PDF Operation Manual Cat Bucyrus CH810B CH816B CH816LB CH818 Face Haulage - 2 MB
This is the complete operation manual for the Cat Bucyrus CH810B, CH816B, CH816LB, and CH818 Face Haulage systems.
The manual provides essential information on safe operation, machine controls, and daily maintenance checks.
It is a critical resource for all personnel working with this heavy-duty mining equipment.
Proper use as described in this guide is key to maintaining a safe and productive mining operation.
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BI000842
Operation Manual
Bucyrus - UN-A-HAULER ®
Model - CH810B, CH816B,
CH816LB, and CH818
Doc. No.: A6474X211
Bucyrus America, Inc. ________________________________________
4041 Wurno Road Telephone: 540-980-4530
Pulaski, VA Fax: 540-994-3763 Internet: www.bucyrus.com
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BI000842
_______________________________________ Before starting to work
Characters and symbols used
The following characters and symbols are used for safety instructions
and important information in the operating manual.
Try to memorize the symbols and their meanings.
DANGER!
Points in the text marked with this symbol draw your attention to
immediately impending danger. Possible consequences are:
very serious injury or even death.
WARNING!
These points contain information on dangerous situations. Possi-
ble consequences are: very serious injury or even death.
CAUTION!
This symbol draws attention to dangerous situations. Possible
consequences are: light to moderately serious injuries and ma-
chine damage.
© BUCYRUS AMERICA, INC.
NOTICE!
Points in the text marked with this symbol draw attention to harm-
ful situations. Possible consequences are: damage to the ma-
chine or damage in the immediate vicinity.
IMPORTANT!
Points in the text marked with this symbol contain useful tips and
information intended to facilitate work for you. They do not warn
about harmful or dangerous situations.
■ Items in lists are marked with bullets.
– Points in sub-lists are marked with a long dash at the start of
the line.
Points in text marked in this way describe individual operations.
Follow these instructions step by step. They will help you carry out
your work faster and more importantly, safer.
______________________________________________________________
A6474X211 VTVI/05 1.5
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BI000842
________________________________ Overview of safety instructions
Installation and start-up
inclined face On inclined faces secure all component parts by chains, e.g. to the sup-
port.
environmental acceptability When working with oils, greases and other chemical substances, ob-
serve the safety regulations applicable to the product.
Dispose of cleaning rags, etc. which have been soiled with oil, grease
or other chemical substances in an environmentally safe manner.
controls When starting up machine, do not operate any controls located inside
the operator’s compartment from outside the compartment.
starting procedures Follow the starting procedure instructions in chapter 5 of this manual.
hazard zone Do not operate any levers, pedals or controls if anyone is in the hazard
zone. (See Hazard zone in Chapter 5 of this manual)
Operation
© BUCYRUS AMERICA, INC.
training Operate the machine only if you have a profound knowledge of the con-
trol elements and their functions. It is necessary that you have been
task trained on the respective UN-A-HAULER ©.
before start-up Before start-up, ensure that there are no persons or obstructions in your
line of travel or in the articulation area when steering the unit.
protective devices Check that all protective devices are installed on the machine and func-
tion properly.
operator’s compartment Clean the operator’s compartment at regular intervals. Ensure that the
operating symbols are legible in order to avoid any operator errors and
resulting accidents.
Never climb onto, or climb out of the machine while it is in motion.
Do not operate the machine with any part of your body outside of the
operator’s compartment in order to prevent body parts from being
crushed between the machine and outside objects .
traveling Use extreme caution when traveling in close quarters or in congested or
blind-travel areas. The warning gong should be sounded to alert per-
sonnel of your movement.
passengers Never carry passengers to prevent the passengers from being thrown
off or crushed between the machine and outside objects.
safety rules Always follow all safety rules of each particular mine when operating
the machine.
problems and malfunctions If problems or malfunctions are encountered while operating the unit, it
must be properly shutdown and the problem corrected immediately.
______________________________________________________________
A6474X211 VTVI/05 2.9
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BI000842
________________________________ Overview of safety instructions
CAUTION!
Be sure that the battery is properly aligned over the battery latch
before moving away from the battery table.
CAUTION!
If the battery is not completely lowered before the UN-A-HAULER®
leaves the battery change station, the battery may fall off or hit the
roof and be damaged.
WARNING!
The "battery" change control lever should never be operated ex-
cept at a battery change station or when it’s necessary to adjust
the battery's terrain clearance. If the "battery" change control
lever is operated in a low roof area, the battery may be damaged.
WARNING!
Never attempt to disconnect a hydraulic hose from the battery lift-
ing cylinders while the battery is in the up position. This could
cause the battery to fall and could result in serious injury.
WARNING!
Before performing maintenance on the machine, disconnect the
© BUCYRUS AMERICA, INC.
electrical power. Either the battery circuit breaker or the machine
circuit breaker must be in the "OFF" position. If work is to be
done inside the electrical controller, the battery should be discon-
nected. Also make sure the capacitor discharge module indicates
that the capacitors are discharged before working inside the con-
troller. Electrical shock and accidental machine movement can
cause serious injuries or even death to you or the maintenance
person.
