Establish a battery identification system giving each battery a code number. A multiple-digit system is suggested.

2. Record specific gravity of the pilot cell or cells before and after each charge. Pilot cells should be selected from those nearest the center of the battery and identified by differently colored vent caps.

They should be representative of the balance of the cells in the battery.

3. Record the number of cycles on a cumulative basis plus maintenance and repair information. Note any irregularities. The use of a "Battery Cycle and Maintenance Record" form is recommended. If variations in specific gravity readings exceed 20 points (.020) and on-charge voltage, after an equalizing charge, varies by more than .15 volts, contact your DBT AMERICA INC. service representative.

4. When the battery is new, and on at least an annually thereafter, read and record the specific gravity and open circuit voltage for all cells of the battery.

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FIGURE 3 – TAKING HYDROMETER READINGS

TABLE 3 SPECIFIC GRAVITY TEMPERATURE CORRECTION CHART Electrolyte Temperature (Degrees Centigrade)

Electrolyte Temperature (Degrees Fahrenheit)

Point Correction

110 107 104 101 98 95 92 89 86 83 80 77 74 71 68 65 62 59 56 53 50 47 44 41 38 35 32

230 221 218 212 209 203 198 194 185 180 176 171 167 158 152 149 140 135 131 128 122 118 113 104 99 95 86

+11 +10 +9 +8 +7 +6 +5 +4 +3 +2 +1 No Correction -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15

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CHAPTER 3 – FIELD SERVICING AND REPAIR Section I. Troubleshooting 3-1. General In addition to the required routine maintenance described in Chapter 2, Section III, storage batteries may, at some time during their service life, require more extensive or unusual care. Such care should be given as soon as it has been determined that a problem exists or that trouble may be developing. This section deals with the means of identifying existing or impending problems and offers possible solutions.

The Troubleshooting Chart, Table 4, defines the most common problems which could occur during a battery's lifetime. If the suggested operational remedies are ineffective, it may be assumed that there is an internal problem and it will be necessary to disassemble the cell or cells to inspect the elements and sediment well. If the cause of the problem can only be corrected by completely replacing cells or the battery, this information should be reported to the person in authority.

3-2. Restoring a Sulfated Battery Continued undercharging a battery, even to a small degree, leads to excessive "sulfation." The same is true of batteries which have been left standing in an uncharged state for an extended period. High temperatures rapidly accelerate sulfation when batteries are left standing in a partially charged condition.

The cells of a sulfated battery will give low specific gravity and voltage readings. The battery will not become fully charged after a single normal charging when sulfation has taken place over a prolonged period.

If the sulfation has not progressed too far, it may be possible to restore the battery to a serviceable condition by using the following special procedures: 1. Thoroughly clean the battery. (See Paragraph 2-14.)

2. Bring the electrolyte level up to a point which is just visible over the separator-protector by adding approved water.

3. Put the battery on charge at the prescribed finishing rate until the rated ampere-hour capacity has been returned to the battery. Record the voltage and specific gravity readings. Correct the specific gravity readings for temperature by using Table 3. If the temperature at any time during these procedures exceeds 110 degrees F., stop the charge and allow the battery to cool to 90 degrees F. or below before continuing. Charge the battery until the specific gravity shows no change during a 4 hour period while taking hourly readings. With automatic charging equipment, the battery may have to be placed on equalizing charge two or three times. If a battery is badly sulfated, the specific gravity may rise only 30 to 40 points (.030 to .040) during the first charge.

4. Place the battery into service and discharge it to a fully discharged condition.

5. Charge the battery again until the specific gravity shows no change during a 4 hour period.

6. Repeat the cycling process until the specific gravity rises to within 30 points of a normal fully charged battery, then place the battery back in routine service. Even though specific gravities may be lower than normal, they should not vary much from cell to cell. If they do, problems other than sulfation may be present. If the spread between the highest and the lowest gravity reading is 50 points or more, refer to the Troubleshooting Chart for help in identifying the problem. If the battery still has not responded to treatment, it should be replaced.

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3-3. Correcting Excessive Self-Discharge While a storage battery is in a charged state, a local electrochemical reaction takes place within the cells, which causes very gradual discharging. This reaction is known as self-discharge. A small amount is quite normal in mine power batteries where grids are made from antimonial lead. The rate of selfdischarge is temperature-related and increases significantly as temperatures rise. Table 4 shows the relationship between temperature and loss of specific gravity. The normal rate at 77 degrees F. to 80 degrees F. is a loss in specific gravity of about one point (.001) per day. This becomes of concern only when a wet battery is to be stored for weeks at a time. It can be ignored as a factor in normal battery operation.

