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ThismanualisintendedtoprovideGENERALproductinformationfor theModelsCH810B,CH816B,CH816LB,andCH818 UN-AHAULERS® .Theillustrations,descriptionsandprocedurescontainedinthispublicationapplyonlytothesemachines.BucyrusAmerica,Inc.reservestherighttorevisemodelsanddesignswithoutprior notice.
This UN-A-HAULER® wasmanufacturedundertheguidelines,proceduresandrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart0, Part75forundergroundcoalmines,andotherapplicablenon-U.S. regulatoryagencystandards.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofBucyrusAmerica, Inc.,andtheseregulatoryagencies,oranyrepairorreplacementof partscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidate theseapprovalsandrenderthisunitunsafetooperate.
StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusAmerica,Inc.Service Representative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
2. Yoursafety 3. 4. 5. Operation Aboutthismanual Aboutthismanual Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork applicableoperatingmanual
machinetype
newoperationmanual
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BUCYRUS – Model,CH810B,CH816B,CH816LBandCH818
SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine. Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor? Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.
Everypersonworkingonthefaceorintheintersectionbetweenface andentryorintheentrymustreadthisoperatingmanual.
Thisincludespersonswho:
■ areinchargeoftransport
■ preparetheriseheading
■ performassembly/disassemblywork
■ operatethemachine
■ eliminatefaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/or
■ supervisetheactivitiesjustindicated.
Whatisthepurposeofthisoperatingmanual? Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Charactersandsymbolsused Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER! Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING! Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION! Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE! Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.
IMPORTANT! Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.
Beforestartingtowork Yoursafety Thischapterprovidesvitalinformationforyoursafety. Payspecialattentiontothischapter.Thesafetyinstructionsandrules ofprocedurewillhelpyoutoavoidhazardoussituationsandtoperform thenecessaryworkassafelyaspossible.
Themachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. Youandotherscanneverthelessbeexposedtodangeroussituations e.g.asaresultofenvironmentalinfluences,machinedamageoroperatorerrors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.AllmodificationsandchangesmustbeapprovedbyBucyrusAmerica,Inc.
UseonlyoriginalsparepartsfromBucyrusAmerica,Inc.Notethatthe useofpartsfromothermanufacturerswillvoidtheguarantee.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations:
■ ofthemine.
■ oftheMinesInspectorand
■ oftheminingsupervisoryauthorities
Pleasereadalsotheoperatingmanualsofthecomponentsrequiredfor operation,e.g.ofgearboxes,electricmotors,etc.,carefullyandthoroughly.Clarifyanyquestions before startingwork.
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training Personnel Operation Themachinemayonlybeoperatedbyqualified,trainedpersonnel. Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit. Readingoftheoperationmanual,especiallythechapteronsafety,shall constituteapartofthistraining.
Youmusthaveadequateknowledgeofthe
■ mechanics,
■ hydraulicsand
■ controlengineering andmustbeabletoprovethisknowledge.
Installationandrepair Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.
Installationandrepairworkon:
■ safetycomponents(pressurereliefvalves,extinguishers,etc.)
■ theelectrics(motors,controllers,etc.)
■ thehydraulics(controls,cylinders,etc.)
mayonlybecarriedoutbyserviceengineersfromBucyrusAmerica, Inc.orbyspeciallyqualifiedpersonnelofthemine.
Operatingconditions Intendeduse TheUN-A-HAULER ® hasbeendesignedandmanufacturedpurelyfor transportingofminedmaterialfromacontinuousminertothemain conveyingsystemfortransportingoutside.
Intendedusesinclude:
■ thetransportofminedmaterialbetweencontinuousminerand mainconveyingsystem.
Unauthorizeduse Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.
Safetyinstructions Generalrules:
Alwaysworkwithfullconcentration.
Familiarizeyourselfwithyourworkingenvironment.
Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).
Informyourcolleaguesof:
■ yourexactlocation.
■ theworkyouareperforming.
■ thetimethatyouwillprobablyrequire.
Startthemachineonlywhenitisinagoodandsafeoperatingcondition andallprotectivedevices,e.g.EMERGENCYSTOPdevices,cover plates,etc.arecorrectlyinstalled.
Observetheacousticandopticalstart-upwarningsofthemachine.
Observethesymbolplatesonthemachine.
PresstheEMERGENCYSTOPswitchimmediatelyintheeventoffault orirregularitiesinoperation.Reportanypeculiaritytoyoursuperiorso thatnecessarymeasurescanbetakenimmediately.
Disconnectthebatterywhileperforming:
■ maintenancework
■ inspectionwork
■ repairwork
Cordonoffyourworkingareawidelyforthemachine.
Neverallowpartsofyourbodytocomebetweenpartswhichcould move,suchase.g.:
■ falsebottoms
■ pivotpoints
■ batterylifts
Connectthesteeringlockoutdevicebeforeperformingmaintenanceor repairsonthemachine.
Safetyinstructions Storageandtransport Maintaintheprescribedstorageperiodsandobservetheinstructions forstorage.
Donotstorematerialsorpartsinthetravelwayorinyourworking area.
Informthepersonsinvolvedabouttheintendedtransportrouteandthe anticipateddurationofthetransport.
Ensurethatthetransportsafetydevicesarecorrectlyfitted.
Fixallmovingpartswithtransportlocks.
Neverstandunderunsupportedpartsorsuspendedloads.
Connecttheliftingequipmentonlytothepointsofattachmentprovided forthatpurpose.Observethedifferentloadlimitsoftheattachment points.Alsoobservetheinstructionsonthetransportsheet.
Onlyusemeansofattachmentwhichareingoodconditionandhave beendesignedfortheloadstobehandled.
Forroundcomponentsusetransportstraps,only.Neverusechainsor steelcablesforthispurpose.
Donotdamagethetreatedorpolishedsurfacesofshafts,sealingsurfaces,etc.
Whenusingmobilehandlingsystemsfortransportmakesurethatthe centerofgravityisaslowaspossible.
Pre-startinspection Readthisentireguidebeforeattemptingtooperatethismachine.
Inspectthemachineandhaveanymalfunctioning,brokenormissing partscorrectedorreplacedbeforeuse.
Verifythatallmaintenancehasbeenperformed.
Verifythatallinstructionandsafetytagsareinplaceandreadable. Theseareasimportantasanyotherequipmentonthemachine.
Cleananyforeignmaterialfromtheoperator’scompartment.
Thismachinewasshippedfromthefactoryequippedwithaprotective canopy.Thecanopymustbesecurelyinplacebeforeoperatingthe unit.
Overviewofsafetyinstructions Installationandstart-up Oninclinedfacessecureallcomponentpartsbychains,e.g.tothesupport.
Whenworkingwithoils,greasesandotherchemicalsubstances,observethesafetyregulationsapplicabletotheproduct.
Disposeofcleaningrags,etc.whichhavebeensoiledwithoil,grease orotherchemicalsubstancesinanenvironmentallysafemanner.
Whenstartingupmachine,donotoperateanycontrolslocatedinside theoperator’scompartmentfromoutsidethecompartment.
Followthestartingprocedureinstructionsinchapter5ofthismanual.
Donotoperateanylevers,pedalsorcontrolsifanyoneisinthehazard zone.(SeeHazardzoneinChapter5ofthismanual)
Operation Operatethemachineonlyifyouhaveaprofoundknowledgeofthecontrolelementsandtheirfunctions.Itisnecessarythatyouhavebeen tasktrainedontherespectiveUN-A-HAULER ©
Beforestart-up,ensurethattherearenopersonsorobstructionsinyour lineoftravelorinthearticulationareawhensteeringtheunit.
Checkthatallprotectivedevicesareinstalledonthemachineandfunctionproperly.
Cleantheoperator’scompartmentatregularintervals.Ensurethatthe operatingsymbolsarelegibleinordertoavoidanyoperatorerrorsand resultingaccidents.
Neverclimbonto,orclimboutofthemachinewhileitisinmotion.
Donotoperatethemachinewithanypartofyourbodyoutsideofthe operator’scompartmentinordertopreventbodypartsfrombeing crushedbetweenthemachineandoutsideobjects.
Useextremecautionwhentravelinginclosequartersorincongestedor blind-travelareas.Thewarninggongshouldbesoundedtoalertpersonnelofyourmovement.
Nevercarrypassengerstopreventthepassengersfrombeingthrown offorcrushedbetweenthemachineandoutsideobjects.
Alwaysfollowallsafetyrulesofeachparticularminewhenoperating themachine.
Ifproblemsormalfunctionsareencounteredwhileoperatingtheunit,it mustbeproperlyshutdownandtheproblemcorrectedimmediately.
Safetyinstructions operator’scompartment
Stopping Donotleavetheoperator’scompartmentwiththeunitrunning.Always properlyshutdowntheunitbeforeleavingtheoperator’scompartment.
Alwaysparktheunitonsolid,levelground.Ifthisisnotpossible,park theunitatarightangletotheslopetopreventaccidentalmovementof themachine.
Useproperflags,warningsorbarrierswhenparkinginareasoftraffic. Chockallfour(4)wheelsinbothdirectionswheneverpossible.
Maintenanceandrepair Besuretoobservetheprescribedmaintenanceandinspectionintervals.
