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
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.
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Steeringlockconnectionsfor shutdownandmaintenance Firesuppressionactuator
Steeringlock storagelocation
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
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“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
(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.
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
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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)
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.
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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.
StarttheUN-A-HAULER ® (seeStartingprocedureinthischapter).
Raisethebatterybypullingthe"BATTERYCHANGE"lever.Continuetoholdthe"BATTERYCHANGE"leverinthispositionuntil thebatteryisnolongerrestingonthebatterytable(Fig.30).
Fig.30:Batterychangeprocedure(verticallift)
Chargedbattery
Batterytable
Batteryliftingcylinderrod
MovetheUN-A-HAULER ® backtoclearthebatterytable(Fig.31).
Fig.31:Batterychangeprocedure(verticallift)
CAUTION!
IfthebatteryisnotcompletelyloweredbeforetheUN-A-HAULER® leavesthebatterychangestation,thebatterymayfallofforhitthe roofandbedamaged.
Lowerthebatterybypushingthe"BATTERYCHANGE"lever. Continuetoholdthe"BATTERYCHANGE"leverinthisposition untilthebatteryliftingcylinderrodsarecompletelyretracted(Fig. 32)
Fig.32:Batterychangeprocedure(verticallift)
Fig.33:Batteryalignment(verticallift) Correct Incorrect
Greasepoint
Batteryliftingcylinderrod Battery
Batterylatch
Thiscompletestheverticalliftbatterychangeprocedure.
Batterychangeprocedure(CH818groundlevel)
TwopeopleareneededtochangethebatteryintheUN-A-HAULER ® SinceonepersonmaystepintotheHazardzone,theotherperson (operatingtheUN-A-HAULER ®)mustbeverycarefulandlookeach timebeforemovinganyleversorpedals.TaketimenowtorefamiliarizeyourselfwiththeHazardzone(Fig.20).
LineupthebatteryendoftheUn-A-HAULER ® withtheplace wherethebatteryistobedeposited(Fig.34)(seeStartingprocedureinthischapter).
Fig.34:Batterychangeprocedure(CH818groundlevel)
Charged battery
Discharged battery
WARNING!
The"battery"changecontrollevershouldneverbeoperatedexceptatabatterychangestationorwhenit’snecessarytoadjust thebattery'sterrainclearance.Ifthe"battery"changecontrol leverisoperatedinalowroofarea,thebatterymaybedamaged.
UnlatchbothbatteryIatchpins(oneperside)beforeplacingthe batteryontheground(Figure35).Ifdifficultyisencounteredin unlatchingthelatchpins,itmaybenecessarytogentlyshakethe batteryupanddownbyusingthebattery"LIFT”controllever.
Batterylatch
Lowerthebatterycompletelytothesurfacebypushingthe "BATTERYCHANGE”controlleverawayfromtheoperator.The bottomofthebatteryshouldtouchthesurface(Fig.36).
WARNING!
Neverattempttodisconnectahydraulichosefromthebatteryliftingcylinderswhilethebatteryisintheupposition.Thiscould causethebatterytofallandcouldresultinseriousinjury.
Discharged battery
Fig.35:Batterychangeprocedure(CH818groundlevel)
Pivotlatch
Batterylatch
Pivotlatch
Fig.36:Batterychangeprocedure(CH818groundlevel)
Afterthebatteryisfullylowered,shutdown-theUN-A-HAULER ® (seeShutdownprocedureinthischapter).
AftershuttingdowntheUN-A-HAULER ®,disconnectthedischargedbattery(Fig.47):
■ Unlockandremovethepadlockatthebatteryconnector.
■ Graspthethreadedlockringandrotateitcounterclockwise (CCW)untilthethreadsaredisengagedanditisfreetoslide awayfromthelockinglug;thelockringisdesignedtomove freelybuttonotcomeofftheplug.
■ Grasptheplugandpullitoutuntiltheplugiscompletelydisconnectedfromthereceptacle;theplugismadetofitvery tightlyinsidethebatteryreceptacleand-shouldnotbedriven outofthereceptacle,dropped,orhandledroughly;iftheplug (orreceptacle)isdamaged,itwillnotfittogetherproperly.