It is possible, however, particularly during the latter stages of a battery's life, for the rate of discharge to become much greater and even limit the battery's duty cycle. Excessive self-discharge may be caused by defective separators or plates which have become shorted at the edges. Edge shorting is usually caused by loss of positive active material which can fill the sediment well or build up on the top or sides of the plates and eventually bridge the space between the positives and negatives. If a shorted condition seems likely, the element should be pulled for examination and the defective separator replaced, shorts cleared, or cells replaced. Usually, if the sediment well is full, salvage is impractical.

3-4. Test Discharge A capacity test is sometimes desirable to determine a battery's actual discharge capability as compared to its 6-hour rated capacity.

This can be a significant diagnostic tool when equipment does not operate as expected and it can help determine when the battery should be replaced. When a battery consistently delivers less than 80% of its rated ampere-hour capacity, either some cells are substandard or the battery has reached the end of its useful life and should be replaced.

A test discharge is performed by discharging a fully charged battery at a fixed rate under carefully controlled test conditions.

Section II. Repairing Batteries 3-5. General Storage batteries which have been damaged or which contain defective cells may, if the rebuilding cost and time are justified, be restored to a serviceable condition.

It is important to check a battery thoroughly if it has been involved in an accident or if it is believed to be defective. A neglected battery will continue to deteriorate even when not in use. Usually rebuilding is justified if the majority of the cells are in good condition.

This section explains how to remove cells from a battery and how to repair them if they are to be salvaged. Some special tools and parts will be required, depending upon the work to be done.

Reference will be made to the use of such special devices but they will not be further identified in this manual. Each manufacturer identifies all tools, accessories, and replacement parts by an appropriate part number. Use this number when making reference to them.

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Before starting any repairs, remove all vent caps from cells to be repaired as well as from all surrounding cells. The space above the electrolyte must be cleared of hydrogen gas before proceeding with repairs. Introduce a low volume air stream (volume and force equal to that produced by fanning each cell with a stiff piece of cardboard or other suitable nonconducting material) into each cell for at least 30 seconds. Be very careful when using air so that the electrolyte is not splashed out of the cell. Do not blow breath into cells. Wear protective face shield or goggles, rubber gloves, and apron. After cells have been purged, cover all vent openings with several layers of water-dampened cloth before starting repairs.

3-7. Removing lntercell Connectors Special intercell connector drills are designed to cut the bond between the cell post and the connector while permitting the post to remain for later rebuilding. The drills come in different sizes. When using them, be careful to cut only as deep as necessary, usually 1/4" to 3/8". Make certain vent plugs are in place. During drilling, try to center on the cover bushing and make sure any lead curl produced does not short across other connectors. After drilling, the intercell connectors can be lifted off with a pair of pliers.

3-8. Removing a Complete Cell After removing connectors as described in Paragraph 3-7, isolate the cell from adjacent cells. This may require cutting of compound or removal of spacers. Use a long spatula or similar tool to free the cell from top to bottom. When the jar walls are free, the cell can be lifted from the battery tray. All cells are heavy so a suitable lifting device, such as an electric hoist, is recommended. Threaded post clamps or cell pullers are available which can be burned or clamped to the posts, and used to pull the cell. Use a non-conducting bar between the loops of the post clamps and hook the hoist to this bar.

After removing the cell, neutralize any acid in the tray with a soda solution and clean up the residue.

When a cell or element is being pulled, it is advisable to have on hand both a replacement jar and a cover in the event that either of the original parts are damaged in the process.

If a wet and charged cell has been pulled and allowed to stand unsupported, the jar walls may bulge and permit the electrolyte level to drop. Do not attempt to adjust electrolyte levels until cells have been reinstalled in the battery.