Informthesupervisorypersonnelandthefacecrewofanymaintenanceandrepairoperations.Givetheminformationontheintended operationsandtheanticipatedduration.
Secureyourworkingareaoverawiderange,inordertoavoidendangeringotherpersons.
Disconnectthebatteryfromthemachinetopreventunauthorizedand unintentionalrestarting.
Protectyourworkareaagainstfallingrocks.
Disconnectthebatteryfrommachinetopreventfromrestartingbefore replacinganydefectivecomponents.
Passdefectivecomponentsremovedonforservicingwithoutdelayin ordertopreventthesepartsbeingreinstalledelsewhere.
Useonlysparepartswhichsatisfythespecifiedtechnicalrequirements. ThisisonlyensuredwithoriginalBucyrusAmerica,Inc.spareparts. Pleaserefertothesparepartslistsfortheordernumbers.
ForraisingtheUN-A-HAULER ® useonly:
■ cribblockswithadequateload-holdingcapacity.
■ hoists,jacksorcraneswithadequateload-carryingcapacity.
Avoiddirectcontactbetweentheskinandhydraulicfluids. Hydraulicfluidcanpenetratetheskinandcauseseriousinfection.
Neverusehydraulicfluidforrinsingorcleaning.Hydraulicfluidrepresentsaveryseriousdangertohealth.
maintenance,repair
Safetyinstructions Onlypersonswhohaveandcandemonstrateaspecialknowledgeof hydraulicsareallowedtoworkonthehydraulicsystem.
Avoid,wheneverpossible,servicing,cleaningorexaminingthemachineincongestedareas.
Avoid,wheneverpossible,servicingorprovidingmaintenancetothe unitunlessthewheelsarechockedandsteeringlockoutdeviceisconnectedtopreventaccidentalmovementoftheunit.
Donotaltertheelectricalorhydraulicsettingsfromthatindicatedinthis manualorassetatthefactory.
Alwaysreplacedamagedorlostdecalsandmetalinstructionplates.
Disconnectthebatterywhenworkingwiththeelectricalsystem,or whenweldingontheunittopreventelectricalshock.
Besurethebatteryareaiswellventilated(clearoffumes)whenitis necessarytoconnectbatterycharger.Fumesfromthebatterycould ignitefromasparkandexplode.
Alwaysfollowallsafetyproceduresofeachparticularminewhenperformingmaintenance.
Itisimportantthatanyprocedurenotspecificallyrecommendedinthis guidebethoroughlyevaluatedfromthestandpointofsafetybeforeitis implemented.
Someillustrationsinthismanualshowguardsorcoverpanelsremoved forpurposesofclarity.Neveroperateunitwithoutguardsorcoverpanelsinplace.
Carryoutavisualinspectionofallthehydrauliccomponentsatregular intervals.Inparticularcheckthat:
■ thehosesarenotpinchedortrapped.
■ thehoseshavenobubblesorblisters.
■ thehoseoroutersheathesofthehosearenotabnormallyrigidor hard.
■ theoutersheathofthehosesisnotdamaged.
■ theconnectorsaresecurelyinsertedintothesockets.
■ theconnectionsareleak-tight.
Ensurethatnodirtentersthehydraulicsystemduringrepairwork.Dirt inthehydraulicsystemcancauseseriousdamageinthewholesystem! Flushoutthehydrauliclinesthoroughlybeforeconnecting.
Safetyinstructions Ifhydraulichosecouplersaredifficulttodisconnectorcannotbedisconnected,thehydrauliclinemaystillbepressurized.Besuretodepressurizethelinebeforedisconnectingcouplers.
Securetheconnectorsofthehydraulicelementsonlywiththeproper couplingclamps.Alwaysfastentheclampscompletelyandwithboth sides.Neverusenails,wireorsimilarmaterialsforsecuring.
Afterfinishingrepairwork,checkallconnectorsandconnectionsfor leaksbeforepressurizingthesystemagain.
permissiblehoses
Useonlyhydraulichosesapprovedfortheprevailingpressures.
Donotuseanyhydraulichoseswithdamagedconnectorsorwornorings.
Replacehydraulichosesonlywithhosesofthesameorahigherquality.
Observethedateofmanufacturestampedonthehydraulichoses. Neverusehydraulichoseswhicharemorethan2yearsold,evenif theyhavenovisiblesignsofdamage.
Nevertrytoholdajumpinghydraulichose.Depressurizethelinein questionimmediately.
Nevertrytorepairdamagedhydraulichoses.
Replacehydraulichosesatthefirstsuspicionofdamage.
layinghydraulichoses
Safetyinstructions Laythehydraulichosesproperlybehindthebracketsandclampsprovidedforthem.
Alwayslayhydraulichosessothey:
■ alwayshavealittleslack.
Fig.1:Layinghydraulichoses,slack Right Wrong
■ arenottwisted.
Fig.2:Layinghydraulichoses,twisting Right Wrong
■ arenotbentdirectlybehindtheconnections. (distancemin.1.5xnominaldiameter).
Fig.3:Layinghydraulichoses,bending Right Wrong
Safetyinstructions ■ alwayshavealittleslack.
Fig.4:Layinghydraulichoses,crossing Right Wrong
■ arenotkinked.
■ donothavetowithstandtensilestrains.
■ areprotectedagainstthermalradiation.
■ areaccessibleatalltimes.
Pushhydraulichosesintothesocketsonlybyhand.Nevertrytodrive thehydraulichosesinwithatoolasthiswilldamagetheconnections.
Wheninstallingthehydraulichoses,ensurethattheycannotbe:
■ tornout,
■ kinked,
■ crushed,
■ drivenoveror
■ twistedbymovementofthemachine.
Fig.5:Layinghydraulichoses,connectionsonmovingparts
Overviewofthesafetyinstructions Thisisasummaryofallthesafetyinstructionswhichhavetobeobservedinthefollowingchapters.Thissummaryisintendedonlytogive youanoverviewofalltheinstructions.Insomecases,thereisnologicalrelationshipbetweentheindividualinstructions.
Chapter3:Storageandtransport Instructionsonthestorageofconcentratesforhydraulicfluidscanbe found,ifrequired,inchapter6inthisoperatingmanual.
IMPORTANT! Takecaretoinsurethatnewsuppliesarestoredseparatelyfrom existingstockandthatremovaltakesplaceonthe“firstin,first out”principle.
Additionalinformationonthedimensionsandweightscanbefoundin chapter6inthisoperatingmanual.
WARNING!
Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads. Useonlysuitableloadhandlingdevices.
Chapter4:Installation CAUTION!
SeriousdamagecanbecausedtotheUN-A-HAULER ® asaresult ofincorrectinstallation. Theunitshouldthereforeonlybeinstalledundertheinstructionof specialistsfromBucyrusAmerica,Inc.
IMPORTANT! Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplanestablished
NOTICE!
Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:
NOTICE!
Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
Overviewofsafetyinstructions WARNING!
Ifeitherofthefiresuppressionactuatorsisactuated,thesystem mustbecompletelyrechargedwithdrychemicalsandexpellants.
DANGER!
Donotoperatethemachineanyoftheguardsorcoversremoved. Youorotherpersonnelcouldbeseriouslyinjuredfrommovingor rotatingparts.
Chapter5:Operation WARNING!
BeforeoperatinganyleversorpedalsontheUN-A-HAULER ® alwaysmakesurenooneisinthehazardzone.Donotoperateany leversorpedalsfromoutsidetheoperator'scompartment.
CAUTION!
Thespeedswitchfootpedalshouldnotbedepressedatthesame timeasthefootbrakepedalorwhentheparkingbrakesareset. Todosomayoverloadthetrammotorsandcouldshortentheir usefulness.TheUN-A-HAULER ® isprovidedwithoverloadprotection,butcontinuedabusecanshortenmotorlife.
IMPORTANT!
FormoredetailedinstructionsontheBUC2000display,referto theBUC2000DualMotorTroubleshootingguide.
WARNING!
Themachinecircuitbreakerde-energizestheelectricalcontroller andmotors.However,electricalpowerisstillpresentinsidethe controllertothecircuitbreaker.Ifthecircuitbreakerinsidethe controllerrequiresservice,thebatterycircuitbreakershouldbe turnedtothe"OFF"positionorthebatteryplugdisconnectedfrom thebattery.
WARNING!
Allelectricalswitchesintheoperator'scompartmentmustbein the"OFF"positionbeforemovingthebatterycircuitbreakerlever tothe"ON"position.
WARNING!
Oncethebreakerhastripped,itwillnotstayinthe“on”position withoutfirstbeingmovedtothe"RESET"position,andthento "ON".
WARNING!
Alwaysmakesurethebatteryholddownisengagedaftereach batterychangeanddisengagedpriortochangingbatteries.The batteriesmaybedamagedifleftunsecuredduringtrammingoperations.
Overviewofsafetyinstructions WARNING!
Beforemovingtheejectorblade/falsebottomcontrollever,verify thatnoonehasanypartofhisbodybetweentheejectorblade/ falsebottomandthefrontoftherear(payload)section.Alsokeep anyobstructionsfrombehindtheejectorblade/falsebottomsoit canreturncompletelytothefrontoftherear(payload)section.
CAUTION!
The"BATTERYCHANGER"levershouldonlybeoperatedatabatterychangestation.Thebatterymaybedamagedifaccidentally raisedinalowroofarea.
