CAT Scoop 488L and 488-6 OPERATION, PREVENTIVE MAINTENANCE TROUBLESHOOTING AND SERVICE GUIDE MANUAL – PDF DOWNLOAD

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CAT Scoop 488L and 488-6 OPERATION, PREVENTIVE MAINTENANCE TROUBLESHOOTING AND SERVICE GUIDE MANUAL – PDF DOWNLOAD

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CAT Scoop 488L and 488-6 OPERATION, PREVENTIVE MAINTENANCE TROUBLESHOOTING AND SERVICE GUIDE MANUAL – PDF DOWNLOAD

Language : English
Pages : 268
Downloadable : Yes
File Type : PDF

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CAT Scoop 488L and 488-6 OPERATION, PREVENTIVE MAINTENANCE TROUBLESHOOTING AND SERVICE GUIDE MANUAL – PDF DOWNLOAD

PREFACE
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, 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 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 li

TABLE OF CONTENTS:

CAT Scoop 488L and 488-6 OPERATION  PREVENTIVE MAINTENANCE TROUBLESHOOTING AND SERVICE GUIDE MANUAL – PDF DOWNLOAD

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 INDICATORS 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
BUC 2000 DASHBOARD DISPLAY (OPTIONAL) 16
GAUGE PANEL (OPTIONAL) 16
DIF-LOK (OPTIONAL) 17
GENERAL HYDRAULIC CONTROL SYSTEM INFORMATION 17
“STEERING” CONTROL LEVER 18
“LEFT-HAND STEERING” CONTROL LEVER (OPTIONAL) 18
“BUCKET” CONTROL LEVER 19
“EJECTOR” CONTROL LEVER 19
“WINCH” CONTROL LEVER (OPTIONAL) 20
“2-SPEEDWINCH” CONTROL 20
“BATTERY CHANGER” CONTROL LEVER 20
HYDRAULIC PTO ACTUATOR 20
BRAKE RELEASE HAND PUMP 20
HAZARD ZONE 21
STARTING PROCEDURE 23
TOWING A DISABLED MACHINE 27
SHUTDOWN PROCEDURE 29
Bucyrus America, Inc
Revised 04-08
MODEL 488L AND 488-II 6 SERIES UN-A-TRAC®
BATTERY CHANGE PROCEDURE (VERTICAL LIFT) 31
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 PERWEEK 52
ONCE PER MONTH 60
EVERY THREE MONTHS 62
LUBRICANT SPECIFICATIONS 65
APPROVED SUPPLIERS 65
LUBRICATION CHART 67
TROUBLESHOOTING PROCEDURES 69
HYDRAULIC SYSTEM (GENERAL) 70
BRAKES (SERVICE)WET DISC 71
BRAKES (AUTOMATICWET 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
RECOMMENDEDWHEEL MOUNTING PROCEDURES: 83
PRECAUTIONS: 83

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

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
Bucyrus America, Inc
Revised 12 – 07
BUCYRUS DIGITAL II DISPLAY CHARGERS
SYMPTOMS AND CAUSES 19
GROUND AND SHORT CIRCUIT TEST 19
TROUBLESHOOTING AND REPLACING POWER SILICON DIODES 20
CHECKING CAPACITORS 20

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

DESCRIPTION PAGE #
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 SCOOP Kessler Axle SERVICE Manual 72.4665.3

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