TABLE 4 TEMPERATURE EFFECT ON BATTERY SELF-DISCHARGE Temperature (Degrees Fahrenheit)

Loss of Specific Gravity Per Day

120 100 80 50

.004 .003 .001 .0005

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TABLE 5 STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

BATTERY OVERHEATS DURING CHARGE

1. Malfunctioning charging equipment.

1. Replace or repair defective charger parts (timer, voltage sensitive relay, control board, etc.)

2. Charging equipment out of adjustment.

2. Adjust start or finish charging rates.

3. Defective or weak cell(s).

3. Replace or repair problem cell(s).

4. Battery worn out and beyond economical repair.

4. Replace battery.

5. High resistance connection within battery.

5. Check for hot wires, cells, intercell connectors, charging plugs, etc. Repair or replace defective component(s).

6. Low electrolyte level.

6. Add water; Just cover separator protector when discharged.

7.Battery charged in the vehicle with battery compartment closed or the tray cover closed.

7. Open the compartment during charge or charge the battery out of the unit with the tray cover opened.

8. Battery over 100 degrees F. when placed on charge.

8. Allow battery to cool below 90 degrees F. before charging.

1. See causes 3 through 8 above.

1. See remedies 3 through 8 above.

2. Worn out bearings, brakes dragging, or other vehicle problem causing high current draw.

2. Repair or replace defective unit problems.

3. Over discharge of battery.

3. a. Require drivers to return battery for recharge when vehicle begins to slow down.

BATTERY OVERHEATS DURING DISCHARGE

b. Put more batteries into service.

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TABLE 5 (Continued) STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

BATTERY NOT COMPLETING FULL WORK SHIFT

1. Battery not fully charged before placed into operation.

1. See that battery has reached full charge specific gravity before placing into operation.

2. Weak, leaking, or defective cell(s) in battery.

2. Repair or replace cell(s) or battery.

3. Grounds or shorts in the battery.

3. Remove grounds or shorts.

4. Battery worn out and beyond economical repair.

4. Replace battery with equal or higher capacity battery.

5. Battery too small for job.

5. a. Replace battery with one having higher capacity. b. Purchase extra batteries (with higher capacity if possible) and change them more frequently.

LOW ELECTROLYTE

6. Electrical or mechanical problem.

6. Troubleshoot vehicle and repair.

1. Cracked or broken jar(s).

1. Replace jar(s) and adjust gravity.

2. Cell missed when watered.

2. More careful attention when watering.

3. Defective or weak cell(s).

3. Repair or replace cell(s)

4. Frequent overcharge.

4. See items 1 and 2 in “Battery Overheats During Charge.”

5. Battery not regularly watered.

5. Water battery regularly.

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TABLE 5 (Continued) STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

UNEQUAL CELL VOLTAGES

1. Grounds in battery.

1. Clean battery.

2. There is a “tap” off the battery for auxiliary equipment (radio, light, etc.)

2. a. Use dropping resistor instead of tap. b. Equalize battery regularly.

3. Battery sluggish due to lack of work.

3. Give battery a deep discharge and equalizing charge.

4. Leaking cell or cover.

4. Replace jar or cover and adjust gravity.

5. Defective or weak cell(s).

5. Repair or replace defective cell(s)

6. Battery worn out beyond economical repair.

6. Replace the battery.

7. Acid loss in few cells by tipping battery over.

7. Adjust specific gravity.

3-9. Removing an Element If the jar is known to be serviceable, it may not be necessary to remove the complete cell. Usually only the element, complete with cover, has to be pulled. This can only be done, however, on those batteries containing a compound type cover-to-jar seal. On these, after removing connectors, draw a warm putty knife through the sealing compound close to the inside jar wall. Use a threaded post clamp or cell puller and hoist to raise the element, with cover in place, first to drain position, and then up and out of the jar.

When pulling an element from a cell which has been removed from a battery, use jar hold-down clamps.

Some batteries are furnished with permanent seals between the cover and jar. With these, if a defect occurs, the complete cell must be pulled and cover-to-jar seal cut or sawed to permit removal of the element. In doing so, both jar and cover must be replaced and resealed in accordance with the correct instructions.

When removing an element, lift it halfway out of the jar and hold it at this position until most of the electrolyte has drained off. Then raise the element to clear the top of the jar. Do not, unless absolutely necessary, expose an element to air longer than five minutes. Oxygen in the air combines with the active material in the negative plates, causing them to oxidize and heat. If the exposure persists, negatives will 30

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discharge. While the element is out of the jar, check the sediment well in the bottom of the jar. If it is full of shed material, the cell probably will have to be replaced.