WARNING!
Thebatterycannotbechangedifthebatteryisnotlevelwhenin theraisedposition.Formoreinformationonhowtochangethe batteryseeBatterychangeprocedureinthischapter.
WARNING!
Neverattempttodisconnectahydraulichosefromthebatteryliftingcylinderswiththebatteryinthe"UP"position.Thiswouldallowthebatterytofallandcouldresultininjury.
WARNING!
Theverticalarticulationcontrolmovesthecenterofthemachine upordownwhileeachendofthemachinemovesupordown (oppositeofthecenter).Makesurenooneisonthemachineor nearthemachinebeforeoperatingthiscontrol.Failuretodoso couldresultintheinjuryordeathofabystanderortotheoperator ifthemachineisusedwithoutacanopy.
WARNING!
Donotactuate“ARTICULATION”functionwhiletrammingthemachineasthiscouldcausethemachinetojamintothetoporbottomcausingdamagetothepassageand/orthemachine.Ifverticaladjustmentisdesired,stopthemachine,makethenecessary adjustment,andthenresumetramming.
CAUTION!
Usecautionwhentravelingdowngrade,exceeding5mph(8kph) withthismachinewillresultintrammotorfailure.
WARNING!
Checkthebatteryconnectionsandthebatterycovers.Theymust beinplaceandlockedtobepermissible.
WARNING!
Neveroperateanyleversorpedalsfromoutsidetheoperator's compartment.
WARNING!
Thisunitisequippedwithacaborcanopy.Becarefulnottohit yourheadwhenenteringorleavingtheoperator'scompartment. Thismachinemustnotbeoperatedwithoutthecanopyinplace.
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Overviewofsafetyinstructions WARNING!
Besurenooneisinthehazardzone(Fig.20)beforeoperatingany leversorpedals.
Nevertrytoadjusttheoperator'sseatwhiletheUN-A-HAULER ® is inmotion.
DonotoperatetheUN-A-HAULER ® withanypartofyourbody outsidetheoperator'scompartmenttopreventhavingbodyparts caughtbetweentheunitandoutsideobjects.
WARNING!
TheUN-A-HAULER ® isequippedwithasolidstatespeedcontroller.Thismeansthatthefartherthespeedswitchfootpedalisdepressed,thefastertheUN-A-HAULER ® willtram.
IMPORTANT! Thetractiveassistcanbeusedasnecessary.However,battery lifewillbeprolongedifthetractiveassistisallowedtoremaindisengagedwhenpossible.
WARNING!
Alwayscheckbeforemovingtheejectorbladeandfalsebottom controllevertomakesurenoonehasanypartoftheirbodybetweentheejectorblade/falsebottomandthefrontoftherear (payload)section.
WARNING!
Neverenterthearticulationareawhilethemachineisrunning. Completelyshutdownthemachineasoutlinedbeforeconnecting thesteeringlockoutdevice.Failuretoobservethisprecaution mayresultininjuryordeath.
WARNING!
Intheeventofanemergency,theUN-A-HAULER ® mayalsobe shutdownbystrikingthepanicstrip.Whenthepanicstripis struck,themachinecircuitbreakerwilltrip.Thisdisconnectsthe motorsandappliestheautomaticemergencybrake.Beprepared forthesuddenstopwhenthepanicstripsarestruck.
WARNING!
TheUN-A-HAULER ® isequippedwithapassivebatteryhold-down system.Thissystemkeepsthebatteryrestingsecurelyonthe framewhiletheUN-A-HAULER ® isinoperation.Thebatteryholddownsystemrequiresnooperatorassistance.However,itisimportantthatthebatterybeproperlyalignedoverthebatterylatch.
NOTICE!
Thebatterytablemustbeplacedonlevelground.
CAUTION!
Besurethatthebatteryisproperlyalignedoverthebatterylatch beforemovingawayfromthebatterytable.
CAUTION!
IfthebatteryisnotcompletelyloweredbeforetheUN-A-HAULER® leavesthebatterychangestation,thebatterymayfallofforhitthe roofandbedamaged.
WARNING!
The"battery"changecontrollevershouldneverbeoperatedexceptatabatterychangestationorwhenit’snecessarytoadjust thebattery'sterrainclearance.Ifthe"battery"changecontrol leverisoperatedinalowroofarea,thebatterymaybedamaged.
WARNING!
Neverattempttodisconnectahydraulichosefromthebatteryliftingcylinderswhilethebatteryisintheupposition.Thiscould causethebatterytofallandcouldresultinseriousinjury.
WARNING!
Beforeperformingmaintenanceonthemachine,disconnectthe electricalpower.Eitherthe batterycircuitbreakerorthemachine circuitbreakermustbeinthe"OFF"position.Ifworkistobe doneinsidetheelectricalcontroller,thebatteryshouldbedisconnected.Alsomakesurethecapacitordischargemoduleindicates thatthecapacitorsaredischargedbeforeworkinginsidethecontroller.Electricalshockandaccidentalmachinemovementcan causeseriousinjuriesorevendeathtoyouorthemaintenance person.
WARNING!
Donotmoveanyhydrauliccontrolleverunlessyouarecertain thateveryoneiscompletelyclearofanymachinemovement.Accidentalmachinemovementcancauseseriousinjuriesoreven deathtoyouorthemaintenanceperson.
WARNING!
Youcouldbeseriouslyinjuredorevenkilledbyfallingloads.Observethesafeworkingloadlimitsofliftingorblockingdevices andkeepasafedistancefromsuspendedloads.
NOTICE!
Ifanyweldingistobedonetomachine,thecircuitbreakersmust beinthe“OFF”positionandthebatteriesdisconnected.Failure todosomaycauseelectricalcomponentdamage.
IMPORTANT!
Thedriveandpumpmotorsdonotrequireperiodiclubrication. Thepumpmotorbearingsaresealed.Thedrivemotorshaveone bearingsealedandtheotherbearingreceiveslubricationfromthe gearcaseoil.
CAUTION!
Donotadjustthehydraulicsystempressuretomorethanthe mainsystemsettingshownonthehydraulicschematicdrawing locatedinthereplacementpartsmanualforyourparticularmachine.
Overviewofsafetyinstructions _________________________________ WARNING!
Inordertocheckandadjustthesteeringsystemreliefpressure,it isnecessarytosteerthemachinetotheturninglimitinbothdirections.Caremustbetakentoavoidhavinganyoneoranypartof yourbodyinthearticulationareawhiletheunitisbeingsteered. Alladjustmentstothesteeringreliefpressuremustbemadefrom insidetheoperator’scompartmentandnotfromoutsidetheunit.
IMPORTANT!
Rememberthatcounterbalancecartridgesadjustoppositeofrelief cartridges.Turningthestemclockwisewillreducepressure.
WARNING!
Mixingpartsofdifferentdesignorfromavarietyofsourcesfor wheelswithpneumatictirescouldcausesevereinjuryordeath.
WARNING!
Whentorquinganywheelboltpattern,alwaystorqueina triangularpattern.
IMPORTANT! Wheelboltsornuts“seatin”duringnormalvehicleoperation. Therefore,itisnecessarytorepeattorquingproceduresas necessarytoseatthewheeltothehub.Plannedperiodicchecks willhelpmaintaincorrecttorquevalues.Allboltsandnuts, regardlessoftype,shouldberegularlycheckedfortightness.
WARNING!
Donotinstallorremovetire/wheelassembliesfromamachine withoutpropertraining.
WARNING!
Checkwheelcomponentsperiodicallyforcracksorbrokenparts. Replaceallcracked,badlyworn,damagedorseverelyrusted components.Whenindoubtreplace.
WARNING!
Donot,underanycircumstances,attempttorework,weld,heator brazeanywheelcomponentsthatarecracked,brokenor damaged.ReplacesuchcomponentswithnewOEMpartsofthe correctsizeandtype.
WARNING!
Mixingwheelpartsofdifferentdesignorfromavarietyofsources ispotentiallydangerous.
WARNING!
Replacebrokenstudsandeachunbrokenstudnexttothebroken one.
WARNING!
Replacealldamagedwheelstudsorbolts.
Chapter6:Technicaldata IMPORTANT!
Duetotheapplicationoffastenersbeingsubjecttogreatstresses andheavyorextremevibration,itisimperativethatallboltsbe appliedwithanadequateamountoftorque.Forthisreasonthis listofrecommendedtorquesettingsfordifferenttypesandsizes offastenersusedhasbeencompiled.
Thetighteningtorquesstatedinthesparepartslistshavetobe observed,aswell,forinstallationandmaintenance.
NOTICE!
UseonlylubricationfluidsandgreasesapprovedbyBucyrus America,Inc.!ThesefluidsandgreaseshavebeentestedatBucyrusAmerica,Inc.andguaranteereliableoperationofthemechanicalandhydraulicfunctionsofthemachine.
IMPORTANT!
Thelubricationfluidsandgreaseslistedinthesametablecanbe mixed.Otherproductsmayonlybeusedifthesuppliercanguaranteethattheyareequivalent.
Differentlycomposedfluidsandgreasesmustnotbemixedas thismaychangetheconsistency,i.e.themixturecanbecome thinnersothatthelubricationeffectisnotsufficient.Itmayalso bedangeroustouselubricatinggreasesandfluidshavingthe samespecificationbasebutdifferentorigins.
