CAT BUCYRUS 488-6 WITH QUICK DETACH SYSTEM OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL – PDF DOWNLOAD

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CAT BUCYRUS 488-6 WITH QUICK DETACH SYSTEM OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL – PDF DOWNLOAD

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CAT BUCYRUS 488-6 WITH QUICK DETACH SYSTEM OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL – PDF DOWNLOAD

Language : English
Pages : 203
Downloadable : Yes
File Type : PDF

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CAT BUCYRUS 488-6 WITH QUICK DETACH SYSTEM OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL – PDF DOWNLOAD

• This manual is intended to provide GENERAL product information for the Model 488 Series UN-A-TRAC®. The illustrations, descriptions and procedures contained in this publication apply only to this Model 488 UN-A-TRAC®. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.
• This Model 488 UN-A-TRAC® was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U. S. regulatory agency standards.
• At the completion of the manufacturing process, this Model 488 UN-A-TRAC® was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this Model 488 UN-A-TRAC®, without the consent of Bucyrus America, Inc., and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America’s instructions, may invalidate these approvals and render this Model 488 UN-A-TRAC® unsafe to operate.
• Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this Model 488 UN-A-TRAC®.
• While this manual attempts to anticipate the most important operations and maintenance needs for this Model 488 UN-A-TRAC®, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America Service Representative immediately.
• This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is nontransferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

TABLE OF CONTENTS:

CAT BUCYRUS 488-6 WITH QUICK DETACH SYSTEM OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL
CAT BUCYRUS 2000 DUAL AND SINGLE MOTOR SOLID STATE CONTROLLERS OPERATION & TROUBLESHOOTING GUIDE
CAT BUCYRUS 5, 6, 8, 10, 12 & 14 BATTERY CHARGERS WITH DIGITAL DISPLAY OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & GUIDE
CAT BUCYRUS MINE POWER STORAGE BATTERIES INSTALLATION USE MAINTENANCE AND REPAIR MANUAL
CAT BUCYRUS BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS MANUAL

PREFACE .1
SYMBOLS AND SPECIAL NOTATIONS .3
MAJOR HAZARDS .5
SAFETY PRECAUTIONS AND GUIDELINES .7
OVERVIEW .7
PRE-START INSPECTION .7
STARTING 7
OPERATING .7
STOPPING 8
MAINTENANCE 8
INTRODUCTION .9
CONTROLS AND INDICATOR 11
SERVICE BRAKE PEDAL .11
FIRE SUPPRESSION ACTUATORS 12
SPEED-SWITCH (ACCELERATOR) FOOT PEDAL .12
LIGHT SWITCH LEVER 12
MASTER SWITCH LEVER 12
PUMP START SWITCH .13
AUTOMATIC PARK BRAKE RELEASE SWITCH .13
CIRCUIT BREAKER RESET LEVER 14
TAPE SWITCH (PANIC STRIP) 15
EMERGENCY DISCONNECT LEVER 15
WARNING GONG .15
LA 2000 DASHBOARD DISPLAY (OPTIONAL) 16
GAUGE PANEL (OPTIONAL) .16
DIF-LOK (OPTIONAL) . 17
GENERAL HYDRAULIC CONTROL INFORMATION .17
“STEERING” CONTROL LEVER 18
“LEFT-HAND STEERING” CONTROL LEVER (OPTIONAL) 18
“TILT” CONTROL LEVER 19
“LIFT” CONTROL LEVER 19
“EJECTOR” CONTROL LEVER 19
“QDS” CONTROL LEVER .19
“PTO / BATT” CONTROL LEVER 20
BRAKE RELEASE HAND PUMP .20
STARTING PROCEDURE 23
TOWING A DISABLED MACHINE 27
SHUTDOWN PROCEDURE .29
BATTERY CHANGE PROCEDURE (VERTICAL LIFT) 32
BATTERY CHANGE PROCEDURE (GROUND LEVEL) 37
GENERAL MAINTENANCE INSTRUCTIONS .45
CRITICAL TORQUE VALUES .47
LUBRICANTS, FLUIDS AND CAPACITIES 47
MAINTENANCE CHECK LIST .49
PERIODIC MAINTENANCE PROCEDURES .51
EVERY SHIFT .51
ONCE PER WEEK .50
ONCE PER MONTH 60
EVERY THREE MONTHS .62
LUBRICANT SPECIFICATIONS 65
APPROVED SUPPLIERS .65
LUBRICATION CHART 67
ONCE PER WEEK .67
TROUBLESHOOTING PROCEDURES .69
HYDRAULIC SYSTEM (GENERAL) 70
BRAKES (SERVICE) WET DISC .71
BRAKES (AUTOMATIC WET DISC) .72
CYLINDERS 72
PUMPS 73
RELIEF VALVES .75
MAJOR MAINTENANCE PROCEDURES .77
CONTACTOR TIP REPLACEMENT .77
DRIVE MOTOR/GEARBOX (SPEED REDUCER) REMOVAL AND REPLACEMENT .78
TIRE/WHEEL INSTALLATION PROCEDURE 81
TIRE/WHEEL STRESSES 81
WHEEL MOUNTING ARRANGEMENTS 81
PROBLEM AREAS 81
WHEEL MOUNTING TIPS 82
RECOMMENDED WHEEL MOUNTING PROCEDURES: 83
PRECAUTIONS: 83