Plate and separator edges may be inspected while the element is suspended above the jar. A more thorough inspection of separators, plate insulation, grids, and active materials may be indicated. If so, lay the element on its side on a clean non-metallic surface. The plates should be at right angles to the table surface so the element can be fanned slightly to permit the removal of separators. Always on negative side.

When reinstalling separators, make certain that the flat side of the separator is against the negative plate and the ribbed side is facing the positive. They should be pushed up until they are flush with the bottom of the element and they should project equally on each side of the plates.

Before installing an element in a previously used jar, wash out any sediment which may have accumulated in the bottom of the jar and clean all compound from around the inside of the top edge.

Clamp the element, if necessary, when reinstalling it in the jar. Make certain that the element is entering the jar properly and that the plates are at right angles to the plate support ribs in the bottom.

When installing an element with a cell cover attached, use a putty knife to guide the lip of the cover past the top edges of the jar.

3-10. Replacing Cell in Battery Cells from which the elements were pulled, or which had damaged jars replaced, should be given an equalizing charge and acid should be adjusted immediately followinging repair before they are returned to service. (See Paragraphs 2-10c and 3-12.)

Before lowering a cell into a battery tray, be sure that it is correctly positioned relative to adjoining cells to which it is to be connected. Cells must be connected in series with the positive side of one cell connected to the negative side of the adjacent cell.

When the problem has been corrected and the cell is returned to the battery tray, the cover must be resealed to the jar. With the exception of those cells which contain a permanent jar-to-cover seal, a special asphalt type sealing compound is used for this purpose. Heat the compound until it melts, but do not let the temperature get above 400°F. Pack any large openings between cover lip and jar wall with cold compound and then pour the hot compound into the sealing groove in two steps. First pour the groove full and soft flame with a torch to improve the adhesion; then fill and flame again. Allow compound to cool and trim excess.

After sealing, pressure test cells for 10 seconds at a maximum of 1.5 psi and reinstall intercell connectors by welding or "burning" them to the terminal posts. A small hot flame is recommended such as is available from a standard commercial burning torch using natural gas and oxygen or propane and oxygen. Carbon burning outfits are also acceptable.

ALWAYS BE SURE THE CELLS ARE PURGED OF GAS, AS EXPLAINED IN PARAGRAPH 3-6, BEFORE USING AN OPEN FLAME OR BURNING ARC ON TOP OF THE BATTERY. 3-11. Replacing a Cell Cover The specific methods used to seal cell covers to both the jar and the terminal posts are as follows:

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a. Sealing Compound and Lead Bushing Design - Probably the most commonly used system, an asphalt type compound is applied to seal the cover to both rubber and plastic jars. Lead bushings, molded into the cover as inserts, are welded or "burned" to the terminal posts to prevent electrolyte leakage around the posts. When replacing a cover of this type, first cut the compound with a warm putty knife. Cut the full depth of the cover adjacent to the jar wall from corner to corner on each of the four sides. Since reuse of covers which have been removed from the element is not recommended, use a post trimmer to cut off the post extensions above the cover. Break the lead bond between post and lead insert by driving the cover down approximately 1/32". The lead insert mold placed over the post and tapped with a hammer serves this purpose. Insert a hook through the vent opening and lift the cover off. Remove all sealing compound adhering to jar wall and neutralize these surfaces and upper portion of all terminal posts, using a cloth moistened with a soda solution. Thoroughly dry all of the neutralized surfaces. Install the new cover, complete cover-to-jar seal, and reburn cell connectors as described in Paragraph 3-10. b. Epoxy Seal and Seal Nut Design - This is one of the newer systems which employs an epoxy or permanent, hard seal between cover and jar. To disassemble a cell of this design requires that the jar be cut and that both jar and cover be replaced. When reassembling with a new jar and cover, it is very important to adhere to the following procedure to obtain an effective seal: 1. Epoxy can be used only on rubber jars and covers.

2. Thoroughly clean cover and jar sealing areas first with xylol (xylene), then with isopropyl alcohol; use a separate cleaning cloth for each.

3. Caulk bottom of seal groove with glass cord. Tamp corners in. Make overlap small. Do not use warm compound with epoxy.

