CAT BUCYRUS 488L & 488-6 Operation Manual (A6474X235) – PDF DOWNLOAD

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CAT BUCYRUS 488L & 488-6 Operation Manual (A6474X235) – PDF DOWNLOAD

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CAT BUCYRUS 488L & 488-6 Operation Manual (A6474X235) – PDF DOWNLOAD

Language : English
Pages : 395
Downloadable : Yes
File Type : PDF

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CAT BUCYRUS 488L & 488-6 Operation Manual (A6474X235) – PDF DOWNLOAD

1. Cat Bucyrus 488L & 488-6 Operation Manual (A6474X235)
2. Cat Bucyrus 5 6 8 10 12 14 & 16 Battery Charger with Digital Display Operation Manual (A6474X230)
3. Cat Bucyrus Dual & Single Motor Controller Operation & Troubleshooting Manual (A6474X226)
4. Cat Bucyrus Mine Power Storage Batteries Installation Use Maintenance & Repair Manual (A6474X26)
5. Cat Bucyrus Battery Charging & Maintenance Instructions (A6474X61)

• This manual is intended to provide GENERAL product information for the Model 488-6 and 488L UN-A-TRAC® . The illustrations, descriptions and procedures contained in this publication apply only to THESE machines. 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 488L & 488-6 Operation Manual (A6474X235) – PDF DOWNLOAD

• Cat Bucyrus 488L & 488-6 Operation Manual (A6474X235)

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
Load units, dimensions, and weights 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 – common 5.6
Hydraulic control panel (standard) 5.9
Hydraulic control panel (with vertical lift and QDS) 5.11
Operator’s compartment with control handle 5.15
Operator’s compartment with control station 5.18
Hazard zone 5.20
Starting procedure with control handle 5.21
Machine operation with control handle 5.22
Shutdown procedure with control handle 5.25
Starting procedure with control station 5.27
Shutdown procedure with control station 5.30
Towing a disabled machine 5.31
Battery change procedure (ground level) 5.32
Battery change procedure (vertical lift) 5.38
Instructions on the maintenance 5.45
Important notes 5.45
Before maintenance 5.45
Critical torque values 5.46
Lubricants, fluids and capacities 5.46
Specific lubrication and maintenance instructions 5.51
Every shift 5.51
Weekly 5.52
Monthly 5.53
Every three months 5.64
Major maintenance 5.71
Drive motor/gearbox removal and replacement 5.71
Tire/wheel installation procedure 5.73
Troubleshooting procedures 5.77
Hydraulic system (general) 5.78
Brakes 5.81
Hydraulic cylinders 5.83
Hydraulic pump 5.84
Valves 5.86
6. Technical data
Technical data 6.3
Tightening torques 6.5
Permissible data 6.11
Lubrication fluids and greases 6.11
7. For your information
For your information 7.3
Our service 7.3
Service address 7.3
Rebuild facility address 7.4

• Cat Bucyrus 5 6 8 10 12 14 & 16 Battery Charger with Digital Display Operation Manual (A6474X230)

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
General precautions 2.8
Risk of explosive gasses 2.8
Personal precautions 2.9
Preparing to charge precautions 2.9
Unit location precautions 2.10
Major hazards 2.10
Storage and transport 2.11
Installation and start-up 2.12
Operation 2.12
Maintenance and repair 2.12
Overview of the safety instructions 2.15
Chapter 2: Your safety 2.15
Chapter 3: Storage and transport 2.15
Chapter 4: Installation 2.15
Chapter 5: Operation 2.16
Chapter 6: Technical data 2.16
3. Storage and transport
Storage and transport 3.3
Storage 3.3
Storage of the machine and spare parts 3.3
Transport 3.4
Load units; dimensions and weights 3.4
Before transport 3.4
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 4.3
Pre-installation check list 4.4
General information 4.5
Safety features 4.6
Standard features 4.8
Environmental ratings 4.8
Ratings and specifications 4.9
Minimum wire size 4.10
Electrical connections and field wiring 4.11
Ground integrity (optional) 4.12
5. Operation
Operation 5.3
How to operate the battery charger 5.3
Who is allowed to operate the battery charger 5.3
When can charging be started? 5.3
Controls and indicators 5.4
Startup procedure 5.5
Fault codes 5.6
Adjustments 5.7
Circuit operation 5.7
Instructions on the maintenance 5.13
Important notes 5.13
Before maintenance 5.13
General maintenance procedures 5.14
Troubleshooting procedures 5.15
General inspection 5.15
Service information 5.15
Troubleshooting information 5.16
Ground short circuit test 5.17
Troubleshooting and replacing power silicon diodes 5.17
Checking capacitors 5.18
6. Technical data
Technical data 6.3
Components of the battery charger 6.3
7. For your information
For your information 7.3
Our service 7.3
Service address 7.3
Rebuild facility address 7.4

