PDF Operators Manual CAT Load Haul Dump Crawler Units (Size 9) - 863 KB
This operator's manual is designed for operators of Caterpillar Load Haul Dump (LHD) Crawler Units (Size 9).
The guide provides crucial instructions on proper machine operation, safety precautions, and daily maintenance checks.
Familiarizing yourself with this information will help enhance job site safety and machine efficiency.
It is an essential document for ensuring the longevity and performance of your Cat LHD equipment.
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BI616744
© Bucyrus
All Rights Reserved
BUCYRUS R
Technical Manual
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BI616744
Bucyrus Australia
Service Equipment Crawler Units
HYDRAULICS
Handling of Hydraulic Fluids
DANGER: High pressure fluids can penetrate skin and enter the
body. These fluid injections may cause severe tissue damage
and loss of limb.
Care and consideration must be taken in regards to careful
routing, adjacent components, warnings, guards, shields and
training.
Relieve pressure before disconnecting hydraulic or other lines.
Tighten all connections before applying pressure. Avoid
contact with escaping fluids.
If a fluid-injection accident occurs, see a doctor immediately.
DO NOT DELAY OR TREAT AS A SIMPLE CUT!
Avoid direct contact between the skin and hydraulic fluids.
Hydraulic fluid can penetrate the skin and cause serious infections.
Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to
health.
Maintenance and Repair
Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work
on the hydraulic system.
Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay
attention that:
The hoses are not pinched or trapped.
The hoses have no bubbles or blisters.
The hoses or the outer sheathes of the hoses are not abnormally rigid or hard.
The outer sheath of the hoses is not damaged.
The connectors are securely inserted into the sockets.
The connections are leak-tight.
Note: Always chance staples when replacing hoses.
Ensure that no dirt enters the hydraulic system during repair work.
Dirt in the hydraulic system can cause serious damage in the whole system! Flush out the hydraulic
lines thoroughly before connecting.
If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may
still be pressurised. Be sure to depressurise the line before disconnecting couplers.
Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten
the clamps completely and with both sides. Never use nails, wire or similar materials for securing.
After finishing repair work, check all connectors and connections for leaks before pressuring the
system again.
Manual No. M00637 10 of 49 Oct 2010
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BI616744
Bucyrus Australia
Service Equipment Crawler Units
Pump station and crawler unit
Transformer station and crawler unit
Pump station front view Transformer station front view
Manual No. M00637 20 of 49 Oct 2010
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BI616744
Bucyrus Australia
Service Equipment Crawler Units
The hoses are connected in parallel connections; H1 of the pendant connects to H1 on the crawler,
H2 on the pendant connects to H2 on the crawler and so on, for the six hoses.
The fittings are designed so that only the correct fittings can be connected into the pendant and the
crawler PTO ports.
Note: Pre operational checks ie: visual inspection of PTO hoses/
connections and perform a pendant controller function test.
Activate deadman and joystick individually to prove correct
functions before use.
Important: Routine checks of the supply pressure filter and the
pilot filter in the valve bank unloader section are required.
Replace filter element when a blockage is indicated to maintain
optimum fluid condition.
The pendant control unit is supplied with a shoulder harness. The unit weighs approximately 11kg,
and has a single 8 position joystick, and a safety valve knob lever.
DANGER: Do not mechanically lock the safety valve knob lever
in the up position. If this is done, any accidental or otherwise
unwanted movement of the joystick will operate the crawler
unit. In the event of this occurring, there is high risk of
equipment damage or injury or death to personnel.
6. When using the pendant control unit, ensure the safety valve knob lever is on the left of the
joystick.
Important: Ensure the LHD is running, the pendant is connected
to the crawler unit, and the 10m hose pack is connected
between the crawler unit and the mobile machine prior to
operating.
7. Pull the safety valve knob lever up to enable the joystick control. The safety valve knob lever is
spring loaded to close and must be held up. There is no safety detent.
Warning: When tramming that the LHD provides ultimate fluid
power removal ie the LHD operator and the pendant/crawler
operator have constant visual contact
8. Operate the joystick lever in the required direction to initiate crawler movement. The joystick is
spring loaded to neutral, so will return to the neutral position when released.
9. Once the crawler unit is in the required position, release the safety valve knob lever.
Accidental movement of the joystick will not operate the crawler once the safety valve knob lever
is released.
Manual No. M00637 30 of 49 Oct 2010
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BI616744
Bucyrus Australia
Service Equipment Crawler Units
Tensioning cylinder
To refit a tensioning cylinder, place the cylinder in the cylinder base securing block then roll the
tensioning hub back into place.
Fit the two tensioning cylinder bolts from inside the grease valve hub.
The grease system should be reconnected correctly as per design.
Refit the track as per procedure, and re-tension the track using a grease gun on the grease valve.
The tension applied to the track should be checked and set according to procedure.
Once correct operation has been confirmed, the covers can be replaced and any isolation and safety
procedures for the task removed.
Manual No. M00637 40 of 49 Oct 2010