PDF Service Guide Manual CAT BUCYRUS DBT CH818 - 888 KB
This complete service guide covers operation, maintenance, and troubleshooting for the CAT Bucyrus DBT CH818.
This manual is an all-in-one resource for keeping your mining equipment in peak condition.
It provides detailed procedures for service tasks, fault finding, and routine maintenance checks.
Technicians and operators will find the step-by-step instructions and clear illustrations invaluable for maximizing uptime and operational safety.
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BI620963
© Bucyrus
All Rights Reserved
BUCYRUS R
Technical Manual
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BI620963
DBT AMERICA INC. MODEL CH818 UN-A-HAULER
MAJOR HAZARDS
AREA HAZARD SAFEGUARDS
WHERE HAZARD CAN WHAT CAN HAPPEN IF HOW TO AVOID
OCCUR PRECAUTIONS AND THE HAZARD
SAFEGUARDS ARE NOT
OBEYED
ENTIRE MACHINE Movement of machine can run Keep alI people out of Hazard
over or crush body parts Zone (page 16). Use extreme
between machine and other caution when moving machine.
objects and cause irreparable The machine should be
injury or death. properly shutdown (see page
21) before the operator leaves
the operator's compartment.
OPERATOR'S AREA Operation of machine with Keep head, arms, hands,
head, arms, or hands outside inside operator's compartment
of operator's compartment at alI times.
could cause irreparable injury
or death if body parts strike or
are crushed between machine
and outside objects.
REAR SECTION Ejector blade or false bottom Keep alI hands, arms, legs,
being returned could cause feet and persons out from
irreparable injury or death if between the front of the rear
body parts or persons are (payload) section and the
crushed between ejector ejector blade/false bottom.
blade/false bottom and the rear The machine must be properly
(payload) section frame. shutdown for service (see
page 21).
CENTER SECTION Machine could be steered Keep alI persons, hands, feet,
(ARTICULATION POINT) crushing persons, hands, feet, legs, out of articulation area
or legs in the articulation area. and off the top and out from
under the machine. Machine
should be properly shutdown
(page 21) before servicing.
The machine must also be
blocked under the battery,
payload end, and center
section.
UNDERNEATH DURING Machine raised for service If machine must be raised for
SERVICE could fall and crush persons or service, it must be securely
body parts underneath. blocked so that all wheels may
safely turn (see maintenance
page 35). The machine must
also be blocked under the
battery, payload end, and
center section.
2
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BI620963
DBT AMERICA INC. MODEL CH818 UN-A-HAULER
WARNING
THE MACHINE CIRCUIT BREAKER SHOULD BE IN THE "OFF" POSITION AND
THE PARKING BRAKE SET BEFORE THE OPERATOR LEAVES THE
OPERATOR'S SEAT. IN AN EMERGENCY, THE OPERATOR CAN STOP THE UN-
A-HAULER BY STRIKING THE PANIC SWITCH WHICH TRIPS THE BREAKER.
THE UNIT CAN ALSO BE STOPPED BY MOVING THE MACHINE CIRCUIT
BREAKER LEVER TO THE "OFF" POSITION.
The machine circuit breaker is not intended as an "ON-OFF" switch for normal operation. Except
in an emergency, the Un-A-Hauler should be shutdown by first moving the master switch to the
"OFF" position and then moving the machine circuit breaker to the "OFF" position.
WARNING
ALL ELECTRICAL SWITCHES IN THE OPERATOR'S COMPARTMENT MUST BE IN
THE "OFF" POSITION BEFORE MOVING THE BATTERY CIRCUIT BREAKER
LEVER TO THE "ON" POSITION.
BATTERY CIRCUIT BREAKER LEVER - The battery circuit breaker is located on the battery.
This circuit breaker has 4 positions: "OFF," to de-energize the machine's electrical systems,
"TRIPPED," when the circuit breaker is overloaded, "RESET," to reset the circuit breaker after it
has tripped, and "ON," for normal operation (Figure 5). The battery circuit breaker should be in
the "OFF" or "TRIPPED" position before the Un-A-Hauler is serviced or when the battery plug is
being connected or disconnected.
WARNING
ONCE THE BREAKER HAS TRIPPED, IT WILL NOT STAY IN THE “ON”POSITION
WITHOUT (FIRST BEING MOVED TO THE "RESET" POSITION, AND THEN TO
"ON".
BATTERY CIRCUIT BREAKER LEVER
BATTERY CIRCUIT BREAKER
FIGURE 5
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BI620963
DBT AMERICA INC. MODEL CH818 UN-A-HAULER
WARNING
NEVER ENTER THE ARTICULATION AREA WHILE THE MACHINE IS RUNNING.