CAT BUCYRUS 2000 DUAL AND SINGLE MOTOR SOLID STATE CONTROLLERS OPERATION & TROUBLESHOOTING GUIDE

PREFACE 2
SYMBOLS AND SPECIAL NOTATIONS 3
MAJOR HAZARDS 5
SAFETY PRECAUTIONS AND GUIDELINES 6
OVERVIEW 6
MAINTENANCE .6
INTRODUCTION 7
BUCYRUS 2000: INNOVATIVE SPEED CONTROL BY BUCYRUS AMERICA, INC 7
GENERAL SPECIFICATIONS .12
FAIL-SAFE OPERATION WILL INCLUDE THE FOLLOWING: 12
DESCRIPTION OF FEATURES 13
BUCYRUS 2000 MOTOR CONTROLLER CONSIST OF: .13
BUCYRUS 2000 MOTOR IGBT PANEL (POWER CONNECTIONS) .13
MICROPROCESSOR BASED LOGIC CARD (CONTROL INPUTS) 13
CONFIGURATION JUMPER TABLE .15
OPTIONAL DASHBOARD DISPLAY FEATURES (SEE FIGURE 9) .15
FAULT MESSAGE CHART 16
OPTIONAL HAND HELD DIAGNOSTICS/CALIBRATOR UNIT 18
PERSONALITY ADJUSTMENT PROCEDURE .19
TRACTION PERSONALITIES (CONTROLLER ADJUSTMENTS) .19
TRACTION STATUS DISPLAY .21
TRACTION TEST DISPLAY .23
TRACTION BDI DISPLAY 24
ERROR CODE LEGEND (STATUS DISPLAY) 25
TROUBLESHOOTING .26
IGBTMEASUREMENTS 27
INDIVIDUAL IGBT MEASUREMENTS 28
DIODEMEASUREMENTS .29
DIODEMEASUREMENTS .30
PANEL MEASUREMENTS 31
DRIVER MEASUREMENTS .32
IGBT DUAL MOTOR PANEL, FIGURE 16 .34
IGBT SINGLEMOTOR PANEL,FIGURE 17 35
IGBT HEAT SINK ASSEMBLY, FIGURE 18 36
SINGLE MOTOR PANEL HARNESS ASSEMBLY, FIGURE 19 37
DUAL MOTOR PANEL HARNESS ASSEMBLY, FIGURE 20 .38
DASHBOARD DISPLAY, FIGURE 21 39
DUAL “Y” HARNESS, FIGURE 22 .40
HARNESS FOR DASHBOARD DISPLAY, FIGURE 23 .41
CALIBRATOR UNIT, FIGURE 24 .42
BUCYRUS 2000 PUMPMOTOR SHUNT, FIGURE 25 42
BUCYRUS 2000 PANELWIRING HARNESS, FIGURE 26 .43

CAT BUCYRUS 5, 6, 8, 10, 12 & 14 BATTERY CHARGERS WITH DIGITAL DISPLAY OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & GUIDE

PREFACE .1
SYMBOLS AND SPECIAL NOTATIONS 2
MAJOR HAZARDS .4
SAFETY PRECAUTIONS AND GUIDELINES .5
OVERVIEW .5
LOCATION .5
PRE-START .5
MAINTENANCE .6
THEORY OF OPERATION FERRORESONANT DESIGN .8
INTRODUCTION .9
GENERAL 9
GENERAL INFORMATION . 10
RECEIVING INSTRUCTIONS . 10
HANDLING . 10
NOMENCLATURE PLATES . 10
ADJUSTMENTS . 10
SPARE PARTS . 10
RATINGS AND SPECIFICATIONS . 11
OUTPUT RATINGS 11
INPUT RATINGS 11
TYPICAL ELECTRICAL SPECIFICATIONS . 11
STANDARD FEATURES 12
OPTIONAL GROUND INTEGRITY 12
ENVIRONMENTAL RATINGS 13
INSTALLATION INFORMATION . 14
MINIMUMWIRE SIZES . 14
ELECTRICAL CONNECTIONS & FIELDWIRING . 14
OPERATION . 16
START UP (ELECTRONIC TIMER) 16
ADJUSTMENTS . 17
CIRCUIT OPERATION . 17
TROUBLESHOOTING 18
GENERAL INSPECTION 18
SERVICE INFORMATION . 18
SYMPTOMS AND CAUSES 19
GROUND AND SHORT CIRCUIT TEST . 19
TROUBLESHOOTING AND REPLACING POWER SILICON DIODES 20
CHECKING CAPACITORS 20

CAT BUCYRUS MINE POWER STORAGE BATTERIES INSTALLATION USE MAINTENANCE AND REPAIR MANUAL

PREFACE . 1
SYMBOLS AND SPECIAL NOTATIONS . 3
MAJOR HAZARDS . 5
SAFETY PRECAUTIONS AND GUIDELINES .7
OVERVIEW . 7
MAINTENANCE 7
CHAPTER 1 – INTRODUCTION . 8
SECTION I. GENERAL . 8
SECTION II. DEFINITIONS . 9
SECTION III. DESCRIPTION AND CONSTRUCTION . 9
SECTION IV. PRINCIPLES OF OPERATION 13
CHAPTER 2 – INSTALLATION, USE, AND MAINTENANCE 16
SECTION I. PREPARATION FOR USE 16
SECTION II. ROUTINE MAINTENANCE . 20
CHAPTER 3 – FIELD SERVICING AND REPAIR . 25
SECTION I. TROUBLESHOOTING 25
SECTION II. REPAIRING BATTERIES 26
CHAPTER 4 – HEALTH AND SAFETY . 35
SECTION I. BATTERY HAZARDS . 35
SECTION II. SAFETY PROCEDURES . 35
CHAPTER 5 – STORAGE AND SHIPMEMT .39

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