• Cat Bucyrus Dual & Single Motor Controller Operation & Troubleshooting Manual (A6474X22)

1. About this manual
About this manual 1.3
Before starting to work 1.3
Who is this manual intended for? 1.3
What is the purpose of this manual? 1.4
Characters and symbols 1.5
2. Your safety
Your safety 2.3
State of the art 2.3
Repair 2.3
Safety instructions 2.4
General rules 2.4
Storage and transport 2.5
Maintenance and repair 2.6
Overview of the safety instructions 2.8
Chapter 3: Operation 2.8
Chapter 4: Technical data 2.8
3. Operation
Operation 3.3
History 3.3
Simplified BUC2000 circuit 3.4
Voltage vs. speed 3.4
Flywheel diode motor current (forward mode) 3.5
Flywheel diode motor current (reverse mode) 3.5
Flywheel diode motor current (direction does not change) 3.6
Flywheel current (low speed) 3.7
Flywheel current (high speed) 3.7
General specifications 3.8
Data logging features 3.11
Microprocessor based logic card 3.12
Microprocessor based logic card diagnostics 3.13
Configuration jumper table 3.14
Optional dashboard display 3.15
Fault message chart 3.16
Optional hand held diag. calibration unit security levels 3.17
Optional hand held diagnostics calibration unit 3.18
Optional hand held diagnostics calibration unit operation 3.19
Personality adjustment procedure 3.19
Traction personalities (controller adjustments) 3.20
Traction status display 3.21
Traction test display 3.23
Traction BDI display 3.23
Error code legend 3.24
IGBT panels and harness assemblies 3.25
Dashboard display and harness assembly 3.31
Panel wiring harness 3.34
Vehicle direction of travel 3.35
Troubleshooting 3.37
IGBT and diode measurements 3.38
IGBT measurements 3.39
Diode measurements 3.40
Panel measurements 3.42
Driver measurements 3.43
Schematics 3.44
4. Tightening torques
Tightening torques 4.3
5. For your information
For your information 5.3
Our service 5.3
Service address 5.3
Rebuild facility address 5.4

• Cat Bucyrus Mine Power Storage Batteries Installation Use Maintenance & Repair Manual (A6474X26)

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 2.7
Pre-start inspection 2.8
Operation 2.8
Maintenance and repair 2.9
Battery hazards 2.10
Safety procedures 2.11
Federal standards 2.11
While handling batteries 2.11
While charging batteries 2.12
While handling acids 2.13
While servicing or repairing batteries 2.14
Overview of the safety instructions 2.15
Chapter 3: Storage and transport 2.15
Chapter 4: Installation 2.15
Chapter 5: Operation 2.15
3. Storage and transport
Storage and transport 3.3
Storage 3.3
Storage methods 3.3
Charged and wet batteries 3.3’
Charged and dry batteries 3.3
Transport 3.4
Load units 3.4
Shipment 3.4
Unpacking upon receipt 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
5. Operation
Operation 5.3
Definitions 5.3
Descriptions and construction 5.3
Charging 5.7
Principles of operation 5.11
Fundamentals of cycling 5.11
Ampere-hour capacity 5.12
Voltage 5.12
Rated capacity 5.12
Sulfation 5.13
Operating cycle 5.13
Service life 5.13
Temperature 5.13
Preparation for use 5.15
Establishing battery requirements 5.15
Acid to water proportions 5.15
Charged and wet batteries 5.15
Instructions on the maintenance 5.17
Important notes 5.17
General 5.17
Specific maintenance instructions 5.19
Every shift 5.19
Weekly 5.21
Monthly 5.22
Annually 5.22
Recordkeeping 5.22
Troubleshooting procedures 5.25
Instructions on the adjustment procedures 5.29
Electrolyte specific gravity 5.29
Restoring a sulfated battery 5.30
Excessive self discharge correction 5.31
Test discharge 5.31
Replacement of parts 5.33
Purging gas 5.33
Removing intercell connectors 5.33
Removing a complete cell 5.34
Removing an element 5.34
Replacing a cell in a battery 5.36
Replacing a cell cover 5.37
Sealing compound and lead bushing design 5.37
Epoxy seal and nut design 5.38
Heat bonded plastic cover-to-jar design 5.38
6. Technical data
Tightening torques 6.3
7. For your information
For your information 7.3
Our service 7.3
Service address 7.3
Rebuild facility address 7.4

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