COMPLETELY SHUTDOWN THE MACHINE AS OUTLINED BEFORE CONNECTING
THE STEERING LOCKOUT DEVICE. FAILURE TO OBSERVE THIS PRECAUTION
MAY RESULT IN INJURY OR DEATH.
CAUTION
THIS UNIT IS EQUIPPED WITH A CANOPY. BE CAREFUL NOT TO HIT YOUR
HEAD WHEN ENTERING OR LEAVING THE OPERATOR'S COMPARTMENT.
WARNING
IN THE EVENT OF AN EMERGENCY, THE UN-A-HAULER MAY ALSO BE
SHUTDOWN BY STRIKING THE PANIC SWITCH. WHEN THE PANIC SWITCH IS
STRUCK, THE MACHINE CIRCUIT BREAKER WILL TRIP. THIS DISCONNECTS
THE MOTORS AND APPLIES THE AUTOMATIC EMERGENCY BRAKE. BE
PREPARED FOR THE SUDDEN STOP WHEN THE PANIC SWITCHS ARE STRUCK.
THIS COMPLETES THE SHUTDOWN PROCEDURE.
22
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BI620963
DBT AMERICA INC. MODEL CH818 UN-A-HAULER
FIGURE 25
3. Lower the battery completely to the surface by pushing the "BATTERY”change control lever
away from the operator. The bottom of the battery should touch the surface (Figure 26).
WARNING
NEVER ATTEMPT TO DISCONNECT A HYDRAULIC HOSE FROM THE BATTERY
LIFTING CYLINDERS WHILE THE BATTERY IS IN THE UP POSITION. THIS
COULD CAUSE THE BATTERY TO FALL AND COULD RESULT IN SERIOUS
INJURY.
FIGURE 26
4. After the battery is fully lowered, shutdown-the Un-A-Hauler (see Shutdown Procedure, page
21).
5. After shutting down the Un-A-Hauler, disconnect the discharged battery (Figure 23):
A. Unlock and remove the padlock at the battery connector .
B. Grasp the threaded lock ring and rotate it counterclockwise (CCW) until the threads are
disengaged and it is free to slide away from the locking lug; the lock ring is designed to
move freely but to not come off the plug.
C. Grasp the plug and pull it out until the plug is completely disconnected from the receptacle;
the plug is made to fit very tightly inside the battery receptacle and-should not be driven out
of the receptacle, dropped, or handled roughly; if the plug (or receptacle) is damaged, it will
not fit together properly.
D. Install the cap which is secured to eac receptacle on the battery by a small chain; this cap is
placed over the threaded receptacle and rotated in a clockwise (CW) direction until hand
tight and until a padlock will fit into the locking lug; the padlocks all use the same key.
6. Connect the jumper cable:
A. Connect the receptacle end of the jumper cable to the plug coming out of the connection
box on the Un-A-Hauler (Figure 27).
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BI620963
DBT AMERICA INC. MODEL CH818 UN-A-HAULER
HYDRAULIC OIL FILTER AND DIRT ALARM
FIGURE 35
CAUTION
DO NOT OPERATE THE UN-A-HAULER WITH THE HYDRAULIC OIL FILTER
INDICATOR IN THE RED ("CHANGE") POSITION. TO DO SO WILL DAMAGE THE
HYDRAULIC SYSTEM.
4. Check the panic strips. Start the Un-A-Hauler, but do not tram. Strike the panic strips to be
certain that they are operating properly, tripping the machine circuit breaker and shutting down
the Un-A-Hauler.
5. Lubricate the battery hold-down latch by placing a small amount of grease between the battery
latch and the Un-A-Hauler frame (Figure 36). (Standard Machines)
BATTERY HOLD-DOWN LATCH LUBRICATION
FIGURE 36
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BI620963
DBT AMERICA INC. MODEL CH818 UN-A-HAULER
H. Replace the cap on the relief valve.
I. Remove the gauge and replace the hose into the relief valve.
BRAKE COOLING CIRCUIT RELIEF VALVE
FIGURE 45
5. Check (and adjust if necessary) the sequence of operation of the false bottom/ejector blade.
WARNING
BEFORE MOVING THE "EJECTOR" CONTROL LEVER, MAKE SURE NO ONE HAS
ANY PART OF HIS BODY BETWEEN THE BACK OF THE EJECTOR BLADE/FALSE
BOTTOM AND THE FRONT OF THE REAR (PAYLOAD) SECTION.