4. Use special epoxy sealant as recommended by the battery manufacturer. Follow instructions provided.

5. Apply epoxy in two pours. Make second pour within two hours after first pour. Fill to top of jar. Do not overfill.

6. Pressure test seal after three hours or more from time of final pouring. Pressure test to 1.5 psi for 10 seconds. d. Heat Bonded Plastic Cover-to-Jar Seal and Lead Bushing Design - This is the newest of the sealing systems used with motive power batteries. To disassemble a cell of this design also requires that the jar be cut and both jar and cover be replaced. The seal between jar and cover is, in effect, a plastic weld. It can only be used with jars and covers made from identical plastic molding material.

Since special techniques must be used when resealing these covers, the battery manufacturer recommends that these cover-to-jar seals not be repaired in the field. Manufacturers' instructions request that such repairs be made in their service stations only.

3-12. Adjusting Specific Gravity of Electrolyte Fully charged cells usually operate at a specific gravity between 1.280 and 1.295. Normally it should never be necessary to adjust the gravity, but upsets, jar breakage, additions of too much water, and careless use of hydrometer can result in electrolyte loss and possible reductions of battery capacity. Lost electrolyte must be replaced but only after it has been determined that charging will not restore the gravity to normal when at the recommended level.

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Therefore a cell or battery should first be given an equalizing charge as described in Paragraph 2-10c.

Never make a gravity adjustment on a cell which does not gas vigorously while on charge.

If, after the equalizing charge, the specific gravity of any cell, corrected for temperature, is lower than normal, it should be adjusted in the following manner: 1. Put battery back on charge at the finish rate until cells are actively gassing to provide proper mixing.

2. Remove electrolyte from the low reading cells until level reaches separator protector.

3. Slowly add 1.400 specific gravity sulfuric acid to the cell while it is still gassing.

4. Wait 15 to 20 minutes for the added acid to become thoroughly mixed, then read the specific gravity. If it is still low, repeat the process until gravity is normal. As a guide, every 1/4" of electrolyte that has been removed and replaced by 1.400 acid will cause the specific gravity to rise 4 to 5 points (.004 to .005).

If the corrected specific gravity of any cell is higher than normal, proceed as follows: 1. While the battery is gassing on charge, withdraw from the cell a small amount of electrolyte and replace with approved water.

2. Repeat, if necessary, at 20 to 30 minute intervals until the desired reading is obtained. Every 1/4" of electrolyte which is replaced with water will cause the specific gravity of the cell electrolyte to drop 4 to 5 points (.004 to .005).

NEVER ADD ACID WITH A SPECIFIC GRAVITY HIGHER THAN 1.400.

STRONGER ACID COULD PERMANENTLY DAMAGE THE CELL. WHEN MIXING OR CUTTING ACID, ALWAYS ADD THE ACID TO THE WATER. NEVER POUR WATER INTO ACID. A VIOLENT REACTION COULD RESULT WHICH MIGHT CAUSE PERSONAL INJURY. WHEN WORKING WITH ACID, ALWAYS USE A FACE SHIELD OR GOGGLES, RUBBER GLOVES, AND AN ACID RESISTANT APRON.

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CHAPTER 4 – HEALTH AND SAFETY Section I. Battery Hazards 4-1. General A lead-acid battery can be very useful, safe source of electrical power. While installing, using, maintaining, or repairing a motive power battery, opportunities exist, however, for exposure to potentially dangerous situations. This section identifies those hazards which could result from improper handling or use.

4-2. Hazards a. A sulfuric acid solution is used as the electrolyte in lead-acid batteries and has a concentration of approximately 37% by weight of sulfuric acid in water. In this diluted state, it is not as hazardous as strong or concentrated sulfuric acid, but it acts as an oxidizing agent and can burn the skin or eyes and destroy clothing made of many common materials such as cotton or rayon. b. An explosive mixture of hydrogen and oxygen is produced in a lead-acid battery while it is being charged. The gases can combine explosively if a spark or flame is present to ignite them. Because hydrogen is so light, it normally rises and diffuses into the air before it can concentrate in any explosive mixture. If it accumulates into gas pockets, as can occur within a cell, it might explode if ignited. c. Electricity is produced by the batteries on discharge and, while most persons cannot "feel" voltages below 35 to 40 volts, all mine power batteries should be regarded as potentially dangerous. A lead-acid battery is capable of discharging at extremely high rates and, under conditions of direct shorting, can cause damage and serious injury. d. The weight of these heavy batteries can easily cause painful strains or crushed hands or feet if improperly lifted or handled. Batteries can be damaged if dropped. The average mine power battery weighs more than one ton, so proper equipment must be provided when changing or handling batteries. e. Burns can result from contact with molten lead or hot compound while repairing a battery. Lead can splash when intercell connectors are being reburned and hot compound can be spilled when resealing covers to jars. The protective gear provided, if worn, will prevent such burns.