Incaseofdoubt,themanufacturerofthelubricationtobeused shouldbecontactedastothecompatibilityofthelubricationin question.
IMPORTANT!
BucyrusAmerica,Inc.expresslypointoutthattheapprovalofthe listedproductsrelatesonlytothepuretechnicaluseinourmechanicalandhydraulicsystems.Theresponsibilityfortheconstituentsusedinthehydraulicconcentratesliessolelywiththe respectivemanufacturer.
NOTICE!
Whenperformingmaintenanceonthemachine,allusedoiland lubricantsshouldbedisposedofperyourlocalEPAstandards.
Overviewofsafetyinstructions _________________________________ Storageandtransport Thischaptercontainsimportantinformationonthecorrectstorageand transportoftheUN-A-HAULER ® Observanceoftheinstructionsandtipswillincreasetheservicelifeand availabilityofthemachine.Youwillalsobeabletocarryoutthetransportworkquickerandmoresafely.Carefulattentiontothepointsin thischapterwillhelpyoutosimplifyyourday-to-daywork.
Storage Componentscoatedwithtemporarycorrosioninhibitorareprotectedfor approximatelysixmonths.
Beforedelivery,thehydraulicallyoperatedequipmentisoperatedand allgearboxes,hydraulicoiltank,etc.arefilledtotheirmaximumfill point.
Storageofthemachineandspareparts Storetheequipmentindoorsorcoverwithatarpaulintoprotectagainst directexposuretosunlight.Storetheelectricalequipment,electronic components,sparepartsofrubberorplastic – suchassealsandhoses – andhydraulicfluidsonlyinclosedroomsattemperaturesof60°F (15°C)to77°F(25°C).
Protecttheequipmentandallsparepartsstoredoutdoorsagainst moistureanddirt,e.g.usingtarpaulins.
Themountingsurfacesofhydrauliccomponentsmustbeprotected againstcorrosionandsealedwithblindplates.Protectthehydraulic plugconnectorsandtheconnectorsoftheelectricalcableswiththe capsandplugssupplied.
Duringshort-termstorage(approximately4weeks)ofequipmentoutdoors,butattemperaturesabovefreezing,electricalcomponentsneed notberemoved.Suchcomponentsmustbeparticularlyprotected againstexcessivetemperatures,dirtandmoisture.
Iftheequipmentistobestoredmorethansixmonths,thehydraulic componentsmustbecompletelyfilledwithacorrosioninhibiting/frostproofingfluidsuche.g.CV50.
Fillthehollowareasofhydrauliccomponents(e.g.thepistonchambers)inhorizontalposition(portsfacingupwards)untiltheystartto overflow.
Thensealtheportswithplasticorsteelplugs.
Theequipmentmustbestoredinawellventilated,dryroom.Donot storeoutdoors.
Storageandtransport Inordertopreventplasticdeformationofthesealelements,cylinders mustbestoredinanuprightposition.Somecylindersmustberemoved sothattheycanbestoredupright.
Afterastorageperiodofapproximatelytwoyears,arandomsample inspectionmustbeperformedtodeterminewhetherthemeasures takenandthemethodofstoragehaspreventeddamage. Onrequest,theinspectioncanbecarriedoutbyBucyrusAmerica,Inc.
Evenwithproperstorage,sealsandhosesaresubjecttonaturalageing.Donotusethesepartsiftheyhavebeenstoredformorethantwo years.
Instructionsonthestorageofconcentratesforhydraulicfluidscanbe found,ifrequired,inchapter6inthisoperatingmanual.
IMPORTANT! Takecaretoinsurethatnewsuppliesarestoredseparatelyfrom existingstockandthatremovaltakesplaceonthe“firstin,first out”principle.
Transport Loadunits;dimensionsandweights Observethetransportsheetsforthemachineandspareparts.They containinformationon:
■ Dimensions
■ Weight
■ liftingpoints,etc.
Additionalinformationonthedimensionsandweightscanbefoundin chapter6inthisoperatingmanual.
WARNING! Useonlyloadhandlingdevicescomplyingwiththetechnicaland legalregulationsforthetransportofloads. Youcouldbeseriouslyinjuredorevenkilledbyfallingloads. Useonlysuitableloadhandlingdevices.
Beforetransport Beforetransportingtheequipmentattemperaturesbelowfreezing,all hydrauliccomponentsoperatedwithemulsion(HFAEorHFAS)must becompletelydrainedandthenfilledwithacorrosioninhibitor/frostproofingfluid(e.g.CV50).
Transportofequipmentattemperaturesbetween -6°F(-21°C)and40° F(-40°C)isonlypermissiblewhencertainmeasuresweretakento meettheseconditionsatthedesignandmanufacturestages.Nevertheless,theindividualpartsanddevicesofthisequipmentmustnotbe subjectedtosuddenimpactloadsatsuchlowtemperaturesandmay onlybeloadedstaticallyorquasi-statically.
Duringtransportofthisequipmentwithfloor-mountedvehiclesatsuch lowtemperatures,measuresmustalsobetakentoensurethatthe partsanddevicesarenotsubjectedtosuddenimpactloads.Atvery lowtemperaturesandonpoorroads,thetransportvehiclespeedmust thereforebelimitedtoamaximumof15mph(25kph)fortrucktransport.
Electricalandelectroniccomponentsmustberemovedforoverseas transportorprolongedstorageoutdoorsunlessthesecomponentsor thecompleteequipmentisprotectedagainstharmfulenvironmental influencesbyasuitablepackaging.
Theelectricalcablesremainintheequipment.Theymustbecarefully protectedagainsttransportdamageandsoilingoftheconnections.
Installation toolbox
Installation Pointstoobservepriortoinstallation
Whoisallowedtocarryoutinstallation?
Installationisonlyallowedtobecarriedoutbypersonnelhavingreceivedadequatetrainingtoperformthistask.
Workon:
thesafetycomponents(pressurereliefvalves,fireextinguishingequipmentetc.)
theelectricalequipment(controlunits,signalingdevices,etc.) And
thehydraulicequipment(cylinders,directionalcontrolvalves,hoses etc.)
shouldonlybecarriedoutbyBucyrusAmerica,Inc.serviceengineers orbyspeciallytrainedpersonnel.
Whichtoolsarerequiredforinstallation?
NospecialtoolsarerequiredtoputtheUN-A-HAULER ®intoservice.
Thebatteryplugsandreceptaclescomewithaspecialwrenchforconnectinganddisconnectingbatteryplugsandreceptacles.
Inaddition,variousitemsofauxiliaryequipmentandmachinesmaybe requiredatthepointofinstallation.
Theseincludei.e.:
■ hoistswithadequateliftingcapacity
■ meansofattachmentwithadequateliftingcapacity
■ unloadingdock
■ jackswithadequateliftingcapacity
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installationplan
Notesoninstallation CAUTION!
SeriousdamagecanbecausedtotheUN-A-HAULER ® asaresult ofincorrectinstallation.
Theunitshouldthereforeonlybeinstalledundertheinstructionof specialistsfromBucyrusAmerica,Inc.
Thesequenceofoperationsduringinstallationmustbeadaptedtothe individualconditionsprevailingatthesite.Beforestartingtheworka detailedlistofstepstobetakenwithrespecttotransportandassembly shouldbepreparedandacorrespondingplanestablished.
IMPORTANT! Thesequenceofoperationsduringinstallationmustbeadaptedto theindividualconditionsprevailingatthesite.Beforestartingthe workadetailedlistofstepstobetakenwithrespecttotransport andassemblyshouldbepreparedandacorrespondingplanestablished
Pre-installationchecklist NOTICE! Themachinewasinspectedpriortoshipmentfromthefactoryto ensureproperfunctioningandinstallationofallcomponents. However,toensurethatnotransitdamagehasoccurred,thefollowingpre-startupchecksshouldbeperformed:
■ performdailymaintenance
■ visuallyinspectallhydraulichosesandelectricalcablesfordamage
■ cleananyforeignmaterialfromtheoperator’scompartment
■ cleananyforeignmaterialfrombehindtheejectorbladeandfalse bottom
■ checksafetyprovisionsforoperationalconditiononfiresuppressionsystem
■ startupthemachineandcheckforcorrectoperationofpanic switch(s)whicharelocatedinsidetheoperator’scompartment
■ checkthatallcoversandguardsareinplaceandsecure
■ checkthatalltagsandinstructionlabelsareinplaceandsecure
■ checkthatoperator’scanopyissecureandinplace
■ startthemachineandallowthehydraulicsystemtowarmupfor five(5)toten(10)minutes
■ checkhydraulicsystempressures(seesparepartsmanualfor properhydraulicschematic)
■ checkallcontrolhandlesandswitchestoensureallmachinefunctionsareoperatingproperly
Safetyfeatures NOTICE!
Theoperatormustbecomefamiliarwithallthesafetyfeaturesand theirlocationonthemachinepriortoinstallationoroperation.
