CAT Bucyrus 488-6DM Operation Manual A6474X245 PDF Download

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Cat Bucyrus 488-6DM Operation Manual (A6474X245) – PDF DOWNLOAD

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Cat Bucyrus 488-6DM Operation Manual (A6474X245) – PDF DOWNLOAD

Language : English
Pages : 369
Downloadable : Yes
File Type : PDF

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Cat Bucyrus 488-6DM Operation Manual (A6474X245) – PDF DOWNLOAD

1. CAT BUCYRUS 488-6DM Operation Manual (A6474X245)
2. CAT BUCYRUS LA5 LA6 LA8 LA10 LA12 & LA14 OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING PARTS & SERVICE GUIDE MANUAL (A6474X193)
3. CAT BUCYRUS MINE POWER STORAGE BATTERIES INSTALLATION USE MAINTENANCE & REPAIR (A6474X26)
4. CAT BUCYRUS 2000 DUAL & SINGLE MOTOR SOLID STATE CONTROLLERS OPERATION & TROUBLESHOOTING MANUAL (A6474X226)
5. CAT BUCYRUS KESSLER AXLES SERVICE MANUAL
6. CAT BUCYRUS BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS (A6474X61)

• This manual is intended to provide GENERAL product information for the Model 488-6DM UN-A-TRAC ®. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.
• This 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 unit 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 unit, without the consent of Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render this unit 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 unit.
• While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. 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 non-transferable. 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 488-6DM Operation Manual (A6474X245) – PDF DOWNLOAD

• CAT BUCYRUS 488-6DM Operation Manual (A6474X245)

1. About this manual
About this manual 1.3
Before starting to work 1.3
Who is this operating manual intended for? 1.3
What is the purpose of this operating manual? 1.4
Characters and symbols 1.5
2. Your safety
Your safety 2.3
Personnel 2.4
Operation 2.4
Installation and repair 2.4
Operating conditions 2.5
Intended use 2.5
Unauthorized use 2.5
Safety instructions 2.7
General rules: 2.7
Storage and transport 2.8
Pre-start inspection 2.8
Installation and start-up 2.9
Operation 2.9
Stopping 2.10
Maintenance and repair 2.10
Overview of the safety instructions 2.15
Chapter 3: Storage and transport 2.15
Chapter 4: Installation 2.15
Chapter 5: Operation 2.16
Chapter 6: Technical data 2.21
3. Storage and transport
Storage and transport 3.3
Storage 3.3
Storage of the machine and spare parts 3.3
Transport 3.4
Before transport 3.5
4. Installation
Installation 4.3
Points to observe prior to installation 4.3
Who is allowed to carry out installation? 4.3
Which tools are required for installation? 4.3
Notes on installation 4.4
Pre-installation check list 4.5
Safety features 4.6
5. Operation
Operation 5.3
How to operate the UN-A-TRAC ® 5.3
Who is allowed to operate the UN-A-TRAC ® 5.3
When can operation be started? 5.3
Controls and indicators 5.4
Operator’s compartment 5.4
General hydraulic control information
(standard machine) 5.13
General hydraulic control information
(QDS bellcrank machine) 5.15
Hazard zone 5.18
Starting procedure 5.19
Machine operation 5.20
Shutdown procedure 5.23
Towing a disabled machine 5.25
Battery change procedure 5.26
Instructions on the maintenance 5.33
Important notes 5.33
Before maintenance 5.33
Critical torque values 5.35
Lubricants, fluids and capacities 5.35
Specific lubrication and maintenance instructions 5.39
Every shift 5.39
Weekly 5.40
Monthly 5.51
Every three months 5.52
Instructions on the adjustment procedures 5.59
Primary hydraulic system pressure 5.59
Steering relief pressure 5.61
Troubleshooting procedures 5.65
Hydraulic system (general) 5.66
Brakes 5.69
Hydraulic cylinders 5.71
Hydraulic pump 5.72
Valves 5.74
6. Technical data
Technical data 6.3
Components of the 488-6DM UN-A-TRAC ® 6.3
Tightening torques 6.7
Permissible data 6.13
Lubrication fluids and greases 6.13
7. For your information
For your information 7.3
Our service 7.3
Service address 7.3
Rebuild facility address 7.4

• CAT BUCYRUS LA5 LA6 LA8 LA10 LA12 & LA14 OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING PARTS & SERVICE GUIDE MANUAL (A6474X193)

PREFACE 1
SYMBOLS AND SPECIAL NOTATIONS 3
MAJOR HAZARDS 5
SAFETY PRECAUTIONS AND GUIDELINES 7
OVERVIEW 7
LOCATION 7
PRE-START 7
STARTING 7
MAINTENANCE 8
PERSONAL PRECAUTIONS 8
THEORY OF OPERATION FERRORESONANT DESIGN 11
INTRODUCTION 13
GENERAL 13
RATINGS AND SPECIFICATIONS 15
OUTPUT RATINGS 15
INPUT RATINGS 15
TYPICAL ELECTRICAL SPECIFICATIONS 15
STANDARD FEATURES 16
OPTIONAL GROUND INTEGRITY 16
ENVIRONMENTAL RATINGS 17
INSTALLATION INFORMATION 19
MINIMUMWIRE SIZES 19
ELECTRICAL CONNECTIONS & FIELDWIRING 19
OPERATION 21
START UP (ELECTRONIC TIMER) 21
ADJUSTMENTS 21
CIRCUIT OPERATION 21
TROUBLESHOOTING 23
GENERAL INSPECTION 23
SERVICE INFORMATION 23
SYMPTOMS AND CAUSES 24
GROUND AND SHORT CIRCUIT TEST 24
TROUBLESHOOTING AND REPLACING POWER SILICON DIODES 25
CHECKING CAPACITORS 25
BATTERY CHARGER REPLACEMENT PARTS 27
491868X3 LA-14 BATTERY CHARGER 480/575 VOLT, 60 HZ 28
491868X4 LA-14 BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 29
491868X5 LA-14-MT BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 30
491868X7 LA-12 BATTERY CHARGER 480/575 VOLT, 60 HZ 31
491868X8 LA-12 BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 32
491868X10 LA-10 BATTERY CHARGER 480/575 VOLT, 60 HZ 33
491868X12 LA-8 BATTERY CHARGER 480/575 VOLT, 60 HZ 35
491868X14 LA-8 BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 36
491868X15 LA-6 BATTERY CHARGER 480/575 VOLT, 60 HZ 37
491868X16 LA-6 BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 38
491868X17 LA-5 BATTERY CHARGER 480/575 VOLT, 60 HZ 39
491868X18 LA-5 BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 40

• CAT BUCYRUS MINE POWER STORAGE BATTERIES INSTALLATION USE MAINTENANCE & REPAIR (A6474X26)

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

• CAT BUCYRUS 2000 DUAL & SINGLE MOTOR SOLID STATE CONTROLLERS OPERATION & TROUBLESHOOTING MANUAL (A6474X226)

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 KESSLER AXLES SERVICE MANUAL

1 Important remarks
2 Lubrication intervals and maintenance instructions
3 General instructions for correct assembly and disassembly
Service tools
4 Assembly drive assembly
5 Assembly hub assembly
6 Assembly panetary gear drive
7 Assembly service brake
8 Assembly parking brake

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