CAT Bucyrus BUC-SCR 120 Series Operating Manual A6474X254 PDF
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CAT Bucyrus BUC-SCR 120 Series Operation Manual A6474X254 – PDF DOWNLOAD
Description
CAT Bucyrus BUC-SCR 120 Series Operation Manual A6474X254 – PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus BUC-SCR 120 Series Operation Manual A6474X254 – PDF DOWNLOAD
Language : English
Pages : 425
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
CAT Bucyrus BUC-SCR 120 Series Operation Manual A6474X254 – PDF DOWNLOAD
This chapter provides important information making it easier for you to
use this manual. You will also be given information on the structure of
the manual and the symbols and characters used.
Before starting to work:
Take care to ensure that the operating manual available to you is applicable
for the type of equipment or machine used.
This operating manual is intended for:
BUC-SCR 120 Series Battery Charger
Serial No.: N/A
and is only permitted to be used for equipment of this type.
The operating manual must be accessible at all times to all persons
working on or with the machine.
It should, if possible, always be available at the place of operation.
Send for a new operation manual immediately if the present manual is
no longer complete or has become illegible.
Who is this operating manual intended for?
This operating manual is intended for those persons who work with or
on the machine.
Every person working on the face or in the intersection between face
and entry or in the entry must read this operating manual.
This includes persons who:
■ are in charge of transport
■ prepare the rise heading
■ perform assembly / disassembly work
■ operate the machine
■ eliminate faults
■ perform daily routine work on the face or in the entry
■ perform maintenance work
■ perform repair work
TABLE OF CONTENTS:
CAT Bucyrus BUC-SCR 120 Series Operation Manual A6474X254 – PDF DOWNLOAD
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
Personal Precautions 2 9
Preparing to Charge Precautions 2 9
Charger Location Precautions 2 10
DC Connection Precautions 2 10
Grounding Instructions 2 10
Storage and Transport 2 11
Pre-Start Inspection 2 11
Installation and Start-up 2 12
Operation 2 12
Maintenance and Repair 2 12
Overview of the safety instructions 2 15
Chapter 3: Storage and transport 2 15
Chapter 4: Installation 2 15
Chapter 5: Operation 2 15
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
Table of contents
BUC-SCR 120 Series Battery Charger
© BUCYRUS AMERICA, INC
Which tools are required for installation 4 3
Notes on installation 4 4
Pre-installation check list 4 5
Features 4 6
Installation 4 7
Location 4 7
Safety Features 4 8
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
Starting procedure 5 10
Shutdown procedure 5 12
Battery changer wiring diagram 5 13
Instructions on the maintenance 5 15
Important notes 5 15
Before maintenance 5 15
General Maintenance Procedures 5 16
Yearly 5 16
Fourth Year 5 16
Seventh Year 5 16
Tenth Year 5 16
Troubleshooting Procedures 5 17
SCR/Diode troubleshooting procedures 5 21
6 Technical data
Technical data 6 3
Tightening torque 6 5
7 For your information
For your information 7 3
Our service 7 3
Service address 7 3
Rebuild facility address 7 4
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 VERSATRAC ® 5 3
Who is allowed to operate the VERSATRAC ® 5 3
When can operation be started? 5 3
Controls and indicators 5 4
Operator’s compartment 5 4
Control handle 5 8
Hazard zone 5 17
Starting procedure 5 18
General 5 18
Machine operation 5 19
Shutdown procedure 5 22
Procedures for loading and unloading
The Longwall roof support 5 24
Loading from the long axis of the shield 5 24
Unloading from the long axis of the shield 5 24
Loading from the side of the shield 5 25
Unloading from the side of the shield 5 26
Towing a disabled machine 5 27
Battery change procedure 5 28
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 third shift 5 39
Weekly 5 46
Monthly 5 52
Every three months 5 53
6 Technical data
Technical data 6 3
Tightening torques 6 9
Permissible data 6 15
Lubrication fluids and greases 6 15
7 For your information
For your information 7 3
Our service 7 3
Service address 7 3
Rebuild facility address 7 4
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
Repair 2 4
Safety instructions 2 2
General rules 2 2
Storage and transport 2 6
Maintenance and repair 2 7
Overview of the safety instructions 2 9
Chapter 3: Operation 2 9
Chapter 4: Technical data 2 11
3 Operation
Operation 3 3
History 3 3
Innovated motor control by Bucyrus 3 3
Basic motor operation 3 6
General specifications 3 8
Features 3 9
System components 3 12
Power connection 3 13
VFD control hard inputs/outputs 3 13
VFD CAN bus inputs 3 20
Configuration chart 3 20
Control system operation 3 23
Controller start-up 3 23
Pump motor 3 24
Release/set the parking brake 3 24
Traction motor 3 25
Direction changes 3 26
Traction braking 3 26
Neutral braking 3 26
Direction braking 3 26
Deceleration braking 3 26
Drivability profiles 3 27
Circuit breaker close timer feature 3 27
Pump cutback timer feature 3 27
Payload counter feature 3 27
Motor encoder 3 28
Roll-off parameter 3 28
Steer feature (800 series machines only) 3 28
Traction control algorithm 3 29
Display 3 29
Troubleshooting 3 37
Fault information codes 3 37
Led fault information flash codes 3 45
Motors 3 46
Bearings 3 46
Temperature 3 47
Multi-data decoder 3 49
Adjustments 3 55
Adjustable parameters 3 55
Parts replacement 3 65
Removal and installation of VFDs 3 65
Connectors 3 65
Power connections 3 67
VFD mounting 3 67
Wiring diagrams 3 69
4 Technical data
Technical data 4 3
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
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
MINIMUM WIRE SIZES 14
ELECTRICAL CONNECTIONS & FIELD WIRING 14
OPERATION 16
START UP (ELECTRONIC TIMER) 16
ADJUSTMENTS 17
CIRCUIT OPERATION 17
TROUBLESHOOTING 18
GENERAL INSPECTION 18
SERVICE INFORMATION 18
DBT America
Revised 01 – 03
DBT DIGITAL DISPLAY CHARGERS
II
SYMPTOMS AND CAUSES 19
GROUND AND SHORT CIRCUIT TEST 19
TROUBLESHOOTING AND REPLACING POWER SILICON DIODES 20
CHECKING CAPACITORS 20
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
Need help? Contact: [email protected]
S.V