Safetyfeaturesinclude: (ReferenceFig.7)
Themachineisequippedwithtwo(2)panicstripslocatedinsidethe operator’scompartment.Oneislocatedtotherightandoneislocated totheleftoftheoperatorwhilesittingintheoperator’sseat.Thepanic strip(s)areusedtobreakthecontrolcircuitonlyinemergencysituations,stoppingallmotors.Strikingwithasmallamountofforcewillactuateeitherpanicstrip.
Themachinewasshippedfromthefactorywithaprotectivecanopy. Ensurethatthecanopyisinplaceandsecureatalltimestoprotectthe operatorfromfalldebris.
Themachineisequippedwithtwo(2)firesuppression(remote)actuators.Oneislocatedtotheoperator’sleftinsidetheoperator’sleftand theotherislocatednexttothebatteryonthesideofthemachineoppositetheoperator.Thisparticularsuppressionsystemispneumatically actuatedandextinguisheswithdrychemicals.Toactuatethesystem fromeitherofthetwo(2)actuators,pullthesafetypinandstrikedownwardontheplunger.Immediatelyaftertheplungerisstruck,drychemicalwillbedispensedthroughoutthemachine.Thefiresuppression systemmustbecompletelyrechargedwithdrychemicalsandexpellantsafterithasbeenactuated.
WARNING! Ifeitherofthefiresuppressionactuatorsisactuated,thesystem mustbecompletelyrechargedwithdrychemicalsandexpellants.
Themachineisequippedwithguardsandcoverstoreducethepossibilityofpersonnelcomingincontactwithrotatingormovingparts.All guardsandcoversmustbeinstalledandsecurelyfastenedduringoperation.
DANGER! Donotoperatethemachineanyoftheguardsorcoversremoved. Youorotherpersonnelcouldbeseriouslyinjuredfrommovingor rotatingparts.
Themachineisequippedwithasteeringlockout.Thelockoutshould beconnectedandsecureduringshutdownandwhileperformingmaintenanceonthemachine.
Themachineisequippedwithacircuitbreakerresetlocatedinsidethe operator’scompartment.Thecircuitbreakerresetmaybeusedtoshutdownthemachineinemergencysituations.
Steeringlockconnectionsfor shutdownandmaintenance Firesuppressionactuator
Steeringlock storagelocation
Panicstrip
Circuitbreaker reset
Panicstrip
Operation Thischaptercontainsimportantinformationontheoperationandmaintenanceofthemachine.Italsoincludesinstructionsonthereplacementofwearparts.
Readthischaptercarefullyandthoroughly.Inparticular,observethe safetyinstructionsinchapter2“Yoursafety”.
HowtooperatetheUN-A-HAULER ® DANGER! Incorrectoperationendangersyourselfandothers! Incorrectoperationofthemachineisoftenthecauseofveryseriousaccidents!
Operatetheunitonlywhenyouhavebeensufficientlytrainedon themachineandhavereadandunderstoodthisoperatingmanual. Shouldanythingbeunclear,pleasecontactyourimmediatesupervisor.
WhoisallowedtooperatetheUN-A-HAULER ®? TheUN-A-HAULER ® isonlyallowedtobeoperatedbypersonswith adequateknowledgeofthecompletemachine.
Thisalsoincludes:
■ whatsafetydevicesareinstalledonthemachine.
■ wherethesesafetydevicesarelocated.
■ howthesesafetydevicesaretobeoperated.
Whencanoperationbestarted?
Operationmustnotbestarteduntilthesafeconditionandproperfunctionofthecompletemachinehasbeencheckedandthedailymaintenanceoperationshavebeencarriedout.
Fig.8:Operator’scompartment
Controlsandindicators Operator’scompartment
Theprimarycontrolsforthemachinearelocatedintheoperator’scompartment(Fig.8).
Note:
Typicaloperator’scompartmentshown, locationofcontrolsmayvary.
firesuppressionactuators WARNING!
BeforeoperatinganyleversorpedalsontheUN-A-HAULER ® alwaysmakesurenooneisinthehazardzone(page20).Donot operateanyleversorpedalsfromoutsidetheoperator'scompartment.
Thetwofiresuppression(remote)actuators(Fig.9)arelocatedtothe operator'sleftintheoperator'scompartmentandbesidethebatteryon thesideofthemachineoppositetheoperator.Thisparticularsuppressionsystemispneumaticallyactuatedandextinguisheswithdrychemicals.Toactuatethefiresuppressionsystemfromeitherofthetwoactuators,pullthesafetypinandstrikedownwardontheplunger.Immediatelyaftertheplungerisstruck,drychemicalwillbedispensed throughoutthetractorthroughsixnozzles,locatedovereachelectric motor,behindthehydrauliccontrolpanel,andintherear(payload) section.
Fig.9:Firesuppressionlocator(typical)
PLUNGER PIN
CO2CARTRIDGE (BOMB)
Thefootbrakepedal(Fig.10)isafoot-operatedpedallocatedinfront of,andtotheleftoftheoperatorandisusedtoapplytheservice brakes.Thefootbrakepedalworkssimilarlytoanautomobilebrake pedal.Thepedalisnormallyoperatedbytheleftfoot.Whenthemachineisfirstactivated,thebrakeaccumulatorpressureshouldbuildup to1500PSI,andisshownonthe"ACCUMULATOR"gauge.When thebrakeshavebeenappliedenoughtimestodropthepressureto 1200PSI,theaccumulatorchargingvalveshouldopen,allowingpressuretobuildbackupto1500PSI.ThebrakingsystemoftheUN-AHAULER ® usesoneset(ineachgearcase)ofspring-applied,pressure-releasedwetdiscbrakesforboththeserviceandautomatic (emergency)brakingsystems.Whenthemachineisstarted,theaccumulatorisfullycharged,andtheBrakeReleaseButtonisdepressed, hydraulicpressurecompressesthemechanicalbrakesprings,releasing thewetdiscbrakes,allowingthemachinetomove.Asthefootbrake pedalisdepressed,thebrakevalvedemodulatespressureinthebrake circuitallowingthemechanicalspringstoengagethebrakediscs. Whenthepedalisreleased,hydraulicpressureagaincompressesthe springs.Anaccumulatorinthesystemallowsforalimitednumberof cyclesshouldhydraulicpressuretothesystemfail.Oncetheaccumulatorpressureisexhausted,therewillbenopressuretocompressthe springsandthebrakeswillbeapplied,stoppingthemachine.
Thispedal(Fig.10),operatedbytherightfoot,isusedtostartthetram (traveling)motorsandregulatethespeedofthemachine.
CAUTION! Thespeedswitchfootpedalshouldnotbedepressedatthesame timeasthefootbrakepedalorwhentheparkingbrakesareset. Todosomayoverloadthetrammotorsandcouldshortentheir usefulness.TheUN-A-HAULER ® isprovidedwithoverloadprotection,butcontinuedabusecanshortenmotorlife.
Fig.10:Brakeandacceleratorpedallocation
Thewarninggong(Fig.11),islocatedtotheoperator'sleft.Itis soundedbystrikingtheknobinthecenterofthegong.Thiswarning gongshouldbeusedinaccordancewiththesafetystandardsatthe minewheretheUN-A-HAULER ® willbeused.
TheUN-A-HAULER ® isequippedwithtwo(2)panicstrips(Fig.11) locatedintheoperator’scompartment.Oneislocatedtotherightand oneislocatedtotheleftwhilesittingintheoperator’sseat.Thepanic stripsareusedtobreakthecontrolcircuitonlyinemergencysituations, stoppingallmotors.Strikingwithasmallamountofforcecanactuate eitherpanicstrip.
TheoptionalBUC2000display(Figure11)islocatedinfrontoftheoperator’sseat.Featuresinclude:
■ batterydischargeindicator
■ hourmeterdisplayingtram-onhours
■ hourmeterdisplayingpump-onhours
■ rotatingdisplayshowing:
1. batteryvoltage
2. pumpmotorcurrent
3. diagnosticfaultstatus
4. trammotorcurrent
IMPORTANT! FormoredetailedinstructionsontheBUC2000display,referto theBUC2000DualMotorTroubleshootingguide.
Fig.11:Panicstrip.Warninggong,andBUC2000displaylocation
“TRACTIONASSIST” Controlhandle Thecontrolhandle(Fig.12),locatedtotheleftoftheoperatorhasa groupofswitchesthatcontrolthefollowing:
IMPORTANT! Formoredetailedcontrolhandleoperatinginstructions,seeStartingproceduresinthischapter.
Thecontrolhandle(Figure12)locatedtotheleftoftheoperatorhasa groupofswitchesthatcontrolthefollowing:
PressdownforTractionAssist.
Tostartthepumpmotor,pressdiagnosticstriggerdownandhold. Thenpress“PUMPMOTOR”buttonandholduntilthepumpmotor starts.Release“PUMPMOTOR”buttonandthenreleasediagnostics trigger.Toturnoffthepumpmotor,press“STOP”buttonor“PUMP MOTOR”button.
Toreleaseparkbrake,(pumpmotormustberunning)pressdiagnostics triggerdownandhold.Thenpress“PARKBRAKE”buttonuntilthe dashboarddisplayindicates“PARKBRAKERELEASED”.Release triggerand“PARKBRAKE”button.Toset“PARKBRAKE”andleave pumpmotorrunning,press“PARKBRAKEBUTTON”.Toturn“OFF” thepumpmotorandsettheparkbrake,press“STOP”buttonor“PUMP MOTOR”button.