■ Installthecapwhichissecuredtothereceptacleonthebattery byasmallchain;thiscapisplacedoverthethreadedreceptacleandrotatedinaclockwise(CW)directionuntilhandtight anduntilapadlockwillfitintothelockinglug;thepadlocksall usethesamekey.
Connectthejumpercable:
■ Connectthereceptacleendofthejumpercabletotheplug comingoutoftheconnectionboxontheUN-A-HAULER ® (Fig. 37).
■ Connecttheplugendofthejumpercabletothefullycharged battery.
■ Securethejumpercableconnectionsbyusingthethreaded lockrings.Theselockringsmustbehandtightbutdonothave tobepadlocked.
■ OnepersonshouldholdthejumpercablesoitwillnotbedamagedorberunoverwhentheUN-A-HAULER ® ismoved.
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Fig.37:Batterychangeprocedure(CH818groundlevel)
Charged battery
Discharged battery
StarttheUN-A-HAULER ® (seeStartingprocedureinthischapter). Gentlypullawayfromthedischargedbatterywhilethesecondpersonholdsthejumpercableawayfrompossibledamage.
LinetheUN-A-HAULER ® upwiththefullychargedbattery.Move themachineforwarduntiltheliftarmsarealignedwiththesidesof thebattery(Fig.38).Continuemovingforwarduntiltheliftarms areincorrectlyalignedundertheslotsinbattery.
Fig.38:Batterychangeprocedure(CH818groundlevel)
Charged battery
Discharged battery
Raisethebatterytothecarrypositionbypullingthe"BATTERY" changecontrollevertowardtheoperator(Fig.39).
Fig.39:Batterychangeprocedure(CH818groundlevel)
Charged battery
ShutdowntheUN-A-HAULER ® (seeShutdownprocedureinthis chapter).Reinsertthelatchpinsonbothsidesofthebattery(Fig. 40).
Fig.40:Batterychangeprocedure(CH818groundlevel)
Batterylatch
Pivotlatch
Batterylatch
Pivotlatch
DisconnectthejumpercableandconnectthechargedbatterydirectlytotheUn-A-Hauler'scable(Fig.47).Remembertobecareful withtheplugs.Aftertheplugisinthereceptacle,thelockring shouldberotatedclockwise(CW)untilhandtight.Thepadlock mustbeinthelockinglugandlockedforthisconnectiontobepermissible.
StarttheUn-A-Hauler(seeStartingprocedureinthischapter.
Thiscompletesthegroundlevelbatterychangeprocedure.
Batterychangeprocedure (CH810BandCH816Bgroundlevel)
TwopeopleareneededtochangethebatteryintheUN-A-HAULER ® SinceonepersonmaystepintotheHazardZone,theotherperson (operatingtheUN-A-HAULER ®)mustbeverycarefuland- lookeach timebeforemovinganyleversorpedals.Taketimenowtorefamiliarize yourselfwiththeHazardzone(Fig.20).
Fig.41:Batterychangeprocedure(CH816groundlevel)
Discharged battery
Charged battery
WARNING!
The"BATTERYCHANGE"controllevershouldneverbeoperated exceptatabatterychangestationorwhenit’snecessarytoadjust thebattery'sterrainclearance.Ifthe"BATTERYCHANGE”control leverisoperatedinalowroofarea,thebatterymaybedamaged.
Unlockthebatterybeforeplacingthebatteryontheground(Fig. 42).Pushthebatteryholddownleverawayfromtheoperator,then pushthebattery“LIFT”controlleverawayfromtheoperatorand holduntilthehooksarecompletelybelowthebatteryliftarmsto unlockthebattery.
Fig.42:Batterychangeprocedure(CH816groundlevel)
Batteryholddownlever
Battery“LIFT”control
Lowerthebatterycompletelytothesurfacebypullingthebattery holddownlevertowardstheoperatorandpushingthe"BATTERY CHANGE”controlleverawayfromtheoperator.Thebottomofthe batteryshouldtouchthesurface(Figure43).
WARNING!
Neverattempttodisconnectahydraulichosefromthebatteryliftingcylinderswhilethebatteryisintheupposition.Thiscould causethebatterytofallandcouldresultinseriousinjury.
Fig.43:Batterychangeprocedure(CH816groundlevel)
Dischargedbattery
Afterthebatteryisfullylowered,shutdowntheUN-A-HAULER ® (seeShutdownprocedureinthischapter).
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