Section II. Safety Procedures 4-3. Federal Standards In 1970, Congress passed the Occupational Safety and Health Act (OSHA). This act established the minimal acceptable standards for safe and healthful working conditions. The safety procedures suggested in this manual have been compiled from standards developed over the years by professional and technical organizations and by battery manufacturers and users. Experience has shown them to be the most effective safety standards. In all cases, they exceed the minimum standards of OSHA for personal safety and include procedures for safeguarding equipment as well.

The safety procedures have been grouped by functional area of most logical application or need.

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4-4. Safety Procedures While Handling Batteries 1. Lift batteries with mechanical equipment, such as an overhead hoist, crane or lift truck. A properly insulated lifting beam, of adequate capacity, should always be used with overhead lifting equipment. Do not use chains attached to a hoist at a single central point forming a triangle. This procedure is unsafe and could damage the steel tray.

2. Always wear safety shoes and safety glasses.

3. Tools, chains, and other metallic objects should be kept away from the top of uncovered batteries to prevent possible short circuits.

4. Battery operated equipment should be properly positioned with switch off, brake set, and battery unplugged when changing batteries or charging them while in the equipment.

5 Personnel who work around batteries should not wear jewelry made from a conductive material.

Metal items can short circuit a battery and could cause severe burns.

6. Only trained and authorized personnel should be permitted to change or charge batteries.

7. Reinstalled batteries should be properly positioned and secured in the unit. Before installing a new or different battery, check both the unit nameplate and battery service weight to make sure that the proper weight battery is being used. A battery of the wrong weight could change the center of gravity and cause equipment to upset.

4-5. Safety Procedures While Charging Batteries 1. Specific areas should be designated for charging batteries.

2. Charging areas should be adequately ventilated. The actual amount of ventilation will depend upon such factors as number and size of batteries being charged at the same time, room size, ceiling height and air-tightness of the building. Hydrogen concentrations above 4% can be explosive.

3. Smoking, open flames, and sparks should all be prohibited in the charging area. Post placards "Hydrogen," "Flammable Gas,” “ No Smoking," and "No Open Flames."

4. Facilities should be provided for flushing and neutralizing spilled electrolyte, for fire protection (including hand-operated fire extinguishers), and for protecting charging equipment from damage by units.

5. Fresh water should always be available in case electrolyte is splashed on skin, clothing, or into eyes. The kinds of equipment available for eye-wash and acid neutralization vary widely. A squeeze bottle containing a buffering solution for relief of acid burns should be located in the immediate work area. These should be clearly identified and readily accessible.

6. Before connecting a battery to, or disconnecting it from, a charger, the charger should be turned off.

Live leads can cause arcing and pitting of battery connector contact surfaces.

7. Make sure that all electrical connections are tight and mechanically sound to prevent any arcing or loss of power.

8. Wear a face shield or goggles, rubber gloves, apron, and boots when checking, filling, charging, or repairing batteries during periods of possible exposure to acid or electrolyte.

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9. When charging an enclosed or covered battery, always keep the battery tray cover, or compartment cover, open during the charging period. This will help to keep the battery cool and disperse the gases.

10. Keep vent caps in place at all times except while servicing or repairing cells. This minimizes the loss of electrolyte and prevents foreign matter from entering the cells.

11. Shut off and disconnect both input and output connections to the charger before charging equipment.

4-6. Safety Procedures While Handling Acids 1. The splashing of acid Into the eyes Is the most dangerous condition which can be encountered while handling sulfuric acid or electrolyte. If this should happen, the eyes should immediately be gently flooded with clean, fresh, running water for at least 15 minutes, followed as quickly as possible with a physician's examination. If the person is wearing contact lenses, they should be removed before rinsing the eyes.

DO NOT USE A BUFFERING OR NEUTRALIZING AGENT IN THE EYES WITHOUT MEDICAL APPROVAL. 2. Acid or electrolyte splashed onto the skin should be washed off under running water. Battery electrolyte will usually only cause irritation of the skin; if a burn develops, it should be treated medically.

