Cat Bucyrus Roof Support HiPAC 10 Variable Frequency Drives (VFD)Battery Powered Operation Manual

Operation and Troubleshooting Manual BUCYRUS - Variable Frequency Drives (VFD) for Battery Powered Equipment Model -

HiPAC 10

Doc. No.:

A6474X273

Bucyrus America, Inc. ________________________________________ 4041 Wurno Road Pulaski, VA

Telephone: 540-980-4530 Fax: 540-994-3763

Internet: www.bucyrus.com

__________________________________________________________

This manual is intended to provide GENERAL product information for Model HiPAC 10 variable frequency drives (VFD) for battery powered equipment. 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 VFD 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.

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 render this unit unsafe to operate.

While this manual attempts to anticipate the most important operations and troubleshooting 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.

© BUCYRUS AMERICA , INC.

ALL RIGHTS RESERVED

________________________________________________ Table of contents

Table of contents 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

© BUCYRUS AMERICA, INC.

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

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Table of contents _________________________________________________

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

_________________________________________________________________ BUCYRUS– Model HiPAC 10 Variable Frequency Drives

© BUCYRUS AMERICA, INC.

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

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1

About this manual

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________________________________________Before starting to work

About this manual 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 applicable operating manual machine type

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: BUCYRUS –

Model HiPAC 10 Variable Frequency Drives (VFD) for Battery Powered Equipment

Serial No.: N/A © BUCYRUS AMERICA, INC.

and is only permitted to be used for equipment of this type. new operation manual

The operating and troubleshooting manual must be accessible at all times to all persons working on or with the VFD. It should, if possible, always be available at the place of operation.

Send for a new operation and troubleshooting manual immediately if the present manual is no longer complete or has become illegible.

Who is this manual intended for?

This manual is intended for those persons who work with or on the VFD. 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: ■ ■ ■ ■ ■ ■

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

supervisory personnel who: ■ ■

initiate and/or supervise the activities just indicated.

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Before starting to work ________________________________________ What is the purpose of this manual? cost-effectiveness

This manual is intended to help you work efficiently and safely with our product. It contains important information on operating and troubleshooting the VFD. Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

© BUCYRUS AMERICA, INC.

service

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 1.4

________________________________________Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

© BUCYRUS AMERICA, INC.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

■

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

) Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

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© BUCYRUS AMERICA, INC.

Before starting to work ________________________________________

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2

Your safety

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__________________________________________________ Personnel

Your safety This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

This machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations. You and others can, nevertheless, be exposed to dangerous situations e.g. as a result of environmental influences, machine damage, or operator errors.

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by Bucyrus America, Inc.

© BUCYRUS AMERICA, INC.

Use only original spare parts from Bucyrus America, Inc. Note that the use of parts from other manufacturers will void the guarantees.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations: ■

of the mine,

■

of the Mine Inspector, and

■

of the mining supervisory authorities.

Personnel Repair As a fundamental rule, repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Electrical repair work may only be carried out by service engineers from Bucyrus America, Inc. or by specially qualified personnel of the mine. All electrical work is to be done by qualified persons, in accordance with all MSHA, Federal, State, and Local regulations.

Except where allowed by MSHA, Federal, State, and Local regulations, before conducting electrical work on this machine: ■

The machine circuit breaker shall be turned off.

■

The battery circuit breaker shall be turned off.

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The battery plug shall be disengaged/removed, and tagged out.

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Personnel ___________________________________________________

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 2.4

___________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 dB(A).

Inform your colleagues of:

© BUCYRUS AMERICA, INC.

safety equipment

■

your exact location,

■

the work you are performing, and

■

the time that you will probably require.

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the machine.

symbol plates emergency stop

disconnect battery

welding

Observe the symbol plates on the machine.

Press the EMERGENCY STOP switch immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Disconnect the battery while performing: ■

maintenance work

■

inspection work

■

repair work

Batteries should be well vented before servicing, particularly if welding or burning on the battery.

Disconnect the battery when working with the electrical system or when welding on the unit to prevent electrical shock.

While welding, the battery must be disconnected to be sure that you do not damage the electrical system and/or any of the electrical components.

WARNING! Study all warning/caution labels and notes related to working with batteries and electric motors. These labels may be on the battery, the motor, and/or on the machine, as well as in this Operator’s manual. Failure to comply with the safety instructions regarding working with batteries and electric motors can result in death or serious injury by electrocution. ______________________________________________________________ A6474X273

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Safety instructions ____________________________________________ cordon off working area moving parts

steering lockout

Cordon off your working area widely for the machine.

Never allow parts of your body to come between parts which could move, such as e.g.: ■

false bottoms

■

pivot points

■

battery lifts

Connect the steering lockout device before performing maintenance or repairs on the machine.

Storage and transport

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.

mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 2.6

© BUCYRUS AMERICA, INC.

Maintain the prescribed storage periods and observe the instructions for storage.

___________________________________________ Safety instructions Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration. securing

Secure your working area over a wide range, in order to avoid endangering other persons.

Disconnect and lock out the battery from the machine to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

© BUCYRUS AMERICA, INC.

replacing components

Disconnect and lock out the battery from machine to prevent from restarting before replacing any defective components.

Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

lifting

maintenance, repair

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Bucyrus America, Inc. spare parts.

Please refer to the spare parts lists for the order numbers.

For raising the machine use only: ■

crib blocks with adequate load-holding capacity.

■

hoists, jacks or cranes with adequate load-carrying capacity.

Only persons who have and can demonstrate a special knowledge of electrics are allowed to work on the electrical system.

Avoid, whenever possible, servicing, cleaning or examining the machine in congested areas.

Avoid, whenever possible, servicing or providing maintenance to the unit unless the wheels are chocked and steering lockout device is connected to prevent accidental movement of the unit.

Do not alter the electrical settings from that indicated in this manual or as set at the factory.

Always replace damaged or lost decals and metal instruction plates.

Disconnect and lock out the battery when working with the electrical system, or when welding on the unit to prevent electrical shock.

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Safety instructions ____________________________________________ Be sure the battery area is well ventilated (clear of fumes) when it is necessary to connect battery charger. Fumes from the battery could ignite from a spark and explode.

Always follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

© BUCYRUS AMERICA, INC.

Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 2.8

________________________________ Overview of safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Operation IMPORTANT! Currently, the State of Pennsylvania does not allow regenerative braking. This law is under consideration. However, currently regenerative braking must be disabled in the State of Pennsylvania only, via setting all braking torques to zero. See adjustable parameters chart.

© BUCYRUS AMERICA, INC.

NOTICE! See the machine parts manual and wiring diagram for the configuration settings shipped for your particular machine serial number.

NOTICE! If at any time after a machine is placed in commission, the tire size, motor size, gear ratio, or any other configuration is changed, the configuration input wires should be changed to match the correct sizes.

IMPORTANT! If the operator releases the “In-Position” switch before the pump motor function is selected, the system will interpret this as a function selected alone and disable it.

NOTICE! MSHA requirements limit the maximum machine tram speed to 6 mph. This occurs automatically through the VFD software and correct hardwired configuration inputs.

IMPORTANT! Current Pennsylvania State law does not allow regenerative braking in the State Of Pennsylvania and it must be disabled in the state of Pennsylvania only.

CAUTION! The service brake and park brake are the primary means for stopping the vehicle.

CAUTION! Disconnect all motor leads before Meggar testing. Electrical system and/or VFD damage may occur if leads remain connected.

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Overview of safety instructions _________________________________ IMPORTANT! The fiber optic cable connections should remain connected, when possible. During troubleshooting, the open connections should not be exposed to dust, grease or other contaminates, as this may block communications, cause intermittent faults and/or shut down the system. Fiber optic cable cleaning pads and kits are available.

CAUTION! Caution should be used when adjusting any parameter. Operators should be made aware of changes to such parameters as machine speeds and torques, braking torques and speeds, acceleration rates, roll-off speeds, and accelerator settings (increased machine speed, sudden acceleration or deceleration) may occur.

IMPORTANT! If the operator selects FS1 before selecting a direction, a SRO fault will be produced and direction selection inhibited.

CAUTION! Caution should be used when adjusting any parameter. Operators should be made aware of changes to such parameters as machine speeds and torques, braking torques and speeds, acceleration rates, roll-off speeds, and accelerator settings as increased machine speed, sudden acceleration or deceleration may occur.

CAUTION! The service brake and park brake are the primary means for stopping the vehicle.

CAUTION! Before removing or installing a VFD, verify that the battery has been disconnected from the machine, that the circuit breakers are in the “OFF” position, and that the battery plug has been disconnected and locked/tagged out. Failure to do so may result in machine damage or injury to you or other personnel.

NOTICE! Due to the properties of the stud material, excessive torque may damage or break the power terminal stud or damage the VFD. NOTICE! Lack of thermal compound, thickly applied thermal compound, and/or debris under the VFD may limit heat transfer from the VFD to the controller bottom plate and may result in thermal cutback of the VFD.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 2.10

© BUCYRUS AMERICA, INC.

IMPORTANT! Currently, the State of Pennsylvania does not allow regenerative braking. This law is under consideration. However, currently regenerative braking must be disabled in the State of Pennsylvania only, via setting all braking torques to zero. See adjustable parameters chart (Table 25): braking torques to be disabled (set to zero) are shown in red. All indicated braking torques (shown in red) must be set to zero when used in the State of Pennsylvania .

________________________________ Overview of safety instructions NOTICE! Improper installation of mounting hardware may limit heat transfer from the VFD to the controller bottom plate and may result in thermal cutback of the VFD.

Chapter 4: Technical data

© BUCYRUS AMERICA, INC.

IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with the correct torque. The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

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© BUCYRUS AMERICA, INC.

Overview of safety instructions _________________________________

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3

Operation

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___________________________________________________Operation

Operation This chapter contains important information on the operation of the model HiPAC 10 variable frequency drive.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in Chapter 2 “Your safety”.

© BUCYRUS AMERICA, INC.

History In the early 1970's, Bucyrus led the way in mining innovation with the introduction of Solid State speed controls for battery-powered underground mining equipment. Solid State controls increased the range and reliability of the battery powered vehicles along with providing smooth, stepless acceleration. Even with solid state speed control, direction change was achieved with the use of electromechanical contactors. These contactors provided an endless source of maintenance problems and consumed excessive amounts of valuable controller-box space. Also, most solid state controllers of the past utilized an electromechanical "bypass" contactor to connect the motor directly to the batteries which caused more contactor problems.

In the 1980’s Bucyrus, in conjunction with Sevcon, developed a contactorless motor controller (X90) to be used exclusively on Bucyrus equipment. The X90 system used a dual-field motor in combination with SCRs (Silicone Controlled Rectifiers) to achieve solid state direction change.

In the 1990’s Bucyrus, in conjunction with Sevcon, developed the BUC 2000 motor controller. The BUC 2000 system used Insulated Gate Bipolar Transistors (IGBTs) to achieve motor control and direction change. Unlike an SCR, an IGBT is turned ON and OFF via a gating electronic signal. This eliminated commutating capacitor banks and coils. The microprocessor based BUC 2000 Logic Card provided complete motor control, and drove both a Diagnostic Dashboard Display along with a hand held Calibrator/Diagnostic Unit.

Now Bucyrus, in conjunction with Sevcon and Baldor, has developed the successful HiPAC 10 motor controller system. The HiPAC 10 system consists of highly efficient AC 3-phase induction motors and variable frequency drives. The HiPAC 10 system provides increased efficiency, no motor brushes or brush holders to contend with, higher torque capabilities, and increased machine speeds.

Innovated Motor Control by Bucyrus The speed of rotation of AC induction motors is directly dependent upon the frequency of the applied AC voltage. In order to control the speed of AC induction motors, it must, therefore, be supplied with a voltage of variable magnitude and variable frequency. Ideally, this voltage would be sinusoidal.

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Operation____________________________________________________ The power circuit stage of the inverter converts a fixed DC voltage into an AC voltage of variable frequency and magnitude. It achieves this by means of high frequency switches (IGBTs), which pulse a DC voltage onto the motor terminals in such a manner as to try and replicate the desired sinusoidal demand. A simplified schematic of the power circuit is shown in Figure 1; it consists of six power switches (IGBTs), two per motor phase.

Fig. 1: Simplified AC power circuit

IGBT Switch M1

IGBT Switch M2

IGBT Switch

IGBT Switch M3

IGBT Switch

AC Induction Motor

IGBT Switch

In order to produce a sinusoidal output on the motor terminals M1, M2, and M3, the six switches are turned on and off at a very high frequency.

Figures 2, 3, 4, and 5 show the switching signal driving one phase of switches and the fundamental sinusoidal waveform which they are replicating. The four figures show: low voltage low frequency; low frequency high voltage; high frequency low voltage; and high frequency high voltage.

Fig. 2: Low frequency low voltage output

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.4

© BUCYRUS AMERICA, INC.

Battery

___________________________________________________Operation Fig. 3: Low frequency high voltage output

© BUCYRUS AMERICA, INC.

Fig. 4: High frequency low voltage output

Fig. 5: High frequency high voltage output

The motor connected is a three phase motor, therefore three of the shown switching signals will be used, each offset by 1200.

Due to the fact that the windings of the motor are inductive, the current in the machine will rise and fall slowly as the voltage is pulsed on and off. The resulting current will be a relatively smooth sinusoidal waveform.

Figure 6 shows two of the three phase currents which result from a modulated voltage waveform.

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Operation____________________________________________________

In summary, the power inverter allows a DC voltage to be applied as an AC voltage; this is achieved by pulsing the switching devices at high frequency. Because the AC voltage is created from a series of pulses of DC link voltage, this AC voltage can be varied in both magnitude and frequency. An AC voltage of variable magnitude and frequency is necessary in order to control the speed of an induction machine.

Basic AC motor operation An AC motor has two basic electrical parts: a stator and a rotor (Fig. 7).

The stator is in the stationary electrical component. It consists of a group of individual electro-magnets arranged in such a way that they form a hollow cylinder, with one pole of each magnet facing toward the center of the group. The term stator is derived from the word stationary. The stator is then the stationary part of the motor. The rotor is the rotating electrical component. It also consists of a group of electromagnets arranged around a cylinder, with the poles facing the stator poles. The rotor is located inside the stator and is mounted on the motor’s shaft. The term rotor is derived from the word rotating. The rotor is the rotating part of the motor. The objective of these motor components is to make the rotor rotate which, in turn, will rotate the motor shaft. this rotation will occur because unlike magnetic poles attract each other and like poles repel. If we progressively change the polarity of the stator poles in such a way that their combined magnetic field rotates, then the rotor will follow and rotate with the magnetic field on the stator.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.6

© BUCYRUS AMERICA, INC.

Fig. 6: Phase current waveform

___________________________________________________Operation Fig. 7: Basic electrical components of an AC motor electro-magnetics

© BUCYRUS AMERICA, INC.

stator

rotor

One way to produce a rotating magnetic field in the stator of an AC motor is to use a three-phase power supply for the stator coils. At any one instant, the direction and intensity of each separate current flow are not the same as the other phases. A complete cycle (from zero to maximum in one direction, to zero to maximum in the other direction, and back to zero) takes one complete revolution of the motor. Therefore, a complete cycle is said to have 360 electrical degress. Each pahse is displaced 120 degrees from the other two phases.

To produce a rotating magnetic field in the stator of a three-phase AC motor, each phase of the three-phase power supply is connected to opposite poles and the associated coils are wound in the same direction. The polarity of the poles of an electro-magnet are determined by the direction of the current flow through the coil.

Therefore, if two opposite stator electro-magnets are wound in the same direction, the polarity of the facing poles must be opposite.