“TRAM or ”
Toactivateatrammingdirection;
Thepumpmotormustberunning.
Theparkbrakemustbereleased.
Pressin-positiondownandhold,presseither“TRAM ”fortram directionor“TRAM ”fortramdirection,holduntilthedashboard displayindicatesdirectionoftravel.
Release“TRAM ”or“TRAM ”dependingondirectionselected andthenreleasein-positiontrigger.
Todisabletramming,presseither“TRAM”buttonandrelease.
“LIGHTS or ”
“DIAGNOSTICS”
Toactivate“LIGHTS”presseither“LIGHTS ”forlightdirectionor “LIGHTS ”forlightdirection.Forautopositionheadlights,whereas theheadlightsfollowthedirectionoftheselectedtramdirection,press in-positiontriggerdownandhold,press“LIGHTS ”release“LIGHTS ”,thenreleasein-positiontrigger.Lightswillstayinautopositionuntil “STOP”,“LIGHTS ”or“LIGHTS ”ispressed.
Pressupformachinediagnostics.
Fig.12:Controlhandle
“TRAM” (BATTERYDIRECTION) “LIGHTS” (BATTERYEND)
circuitbreakerresetlever
“LIGHTS” (TRAILEREND)
“TRAM” (TRAILERDIRECTION)
DIAGNOSTICS
IN-POSITION
Alsousedtoturnunitoff,thislever(Fig.13),locatedtotherightofthe operatorisusedtoresetthecircuitbreakerwhenithastripped.This circuitbreakerislocatedintheelectricalcontrollerenclosure.
Themachinecircuitbreakerisnotintendedasan"ON-OFF"switchfor normaloperation.Exceptinanemergency,theUN-A-HAULER ® shouldbeshutdownbyfirstdepressingthe“STOP”buttonlocatedon thecontrolhandleandthenmovingthemachinecircuitbreakertothe "OFF"position.
WARNING!
Themachinecircuitbreakerde-energizestheelectricalcontroller andmotors.However,electricalpowerisstillpresentinsidethe controllertothecircuitbreaker.Ifthecircuitbreakerinsidethe controllerrequiresservice,thebatterycircuitbreakershouldbe turnedtothe"OFF"positionorthebatteryplugdisconnected fromthebattery.
WARNING!
Allelectricalswitchesintheoperator'scompartmentmustbein the"OFF"positionbeforemovingthebatterycircuitbreakerlever tothe"ON"position.
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batterycircuitbreakerlever
Fig.13:Circuitbreakerresetleverlocation
Circuitbreaker resetlever
Thebatterycircuitbreakerislocatedonthebattery.Thiscircuitbreaker has4positions:"OFF,"tode-energizethemachine'selectricalsystems, "TRIPPED,"whenthecircuitbreakerisoverloaded,"RESET,"toreset thecircuitbreakerafterithastripped,and"ON,"fornormaloperation (Fig.14).Thebatterycircuitbreakershouldbeinthe"OFF"or "TRIPPED"positionbeforetheUN-A-HAULER ® isservicedorwhen thebatteryplugisbeingconnectedordisconnected.
WARNING!
Oncethebreakerhastripped,itwillnotstayinthe“on”position withoutfirstbeingmovedtothe"RESET"position,andthento "ON".
Fig.14:Typicalbatterycircuitbreakerresetlever
“RESET”
“OFF”
“TRIPPED”
“ON”
Fig.15:Optionalbatterycircuitbreakerresetlever
“(PUSH)” “OFF”
“(PULL)” “ON”
ThebatteryholddownavailableonModelsCH816BandCH816LB (Fig.16),itislocateddirectlyinfrontoftheoperator’sseat.Itisused tosecurethebatteryinpositionduringtrammingoperations.Toengagetheholddown,pushthehandleawayfromtheoperatorandto unlock,pullthehandletowardstheoperator.OntheModelCH818the batteryisautomaticallysecured.
WARNING! Alwaysmakesurethebatteryholddownisengagedaftereach batterychangeanddisengagedpriortochangingbatteries.The batteriesmaybedamagedifleftunsecuredduringtrammingoperations.
Fig.16:Batteryholddownleverlocation
Themachineisequippedwithalightswitch(Fig.17)thatisusedto deenergizeallpowertothefrontandrearheadlights.Locationmay vary.
Fig.17:Lightswitch.
“EJECTOR”
“ARTICULATION” (OPTIONAL)
“BATTERYCHANGER”
Generalhydrauliccontrolsysteminformation Intheoperator'scompartmentisagroupofcontrollevers(Fig.18). Theseleverscontrolthesteering,ejectorblade/falsebottom,battery changer,optionalarticulation,andP.T.O.bymeansofahydraulicvalve banklocatedbehindthepaneltotheoperator'sright.Totheleftofthe operatoristhesteeringcontrollever.Thehydraulicsystempressure reliefvalveissetatthefactoryat,andshouldnotbechanged(Referto thehydraulicschematicforyourparticularmachine).Shouldthe "SYSTEMPRESSURE"gauge(Fig.18)readmorethan1800PSI, shutdowntheUN-A-HAULER ® andcallamaintenanceperson(see Shutdownprocedureinthischapter).
WARNING!
Makesurenooneisinthehazardzone(seeHazardzoneinthis chapter)beforeoperatinganyleversorpedalsandneveroperate anyleversorpedalsfromoutsidetheoperator'scompartment.
“P.T.O.”
“ACCUMULATOR”
Steeringcontrollever “BRAKEPRESSURE” “SYSTEMPRESSURE”
Fig.18:Hydrauliccontrolleversandgauges
The“STEERING”controllevertotheleftoftheoperator(Fig.18)is usedtosteertheUN-A-HAULER ®.Tosteerleftwhilemovingforward (rightwhilemovinginreverse),pullthesteeringcontrolleverslowly towardtheoperator.Toturnrightwhilemovingforward(leftwhilemovinginreverse),pushthesteeringcontrolleverslowlyawayfromthe operator.
The"EJECTOR"lever(Fig.18),operatestheejectorblade/falsebottom,locatedintherearsection.Theejectorblade/falsebottompushes outeverythinginitspath,emptyingtherearsection.Whenthe "EJECTOR"leverispushedbytheoperator,theejectorblade/false bottomshouldmovetowardtherearoftheunit(extend).Whenthe "EJECTOR"leverispulledbytheoperator,theejectorblade/falsebottomshouldmovetowardtheoperator(retract).Whentheejector blade/falsebottomisnotbeingused,itshouldberestingintheretractedposition.
“BATTERYCHANGER” controllever WARNING! Beforemovingtheejectorblade/falsebottomcontrollever,verify thatnoonehasanypartofhisbodybetweentheejectorblade/ falsebottomandthefrontoftherear(payload)section.Alsokeep anyobstructionsfrombehindtheejectorblade/falsebottomsoit canreturncompletelytothefrontoftherear(payload)section.
The"BATTERYCHANGER"lever(Fig.18)controlsthebatterychangingsystem,whichismadeupoftwohydrauliccylinders(batterylifting cylinders),oneoneachsideofthebattery.Whenthe"BATTERY CHANGER"controlleverispulledbytheoperator,thebattery-lifting cylinderswillraisethebattery.Pushingthehandleawayfromtheoperatorwilllowerthebattery.Onverticalliftbatterychangesystemsthe batteryliftcylindersareequippedwithpassivehold-downdevicesto preventthebatteryfrommovinginsidethemachine.Thehold-down pressureisregulatedbyareliefvalveinthesystem(refertotheMaintenancesectionofthisguide).
CAUTION! The"BATTERYCHANGER"levershouldonlybeoperatedatabatterychangestation.Thebatterymaybedamagedifaccidentally raisedinalowroofarea.
WARNING!
Thebatterycannotbechangedifthebatteryisnotlevelwhenin theraisedposition.Formoreinformationonhowtochangethe batteryseeBatterychangeprocedureinthischapter.
WARNING!
Neverattempttodisconnectahydraulichosefromthebatteryliftingcylinderswiththebatteryinthe"UP"position.Thiswould allowthebatterytofallandcouldresultininjury.
automaticemergencybrakes
“ARTICULATION”controllever (optional) Theautomaticemergencybrakesarespring-applied(on),pressurerelease(off)brakeslocatedinsidethegearreducers.BeforetheUN-AHAULER ® ismoved,theautomaticemergencybrakesmustbereleased.Iftheyarenotreleased,thebrakeswilldragandbedamaged. Thedrivetrainandtheelectricalsystemwillalsobedamaged.Anyof thefollowingconditionswillapplytheautomaticemergencybrakes:
Thepanicbarisstruck,trippingthemachinecircuitbreaker.
The“STOP”buttonlocatedonthecontrolhandleisdepressed.
Thebatterycircuitbreakerisinthe"OFF"or"TRIPPED"position.
Themachinecircuitbreakerisinthe"OFF"or"TRIPPED"position.
Toreleasetheautomaticemergencybrakes:
Thebatterycircuitbreakerandmachinecircuitbreakerleversmust beinthe“ON”position.
Thepumpmotormustberunning.
Pressthetriggeronthecontrolhandleandholdanddepress “PARKBRAKE”buttonandholduntilthedashboarddisplayindicatesparkbrakereleased(Figure4,page5.9).