3. When electrolyte is splashed on clothing, use a weak solution of bicarbonate of soda, as soon as possible, to neutralize the acid.

4. A carboy tilter or safety siphon should be provided for handling acid from a carboy container. Use the protective box when moving a carboy. Store acid in a cool place out of the direct rays of the sun. Use only glass, rubber containers, lead, or acid-resistant plastic containers when storing acid or electrolyte.

5. When mixing acid to prepare electrolyte, always pour the acid slowly into the water and stir constantly to mix well. Never pour water Into acid. Never use sulfuric acid solutions which are over 1.400 specific gravity.

6. Apply a neutralizing solution, such as bicarbonate of soda and water, when acid is spilled on floor.

Clean up affected area promptly. A mixture of one pound of soda to one gallon of water is recommended.

4-7. Safety Procedures While Servicing or Repairing Batteries.

1. Disconnect the battery from the unit when servicing or repairing either the battery or the equipment.

Also make certain the battery is disconnected from the charger before handling or repairing the battery.

2. Before repairing a battery, remove all of the vent caps and blow out each cell with a low pressure air hose to remove any residual gas. Use only a gentle stream of air to avoid splashing electrolyte.

Do not blow breath Into cells.

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3. Open or "break" the circuit before repairing damaged or dirty terminal plugs or receptacles connected to a battery by removing and insulating one terminal lead at a time.

4. When melting sealing compound in preparation for resealing cells, be careful not to puncture the top section of unmelted compound with a screw driver or other pointed object. A build-up of pressure from the melted compound in the bottom could cause liquid compound to squirt and inflict a severe burn. Do not allow compound to ignite by overheating. Compound becomes workable at 400 to 425 degrees F. 5. Check batteries frequently for acid leakage or signs of corrosion.

6. Use insulated tools whenever possible when working on batteries. If possible, also cover the terminals and connectors of a battery with a sheet of plywood or other insulating material to prevent short circuits.

7. When taking specific gravity readings, use a face shield or goggles and read the hydrometer with your eye at about the same level as the electrolyte. Return all electrolyte to the cell.

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CHAPTER 5 – STORAGE AND SHIPMEMT 5-1. General Follow these guidelines for those occasions when batteries must be stored, in either a wet or dry state, and for possible reshipment to other areas.

5-2. Storage Methods a. Charged and Wet Batteries - Lead acid batteries may be stored in a charged and wet (filled with electrolyte) condition when necessary for periods of up to several months. During such periods they should be stored in a clean, cool, dry, and well ventilated location away from radiators, hot air ducts, or other sources of heat, and protected from exposure to direct sunlight. Before being stored, the battery should be fully charged and the electrolyte brought to the proper level. Any leads should be disconnected or insulated to prevent accidental discharge. The top of the battery should be protected from dust, foreign matter, and moisture. Do not attempt to dismantle the battery.

If the average storage temperature is 80 degrees F. or higher, the specific gravity of the electrolyte should be checked at least monthly. If below 80 degrees F., check gravities at least every two months.

Whenever the specific gravity, corrected to 80 degrees F., falls to 1.240 or below, the battery should be given a freshening charge as described in Paragraph 2-10d. A freshening charge is also recommended just before returning a battery to service. b. Charged and Dry Batteries - New batteries are often supplied charged and dry (without electrolyte).

Batteries in this condition can remain in storage, unattended, for a period of at least two years. They should be stored in a cool, dry place with vent caps tightly closed. Average temperatures should not exceed 80 degrees F. Batteries should not be stored near radiators, hot air ducts, or other sources of heat, and should be protected from exposure to direct sunlight. The top of the battery should be protected from dust, foreign matter, and moisture. Charged and dry batteries when removed from storage should be activated as described in Paragraph 2-4a.

5-3. Shipment a. Charged and Wet Batteries - Depots or using organizations may make shipments of motive power batteries in a charged and wet condition if intended for use within a period of 90 days. The battery service weight is usually stamped into the steel tray near one of the lifting holes.

Before crating a wet battery for shipment, it should be given a freshening charge as described in Paragraph 2-10d. A tag should be attached to both the battery and the crate showing the date of the last charge and the specific gravity of the electrolyte at the completion of the charge. Make certain that the battery is properly protected when crated. The receiving organization should be alerted also to the need for a freshening charge before the battery is put into service. b. Charged and Dry Batteries - Depots will normally make domestic and export shipments of new batteries which usually will be in a charged and dry condition. Batteries, and the accompanying electrolyte in separate carboys, which are intended for export shipment must be packaged in accordance with approved methods.