WARNING!
Do not move any hydraulic control lever unless you are certain
that everyone is completely clear of any machine movement. Ac-
cidental machine movement can cause serious injuries or even
death to you or the maintenance person.
WARNING!
You could be seriously injured or even killed by falling loads. Ob-
serve the safe working load limits of lifting or blocking devices
and keep a safe distance from suspended loads.
NOTICE!
If any welding is to be done to machine, the circuit breakers must
be in the “OFF” position and the batteries disconnected. Failure
to do so may cause electrical component damage.
IMPORTANT!
The drive and pump motors do not require periodic lubrication.
The pump motor bearings are sealed. The drive motors have one
bearing sealed and the other bearing receives lubrication from the
gear case oil.
CAUTION!
Do not adjust the hydraulic system pressure to more than the
main system setting shown on the hydraulic schematic drawing
located in the replacement parts manual for your particular ma-
______________________________________________________________
chine.
A6474X211 VTVI/05 2.19
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BI000842
_______________________________________________________________
4 Installation
________________________________________________________________
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BI000842
___________________________________________________Operation
Operation
This chapter contains important information on the operation and main-
tenance of the machine. It also includes instructions on the replace-
ment of wear parts.
Read this chapter carefully and thoroughly. In particular, observe the
safety instructions in chapter 2 “Your safety”.
How to operate the UN-A-HAULER ®
DANGER!
Incorrect operation endangers yourself and others!
Incorrect operation of the machine is often the cause of very seri-
ous accidents!
Operate the unit only when you have been sufficiently trained on
the machine and have read and understood this operating manual.
Should anything be unclear, please contact your immediate super-
visor.
© BUCYRUS AMERICA, INC.
Who is allowed to operate the UN-A-HAULER ®?
The UN-A-HAULER ® is only allowed to be operated by persons with
adequate knowledge of the complete machine.
This also includes:
■ what safety devices are installed on the machine.
■ where these safety devices are located.
■ how these safety devices are to be operated.
When can operation be started?
Operation must not be started until the safe condition and proper func-
tion of the complete machine has been checked and the daily mainte-
nance operations have been carried out.
______________________________________________________________
A6474X211 VTVI/05 5.3
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BI000842
___________________________________________________Operation
“STEERING” control lever The “STEERING” control lever to the left of the operator (Fig. 18) is
used to steer the UN-A-HAULER ®. To steer left while moving forward
(right while moving in reverse), pull the steering control lever slowly
toward the operator. To turn right while moving forward (left while mov-
ing in reverse), push the steering control lever slowly away from the
operator.
“EJECTOR” control lever The "EJECTOR" lever (Fig. 18), operates the ejector blade/false bot-
tom, located in the rear section. The ejector blade/false bottom pushes
out everything in its path, emptying the rear section. When the
"EJECTOR" lever is pushed by the operator, the ejector blade/false
bottom should move toward the rear of the unit (extend). When the
"EJECTOR" lever is pulled by the operator, the ejector blade/false bot-
tom should move toward the operator (retract). When the ejector
blade/false bottom is not being used, it should be resting in the re-
tracted position.
WARNING!
Before moving the ejector blade/false bottom control lever, verify
that no one has any part of his body between the ejector blade/
false bottom and the front of the rear (payload) section. Also keep
© BUCYRUS AMERICA, INC.
any obstructions from behind the ejector blade/false bottom so it
can return completely to the front of the rear (payload) section.
“BATTERY CHANGER” The "BATTERY CHANGER" lever (Fig. 18) controls the battery chang-
control lever ing system, which is made up of two hydraulic cylinders (battery lifting
cylinders), one on each side of the battery. When the "BATTERY
CHANGER" control lever is pulled by the operator, the battery-lifting
cylinders will raise the battery. Pushing the handle away from the op-
erator will lower the battery. On vertical lift battery change systems the
battery lift cylinders are equipped with passive hold-down devices to
prevent the battery from moving inside the machine. The hold-down
pressure is regulated by a relief valve in the system (refer to the Main-
tenance section of this guide).
CAUTION!
The "BATTERY CHANGER" lever should only be operated at a bat-
tery change station. The battery may be damaged if accidentally
raised in a low roof area.
WARNING!
The battery cannot be changed if the battery is not level when in
the raised position. For more information on how to change the
battery see Battery change procedure in this chapter.
WARNING!
Never attempt to disconnect a hydraulic hose from the battery lift-
ing cylinders with the battery in the "UP" position. This would
allow the battery to fall and could result in injury.
______________________________________________________________
A6474X211 VTVI/05 5.13
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BI000842
___________________________________________________Operation
Battery change procedure (Vertical lift)
Two people are needed to change the battery in the UN-A-HAULER ®.
Since one person may step into the Hazard Zone, the other person
(operating the UN-A-HAULER ®) must be very careful and look each
time before moving any levers or pedals. Take time now to refamil-
iarize yourself with the Hazard zone (Fig. 20).
WARNING!