A. When the ejector/false bottom is being retracted, the ejector blade should return to the back
of the false bottom before the false bottom starts to move.
B. When the ejector blade/false bottom is extended, the false bottom should extend before the
ejector blade extends. When the ejector blade/false bottom is retracted, the ejector blade
should retract before the false bottom retracts.
To adjust the sequence valve:
C. Extend the ejector blade/false bottom to the rear of the payload section and shutdown the
machine (see Shutdown Procedure, Page 21).
D. Adjust the sequence valve.
E. Start the machine and cycle the ejector blade/false bottom.
F. Repeat the procedure until the adjustment is complete.
6. Clean or replace the suction strainer inside the hydraulic oil tank.
A. Remove the suction hose to the pump and allow the oil to drain.
B. Remove the old strainer by unscrewing it from the fittings that hold the strainer inside the
tank (Similar to Figure 46).
C. Replace the strainer with a new one or thoroughly clean the old one with kerosene and a
soft brush. Dry the cleaned strainer with air before replacing it in the tank.
D. Replace the strainer in the tank and tighten hand-tight.
E. Replace the suction hose.
F. Refill with hydraulic oil (for Lubricant Specifications, see page 36).
52
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BI620963
DBT AMERICA INC. MODEL CH818 UN-A-HAULER
EXCESSIVE 1. Defective ball valve in 1. Replace ball valve.
ACCUMULATOR LEAKAGE charging valve.
WHEN BRAKES ARE NOT
BEING USED 2. Defective guide in charging 2. Replace guide.
valve.
3. Seal leaking in charging 3. Replace seal.
valve.
4. Guide sticking in plug due to 4. Remove and clean the
contamination. guides.
5. Defective seal on piston. 5. Replace seal.
INSUFFICIENT BRAKES 1. Broken pressure regulating 1. Replace pressure regulating
spring. spring.
HYDRAULIC CYLS.
CYLINDER DRIFTS 1. Piston seal leak. 1. Replace seals.
2. Other circuit leaks. 2. Correct leaks.
CYLINDER FAILS TO MOVE 1. Pressure too Iow. 1. Check pressure at cylinder
THE LOAD WHEN to make circuit requirements.
ACTUATED
2. Piston seal leak. 2. Replace seals.
3. Piston rod broken at piston 3. Disassemble and replace
end. piston rod.
4. Contamination in hydraulic 4. Disassemble and replace
system resulting in scored necessary parts.
cylinder bore.
ERRATIC OR CHATTER IN 1. Excessive friction due to 1. Correct cylinder to load
OPERATION misalignment. alignment.
EXCESSIVE OR RAPID 1. Excessive high back 1. Correct pressure
PISTON SEAL WEAR pressure due to over adjustment.
adjustment.
CYLINDER BODY SEAL 1. Excessive pressure. 1. Reduce pressure to rated
LEAK limits.
2. Seal is pinched or extruded. 2. Replace cylinder body seal.
3. Seal deterioration (soft or 3. Check compatibility of seal
gummy). material with operating fluid.
Replace oil.
TROUBLE, SYMPTOM OR PROBABLE CAUSE TEST, CHECK AND/OR
CONDITION REMEDY
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BI620963
DBT AMERICA INC. MODEL CH818 UN-A-HAULER
BRAKE PACK INSTALLATION
FIGURE 50
PLANETARY WHEEL END REMOVAL AND REPLACEMENT
1. Planetary Wheel End Removal:
A. Raise and securely block the Un-A-Hauler's drive wheels off the ground.
B. Remove the tire-wheel assembly.
C. Attach a sling and hoist to the wheel end and take up any slack in the sling.
D. Remove the bolts that secure the wheel end to the frame.
2. Planetary Wheel End Replacement:
WARNING
THE CORRECT NUMBER OF SHIMS TO USE IN BETWEEN THE GEAR CASE AND
PLANETARY WHEEL END MUST BE DETERMINED BEFORE INSTALLING EITHER
THE GEAR CASE OR THE PLANETARY WHEEL END (SEE SHIM PROCEDURE
THAT FOLLOWS).
A. Clean all mating surfaces (wheel end and frame) thoroughly.
B. Place the correct number of shims (as determined in the shim procedure) on the gear case.
C. Using a sling and hoist, raise the wheel end to the frame.
D. Align the gearing.
E. Secure the wheel end to the frame with the bolts torqued to 240 ft./lbs. (lubricated threads)
540 Nm (dry threads). The wheel end mounting bolts should be tightened in the sequence
shown in Figure 53.
F. Check all oil levels before operating the unit.
72