CAT BUCYRUS 488 WITH CONTROL HANDLE OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL (A6474X260) – PDF DOWNLOAD

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CAT BUCYRUS 488 WITH CONTROL HANDLE OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL (A6474X260) – PDF DOWNLOAD

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CAT BUCYRUS 488 WITH CONTROL HANDLE OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL (A6474X260) – PDF DOWNLOAD

Language : English
Pages : 191
Downloadable : Yes
File Type : PDF

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CAT BUCYRUS 488 WITH CONTROL HANDLE OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL (A6474X260) – PDF DOWNLOAD

1. CAT BUCYRUS 488 WITH CONTROL HANDLE OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL (A6474X260)
2. CAT BUCYRUS 2000 DUAL AND SINGLE MOTOR SOLID STATE CONTROLLERS OPERATION & TROUBLESHOOTING MANUAL (A6474X226)
3. CAT BUCYRUS MINE POWER STORAGE BATTERIES INSTALLATION USE MAINTENANCE & REPAIR MANUAL (A6474X26)
4. CAT BUCYRUS LA10C BATTERY CHARGER OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL (A6474X95MC)
5. CAT BUCYRUS BATTERY CHARGING & MAINTENANCE INSTRUCTIONS

• 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, but with modifications only approved in China for China MA acceptance.
• 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, State and local 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 WITH CONTROL HANDLE OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL (A6474X260) – PDF DOWNLOAD

• CAT BUCYRUS 488 WITH CONTROL HANDLE OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL (A6474X260)

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
CONTROL HANDLE 12
CIRCUIT BREAKER RESET LEVER 14
TAPE SWITCH (PANIC STRIP) 15
WARNING GONG 15
BUC 2000 DASHBOARD DISPLAY 16
GAUGE PANEL (OPTIONAL) 16
“LEFT-HAND STEERING” CONTROL LEVER 18
“BUCKET” CONTROL LEVER 19
“EJECTOR” CONTROL LEVER 19
“WINCH” CONTROL LEVER (OPTIONAL) 19
“2-SPEED WINCH” CONTROL 19
“BATTERY CHANGER” CONTROL LEVER 20
HYDRAULIC PTO ACTUATOR 20
BRAKE RELEASE HAND PUMP 20
STARTING PROCEDURE 23
TOWING A DISABLED MACHINE 27
SHUTDOWN PROCEDURE 29
BATTERY CHANGE PROCEDURE 31
GENERAL MAINTENANCE INSTRUCTIONS 39
CRITICAL TORQUE VALUES 41
LUBRICANTS, FLUIDS AND CAPACITIES 41
MAINTENANCE CHECK LIST 43
PERIODIC MAINTENANCE PROCEDURES 45
EVERY SHIFT 45
ONCE PER WEEK 46
ONCE PER MONTH 51
EVERY THREE MONTHS 53
LUBRICANT SPECIFICATIONS 55
APPROVED SUPPLIERS 55
LUBRICATION CHART 57
ONCE PER WEEK 57
TROUBLESHOOTING PROCEDURES 59
HYDRAULIC SYSTEM (GENERAL) 60
BRAKES (SERVICE) WET DISC 61
BRAKES (AUTOMATIC WET DISC) 62
CYLINDERS 62
PUMPS 63
RELIEF VALVES 65
MAJOR MAINTENANCE PROCEDURES 67
DRIVE MOTOR/GEARBOX (SPEED REDUCER) REMOVAL AND REPLACEMENT 67
TIRE/WHEEL INSTALLATION PROCEDURE 70
TIRE/WHEEL STRESSES 70
WHEEL MOUNTING ARRANGEMENTS 70
PROBLEM AREAS 70
WHEEL MOUNTING TIPS 71
RECOMMENDED WHEEL MOUNTING PROCEDURES: 72
PRECAUTIONS: 72

• CAT BUCYRUS 2000 DUAL AND 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 MINE POWER STORAGE BATTERIES INSTALLATION USE MAINTENANCE & REPAIR MANUAL (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 LA10C BATTERY CHARGER OPERATION PREVENTIVE MAINTENANCE TROUBLESHOOTING & SERVICE MANUAL (A6474X95MC)

IMPORTANT SAFETY INSTRUCTIONS 1
MAJOR HAZARDS 2
SAFETY PRECAUTIONS AND GUIDELINES 3
OVERVIEW 3
LOCATION 3
PRE-START 3
STARTING 3
MAINTENANCE 3
PERSONAL PRECAUTIONS 4
THEORY OF OPERATION 6
INTRODUCTION 7
GENERAL 7
INPUT RATINGS
A C VOLTAGE 7
INPUT FREQUENCY RANGE 7
INPUT CURRENT & BATTERY CAPACITIES 7
METERS 7
MOUNTING 7
OUTPUT RATINGS
D C VOLTAGE 8
OUTPUT CURRENT 8
REGULATION 8
INPUT PROTECTION 8
OUTPUT PROTECTION 8
AUTOMATIC ELECTRONIC TIMER 8
GROUND INTEGRITY 8
INSTALLATION INFORMATION
MINIMUM WIRE SIZES 10
ELECTRICAL CONNECTIONS & FIELD WIRING 10
A.C INPUT 10
D.C INPUT 11
OPERATION
START UP 13
ADJUSTMENTS 13
CIRCUIT DESCRIPTIONS
CIRCUIT OPERATION 14
TROUBLESHOOTING
GENERAL INSPECTION 17
SERVICE INFORMATION 17
SYMPTOMS & CAUSES 18
GROUND AND SHORT CIRCUIT TEST 18
TESTING SILICONE DIODES 19
TESTING CAPACITORS 19

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