The UN-A-HAULER ® is equipped with a passive battery hold-
down system. This system keeps the battery resting securely on
the frame while the UN-A-HAULER ® is in operation. The battery
hold-down system requires no operator assistance. However, it is
important that the battery be properly aligned over the battery
latch.
NOTICE!
The battery table must be placed on level ground and the tires
fully inflated (155 psi).
Line up the battery end of the machine with an empty battery table
© BUCYRUS AMERICA, INC.
(Fig. 23) (see Starting procedure in this chapter).
Fig. 23: Battery change procedure (vertical lift)
Battery table Discharged battery
Battery table
Charged battery
______________________________________________________________
A6474X211 VTVI/05 5.23
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BI000842
___________________________________________________Operation
Fig. 37: Battery change procedure (CH818 ground level)
Charged
battery
Discharged
battery
© BUCYRUS AMERICA, INC.
Start the UN-A-HAULER ® (see Starting procedure in this chapter).
Gently pull away from the discharged battery while the second per-
son holds the jumper cable away from possible damage.
Line the UN-A-HAULER ® up with the fully charged battery. Move
the machine forward until the lift arms are aligned with the sides of
the battery (Fig. 38). Continue moving forward until the lift arms
are in correctly aligned under the slots in battery.
Fig. 38: Battery change procedure (CH818 ground level)
Charged
battery
Discharged
battery
Jumper cable
______________________________________________________________
A6474X211 VTVI/05 5.33
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BI000842
________________________________________________ Maintenance
Critical torque values
Torque values are expressed in lubricated and dry thread values. Lu-
bricated thread torque values should be used any time the bolt threads
are covered with oil, grease, anti-seize or thread-locking compounds.
Dry thread torque values should be used when threads are completely
clean and dry.
Table 1: Critical torque values
Location Bolt size Grade Dry Lubricated
Steering cylinder pins 400 240
Tire-Wheel mounting bolts 3/4-16UNF Grade 8 420 250
(Front) X2-1/2
Tire-Wheel mounting bolts 3/4-16UNF Grade 8 420 250
(Rear) X2
Planetary wheel end-to-frame 3/4-NC Grade 8 380 230
mounting bolts 3-1/4
Gear case-to-frame mounting 3/4-NC Grade 8 380 230
bolts 2-1/4
© BUCYRUS AMERICA, INC.
Drive motor-to-gear case 3/4-NC Grade 5 380 230
mounting bolts 2-3/4
Center section (Outer ring) 7/8-NC Grade 8 650 N/A
(810 & 816) * See note 1 9
Center section (Inner ring) 1 1/4 NC Grade 8 1886
(810 & 816) * See note 1 9
Notes:
1. Retorque of these bolts should not be required due to the use of
prevailing torque locknuts. If bolts require to be retorqued, new
bolts and locknuts must be installed.
Lubricants, fluids and capacities
Table 2: Lubricants, fluids and capacities
Location Specification Approximate capacity Notes
Hydraulic oil Spec. 100-1 72 Gallons (816 and 818) 1
65 Gallons (810)
Drive sump (Gear case) Spec. 100-8 4 Gallons Each 2, 3
Multi-Purpose grease Spec. 100-3 As Required 4
Notes:
1. With false bottom/ejector blade completely retracted.
2. 4 gallons of oil to completely fill dry system. Actual level should be
checked after running unit to fill cooling system. Use dipsticks (one
in each drive gear case) to check oil level.
3. Drain gear case and wheel end separately. Fill gear case only to
proper level on dipstick.
4. Pump grease into fitting until old grease can be observed coming
out of component.
______________________________________________________________
A6474X211 VTVI/05 5.43
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BI000842
________________________________________________ Maintenance
gear cases and Change the oil in both gear cases and planetary wheel ends after the
planetary wheel ends first week of service (Fig. 60).
Remove the drain plug (or hose connection if equipped with rear
tractive assist) from the gear case and from the planetary wheel
end and allow the oil to completely drain.
Replace the drain plugs and refill with oil to full level on dipstick or
until oil begins to flow from check/level plug.
Fig. 60: Gear case and planetary wheel end lubrication
Oil level dip stick
Fill plug
Breather and
Drain plug optional oil
level plug
© BUCYRUS AMERICA, INC.
Cooling oil outlet
Wheel end
drain plug
wheel mounting bolts Check the wheel mounting bolts (Fig. 61). The mounting bolts should
be torqued to 300 ft-lbs on the Model 810 and to 380 ft-lbs on Models
816 and 818. Use Loctite 242 on wheel mounting bolts.
Fig. 61: Wheel mounting bolts
Check torque of wheel
mounting bolts on all 4 tire
and wheel assemblies
______________________________________________________________
A6474X211 VTVI/05 5.53
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BI000842
________________________________________________ Maintenance
hydraulic oil suction strainer Clean or replace the hydraulic suction strainer inside the hydraulic oil
tank (Fig. 74).
Remove the drain plug from the hydraulic oil tank to allow the oil to
drain.
Remove the oil tank cover and gasket.
Reach through opening in tank and unscrew strainer from fitting.
Replace the strainer with a new one or thoroughly clean the old
one with kerosene and a soft brush. Dry the cleaned strainer with