WHENEVER BATTERIES ARE REGULATIONS WILL APPLY. 39

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BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS ALWAYS WEAR SAFETY GLASSES AND PROTECTIVE CLOTHING WHEN SERVICING BATTERIES. NEUTRALIZE ANY ACID SPILLS IMMEDATELY. IF ACID CONTACTS ANY PART OF THE BODY, FLUSH IMMEDATELY WITH RUNNING WATER AND SEEK MEDICAL ATTENTION. CARE SHOULD BE TAKEN AT ALL TIMES TO AVOID ELECTRICAL SHOCK FROM THE BATTERY OR CHARGER. THE CHARGER MUST BE TURNED OFF BEFORE CONNECTING OR DISCONNECTING THE LEAD(S) TO THE BATTERY. I.

CHARGING A.

Tray covers should be open during charge.

B.

Be sure charger switch is in “OFF” position.

C.

Check plugs and receptacles to be sure they are clean and in good condition. Connect the charger to the battery.

NEVER CONNECT OR DISCONNECT THE BATTERY AND CHARGER UNLESS THE CHARGER IS TURNED OFF. DAMAGE TO THE PLUGS AND RECEPTACLES WILL OCCUR. ALSO AN ARC WILL BE DRAWN THAT COULD BE A SAFETY HAZARD. D.

Turn switch “ON”, and press “START” to start daily charge. Check ammeter to be sure battery is charging and charger is operating correctly.

E.

Charger is fully automatic and will stop charging when it recognizes a fully charged battery in approximately 8 hours.

F.

Full charge specific gravity reading should be 1.280 to 1.295. Higher readings will result due to low water levels. Do not over water battery as lost acid will result in less work per charge and shorten battery life.

ALL SPECIFIC GRAVITY READINGS ARE BASED ON BATTERY TEMPERATURE OF 25 DEGREES C.

II.

III.

IV.

EQUALIZING CHARGE A.

After the daily 8-hour charge is complete, turn switch “ON” and press “START” (If equipped) for an equalizing charge once per week.

B.

When equalizing charge is completed and automatic electronic timer has turned charger off, read specific gravity of each cell and record. If variations of 10 or 20 points of specific gravity are recorded, call a Bucyrus America, Inc. Technician. If cells show variations of 0.1 or more, call a Bucyrus America, Inc. Technician.

OPERATING INSTRUCTIONS A.

Do not charge or operate in service if temperature of battery reaches 46 degrees C. High temperatures are a result of improper charger adjustments, high discharge rates, over discharging, short cycling, and low water levels.

B.

Keep plugs and receptacles clean and adjusted for tension. If plug is hot, it is not making good contact. Remember the battery has current at all times. Be careful when working on plugs and receptacles.

C.

Vent caps should only be removed to check water level, temperature, and specific gravity, or to add water. Be sure they are in place and tight at all times.

D.

Do not weld, grind or allow sparks or allow flame near battery. Do not allow tools or any other metal to be laid on connector of battery.

E.

Never add anything to the battery except approved water.

F.

Never add acid to battery.

WATERING A.

Add approved water to 1/4” (6.35 mm) below vent well only at the end of charge.

Filling to this level before charging will cause acid overflow. Acid attacks external battery parts. Any acid loss from the battery will result in power loss and shortened life.

B.

Replace vent caps securely.

6.35 mm .63 mm

V.

CLEANING A.

Wash battery at least weekly using soda and water, then rinse with plain water 1 lb. (0.45 kg) soda to 1 gal. (3.78 l) water mixture). Vent caps should be in place when washing battery.

B.

Dirty batteries create grounds, reduce work time, increase battery cost, and shorten life. Correctly charged, watered, and cleaned batteries give longer work time per shift per charge, reduced cost, and longer life.

BUCYRUS AMERICA, INC. HAS COMPLETE SERVICE FOR BATTERIES AND CHARGERS AT YOUR MINE SITE. WE ALSO HAVE COMPLETE BATTERY REBUILD CENTERS FOR QUICK TURNARROUND ON BATTERY AND CHARGER REBUILDS.

P/N A6474X61 Revised 12 – 07 BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS