CAT Bucyrus CH816C AC Operation Manual A6474X257 - PDF DOWNLOAD

BI620982

Operation Manual Bucyrus - UN-A-HAULER ® Model - CH816C AC Doc. No.:

A6474X257

Bucyrus America, Inc. ________________________________________ 4041 Wurno Road Pulaski, VA 24301

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

Internet: www.bucyrus.com

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This manual is intended to provide GENERAL product information for the Model CH816C AC UN-A-HAULER ® . The illustrations, descriptions and procedures contained in this publication apply only to this machine. 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

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________________________________________________ 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..............................................2.22

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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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 Operator’s compartment right ......................................... 5.5 Left hand control lever .................................................... 5.9 Right hand control lever .................................................5.13 Hazard zone........................................................................5.18 Starting procedure ..............................................................5.19 Machine operation .........................................................5.20 Shutdown procedure...........................................................5.23 Battery change procedure .................................................5.25 Instructions on the maintenance.........................................5.35 Important notes ..............................................................5.35 Before maintenance.......................................................5.35 Critical torque values .....................................................5.37 Lubricants, fluids and capacities ....................................5.37 Specific lubrication and maintenance instructions ..............5.38 Every shift ......................................................................5.40 Every third shift ..............................................................5.40 Weekly ...........................................................................5.44 Every two weeks ............................................................5.50 Monthly...........................................................................5.51 Hydraulic System Overview.....................................................5.61 Main Hydraulic System .......................................................5.61 What is Load Sensing? ...................................................5.61 Main Pump......................................................................5.62 Control Valves.................................................................5.63 Load Eject ......................................................................5.65 Tank Power Fill ...............................................................5.66 Battery Lift Suspension ...................................................5.67 Brake System......................................................................5.68 Auxiliary Pump ................................................................5.68 Unloading Valve..............................................................5.68 Accumulator ....................................................................5.69 Brake Valves...................................................................5.69 Brakes .............................................................................5.70 Two Wheel Assist Hydraulic System ..................................5.72 Pumps.............................................................................5.72 Circuit Valves ..................................................................5.74 Wheel Motors..................................................................5.74 Operating the Two Wheel Assist ....................................5.75 Filtration ..............................................................................5.76 Hydraulic Oil Filters.........................................................5.76 Gear Oil Filters................................................................5.77

_________________________________________________________________ Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

5. Operation

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________________________________________________ Table of contents 5. Operation (continued)

© BUCYRUS AMERICA, INC.

Hydraulics Adjustments and Settings ......................................5.79 Main System ......................................................................5.79 Margin Pressure.............................................................5.80 Main Relief Valve ...........................................................5.81 Load Sense Relief Valve................................................5.82 Pressure Switch .............................................................5.82 Pressure Limiters ...........................................................5.83 Sequence Valve.............................................................5.84 Battery Lift Suspension ..................................................5.85 Battery Lift Relief Valve..................................................5.86 Steering Cylinder Relief Valves .....................................5.86 Auxiliary/Brake System .......................................................5.88 Auxiliary Relief Valve .....................................................5.88 Unloading Valve.............................................................5.90 Two Wheel Assist System ..................................................5.90 Charge Relief Valve .......................................................5.90 Assist Relief Valve .........................................................5.91 Pump Displacement Adjustments..................................5.91 Spool Stroke Limiters..........................................................5.93 Limiting Steering Spool.......................................................5.93 Tailgate Go Switch Adjustment...........................................5.94 Troubleshooting procedures ...............................................5.95 Hydraulic system (general) ............................................5.96 Brakes ............................................................................5.99 Hydraulic cylinders....................................................... 5.101 Hydraulic pump ............................................................ 5.102 Valves .......................................................................... 5.105 Major maintenance ........................................................... 5.107 Drive motor/ gear case removal and replacement....... 5.107 Gear case and brake module disassembly and assy. . 5.109 Planetary wheel end removal and replacement .......... 5.111 Gear case and planetary wheel end shim procedure Number 1 ..................................................................... 5.112 Gear case and planetary wheel end shim procedure Number 2 ..................................................................... 5.113 Gear case and planetary wheel end shim procedure Number 3 (alternate procedure) .................................. 5.115 False bottom/ ejector cylinder replacement ................. 5.117 Accumulator operation and precharging procedure .... 5.119 2-Wheel assist removal procedure .............................. 5.121 Rear (hydraulic) wheel motor removal and replacement ..................................................................................... 5.122 BBC06 Series with brakes mechanical disconnect procedure ..................................................................... 5.123 Tire/wheel installation procedure ................................. 5.124 Recommended wheel mounting procedures ............... 5.127 Hydraulic pump and motor removal and replacement. 5.128 Tailgate assembly removal procedure ......................... 5.129 Battery lift assembly removal procedure...................... 5.130 Pedal assembly removal procedure ............................ 5.131 Canopy removal procedure.......................................... 5.132

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________________________________________________ Table of contents 6. Technical data Technical data........................................................................6.3 Components of the CH816C AC UN-A-HAULER ® ............6.3 Gauge Chart .......................................................................6.4 Tightening torques ..............................................................6.5 Permissible data .................................................................6.11 Lubrication fluids and greases .......................................6.11

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

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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 America, Inc. – Model CH816C AC UN-A-HAULER ® 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

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_______________________________________ 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 ________________________________________

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2

Your safety

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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..

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

© BUCYRUS AMERICA, INC.

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.

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© BUCYRUS AMERICA, INC.

and must be able to prove this knowledge.

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_________________________________________ 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 __________________________________________

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___________________________________________ 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)

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:

welding

■

maintenance work

■

inspection work

■

repair work

Batteries should be well vented before servicing particularly if welding or burning on the battery.

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

While welding the battery must be disconnected to be sure that you do not damage the electrical system and/or any of the electrical system components.

cordon off working area moving parts

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.: (continued on next page)

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Safety instructions ____________________________________________

steering lockout

■

false bottoms

■

pivot points

■

battery lifts

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

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.

Never stand under unsupported parts or suspended loads. means of attachment

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

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.

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© BUCYRUS AMERICA, INC.

Fix all moving parts with transport locks.

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___________________________________________ 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.

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© 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.

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___________________________________________ 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.

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

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© BUCYRUS AMERICA, INC.

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

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___________________________________________ 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

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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

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© 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.

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________________________________ 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 with any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts.

Chapter 5: Operation

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 HiPAC 10 display, refer to the HiPAC 10 Display Troubleshooting guide.

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.

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.

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© BUCYRUS AMERICA, INC.

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.

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________________________________ Overview of safety instructions WARNING! Before moving the ejector blade/false bottom control button, 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 LIFT/ LOWER” handle should only be operated at a battery change station. The battery may be damaged if accidentally raised in a low roof area.

© BUCYRUS AMERICA, INC.

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.

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! 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.

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Overview of safety instructions _________________________________ WARNING! Be sure no one is in the hazard zone (Fig. 23) 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.

WARNING! Always check before moving the ejector blade and false bottom control button 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.

WARNING! In the event of an emergency, the UN-A-HAULER ® may also be shutdown by striking the tape switch panic bars or the emergency stop switch. When the tape switch panic bar (s) is struck, the tram and pump motors will shut down. If the emergency stop switch is pressed, the machine circuit breaker will trip. This disconnects the motors and applies the automatic emergency brake. Be prepared for a sudden stop when the emergency stop switch or the tape switch panic bar (s) is pressed.

WARNING! The UN-A-HAULER ® is equipped with a passive battery hold-down system. This system keeps the battery resting securely on the frame while the UN-A-HAULER ® is in operation. The battery holddown system requires no operator assistance. However, it is important that the battery be properly aligned over the battery latch.

WARNING! The BATTERY LIFT/ LOWER function 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 LIFT/ LOWER handle is operated in a low roof area, the battery may be damaged.

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© BUCYRUS AMERICA, INC.

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.

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________________________________ Overview of safety instructions 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. 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 button 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.

© BUCYRUS AMERICA, INC.

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.

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! 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.

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

NOTICE! The battery needs to be suspended prior to pressing the battery hold down lock or battery hold down release buttons to reduce stress on the frame, battery lift and batteries.

WARNING! Opening the accumulator dump flow control valve will cause the batteries to fall to the ground immediately. Do not open without making sure the areas around and underneath the batteries are clear.

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Overview of safety instructions _________________________________ CAUTION! Do not release the brakes manually without ensuring that proper precautions have been to taken to stop the machine from rolling away out of control.

NOTICE! Never attempt to alter the system to allow the machine to be started with the brakes released.

NOTICE! Opening accumulator dump valve will cause the battery to drop to the ground immediately. Do not open valve before checking and clearing the area around the battery.

NOTICE! Do not adjust the minimum adjustment. This is set on a test stand by the manufacturer. Adjusting this to anything other than zero will result in the pump overheating and eventually lead to failures CAUTION! Use caution when elevating the machine. Insure that all areas around the machine are clear of equipment and personal to avoid injury. During this process the wheels will turn. It is important that the machine is elevated to a point where the wheels are a safe distance from the ground.

NOTICE! Replace the brake spring assembly each time the disc pack is replaced.

WARNING! Failure of a re-used brake spring shall reduce the brake effectiveness.

WARNING! The correct number of shims to use in between the gear case and planetary wheel end must be determined before installing either the gear case or the planetary wheel end (see shim procedure that follows).

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NOTICE! Do not tram the machine for extended periods of time while setting the assist relief. Take quick readings to eliminate overheating the machine.

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________________________________ Overview of safety instructions 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 WARNING! Because you will be working in between the false bottom and the front of the rear (payload) section, you must completely shutdown the unit (see shutdown procedure) and disconnect the battery plug to prevent accidental movement of the false bottom.

NOTICE! A "port-a-power" unit can be used to press the cylinder end pins out from the false bottom cylinders by inserting the unit between the rear section frame and the pin.

© BUCYRUS AMERICA, INC.

WARNING! Do not disconnect any hoses in the brake system until all pressure has been relieved and the “accumulator” gauge indicates "0” bar.

WARNING! Do not use oxygen or any gas other than nitrogen.

WARNING! Do not exceed 55 bar precharge pressure.

NOTICE! For recharging only.

WARNING! Thoroughly cleaned mating surfaces, bolts, bolt holes and accurately torqued mounting bolts are essential for proper operation of the rear (hydraulic) wheel motors. mounting bolts used in this assembly should be cleaned and coated with a threadlocking compound and tightened to the "lubricated" torque value.

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.

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Overview of safety instructions _________________________________

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! Replace all damaged wheel studs or bolts.

WARNING! Because you will be working with the battery lift cylinders, you must completely shutdown the unit (see shutdown procedure) and disconnect the battery plug to prevent accidental movement of the cylinders.

Chapter 6: Technical data 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.

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.

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© BUCYRUS AMERICA, INC.

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

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________________________________ Overview of safety instructions 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.

© BUCYRUS AMERICA, INC.

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.

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

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Overview of safety instructions _________________________________

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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.

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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.

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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.

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________________________________________ 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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Storage and transport _________________________________________

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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.)

© BUCYRUS AMERICA, INC.

the electrical equipment (control units, signaling devices, etc.)

And 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

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__________________________________________________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

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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.

Safety features include: (Reference Fig. 6)

canopy

fire suppression

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 shut down the tram and pump motors. Striking with a small amount of force will actuate either panic strip.

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 falling debris.

The machine is equipped with two (2) fire suppression (remote) actuators.

One is located to the operator’s left inside the cab and the other is located on the opposite side of the operator on top of the machine. 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.

emergency stop button

The machine is equipped with an emergency stop button. The emergency stop button may be used to shutdown the machine in emergency situations.

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© BUCYRUS AMERICA, INC.

panic strip (s)

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__________________________________________________Installation Fig. 6: Safety features on the UN-A-HAULER ® Steering lock location for shutdown and maintenance

© BUCYRUS AMERICA, INC.

Steering lock storage location

Canopy

Circuit breaker reset

Fire suppression actuator

Panic strip

Panic strip

Emergency stop

Fire suppression actuator

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

Center section

Trailer end

Operator’s compartment

False Bottom Hose carrier

Hydraulic oil tank

Operator canopy

Vertical articulation

Tractor end

Battery

Controller

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False bottom

Tailgate

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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. Left side shown below (Fig. 8).

Fig. 8: Operator’s compartment Brake pedal

HiPAC 10 display

Left control handle

Accelerator/ brake assembly adjustment knob

Emergency stop

Panic strip

Right control handle

Fire suppression actuator Panic strip

Left control handle

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

Seat

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Speed switch (Accelerator)

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___________________________________________________Operation Controls and indicators (continued) Fig. 9: Operator’s compartment (right side)

Warning gong

Panic strip

© BUCYRUS AMERICA, INC.

Circuit breaker reset

Right control handle

Payload counter

Gauge panel

Emergency brake release hand pump

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

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Operation____________________________________________________ WARNING! Before operating any levers, buttons or pedals on the UN-AHAULER ® always make sure no one is in the hazard zone (page 23). Do not operate any levers, buttons or pedals from outside the operator's compartment. fire suppression actuators

The two fire suppression (remote) actuators (Fig. 10) are located to the operator's left in the operator's compartment and on the opposite side of the operator’s compartment. 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. 10: Fire suppression location

ACTUATOR

PLUNGER

PIN

ACTUATOR

CO2 CARTRIDGE (BOMB)

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___________________________________________________Operation brake pedal (service)

The foot brake pedal (Fig. 11) 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 1,800 PSI, and is shown on the "ACCUMULATOR" gauge . When the brakes have been applied enough times to drop the pressure to 1,500 PSI, the accumulator unloading valve should open, allowing pressure to build back up to 1,800 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. 11), 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. 11: Brake and accelerator pedal location

Brake pedal

Accelerator pedal

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Operation____________________________________________________ warning gong

The warning gong (Fig. 12), is located to the operator's right. 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 shut down the tram and pump motors. Striking with a small amount of force can actuate either panic strip.

HiPAC 10 Display

The HiPAC 10 display (Figure 12) is located in front of the operator’s seat. If the display indicates “SYSTEM OKAY” when the unit is started, continue. If any other message is displayed, turn “OFF” battery circuit breaker and contact Bucyrus America, Inc. service department.

Fig. 12: Panic strip. Warning gong, and HiPAC 10 display location

Panic strip

HiPAC 10 display

Warning gong

Panic strip

Left control handle

_________________________________________________________________ 5.8 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

IMPORTANT! For more detailed instructions on the HiPAC 10 display, refer to the HiPAC 10 Display Troubleshooting guide.

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___________________________________________________Operation Left Control handle The left control handle (Fig. 13), located to the left of the operator has a group of switches that control the following:

© BUCYRUS AMERICA, INC.

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

“TRACTION ASSIST”

A rear tractive assist package is available that provides on-demand, 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 (Fig. 13). To disengage the rear wheels, release the button.

“PUMP MOTOR”

To start the pump motor, press in-position trigger down and hold. Then press “PUMP MOTOR” button and hold until the pump motor starts.

Release “PUMP MOTOR” button and then release left handle inposition 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 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.

“STOP” “TRAM  or ”

To set the park brake, and to de-energize the tram and pump motors press the “STOP” button.

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.

“DIAGNOSTICS”

Press trigger up for machine diagnostics and to choose display screens after running.

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Operation____________________________________________________ Fig. 13: Control handle “PARK BRAKE”

“TRACTION ASSIST”

“STOP”

“LIGHTS”

“LIGHTS”

“TRAM

“TRAM”

DIAGNOSTICS

IN-POSITION

Steering

The “STEERING” control lever to the left of the operator (Fig. 14) 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.

Fig. 14: Steering

_________________________________________________________________ 5.10 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

“PUMP MOTOR”

BI620982

___________________________________________________Operation machine circuit breaker reset lever

Also used to turn machine off, this lever (Fig. 15), 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 left 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.

Fig. 15: Circuit breaker reset lever location

© BUCYRUS AMERICA, INC.

Circuit breaker reset lever

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. 16). 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.

NOTICE! 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".

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Operation____________________________________________________ Fig. 16: Typical battery circuit breaker reset lever

automatic emergency brakes

“TRIPPED”

“OFF”

“RESET”

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, stopping the machine.  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 battery circuit breaker and machine circuit breaker levers must be in the “ON” position.  The pump motor must be running.  Press the trigger on the control handle and hold and depress “PARK BRAKE” button (Fig. 13) and hold until the dashboard display indicates park brake released.  Release the trigger and “PARK BRAKE” button.

_________________________________________________________________ 5.12 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

“ON”

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___________________________________________________Operation Right control handle “BATTERY HOLD LOCK/ RELEASE” buttons

The “BATTERY HOLD LOCK/ RELEASE” buttons (Fig. 17) are located on the right control handle to the right of the operator’s seat. They are used to secure the battery in position during tramming operations. To engage the hold down lock, push the battery hold down lock button in conjunction with the “TRACTION ASSIST” button on the left control handle. To release the battery hold down, push the battery hold down unlock button in conjunction with the “TRACTION ASSIST” button on the left control handle.

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.

NOTICE! Battery needs to be suspended prior to pressing the battery hold down lock or battery hold down unlock buttons to reduce stress on the frame, battery lift and batteries.

“EJECTOR” buttons

The "EJECTOR" buttons (Fig. 17), operate 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 " button is pushed by the operator, the ejector blade/false bottom should move toward the rear of the unit (extend). When the "EJECTOR " button is pushed 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. To activate automatic ejector out, pull trigger on the left control handle and press the "EJECTOR " on the right control handle and then release right control handle eject button and left control handle trigger to fully activate. To activate automatic retract in, use same control handle sequence with the "EJECTOR " button and the false bottom will stop in the load position.

WARNING! Before moving the ejector blade/false bottom control buttons, 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.

“ARTICULATION” handle

The vertical articulation (Fig. 18) is controlled by moving the right control handle (Fig. 17) foreword and back while holding the left hand control handle trigger. This 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 toward the back of the cab in conjunction with the left trigger 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 foreword in conjunction with the left trigger causes the center of the machine (and the operator) to move downward while the battery and payload end move up (Fig. 18).

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Operation____________________________________________________ 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.

“BATTERY LIFT/ LOWER” handle

The BATTERY LIFT/ LOWER function is controlled by moving the right control handle (Fig. 17) left and right while holding the left hand control handle trigger and is made up of two hydraulic cylinders (battery lifting cylinders), one on each side of the battery. When the BATTERY LIFT/ LOWER control handle is pushed to the right by the operator while holding the left hand control handle trigger, the battery-lifting cylinders will raise the battery. Pulling the handle to the left while holding the left hand control handle trigger will lower the battery. On the QDS style battery lift 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 LIFT/ LOWER” handle 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.

“TAILGATE”

The tailgate lowers automatically when the "EJECTOR " button (Fig. 17) is pushed and raises when the ejector blade and false bottom are retracted.

disconnect switch (optional)

A 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.

_________________________________________________________________ 5.14 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

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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___________________________________________________Operation Fig. 17: Right control handle buttons and positions

Battery hold down unlock

© BUCYRUS AMERICA, INC.

Battery hold down lock

Vertical articulation down Vertical articulation down

Battery lift down

Ejector retract

Battery lift up

Ejector extend

Vertical articulation up

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

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payload counter

The payload counter (Fig. 19) is a button located above the hydraulic gauges on the right side of the operator. This can be pressed after each load to count loads. Press and hold for 5 seconds to clear count.

“ACCUMULATOR PRESSURE” gauge

Should the "ACCUMULATOR PRESSURE" gauge (Fig. 19) read more than 2,500 PSI, shutdown the UN-A-HAULER ® and call a maintenance person (see Shutdown procedure in this chapter).

“SYSTEM PRESSURE” gauge

The hydraulic system pressure relief valve is set at the factory, and should not be changed (Refer to the hydraulic schematic for your particular machine). Should the "SYSTEM PRESSURE" gauge (Fig. 19) read more than 3,000 PSI, shutdown the UN-A-HAULER ® and call a maintenance person (see Shutdown procedure in this chapter).

“TRAILER BRAKE PRESSURE” gauge

Should the "TRAILER BRAKE PRESSURE" gauge (Fig. 19) read more than 400 PSI, shutdown the UN-A-HAULER ® and call a maintenance person (see Shutdown procedure in this chapter).

“TRACTOR BRAKE PRESSURE” gauge

Should the " TRACTOR BRAKE PRESSURE" gauge (Fig. 19) read more than 1,400 PSI, shutdown the UN-A-HAULER ® and call a maintenance person (see Shutdown procedure in this chapter).

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 left 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.

Fig. 19: Right side control lever and gauges Payload counter

“ACCUMULATOR PRESSURE” gauge “TRAILER BRAKE PRESSURE” gauge

“SYSTEM PRESSURE” gauge

Brake release hand pump

“TRACTOR BRAKE PRESSURE” gauge

_________________________________________________________________ 5.16 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

BI620982

___________________________________________________Operation seat adjustment

The seat (Fig. 20) can be adjusted as required to accommodate the operator.

Fig 20. Seat adjustments

Seat front/ back adjustment

© BUCYRUS AMERICA, INC.

Arm rest angle adjustment

Seat back incline adjustment

right control handle adjustment

The right control handle (Fig. 21) location can pivot closer or farther from the operator to facilitate operator entry. To adjust, pull adjustment pin and rotate as required.

Fig. 21 Right control handle adjustment

Adjustment pin

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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. 22: Hazard zone

_________________________________________________________________ 5.18 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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___________________________________________________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.

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.

© 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.

General  1. Disconnect the steering lockout device (Fig. 6).  2. Sit in the operator's seat and adjust the seat position relative to the foot and hand controls. The accelerator assembly can also be adjusted.

WARNING! Be sure no one is in the hazard zone (Fig. 22) 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 UN-A-HAULER ® may be shutdown at any time by striking the tape switch panic bars or the emergency stop switch.

When the tape switch panic bar (s) is struck, the tram and pump motors will shut down. If the emergency stop switch is pressed, the machine circuit breaker will trip. This disconnects the motors and applies the automatic emergency brake. Be prepared for a sudden stop when the emergency stop switch or the tape switch panic bar (s) is pressed.  4. “Stop” button may be pressed at any time to set the park brake, and to de-energize the tram and pump motors (Fig. 23).

Note: Refer to Fig. 23 for illustration of control handle.

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Operation____________________________________________________ Fig. 23: Control handle “PARK BRAKE “ WITH “PUMP MOTOR” RUNNING PRESS “INPOSITION TRIGGER” AND “PARK BRAKE “ TO RELEASE PARK BRAKE. PRESS “PARK BRAKE “ TO SET PARK BRAKE

”PUMP MOTOR” PRESS “IN-POSITION TRIGGER” AND “PUMP MOTOR” TO START “PUMP MOTOR”.

PRESS “PUMP MOTOR” TO STOP PUMP MOTOR.

“TRACTION ASSIST” PRESS DOWN FOR TRACTION ASSIST.

“STOP “ PUSH DOWN FOR STOP

“LIGHTS” PRESS “LIGHTS” TO ACTIVATE  LIGHTS.

" TRAM” WITH PUMP MOTOR RUNNING AND BRAKE RELEASED PRESS “IN-POSITION TRIGGER” AND “ TRAM” TO ACTIVATE  TRAM DIRECTION. PRESS  TRAM TO DISABLE  TRAM DIRECTION.

“ TRAM “ WITH PUMP MOTOR RUNNING AND BRAKE RELEASED PRESS “IN-POSITION TRIGGER” AND “ TRAM “ TO ACTIVATE  TRAM DIRECTION. PRESS “ TRAM “ TO DISABLE  TRAM DIRECTION.

“DIAGNOSTICS TRIGGER” PUSH UP FOR DIAGNOSTICS

“IN-POSITION TRIGGER” PUSH DOWN FOR INPOSITION

Machine operation  1. Turn the battery circuit breaker and/or disconnect switch (if equipped) to the “ON” position.  2. Press “DIAGNOSTICS TRIGGER” to begin on board diagnostics.  3. Hold “DIAGNOSTICS TRIGGER” until a message is displayed on the HiPAC 10 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 “DIAGNOSTICS TRIGGER” and set machine circuit breaker.

_________________________________________________________________ 5.20 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

“ LIGHTS “ PUSH DOWN FOR  LIGHTS.

BI620982

___________________________________________________Operation  6. Test emergency stop switch before beginning each shift. Press emergency stop switch and machine circuit breaker should trip.

If machine circuit breaker fails to trip, turn “OFF” battery circuit breaker and/or disconnect switch (if equipped) and contact Bucyrus America, Inc. service department. If emergency stop switch trips machine circuit breaker, repeat steps 1 through 5 and proceed to step 7.

© BUCYRUS AMERICA, INC.

 7. Test tape switch panic bars before beginning each shift. Press left side tape switch and tram and pump motors should shut down. Repeat steps 1 through 5 and press right side tape switch and tram and pump motors should shut down. If motors fail to shut down 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 shut down the tram and pump motors, repeat steps 1 through 5 and proceed to Step 8.  8. Test all right and left control handle functions before beginning each shift. Follow steps 9 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.  9. To start pump motor, press “IN-POSITION TRIGGER” and hold. Then press “PUMP MOTOR” and hold until the pump motor starts. Release “PUMP MOTOR” and then release “INPOSITION TRIGGER”.  10. To turn off the pump motor, press “STOP “ or “PUMP MOTOR”.  11. To release the park brake; ■

the pump motor must be running

■

press “IN-POSITION TRIGGER” and hold, press “PARK BRAKE “ and hold until the dashboard display indicates “PARK BRAKE RELEASED”

■

release “PARK BRAKE “ and then “IN-POSITION TRIGGER”

 12. To set the park brake and leave the pump motor running, press “PARK BRAKE “ .  13. To turn OFF the pump motor and set the park brake, press “STOP “ or “PUMP MOTOR”.

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Operation____________________________________________________  14. To activate a tramming direction; ■

the pump motor must be running

■

the park brake must be released

■

press “IN-POSITION TRIGGER” 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” .

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

 16. To change direction of travel, press “IN-POSITION TRIGGER” and hold, then press either “ TRAM “ or “ TRAM” and hold until the dashboard display indicates direction of travel. Then release “ TRAM “ or “TRAM” depending on direction selected and then release “IN-POSITION TRIGGER”.  17. Each time the direction of travel is changed, the foot pedal will require recycling through the off position.  18. To disable tramming, press “ TRAM “ or “ TRAM” .  19. To leave pump motor running, set park brake, and disable tramming, press “PARK BRAKE “.  20. To disable tramming, turn off the pump motor and set the park brake, press “STOP “ or “PUMP MOTOR”.  21. To activate the optional traction assist function, press “TRACTION ASSIST”.

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.  22. Press “LIGHTS” then release “LIGHTS” for  direction lights.  23. Press “ LIGHTS “ then release “ LIGHTS “ for  direction lights.  24. To turn off all lights, press “LIGHTS” and “ LIGHTS “ simultaneously and then release both “LIGHTS” and “ LIGHTS “ simultaneously.

_________________________________________________________________ 5.22 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

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.

BI620982

___________________________________________________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. Push the ejector blade/false bottom control button “EJECTOR " 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. 23 for illustration of left control handle.  2. Before leaving the operator’s compartment, press “STOP” 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. 7): ■

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.

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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 tape switch panic bars or the emergency stop switch. When the tape switch panic bar (s) is struck, the tram and pump motors will shut down. If the emergency stop switch is pressed, the machine circuit breaker will trip. This disconnects the motors and applies the automatic emergency brake. Be prepared for a sudden stop when the emergency stop switch or the tape switch panic bar (s) is pressed.

Fig. 24: Steering lockout device

© BUCYRUS AMERICA, INC.

Steering lock (storage)

Steering lock (installed location) Turnbuckle adjustment

_________________________________________________________________ 5.24 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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

Since one person will step into the Hazard Zone each time a cable is disconnected or connected to the battery, the other person (operating the UN-A-HAULER ®) must be very careful and look each time before moving any buttons or pedals. Take time now to re-familiarize yourself with the Hazard Zone (Fig. 22) and the names of the battery changing components (Fig. 25).

Fig. 25: Battery plug and receptacle Locking lug

Wrench

© BUCYRUS AMERICA, INC.

Receptacle

Threaded lock ring Battery assembly Plug assembly

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Operation____________________________________________________  Line up the battery end of the UN-A-HAULER ® with the place where the battery is to be deposited (Fig. 26) (see Starting procedure in this chapter).

Fig. 26: Battery change procedure

Discharged battery

WARNING! The "BATTERY LIFT/ LOWER” control handle 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 LIFT/ LOWER” control handle is operated in a low roof area, the battery may be damaged.

NOTICE! The battery needs to be suspended prior to pressing the battery hold down lock or battery hold down release buttons to reduce stress on the frame, battery lift and batteries.

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.

_________________________________________________________________ 5.26 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Charged battery

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___________________________________________________Operation



 Unlock the battery before placing the battery on the ground. To unlock the battery, push the “BATTERY UNLOCK” button (Fig. 27) in conjunction with the “TRACTIVE ASSIST” button.

Fig. 27: Battery change procedure

Battery hold down unlock

© BUCYRUS AMERICA, INC.

Battery hold down lock

Ejector retract

Ejector extend

 Lower the battery completely to the surface. To lower the battery, pull the "BATTERY LIFT/ LOWER” control handle left toward the battery and hold as the battery lowers. The bottom of the battery should touch the surface (Fig. 28).

Fig. 28: Battery change procedure Discharged battery

______________________________________________________________ A6474X257 VTVI/04 5.27

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Operation____________________________________________________

■

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. 29).

■

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.

_________________________________________________________________ 5.28 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 After the battery is fully lowered, shutdown the UN-A-HAULER ® (see Shutdown procedure in this chapter).   After shutting down the Un-A-Hauler®, disconnect the discharged battery:

BI620982

___________________________________________________Operation Fig. 29: Battery change procedure

Discharged battery

© BUCYRUS AMERICA, INC.

Charged battery

Jumper cable

 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 (Fig. 30). Move the machine forward until the lift arm is aligned with the hooks in the battery (Fig. 31). Continue to slowly move the machine until the battery hooks and lift arms are in the correct position.

Fig. 30: Battery change procedure

Discharged battery

Charged battery

Jumper cable

______________________________________________________________ A6474X257 VTVI/04 5.29

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Operation____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 31: Battery change procedure

 Raise the battery to the carry position (Fig. 32) by pushing the "BATTERY LIFT/ LOWER” control handle (Fig. 17) to the right toward the trailer.

Fig. 32: Battery change procedure Charged battery

_________________________________________________________________ 5.30 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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___________________________________________________Operation  Push the “BATTERY HOLD LOCK” button to lock the battery in place (Fig. 33)

© BUCYRUS AMERICA, INC.

Fig. 33: Battery change procedure

 Shutdown the UN-A-HAULER ® (see Shutdown procedure in this chapter).  Disconnect the jumper cable (Fig. 34, 34, and 36).

Fig. 34: Battery change procedure

______________________________________________________________ A6474X257 VTVI/04 5.31

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Operation____________________________________________________

Fig. 36: Battery change procedure

_________________________________________________________________ 5.32 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Fig. 35: Battery change procedure

BI620982

___________________________________________________Operation  Connect the charged battery directly to the machine’s cable (Fig. 37). 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.

© BUCYRUS AMERICA, INC.

Fig. 37: Battery change procedure

 Start the UN-A-HAULER ® (see Starting procedure in this chapter).  This completes the ground level battery change procedure.

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© BUCYRUS AMERICA, INC.

Operation____________________________________________________

_________________________________________________________________ 5.34 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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________________________________________________ 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.

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. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

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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.

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.

_________________________________________________________________ 5.36 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

■

BI620982

________________________________________________ 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

300

Grade 8

420

300

Grade 8

380

230

Grade 8

380

230

Grade 5

380

230

Grade 8

650

N/A

Grade 8

1886

N/A

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) * See note 1 Center section (Inner ring) * 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

Approximate capacity 72 Gallons

Notes 1

Drive sump (Gear case)

Spec. 100-8

4 Gallons Each

2, 3

Multi-Purpose grease

Spec. 100-3

As Required

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.

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Maintenance _________________________________________________ Table 3: Lubrication and maintenance schedule Item

Description

Places

Lubricant

Specification

Every shift 1

Panic strips (Check)

2

2

Center section pivots

4

Century Replex 2

Spec. 100-3

3

Steering cylinders (rod and base end)

4

Century Replex 2

Spec. 100-3

4

Center section ball bearing

9

Century Replex 2

Spec. 100-3

5

Ejector hose carrier

2

Century Replex 2

Spec. 100-3

6

Battery change assembly

6

Century Replex 2

Spec. 100-3

7

Articulation cylinders

4

Century Replex 2

Spec. 100-3

8

Articulation pivot

2

Century Replex 2

Spec. 100-3

9

Tail gate cylinders (If equipped)

4

Century Replex 2

Spec. 100-3

10

Battery change cylinders

4

Century Replex 2

Spec. 100-3

11

Fasteners (Nuts, bolts and screws)

Inspect

12

Electrical cables, conduits and glands

Inspect

13

Hydraulic hoses and connections

Inspect

14

Tires (Inspect)

4

15

Headlights (Inspect)

4

16

Reflectors and warning tags

Inspect

17

Hydraulic oil level (Check)

1

Century Hydraulic AW 68

Spec. 100-1

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

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 Main filter (Inspect/change as required) Return filter (Inspect/change as required)

2

Auxiliary Filter (Inspect/change as required) Gear Oil Filters

1

21 22 23 24 25 26 27 28 29

4 4 2 2 1 1 1

2

Every two weeks 30

Control handles and steering linkage

13

_________________________________________________________________ 5.38 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Every third shift

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________________________________________________ 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

Main filter (Change)

1

42

Return filter (Change)

1

43

Auxiliary Filter (Change)

1

44

Gear Oil Filters

2

*Century Centraulic R&O 150

Spec. 100-8

4

Check Bearing grease

* If equipped with Fairfield gearbox, use Renolin RO 220 150 VG 220 hydraulic fluid.

Fig. 38: Lubrication chart 15

19

28, 43

8

2, 18

19, 26, 32, 38, 41

7

5

31

37

10

6

3, 21 29, 44

17, 39

27, 42

4

1, 19, 24, 25, 30, 35, 36

15

20, 33

14, 22, 34

23, 40

9

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Maintenance _________________________________________________ Specific lubrication and maintenance procedures Every shift panic strips

Check the panic strips located inside the operator’s compartment (Fig. 39). 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.

Panic strip

Panic strip

Every third shift center section pivots

Lubricate the center section pivot points with Spec. 100-3 through the grease fittings located on the center section assembly (Fig. 40). Pump grease into the fittings until new grease can be observed coming out of the bearings.

steering cylinders

Lubricate the steering cylinders with Spec. 100-3 through the grease fittings located on the rod and base end of each cylinder (Fig. 40).

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 with Spec. 100-3 through the grease fittings located around the ball bearing (Fig. 40). Pump grease into the fittings until new grease can be observed coming out of the bearings.

_________________________________________________________________ 5.40 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Fig. 39: Panic strips

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________________________________________________ Maintenance Fig. 40: Center section and steering cylinders lubrication points

Center section pivots (4 places)

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

© BUCYRUS AMERICA, INC.

Center section ball bearing (9 places)

ejector hose carrier

Lubricate the ejector hose carrier with Spec. 100-3 through the grease fittings located at the two (2) pivot points (Fig. 41). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 41: Ejector hose carrier lubrication points Grease fitting

battery change assembly

Grease fitting

Lubricate the battery change assembly with Spec. 100-3 through the grease fittings located on the two lubrication blocks. Also lubricate each of the moving parts on the assembly (Fig. 42).

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Maintenance _________________________________________________ Fig. 42: Battery change assembly lubrication points

Lubrication point

Lubrication point

Lubrication point

Lubrication point

articulation cylinders

Lubricate the articulation cylinders with Spec. 100-3 through the grease fittings located on the two (2) lubrication blocks and cylinder rod ends (Fig. 43). Pump grease into the fittings until new grease can be observed coming out of the bushings.

articulation pivot

Lubricate the articulation pivot pins with Spec. 100-3 through the grease fittings located on the two (2) lubrication blocks (Fig. 43). Pump grease into the fittings until new grease can be observed coming out of the bushings.

Fig. 43: Articulation cylinders lubrication points Articulation cylinder grease fitting

Articulation cylinder grease fitting Lubrication block location for lower cylinder and pivot point grease fittings

Lubrication block location for lower cylinder and pivot point grease fittings

_________________________________________________________________ 5.42 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Lubrication point

BI620982

________________________________________________ Maintenance tailgate cylinders (if equipped)

Lubricate the tailgate cylinders with Spec. 100-3 through the grease fittings located on the cylinder rod and base ends (Fig. 44). Pump grease into the fittings until new grease can be observed coming out of the bushings.

Fig. 44: Tailgate cylinders lubrication points

Grease fitting

© BUCYRUS AMERICA, INC.

battery change cylinders

Grease fitting

Lubricate the battery change cylinders with Spec. 100-3 through the grease fittings located on the cylinder rod and base ends (Fig. 45).

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

Fig. 45: Battery change cylinders lubrication points

Grease fitting

Fasteners (nuts, bolts and screws)

Grease fitting

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.

______________________________________________________________ A6474X257 VTVI/04 5.43

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Maintenance _________________________________________________ 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.

hydraulic oil level

Check the hydraulic oil level by looking at the sight glass located on the oil tank (Fig. 46). If the oil level is low, add oil through the power fill hose located on the right of the tank until oil is visible in the sight glass.

Power fill hose

Sight glass

Grease fitting

Weekly center section pins and nuts

Inspect the center section pins and nuts for looseness or wear (Fig. 7).

Tighten where necessary and replace any worn parts.

Fig. 47: Center section and steering cylinder pins and nuts Inspect center section pivot pins and nuts

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

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

_________________________________________________________________ 5.44 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Fig. 46: Hydraulic oil level

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________________________________________________ Maintenance fire suppression system

Check the fire suppression system (Fig. 48).  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. 48: Fire suppression system Actuator

Nozzle (6 locations)

Chemical tanks (2)

Actuator

Fill cap

Tank Nozzle opening

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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. 49).  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. 49: Gear case and planetary wheel end lubrication

Level plug

© BUCYRUS AMERICA, INC.

Drain plug

Fill plug

Wheel end drain plug

_________________________________________________________________ 5.46 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

BI620982

________________________________________________ Maintenance steering cylinder pins and nuts

Inspect the steering cylinder pins and nuts for looseness or wear (Fig. 50). Tighten where necessary and replace any worn parts.

Fig. 50: Center section and steering cylinder pins and nuts Center section pivot pins and nuts

Steering cylinder (s) fasteners (rod and base end)

© BUCYRUS AMERICA, INC.

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

wheel mounting bolts

Check the wheel mounting bolts (Fig. 51). The mounting bolts should be torqued to 300 ft-lbs. Use Loctite 242 on wheel mounting bolts.

Fig. 51: Wheel mounting bolts

Wheel mounting bolts (4 places)

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Maintenance _________________________________________________ wheel end spindle bolts

Check the wheel end spindle mounting bolts (Fig. 52). The mounting bolts should be torqued to 450 ft-lbs .

Fig. 52: Wheel end spindle bolts Spindle

foot pedal pivot bearings

brake pedal

Lubricate the foot pedal pivot bearings with Spec. 100-3 through the grease fittings located on each bearing (Fig. 53). Pump grease into the fittings until new grease can be observed coming out of the bearings.

Lubricate the brake pedal with Spec. 100-3 through the grease fitting located on the pedal (Fig. 53). Pump grease into the fittings until new grease can be observed coming out of the bearings.

Fig. 53: Foot and brake pedal lubrication

Foot pedal Brake pedal

Grease fitting

Grease fitting

_________________________________________________________________ 5.48 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Mounting bolts

BI620982

________________________________________________ Maintenance main filter

Inspect the main filter dirt alarm (Fig. 54) located on the head of the filter. If the alarm indicates the filter element is dirty, replace element.

Fig. 54: Main filter

return filter

Remove the return filter element and visually inspect the element (Fig. 55). If the filter element is dirty, replace element.

© BUCYRUS AMERICA, INC.

Fig. 55: Return filter

auxiliary filter

Inspect the dirt alarm on the auxiliary filter (Fig. 56). If the alarm indicates the filter element is dirty, replace element.

Fig. 56: Auxiliary filter

______________________________________________________________ A6474X257 VTVI/04 5.49

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Maintenance _________________________________________________ gear oil filters

Inspect the two (2) gear oil spin on filter element dirt alarms (Fig. 57) located on the head of each filter. If the alarms indicate that the elements are dirty, replace elements.

Fig. 57: Gear oil filters

Every two weeks control handles and steering linkage

Lubricate the control handles and steering linkage with Spec. 100-3 through the grease fittings (Fig. 58). Pump grease into the fittings until new grease can be observed coming out. Check for loose wires and connections.

Fig. 58: Control handles and steering linkage lubrication Grease fitting

Control handle (s) grease fitting access area location

_________________________________________________________________ 5.50 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Gear oil filters

BI620982

________________________________________________ Maintenance Monthly drive and pump motor (s)

Inspect the drive and pump motors (Fig. 59).  Be sure that the machine circuit breaker lever is in the "OFF" position.  Remove the inspection cover.  Inspect the windings, bearings, and motor connections.

–

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

–

The leads and motor connections should be examined for corrosion, burn spots and for tightness.

© BUCYRUS AMERICA, INC.

 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. 59: Drive and pump motors Pump motor

2-wheel assist motor

Drive motor

Drive motor

______________________________________________________________ A6474X257 VTVI/04 5.51

BI620982

Maintenance _________________________________________________ gear cases and planetary wheel ends

Change the oil in both gear cases and planetary wheel ends (Fig. 60).  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. 60: Gear case and planetary wheel end lubrication

Drain plug

Fill plug

© BUCYRUS AMERICA, INC.

Level plug

Wheel end drain plug

wheel mounting bolts

Check the wheel mounting bolts (Fig. 61). The mounting bolts should be torqued to 300 ft-lbs. Use Loctite 242 on wheel mounting bolts.

Fig. 61: Wheel mounting bolts

Wheel mounting bolts (4 places)

_________________________________________________________________ 5.52 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

BI620982

________________________________________________ Maintenance hydraulic system pressure

Check the hydraulic system pressure (Fig. 62).

WARNING! Before moving the “EJECTOR” control button, 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.   Push the “EJECTOR” control button retract (left button) until the ejector blade/false bottom has completely returned to the front of the rear (payload) section.  Continue to hold the “EJECTOR” button 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. 62: Check the hydraulic system pressure Ejector retract

Ejector extend

“SYSTEM PRESSURE” gauge

______________________________________________________________ A6474X257 VTVI/04 5.53

BI620982

Maintenance _________________________________________________ steering relief pressure

Check the steering system relief pressure (Fig. 63).

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.   Steer the unit to the turning limit in either direction and read the pressure indicated on the “SYSTEM PRESSURE” gauge.  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.

Fig. 63: Check the hydraulic system pressure © BUCYRUS AMERICA, INC.

“STEERING” control lever

“SYSTEM PRESSURE” gauge

_________________________________________________________________ 5.54 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

BI620982

________________________________________________ Maintenance brake cooling relief pressure

Check the brake cooling relief pressure (Fig. 64).  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. 64: Brake cooling relief pressure

Pressure gauge connection

Brake cooling relief valve

______________________________________________________________ A6474X257 VTVI/04 5.55

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Maintenance _________________________________________________ ejector/false bottom sequence valve

Check the ejector/false bottom sequence valve.

WARNING! Before moving the “EJECTOR” buttons, 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 before 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 buttons, 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 before 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.

_________________________________________________________________ 5.56 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

ejector/false bottom/ tailgate sequence valve

BI620982

________________________________________________ Maintenance hydraulic oil suction strainer

Clean or replace the hydraulic suction strainer (s) inside the hydraulic oil tank (Fig. 65).  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 the two (2) strainers from the fittings.  If the strainer (s) is not torn or damaged, it can be cleaned using kerosene and a soft brush and dried thoroughly. If strainer (s) is damaged, it must be replaced.  Replace the strainers in the tank and tighten hand-tight.  Inspect cover gasket for damage and replace if necessary.

© BUCYRUS AMERICA, INC.

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

Fig. 65: Hydraulic oil suction strainer maintenance

Fill cap

Sight glass Cover and gasket

______________________________________________________________ A6474X257 VTVI/04 5.57

BI620982

Maintenance _________________________________________________ rear wheel bearings (if equipped)

Clean , inspect and grease the rear (payload) section hubs (Fig. 66).  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.

 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. 66: Rear wheel bearings lubrication

Seal Bearing cup

Spindle

© BUCYRUS AMERICA, INC.

 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.

Bearing cone Hub

Seal

Retaining ring Bearing cup

Bearing cone

Grease fitting

Gasket Cover

_________________________________________________________________ 5.58 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

BI620982

________________________________________________ Maintenance main filter

Change the main filter elements (Fig. 67). If the element is extremely dirty, a more frequent interval may be needed.

Fig. 67: Main filter

return filter

Change the return filter elements (Fig. 68). If the element is extremely dirty, a more frequent interval may be needed.

© BUCYRUS AMERICA, INC.

Fig. 68: Return filter

auxiliary filter

Change the auxiliary filter elements (Fig. 69). If the element is extremely dirty, a more frequent interval may be needed.

Fig. 69: Auxiliary filter

______________________________________________________________ A6474X257 VTVI/04 5.59

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Maintenance _________________________________________________ gear oil filters

Change the two (2) gear oil spin on filter elements (Fig. 70). If the elements are extremely dirty, a more frequent interval may be needed.

Fig. 70: Gear oil filters

© BUCYRUS AMERICA, INC.

Gear oil filters

_________________________________________________________________ 5.60 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

BI620982

____________________________________ Hydraulic System Overview Hydraulic system overview This chapter contains information on the main hydraulic system, the brake system, and the two wheel assist system. The details in this section are to give you a better understanding of how the overall system works.

Main hydraulic system The main hydraulic system is powered by a load sensing pressure compensated hydraulic system with manifold mounted control valves.

© BUCYRUS AMERICA, INC.

What is load sensing?

Load sensing is the continuous detection of the load by the pump control.

The pump control will vary pump output flow to meet the load, according to the requirements at any particular moment. This control is obtained from the pump control seeking a constant pressure difference between pressure at the pump and the pressure of the load. This pressure differential is set within the pump control and referred to as the “margin”.

When the actual system differential is less than the margin, the pump provides more flow. When the system differential is the same as the margin, the pump will maintain a certain flow. If the system differential exceeds the margin, the pump will reduce its output flow. A load sense pump will only develop the amount of flow that is required by the system. The system pressure is always the load pressure (working pressure) plus the margin pressure. advantages of load sensing

margin pressure

At idle a gear pump will maintain full flow at very low pressures. A straight pressure compensated system at idle will maintain full system pressure at virtually zero flow (enough to make up for internal leakage).

A load sense pump at idle will develop pressure to the margin pressure setting while only delivering enough flow to make up for leakage. This adds to the efficiency of the system and allows the system to run much cooler.

The load sense regulator is a directional control valve that is pilot operated. The regulator either sends system pressure to the stroking mechanism or drains pressure from the stroking mechanism to the pump case (Fig. 71). The regulator is piloted on one side by system pressure to take the pump off stroke, and on the other side is piloted by the load sense signal to bring the pump on stroke. An adjustable spring is also used on the regulator to shift it to bring the pump on stroke. At idle (zero pressure on load sense) the pressure required to overcome the spring to keep the pump off stroke is the margin pressure. Adjusting the spring force will adjust the margin pressure. The margin pressure will be seen on a system pressure gauge while the system is at idle. The pressure reading on the system pressure gauge is the working pressure at a function plus the margin pressure.

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Hydraulic System Overview _____________________________________ To bring the pump on stroke, system pressure goes through the compensator in the valve bank and is sent back to the pump through the load sense line. This is the signal that shifts the regulator in the pump and brings the pump on stroke. Increasing the margin pressure shifts the regulator and increases the response of the pump. However, the margin pressure is a parasitic loss to the system. Setting the margin pressure higher results in more energy lost to heat in the system. Typical load sense systems operate with the margin pressure around 250 psi. We set the margin pressure at 500 psi to increase response.

Fig. 71: Main pump schematic Load sense regulator

Stroking mechanism

Main pump The main pump used on this machine is load sensing, self priming (requires no charge pressure), variable volume axial piston pump designed for open loop applications. The maximum displacement of the pump is 75 cc/rev (4.58 in3/rev). At maximum displacement and maximum motor speed, the pump will produce approximately 34.5 GPM. The pump contains a horsepower limiting module which is located in the controller (Fig. 72) with the load sense regulator. A silencer is used on this pump to reduce noise and pressure pulsation.

Fig. 72: Main pump with HP limiting and silencer

Silencer

Controller

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Summated power control

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____________________________________ Hydraulic System Overview horsepower limiting

The main pump limits the amount of horsepower it will require by a relation between the system pressure and the angle of the swash plate.

The angle of the swash plate is a directly proportional to the amount of flow the pump is delivering. The summated power control acts very similar to the load sense regulator. It is a directional control valve that either applies pressure or drains presssure from the stroking mechanism (Fig. 71). System pressure is applied to one side of the valve while a set of spings on the other side of the valve is connected to a feedback from the swash plate. Horsepower is a function of flow and pressure. Using the system pressure and the feedback of the swash plate angle, which is directly prorportional to flow, the springs can be adjusted so that the pump destrokes at a certain horsepower.

The springs are internal to the controller and are non-adjustable. The horserpower limit is set on a test stand at the manufacturer’s facility.

© BUCYRUS AMERICA, INC.

Control valves To control the cylinder functions the machine uses proportional directional spool valves. There are two separate valve stacks on the machine. One is located on the tractor that controls the cylinder functions on the tractor. The second is located in the trailer and controls the load eject. Both valve stacks consist of a subplate, an inlet section, valve sections, and solenoids (Fig. 73). manifold mounted

The sub-plate in each valve stack is a series of manifolds that are bolted together. The manifold does not contain any moving parts or adjustments. There are no linkages between sections and the manifold. O-rings between the sections and manifolds are located in grooves on each section. The inlet section and valve sections bolt directly to the manifold. All ports are hose connections made on the manifold. This allows for the removal and replacement of valve sections without having to disconnect a single hose.

Fig. 73: Sub-plate mounted valve stack

Valve sections

Solenoid

Inlet section

Subplate

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inlet sections

For this style of valve stack, the inlet section will determine whether the valve stack is setup for a fixed volume pump or a variable volume pump. Both of the valve banks on this machine use the same type of inlet that is setup for a variable volume pump. However, there is a significant difference between the inlet sections on the tractor and trailer valve stacks. The inlet section on the trailer valve bank contains the main relief and the load sense relief for the entire system. There is no need for a relief valve in the trailer valve stack because the valve stacks are plumbed in parallel. Each inlet section also contains a pressure reducing valve that creates pilot pressure that the solenoids use to shift the spools.

valve sections

Each valve section contains the spool, a pressure compensator, a shuttle valve, and a pressure limiter (Fig. 74). The pressure drop across the spool is monitored by the pressure compensator. The compensator limits flow to the spool based on a certain pressure drop (set by the compensator spring rate). The spool and pressure compensator are sized to only allow a certain amount of flow to each function. The steering and load eject sections are set to maximum flow while all of the other sections allow only a limited amount of flow to the function. The load sense signal is sent to the pump through a series of shuttle valves.

A shuttle valve in each section sends the highest signal to the pump, which brings the pump on stroke to meet the highest demand.

Fig. 74: Trailer valve bank schematic

Pressure reducing valve

Pressure limiter

Main relief

Load sense relief Pressure compensator

pressure limiting

Pressure limiting on each section is similar to work port reliefs. A work port relief is simply a relief valve that dumps flow to tank after the pressure setting is achieved. This creates heat and is much more inefficient than a pressure limiter. A pressure limiter is simply a relief valve in the load sense line. As the pressure limiter only allows the load sense line to reach a set pressure, the pressure compensator will only allow enough flow through to achieve that pressure. The pump then destrokes and only maintains enough flow to maintain the pressure at the limiter setting. This is much more efficient than a work port relief since the pump only develops the amount of pressure required by the work. There is not any significant amount of flow going over a relief.

_________________________________________________________________ 5.64 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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Hydraulic System Overview _____________________________________

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____________________________________ Hydraulic System Overview solenoids

With the exception of the steering section, all valve sections are activated by MSHA approved 24 V dual coil solenoids. Each solenoid is bolted to the valve section with three bolts. There are two O-rings between the solenoid and valve section. When a coil is activated, the armature pin of the solenoid presses down on a stem in the valve section. Pressing on this stem sends pilot pressure to the end of the spool and shifts the spool into position.

Load eject

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The trailer valve stack, sequence valve and GO switch are used to control the the false bottom, ejector, and tailgate cylinders. The load eject function has a manual and automatic mode. To eject the load manually, press the eject button on the right hand control stick. In manual mode the button has to be held for the load to continue to eject.

If the button is released, the eject cycle will stop. To eject the load automatically, hold down the trigger on the left hand control stick and then press the eject button. After releasing the button and trigger, the load will continue to eject until the end of the cycle.

The retract cycle also has a manual and automatic mode. Manual mode is activated by pressing the retract button on the right hand control stick, and the automatic mode is activated by holding down the trigger on the left hand control stick and then pressing the retract button. In manual mode, the retract cycle will pause in the load position. Retracting the false bottom once it has reached the load position must be done in manual mode. eject cycle

The first stage of the eject cycle is lowering the tailgate. The tailgate is lowered by activating the second section of the trailer valve bank. A time delay is used to allow the tailgate to drop before activating the first section of the trailer valve bank. Activation of the first section sends flow to the sequence valve. The sequence valve holds the ejector blade in place until the false bottom is fully extended. The kickdown cartridge in the sequence valve is set to open at a pressure slightly higher than the pressure required to extend the false bottom with a load (Fig. 76). After the false bottom is extended, the pressure will rise to open the kickdown cartridge. Flow is then sent to the ejector cylinder.

The kickdown cartridge requires a certain pressure to open. Once it is opened the pressure is allowed to drop to working pressure. The kickdown cartridge will remain open as long as continuous flow is going through the cartridge.

retract cycle

In addition to use of the valve bank and sequence valve to extend, the retract cylce also requires a GO switch. The GO switch is a proximity sensor that deteremines the position of the false bottom. The position of the false bottom is used to determine when the tailgate can be raised. If the false bottom is in the zone where it would interfere with the tailgate raising, pressing the retract button will first activate the first section of the trailer valve bank. The first section sends flow to the sequence valve. The sequence valve will hold the false bottom in place until the ejector cylinder has been fully retracted (Fig. 75).

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Hydraulic System Overview _____________________________________ During the retract cycle, the sequence valve operates opposite of how it functions during the extend cycle. After the ejector cylinder is retracted, the sequence sends flow to the false bottom cylinders and begins to retract. Once the valve bottom clears the zone of interference with the tailgate, the first section is deactivated and the retraction of the false bottom stops. The second section is then activated and the tailgate is raised. In automatic mode, a timer is set to stop the retract cycle after the tailgate is raised. In manual mode, a timer is set so that the cycle pauses in the load position. After a short time, the second section is deactivated and the first section is activated. Since the ejector cylinder is already retracted, the kickdown cartridge in the sequence valve opens immediately and the false bottom cylinders finish the retract cycle.

© BUCYRUS AMERICA, INC.

Fig. 75: Schematic showing eject and retract functions

Tank power fill A flow divider is used as a power fill pump. Pumping flow into the outlet of a flow divider instead of the inlet makes the flow divider act as a pump. Suction will be produced in the line on the other outlet. The combined flow of the flow going into the two outlet ports will then flow out of the inlet port.

The flow that drives the power fill pump is teed off of the main pressure line going to the tractor valve bank. A ball valve is inline between the tee and the power fill pump. With the ball valve open flow is sent to power fill pump and suction is created on the open line. The combined flow is then tied into the return line and passes through the return filter before entering the tank.

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____________________________________ Hydraulic System Overview With the pump at idle, the system flow is virtually zero. The system pressure is equal to the margin pressure. When the ball valve is opened, the margin pressure will drop and the pump develop the amount of flow that it requires to reach the margin pressure. Therefore the power fill pump will operate at the margin pressure (500 psi).

Battery lift suspension

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A hydraulic suspsension is used on the battery lift to relieve stress on the frame, battery lift, and batteries. An HIC suspension block, two accumulator, and a flow control valve are used to allow the battery lift cylinders to move slightly when under shock loads.

Both bore ends of the lift cylinders are tied to tank when the valve section is in neutral. This allows for free flow of the fluid out of the bore end of the cylinder if the shock load raises the battery. As a shock load raises the battery, fluid from the accumulator fills the rod ends of the lift cyinders (Fig. 76). A shock load that pushes the battery down sends fluid from the rod end to the accumulator. The second accumulator was added to the bore end to provide additional damping. An adjustable flow control valve limits the amount of flow and pressure that is sent to the accumulator. This flow control valve is used to dump the accumulator pressure when the machine requires service work. The weight of the batteries will push fluid from the rod ends of cylinder through the flow control and to the tank.

WARNING! Opening the accumulator dump flow control valve will cause the batteries to fall to the ground immediately. Do not open without making sure the areas around and underneath the batteries are clear.

Fig. 76: Battery lift suspension schematic

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Hydraulic System Overview _____________________________________ Brake system The 816C is equipped with brakes in both gearboxes connected to the front wheels. Trailer brakes on the rear wheels are also available with the tractive assist option. All brakes on the machine are spring applied and hydraulic release. The brake system is powered by a small gear pump that charges an accumulator.

Auxiliary pump The pump on the brake system is a gear pump with a displacement of 4.95 cc/rev (0.30 in3/rev). This pump produces approximately 2.2 GPM. This pump is mounted using a 2-bolt flange and either bolts directly to the load sense pump (Fig. 77) or the charge pump used on the tractive assist option.

© BUCYRUS AMERICA, INC.

Fig. 77: Load sense and auxiliary pump assembly

Main system pump

Auxiliary pump

Unloading valve The unloading valve is used to unload the pump after the accumulator is charged. The valve acts as a pilot operated directional control valve.

A spring holds the spool in positon so that the pump flow is delivered to the accumulator until the maximum or cut-off pressure is achieved.

Pressure from downstream of the valve is sent to the pilot port which acts in the opposite direction of the spring on the spool (Fig. 78). Once the cut-off pressure is achieved, the spool shifts and diverts pump flow to tank. The spool will shift to recharge the accumulator

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____________________________________ Hydraulic System Overview once the pilot signal to the valve drops below 85% of the cut-off pressure setting. A check valve is hard plumbed to the accumulator outlet port of the valve to prevent return flow from the accumulator through the unloading valve.

Fig. 78: Unloading valve schematic with check valve

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Accumulator The 816C machine uses piston type gas accumulators. The gas side of the accumulator is precharged to 1,000 psi with nitrogen gas.

Accumulator pressure is used to release the brakes while the machine is in operation. For a machine without trailer brakes, a 1 gallon accumulator is adequate. To prevent the unloading valve from cycling excessively, two 1.5 gallon accumulators are used for machines with trailer brakes. The trailer brakes require more volume to release than the standard front brakes.

Brake valves A demodulating brake valve is used for both standard brakes and trailer brakes. A different valve is required for each as they require different pressures to release. demodulating valve

Pressure at the outlet of a demolutating valve is regulated to a specific setting. As long as the pressure at the inlet of the valve is higher than the setting the pressure at the outlet will remain constant at the specified pressure. This allows the pressure of the accumulator to rise and fall while maintaining a constant brake release pressure.

The demodulating valve is a manually operated valve that is acuated by the brake pedal. As the mechanism is depressed the valve shifts to block pressure from the “P” port and allows oil from the “A” port to drain to tank (Fig. 79). With the mechanism fully depressed the “A” port is open directly to tank and will have a pressure reading of zero. After the brake pedal is released, the spring will return the valve to the position where it delivers a regulated pressure to the brakes.

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Hydraulic System Overview _____________________________________ Fig. 79: Demodulating brake valve schematic

brake valve settings

Both the standard brake valve and the trailer brake valve have a nonadjustable setting. The standard brake valve has regulated pressure setting of 1,250 psi. The setting on the trailer brake valve is 325 psi.

All machines are equipped with brakes in the front tram gearboxes.

Additional trailer brakes are an option that is only available with the tractive assist option. Both standard and trailer brakes are spring applied and hydraulic release. standard brakes

The standard brakes on the machine are located in each of the front tram gearboxes on both sides of the machine. The minimum pressure to fully release the brakes is 1,100 psi. The maximum allowable pressure to the brakes is 1,400 psi.

trailer brakes

The trailer brakes are located in each of the wheel motors used for tractive assist. To fully release the standard trailer brakes, a pressure of 232 psi has to be applied to the brakes. The maximum allowable brake pressure is 580 psi. Requirements may vary if option is not standard.

normal brake operation

In normal operation, the brakes are released using accumulator pressure via a solenoid valve. The solenoid valve normally drains the pressure port of the brake valve to tank. Energizing the solenoid by pressing the button on the control stick delivers accumulator pressure to the brake valve(s). As long as the brake pedal is not depressed, a regulated pressure signal will be delivered to the brakes and they will be released (Fig. 80).

Brake pressure can be relieved to set the brakes up two different ways in normal operation. The first is depress the brake pedal. As the brake pedal is activated, the brake valve diverts oil from the brakes to tank.

Since the brake valves are proportional, the brakes will create more stopping force the further the brake pedal is pushed. With the brake pedal fully depressed, the brake pressure will go to zero and the brakes will put out maximum effort. The second way to set the brakes is to deenergize the brake solenoid. The solenoid can be de-energized by either pressing the brake release button after the brakes have been released or by turning the machine off. De-engergizing the solenoid

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Brakes

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____________________________________ Hydraulic System Overview blocks accumulator pressure from the brake valve and drains the brake valve pressure port to tank (Fig. 80). This immediately brings the brake pressure to zero which causes the brakes to give maximum effort.

© BUCYRUS AMERICA, INC.

Fig. 80: Brake system schematic with trailer brake option

The machine is provided with a hand pump that can be used to manually release the brakes in the event the machine must be moved with the power off.

CAUTION! Do not release the brakes manually without ensuring that proper precautions have been taken to stop the machine from rolling away out of control.

To release the brakes manually the flow control on the hand pump must be turned in clockwise. Without the flow control closed oil will simply go to tank instead of building brake pressure. Pumping the hand pump with the valve close will deliver oil from the pump through the hand pump contol valve and brake valves and build pressure at the brakes (Fig. 81). Before attempting to move the machine ensure that the reading on the brake pressure gauges are above the respective release pressures.

To set the brakes after they have been release manually the flow control valve on the hand pump must be opened by turning counterclockwise. A pilot valve in the hand pump control valve is there as a safety device. If the machine is started after the brakes have been released manually, a pilot signal from the auxiliary pump pilot opens the valve and drains the brake pressure to tank (Fig. 81).

Notice!

Never attempt to alter the system to allow the machine to be started with the brakes released.

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Hydraulic System Overview _____________________________________

Two wheel assist hydraulic system The two wheel assist hydraulic system is comprised of two hydrostatic circuits that is charged by a gear pump that mounts between the main pump and auxiliary pump.

Pumps There are a total of three pumps used on the assist system. The two pumps that drive the rear tram motors are identical. These two pumps are mounted to a mechanical PTO on the front tram gearboxes. The third pump is a gear pump that is mounted between the main pump and auxiliary pump (Fig. 82).

Fig. 82: Main pump assembly with two wheel assist option

Assist charge pump

Main pump

Auxiliary pump

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Fig. 81: Manual brake release schematic

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____________________________________ Hydraulic System Overview variable volume assist pumps

The two pumps that drive the rear wheel motors are variable volume motors that we use as hydrostatic pumps. The maximum displacement is 75 cc/rev (4.58 in3/rev). With a maximum input speed from the gearbox of 2,300 RPM the maximum flow available is 43.3 GPM. In most applications the pumps will be stroke limited to match the speed of the rear wheels to within 4 RPM of the front wheels.

A pilot signal is required to bring the pumps on storke. Without pressure at the X port on the pumps the displacement will be near zero.

A pressure of 145 psi is required to bring the pumps fully on stroke.

A manifold is bolted directly to the outlet ports of the pump (Fig. 83).

Combining functions into the manifold that bolts to the pump is a way to conserve space elsewhere on the machine. The manifold consists of a charge relief, bi-directional high pressrue relief, and two check valves.

The charge relief and check valves are used to provide make-up oil to the closed loop. The bi-directional relief is the high pressure setting for the hydrostatic circuit.

© BUCYRUS AMERICA, INC.

Fig. 83: Tractive assist pump and manifold assembly

Manifold

Tractive assist pump

charge pump

The charge pump is a “pancake” style gear pump with a through drive.

This allows for the charge pump to mount between the main pump and the auxiliary pump (Fig. 82). A displacement of 22.5 cc/rev (1.37 in3/ rev) will produce a flow of appoximately 10.1 GPM. The flow from the charge pump provides make-up oil to both hydrostatic circuits.

The cartridge that is located on the top of the charge pump (Fig. 82) is a plug. This pump has the option of using a cold start relief. Our application does not require this relief so the cavity is plugged.

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Hydraulic System Overview _____________________________________ Circuit valves The assist circuit valve contains three pilot operated valves. Without a pilot signal two of the pilot operated valves are used to block the A and B ports of the pump. The A and B ports of the motor are tied together and drained to tank. The third pilot operated valve ties the A and B ports of the pump together, but these are not drained to tank (Fig. 84).

When a pilot signal is delivered to the X port, the three pilot operated valves all shift. The valves shifting breaks the connection between the A and B ports of the pump and completes the hydrostatic loop between the pump and motor. A minimum pressure of 150 psi is required to shift the pilot operated valves.

© BUCYRUS AMERICA, INC.

Fig. 84: Circuit valve schematic

Wheel Motors The wheel motors used on the two wheel assist circuit are radial piston motors. These motors are available with or without brakes. The displacement of these motors will vary depending on application.

To freewheel the motor the A and B ports must be tied together and open to tank. To engage the motor the A and B ports must be connected to the pump. The charge pressure in this pump circuit forces the pistons into motion. This system uses the circuit valve to engage and freewheel the motor.

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____________________________________ Hydraulic System Overview Operating the two wheel assist During normal operation of the machine the two wheel assist is disengaged. The A and B ports of the motor are tied together via the circuit valve which causes the pistons to retract. With the pistons retracted the motors are freewheeling. Zero pressure at the X ports of the pumps will result in very little flow in the closed loop.

© BUCYRUS AMERICA, INC.

Pressing the tractive assist button on the control stick will engergize the assist solenoid. The solenoid will remain engergized until the button is released. Engergizing the solenoid sends pilot pressure from the trailer valve bank to the X ports on the pumps and circuit valves (Figure 85).

The pilot operated valves in the circuit valve shift to connect the pumps and motors. The charge pressure provided to the pump circuit then engages the wheel motors. The pilot signal to the pumps brings them on stroke. The rear wheels will then turn at the same approximate speed as the front wheels.

Releasing the tractive assist button on the control stick de-engergizes the solenoid. This removes pilot pressure from the X ports. The pumps are come off stroke, the pilot operated valves in the circuit valve shift, and the wheel motors disengage.

Fig. 85: Two wheel assist schematic

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Hydraulic System Overview _____________________________________ Filtration The 816C is equipped with five oil filters. Three filters are used to clean the oil in the hydraulic system. Two filters are used to clean the oil in the front tram gearboxes.

Hydraulic oil filters A main, return, and auxiliary hydraulic filter are used on the 816C. All three filters are rated to 5 micron. They each have a bypass valve and a dirt indicator. The bypass valve crack pressure is 40 psi.

return filter

auxiliary filter

The main filter is located in the pump compartment (Fig. 86). Flow produced by the main pump passes through the main filter before any other component.

The return filter is a tank mounted filter. The head of the filter rests on the top of the tank while the element is inside the tank. It is mounted on the top of the rear corner of the oil tank (Fig. 86). Return flow from the two valve banks is combined and passed through the return filter before returning to the tank. The flow from the power fill also passes through the return filter before going to tank.

The auxiliary filter is located behind a cover in the compartment next to the control box (Fig. 86). Flow from the auxiliary pump passes through the auxiliary filter before going to the unloading valve.

Fig. 86: Machine layout showing filter locations Return filter

Main filter

Auxiliary filter

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main filter

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____________________________________ Hydraulic System Overview Gear oil filters Two filters are used to filter the oil in the front tram gearboxes. Each gearbox has an internal pump that is used to circulate the gear oil through the filters. Both filters are mounted next to each other under the top plate behind the front tram motors (Fig. 87).

Fig. 87: Two wheel assist schematic

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Gear oil filters

These filters are spin-on filters. The element has a 10 micron rating. A bypass valve is used on the head of the filter. The bypass valve crack pressure is 25 psi. The visual indicator will indicate to change the filter at a 22 psi pressure drop.

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© BUCYRUS AMERICA, INC.

Hydraulic System Overview _____________________________________

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_____________________________________ Adjustments and Settings Adjustments and settings This section contains information on the adjustments and settings for the overall system. The details in this section are to provide information on how to set all adjustments on the machine.

Main system

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The main system adjustments and settings consists of the settings that control the load sense system and all of the cylinder functions. calibrated multi-gauge

It is important that the margin pressure, main relief, and load sense relief are set accurately. To insure that these settings are accurate a calibrated multi-gauge is required. The pressure switch located in the pump compartment picks up system pressure off of the M port of the trailer valve bank. Disconnect the hose from the pressure switch and connect to the multi-gauge to accurately set these pressures. Using a multi-gauge in this location allows a person to read the gauge as they are making the adjustments.

overrides on control valves

The control valves are equipped with two manual overrides. The first and easiest to use is the override buttons on the solenoids (Fig. 88).

Pressing a solenoid override pushes the armature pin normally activated by the solenoid into a valve on control valve. This valve then sends pilot pressure to shift the spool.

The second override is the pivot arm that acts directly on the spool (Fig. 88). There are threaded holes on the pivot for mounting levers which can be used for leverage by inserting a bolt or screwdriver. This override directly shifts the spool and does not depend on pilot pressure.

While setting pressures and making adjustments, these overrides make it easy to cycle functions from the pump compartment. These overrides will also allow for the independent operation of the tailgate and false bottom/ejector sections.

NOTICE! Never operate the machine without having a person in the operator’s cab.

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Adjustments and Settings ______________________________________ Fig. 88: Control valve with manual overrides

Solenoid override

Pivot arm

The margin pressure adjustment is located on the top of the main pump (Fig. 89). The margin pressure is the system pressure reading while at idle. Before making the adjustment, the 13 mm jam nut has to be turned out counterclockwise. Turn the 6 mm adjustment screw until the gauge reads 500 psi. Turning the screw clockwise will raise the pressure while turning the screw counterclockwise will lower the pressure. After setting the margin pressure to 500 psi, cycle a function a couple of times to insure that the margin pressure returns to 500 psi.

It is important that the margin adjustment does not exceed 500 psi. A high setting induces higher inefficiencies and will most likely cause operational problems with the pump motor cutback switch.Once the setting is obtained, hold the adjusment screw in place while turning the jam nut clockwise until tight.

Fig. 89: Pump assembly with two wheel assist option

Margin pressure adjustment

_________________________________________________________________ 5.80 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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Margin pressure

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_____________________________________ Adjustments and Settings Main relief The main relief valve setting is 3,000 psi. Since the load sense relief valve will limit system pressure to 2,800 psi, the load sense relief valve needs to be increased before setting the main relief valve. Both of the main relief valve and load sense relief valve adjustments are located on the inlet section of the trailer valve bank (Fig. 90). To measure the setting of the relief valves a function must be deadheaded. With the tailgate lowered, use the manual override that lowers the tailgate to make pressure readings while setting the relief valves.

Fig. 90: Trailer valve bank with relief valves Main relief adjustment

© BUCYRUS AMERICA, INC.

Load sense relief adjustment

The main relief valve and load sense adjustment screws are both secured with a jam nut and covered by a cap. First, remove the caps from both adjustments. There is a 12 mm hex on the caps. Next, loosen the jam nuts by turning counterclockwise. The jam nuts are also 12 mm. A 12 mm or 1/2” thin wall socket will make it easier to turn the jam nut on the main relief adjustment.

Both the adjustment screws are adjusted with a 3 mm allen wrench.

Turn the main relief valve adjustment clockwise two full turns, and turn the load sense relief valve adjustment counterclockwise two full turns.

Deadhead the tailgate and note the system pressure. If the pressure was above 3,000 psi, turn the main relief setting counterclockwise until the pressure drops to 3,000 psi. If the pressure was below 3000 psi, turn the main relief setting clockwise until the pressure increases to 3,000 psi. If turning the main relief clockwise does not or stops increasing the pressure, turn the load sense adjustment clockwise two full turns and try adjusting the main relief valve again. If there is not an increase in pressure after turning the load sense valve adjustment clockwise, then increase the setting on the pressure limiter of the tailgate section. After obtaining a reading of 3,000 psi, cycle the tailgate function multiple times to insure the setting is repeatable. Next, tighten the jam nut on the main relief valve adjustment. Deadhead the tailgate section again to insure the setting did not change when tightening the jam nut. Finally, replace cap and proceed to setting the load sense relief valve.

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Adjustments and Settings ______________________________________ Load sense relief It is good practice to reset the main relief if the load sense relief needs adjusting. The load sense relief is located on the trailer valve bank (Fig. 90). Start by removing the cap (12 mm hex) and loosening the 12 mm jam nut by turning counterclockwise. Turn adjustment using 3 mm allen wrench clockwise to increase pressure and counterclockwise to decrease pressure. Adjust until gauge reads 2,800 psi when the tailgate section is deadheaded. If pressure will not rise to 2,800 psi, increase setting on tailgate section pressure limiter. After the 2,800 psi reading is obtained, deadhead the tailgate section multiple times to insure a repeatable reading. Next, tighten the jam nut by turning clockwise. Finally, take another pressure reading to insure that the setting did not change while tightening the jam nut and replace cap.

A pressure switch is used to measure system pressure which determines when the pump motor goes into cutback mode. It is located in the pump compartment above the pump motor (Fig. 91). The adjustable range is from 45-580 psi. Turn the adjustment knob clockwise until the switch is set at the maximum setting. If the switch is set below the margin pressure (500 psi), the pump motor will remain in cutback mode.

Fig. 91: Pressure switch in pump compartment Pressure switch

Adjustment knob

Pump motor

_________________________________________________________________ 5.82 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Pressure switch

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_____________________________________ Adjustments and Settings Pressure limiters Each section on the control valve has a pressure limiter which limits the pressure available beyond that section’s ports. The pressure limiter is located on the top of each valve section (Fig. 92). Initially all pressure limiters are set above the 3,000 psi main relief setting.

© BUCYRUS AMERICA, INC.

Fig. 92: Pressure limiters

Pressure limiter

Pressure limiter

To adjust a pressure limiter first remove cap (12 mm hex). Next loosen 12 mm jam nut by turning counterclockwise. Turn adjustment screw with 3 mm allen wrench clockwise to increase pressure and counterclockwise to decrease pressure. After adjustment tighten jam nut by turning counterclockwise and replace cap.

Deadhead the respective function and read system pressure to determine pressure limiter setting. Working pressure at the function is equal to the system pressure minus the margin pressure (500 psi).

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Adjustments and Settings ______________________________________ Sequence valve The sequence valve is used to control the false bottom and ejector cylinder. It is located in the bottom of the compartment between the pump compartment and rear wheel. (Fig. 93). There is no hydraulic adjustments that effect the tailgate in the load eject sequence.

Fig. 93: False bottom and ejector sequence valve Extend adjustment screw

Sequence valve

Setting the sequence valve requires the cycling of the false bottom and ejector mulitple times. During this process it is best to use the manual overrides on the valve bank. Lower the tailgate using the manual override before starting. setting the extend sequence

Start by turning the 9/16” jam nut counterclockwise to loosen. Use a 5/32” allen wrench and turn the adjustment screw counterclockwise until it reaches it’s maximum limit. While activating the extend on the false bottom/ejector valve section, turn the adjustment clockwise until the ejector does not move until the false bottom cylinder fully extend.

Once this setting is achieved, hold the adjustment screw in place while tightening the jam nut by turning clockwise.

setting the retract sequence

Start by turning the 9/16” jam nut counterclockwise to loosen. Use a 5/32” allen wrench and turn the adjustment screw counterclockwise until it reaches it’s maximum limit. While activating the retract on the false bottom/ejector valve section, turn the adjustment clockwise until the false bottom stops moving. If the false bottom begins to move during the second stage of the ejector cylinder, continue to turn the adjustment clockwise until false bottom stops. Insure that the false bottom does not move until the ejector is fully retracted. After the proper sequence is obtained, hold the adjustement screw in place while tightening the jam nut by turning clockwise.

_________________________________________________________________ 5.84 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Retract adjustment screw

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_____________________________________ Adjustments and Settings Battery lift suspension The battery lift suspesnsion uses two accumulators to dampen battery bounce. One accumulator is located under the tram gearbox on the operator’s side. The second is located on the other side of the wall from the valve bank next to the foot pedal mount (Fig. 94). Both accumulators must have a gas precharge of 1,200 psi to optimally dampen battery bounce.

Fig. 94: Flow control valves on tractor frame Accumulator dump

© BUCYRUS AMERICA, INC.

Battery suspsenion accumulator

Battery lift relief valve Battery suspsenion accumulator

NOTICE! Operating the machine without the designed gas precharge will result in unsatisfactory operating conditions and can also lead to early fatigue failures in the battery or battery lift mechanism.

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Adjustments and Settings ______________________________________ accumulator dump valve

Turn the accumulator dump counterclockwise to relieve accumulator pressure. After pressure is relieved, turn valve clockwise until it reaches the limit. Failure to close valve will result in the battery lift suspension to function incorrectly.

NOTICE! Opening accumulator dump valve will cause the battery to drop to the ground immediately. Do not open valve before checking and clearing the area around the battery.

Battery lift relief valve

Using the right hand control stick activate the section that lowers the battery. With the adjustment on the relief valve turned all the way out the machine will not raise up when pressing the battery against the ground. The main system pressure gauge will read the relief valve setting plus the margin pressure. Setting the relief valve at 2,000 psi will require a main system pressure gauge reading of 2,500 psi. Turn the adjustment screw clockwise until the main system pressure gauge reads 2,500 psi. Hold the adjustment screw in place with the allen wrench while turning the jam nut clockwise to tighten. This setting will prevent the machine from raising up when the battery is pressed against the ground. If the machine lifts off the ground when the battery is pressing against the ground, decrease the setting.

Steering cylinder relief valves The steering cylinders each contain two relief valves. Both the extend and retract ports have a relief valve that drain to a common tank port.

The relief valves are located on the cylinder port manifolds (Figure 95).

They are preset from the factory at 3,000 psi, therefore new parts do not require adjustment.

To set the relief valves the main relief and load sense relief will need to be increased above 3,500 psi (see page 5.81). The setting on the steering cylinder relief valves is set above normal operation and is only intended to relieve pressure spikes.

Before making adjustments to the steering relief valve install the steering lock mechanism.

_________________________________________________________________ 5.86 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

The battery relief valve is used to protect the frame structure of the battery itself and the lifting mechanism. It is hard plumbed to the HIC suspension block (Figure 94). Start by removing the cap on the adjustment screw using a 9/16” wrench. Next, loosen the 9/16” jam nut by turning counterclockwise. Turn the adjustment screw counterclockwise using a 5/32” allen wrench until the maximum limit is reached. To set the battery lift relief valve lower the battery to the ground using the right hand control stick.

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_____________________________________ Adjustments and Settings Fig. 95: Steering cylinder with relief valves Extend relief valve adjustment

© BUCYRUS AMERICA, INC.

Port manifold

Retract relief valve adjustment

WARNING! Never make adjustments to steering cylinder relief valves without the steering lock mechanism in place. Never take pressure readings while standing in the pinch point even with the steering lock mechanism installed.

On the operator’s side steering cylinder turn the 9/16” jam nut on the extend relief valve counterclockwise to loosen. Measure the pressure setting by pushing the steering lever. Adjust the extend relief valve by turning the 5/32” hex socket adjustment screw until the measured reading is 3,500 psi on the main system pressure gauge. The system pressure gauge will read the relief valve setting plus the margin pressure. Turn the adjustment screw clockwise to increase the setting and counterclockwise to decrease the setting. If turning the adjustment screw clockwise does not increase the pressure, first check that the main relief and load sense relief valves are set higher than 3,500 psi. If the settings for these valves are higher than 3,500 psi, increase the pressure setting on the off-side steering cylinder relief valves. Once the correct setting is achieved, turn the jam nut clockwise to tighten while holding the adjustment screw in place.

Repeat this procedure to set the retract relief valve on the same cylinder. To measure the setting of the retract relief valve pull on the steering lever.

After setting both relief valves on the operator’s side cylinder, proceed to setting the relief valves in the off-side cylinders. Loosen the jam nut on the extend relief valve by turning counterclockwise. Turn the adjustment screw counterclockwise in quarter turn increments while checking the pressure setting between each turn. Meaure the pressure setting by pulling on the steering lever. Once the pressure reading drops below 3,500 psi on the main system pressure gauge, turn the adjustment screw clockwise a quarter of a turn. Hold the adjustment screw in place and turn the jam nut clockwise to tighten.

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Adjustments and Settings ______________________________________ Repeat this procedure to set the retract relief valve on the off-side cylinder. Push on the steering lever to measure the pressure setting for the off-side cylinder retract relief valve.

IMPORTANT! After setting the steering cylinder relief valves the main relief and load sense relief valves must be reset (See page 5.81)

Auxiliary/Brake System The auxiliary/brake system adjustments and settings consist of the auxiliary relief valve and unloading valve. Adjusting the auxiliary relief valve will require the unloading valve to be reset.

Auxiliary relief valve

Fig. 96: Accumulator/tank manifold in tractor frame Tractor valve bank

Accumulator/ tank manifold

Needle valve adjustment

Next, the unloading valve has to be adjusted to the maximum limit to allow the circuit to build pressure to the auxiliary relief valve setting.

Access the unloading valve through the operator’s side top cover on the nose cone (Fig. 97). Loosen the 9/16” jam nut on the unloading valve adjustment by turning counterclockwise. Turn the adjustment on the unloading valve clockwise until the maximum limit is reached. The hex on the unloading valve adjusment screw is 9/16”.

_________________________________________________________________ 5.88 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Before setting the auxiliary relief valve, close the needle valve on the accumulator/tank manifold by turning clockwise. The manifold is located in the center compartment of the tractor frame (Fig. 96).

Closing this valve allows the accumulator to hold pressure.

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_____________________________________ Adjustments and Settings Fig. 97: Unloading valve in nose cone frame

© BUCYRUS AMERICA, INC.

Adjustment screw

Check valve

Unloading valve

With the unloading valve turned all the way in, the accumulator pressure gauge will read the auxliary relief valve setting. The auxiliary relief valve is located on the wall above the pump assembly (Fig. 98).

Turn the 5/32” jam nut on the relief valve counterclockwise to loosen.

Turn adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure. The adjustment screw has a 9/16” hex. Make adjustments until accumulator gauge reads 2,250 psi.

After setting is obtained, turn jam nut clockwise until tight. Proceed to setting the unloading valve.

Fig. 98: Auxiliary relief valve in pump compartment

Adjustment screw

Auxiliary relief valve

Main pump

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Adjustments and Settings ______________________________________ Unloading Valve The unloading valve is located under the top cover on the operator’s side of the nose cone (Fig. 97). Start by turning the 9/16” jam nut counterclockwise to loosen. Turn the adjustment screw clockwise until it reaches it’s limit. The adjustment screw has a 9/16” hex. Then turn the adjustment screw three full turns counterclockwise.

Open the needle valve on the accumulator/tank manifold (Fig. 96).

Once the pressure on the accumulator gauge has dropped to near zero, close the needle valve. As the accumulator charges, note the pressure on the accumulator gauge when the unloading valve shifts and the pressure stops rising. The pressure reading at that point is the setting of the unloading valve.

Two wheel assist system The two wheel assist system adjustments and settings consist of the charge relief valve, assist relief valve, and the pump stroke limiters. All three of these adjustments and settings are located on the assist pump and manifold assembly.

Charge relief valve The charge relief valve is located on the manifold that is bolted to the assist pump (Fig. 99). There are two charge relief valves in the system.

The valves are non-adjustable and are set at 348 psi.

Fig. 99: Assist pump and manifold assembly

Assist relief valve

Charge relief valve

_________________________________________________________________ 5.90 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

The unloading valve setting is 1,800 psi. Turn the adjustment screw clockwise to increase the setting and counterclockwise to decrease the setting. After each adjustment, open and close the needle valve to dump accumulator pressure in order to take a reading of the unloading valve setting.

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_____________________________________ Adjustments and Settings Assist Relief Valve The assist relief valve is located in the manifold that is bolted to the assist pumps next to the charge relief valve (Fig. 99). A separate relief valve is used for each closed loop circuit. To set the relief valve the machine must raised so that all four wheels are off the ground.

CAUTION! Use caution when elevating the machine. Insure that all areas around the machine are clear of equipment and personal to avoid injury. During this process the wheels will turn. It is important that the machine is elevated to a point where the wheels are a safe distance from the ground.

Turn the 17 mm jam nut on the relief valve counterclockwise to loosen.

Next disconnect the hose from the fitting in the B port of the manifold block. Place 3/4” JIC (#12) cap on fitting in the B port. Remove 3/8” SAE O-ring (#6) plug from MB port. Connect 6000 psi rated gauge to MA port. © BUCYRUS AMERICA, INC.

Using the control stick select front tram mode. Press the accelerator pedal to tram the machine forward. With the circuit deadheaded, the reading on the gauge while tramming will be the relief valve setting.

Set the assist relief valve to 5000 psi by turning the adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure. Use a 5 mm allen wrench to turn adjustment screw.

NOTICE! Do not tram the machine for extended periods of time while setting the assist relief. Take quick readings to eliminate overheating the machine. bi-directional relief valves

Once the 5,000 psi setting is obtained, turn the jam nut clockwise to tighten. Repeat this process on the opposite pump to set second relief valve if necessary.

The assist relief valves are bi-directional and will relieve the circuit at the same pressure regardless of tram direction. The above procedure details setting the relief valves by plugging B port and tramming forward. It is also possible to set the relief valves by plugging the A port and tramming in reverse.

Pump displacement adjustments The assist pumps have two adjustments that will control the displacement of the pump. Both adjustments are located opposite of the shaft on the rear face of the pump (Fig. 100).

minimum adjustment

The minimum displacement adjustment screw controls the displacement while the pressure at the X port is zero. In this condition the flow should be zero. Thus, the minimum adjustment is set to zero.

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Adjustments and Settings ______________________________________ NOTICE! Do not adjust the minimum adjustment. This is set on a test stand by the manufacturer. Adjusting this to anything other than zero will result in the pump overheating and eventually lead to failures.

Fig. 100: Displacement adjustments on the assist pumps Maximum displacement adjustment

maximum adjustment

The maximum displacement adjustment screw controls the displacement of the pump when the X port is pressurized. This will directly control the flow developed by the pump and delivered to the wheel motors. In production the maximum displacements are set so that the rear wheels turn from 0 to 4 RPM faster than the front wheels.

The machine must have all four wheels raised off the ground to make these adjustments.

CAUTION! Use caution when elevating the machine. Insure that all areas around the machine are clear of equipment and personal to avoid injury. During this process the wheels will turn. It is important that the machine is elevated to a point where the wheels are a safe distance from the ground.

First, make a mark on the outside of each wheel with either tape or paint. Use this mark to count revolutions of the wheel. While tramming at full speed, count the number of revolutions the front operator’s side wheel and the rear operator’s side wheel makes in one minute. If the rear wheel is either slower or more than 4 RPM faster than the front wheel, loosen the 19 mm jam nut on the maximum adjustment by turning counterclockwise. Then turn the maximum adjustment screw clockwise to decrease the speed of the rear wheel or counterclockwise to increase the speed of the rear wheel. Count the revolutions of the two wheels again and continue making adjustments until the rear wheel is either equal to or less than 4 RPM faster than the front wheel. Use a 6 mm allen wrench to turn the adjustment screw. After this setting is achieved, lock down the jam nut by turning clockwise.

Set the off side wheel motor speed using the same process as above for the operator’s side.

_________________________________________________________________ 5.92 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Minimum displacement adjustment

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_____________________________________ Adjustments and Settings Spool Stroke Limiters Each valve section has a spool stroke limiter for each direction. Since the valves are load sensing, the spool stroke limiters can be used on any section to limit the amount of flow through the section without increasing the pressure. The spool stroke limiters are located on the pivot mechanism that is used to shift the spool manually (Fig. 101).

Turning out the adjustment screws will cause them to hit the spool stops and thus limit the travel of the spool.

Fig. 101: Spool stroke limiters on valve section Set screw

Adjustment screw

© BUCYRUS AMERICA, INC.

Spool stop

Adjustment screw Pivot mechanism

Limiting Steering Spool The steering valve section is oversized and has the compensator removed to increase steering response time. With the compensator removed the section will bring the pump on full stroke regardless of demand. Oversizing the spool allows full flow through the section without having to fully shift the spool. Since fully shifting the spool is not necessary to achieve full flow, the spool limiters are adjusted to limit the travel of the steering control stick. Limiting the travel of the control stick reduces the amount of movement the operator must make to steer the machine.

Remove the hardware that attaches the steering cable to the pivot mechanism on the valve section if necessary. Using a 3 mm allen wrench loosen each set screw by turning counterclockwise. Turn each adjustment screw on the spool limiters clockwise until the screws are 1/8” past flush. Tighten set screws by turning clockwise. Replace the hardware attaching the steering cable.

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Adjustments and Settings ______________________________________



Be sure the machine is not running and that the battery has been fully disconnected.



During replacement or after installation of the magnetic switch (Fig. 102) the following must take place to proper adjust the switch.



As you install the magnetic switch you must leave the two mounting screws loose enough to slide the magnetic switch for adjustment.



After the magnetic switch has been installed into the mounting bracket you must measure from the signal face of the switch to the underside of the false bottom where the magnetic strip is mounted. The measurement must be approx. 2.25 – 2.75 between these surfaces.



Then the mounting screws can be fastened securely to hold the switch in place.

Fig. 102: Tailgate go switch adjustment

Magnetic strip

Go button

_________________________________________________________________ 5.94 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Tailgate go switch adjustment

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_____________________________________________ Troubleshooting Troubleshooting procedures The following section lists possible problems encountered when servicing the UN-A-HAULER ® and can aid in locating and correcting these problems.

This following sections cover basic hydraulic components, brakes, hydraulic cylinders, hydraulic pumps and valves, with each listed in a trouble-cause-remedy format.

For operation and troubleshooting instructions on the HiPAC 10 Display control panel, see the HiPAC 10 Display Series Operation and Troubleshooting” guide.  Use insulated gloves and tools where possible.

© BUCYRUS AMERICA, INC.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

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Troubleshooting ______________________________________________ Hydraulic system (general) Table 4: Hydraulic system (general) troubleshooting Trouble, symptom or cause

Probable cause

dirty oil  Components not properly cleaned after servicing.  Air breather left off.

Test, check and/or remedy  Disassemble components and re-clean parts.  Replace breather.

 Hose lines not properly covered  Clean hose lines after servicing. after servicing machine.

foaming oil  Return of tank lines not below fluid level. Check oil level.

 Replace elements at proper intervals.  Replace broken hoses or lines.

 Oil contaminated with incompatible foreign matter.

 Drain out oil and replace with clean oil.

 Suction leak to pump aerating oil.

 Replace or tighten fittings and lines.

moisture in oil  Soluble oil solution splashing into poorly sealed tank gasket or fill holes left open.

 Drain out and refill with clean oil. Check fill pipes to see if they are properly closed.

 Moisture in cans or used replacement oil.

 Replace with new cans of oil.

 Extreme temperature differential  Replace with recommended oil in certain geographical locafor correct temperature range. tions. overheating of system  Fluid viscosity too high.

 Check fluid specs.

 Excessive slippage or internal  Fluid viscosity too low. leakage past pump or cylinders. overheating of system  Improper air circulation around reservoir.

 Check to see if the area around the reservoir is clear.

 System relief valve set too high or too low.

 Reset the relief valve to specifications.

foreign matter sources  Sealing compound (pipe dope, in the circuit Teflon tape).

 Clean or replace seals.

 Burrs inside piping components.  Disassemble piping components and remove any burrs.

_________________________________________________________________ 5.96 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 Filter elements not replaced at proper intervals or when indicated.

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_____________________________________________ Troubleshooting Table 4 (continued): Hydraulic system (general) troubleshooting Trouble, symptom or cause

Probable cause

foreign matter sources  Tag ends of packing coming in the circuit (continued) loose.

 Remove old packing and replace with new.

 Lines left unprotected and dirty, repaired components.

 Drain and replace oil.

 Repair parts not properly protected while stored.

 Clean parts thoroughly before installation.

Accumulator unloading cycle  Leaking accumulator lines or repeats frequently when fittings. accumulator is not normally being discharged in service  Accumulator gas charge too low.

 Check lines and fittings for leaks and correct.  Check accumulator gas charge.

 Line to accumulator plugged.

 Check accumulator.    Replace line.

 Brake valve leaking 

 Check leakage in valve, replace if necessary.

 Dump valve not closed all the way.

 Close dump valve fully. 

 Defective unloading valve.

 Replace unloading valve.

 Accumulator gas charge too high. © BUCYRUS AMERICA, INC.

Test, check and/or remedy

Accumulator starts to charge but  No oil or low oil in tank. doesn’t reach high limit  Defective or worn pump (pump doesn’t deliver full flow or pressure).

 Check oil level.  Check pump pressure and flow.

 Defective system relief valve  Check relief valve. (valve leaking or has low setting so full flow and pressure are not available).  Defective charging valve.

 Replace valve.

 Relief valve setting too low.

 Check valve setting.

accumulator charging time  No oil or low oil level in tank.  Check oil level. too long  Pump worn or defective and not  Check pump. delivering full flow or pressure.  Defective unloading valve.

 Replace unloading valve.

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Troubleshooting ______________________________________________ Table 4 (continued): Hydraulic system (general) troubleshooting Probable cause

accumulator fails to  No oil or low oil level in tank. start charging  Worn or defective pump.

Test, check and/or remedy  Check oil level.  Check pump pressure and flow.

 Defective relief valve.

 Check relief valve setting.

 Defective charging valve.

 Replace charging valve.

 Dump valve open.

 Close valve.

very rapid cycling of  Leaking accumulator lines or unloading valve fittings.

 Check lines and fittings for leaks and correct.

 Accumulator gas charge too low.

 Check accumulator gas charge.

 Accumulator gas charge too high.  Line to accumulator plugged.

 Check accumulator.    Replace line.

 Brake valve leaking 

 Check leakage in valve, replace if necessary.

 Dump valve not closed all the way.

 Close dump valve fully. 

 Defective unloading valve.

 Replace unloading valve.

. excessive accumulator  Damaged lines or connections  Repair or replace as required. cycling when brakes in circuit. are not being used  Valve (s) in any branch of this  Isolate circuits to locate the source circuit contaminated or damof the leakage and clean or replace aged. as required.

_________________________________________________________________ 5.98 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Trouble, symptom or cause

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_____________________________________________ Troubleshooting Brakes Table 5: Brakes troubleshooting Trouble, symptom or cause

Probable cause

brakes slow to apply  Defective brakes.  Pedal linkage out of adjustment.  Damaged hydraulic brake lines.  Defective brake pedal valve.

Test, check and/or remedy  Check brakes.  Adjust linkage.  Check lines for dents that restrict flow of oil.  Test individual valve performance and replace brake valve (s) as required.

brakes won’t release  Pedal linkage out of adjustment  Check for proper adjustment or binding. and binding.

© BUCYRUS AMERICA, INC.

 Brake release controls not func-  Inspect brake release solenoid, tioning properly. pilot valves and brake release hand pump.  Defective brakes.

 Check brakes.

 Defective brake pedal valve.

 Test individual valve performance and replace brake valve (s) as required.

 No accumulator pressure.

 See accumulator troubleshooting (Table 4).

insufficient brakes  Pedal linkage out of adjustment.  Brake line mashed.  Defective brakes.  Brake valve defective. brakes will not release  Defective brakes. completely  Oil Level.  Pedal linkage out of adjustment.  Air in brakes.  Defective brake valve.  Brake release controls not functioning properly.

 Adjust linkage.  Check lines and replace.  Repair or replace as required.  Test valves performance and replace valve as required.  Check brakes.  Check oil level and fill as required.  Adjust pedal linkage.  Bleed brakes.  Replace brake valve.  Inspect brake release solenoid, pilot valves and brake release hand pump.

 Low accumulator pressure.

 See accumulator troubleshooting (Table 4). ____________________________________________________________ A6474X257

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Troubleshooting ______________________________________________ Table 5 (continued): Brakes troubleshooting Trouble, symptom or cause

Probable cause

excessive braking  Defective brakes.

Test, check and/or remedy  Check brakes.

 Defective brake valve.

 Replace brake valve.

 Solenoid failure.

 Replace solenoid.

no brakes  Pedal linkage out of adjustment.  Adjust pedal linkage.  Broken or mashed brake line.

 Check lines for breaks or mashed condition.

 Defective or worn brakes.

 Check brakes.

 Defective brake valve.

 Replace brake valve.  Replace as required.

_________________________________________________________________ 5.100 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Excessive accumulator  Defective brake pedal valve (s) leakage when brakes are applied

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_____________________________________________ Troubleshooting Hydraulic cylinders Table 6: Hydraulic cylinder troubleshooting Trouble, symptom or cause

Probable cause

© BUCYRUS AMERICA, INC.

cylinder drifts  Piston seal leak.

Test, check and/or remedy  Repair seals or replace cylinder.

 Control cartridge by-passing.

 Replace cartridge or cylinder as required.

 Other circuit leaks.

 Correct leaks.

cylinder fails to move the load  Pressure too low. when actuated

 Check pressure at cylinder to meet circuit requirements.

 Piston seal leak.

 Repair seals or replace cylinder.

 Piston rod broken at piston end.

 Repair as required or replace cylinder.

 Contamination in hydraulic system resulting in scored cylinder bore. erratic or chatter in operation  Excessive friction due to misalignment and/or side loading.  Air in circuit. excessive or rapid piston  Excessive system pressure seal wear due to over adjustment.  Excessive friction due to misalignment and/or side loading. cylinder body seal leak  Excessive pressure.  Seal is pinched or extruded.  Seal deterioration (soft or gummy).

the piston is leaking  Dirt has scored the piston or the rod. the piston freezes to the tube  Scoring in the piston.

Packing and gasket leaks  Excessive heat. develop

 Replace cylinder.

 Correct cylinder to load alignment.  Cycle cylinder to full stop positions to purge air.  Correct pressure adjustment to rated limits.  Correct cylinder to load alignment.  Reduce pressure to rated limits.  Replace cylinder body seal.  Check compatibility of seal material with operating fluid. Replace oil.  Replace rod.  Replace.  Replace packing and gasket.

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Troubleshooting ______________________________________________ Hydraulic pump Table 7: Hydraulic pump troubleshooting Trouble, symptom or Probable cause cause pump makes excessive  Vacuum leaks in suction line. noise

Test, check and/or remedy  Check for leaks in fittings or damaged suction lines.

 Poor alignment with drive mechanism.

 Align pump and pump motor.

 Incorrect fluid in system.

 Check fluid specs.

 Relief valve set too high.

 Check relief pressure.

 Seal deterioration (hard or loss of elasticity).

 Replace seal.

 Seal deterioration (loss of radial  Replace seal . squeeze due to flat spots or wear on O.D. or I. D.). seal leak  Torn or worn seals.

 Replace seal.

 Gland bearing worn.

 Replace gland and seals.

 Seal deterioration (soft or gummy).

 Replace seal.

 Seal deterioration (hard or loss of elasticity).

 Replace seal.

 Seal deterioration (flat spots on I.D.).

 Replace seal.

 Aeration of fluid in reservoir.

 Correct air leak.

 Worn or damaged gears and housing.

 Replace gears and housing.

 Worn or faulty bearing.

 Replace faulty bearing.

 Reversed rotation.

 Check pump motor wiring.

 Plugged or restricted suction line or suction strainer.

 Clean by removing the plugged area.

 Plugged reservoir filter breather .

 Clean reservoir. Clean breather.

_________________________________________________________________ 5.102 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 Vacuum leaks in the pump shaft  Check pump. seal.

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_____________________________________________ Troubleshooting Table 7 (continued): Hydraulic pump troubleshooting Trouble, symptom or cause

Probable cause

© BUCYRUS AMERICA, INC.

seal leak (continued)  Oil viscosity too high or operating temperature too low.

Test, check and/or remedy  Replace with recommended oil.

 Air leak in suction line or fittings.

 Replace lines or fittings if badly worn.

 Loose or worn pump parts.

 Replace worn pump parts.

 Air leak at pump shaft seal.

 Replace pump shaft seals.

 Oil level too low and drawing air in through inlet pipe opening.

 Check oil level.

 Air bubbles in intake oil.

 Check oil level and tighten any loose fittings.

 Pump housing bolts loose or not properly torqued.

 Tighten the housing bolts and re-torque bolts.

pump failure to deliver oil  Low oil Level in reservoir.

 Fill to proper level.

Note: pump at idle delivers zero  Oil intake hose suction strainer flow in load sense system. plugged.

 Clean or replace strainer.

 Air leak in suction line and preventing priming.

 Tighten or replace suction lines.

 Incorrect margin pressure setting.  Set margin on load sense main relief.  Oil viscosity too high.

 Replace with recommended oil.

 Wrong shaft rotation.

 Check pump motor wiring.

 Pump shaft or parts broken.

 Replace shaft or broken parts.

 Dirt in pump.

 Clean pump .

oil leakage around pump  Shaft seal worn.  Head of oil on suction hose connection leaking.

 Replace seals.  Tighten bolts. Tighten or replace connections.

____________________________________________________________ A6474X257 VTVI/04 5.103

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Troubleshooting ______________________________________________ Table 7 (continued): Hydraulic pump troubleshooting Probable cause

excessive pump wear  Abrasive dirt in hydraulic oil being circulated through the system.

Test, check and/or remedy  Replace oil with clean hydraulic oil.

 Oil viscosity too low.

 Replace with recommended oil.

 System pressure exceeding pump rating.

 Relief valve out of adjustment.

 Pump misalignment.

 Realign pump.

pump parts inside the housing  Seizure due to lack of oil. are broken  Excessive system pressure above maximum pump rating.

 Check oil level.  Relief valve out of adjustment.

 Excessive torquing to housing bolts.

 Loosen bolts and then retorque.

 Solid matter being drawn in from reservoir and wedged in pump.

 Remove and clean clogged area.

_________________________________________________________________ 5.104 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Trouble, symptom or cause

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_____________________________________________ Troubleshooting Valves Table 8: Valve troubleshooting Trouble, symptom or cause

Probable cause

the operating pressure cannot be  Valve spring broken. changed  Open valve in the system.

© BUCYRUS AMERICA, INC.

 Margin pressure set too low.

Test, check and/or remedy  Replace the spring.  Find and close open valve.  Check margin pressure setting on pump.

the valve piston sticks  Dirt in the system.

 Remove the valve and clean it thoroughly; flush the system as necessary.

certain passages are blocked or  Dirt in the system. pressure fluctuates

 Remove the valve and clean it thoroughly; flush the system as necessary.

the pressure fluctuates and there  Air in the system. is extreme noise in the valve

 Check for leaks. Bleed load sense lines.

the valve leaks internally  Valve piston and body worn. excessive leakage or sticking  Valve excessively hot. pistons occurs     Dirt in the system.

 Replace the valve.  1. Remove the valve and clean it thoroughly; flush the system.  2. Check load sense and main relief setting.  Replace oil.

valves are hot  Main relief set lower than load sense relief.

 Check settings.

operating pressure too low on a  Pressure limiter set too low. function  Main relief or load sense relief too low.

 Check setting.  Check setting.

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© BUCYRUS AMERICA, INC.

Troubleshooting ______________________________________________

_________________________________________________________________ 5.106 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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___________________________________________ Major Maintenance Drive motor/ gear case removal and replacement WARNING! Power must be removed by unplugging the battery plug before servicing the motors. drive motor removal



Disconnect the power cables to the motor. Unpack the motor gland and completely remove the wiring and conduit from the motor.



Attach a crane or hoist, capable of lifting the motor, to the eyebolt (Fig. 103) on top of the motor and take up any slack in hoist chain.

 Remove the four bolts that attach the motor to the gear case. Access holes are provided in the frame to the bottom motor bolts.

Cover the reducer opening to prevent foreign matter from entering the gear case. © BUCYRUS AMERICA, INC.

 Lift the motor out of the unit.

Fig. 103: Drive assembly component removal

Drive motor

Gear case Wheel end

drive motor replacement

 Verify that motor pinion gear is installed.



 Clean all mating surfaces (motor and gear case.)  Lower motor into unit and align bolt holes.  Bolt motor onto gear reducer turning pinion gear as necessary to align gears.

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Major Maintenance ____________________________________________  Torque bolts to 240 ft-lb (Lubricated threads) 400 ft-lb (Dry threads)  Reconnect cable leads.  Replace inspection cover.

WARNING! Power must be removed by unplugging the battery plug before servicing the motors. drive motor and gear case removal

 Remove the motor inspection cover and disconnect the power cables to the motor. Unpack the motor gland and completely remove the wiring and conduit from the motor.  Attach a crane or hoist, capable of lifting the motor and gear case and take up any slack in the hoist chain.

 Lift the motor/gear case up just far enough to remove the brake hoses attached to the gear case.  Lift the motor/gear case out of the unit.

WARNING! The correct number of shims to use in between the gear case and planetary wheel end must be determined before installing either (see shim procedure that follows). motor/gear case replacement

 Attach motor to gear case and torque bolts to 240 ft-lb (lubricated threads) 400 ft-lb (dry threads).  Clean all mating surfaces (gear case and frame) thoroughly.  Hoist motor/gear case close to its location in the frame.  Align case and mating flange and pull case squarely into the flange. Torque the mounting bolts to 240 ft-lb (lubricated threads) (400 ft-lb dry threads). The gear case must be squarely against the frame and tight. Misalignment of the motor/gear case to the frame and wheel end will cause premature wear and failure.  Check all oil levels before operating the unit.

_________________________________________________________________ 5.108 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 Remove the bolts that attach the gear case to the frame.

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___________________________________________ Major Maintenance Gear case and brake module disassembly and assembly WARNING! Failure to observe the following procedures may result in bodily injury.

NOTICE! Replace the brake spring assembly each time the disc pack is replaced.

WARNING! Failure of a re-used brake spring shall reduce the brake effectiveness.

WARNING! The retainer plate is under spring force. Remove hydraulic pressure before disassembly. Set the parking brake.

© BUCYRUS AMERICA, INC.

brake spring removal

Disassembly procedure for removal of brake springs:  Loosen the retaining screws (Fig. 104) by consecutively rotating the screws two turns counterclockwise. Continue this procedure until the brake spring pressure has been released.  When the retaining screws have been rotated sufficiently to release spring pressure, the screws can be completely backed out by hand.  Remove the bolts from the spring clamp.

WARNING! The retainer plate is under spring force. Remove hydraulic pressure before disassembly. Set the parking brake.  Remove the spring clamp.  Remove the brake spring.

Fig. 104: Brake pack removal

Retainer plate Retaining screws

Spring clamp

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Major Maintenance ____________________________________________ brake spring installation

Assembly procedure for installation of brake springs (Fig. 105):  Insert the brake spring assembly into the pilot diameter in the brake piston.  Lay the spring clamp over the spring assembly.  Insert all retaining screws into the holes in the spring clamp while aligning the screws with the tapped holes in the housing.  Tighten the screws by hand until all of the screw threads are hand tight.  Tighten the screws 2 turns consecutively until the spring clamp is snug against the housing.  Torque the screws in a crisscross pattern to 46 ft-lb .

Fig. 105: Brake pack installation

“O” Ring

© BUCYRUS AMERICA, INC.

Gear case

Shim (as required)

Spacer

Piston Spring Disc pack

Seal Spring clamp

Screw, self-locking

_________________________________________________________________ 5.110 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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___________________________________________ Major Maintenance Planetary wheel end removal and replacement Planetary Wheel End Removal

 Raise and securely block the Un-A-Hauler's drive wheels off the ground.  Remove the tire-wheel assembly.  Attach a sling and hoist to the wheel end and take up any slack in the sling.  Remove the bolts that secure the wheel end to the frame.

WARNING! The correct number of shims to use in between the gear case and planetary wheel end must be determined before installing either the gear case or the planetary wheel end (see shim procedure that follows).

© BUCYRUS AMERICA, INC.

Planetary Wheel End Replacement

 Clean all mating surfaces (wheel end and frame) thoroughly.  Place the correct number of shims (as determined in the shim procedure) on the gear case.  Using a sling and hoist, raise the wheel end to the frame.  Align the gearing.  Secure the wheel end to the frame with the bolts torqued to 240 ft./ lbs. (lubricated threads) 540 Nm (dry threads). The wheel end mounting bolts should be tightened in the sequence shown in Fig. 106.  Check all oil levels before operating the unit.

Fig. 106: Bolt torque sequence

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Major Maintenance ____________________________________________ Gear case and planetary wheel end shim procedure number 1 (shimming procedure does not apply to Fairfield gearboxes) 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 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.

For an alternate, easier shimming procedure, refer to Gear case and planetary wheel end shim procedure number 3 in this chapter.

To calculate the required amount of shims for the gear case and planetary wheel end proceed as follows (Fig. 107).  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

_________________________________________________________________ 5.112 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© 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.

BI620982

___________________________________________ Major Maintenance Gear case and planetary wheel end shim procedure number 2 (shimming procedure does not apply to Fairfield gearboxes) 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 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.

For an alternate, easier shimming procedure, refer to Gear case and planetary wheel end shim procedure number 3 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. 107).  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.

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Major Maintenance ____________________________________________

© BUCYRUS AMERICA, INC.

Fig. 107: Gear case and planetary wheel end shim procedure

_________________________________________________________________ 5.114 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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___________________________________________ Major Maintenance Alternate gear case and planetary wheel end shim procedure number 3 (shimming procedure does not apply to Fairfield gearbox) 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 from 0.005” to 0.030” (loose).

NOTICE! The following procedure is an alternate, easier procedure that can be used instead of Procedure 1 or 2.

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. © BUCYRUS AMERICA, INC.

 1. To determine the correct number of shims required to fill the gap between the wheel end mounting surface and the brass sleeve: use a straight edge across the wheel end mounting surface on the wheel well plate on the UnA-Hauler® tractor frame. Add the correct number of shims to fill gap between sleeve and appropriate straight edge being used.  2. Each shim is 0.025” thick. For example, if gap is 0.125” total, this will require five shims to fill this gap. Once you have determined the correct number of shims to fill gap, then remove the shims from the pinion shaft. Make certain during the process of determining the proper number of shims that the straight edge is resting against the mounting surface as you shim it outward. Do not have any gaps between the mounting surface and the straight edge during this process and make sure the sleeve is pushed back into the reducer until there is no slack present.  3. After removing the shims, record measurement. For example 0.125”, equates to five shims total as shown in the example above.  4. Document the measurement that is stamped on the mounting face of the wheel end. For example, a measurement of 0.083” could be a typical measurement.  5. Subtract stamped wheel end measurement from the total number of shims recorded from the above process. establishing the gap to be filled. For example 0.083” subtracted from 0.125” equals 0.042”. This means one shim needs to be added behind the sleeve. This will leave a clearance of 0.017”. Proper clearance of 0.005” to 0.030” must be maintained . ______________________________________________________________ A6474X257

VTVI/04

5.115

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Major Maintenance ____________________________________________

© BUCYRUS AMERICA, INC.

Fig. 108: Gear case and planetary wheel end shim procedure 3

_________________________________________________________________ 5.116 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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___________________________________________ Major Maintenance False bottom/ejector cylinder replacement WARNING! Because you will be working in between the false bottom and the front of the rear (payload) section, you must completely shutdown the unit (see shutdown procedure) and disconnect the battery plug to prevent accidental movement of the false bottom. to remove false bottom

The ejector blade/false bottom assembly is operated by three hydraulic cylinders - one on the ejector blade and two on the false bottom.  Extend false bottom to within 152 mm to 304 mm from the end of the machine (by hand if necessary).  Shutdown the machine.  Remove false bottom cylinder covers.

© BUCYRUS AMERICA, INC.

 Remove bolts (4 each) from false bottom cylinder clevis (2) located in outer end of false bottom.  Start-up machine and fully extend false bottom cylinders. (Note: Be sure all persons are away from the false bottom before startup). The cylinders will push out the clevises out from the false bottom exposing the pins.  Shutdown the machine.  Remove pins from rod end clevis that are now exposed.  Start up machine and retract false bottom cylinders.  Shutdown machine.  Remove cylinder end pins and remove false bottom cylinders.

NOTICE! A "port-a-power" unit can be used to press the cylinder end pins out from the false bottom cylinders by inserting the unit between the rear section frame and the pin.

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Major Maintenance ____________________________________________ Fig. 109: False bottom and ejector blade assembly

Cylinder pins

False bottom cylinder

Ejector blade cylinder

Access hole

False bottom cylinder clevis

False bottom cylinder

to install false bottom cylinders

Ejector blade

False bottom

 Slide false bottom cylinders through the access holes in the rear of the false bottom.  Connect the base end of the cylinder to the cylinder clevis at the front of the false bottom using the false bottom cylinder pins.  Connect the hydraulic hoses to the false bottom cylinders.  Start the machine and very slowly extend the false bottom cylinders until the rod end of the cylinder extends out through the access hole in the false bottom.  Attach a rear false bottom cylinder clevis to each false bottom cylinder.  Slowly retract the false bottom cylinders, pulling the clevises back to their mounting holes in the false bottom.  Bolt the clevises to the false bottom.

_________________________________________________________________ 5.118 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Cylinder pins

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___________________________________________ Major Maintenance Accumulator operation and precharging procedure operation

The accumulator used in the Un-A-Hauler’s braking system is a hydropneumatic bladder accumulator working essentially as a fluid pressure storage chamber. Incompressible fluid (hydraulic oil) is stored against a compressible force of gas (nitrogen) to act as a secondary source of pressure.

© BUCYRUS AMERICA, INC.

The flexible rubber bladder in the accumulator shell is precharged to 40 bar with nitrogen gas. If the fluid pressure in the accumulator is less than 40 bar, the accumulator charging valve opens, allowing the hydraulic pump to force hydraulic oil into the fluid chamber of the accumulator. As fluid is forced into the chamber, the nitrogen gas in the bladder compresses until the gas pressure becomes equal to the system pressure. At 130 bar the accumulator charging valve closes until the fluid pressure has dropped back to below 100 bar.

WARNING! Do not disconnect any hoses in the brake system until all pressure has been relieved and the “accumulator” gauge indicates "0” bar. precharging bladder

 Mount hose assembly gland nut on pressure regulator. Use "oil pumped or dry nitrogen" which is commercially available (Reference Fig. 110).

WARNING! Do not use oxygen or any gas other than nitrogen.  Attach swivel connector of hose assembly to gas valve. Hand tighten sufficiently to compress gasket swivel connector in order to prevent gas leakage.  Pre-charge bladder slowly to about 0.68 bar before completely tightening the valve stem nut. Use a second wrench on the valve stem flats to react the torque applied to the stem nut.  Proceed to inflate accumulator to predetermined pressure (40 bar) by slowly opening the pressure regulator valve on nitrogen cylinder, closing it occasionally to allow needle on pressure gauge to stabilize (thus giving accurate reading of pre-charge pressure).

When correct pre-charge has been reached, close pressure regulator valve on nitrogen cylinder securely.

WARNING! Do not exceed 55 bar precharge pressure. 

Bleeder valve can be used to let out any gas pressure in excess of desired pre-charge.



Replace dynaseal and valve guard.

______________________________________________________________ A6474X257 VTVI/04 5.119

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Major Maintenance ____________________________________________ Fig. 110: Precharging and recharging accumulator

Pressure gauge

Cap

NOTICE! For recharging only. recharging bladder

 Exhaust all hydraulic pressure from the system. Remove valve guard and dynaseal (Fig. 110). Then, follow "Precharging bladder" steps.

_________________________________________________________________ 5.120 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Accumulator

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___________________________________________ Major Maintenance 2-Wheel assist pump removal procedure remove 2-wheel assist pump



Attach a crane or hoist, capable of lifting the pump and take up any slack in hoist chain.

 Remove the bolts that attach the pump assembly (Fig. 111) to the gear case.  Lift the pump assembly out of the unit.

Fig. 111: 2-Wheel assist pump

© BUCYRUS AMERICA, INC.

Assist pump

Gear case

Drive motor

______________________________________________________________ A6474X257 VTVI/04 5.121

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Major Maintenance ____________________________________________ Rear (hydraulic) wheel motor removal and replacement. rear wheel motor removal

 Remove the tire/wheel unit.  Mark (for later identification) and remove the hoses from the hydraulic motor. Cover the hose ends to prevent foreign matter from entering while disconnected.  While the hoses are disconnected, verify proper operation of the hydraulic system connected to the motor. If problems are found in the hydraulic system, correct the problems and reconnect the motor.  Plug the working pressure and casing oil connections after detaching the hoses.

 Remove the bolts that hold the hydraulic wheel motor (Fig. 112) to the frame and lift the assembly away from the frame.  Drain the oil from the hydraulic motor.  Clean the motor externally and place the assembly on a clean working surface.

Fig. 112: Rear hydraulic motor Wheel assembly (ref.)

Wheel motor

Rear frame (ref.)

_________________________________________________________________ 5.122 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 Attach a hoist and sling to the motor assembly and take up any slack in the sling.

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___________________________________________ Major Maintenance WARNING! Thoroughly cleaned mating surfaces, bolts, bolt holes and accurately torqued mounting bolts are essential for proper operation of the rear (hydraulic) wheel motors. Mounting bolts used in this assembly should be cleaned and coated with a threadlocking compound and tightened to the "lubricated" torque value. rear wheel motor replacement

 Thoroughly clean all mating surfaces and bolt holes, removing all dirt, oil, metal particles and paint.  Bolt the wheel hub to the motor and tighten the bolts to 300 ft-lb (lubricated), 640 ft-lb (dry).  Using a hoist and sling, move the wheel motor assembly to the frame. Bolt the motor assembly to the frame and tighten the bolts to 240 ft-lb (lubricated), 400 ft-lb (dry).  Fill the motor with clean hydraulic oil.

© BUCYRUS AMERICA, INC.

 Reconnect the hydraulic hoses to the wheel motor. wheel motor

BBC06 Series with brakes mechanical disconnect procedure (when supplied with rear wheel brakes)  Remove the M20 plug from the center of the brake cover using an allen wrench.  Use an M16 x 60 ”full thread” bolt with a nut attached to mechanically release the brake.  Insert the release bolt into the brake piston through the hole in the brake housing. Screw the bolt in by hand until it bottoms out in the brake piston. Note: the brake piston has a threaded hole to accept the M16 bolt.  Tighten the release nut on full turn while holding the bolt still to release the brake.  The brake will not re-engage until the bolt is released.

Fig. 113: Wheel motor

Nut

Bolt

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Major Maintenance ____________________________________________ Tire/wheel installation procedure The following installation procedures are for general guidance when installing a tire/ wheel assembly (Fig. 114) 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.

_________________________________________________________________ 5.124 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Fig. 114: Tire/ wheel assembly

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___________________________________________ Major 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.

______________________________________________________________ A6474X257 VTVI/04 5.125

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Major Maintenance ____________________________________________ Fig. 115: 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.

_________________________________________________________________ 5.126 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Fig. 116: Torque patterns

BI620982

___________________________________________ Major 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.

______________________________________________________________ A6474X257 VTVI/04 5.127

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Major Maintenance ____________________________________________ Hydraulic pump and motor removal and replacement WARNING! Power must be removed by unplugging the battery plug before servicing the motors. motor removal



Remove the pump motor strap (Fig. 117) and all hoses connected to the pumps. Disconnect the power cables to the motor. Unpack the motor gland and completely remove the wiring and conduit from the motor.



Attach a crane or hoist, capable of lifting the motor, to the eyebolt on top of the motor and take up any slack in hoist chain.

 Remove the bolts that attach the motor assembly to the frame.  Lift the motor assembly out of the unit. © BUCYRUS AMERICA, INC.

Fig. 117: Drive assembly component removal

Pump motor

Main pump

Auxiliary pump

drive motor replacement

 Verify that motor pinion gear is installed.  Clean all mating surfaces.  Lower motor into unit and align bolt holes.  Bolt motor onto frame and attach motor strap.

_________________________________________________________________ 5.128 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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___________________________________________ Major Maintenance Tailgate assembly removal procedure WARNING! Because you will be working close to the false bottom, you must completely shutdown the unit (see shutdown procedure) and disconnect the battery plug to prevent accidental movement of the false bottom. remove tailgate assembly

The tailgate assembly (Fig. 118) is operated by two hydraulic cylinders.  Fully extend the tailgate by pressing the ejector extend button on the right control handle until the tailgate lowers fully.  Shutdown the machine. 

Fully support the tailgate assembly.

© BUCYRUS AMERICA, INC.

 Remove upper bolts and pin from tailgate cylinder clevis (2) located in outer end of tailgate.  Start-up machine and fully retract the tailgate cylinders. (Note: Be sure all persons are off of and away from the machine before startup). The cylinders will pull out the clevises out from the tailgate assembly.  Shutdown the machine.  Remove lower pins and bolt from the tailgate assembly.  Remove tailgate.

Fig. 118: Tailgate assembly

Upper bolt and pin

Lower bolt and pin

______________________________________________________________ A6474X257 VTVI/04 5.129

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Major Maintenance ____________________________________________ Battery lift assembly removal procedure WARNING! Because you will be working with the battery lift cylinders, you must completely shutdown the unit (see shutdown procedure) and disconnect the battery plug to prevent accidental movement of the cylinders. battery lift assembly

The battery lift assembly (Fig. 119) is operated by two hydraulic cylinders - one on each side.  Raise battery assembly to top position. 

Attach a crane or hoist, capable of lifting the assembly, to the assembly and take up any slack in hoist chain.

 Shutdown the machine.

 Remove the cylinder pins that attach the lift assembly to the cylinders.  Remove the lift pins from the assembly  Lift the assembly out of the unit.

Fig. 119: Battery lift assembly

Cylinder pin

Lift pin

Cylinder pin

Lift pin

_________________________________________________________________ 5.130 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

 Remove hydraulic hoses to the lift pins cylinders.

BI620982

___________________________________________ Major Maintenance Pedal assembly removal procedure pedal assembly

The pedal assembly (Fig. 120) can be adjusted and removed as required.  Shut down the machine.   

Attach a crane or hoist, capable of lifting the assembly and take up any slack in hoist chain.

Disconnect the accelerator connections.

 Remove the hydraulic hoses from the brakes.  Remove adjustment bolts from the assembly.  Remove the bolts that attach the assembly to the frame.

© BUCYRUS AMERICA, INC.

 Lift the assembly out of the unit.

Fig. 120: Pedals and carrier assembly Adjustment bolts Assembly bolts

______________________________________________________________ A6474X257 VTVI/04 5.131

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Major Maintenance ____________________________________________ Canopy removal procedure DANGER! Do not operate the machine with the canopy removed. You or other personnel could be seriously injured. canopy assembly

The canopy (Fig. 121) can be adjusted and removed as required.  Shut down the machine. 

Attach a crane or hoist, capable of lifting the canopy, and take up any slack in hoist chain.

  Remove the bolts that attach the canopy to the frame.  Lift the assembly out of the unit.

Adjustment bolts © BUCYRUS AMERICA, INC.

Fig. 121: Canopy assembly

Adjustment bolts

_________________________________________________________________ 5.132 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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_______________________________________________________________

6

Technical data

________________________________________________________________

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________________________________________________________________

_________________________________________________________________

BI620982

_______________________________________________ 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 CH816C AC UN-A-HAULER ® Technical data sheet

© BUCYRUS AMERICA, INC.

general

performance

Overall length: Overall width tractor (extended deck option): Overall width tractor (w/out extended deck): Overall width trailer: Wheelbase: Weight (empty less battery): Weight (w/ 120-SS100-17 battery, 192 KWh): Weight (w/ 120-SS125-17 battery, 240 KWh): Design gross vehicle weight: w/ 120-SS100-17 battery, 192 KWh: w/ 120-SS125-17 battery, 240 KWh: Cubic feet capacity (max. payload—calculated) heaped with no sideboards: heaped with 6” sideboards: Ground clearance with 44” tires: with 50” tires: Canopy height (min) with 44” tires: with 50” tires: Trailer height with 44” tires at top of false bottom: with 50” tires at top of false bottom: Trailer frame height (with 44” tires):

approx. 40’ 5” approx. 11’ 2” approx. 10’ 10” approx. 10’ 8” approx. 19’ 9” approx. 59,580 lbs approx. 81,500 lbs approx. 85,000 lbs

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. 117,500 lbs approx. 121,000 lbs approx. 636 ft³ approx. 707 ft³ approx. 12” approx. 14” approx. 52” approx. 54” approx. 48” approx. 53” approx. 44”

approx: 0-6 mph approx: 24 seconds approx: (+) 15° approx: (-) 10°

______________________________________________________________ A6474X257 VTVI/04 6.3

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Technical data ________________________________________________ Table 9: Gauge chart for CH816C AC and CH816HC AC Un-AHaulers lbs/in2

System pressure gauge Normal Reading

2800

Minimum reading

2700

Maximum reading Normal Reading Minimum reading

1250 1200

Maximum reading

1300

lbs/in2

Margin pressure Normal Reading Minimum reading Maximum reading

Optional (Brake pressure gauge -- Rear) Normal Reading Minimum reading Maximum reading

500 350 500

lbs/in2 325 355 295

lbs/in2

Accumulator gauge Normal charging range Minimum reading Maximum reading

Gauge chart for CH816HC AC Un-A-Hauler

3000

lbs/in2

Brake pressure gauge (Front)

1500 - 1800 1350 2000

lbs/in2

System pressure gauge Normal Reading Minimum reading Maximum reading

2800 2700 3000

lbs/in2

Brake pressure gauge (Front) Normal Reading Minimum reading Maximum reading

1250 1200 1300

lbs/in2

Margin pressure Normal Reading Minimum reading Maximum reading

Optional (Brake pressure gauge -- Rear) Normal Reading Minimum reading Maximum reading

500 350 500

lbs/in2 1000 950 1050

lbs/in2

Accumulator gauge Normal charging range Minimum reading Maximum reading

1500 - 1800 1350 2000

_________________________________________________________________ 6.4 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Gauge chart for CH816C AC Un-A-Hauler

BI620982

___________________________________________ 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 10: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

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 11: 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

______________________________________________________________ A6474X257 VTVI/04 6.5

BI620982

Tightening torques ____________________________________________ Table 12: FSR hex bolts (SAE 5 and 325 steel) 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”

4,504 ft-lbs

2 ¼”

6,497 ft-lbs

2 ½”

7,144 ft-lbs

2 ¾”

12,092 ft-lbs

3”

15,744 ft-lbs

Table 13: Socket, flat, & button head cap screws (Steel only) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting 26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs 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

_________________________________________________________________ 6.6 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Nominal diameter

BI620982

___________________________________________ Tightening torques Table 14: Untreated screw, black finish (Coarse thread) Property class

Torque

5.6 8.8 10.9 12.9

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

Torque

5.6 8.8 10.9 12.9

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

Torque

5.6

Nm

470

Ft-lbs 8.8 10.9 12.9

Ma

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

635

865

1111

1440

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

______________________________________________________________ A6474X257 VTVI/04 6.7

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Tightening torques ____________________________________________ Table 15: 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

Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5

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

Table 15: 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

_________________________________________________________________ 6.8 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Table 15: Untreated screw, black finish (Fine thread, continued)

BI620982

___________________________________________ Tightening torques Table 16: 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 16: 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

______________________________________________________________ A6474X257 VTVI/04 6.9

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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 17: 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 17: 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

_________________________________________________________________ 6.10 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Property class

BI620982

___________________________________________ 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.

______________________________________________________________ A6474X257 VTVI/04 6.11

BI620982

Permissible media ____________________________________________ Approved suppliers:

Supplier

Brand name

1

Amoco Oil Company

Amoco AW oil No.68

2

Gulf oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

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

_________________________________________________________________ 6.12 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Table 18: Anti-wear hydraulic oil (Spec 100-1)

BI620982

___________________________________________ Permissible media

© BUCYRUS AMERICA, INC.

Table 19: 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

13

Conoco Inc.

608 Almosal Vari-Purpose Gear Lubricant 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

______________________________________________________________ A6474X257 VTVI/04 6.13

BI620982

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 21: 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

_________________________________________________________________ 6.14 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Table 20: Extreme pressure motor bearing grease (Spec. 100-3)

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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

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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

_________________________________________________________________ 6.16 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Table 23: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

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© BUCYRUS AMERICA, INC.

Table 24: 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

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1

Amoco Oil Company

American Industrial oil No. 150

2

Gulf Oil

Harmony 150

3

Mobil Oil Corporation

DTE Oil EX. Heavy

4

Chevron U.S.A.

5

Sun Oil Company

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 26: 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

_________________________________________________________________ 6.18 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

© BUCYRUS AMERICA, INC.

Table 25: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

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© BUCYRUS AMERICA, INC.

Table 27: 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 28: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

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_________________________________________________________________ 6.20 Bucyrus America, Inc. – Model CH816C AC UN-A-HAULER ®

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For your information

________________________________________________________________

BI620982

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BI620982

_________________________________________________ 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 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 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

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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 America, Inc. – Model CH816C AC UN-A-HAULER ®