Releasethetriggerand“PARKBRAKE”button.
Theverticalarticulationcontrol(Fig.18)actuatesacylinderinthecentersectionthatenablestheoperatorto"bend"themachinetoimprove theramp-uporhump-overabilitiesofthemachineinstantlyasrequired bytheconditionsofthebottomatanygiventime.Pullingthelevertowardstheoperatorcausesthecenterofthemachine(andtheoperator) toriseupwardwhilethebatteryandpayloadendbothgodown.Care mustbetakennottodrivethecanopyintothetopinlowcoalconditions.Pushingtheleverawayfromtheoperatorcausesthecenterof themachine(andtheoperator)tomovedownwardwhilethebattery andpayloadendmoveup(Fig.19).
WARNING!
Theverticalarticulationcontrolmovesthecenterofthemachine upordownwhileeachendofthemachinemovesupordown (oppositeofthecenter).Makesurenooneisonthemachineor nearthemachinebeforeoperatingthiscontrol.Failuretodoso couldresultintheinjuryordeathofabystanderortotheoperator ifthemachineisusedwithoutacanopy.
WARNING!
Donotactuate“ARTICULATION”functionwhiletrammingthemachineasthiscouldcausethemachinetojamintothetoporbottomcausingdamagetothepassageand/orthemachine.Ifverticaladjustmentisdesired,stopthemachine,makethenecessary adjustment,andthenresumetramming.
Fig.19:UN-A-HAULER®shownin“UP”articulatedposition
Theoptionaltailgatelowersautomaticallywhenthe“EJECTOR”control leverisengagedandraiseswhentheejectorbladeandfalsebottom areretracted.
Anoptionaldisconnectswitchisavailabletodisconnectpowertothe motorsthroughaswitchlocatedinanenclosurenearthecontroller.To disconnectpower,pushinthedisconnectbutton.Toresettheswitch, pullthebuttonbackout.
Anoptionalreartractiveassistpackageisavailablethatprovidesondemand,hydraulically-drivenrearwheelstoassisttravelinareasof badbottomconditions.Toengagetherearwheels,pressdownthe reartractiveassistbuttonlocatedonthecontrolhandleandrelease (Fig.13).Todisengagetherearwheels,pressthebuttonagainand release.
Theautomaticemergencybrakesarespring-applied(on),pressurerelease(off)brakeslocatedinsidethegearreducers.Theautomatic (park)brakeisnormallyreleasedusingthe"PARKBRAKE"release buttonlocatedonthecontrolhandle(see"AUTOMATICEMERGENCY BRAKES”,inthischapter).Shouldhydraulicsystemfailureoccur,the automatic(park)brakecanbereleasedusingthemanualbrakerelease handpump.Toreleasethebrakesusingthehandpump,turnthehand pumpselectorvalvetothesetposition.Pumpthehandpumpuntilthe brakereleasevalveindicatestherequiredminimum1500psi.
Hazardzone Thehazardzoneexistsunless:
Thebatteryplugisdisconnectedfromthebattery,OR;
Themachinecircuitbreakerisinthe“OFF”or“TRIPPED”position, OR;
Thebatterycircuitbreakerisinthe“OFF”or“TRIPPED”position.
Fig.20:Hazardzone Startingprocedure Afterreadingthepreviousdescriptionsandlocatingeachcontrol,the operatorisreadytooperatetheUN-A-HAULER ®.Anexperiencedoperatorshouldmonitoranewoperator'sindoctrinationtothestarting procedure.
CAUTION!
Usecautionwhentravelingdowngrade,exceeding5mph(8kph) withthismachinewillresultintrammotorfailure.
WARNING!
Checkthebatteryconnectionsandthebatterycovers.Theymust beinplaceandlockedtobepermissible.
WARNING!
Neveroperateanyleversorpedalsfromoutsidetheoperator's compartment.
WARNING!
Thisunitisequippedwithacaborcanopy.Becarefulnottohit yourheadwhenenteringorleavingtheoperator'scompartment. Thismachinemustnotbeoperatedwithoutthecanopyinplace.
General
1. Disconnectthesteeringlockoutdevice(Fig.22).
2. Sitintheoperator'sseatandadjusttheseatpositionrelativeto thefootandhandcontrols.
WARNING!
Besurenooneisinthehazardzone(Fig.20)beforeoperatingany leversorpedals.
Nevertrytoadjusttheoperator'sseatwhiletheUN-A-HAULER ® isinmotion.
DonotoperatetheUN-A-HAULER ® withanypartofyourbody outsidetheoperator'scompartmenttopreventhavingbodyparts caughtbetweentheunitandoutsideobjects.
3. Thetapepanicstripsmaybepressedatanytimetotripthe machinecircuitbreaker,settheparkbrake,andtode-energize thetramandpumpmotors.
4. Stopbutton“J3”maybepressedatanytimetosetthepark brake,andtode-energizethetramandpumpmotors(Fig.21).
Note:RefertoFig.21forillustrationofcontrolhandle.
Fig.21:Controlhandle
“J7”
PRESS“J2”AND“J7”TO STARTPUMPMOTOR.
PRESS“J7”TOSTOPPUMP MOTOR.
“J12” PRESSDOWNFOR TRACTIONASSIST.
“J4”
PRESS“J4”TOACTIVATE LIGHTS. PRESS“J2”AND“J4”FORAUTOLIGHTS. AUTOLIGHTSFOLLOWDIRECTIONOF TRAVEL.
“J8” WITHPUMPMOTORRUNNINGPRESS“J2”AND“J8” TORELEASEPARK BRAKE.
PRESS“J8”TOSETPARK
“J9” WITHPUMPMOTORRUNNINGANDBRAKE RELEASEDPRESS“J2”AND“J9”TO ACTIVATE TRAMDIRECTION.
PRESS“J9”TODISABLE TRAMDIRECTION.
“J3” PUSHDOWNFORSTOP
“J6” PUSHDOWNFOR LIGHTS.
“J10” WITHPUMPMOTORRUNNINGAND BRAKERELEASEDPRESS“J2”AND “J10”TOACTIVATE TRAMDIRECTION. PRESS“J10”TODISABLEðTRAM
“J2” PUSHDOWNFOR IN-POSITION
Machineoperation “J11” PUSHUPFOR DIAGNOSTICS
1. Turnthebatterycircuitbreakerand/ordisconnectswitch(if equipped)tothe“ON”position.
2. Press“J11”tobeginonboarddiagnostics.
3. Hold“J11”untilamessageisdisplayedontheBUC2000display.
4. Ifthedisplayindicates“SYSTEMOKAY”continue,ifanyother messageisdisplayed,turn“OFF”batterycircuitbreakerand/or disconnectswitch(ifequipped)andcontactBucyrusAmerica, Inc.servicedepartment.
5. Release“J11”andsetmachinecircuitbreaker.
6. Testtapeswitchpanicbarsbeforebeginningeachshift,press leftsidetapeswitchandmachinecircuitbreakershouldtrip. Repeatsteps1through5andpressrightsidetapeswitchand machinecircuitbreakershouldtrip.Ifmachinecircuitbreaker failstotrip,fromeithertapeswitch,turn“OFF”batterycircuit breakerand/ordisconnectswitch(ifequipped)andcontactBucyrusAmerica,Inc.servicedepartment.Ifbothtapeswitch panicbarstripmachinecircuitbreaker,repeatsteps1through 5andproceedtostep7.
7. Testallcontrolhandlefunctionsbeforebeginningeachshift. Followsteps8through24.Ifanyfunctiondoesnotoperate correctly,turn“OFF”circuitbreaker(s)anddisconnectswitch (ifequipped)andcontactBucyrusAmerica,Inc.servicedepartment.
8. Tostartthepumpmotor,press“J2”andhold.Thenpress“J7” andholduntilthepumpmotorstarts.Release“J7”andthen release“J2”.
9. Toturnoffthepumpmotor,press“J3”or“J7”.
10. Toreleasetheparkbrake;
■ thepumpmotormustberunning
■ press“J2”andhold,press“J8”andholduntilthe dashboarddisplayindicates“PARKBRAKERELEASED”
■ release“J8”andthen“J2”
11. Tosettheparkbrakeandleavethepumpmotorrunning,press “J8.
12. Toturn“OFF”thepumpmotorandsettheparkbrake,press “J3”or“J7”.
13. Toactivateatrammingdirection;
■ thepumpmotormustberunning
■ theparkbrakemustbereleased
■ press“J2”andhold,presseither“J9”for tramdirection or“J10”for tramdirection,holduntilthedashboarddisplayindicatesdirectionoftravel.
■ release“J9”or“J10”dependingondirectionselectedand thenrelease“J2.
14. Thefootpedalmaynowbedepressedtocontrolthemachine.
WARNING! TheUN-A-HAULER ® isequippedwithasolidstatespeedcontroller.Thismeansthatthefartherthespeedswitchfootpedalisdepressed,thefastertheUN-A-HAULER ® willtram.
15. Tochangedirectionoftravel,press“J2”andhold,thenpress either“J9”or“J10”andholduntilthedashboarddisplayindicatesdirectionoftravel.Thenrelease“J9”or“J10”depending ondirectionselectedandthenrelease“J2”.
16. Eachtimethedirectionoftravelischanged,thefootpedalwill requirerecyclingthroughtheoffposition.
17. Todisabletramming,press”J9”or“J10”.
18. Toleavepumpmotorrunning,setparkbrake,anddisable tramming,press“J8”.
19. Todisabletramming,turnoffthepumpmotorandsetthepark brake,press“J3”or“J7”.
20. Ifequipped,toactivatetheoptionaltractionassistfunction, press“J12”.
IMPORTANT! Thetractiveassistcanbeusedasnecessary.However,battery lifewillbeprolongedifthetractiveassistisallowedtoremaindisengagedwhenpossible.
21. Press“J4”thenrelease“J4”for directionlights.
22. Press“J6”thenrelease“J6”for directionlights.
23. Forautopositionheadlights,whereastheheadlightsfollowthe directionoftheselectedtramdirection,press“J2”andhold, press“J4”release“J4”,thenrelease“J2”.Lightswillstayin autopositionuntil“J3”,“J4”or“J6”ispressed.
24. Toturnoffalllights,press“J4”and“J6”simultaneouslyand thenreleaseboth“J4”and“J6”simultaneously.
Shutdownprocedure TramtheUN-A-HAULER ® toitsdesignatedparkingplace.
StoptheUN-A-HAULER ® byreleasingthespeed-switchfootpedal anddepressingthefootbrakepedal.Whenthespeed-switchfootpedal isreleased,thetram(traveling)motorswillstop.Applyingthefoot brakewillstopforward(orreverse)motion.Thehydraulicpump'selectricmotorwillstillberunning,makingawhiningsound.
WARNING!
Alwayscheckbeforemovingtheejectorbladeandfalsebottom controllevertomakesurenoonehasanypartoftheirbodybetweentheejectorblade/falsebottomandthefrontoftherear (payload)section.
1. Pulltheejectorblade/falsebottomcontrollevertowardtheoperatortomovetheejectorblade/falsebottomtothefrontofthe rear(payload)section.Thereshouldbenoobstructionsbehind theejectorblade/falsebottom.
Note:RefertoFig.21forillustrationofcontrolhandle.
2. Beforeleavingtheoperator’scompartment,pressJ3”toturn “OFF”themachine.
3. Turn“OFF”themachinecircuitbreaker.
4. Turn“OFF”batterycircuitbreakerand/ordisconnectswitch(if equipped)beforeleavingthemachinearea.
5. Connectthesteeringlockoutdevice(Fig.22):
■ removethesteeringlockoutdevicefromitsstoragelugs
■ removethehitchpinfromtheendfarthestfromthecenter section
■ adjustturnbuckleuntilholeslineupbetweentheturnbuckle lugandthefrontsectionlug
■ insertthehitchpinintothefrontsectionlugthroughthe turnbuckle
WARNING!
Neverenterthearticulationareawhilethemachineisrunning. Completelyshutdownthemachineasoutlinedbeforeconnecting thesteeringlockoutdevice.Failuretoobservethisprecaution mayresultininjuryordeath.
CAUTION! Thisunitisequippedwithacanopy.Becarefulnottohityour headwhenenteringorleavingtheoperator'scompartment.
WARNING! Intheeventofanemergency,theUN-A-HAULER ® mayalsobe shutdownbystrikingthepanicstrip.Whenthepanicstripis struck,themachinecircuitbreakerwilltrip.Thisdisconnectsthe motorsandappliestheautomaticemergencybrake.Beprepared forthesuddenstopwhenthepanicstripsarestruck.
Fig.22:Steeringlockoutdevice
Lengthen Lug Pin
Steeringlock (Installed)
Steeringlock (Storagelocation)
Batterychangeprocedure(Verticallift)
TwopeopleareneededtochangethebatteryintheUN-A-HAULER ® SinceonepersonmaystepintotheHazardZone,theotherperson (operatingtheUN-A-HAULER ®)mustbeverycarefulandlookeach timebeforemovinganyleversorpedals.TaketimenowtorefamiliarizeyourselfwiththeHazardzone(Fig.20).
WARNING!
TheUN-A-HAULER ® isequippedwithapassivebatteryholddownsystem.Thissystemkeepsthebatteryrestingsecurelyon theframewhiletheUN-A-HAULER ® isinoperation.Thebattery hold-downsystemrequiresnooperatorassistance.However,itis importantthatthebatterybeproperlyalignedoverthebattery latch.
NOTICE!
Thebatterytablemustbeplacedonlevelgroundandthetires fullyinflated(155psi).
Lineupthebatteryendofthemachinewithanemptybatterytable (Fig.23)(seeStartingprocedureinthischapter).
Fig.23:Batterychangeprocedure(verticallift)
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WARNING! The"BATTERYCHANGE"levershouldneverbeoperatedexcept atabatterychangestation.Ifthe"BATTERYCHANGE"leveris operatedinalowroofarea,thebatterymaybedamaged.
Neverattempttodisconnectahydraulichosefromthebatteryliftingcylinderswhilethebatteryisintheupposition.Thiswould allowthebatterytofallandcouldresultinseriousinjury.Toservicethebatteryliftingcylinders,thebatterymustberestingsecurelyonabatterychangetable.
Raisethebatterytraycompletelybypullingthe"BATTERY CHANGE"lever.Thebatteryshouldremainlevelasitrises.The bottomofthebatteryshouldriseabovethetopofthebatterytable (Fig.24).Ifthebatteryislevel,proceedtonextstep.Ifonesideof thebatterygoesupfasterthantheotherside,lowerthebatteryby pushingthe"BATTERYCHANGE"leverandcontinuetoholdthe leverinthispositionforone-halftooneminuteafterthebatteryis seated.Trytoraisethebatteryagain.Ifdifficultyinraisingthebatterylevelisstillencountered,shutdownthemachineandcalla maintenanceperson.Thebatterycannotbechangedifitisnot levelwhenintheraisedposition.
Fig.24:Batterychangeprocedure(verticallift)
Dischargedbattery
Batterytable
Batteryliftingcylinderrod
Afterthebatteryisfullyraised,tramthemachineforwarduntilthe batteryispositionedcompletelyoverthebatterychangetable(Fig. 25).
Fig.25:Batterychangeprocedure(verticallift)
Dischargedbattery
Batterytable
Batteryliftingcylinderrod
Lowerthebatteryontothebatterytablebypushingthe"BATTERY CHANGE"leverawayfromtheoperatorandholdingtheleveruntil thebatteryliftingcylinderrodsarecompletelyretracted(Fig.26).
Fig.26:Batterychangeprocedure(verticallift)
Dischargedbattery
Batterytable
Batteryliftingcylinderrod
Shutdownthemachine(seeShutdownprocedureinthischapter).
Aftershuttingdownthemachine,disconnectthedischargedbattery.
■ Movethebatterycircuitbreakertothe"OFF"position.
■ Unlockandremovethepadlockatthebatteryconnector(Fig. 47).
■ Graspthethreadedlockringandrotateitcounterclockwise (CCW)untilthethreadsaredisengagedanditisfreetoslide awayfromthelockinglug;thelockringisdesignedtomove freelybutnottocomeofftheplug.
Batterytable
Charged battery
Batterytable
Discharged battery
■ Grasptheplugandpullitout,untiltheplugiscompletelydisconnectedfromthereceptacle;thisplugismadetofitvery tightlyinsidethebatteryreceptacleandshouldnotbedriven outofthereceptacle,dropped,orhandledroughly;iftheplug (orreceptacle)isdamaged,itwillnotfittogetherproperly.
■ Installthecapwhichissecuredtoeachreceptaclebyasmall chain;thiscapisplacedoverthethreadedreceptacleandrotatedinaclockwise(CW)directionuntilhandtightandapadlockwillfitintothelockinglug;thepadlocksallusethesame key.
Connectthejumpercable:
■ ConnectthereceptacleendofthejumpercabletotheUN-AHAULER ® andconnecttheplugendofthejumpercabletothe fullychargedbattery(Fig.27).
■ Securethejumpercableconnectionsbyusingthethreaded lockrings.Theselockringsmustbehandtightbutdonothave tobepadlocked.Onepersonshouldholdthejumpercableso itwillnotbedamagedorrunoverwhenthemachineismoved.
Jumpercable
Fig.27:Batterychangeprocedure(verticallift)
Lineupthemachinewiththechargedbattery(Fig.28)withthecylindersinthe“DOWN”position.Movethemachineuntilthebattery isinpositionoverthebatteryliftingcylinders(Fig.29).
Fig.28:Batterychangeprocedure(verticallift)
Discharged battery
Jumpercable
Charged battery
Fig.29:Batterychangeprocedure(verticallift)
Chargedbattery
Batteryliftingcylinderrod
Batterytable
CAUTION!
Besurethatthebatteryisproperlyalignedoverthebatterylatch beforemovingawayfromthebatterytable(Fig.33).
DisconnectthejumpercableandconnectthechargedbatterydirectlytotheUn-A-Hauler'scable.Remembertobecarefulwiththe plugandtolineuptheconnectorprongswheninsertingtheplug. Aftertheplugisinthereceptacle,thelockringshouldberotated clockwise(CW)untilhandtight.Thepadlockmustbeinthelockinglugandlockedforthisconnectiontobepermissible.
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