Thus, as the phases shift their current flow, the resultant N and S poles move clockwise around the stator, producing a rotating magnetic field.

The rotor acts like a bar magnet being pulled along by the rotating magnetic field.

Induction is a characteristec of magnetism. It is a natural phenomena which occurs when a conductor is moved through an existing magnetic field or when a magnetic field is moved past a conductor. In either case, the relative motion of the two causes an electric current to flow in the conductor. This is referred to as “induced” current flow. In other words, in an induction motor the current flow in the rotor is not caused by any direct connection of the conductors to a voltage source, but rather by the influence of the rotor conductors cutting across the lines of flux produced by the stator magnetic fields.

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Operation____________________________________________________ The indcued current which is produced in the rotor results in a magnetic field around the rotor conductors. This magnetic field around each rotor condcutor will cause each rotor conductor to act like a permanent magnet. As the magnetic field or the stator rotates, due to the effect of the three-phase AC power supply, the induced magnetic field of the rotor will be attracted and will follow the roation. The rotor is connected to the motor shaft, so the shaft will rotate and drive the connected load.

General specifications

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The maximum current limit default setting is 800 amps for each traction motor and 200 amps for the pump motor.

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The current limit is preset and is not adjustable.

■

Traction functions operate at a speed that is directly proportional to the accelerator (FS1) demand. (Fig. 8).

■

Two pump motor speeds are available: high-speed normal working mode and low-speed energy savings mode. The speeds are selected automatically via a hydraulic pressure switch which senses hydraulic pressure demand.

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Traction and pump motor current is continuously monitored in the motor.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.8

© BUCYRUS AMERICA, INC.

The Bucyrus HiPAC 10 variable frequency drive system (VFD) is designed to operate from a 240 VDC nominal battery and controls one or two AC induction traction motors and one AC induction pump motor.

___________________________________________________Operation Fig. 8: Accelerator curve

Accelerator Demand

Accelerator Linear Curve 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

© BUCYRUS AMERICA, INC.

0%

Creep Speed

20%

40%

60%

80%

100%

Machine Speed Features The Bucyrus Model HiPAC 10 variable frequency drive system (VFD) incorporates a variety of independent protection systems. These improve reliability, shield the motors and VFDs from overload, protect the machine from inadvertent abuse, and help to protect workers from potential harm from malfunctioning equipment. fail safe/look ahead protection

The system utilizes the main circuit breaker as a means of failsafe protection by mechanically disconnecting the motor from the battery supply in the event of drive failure. There are two parts to this, look-ahead and failsafe protection: ■

The look-ahead feature is where the traction system monitors the vital parts of the controller and motor and, according to their conditions, will or will not allow the circuit breaker to be closed.

■

The failsafe feature is where at any point, if the system detects any part of the controller or motor to be non-operational and/or faulty, the system can open the main circuit breaker.

Additionally, due to the inherent advantage of an AC motor, if there is a failure in any of the motor phases or drive controller phases, the motor will come to a stop and can no longer be driven, even if a faulty drive controller were to continue to pulse the remaining two phases.

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Operation____________________________________________________ Motor overload is defined as running the motor beyond the manufacturer’s continuous rated specification up to a specified maximum limit.

Operating the machine in this way allows more power to be produced for shorter periods of time. This is acceptable use of the motor as long as consideration is given to the extra heating effect in the motor. HiPAC 10 implements three parallel and independent temperature measurements in the motor: ■

PTC temperature probe embedded in the motor: The voltage proportional to temperature formed across this device represents the internal winding temperature and is fed back in to the controller and converted to a real temperature.

■

A thermal switch is also attached to the motor which changes state above a certain temperature, this is fed to the controller and when activated cuts the available power to the motor to 30% of maximum.

■

A motor temperature estimate is implemented in software which predicts the current motor temperature based upon the current in the motor, its thermal time constant and impedance.

The actual temperature measurements are used to determine a power limit cutback such that when the manufacturer specified maximum temperature is reached, shaft output power has been cutback to zero (see Fig. 8).

Fig. 9: Power limit cutback

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© BUCYRUS AMERICA, INC.

overload

___________________________________________________Operation short circuit protection

In the event of motor over current the software will attempt to resist the over current by applying voltage to oppose it. However if the situation is unrecoverable, in the case of a dead short for example, a hardware trip will disable the inverter putting the outputs into a high impedance state.

battery over voltage/under voltage protection

The HiPAC 10 prevents over voltage of the inverter DC link and hence the charging voltage of the battery using a continuous monitoring of this voltage.

IMPORTANT! Currently, the State of Pennsylvania does not allow regenerative braking. This law is under consideration. However, currently regenerative braking must be disabled in the State of Pennsylvania only, via setting all braking torques to zero. See adjustable parameters chart.

© BUCYRUS AMERICA, INC.

Fig. 10: Voltage monitoring

As the machine brakes regeneratively, the DC link will rise (Fig. 10). If the voltage encroaches into the shaded cutback region (260V – 276V), then the amount of power generated is reduced, which results in a reduced braking effort. The amount of braking effort applied while in cutback is a balance which will be struck between the amount of generated voltage and the braking effort. As the amount of braking energy is reduced (by reduction of motor shaft input power), the increased voltage situation is reduced and controlled directly. By this scheme, the battery voltage cannot exceed the maximum voltage and braking effort cannot be completely removed.

Under voltage protection is implemented as a way of preventing the controller from drawing power from the battery which would cause the battery supply voltage to drop below the point of operation (150 VDC).

______________________________________________________________ A6474X273 VSVI/00 3.11

Operation____________________________________________________ Table 1: Battery over voltage/under voltage protection parameters

Over Voltage Protection Under Voltage Protection controller temperature

Start of Cutback

100% Cutback

260 Volts (2.16 V/Cell) 160 Volts (1.33 V/Cell)

276 Volts (2.30 V/Cell) 150 Volts (1.25 V/Cell)

As the controller temperature increases, torque to the motor is cutback in attempts to reduce performance, but keep the machine operational.

Once in cutback, the maximum torque is reduced proportionally from 100% to 0% available torque.

Table 2: Torque cutback parameters Start of Cutback 95°C (203°F) 90°C (194°F)

100% Cutback 105°C (221°F) 100°C (212°F)

Bucyrus model HiPAC 10 VFD system components ■

One or two AC induction traction motors

■

One or two traction motor VFDs

■

One AC induction pump motor

■

One pump motor VFD

■

Dashboard display

■

Connecting wire harness “A”

■

Connecting wire harness “B”

■

Connecting wire harness “C”

■

Connecting wire harness “D”

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.12

© BUCYRUS AMERICA, INC.

Pump Motor VFD Traction Motor VFD

___________________________________________________Operation Bucyrus model HiPAC 10 VFD system power connections for each traction motor controller and pump motor controller ■

Battery positive (240VDC)

■

Battery negative

■

Each motor connection, 3-phase M1/T1, M2/T2, and M3/T3.

VFD control hard inputs/outputs Each VFD is equipped with four connectors: “A”, “B”, “C”, and “D”.

© BUCYRUS AMERICA, INC.

With dual traction motor systems, the supervisor and auxiliary traction VFDs are the same part number and contain the same software, however pin A26 hardwired configuration will signal the traction VFD whether to power up as the supervisor or as the auxiliary traction controller.

______________________________________________________________ A6474X273 VSVI/00 3.13

Operation____________________________________________________ Table 3: Supervisor traction VFD, connector “A” Connector/Pin

Not Used

A1

V+ to encoder

A2

V- to encoder

A3

Encoder input "A"

A4

Encoder input "B"

A5

Gear Configuration (1)

A6

Gear Configuration (2)

A7

Gear Configuration (3)

A8

Gear Configuration (4)

A9

Gear Configuration (5)

A10

Tram motor quantity

A11

Circuit Breaker Auxiliary switch

A12

Stop

A13

Not Used Not Used Not Used Not Used Not Used Not Used Motor thermal sensor input Tram motor size Motor temperature switch Not Used Not Used 24 VDC common input to VFD Traction supervisor identifier (digital input) Not Used 24 VDC common input to VFD -Supply (for A26) Not Used

A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30

24 VDC Common supply to motor temp. sensors

A31

Not Used

A32

Not Used

A33

CAN high

A34

CAN low

A35

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.14

© BUCYRUS AMERICA, INC.

Input Description

___________________________________________________Operation Table 4: Supervisor traction VFD, connector “B” Input Description

Connector/Pin

Not Used

B1

Not Used

B2

Not Used

B3

Not Used

B4

CAN high

B5

CAN low

B6

Not Used

B7

Not Used

B8

Table 5: Supervisor traction VFD, connector “C”

© BUCYRUS AMERICA, INC.

Input Description

Connector/Pin

+24VDC Supply input

C1

Not Used

C2

UVR Driver (24VDC Common)

C3

Park Brake Solenoid Driver (24VDC Common)

C4

Main Machine Circuit Breaker "On" Output

C5

Not Used

C6

Not Used

C7

Not Used

C8

Table 6: Supervisor traction VFD, connector “D” Input Description

Connector/Pin

Not Used

D1

Pre-Charge Feed from B+

D2

Not Used Not Used Not Used Not Used Not Used Not Used

D3 D4 D5 D6 D7 D8

______________________________________________________________ A6474X273 VSVI/00 3.15

Operation____________________________________________________

Input Description

Connector/Pin

Not Used V+ to encoder V- to encoder Encoder input "A" Encoder input "B" Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Motor thermal sensor input Tram motor size Motor temperature switch +Supply (for A26) Not Used Power supply 24 VDC common for display Traction auxiliary identifier (digital input) Not Used 24 VDC common input to VFD Not Used Not Used 24 VDC Common supply to motor temp. sensors Not Used Not Used CAN high CAN low

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.16

© BUCYRUS AMERICA, INC.

Table 7: Auxiliary traction VFD, connector “A”

___________________________________________________Operation Table 8: Auxiliary traction VFD, connector “B” Input Description

Connector/Pin

Not Used

B1

Not Used

B2

Not Used

B3

Not Used

B4

Not Used/CAN high

B5

Not Used/CAN low

B6

Not Used Not Used

B7 B8

© BUCYRUS AMERICA, INC.

Table 9: Auxiliary traction VFD, connector “C” Input Description

Connector/Pin

+24VDC Supply input

C1

Not Used

C2

Not Used

C3

Not Used

C4

Not Used

C5

Not Used

C6

Not Used

C7

Not Used

C8

Table 10: Auxiliary traction VFD, connector “D” Input Description

Connector/Pin

Not Used

D1

Pre-Charge Feed from B+

D2

Not Used

D3

Not Used

D4

Not Used

D5

Not Used

D6

Not Used

D7

Not Used

D8

______________________________________________________________ A6474X273 VSVI/00 3.17

Operation____________________________________________________

Input Description

Connector/Pin

Not Used Not Used Not Used Not Used Not Used Tire Configuration (1) Tire Configuration (2) Tire Configuration (3) Tire Configuration (4) Vehicle type (1) Vehicle type (2) Optional hydraulic filter switch Not Used Not Used Not Used Drain wire connection Not Used Not Used Not Used Motor thermal sensor input Motor temperature switch Not Used Not Used Not Used Power supply 24 VDC common for display Not Used Not Used 24 VDC common input to VFD Not Used Not Used 24 VDC Common supply to motor temp. sensors Power supply +24 VDC for display Not Used CAN high CAN low

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.18

© BUCYRUS AMERICA, INC.

Table 11: Pump VFD, connector “A”

___________________________________________________Operation Table 12: Pump VFD, connector “B” Input Description

Connector/Pin

Not Used Not Used Not Used Not Used Not Used/CAN high Not Used/CAN low Not Used Not Used

B1 B2 B3 B4 B5 B6 B7 B8

Table 13: Pump VFD, connector “C”

© BUCYRUS AMERICA, INC.

Input Description

Connector/Pin

+24VDC Supply input Not Used

C1 C2

Pump motor running output

C3

Not Used Not Used Not Used Not Used

C4 C5 C6 C7

Not Used

C8

Table 14: Pump VFD, connector “D” Input Description

Connector/Pin

Not Used Pre-Charge Feed from B+ Not Used Not Used Not Used Not Used Not Used Not Used

D1 D2 D3 D4 D5 D6 D7 D8

______________________________________________________________ A6474X273 VSVI/00 3.19

Operation____________________________________________________ VFD CAN bus inputs Machine control inputs are transmitted to the supervisor traction VFD via the CAN bus line. The CAN bus line connects to the supervisor traction VFD on connector “B”, pins B5 and B6.

These machine control inputs are generated by individual switches or potentiometers in an MSHA approved intrinsically safe circuit, through a junction box encoder, barrier and multi-data decoder unit. The multidata decoder unit is connected directly to the supervisor traction VFD via the CAN bus.

Park Brake Pressure Switch Pump Pressure Switch Payload Counter Switch Accelerator FS1 (Foot Switch 1) Accelerator potentiometer Left Hand Control Handle In-Position Left Hand Control Handle Diagnostics Left Hand Control Handle Pump Motor Start/Stop Left Hand Control Handle Park Brake Release/Set Left Hand Control Handle <-- Tram direction enable/disable Left Hand Control Handle --> Tram direction enable/disable Left Hand Control Handle Stop Left Hand Control Handle Traction Assist Oil Level Switch Towing Mode Switch Speed Cutback (Payload Limit) Switch

Configuration chart The HiPAC 10 system was designed to operate several machine types: coal hauler, UN-A-TRAC® , VERS-A-TRAC® , single motor, dual motor, 75 hP, and 100 hPtraction motors. To help the maintenance person, and to limit warehouse inventories, each VFD includes software to operate all of the listed equipment. With the maintenance person inmind, all essential machine configuration inputs are hardwired at the factory.

NOTICE! See the machine parts manual and wiring diagram for the configuration settings shipped for your particular machine serial number.

These inputs provide the supervisor traction VFD with all critical information for normal machine duty, such as tire size, gear ratio, motor size, motor quantity, and vehicle type.

Upon power up or change-out of a supervisor traction VFD, this valuable information is automatically supplied to the new supervisor traction VFD without any user input. This saves maintenance time and programming.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.20

© BUCYRUS AMERICA, INC.

Table 15: Supervisor traction VFD CAN bus inputs

___________________________________________________Operation NOTICE! If at any time after a machine is placed in commission, the tire size, motor size, gear ratio, or any other configuration is changed, the configuration input wires should be changed to match the correct sizes.

© BUCYRUS AMERICA, INC.

Table 16: Tire size configuration chart X10

X9

X8

X7

24

Calculation Point Rolling Radius (inches) 11.3

0

0

0

0

25 – 28

28

12.8

0

0

0

1

29 – 32

32

15.1

0

0

1

0

33 – 35

35

16.4

0

0

1

1

36 – 38

38

17.8

0

1

0

0

39 – 42

42

19.9

0

1

0

1

43 – 44

44

20.3

0

1

1

0

45 – 46

46

20.8

0

1

1

1

47 – 48

48

21.5

1

0

0

0

49 – 51

51

23.6

1

0

0

1

52

52

24.2

1

0

1

0

53 – 54

54

26.5

1

0

1

1

55

55

25.0

1

1

0

0

56 – 59

59

26.2

1

1

0

1

60

60

27.4

1

1

1

0

Spare

not used

1

1

1

1

Tire Size Range (inches)

Calculation Point Tire Size (inches)

22 – 24

Table 17: Tram motor quantity configuration chart Tram Motor Qty

X6

Dual Motor

0

Single Motor

1

______________________________________________________________ A6474X273 VSVI/00 3.21

Operation____________________________________________________

Gear Ratio : 1

X5

X4

X3

X2

X1

45.27 – 51.26

Calculation Point 45.27:1

0

0

0

0

0

51.27 – 57.26

51.27:1

0

0

0

0

1

57.27 – 63.26

57.27:1

0

0

0

1

0

63.27 – 69.42

63.27:1

0

0

0

1

1

69.43 – 72.99

69.43:1

0

0

1

0

0

73.00 – 75.52

73.00:1

0

0

1

0

1

75.53 – 76.35

75.53:1

0

0

1

1

0

76.36 – 79.98

76.36:1

0

0

1

1

1

79.99 – 82.86

79.99:1

0

1

0

0

0

82.87 – 86.45

82.87:1

0

1

0

0

1

86.46 – 89.20

86.46:1

0

1

0

1

0

89.21 – 92.51

89.21:1

0

1

0

1

1

92.52 – 96.26

92.52:1

0

1

1

0

0

96.27 – 97.83

96.27:1

0

1

1

0

1

97.84 – 104.03

97.84:1

0

1

1

1

0

104.04 – 110.03

104.04:1

0

1

1

1

1

110.04 – 116.03

110.04:1

1

0

0

0

0

116.04 – 122.03

116.04:1

1

0

0

0

1

122.04 – 129.19

122.04:1

1

0

0

1

0

129.20 – 134.03

129.20:1

1

0

0

1

1

134.04 – 140.03

134.04:1

1

0

1

0

0

140.04 – 146.03

140.04:1

1

0

1

0

1

146.04 – 152.03

146.04:1

1

0

1

1

0

152.04 – 157.03

152.04:1

1

0

1

1

1

157.04 – 164.24

157.04:1

1

1

0

0

0

164.25 – 174.24

164.25:1

1

1

0

0

1

174.25 – 177.71

174.25:1

1

1

0

1

0

177.72 – 187.71

177.72:1

1

1

0

1

1

187.72 – 197.71

187.72:1

1

1

1

0

0

197.72 – 207.71

197.72:1

1

1

1

0

1

207.72 – 217.71

207.72:1

1

1

1

1

0

217.72 – 227.71

217.72:1

1

1

1

1

1

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.22

© BUCYRUS AMERICA, INC.

Table 18: Gear ratio configuration chart

___________________________________________________Operation Table 19: Tram motor size configuration chart Tram Motor Size

X14

75 hp

1

100 hp

0

Table 20: Vehicle type configuration chart Machine Type

X12

X11

UN-A-HAULER (800 series)

0

0

UN-A-TRAC (400 series)

0

1

VERSATRAC (600 series)

1

0

Spare (not used)

1

1

© BUCYRUS AMERICA, INC.

Control System Operation Controller Start-up The VFDs are supplied control power from a 24V DC-DC converter.

The VFDs get powered up when the operator manually closes the battery circuit breaker on the battery assembly and the E-stop push button in the operator’s compartment is released.

A valid start-up sequence is described as follows: ) Press and hold the diagnostics momentary switch. The VFDs energize the pre-charge circuit and the controller start-up device checks are performed. This is done within a matter of seconds. If all checks are okay, the supervisor traction VFD will energize the main circuit breaker UVR Coil (Pin C3) and signal the operator that it is OK to close the main machine circuit breaker on the display. ) The operator should then be able to release the diagnostics momentary switch. ) The operator is required to then close the main machine circuit breaker supplying full battery power to the VFDs. Once the main machine circuit breaker is determined closed by the supervisor VFD through the use of the circuit breaker auxiliary switch (Pin A12 on supervisor VFD), the system is ready for pump motor operation.

Note: Once the main machine circuit breaker is closed, the Diagnostics momentary switch becomes the trigger to change screens on the display.

______________________________________________________________ A6474X273 VSVI/00 3.23

Operation____________________________________________________ Pump motor After the successful start-up process, the pump VFD is ready to begin operation, by ramping up to full speed.

Requirements for starting the pump motor: ■

Successful vehicle start-up has occurred (main circuit breaker closed).

■

The operator is required to hold the in-position switch as well as press the pump momentary switch.

■

At this point the pump will immediately ramp up to full speed and the pump monitor output is activated (pump VFD, Pin C3). Both buttons can now be released.

■

The operator can stop the pump motor drive and disable the pump monitor output by triggering the pump momentary switch only a second time.

■

Pump monitor output (pump, VFD, Pin C3) signals a relay or PLC that the pump motor is running.

■

Triggering the stop momentary switch at any time will disable the pump drive and monitor output.

Release/set the parking brake Requirements for releasing or setting the parking brake: ■

Successful vehicle start-up has occurred (main circuit breaker closed).

■

The pump motor must be running to release the parking brake.

■

The operator is required to hold the in-position switch as well as pressing the park brake momentary switch to release the parking brake (s).

IMPORTANT! If the operator releases the in-position switch before the function selected, the system will interpret this as a function selected alone and disable it.

The park brake solenoid is then energized through the supervisor VFD (Pin C4)

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.24

© BUCYRUS AMERICA, INC.

IMPORTANT! If the operator releases the in-position switch before the pump motor function is selected, the system will interpret this as a function selected alone and disable it.

___________________________________________________Operation ■

In order to set the parking brakes, the operator need only trigger the park brake momentary switch a second time. The park brake solenoid is then de-energized. The pump motor, however, remains running.

■

Triggering the “Pump” or “Stop” momentary switches will set the parking brakes as well as disable the pump motor.

Traction motor

© BUCYRUS AMERICA, INC.

Requirements for tramming the machine, to drive forward or reverse: ■

Successful vehicle start-up has occurred (main circuit breaker closed).

■

The pump motor must be running.

■

The park brake must be released.

■

The operator is required to hold the “In-Position” switch as well as trigger the “Forward” or “Reverse” momentary switch.

IMPORTANT! If the operator releases the “In-Position” switch before the function selected, the system will interpret this as a function selected alone and disable it.

■

In order to disable tram, the operator need only trigger the “Forward” or “Reverse” momentary switch a second time. Tram drive is then disabled, however the pump motor remains running and the park brake remains released.

■

Triggering the “Park Brake” button disables tram and applies the park brake, however the pump motor remains running.

■

Triggering the “Pump” or “Stop” momentary switches will disable tram, set the parking brake (s), and disable the pump motor.

■

With a tram direction active, the operator is then required to select the FS1 switch and accelerate using the foot pedal accelerator module. The vehicle will accelerate to the demand based on the acceleration delay parameter setting and maximum speed setting.

NOTICE! MSHA requirements limit the maximum machine tram speed to 6 mph. This occurs automatically through the VFD software and correct hardwired configuration inputs.

IMPORTANT! If the operator selects FS1 before selecting a direction, a SRO fault will be produced and direction selection inhibited.

______________________________________________________________ A6474X273 VSVI/00 3.25

Operation____________________________________________________ Direction changes In order to change from one direction to another: ) Hold the “In-Position” switch and ) Trigger the forward or reverse momentary switch, ) Then the operator must recycle the foot pedal (FS1 switch) before the new direction is recognized by the Motor Controller.

Traction braking Regenerative braking is done in compliance to the MSHA regulations on battery powered vehicles.

Neutral braking This helpful braking method is done using Regenerative braking and its strength is set according to an adjustable parameter. This braking occurs when the FS1 switch is opened while driving.

CAUTION! The service brake and park brake are the primary means for stopping the vehicle.

Direction braking This helpful braking method is also done using Regenerative braking and its strength is set according to an adjustable parameter as well.

This braking occurs when there has been a valid direction change. It is typically set to a stronger level than neutral braking.

CAUTION! The service brake and park brake are the primary means for stopping the vehicle.

Deceleration braking This helpful braking method is also done using Regenerative braking and its strength is set according to an adjustable parameter as well.

This braking occurs if the accelerator is decreased from a higher speed to a lower speed until the new lower speed level is reached.

CATUION! The service brake and park brake are the primary means for stopping the vehicle.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.26

© BUCYRUS AMERICA, INC.

IMPORTANT! Current Pennsylvania State law does not allow regenerative braking in the State Of Pennsylvania and it must be disabled in the state of Pennsylvania only.

___________________________________________________Operation Drivability profiles There are three selectable drivability profiles that can be set in the controller.

■

The baseline profile is used to set the vehicle maximum performance characteristics. This is the normal operation mode.

■

The payload limit profile is used to set the vehicle maximum performance characteristics to a lower level. This is typically used to lower the maximum machine speed when carrying heavy loads, navigating bad floor conditions, or for operator training.

■

The BDI Cutback profile will become active when the BDI cutout level is reached. It is set to limit the vehicle performance to conserve battery and further alert the operator of the low battery condition. Typically the maximum machine speed is set to a lower level in this profile.

© BUCYRUS AMERICA, INC.

Circuit breaker close timer feature This feature will allow a timer to be set where the circuit breaker needs to be closed once the controller determines it is safe to do so. If the operator does not close the circuit breaker on time, the controller will force the operator to do a power recycle in order to try and close the circuit breaker again. This is typically set at 15 minutes.

Pump cutback timer feature This feature will cut back the pump speed if no pump functions are activated within a settable time through the use of a pump pressure switch input.

Once any function requiring the pump motor speed to increase is activated the pump pressure switch will activate, signaling the pump VFD to immediately ramp the pump motor to full speed demand. When not active, it will allow cutback of the pump motor speed to conserve energy. The pump cutback ramp rate and cutback delay time are adjustable parameters.

Payload counter feature This feature is designed so that the operator can keep a count of every trip or load made or shields moved, etc… When the counter input is selected, it will increment the counter shown on the display by one. If the operator holds the counter for more than 5 seconds, the counter will reset to zero.

______________________________________________________________ A6474X273 VSVI/00 3.27

Operation____________________________________________________ Motor encoder (feedback device) The HiPAC 10 traction motors utilize an encoder mounted on back of the motor for motor speed and direction of travel feedback. The use of the encoder is required in the traction application for optimum machine performance. The encoder is a four wire device, two wires are the power supply feed, and two wires provide a waveform signal to the VFDs for machine speed and direction of travel.

The encoder is required for correct traction motor operation, reversed waveform signal wires, loose or poor connections, improper installation, or slippage on the motor shaft may cause erratic traction motor performance, and DSP faults on the system.

Roll-off parameter

CAUTION! The service brake and park brake are the primary means for stopping the vehicle.

Steer feature (800 series machines only) Steering cutback for 800 series coal haulers is required to help with turning, to save energy, and to save tire wear.

During drive, if one motor over-speeds the limit for the required demand, the other motor controller will back down the demand to its motor to keep the faster wheel at the desired speed without trying to push it through faster. This will inhibit the inside wheel on a turn from increasing speed to try and keep demanded speed by pushing the outside wheel and similarly will keep the outside wheel from going into braking trying to hold the demanded speed.

The software is written to prevent one motor from braking at any time if the other motor is driving.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.28

© BUCYRUS AMERICA, INC.

The roll-off parameters are adjustable and meant to help limit a stationary machine’s roll off speed down a grade should the operator release the accelerator foot pedal, park brake, and service brake.

___________________________________________________Operation Traction control algorithm (dual motor 400 and 600 series machines) Power balancing software is incorporated into the system to force both front and rear traction VFDs and motors to share the torque load as evenly as possible to prevent one motor from doing the majority of the work required and to evenly share the thermal daily load cycle when possible. Uneven loads on the traction motors occur from varying floor conditions, tire wear, etc.

Display

© BUCYRUS AMERICA, INC.

The transflective screen on this display module is designed for viewing indoors and out with low light levels. Status items are output to the display across the CAN bus. This is intended for the operator to use in determining the status of the drive system as well as for troubleshooting purposes.

In addition to faults, warnings, and configuration screens, the display provides many vehicle performance parameters such as battery voltage and battery shift life remaining.

The display has multiple screens and needs to toggle between the screens based on the selection of the diagnostics switch input (only after the main circuit breaker is closed). The system will always start with the same splash screen and then, after the main circuit breaker is closed, default to the main operating screen. When an alternate screen is selected, that screen will remain until the operator selects another alternate screen or the unit is powered down. Alternate screens are selected by toggling the diagnostic switch up twice consecutively in approximately 1 second activations.

Fig 11: Display assembly

______________________________________________________________ A6474X273 VSVI/00 3.29

Operation____________________________________________________ Fig. 12: Initial splash screen when diagnostics is selected

After the diagnostic checks are complete, the “SYSTEM OK, CLOSE CIRCUIT BREAKER” with vehicle configuration data screen (Fig. 13) will be displayed.

Configuration data is supplied from the machine configuration wiring (see page 3.18). The machine configuration may be verified on this screen.

Fig.13: “SYSTEM OK, CLOSE CIRCUIT BREAKER” screen

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.30

© BUCYRUS AMERICA, INC.

vehicle configuration data

___________________________________________________Operation main screen

The main screen (Fig. 14) is displayed after the main circuit breaker is turned on by the operator.

Fig. 14: Main screens

Number of trips (or loads) moved (entered by the operator)

Park brake applied indicator

© BUCYRUS AMERICA, INC.

Total hours logged by the display

Distance traveled on current battery

Machine picture updates to the machine type, based on configuration wiring

% Battery life remain (1 bar = 10%)

Payload cutback speed

Actual machine battery voltage

______________________________________________________________ A6474X273 VSVI/00 3.31

Operation____________________________________________________ Fig. 15: Vehicle status monitor screen

Total operational hours recorded on each VFD

Switch input active (closed) (black oval)

Switch input inactive (open) (empty oval)

Accelerator voltage shown in actual voltage

Accelerator % = % full speed demand requested by pressing the accelerator pedal

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.32

© BUCYRUS AMERICA, INC.

Fig. 16: Vehicle inputs monitor screen (for troubleshooting)

___________________________________________________Operation distance log

The distance log (Fig. 17) displays the total footage accumulated on each of the last five battery changes with time-date stamp. The odometer indicates the total footage recorded on this display.

Note: If the display is replaced, the Odometer will reset to zero (0).

© BUCYRUS AMERICA, INC.

Fig. 17: Distance log

fault log

The fault log (Fig. 18) includes the node, the fault identification number, the fault description, and the number of times the fault has occurred.

Fig. 18: Fault log

extended fault log

The extended fault log help screen (Fig. 19) is entered by pressing and holding the diagnostics button for five (5) seconds. After the extended fault log screen comes up, quick presses of the diagnostics button will toggle to each of the faults logged. To exit the extended fault log help screen, press and hold the diagnostics button for five (5) seconds.

______________________________________________________________ A6474X273 VSVI/00 3.33

Operation____________________________________________________ Fig. 19: Extended fault log help screen

Temperature monitor screens (Fig. 20) are provided for the controller and motor and for each tram motor and pump motor.

Fig. 20: Temperature monitor screen

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.34

© BUCYRUS AMERICA, INC.

temperature monitor screen

___________________________________________________Operation active fault on system screen

The active fault on system screen is shown in Fig. 21.

Fig. 21: Active fault on system screen

© BUCYRUS AMERICA, INC.

Location of active fault description

extended active fault on system help screen

To enter the extended active fault system help screen (Fig. 22), press and hold the diagnostics button for five (5) seconds. After the extended screen comes up, quickly pressing the diagnostics button will toggle to each of the faults logged. To exit the extended active fault system help screen, press and hold the diagnostics button for five (5) seconds.

Fig. 22: Extended active fault on system help screen

______________________________________________________________ A6474X273 VSVI/00 3.35

© BUCYRUS AMERICA, INC.

Operation____________________________________________________

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.36

____________________________________________ Troubleshooting Troubleshooting Fault information codes Should a fault occur with any of the HiPAC components, a fault message will be displayed across the top of the display. More information on the fault can be seen by simply holding the diagnostic switch closed for 5 seconds, this will bring up a detailed fault screen. If more than one fault occurs, each detailed fault screen can be seen by toggling through the screens by short presses of the diagnostic switch.

To return to the main screen, simply hold the diagnostics screen closed for 5 seconds again.

© BUCYRUS AMERICA, INC.

Table 21: Fault information codes Fault ID 0x34c1

Fault description Internal Controller Fault

Fault help

0x4541

Fan Fault

0x4542

Low Oil Fault

0x4543

Service Hydraulic Filter

0x4544

Pump Current Low

Pump current is not flowing indicating that pump is not attached to drive or drive has not power to B+.

0x4545

Vehicle Isolation Fault

0x4546

No speed indication

Some leakage path between B+ and Band 24V or 0V has been detected. For safety, this should be investigated.

Motor has remained at 0 RPM for 5s with greater than 25% of maximum torque being applied. Is the encoder signal OK?

0x45c1

BDI Warning

The battery charge has reduced to the warning level. Recharge the battery as soon as possible.

0x45c2

BDI Cutout

Battery charge reduced to cutout level.

Max speed may be reduced. Recharge the battery immediately.

0x45c3

Low Battery

Battery under voltage has occurred for the protection of the delay. Check if batteries need charging or are faulty.

0x45c4

High Battery

Can occur during regenerative braking.

Check battery connections, UVR and CB. Possible controller fault.

0x45c5

High Capacitor

Recycle Power. If fault does not clear, replace controller.

The internal fans are faulty. Blow out fans with air. If it persists, replace drive to prevent early thermal cutout.

Check Oil level and switch for proper operation.

Hydraulic oil filter needs cleaning, or sensor wires detached.

Capacitor voltage over 380v. Check all battery and CB connections and tips.

Possible controller fault. ______________________________________________________________ A6474X273

VSVI/00

3.37

Troubleshooting ______________________________________________ Table 21: Fault information codes, continued Fault description

Fault help

0x45c6

Vbat below rated minimum

Battery volts below 150v. Check all battery and CB connection tips. Recharge battery.

0x45c7

Vbat above rated maximum

Battery voltage over 380v. Check all battery and CB connections and tips.

Possible controller fault.

0x45c8

Vcap above rated maximum

Capacitor voltage over 380v. Check all battery and CB connections and tips.

Possible controller fault.

0x45C9

Caps not discharged

Drive is attempting to discharge the caps but lethal voltages may be present. Exercise extreme caution.

0x4601

Heat sink too cold

Controller below -30°C. Verify temperature reading. Replace controller if not accurate.

0x4602

Heat sink too hot

0x4603

Motor in thermal cutback

This unit is above 85°C. Limit operation or shutdown. Check unit temperature is accurate, unit may be faulty.

This motor is too hot. Limited operation or shutdown. Check motor temp switch.

0x4604

Power switch silicon too hot (IGBT)

An estimate of the silicon temperature switch (IGBT) is within 10°C of max allowed temp. Ensure adequate cooling of control enclosure.

0x4681

Unit in Preop

0x4682

Units still Initializing

This unit is in PRE-OP. Use DriveWizard to set into OPERATIONAL mode or replace controller.

Expected CAN messages not all received yet. Cycle power. If fault persists, check multi-data decoder, fiber optic cable, a “B” harness.

0x4782

24V supply low

Check supply input to drives. Recycle power. If fault does not clear replace controller.

0x4783

24V supply high

Check supply input to drives. Recycle power. If fault does not clear replace controller.

0x47c1

Service Required (optional)

The service interval has elapsed. It is recommended that the vehicle undergo the specified maintenance.

0x4881

Stop Switch Activated

The STOP button, Tape switch, or FS relay was activated. Check switches, wiring, and I/O module operation.

0x4882

Seat Fault (currently not used)

Re-select neutral by opening FS1 and the direction switches. Close the seat switch then re-select drive.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.38

© BUCYRUS AMERICA, INC.

Fault ID

____________________________________________ Troubleshooting Table 21: Fault information codes, continued

© BUCYRUS AMERICA, INC.

Fault ID

Fault description

Fault help

0x4883

Two Direction Fault

Both tram direction switches are seen active.

0x4884

SRO Fault

FS1 selected before a direction. Clear FS1 selection, retry sequence. Check FS1 and DIR switches.

0x4885

Sequence Fault

0x4886

FS1 Recycle Fault

0x4887 0x4981

Inch Fault (currently not used) Throttle Fault

FS1 or direction switch selected at power-up. Repeat selection sequence.

Check FS1 and DIR switches.

FS1 must be recycled to complete this direction change.

An invalid selection of inch switches is selected or the seat is still closed.

0x49C1

Pre-charge Fail

DC link voltage has not come up in time. Could be in thermal cut out, wait 10mins for reset and recycle controller.

0x49C2

Pre-charge Timeout

0x4c41

Too many units on network

DC link voltage has not come up in time. Could be in thermal cut out, wait 10mins for reset and recycle controller.

An invalid number of units (nodes) has been specified in the configuration.

0x4d01

Circuit Breaker open

The main CB is open or has not been closed within the CB close timer parameter. Check CB aux switch operation.

0x4d02

Circuit Breaker welded

The main CB is welded closed or the CB aux switch is faulty. Check CB aux switch operation.

0x4d03

DC Link Collapsed

DC link has collapsed on node, indicating a bad connection to B+ on the drive or an internal mechanical issue.

0x4F01

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x4F02

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x4F41

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F42

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F43

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

Accelerator >20% at power-up. Verify that the foot pedal is releasing and connections to IO module are solid.

______________________________________________________________ A6474X273 VSVI/00 3.39

Troubleshooting ______________________________________________ Table 21: Fault information codes, continued Fault description

Fault help

0x4F44

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F45

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F46

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F47

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F48

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F49

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F4A

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F4B

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F4C

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x4F4D

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x4F4E

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F4F

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F50

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F51

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F52

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F53

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F54

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x4F55

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x5041

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x5042

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.40

© BUCYRUS AMERICA, INC.

Fault ID

____________________________________________ Troubleshooting Table 21: Fault information codes, continued Fault ID 0x5043

Fault description

Fault help

Internal Controller Fault

© BUCYRUS AMERICA, INC.

Recycle Power. If fault does not clear, replace controller.

0x5044

Internal Controller Fault

Recycle Power. If fault does not clear, replace controller.

0x5081

Invalid Steering Switches (currently not used)

An invalid combination of steering switches such as left and right has been seen.

0x5101

Circuit Breaker Open Circuit

DC Link voltage has not come up after line closure has been attempted.

0x5102

Circuit Breaker Welded

DC Link voltage is already high prior to line closure.

0x5181

Digital Input Wire Off

Digital input wire off detected on input.

Check integrity of wiring loom.

0x5182

Analogue Input Wire Off

0x5183

Contactor driver, UVR driver, solenoid driver, or other driver usage

Analogue input is out of range or has some wire off issues. Check integrity of wiring loom.

Coil is drawing high current. Check wiring and coils for S/C. Possible controller fault.

0x5184

Contactor driver, UVR driver, solenoid driver, or other driver usage

Check wiring and coil. Possible Controller Fault.

0x5185

Contactor driver, UVR driver, solenoid driver, or other driver usage

0x51c1

24 Volt Supply Interrupt

Check wiring and coil. Possible Controller Fault.

Check DC-DC Converter for 24 Volt output. Check 24 Volt supply wiring.

Recycle Poser. Possible controller fault.

0x52c1

Motor Encoder Fault

Encoder signal is corrupted. Check wiring encoder for shorts or breaks.

Replace encoder.

0x52c2

Motor Over-Current Fault

Excessive current has been seen in the motor, and the controller has been unable to bring the current under control by normal means.

0x5301

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5302

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5303

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

______________________________________________________________ A6474X273 VSVI/00 3.41

Troubleshooting ______________________________________________ Table 21: Fault information codes, continued Fault description

Fault help

0x5304

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5305

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5306

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5307

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5308

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5309

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x530A

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x530B

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x530C

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x530D

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x530E

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x530F

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5310

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5311

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5312

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.42

© BUCYRUS AMERICA, INC.

Fault ID

____________________________________________ Troubleshooting Table 21: Fault information codes, continued

© BUCYRUS AMERICA, INC.

Fault ID

Fault description

Fault help

0x5313

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5314

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5315

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5316

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5317

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5318

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5319

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5341

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5342

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5343

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5344

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5381

CAN bus Fault

Check CAN Wiring and Power Supplies to affected CAN nodes. Check Toroids on CAN Bus Wires.

0x5741

Internal Controller Fault

0x54c1

Over Voltage Trip

Recycle Power. If fault does not clear, replace controller.

Capacitor Voltage over 380 Volts.

Check all battery and circuit breaker connections and tips. Possible controller fault.

______________________________________________________________ A6474X273 VSVI/00 3.43

Troubleshooting ______________________________________________ Table 21: Fault information codes, continued Fault description

0x54c2

DSP PF Fault

0x54c3

IGBT S/C M1 Top

0x54c4

IGBT S/C M1 Bottom

0x54c5

IGBT S/C M2 Top

0x54c6

IGBT S/C M2 Bottom

0x54c7

IGBT S/C M3 Top

0x54c8

IGBT S/C M3 Bottom

0x54c9

IGBT Tests Incomplete

0x54CA

M1 Low IGBT Driver Failed

0x54CB

M1 High IGBT Driver Failed

0x54CC

M2 Low IGBT Driver Failed

0x54CD

M2 High IGBT Driver Failed

0x54CE

M3 Low IGBT Driver Failed

0x54CF

M3 High IGBT Driver Failed

Fault help Severe over-current occurred. Recycle power. If fault does not clear replace controller. Check encoder, motor, motor cable, toroids, and wiring.

M1 Terminal shorted to B+. Check for controller or motor or cable shorts to B+ terminal of controller.

M1 Terminal shorted to B-. Check for controller or motor or cable shorts to Bterminal of controller.

M2 Terminal shorted to B+. Check for controller or motor or cable shorts to B+ terminal of controller.

M2 Terminal shorted to B-. Check for controller or motor or cable shorts to Bterminal of controller.

M3 Terminal shorted to B+. Check for controller or motor or cable shorts to B+ terminal of controller.

M3 Terminal shorted to B-. Check for controller or motor or cable shorts to Bterminal of controller.

Recycle Power. If fault does not clear, replace controller.

The controller has not been able to turn on the bottom power switch attached to M1. Disconnect motor and repeat. Possible controller fault.

The controller has not been able to turn on the top power switch attached to M1.

Disconnect motor and repeat. Possible controller fault.

The controller has not been able to turn on the bottom power switch attached to M2. Disconnect motor and repeat. Possible controller fault.

The controller has not been able to turn on the top power switch attached to M2.

Disconnect motor and repeat. Possible controller fault.

The controller has not been able to turn on the bottom power switch attached to M3. Disconnect motor and repeat. Possible controller fault.

The controller has not been able to turn on the top power switch attached to M3.

Disconnect motor and repeat. Possible controller fault.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.44

© BUCYRUS AMERICA, INC.

Fault ID

____________________________________________ Troubleshooting LED fault information flash codes The HiPAC 10 display should always be the first choice for fault information. However, should it not be available, the following limited LED flash codes (Table 22) are available.

Table 22: LED flash fault codes Fault

© BUCYRUS AMERICA, INC.

Software configuration out of range, recycle power, replace drive if fault doesn't clear.

Sequence fault, or recycle power, replace drive if fault doesn't clear.

Hardware protection fault, recycle power, replace drive if fault doesn't clear.

Main Circuit breaker fault, check wiring also, recycle power, replace drive if fault doesn't clear.

Vehicle wiring faults, recycle power, replace drive if fault doesn't clear.

Analog input fault to VFD, check wiring and inputs, recycle power, replace drive if fault doesn't clear. May also indicate a bad accelerator.

Battery Voltage faults, check connections, change battery, recycle power, replace drive if fault doesn't clear.

Thermal cutback faults, check heat sink, check thermistors, check wiring, check temperature switch, recycle power, replace drive if fault doesn't clear.

Not Used Thermal cutback faults, check heat sink, check thermistors, check wiring, check temperature switch, recycle power, replace drive if fault doesn't clear.

# of Flashes 1 2 3 4 5 6 7 8 9 10

Motor control faults, check encoder, check wiring, check drive inputs, recycle power, replace drive if fault doesn't clear.

11

CAN OPEN faults, check toroids, ground wires, shielding wires, cable routing, CAN bus wiring, recycle power, replace drive if fault doesn't clear.

12

Internal software faults, recycle power, replace drive if fault doesn't clear.

Multi-Data decoder fault, Check CAN bus wiring, replace Multi-Data Decoder, recycle power, replace drive if fault doesn't clear.

Service machine faults, typically not used.

13 14 15

______________________________________________________________ A6474X273 VSVI/00 3.45

Troubleshooting ______________________________________________ Motors

■

No brush or brush holders.

■

Total system approach to insure motor and VFD are matched together for optimum performance.

■

Larger rotor design and increased torque and horsepower.

■

Higher power density and smaller frame size.

■

High quality, high temperature, inverter grade, corona eliminating, class “H” VPI epoxy resin insulation system for longer life expectancy. Fully compatible on adjustable frequency power.

■

Increased RPM capabilities, increased machine speeds.

■

Increased efficiencies, and increased performance.

■

Totally enclosed, MSHA certified, non-vented enclosure prevents ingress of dust, grit, and/or moisture.

Bearings The pump motor has a maintenance free sealed bearing.

The traction motor(s) have a maintenance free sealed bearing on the non-driven end. The driven end bearing is lubricated by the gear box.

Motor Meggar testing CAUTION! Disconnect all motor leads before Meggar testing. Electrical system and/or VFD damage may occur if leads remain connected. ) Meggar each winding with motor leads disconnected. ) Per the IEEE 43 version 2000, meg each winding for 60 seconds before taking a reading. If the value is 5 meg ohms or greater @ 40°C it is okay.

■

A value below 5 meg ohms indicates possible insulation breakdown, shorted winding, contamination in the motor and/or moisture.

The motor is questionable.

■

If a very low or 0 reading, the motor most likely has a ground or shorted winding and may need to be rewound.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.46

© BUCYRUS AMERICA, INC.

The HiPAC 10 system utilizes highly efficient, higher power density, AC 3-phase induction motors resulting in:

____________________________________________ Troubleshooting Temperature Each motor is equipped with a temperature switch and sensor.

Temperature switch operation ■

Normally open for acceptable motor temperature.

■

Normally closed for abnormal high motor temperatures.

Temperature sensor operation

© BUCYRUS AMERICA, INC.

The temperature sensor resistance changes with temperature. Actual temperature readings may be verified by measurement of the temperature sensor resistance (Table 23).

______________________________________________________________ A6474X273 VSVI/00 3.47

Troubleshooting ______________________________________________

°C

°F

Resistance (ohms)

-40

-40

359

-30

-22

391

-20

-4

424

-10

14

460

0

32

498

10

50

538

20

68

581

25

77

603

30

86

626

40

104

672

50

122

722

60

140

773

70

158

826

80

176

882

90

194

940

100

212

1000

110

230

1062

120

248

1127

130

266

1194

140

284

1262

150

302

1334

160

320

1407

170

338

1482

180

356

1560

190

374

1640

200

392

1722

210

410

1807

220

428

1893

230

446

1982

240

464

2073

250

482

2166

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.48

© BUCYRUS AMERICA, INC.

Table 23: Motor temperature sensor KTY84/130

____________________________________________ Troubleshooting Multi-Data Decoder The multi-data decoder CANopen/DF1 system encodes digital and analog signals to the CANOpen and DF1 protocols, utilizing four main components: ■ ■ ■ ■

Data Barrier Encoder (located in junction box) Multi-data decoder Fiber-optic cable

Reference Fig. 26 Operation

© BUCYRUS AMERICA, INC.

Individual switches and potentiometers provide digital and analog inputs to the encoder. These switches and potentiometers may be located outside of an explosion-proof enclosure.

The encoder takes signals from up to 20 digital switch inputs and 4 analog devices and encodes them to one output line.

The encoder is connector to an MSHA approved Intrinsically Safe Data Barrier via 3 wires, the data line, 24 VDC power and common.

The MSHA approved Intrinsically Safe Data Barrier limits the available output energy to MSHA accepted levels.

The MSHA approved Intrinsically Safe Data Barrier also connects to the multi-data decoder through a short fiber optic cable.

IMPORTANT! The fiber optic cable connections should remain connected, when possible. During troubleshooting, the open connections should not be exposed to dust, grease or other contaminates, as this may block communications, cause intermittent faults and/or shut down the system. Fiber optic cable cleaning pads and kits are available.

The multi-data decoder decodes the encoded digital and analog signals then formats the signals so they can be interpreted by the HiPAC Supervisor VFD through the CAN bus connections, and interpreted by the programmable controller through the DF1 connections.

CANOpen CANOpen is a standardized network technology that provides communication objects for real time data, configuration data, special functions, and network management. CANOpen systems are often found in medical equipment, off-road vehicles, electronics, maritime, transportation, and automation.

DF1 DF1 is serial based communication protocol that is used to communicate with Allen Bradley programmable controllers (PLC).

______________________________________________________________ A6474X273 VSVI/00 3.49

Troubleshooting ______________________________________________ Troubleshooting System Inputs Inputs to the encoder may be monitored in the encoder junction box (Fig. 25). The encoder junction box includes a power on LED indicator and a test probe with a corresponding LED indicator. Each switch input may be checked with the test probe to determine if the input is being received by the encoder.

System Outputs The outputs may be monitored on either the HiPAC 10 display Vehicle Inputs Monitor Screen (Fig. 23) or on the Programmable Controller (PLC) LED indication card (Fig. 24 and Table 24).

© BUCYRUS AMERICA, INC.

Fig. 23: Vehicle inputs monitor screen

Fig. 24: Programmable controller (PLC) LED indication chart

Input/output monitoring

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.50

____________________________________________ Troubleshooting Fig. 25: Encoder junction box

© BUCYRUS AMERICA, INC.

Test probe

Table 24 lists all available options. check your machine operation guide and wiring diagram for options included on your particular machine.

______________________________________________________________ A6474X273 VSVI/00 3.51

Troubleshooting ______________________________________________ Table 24: PLC output 2 module Switch input description

0/1

Diagnostics

0/2

Tram direction ←

0/3

Tram direction →

0/4

Headlights ←

0/5

Headlights →

0/6

Traction assist

0/7

Pump motor

0/8

Park brake

0/9

Stop

0/10

Battery lock

0/11

Battery unlock

0/12

Ejector in

0/13

Ejector out

0/14

Battery up

0/15

Battery down

0/16

Articulation up

0/17

Articulation down

0/18

Payload counter

0/19

Park brake pressure

0/20

Pump pressure cut-back

0/21

Oil level

0/22

FS1 (foot switch)

0/23

Accelerator (potentiometer)

0/24

Speed cutback (payload limit)

0/25

False bottom magnetic switch

0/26

Towing mode

0/27

Lost communication to PLC from Decoder

Right hand control handle

In-position Left hand control handle

0/0

02/28-0/31 Not used

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.52

© BUCYRUS AMERICA, INC.

Output

____________________________________________ Troubleshooting

Data Barrier Input voltage: 24 VDC Output voltage: 3-5 VDC and fiber optic Encoder: Input voltage: 3-5 VDC Output voltage: 3-5 VDC Multi-Data Decoder: Input: 24VDC and fiber optic Output: CAN Buss and DF1 Communications

© BUCYRUS AMERICA, INC.

Fig. 26: Multi-data decoder

______________________________________________________________ A6474X273 VSVI/00 3.53

© BUCYRUS AMERICA, INC.

Troubleshooting ______________________________________________

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.54

_______________________________________ Adjustment procedures Adjustments Adjustable parameters Table 24 lists adjustable parameters for each machine type: 400, 600, and 800 series vehicles.

Upon installation of a new supervisor VFD, and based on the machine hard wired configuration inputs, the adjustable parameters will fall to the default settings based on the machine model.

The operator may change the parameters as desired with the appropriate password.

It is recommended that any changes made for operator preference be recorded in the operators manual for future reference.

© BUCYRUS AMERICA, INC.

Should the supervisor VFD be replaced for any reason, all parameters revert back to the default adjustable parameter settings.

To enter the adjustable parameters menu on the display, press and hold the control handle “stop” and “traction assist” buttons simultaneously to bring up the password screen (Fig. 27).

Fig. 27: Password screen

The password may be entered by use of the control handle diagnostics, traction assist, and stop buttons.

■

The diagnostics switch acts as an “enter key” or acknowledgment key.

■

The traction assist button increments the display value up.

■

The stop button increments the display value down.

Once the password has been accepted, the different menus and functions may be navigated and changed using the same three control handle buttons, diagnostics, traction assist, and stop buttons.

______________________________________________________________ A6474X273 VSVI/00 3.55

Adjustment procedures ________________________________________

Fig. 29: Typical parameter change screen

To exit the adjustable parameters menu, press and hold the control handle “stop” and “traction assist” buttons simultaneously and the display will return to its normal operating mode.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.56

© BUCYRUS AMERICA, INC.

Fig. 28: Initial configuration screen

_______________________________________ Adjustment procedures IMPORTANT! Currently, the State of Pennsylvania does not allow regenerative braking. This law is under consideration. However, currently regenerative braking must be disabled in the State of Pennsylvania only, via setting all braking torques to zero. See adjustable parameters chart (Table 25): all braking torques to be disabled (set to zero) are shown in red. All indicated braking torques (shown in red) must be set to zero when used in the State of Pennsylvania.

CAUTION! Caution should be used when adjusting any parameter. Operators should be made aware of changes to such parameters as machine speeds and torques, braking torques and speeds, acceleration rates, roll-off speeds, and accelerator settings (increased machine speed, sudden acceleration or deceleration) may occur.

© BUCYRUS AMERICA, INC.

CAUTION! The service brake and park brake are the primary means for stopping the vehicle.

______________________________________________________________ A6474X273 VSVI/00 3.57

Adjustment procedures ________________________________________ Table 25: Adjustable parameters

Menu1 Menu2

Menu3

Description

Bucyrus Passcode level

Min

Max Step

400 600 800 Series Series Series Default Default Default

Units

Description

Performance Parameters Setup Items Timers

CB close timer

1

0

20

1

15

15

15

Power down Timer

1

0

12000

1

3

3

3

Once diagnostics has been activated, and system okay to set circuit breaker is displayed, time period allowed Minutes before disabling diagnostics Required power down time in-between diagnostic activaSeconds tions

bdi reset

1

0

2.55

0.01

2.12

2.12

2.12

bdi empty

1

0

2.55

0.01

1.56

1.56

1.56

bdi cutback

1

0

100

1

2

2

2

bdi warning

1

0

100

1

5

5

5

Battery discharge rate

1

16

200

1

32

32

32

254 Volts (2.12 volts/cell * 120 cells) required after Volts/ battery charge cycle is comCell plete to reset display BDI to full 10 bars of charge level remaining.

187.2 Volt (1.56 volts/cell * Volts/cell 120 cells) indication of discharged battery % re- BDI cutback parameters maining invoked at this point % re- BDI Warning message dismaining played at this point Time period which battery voltage must drop below Seconds discharge threshold for bdi to decrement bars down

Accelerator Parameters

Accel Start

1

Accel End

1

Accel type

1

0

5.00

0.01

4.00

4.00

4.00

0 5.00 0.01 0.40 Linear, Curved, Linear Crawl

0.40

0.40

Linear

Linear

Accelerator start voltage, with FS1 closed 4V = 0 speed, must be adjusted to match or to be below actual voltage achieved at time of FS1 closure to have good creep speed.

Accelerator end voltage, with accelerator fully pressed must be adjusted to match or to be above actual voltage achieved at time of full pedal press to have full speed machine operation.

Type of accelerator pedal action.

Driveability Items Baseline parameters (normal driving mode) Baseline max drive torque

Baseline direction

2

0

0.90

1

0.55

% of Multiplier for max driving max. torque allowed. torque Adjustable regenerative % of braking torque allowed durmax. ing direction change. Must torque be set to Zero in the State of Pennsylvania

0.08 0.06 0.08 braking 1 0 _________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.58

© BUCYRUS AMERICA, INC.

BDI Parameters

_______________________________________ Adjustment procedures Table 25: Adjustable parameters, continued

© BUCYRUS AMERICA, INC.

Menu1 Menu2

Menu3

Description

Bucyrus Passcode level

Min

Max

400 600 800 Series Series Series Step Default Default Default

Baseline neutral braking

1

0

1

0.01

0.08

0.06

0.08

Baseline Max speed fwd

1

1.0

6.0

0.1

5.0

4.2

4.2

Baseline Max speed rev

1

1.0

6.0

0.1

5.0

4.2

4.2

Baseline acceleration delay

1

10

2500

10

600

800

600

Baseline Dir Accel Rate

1

10

10000

1

600

800

600

Baseline Neut Accel Rate

1

10

10000

1

600

800

600

Baseline Drive Decel Rate

1

10

10000

1

600

450

600

Baseline Dir Decel Rate

1

10

10000

1

1000

850

1000

1

10

10000

1

1000

850

1000

Baseline Neut Decel Rate Payload Limit parameters (requires optional payload speed limit switch on machine to enter this menu) Payload limit max drive torque

Payload limit direction braking

Payload limit neutral braking

Units

Description

Adjustable regenerative braking torque allowed dur% of ing neutral braking (foot max. raised from accelerator torque pedal), Must be set to Zero in the State of Pennsylvania Maximum machine speed (in addition to this, the superviMPH sor VFD limits the machine speed to the RPM rating of the traction motor) Maximum machine speed (in addition to this, the superviMPH sor VFD limits the machine speed to the RPM rating of the traction motor) Rate of machine speed rise RPM/ from zero speed to maximum Second speed as dictated by accelerator pedal demand.

Rate of machine speed rise from zero speed to maximum RPM/ speed set by accelerator Second pedal demand after a direction change.

Rate of machine speed rise from zero speed to maximum RPM/ speed set by accelerator Second pedal demand after going to neutral.

Rate of deceleration when regenerative braking, from a RPM/ higher accelerator demand Second to a lower accelerator demand.

Rate of deceleration when RPM/ regenerative braking during Second a direction change.

Rate of deceleration when RPM/ regenerative braking when Second going from drive to neutral.

Multiplier for max driving torque allowed.

2

1

1

0

0

0

1

1

1

0.01

0.01

0.01

0.90

0.08

0.08

1

0.06

0.06

0.55

0.08

Adjustable regenerative braking torque allowed during direction change, Must be set to Zero in the State of Pennsylvania.

0.08

Adjustable regenerative braking torque allowed during neutral braking (foot raised from accelerator pedal), Must be set to Zero in the State of Pennsylvania

______________________________________________________________ A6474X273 VSVI/00 3.59

Adjustment procedures ________________________________________ Table 25: Adjustable parameters, continued

Menu3

Min

400 600 800 Series Series Series Max Step Default Default Default

Payload limit Max speed fwd

1

1.0

6.0

0.1

3.3

2.5

3.3

Payload limit Max speed rev

1

1.0

6.0

0.1

3.3

2.5

3.3

Payload limit acceleration delay

1

10

2500

10

600

800

600

Payload limit Dir Accel Rate

1

10

10000

1

600

800

600

Payload limit Neut Accel Rate

1

10

10000

1

600

800

600

Payload limit Drive Decel Rate

1

10

10000

1

600

450

600

Payload limit Dir Decel Rate

1

10

10000

1

1000

850

1000

1

10

10000

1

1000

850

1000

0

baseline max 0.01

Payload limit Neut Decel Rate BDI Cutback parameters (this menu is active once BDI cutback has been reached, based on BDI parameter settings) ) BDI max drive torque

BDI direction braking

BDI neutral braking

BDI Max speed fwd

2

1

1

1

Units

Description

Maximum machine speed (in addition to this, the supervisor VFD limits the machine speed to the RPM rating of the traction motor) Maximum machine speed (in addition to this, the supervisor VFD limits the machine speed to the RPM rating of the traction motor) Rate of machine speed rise from zero speed to maximum speed as dictated by accelerator pedal demand.

Rate of machine speed rise from zero speed to maximum RPM/s speed set by accelerator pedal demand after a direction change.

Rate of machine speed rise from zero speed to maximum RPM/s speed set by accelerator pedal demand after going to neutral.

Rate of deceleration when regenerative braking, from a RPM/s higher accelerator demand to a lower accelerator demand.

Rate of deceleration when RPM/s regenerative braking during a direction change.

Rate of deceleration when RPM/s regenerative braking when going from drive to neutral.

Multiplier for max driving torque allowed.

0.90

1

0.55

0

baseline max 0.01

0.08

0.06

0.08

0

baseline max 0.01

0.08

0.06

0.08

Adjustable regenerative braking torque allowed during direction change, Must be set to Zero in the State of Pennsylvania Adjustable regenerative braking torque allowed during neutral braking (foot raised from accelerator pedal), Must be set to Zero in the State of Pennsylvania

2.8

Maximum machine speed (in addition to this, the supervisor VFD limits the machine speed to the RPM rating of the traction motor)

1.0

6.0

0.1

2.8

2.5

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.60

© BUCYRUS AMERICA, INC.

Menu1 Menu2

Bucyrus Passcode level

_______________________________________ Adjustment procedures Table 25: Adjustable parameters, continued

Menu1 Menu2

Menu3

Description

Bucyrus Passcode level

Min

400 600 800 Series Series Series Max Step Default Default Default

BDI Max speed rev

1

1.0

6.0

0.1

2.8

2.5

2.8

BDI acceleration delay

1

10

2500

10

600

800

600

Units

RPM/s BDI Dir Accel Rate

1

10

10000

1

600

800

600

© BUCYRUS AMERICA, INC.

RPM/s BDI Neut Accel Rate

1

10

10000

1

600

800

600

BDI Drive Decel Rate

1

10

10000

1

600

450

600

BDI Dir Decel Rate

1

10

10000

1

1000

850

1000

BDI Neut Decel Rate

1

10

10000

1

1000

850

1000

RPM/s

RPM/s RPM/s

Description Maximum machine speed (in addition to this, the supervisor VFD limits the machine speed to the RPM rating of the traction motor) Rate of machine speed rise from zero speed to maximum speed as dictated by accelerator pedal demand.

Rate of machine speed rise from zero speed to maximum speed set by accelerator pedal demand after a direction change.

Rate of machine speed rise from zero speed to maximum speed set by accelerator pedal demand after going to neutral.

Rate of deceleration when regenerative braking, from a higher accelerator demand to a lower accelerator demand.

Rate of deceleration when regenerative braking during a direction change.

Rate of deceleration when regenerative braking when going from drive to neutral.

Pump parameters % of max pump speed

1

25

100

1

65

65

80

Time until Pump speed is cutback

1

0

250

1

2

2

2

Pump Motor Minimum Speed

2

0

1800

1

1700

1700

1700

% of Percentage of maximum pump speed available during cutRPM back energy savings mode. setting Time delay before leaving Seconds normal speed and going into speed cutback Normal running speed of RPM pump motor

Roll off parameters Nm Maximum torque applied in Roll Off

1

0

100.0

0.5

17.5

17.5

17.5

Maximum speed allowed in Roll Off

1

100

2000

50

900

900

900

RPM

Maximum braking torque allowed during machine roll off down a hill, Must be set to Zero in the State of Pennsylvania.

Maximum speed machine is allowed to roll off down a hill.

Data Logging Display logs

clear data log

1

No No No chan change change ge, , reset , reset reset

Clears temperature log

______________________________________________________________ A6474X273 VSVI/00 3.61

Adjustment procedures ________________________________________ Table 25: Adjustable parameters, continued

Menu1 Menu2

Bucyrus Passcode Menu3 Description level set data log interval 1 clear fault log

1

400 600 800 Units Description Series Series Series Min Max Step Default Default Default 600 600 600 Seconds Sample rate logged 1 600 1 Clears fault log on display No change, reset only

Display Parameters Configuration settings

1

Clock format

1

Date format Display Contrast

1 1

Distance Format Clock settings hours mins day of month

1

month year

1 1 1

1 1

Metric= 0, Imperial = 1 Metric Metric Metric 12Hour = 0, 24Hour = 12Hour 12Hour 12Hour 1 DDMMYY = 0, MMDD MMDD MMDD MMDDYY = 1 YY YY YY 153 153 153 1 255 1 feet = 0, meters = 1, miles = 2, kilometers =3 Feet Feet Feet

Contrast darker or lighter Travel distance unit of measure

Hours Minutes Day

0 23 1 0 59 1 1 31 1 January = 1, February = 2, March = 3, April = 4,May = 5, June = 6, July = 7, August = 8,September = 9, October = 10, November = 11, December = 12 2000 2050 1

Month

Year

vehicle description Auto-Manual selection

2

Vehicle Type

2

Auto or User selections Un-A-Hauler, Un-ATrac, Vers-A-Trac

Auto

Auto

Auto

Traction Motor Type

2

2x75HP, 2x100HP, 1x75HP, 1x100HP

Pump Motor Type

2

48HP, 60HP

Vehicle Gear Ratio Vehicle Tire Diameter

2

From BUC table

2

Vehicle Orientation

2

From BUC table FWD is right, FWD is FWD is FWD is FWD is Right Right Right left

Auto configured from hard wired configuration inputs.

Direction of travel

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.62

© BUCYRUS AMERICA, INC.

Units Format

Motor and VFD temperatures measured in °C, change to imperial to see temperatures in °F. Time format in 12 hour time or 24 hour military time style Set to day/month/year format.

_______________________________________ Adjustment procedures Table 25: Adjustable parameters, continued

Menu3

Description

400 600 800 Series Series Series Max Step Default Default Default

Units

Description

Traction 1 Build Sw. Ver. Serial No.

1 1

n/a n/a

Software Version Serial No.

Traction 2 Build Sw. Ver. Serial No.

1 1

n/a n/a

Software Version Serial No.

Pump Build Sw. Ver. Serial No.

1 1

n/a n/a

Software Version Serial No.

Display Build Sw. Ver.

1

n/a

Serial No.

1

n/a

Software Version Serial No.

© BUCYRUS AMERICA, INC.

Menu1 Menu2 System Build

Bucyrus Passcode level Min

______________________________________________________________ A6474X273 VSVI/00 3.63

© BUCYRUS AMERICA, INC.

Adjustment procedures ________________________________________

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.64

____________________________________________Parts replacement Parts replacement Removal and installation of VFDs The following section outlines the removal and installation of VFDs. CAUTION! Before removing or installing a VFD, verify that the battery has been disconnected from the machine, that the circuit breakers are in the “OFF” position, and that the battery plug has been disconnected and locked/tagged out. Failure to do so may result in machine damage or injury to you or other personnel.

Connectors Locking type connectors are used on the VFDs (Fig. 30).

© BUCYRUS AMERICA, INC.

To remove a connector: ) Verify that the battery has been disconnected from the machine, that the circuit breakers are in the “OFF” position, and that the battery plug is disconnected and locked/tagged out. ) Remove the cover from the controller. ) Locate the VFD and identify the connectors. The connectors are labeled “A”, “B”, “C”, and “D”. ) The connectors are equipped with a screwdriver slot to release the latch (Fig. 31). Insert the screwdriver into the latch and lift up. ) Pull up firmly to remove the connector.

To install a connector: ) Verify that the correct connector is selected. Each connector is labeled “A”, “B”, “C”, and “D” for correct installation. ) Press connector down firmly to lock in place. Locking latch (Fig. 31) must be firmly fastened for mating.

______________________________________________________________ A6474X273 VSVI/00 3.65

Parts replacement_____________________________________________ Fig. 30: Typical VFD

Power connections (5)

Mounting hardware (4) (2 located on each side)

Fig. 31: Connector

Screwdriver slot to lift latch for unmating

Locking latch must be securely fastened for mating

Plug and header must be of identical as “A”, “B”, “C”, and “D” before mating.

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.66

© BUCYRUS AMERICA, INC.

Connectors (4)

____________________________________________Parts replacement Power connections Power connections (Fig. 30) utilize studs made of a special currentcarrying material, along with nuts, flat washers, and lock washers. Due to the properties of the material, excessive torque values may damage or break the power terminal stud or damage the VFD. The correct torque for the power connections is 9 ft-lbs ± 10% (13.5 Nm ± 10%).

Do not exceed this torque value.

NOTICE! Due to the properties of the stud material, excessive torque may damage or break the power terminal stud or damage the VFD.

VFD mounting

© BUCYRUS AMERICA, INC.

) Remove all old thermal compound from the bottom plate of the controller enclosure. Make sure the plate is free of all debris, rust, etc. ) Apply a thin coat of thermal compound to the VFD. The thermal compound should cover the entire mounting surface of the VFD. Do not apply thick coats of thermal compound as they may leave voids and limit heat transfer.

NOTICE! Lack of thermal compound, thickly applied thermal compound, and/or debris under the VFD may limit heat transfer from the VFD to the controller bottom plate and may result in thermal cutback of the VFD. ) Mount the VFD to the controller bottom plate. Mounting hardware (Fig. 37) must be properly installed to insure proper heat transfer from the VFD to the bottom plate of the controller. The correct torque for the VFD mounting hardware is 32 ft-lbs ± 10% (44 Nm ± 10%).

NOTICE! Improper installation of mounting hardware may limit heat transfer from the VFD to the controller bottom plate and may result in thermal cutback of the VFD.

______________________________________________________________ A6474X273 VSVI/00 3.67

© BUCYRUS AMERICA, INC.

Parts replacement_____________________________________________

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.68

_____________________________________________ Wiring diagrams Wiring diagrams

© BUCYRUS AMERICA, INC.

See you machine parts manual for the complete machine wiring diagram applicable to your particular machine.

______________________________________________________________ A6474X273 VSVI/00 3.69

Wiring diagrams ______________________________________________

© BUCYRUS AMERICA, INC.

Fig. 32: Traction supervisor VFD diagram

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.70

_____________________________________________ Wiring diagrams

© BUCYRUS AMERICA, INC.

Fig. 33: Traction auxiliary VFD diagram

______________________________________________________________ A6474X273 VSVI/00 3.71

Wiring diagrams ______________________________________________

© BUCYRUS AMERICA, INC.

Fig. 34: Pump VFD diagram

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.72

_____________________________________________ Wiring diagrams

© BUCYRUS AMERICA, INC.

Fig. 35: Harness assembly A

______________________________________________________________ A6474X273 VSVI/00 3.73

Wiring diagrams ______________________________________________

© BUCYRUS AMERICA, INC.

Fig. 36: Harness assembly B (CAN bus cable)

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.74

_____________________________________________ Wiring diagrams

© BUCYRUS AMERICA, INC.

Fig. 37: Harness assembly C

______________________________________________________________ A6474X273 VSVI/00 3.75

Wiring diagrams ______________________________________________

© BUCYRUS AMERICA, INC.

Fig. 38: Harness assembly D

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 3.76

_______________________________________________________________

4

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

___________________________________________ Tightening torques Tightening torques NOTICE! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with the correct torque. The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

13.5Nm ± 10% (9 ft-lb ± 10%) 44 Nm ± 10% (32 ft-lb ± 10%)

© BUCYRUS AMERICA, INC.

Controller terminal torque: Controller mounting torque:

______________________________________________________________ A6474X273 VSVI/00 4.3

© BUCYRUS AMERICA, INC.

Tightening torques ____________________________________________

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 4.4

_______________________________________________________________

5

For your information

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

© BUCYRUS AMERICA, INC.

Service address Beckley, WV 200 George Street, Suite 4 Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA (Corporate Headquarters) 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 Oak Hill, WV 25901

Paonia, CO P.O. Box 566 Paonia, CO 81428

Price, UT 1814 North 1500 West P.O. Box 1016 Price, UT 84501 Phone: (435) 637-3930 Fax: (435) 637-9754

719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846 Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

______________________________________________________________ A6474X273 VSVI/00 5.3

Our service __________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

© BUCYRUS AMERICA, INC.

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

_________________________________________________________________ BUCYRUS – Model HiPAC 10 Variable Frequency Drives 5.4

A6474X275 June 2012

Operation and Maintenance Manual SH650 VFD Roof Support Carrier

__________________________________________________________ This manual is intended to provide GENERAL product information. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. The manufacturer reserves the right to revise models and designs without prior notice.

This machine was manufactured under the guidelines, procedures and requirements of the appropriate regulatory agencies.

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 the manufacturer and these regulatory agencies, or any repair or replacement of parts contrary to the manufacturer’ 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. 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.

© 2012 ALL RIGHTS RESERVED

_________________________________________________Table of contents

Table of contents 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

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

________________________________________________________________ A6474X275

REV 06

Table of contents _________________________________________________ 5. Operation Operation ................................................................................. 5.3 How to operate the machine ................................................ 5.3 Who is allowed to operate the machine? ........................ 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 ....................................................................... 5.18 Starting procedure.............................................................. 5.19 General.......................................................................... 5.19 Machine operation......................................................... 5.20 Shutdown procedure .......................................................... 5.23 Procedures for loading and unloading The Longwall roof support.................................................. 5.25 Loading from the long axis of the shield........................ 5.25 Unloading from the long axis of the shield .................... 5.25 Loading from the side of the shield ............................... 5.26 Unloading from the side of the shield............................ 5.27 Towing a disabled machine................................................ 5.28 Battery change procedure .................................................. 5.29 Instructions on the maintenance ........................................ 5.35 Important notes ............................................................. 5.35 Before maintenance ...................................................... 5.35 Critical torque values..................................................... 5.37 Lubricants, fluids and capacities ................................... 5.37 Specific lubrication and maintenance instructions ............. 5.41 Every third shift.............................................................. 5.41 Weekly........................................................................... 5.48 Monthly .......................................................................... 5.54 Every three months ....................................................... 5.55

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

________________________________________________________________ SH650 VFD Roof Support Carrier

_______________________________________________________________

1

About this manual

________________________________________________________________

_______________________________________________________________

________________________________________________________________

___________________________________________ Before starting to work

About this manual 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 applicable operating manual

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

machine type

This operating manual is intended for SH650 VFD machine and is only permitted to be used for equipment of this type.

new operation manual

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



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

supervisory personnel who: 

initiate and/or



supervise the activities just indicated.

______________________________________________________________ A6474X275 REV 06 1.3

Before starting to work ____________________________________________ What is the purpose of this operating manual? cost-effectiveness

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

service

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For your safety”with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

________________________________________________________________ 1.4 SH650 VFD Roof Support Carrier

___________________________________________ Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

■

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

______________________________________________________________ A6474X275 REV 06 1.5

Before starting to work ____________________________________________

________________________________________________________________ 1.6 SH650 VFD Roof Support Carrier

_______________________________________________________________

2

Your safety

________________________________________________________________

_______________________________________________________________

________________________________________________________________

______________________________________________________ Personnel

Your safety This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage, or operator errors.

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved by the manufacturer.

Use only original spare parts. Note that the use of parts from other manufacturers will void the guarantee.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine,

■

of the mine inspector, and

■

of the mining supervisory authorities.

Please read also the operating manuals of the components required for operation, e.g. of gearboxes, electric motors, etc., carefully and thoroughly. Clarify any questions before starting work.

______________________________________________________________ A6474X275 REV 06 2.3

Personnel _______________________________________________________ Personnel Operation training

The machine may only be operated by qualified, trained personnel.

The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit. Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

Installation and repair As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on: ■

safety components (pressure relief valves, extinguishers, etc.),

■

the electrics (motors, controllers, etc.), anf

■

the hydraulics (controls, cylinders, etc.)

may only be carried out by service engineers from or by specially qualified personnel of the mine.

________________________________________________________________ 2.4 SH650 VFD Roof Support Carrier

_____________________________________________ Operating conditions Operating conditions Intended use The machine has been designed and manufactured purely for transporting of long wall support shields and utility work.

Intended uses include: ■

the transport of long wall support shields.

■

use during clean up and utility work.

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.

■

the transport of persons

The manufacturer accepts no liability for any damage resulting from any such unauthorized use.

______________________________________________________________ A6474X275 REV 06 2.5

Operating conditions _____________________________________________

________________________________________________________________ 2.6 SH650 VFD Roof Support Carrier

_______________________________________________ Safety instructions Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

Always wear your personal protective equipment. This also includes ear protectors as the noise emitted by other equipment in the area may at times exceed 85 db(A).

Inform your colleagues of:

safety equipment

■

your exact location.

■

the work you are performing.

■

the time that you will probably require.

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the machine.

symbol plates emergency stop (panic strip)

disconnect battery

welding

Observe the symbol plates on the machine.

Press the EMERGENCY STOP switch immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Disconnect the battery while performing: ■

maintenance work

■

inspection work

■

repair work

Batteries should be well vented before servicing, particularly if welding or burning on the battery.

Disconnect the battery when working with the electrical system or when welding on the battery to prevent electrical shock.

While welding, the battery must be disconnected to ensure that the electrical system and/or electrical system components are not damaged.

cordon off working area

Cordon off your working area widely for the machine.

______________________________________________________________ A6474X275 REV 06 2.7

Safety instructions _______________________________________________ moving parts

steering lockout

Never allow parts of your body to come between parts which could move, such as: ■

fork lifts

■

pivot points

■

battery lifts

Connect the steering lockout device before performing maintenance or repairs on the machine.

Storage and transport Maintain the prescribed storage periods and observe the instructions for storage. Do not store materials or parts in the travel way or in your working area. Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted. Fix all moving parts with transport locks. Never stand under unsupported parts or suspended loads.

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also, observe the instructions on the transport sheet.

means of attachment

Only use means of attachment which are in good condition and have been designed for the loads to be handled. For round components, use transport straps only. Never use chains or steel cables for this purpose. Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.

mobile handling equipment

When using mobile handling systems for transport, make sure that the center of gravity is as low as possible.

Pre-start inspection operation

Read this entire guide before attempting to operate this machine.

inspection

Inspect the machine and have any malfunctioning, broken, or missing parts corrected or replaced before use.

maintenance instruction and safety tags

operator’s compartment cab/canopy

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

These are as important as any other equipment on the machine.

Clean any foreign material from the operator’ s compartment.

This machine was shipped from the factory equipped with a protective cab/canopy. The cab/canopy must be securely in place before operating the unit.

________________________________________________________________ 2.8 SH650 VFD Roof Support Carrier

____________________________________ Overview of safety instructions Installation and start-up inclined face

environmental acceptability

On inclined faces secure all component parts by chains, e.g. to the support.

When working with oils, greases, and other chemical substances, observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease, or other chemical substances in an environmentally safe manner.

controls

When starting up machine, do not operate any controls located inside the operator’ s compartment from outside the compartment.

starting procedures

Follow the starting procedure instructions in chapter 5 of this manual.

hazard zone

Do not operate any levers, pedals, or controls if anyone is in the hazard zone. (See Hazard zone in Chapter 5 of this manual)

Operation training

Operate the machine only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective machine.

before start-up

Before start-up, ensure that there are no persons or obstructions in your line of travel or in the articulation area when steering the unit.

protective devices

Check that all protective devices are installed on the machine and function properly.

operator’s compartment

Clean the operator’ s compartment at regular intervals. Ensure that the operating symbols are legible to avoid any operator errors and resulting accidents.

Never climb onto or out of the machine while it is in motion.

Do not operate the machine with any part of your body outside of the operator’ s compartment in order to prevent body parts from being crushed between the machine and outside objects .

traveling

Use extreme caution when traveling in close quarters or in congested or blind-travel areas. The warning gong should be sounded to alert personnel of your movement.

passengers

Never carry passengers to prevent the passengers from being thrown off or crushed between the machine and outside objects.

safety rules

Always follow all safety rules of each particular mine when operating the machine.

problems and malfunctions

If problems or malfunctions are encountered while operating the unit, it must be properly shutdown and the problem corrected immediately.

______________________________________________________________ A6474X275 REV 06 2.9

Safety instructions _______________________________________________ Stopping operator’s compartment

Do not leave the operator’ s compartment with the unit running. Always properly shutdown the unit before leaving the operator’ s compartment.

parking

Always park the unit on solid, level ground. If this is not possible, park the unit at a right angle to the slope to prevent accidental movement of the machine.

Use proper flags, warnings, or barriers when parking in areas of traffic.

Chock all four (4) wheels in both directions whenever possible.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration. securing

Secure your working area over a wide range to avoid endangering other persons.

Disconnect the battery from the machine to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

replacing components

Disconnect the battery from machine to prevent restarting before replacing any defective components.

Pass on defective components removed for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

lifting

handling of hydraulic fluids

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original spare parts. Please refer to the spare parts lists for the order numbers.

For raising the machine use only: ■

crib blocks with adequate load-holding capacity and

■

hoists, jacks or cranes with adequate load-carrying capacity.

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

Never use hydraulic fluid for rinsing or cleaning. Hydraulic fluid represents a very serious danger to health.

________________________________________________________________ 2.10 SH650 VFD Roof Support Carrier

_______________________________________________ Safety instructions maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work on the hydraulic system.

Avoid, whenever possible, servicing, cleaning or examining the machine in congested areas.

Avoid, whenever possible, servicing or providing maintenance to the unit unless the wheels are chocked and steering lockout device is connected to prevent accidental movement of the unit.

Do not alter the electrical or hydraulic settings from that indicated in this manual or as set at the factory.

Always replace damaged or lost decals and metal instruction plates.

Disconnect the battery when working with the electrical system or when welding on the unit to prevent electrical shock.

Be sure the battery area is well ventilated (clear of fumes) when it is necessary to connect battery charger. Fumes from the battery could ignite from a spark and explode.

Always follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that: ■

the hoses are not pinched or trapped,

■

the hoses have no bubbles or blisters,

■

the hose or outer sheathes of the hose are not abnormally rigid or hard,

■

the outer sheath of the hoses is not damaged,

■

the connectors are securely inserted into the sockets, and

■

the connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage in the whole system!

Flush out the hydraulic lines thoroughly before connecting.

______________________________________________________________ A6474X275 REV 06 2.11

Safety instructions _______________________________________________ If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressurizing the system again. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn orings.

Replace hydraulic hoses only with hoses of the same or a higher quality.

Observe the date of manufacture stamped on the hydraulic hoses.

Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

laying hydraulic hoses

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so they: ■

always have a little slack.

Fig. 1: Laying hydraulic hoses, slack Right

Wrong

________________________________________________________________ 2.12 SH650 VFD Roof Support Carrier

_______________________________________________ Safety instructions ■

are not twisted.

Fig. 2: Laying hydraulic hoses, twisting Right

■

Wrong

are not bent directly behind the connections. (distance min. 1.5 x nominal diameter).

Fig. 3: Laying hydraulic hoses, bending Right

■

Wrong

always have a little slack.

Fig. 4: Laying hydraulic hoses, crossing Right

Wrong

______________________________________________________________ A6474X275 REV 06 2.13

Safety instructions _______________________________________________

■

are not kinked.

■

do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

When installing the hydraulic hoses, ensure that they cannot be: ■

torn out,

■

kinked,

■

crushed,

■

driven over or

■

twisted by movement of the machine.

Fig. 5: Laying hydraulic hoses, connections on moving parts Right

Wrong

________________________________________________________________ 2.14 SH650 VFD Roof Support Carrier

_______________________________________________________________

3

Storage and transport

________________________________________________________________

_______________________________________________________________

________________________________________________________________

____________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the machine. Observance of the instructions and tips will increase the service life and availability of the machine. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

Components coated with temporary corrosion inhibitor are protected for approximately six months.

Before delivery, the hydraulically operated equipment is operated and all axles, gear boxes, hydraulic oil tank, etc. are filled to their maximum fill point.

Storage of the machine and spare parts no direct exposure to sunlight

dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic –such as seals and hoses –and hydraulic fluids only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).

Protect the equipment and all spare parts stored outdoors against moisture and dirt, e.g. using tarpaulins.

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied.

short-term storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt, and moisture.

long-term storage

If the equipment is to be stored more than six months, the hydraulic components must be completely filled with a corrosion inhibiting/frostproofing fluid such as CV 50.

Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow, then seal the ports with plastic or steel plugs.

The equipment must be stored in a well ventilated, dry room. Do not store outdoors.

______________________________________________________________ A6474X275 REV 06 3.3

Storage and transport _____________________________________________ plastic deformation

In order to prevent plastic deformation of the seal elements, cylinders must be stored in an upright position. Some cylinders must be removed so that they can be stored upright.

random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage. On request, the inspection can be carried out by Bucyrus America, Inc.

natural aging

Even with proper storage, seals and hoses are subject to natural ageing. Do not use these parts if they have been stored for more than two years.

HFA fluids

Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in chapter 6 in this operating manual.

IMPORTANT! Take care to insure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out”principle.

Transport Load units: dimensions and weights Observe the transport sheets for the machine and spare parts. They contain information on: ■

dimensions,

■

weight,

■

lifting points, etc.

Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

________________________________________________________________ 3.4 SH650 VFD Roof Support Carrier

____________________________________________ Storage and transport Before transport temperatures below freezing

Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibitor/frostproofing fluid (e.g. CV 50).

Transport of equipment at temperatures between -6° F (-21° C) and -40° F (-40° C) is only permissible when certain measures were taken to meet these conditions at the design and manufacture stages. Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and may only be loaded statically or quasi-statically.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport.

electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

______________________________________________________________ A6474X275 REV 06 3.5

Storage and transport _____________________________________________

________________________________________________________________ 3.6 SH650 VFD Roof Support Carrier

_______________________________________________________________

4

Installation

________________________________________________________________

_______________________________________________________________

________________________________________________________________

_____________________________________________________ Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on the safety components (pressure relief valves, fire extinguishing equipment etc.), the electrical equipment (control units, signaling devices, etc.), and the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by Bucyrus America, Inc. service engineers or by specially trained personnel.

Which tools are required for installation? tool box

No special tools are required to put the machine into service.

The battery plugs and receptacles come with a special wrench for connecting and disconnecting battery plugs and receptacles.

In addition, various items of auxiliary equipment and machines may be required at the point of installation.

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

______________________________________________________________ A6474X275 REV 06 4.3

Installation ______________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the machine as a result of incorrect installation. The unit should, therefore, only be installed under the instruction of specialists from Bucyrus America, Inc. installation plan

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established

________________________________________________________________ 4.4 SH650 VFD Roof Support Carrier

_____________________________________________________ Installation Pre-installation check list NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, a prestartup check should be performed.

The pre-startup check should include: ■

perform daily maintenance

■

visually inspect all hydraulic hoses and electrical cables for damage

■

clean any foreign material from the operator’ s compartment

■

if equipped with bucket, clean any foreign material from behind the ejector blade

■

check safety provisions for operational condition on fire suppression system

■

start up the machine and check for correct operation of panic switch (s) which are located inside the operator’ s compartment

■

check that all covers and guards are in place and secure

■

check that all tags and instruction labels are in place and secure

■

check that operator’ s canopy is secure and in place

■

start the machine and allow the hydraulic system to warm up for five (5) to ten (10) minutes

■

check hydraulic system pressures (refer to the hydraulic schematic supplied for your particular machine for pressure settings)

■

check all control handles and switches to ensure all machine functions are operating properly

______________________________________________________________ A6474X275 REV 06 4.5

Installation ______________________________________________________ Safety features NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

Safety features include: (Reference Fig. 6) panic strip (s)

The machine is equipped with two (2) panic strips located inside the operator’ s compartment: one to the right and one to the left of the operator while sitting in the operator’ s seat. The panic strip (s) are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force will actuate either panic strip.

canopy/cab

The machine was shipped from the factory with a protective canopy/ cab. Ensure that the canopy/cab is in place and secure at all times to protect the operator from falling debris.

fire suppression

The machine is equipped with two (2) fire suppression (remote) actuators: one located to the operator’ s right inside the operator’ s compartment and the other located on the middle frame in the pump motor compartment on the off-side of the machine. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

guards and covers

The machine is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.

DANGER! Do not operate the machine with any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts.

steering lockout

The machine is equipped with a steering lockout. The lockout should be connected and secure during shutdown and while performing maintenance on the machine.

circuit breaker reset

The machine is equipped with a circuit breaker reset located inside the operator’ s compartment. The circuit breaker reset may be used to shutdown the machine in emergency situations.

emergency stop button

The machine is equipped with an emergency stop button that may be used to shut the machined down in the event of an emergency.

________________________________________________________________ 4.6 SH650 VFD Roof Support Carrier

_____________________________________________________ Installation warning gong

The machine is equipped with a warning gong located inside the operator’ s compartment to the right of the operator. This warning gong should be used in accordance with the safety standards at the mine where the machine is being used.

Fig. 6: Safety features on the machine

Steering lock (Storage location)

Steering lock (Locked location)

Canopy/cab

Fire suppression actuator

Emergency stop button

Panic strip

Warning gong

Fire suppression actuator

Panic strip

Circuit breaker reset

Operator’ s compartment

______________________________________________________________ A6474X275 REV 06 4.7

Installation ______________________________________________________ Fig. 7: Overview of the machine

Controller

Center section

Rear frame

Battery

Front frame Operator’ s compartment

Winch

Middle frame

Tilt/lift assembly

Hydraulic oil tank and pump drive

________________________________________________________________ 4.8 SH650 VFD Roof Support Carrier

_______________________________________________________________

5

Operation

________________________________________________________________

_______________________________________________________________

________________________________________________________________

______________________________________________________ Operation

Operation This chapter contains important information on the operation and maintenance of the machine. It also includes instructions on the replacement of wear parts. Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

How to operate the machine DANGER! Incorrect operation endangers yourself and others! Incorrect operation of the machine is often the cause of very serious accidents! Operate the unit only when you have been sufficiently trained on the machine and have read and understand this operating manual. Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the machine?

The machine is only allowed to be operated by persons with adequate knowledge of the complete machine.

This includes: ■

what safety devices are installed on the machine,

■

where these safety devices are located, and

■

how these safety devices are to be operated.

When can operation be started?

Operation must not be started until the safe condition and proper function of the complete machine has been checked and the daily maintenance operations have been carried out.

______________________________________________________________ A6474X275 REV 06 5.3

Operation _______________________________________________________ Controls and indicators Operator’s compartment The primary controls for the machine are located in the operator’ s compartment (Fig. 8).

Fig. 8: Operator’s compartment Service brake pedal

HiPAC 10 display “SYSTEM” pressure

Speed switch (Accelerator) pedal

“EMERGENCY BRAKE” pressure

“ACCUMULATOR” pressure

Fork lift/tilt control

Panic strip

Emergency stop button

Panic strip

Warning gong Fire suppression actuator

“WINCH” control lever “WINCH SPEED” selector valve “PTO/Cab “ selector valve

“OPT/GLBC” control lever

Circuit breaker reset lever “PTO/CAB” control lever

Control handle and left hand steering lever

Seat

Brake release hand pump (not shown - located on floor on operator’ s right side)

Note: Typical operator’ s compartment shown, location of controls may vary.

________________________________________________________________ 5.4 SH650 VFD Roof Support Carrier

______________________________________________________ Operation WARNING! Before operating any levers or pedals on the machine always make sure no one is in the hazard zone (see Hazard zone in this chapter). Do not operate any levers or pedals from outside the operator's compartment. fire suppression actuators

The machine is equipped with two (2) fire suppression (remote) actuators (Fig. 9). One is located to the operator’ s right inside the operator’ s compartment and the other is located on in the pump motor compartment of the off-side of the machine. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward (push) on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

NOTICE! If either of the fire suppression actuator are actuated, the system must be completely recharged with dry chemicals and expellants.

Fig. 9: Fire suppression locator (typical) Actuator

Actuator

Plunger Pin

CO2 cartridge

______________________________________________________________ A6474X275 REV 06 5.5

Operation _______________________________________________________

NOTICE! This machine is equipped with four (4) axle mounted, HRSA (Hydraulic Released Spring Applied), wet multi-disc failsafe brakes, which are designed to suit all (i.e. Service/Emergency/ Park) brake requirements necessary for safe operation of this machine. brake pedal (service)

The service brake pedal (Fig. 10) is a foot operated pedal located in front of the operator and is situated for actuation by the operator’ s left foot. Service brake actuation is a reverse modulating (de-modulating) process which reduces the pressure supplied to the HRSA (Hydraulic Released Spring Applied) brakes as the pedal is depressed. The brake system for this machine has also been designed to provide isolated (front/rear) brake circuits via dual reverse modulating brake valves that are controlled via one common foot pedal. This design provides a safer and more efficient system which is easily maintained for secure performance.

Brake system operating pressure is regulated to a maximum limit of 1700 psi and is achieved via internal controls within the brake pedal valves themselves.

WARNING! These valves are designed specifically for their application and are pre-set during manufacturing. The operating pressure is not adjustable. When system pressure isn’t suitable, it must be replaced with a new OEM valve. Failure to heed this warning may result in property damage or injury or death to personnel.

accelerator pedal

This pedal (Fig. 10), operated by the right foot, is used to start the tram (traveling) motors and regulate the speed of the machine.

CAUTION! The speed switch foot pedal should not be depressed at the same time as the foot brake pedal or when the parking brakes are set.

To do so may overload the tram motors and could shorten their usefulness. The machine is provided with overload protection, but continued abuse can shorten motor life.

Fig. 10: Brake and accelerator pedal location Emergency brake pressure gauge

Brake pedal

Accelerator pedal

________________________________________________________________ 5.6 SH650 VFD Roof Support Carrier

______________________________________________________ Operation warning gong

The warning gong (Fig. 11), is located to the operator's right. It is sounded by striking the knob in the center of the gong. This warning gong should be used in accordance with the safety standards at the mine where the machine will be used.

panic strip (s)

The machine is equipped with two (2) panic strips (Fig. 11) located in the operator’ s compartment. One is located to the right and one is located to the left while sitting in the operator’ s seat. The panic strips are used to break the control circuit only in emergency situations, stopping all motors. Striking with a small amount of force can actuate either panic strip.

HiPAC 10 display

The HiPAC 10 display is located in front of the operator’ s seat. If the display indicates “SYSTEM OK”when the machine is started, you maycontinue. If any other message is displayed, turn the battery circuit breaker to “OFF”and contact your immediate service personnel or your Bucyrus America, Inc. service department.

emergency stop button

The emergency stop button (Fig. 11) is located in front of the operator.

It can be used to stop the machine in the event of an emergency.

IMPORTANT! For more detailed instructions on the HiPAC 10 display, refer to the HiPAC Variable Frequency Drive Operation and Troubleshooting guide.

Fig. 11: Panic strip, warning gong, HiPAC 10 display, and emergency stop button location Emergency stop button

HiPAC 10 display

Panic strip

Warning gong

Panic strip

______________________________________________________________ A6474X275 REV 06 5.7

Operation _______________________________________________________ Control handle The control handle (Fig. 12), located to the left of the operator has a group of switches that control the following: IMPORTANT! For more detailed control handle operating instructions, see Starting procedures in this chapter.

“TRACTION ASSIST”

To activate traction assist (differential locks) press down and hold the “TRACTION ASSIST”button. Releasing the button disengages traction assist.

CAUTION! The “TRACTION ASSIST”(dif-lok) should not be engaged during spin-out or while in a turn or damage to the axle (s) can occur.

“PUMP MOTOR”

To start the pump motor, press the diagnostics button down and hold, then press “PUMP MOTOR”button and hold until the pump motor starts. Release “PUMP MOTOR”button and then release diagnostics button. To turn off the pump motor, press the “STOP”button or “PUMP MOTOR”button.

“PARK BRAKE”

To release the park brake, (pump motor must be running) press diagnostic button and hold, then press “PARK BRAKE”button until the dashboard display indicates “PARK BRAKE RELEASED”. Release “PARK BRAKE”button and then release the diagnostics button. To set “PARK BRAKE”and leave pump motor running, press “PARK BRAKE BUTTON”. To turn “OFF”the pump motor and set the park brake, press “STOP” or “PUMP MOTOR”button.

“TRAM  or ”

To activate a tramming direction:  The pump motor must be running.  The park brake must be released.  Press trigger down and hold, press either “TRAM ”for tram direction or “TRAM ”for tram direction, hold until the dashboard display indicates direction of travel.  Release “TRAM ”or “TRAM ”depending on direction selected and then release trigger.  To disable tramming, press either “TRAM”button and release.

WARNING! If tramming has be disabled and the pump motor remains energized, the machine may continue to roll or may be induced to roll, unless the service brakes or the automatic (emergency)/park brake controls have been applied to stop/hold the machine. Failure to heed this warning could result in property damage or in injury or death to personnel.

________________________________________________________________ 5.8 SH650 VFD Roof Support Carrier

______________________________________________________ Operation “LIGHTS  or ”

To activate “LIGHTS”press either “LIGHTS ”or “LIGHTS ”for light direction. For auto position headlights (headlights follow the tram direction), press and hold the in-position button, press and release “LIGHTS ”, and then release the in-position button. Lights will stay in auto position until “STOP”, “LIGHTS ”or “LIGHTS ”is pressed. If equipped with all position lights (all headlights, front and rear, are on) press and hold the in-position button, press “LIGHTS ”, and then release the in-position button. Lights will stay in all position until “STOP”, “LIGHTS ”or “LIGHTS ”is pressed.

“DIAGNOSTICS”

Press the upper button for machine diagnostics.

Fig. 12: Control handle “PUMP START”

“TRACTION ASSIST”

“LIGHTS” (Battery end)

“TRAM” (Battery direction)

“PARK BRAKE”

“STOP”

“LIGHTS” (tilt/lift end)

“TRAM” (Tilt/lift direction)

Diagnostics button

In-position button

battery circuit breaker reset

The battery circuit breaker (Fig. 13) is located on the battery. This circuit breaker has four (4) positions: “OFF”to de-energize the machine’ s electrical systems, “TRIPPED”for when the circuit breaker is overloaded, “RESET”to reset the circuit breaker after it has tripped, and “ON for normal operation.

NOTICE! Once the breaker has tripped, it must be moved to the “RESET” position and then to “ON”. The breaker will not stay in the “ON” position after being tripped until it is first moved to “RESET”.

______________________________________________________________ A6474X275 REV 06 5.9

Operation _______________________________________________________ Fig. 13: Typical battery circuit breaker reset lever “ON”

machine circuit breaker reset lever

“TRIPPED”

“OFF”

“RESET”

Also used to turn machine off, this lever (Fig. 14), located to the right of the operator is used to reset the circuit breaker when it has tripped.

This circuit breaker is located in the electrical controller enclosure.

The machine circuit breaker is not intended as an "ON-OFF" switch for normal operation. Except in an emergency, the machine should be shutdown by first depressing the “STOP”button located on the left control handle and then moving the machine circuit breaker to the "OFF" position.

WARNING! The machine circuit breaker de-energizes the electrical controller and motors. However, electrical power is still present inside the controller to the circuit breaker. If the circuit breaker inside the controller requires service, the battery circuit breaker should be turned to the "OFF" position or the battery plug disconnected from the battery.

Fig. 14: Circuit breaker reset lever Hand pump handle (not shown)

Circuit breaker reset

________________________________________________________________ 5.10 SH650 VFD Roof Support Carrier

______________________________________________________ Operation “OPT/GLBC”control lever

The "OPT/GLBC" control lever located to the operator’ s left (Fig. 15) controls the battery changing system, which is made up of two hydraulic cylinders (battery lifting cylinders). When the "BATTERY CHANGER" control lever is lifted by the operator, the battery-lifting cylinders will raise the battery. Lowering the handle will lower the battery.

The battery can be lowered to the ground for battery change without tables or pedestals or raised above frame level to improve mobility in certain conditions. The control lever can also be used to control optional features that can be added to the machine as chosen. The “OPTION/GLBC LIFT”diversion valve located to the operator’ s right must be rotated or placed in it’ s appropriate position before operating the “GLBC/OPT.”control lever.

CAUTION! For more information on how to change the battery, see Battery change procedure is this chapter. If the machine is in a low roof area, the battery may be damaged if raised too high or cause damage to other machine apparatus if lowered excessively.

WARNING! Never attempt to disconnect a hydraulic hose from the battery lifting cylinders with the battery in the “UP”position. If maintenance is required in the “UP”position always securely block the lift mechanism to prevent unintentional travel of the mechanism from occurring. Never allow any part of the body to be under the battery in the raised position without first securing the mechanism in its elevated position with appropriate blocking (cribbing) materials. The battery could fall and result in injury or death.

“PTO/CAB”control lever

The "PTO/CAB" control lever located to the operator’ s left (Fig. 16) controls the hydraulic “PTO”and “CAB”functions. The “PTO/CAB”diversion valve, located to the operator’ s right, must be rotated or placed in the appropriate position before operating the “GLBC/OPT.”control lever. When the "PTO" control lever is lifted by the operator, the “B” port is pressurized. Lowering the handle pressurize the “A”port. When the "CAB" control lever is lifted by the operator, the hydraulic cab will raise. Lowering the handle lowers the hydraulic cab.

CAUTION! Do not operate the “PTO”system continuously for more than 30 minutes at a time.

Never block or tie the “PTO”function in an active position.

______________________________________________________________ A6474X275 REV 06 5.11

Operation _______________________________________________________ Fig. 15: “BATTERY CHANGE”and “PTO”control lever location

“OPTION/ GLBC LIFT” selector valve (if required)

“OPT/GLBC.” control lever

“PTO/CAB control lever

“PTO/CAB” selector valve

“WINCH”control lever

The "WINCH" control lever located to the operator’ s left (Fig. 16) controls the winch and wire rope assembly. When the control lever is pushed to the right the winch reels “OUT”. When the control lever is pushed to the left, the winch reels “IN”.

“WINCH SPEED” diversion valve

The “WINCH SPEED”diversion valve (Fig. 16) is located to the right of the operator’ s seat. It allows the operator to speed up or slow down the speed of the winch. To increase the speed of the winch, rotate the knob to the left. To decrease the speed of the winch, rotate the knob to the right. (If the diversion valve is push/pull, pull the handle out to increase speed and push the handle in to decrease speed.)

fork lift/tilt control lever

The lift/tilt control lever (Fig. 16) located to the operator’ s right (Fig. 15) controls the tilt and lift functions of the fork mechanism or the optional bucket or optional lift plate. The lift/tilt control lever has four positions: “TILT DOWN”, “TILT UP”, “LIFT”and “DOWN”. Push the lever forward (away from the operator) to lower the forks down and pull the lever backwards (towards the operator) to raise the forks up.

Move the lever to the left to tilt the forks up and move the lever to the right to tilt the forks down Fig. 16: “WINCH”, 2-speed winch and tilt/lift control lever locaFork lift/tilt control lever

“WINCH” control lever

“WINCH SPEED” selector valve

________________________________________________________________ 5.12 SH650 VFD Roof Support Carrier

______________________________________________________ Operation NOTICE! Standard diagnostic logic designed into the electrical system of the machine should inhibit the tramming operation of the machine unless the brakes have been selectively released. An optional pressure switch control is abailable to further insure that the brakes have been released before the tramming operation may be actuated. A brake release hand pump is provided to permit brake release operation in the event the powered operation of the machine cannot be attained. automatic emergency brakes

The automatic emergency brakes are spring-applied (on), pressure release (off) internal wet multi-disc failsafe brakes located on each axle shaft. Before the machine is moved, the automatic emergency brakes must be released. If they are not released, the brakes will drag and be damaged. The drive train and the electrical system could also be damaged. Any of the following conditions will apply the automatic emergency brakes:  The panic strip (s) is struck, tripping the machine circuit breaker.  The “STOP”button located on the control handle is depressed.  The circuit breaker is in the "OFF" or "TRIPPED" position.  Starting a machine that was previously disabled and which had the brakes released with the brake hand pump.

To release the automatic emergency brakes:  The circuit breaker lever must be in the “ON”position.  The pump motor must be running.  Press and hold the diagnostic button on the control handle, then depress and hold the “PARK BRAKE”button until the dashboard display indicates park brake released (Fig. 12).  Release the trigger and “PARK BRAKE”button.

steering control lever

The steering control lever to the left of the operator (Fig. 17) is used to steer the machine. The steering control lever is mounted on a swing arm that must be moved towards the operator and latched before the unit is started or moved. To steer left while moving forward (right while moving in reverse), push the steering control lever slowly away from the operator. To turn right while moving forward (left while moving in reverse), pull the steering control lever slowly toward the operator. If the steering control lever is jerked or moved too fast, the machine will respond abruptly and could result in ppersonal injury or could casue payloads being carried to become unstable and/or unsecured. This fast movement could be dangerous in a crowded area or narrow space.

______________________________________________________________ A6474X275 REV 06 5.13

Operation _______________________________________________________ WARNING! The steering control lever must be moved to the correct operating position and latched (Fig. 17) before the machine is started or moved. Attempting to steer the machine with the steering control lever in the incorrect position could cause serious injury or death to the operator or anyone close to the machine.

Fig. 17: Steering control lever

Steering control lever

Swing arm position for machine operation

________________________________________________________________ 5.14 SH650 VFD Roof Support Carrier

______________________________________________________ Operation pressure gauges

Located to the right of the operator’ s seat are three (3) pressure gauges (Fig. 18) that provides the operator with a continuous reading of the “ACCUMULATOR”, “SYSTEM”and “BRAKE”pressures.

WARNING! If the “ACCUMULATOR”pressure drops below 1,600 psi, shutdown the machine (see Shutdown procedure in this chapter) and call a maintenance person.

WARNING! If the “SYSTEM”pressures are outside (+/- 100 psi) of their normal operating range, (refer to the hydraulic schematic supplied for your particular machine for correct pressure settings), shutdown the machine (see Shutdown procedure in this chapter) and call a maintenance person.

WARNING! If the emergency “BRAKE”pressure drops below 1,600 psi, shutdown the machine (see Shutdown procedure in this chapter) and call a maintenance person.

brake release hand pump

The automatic emergency brakes are spring-applied (on), pressurerelease (off) internal wet disc brakes located on each wheel end. The automatic (park) brake is normally released using the "PARK BRAKE" release button located on the control handle (see "AUTOMATIC EMERGENCY BRAKES”, in this chapter). Should electrical or hydraulic system failure occur, the automatic (park) brake can be released using the manual brake release hand pump (Fig. 18).

To release the automatic emergency/park brakes with the machine deenergized proceed as follows:  Turn the selector valve handle on the hand pump to the “PUMP TO RELEASE”position.  Remove the pump handle retaining ring.  Pump the hand pump until the “EMERGENCY BRAKE”gauge reads the minimum 1,600 psi.

To reset the automatic emergency/park brakes proceed as follows:  Turn the selector valve handle on the hand pump to the “NORMAL RE-APPLY”position.  Push the hand pump handle down and reinstall the retainer pin.

WARNING! The machine must be chocked at all four (4) wheels before releasing the automatic emergency/park brakes with the hand pump.

The machine could run away out of control and cause damage to the machine or injury or death the operator or other persons.

______________________________________________________________ A6474X275 REV 06 5.15

Operation _______________________________________________________ Fig. 18: Pressure gauges and brake release hand pump location “SYSTEM” pressure gauge

Emergency “BRAKE” pressure gauge

“ACCUMULATOR” pressure gauge

Brake release hand pump

auto horn (optional)

The machine may be equipped with an automatic horn. When the autohorn switch (Fig. 19) is on, the horn will sound whenever the following actions are activated:    

the breaker is turned on the pump is turned on the brake is released a direction (forward or reverse) is selected

If the switch is turned off, the horn can be sounded by pressing the “PUMP”button on the control handle.

Fig. 19: Auto horn

________________________________________________________________ 5.16 SH650 VFD Roof Support Carrier

______________________________________________________ Operation methane monitor (optional)

The machine may be equipped with an methane monitoring system. horn. Consult the manufacturer’ s information for methane monitoring setup, operation, and maintenance instructions.

IMPORTANT! It is the responsibility of the machine owner/operator to know and follow all regulations regarding methane monitoring requirements including, but not limited to, daily operation, maintenance, and testing.

______________________________________________________________ A6474X275 REV 06 5.17

Operation _______________________________________________________ Hazard zone The hazard zone exists unless:  The battery plug is disconnected from the battery, OR;  The battery circuit breaker is in the “OFF”or “TRIPPED”position.

Fig. 20: Hazard zone

________________________________________________________________ 5.18 SH650 VFD Roof Support Carrier

______________________________________________________ Operation Starting procedure After reading the previous descriptions and locating each control, the operator is ready to start the machine. An experienced operator should monitor a new operator's indoctrination to the starting procedure.

CAUTION! Use caution when traveling down grade, exceeding 5 mph (8 kph) with this machine will result in tram motor failure.

WARNING! Check the battery connections and the battery covers. They must be in place and locked to be permissible.

WARNING! Never operate any levers or pedals from outside the operator's compartment. All switches in the operator’s compartment must be in the “OFF”position before the battery circuit breaker is moved to the “ON”position.

WARNING! This unit is equipped with a cab or canopy. Be careful not to hit your head when entering or leaving the operator's compartment.

This machine must not be operated without the canopy in place.

General 1. Disconnect the steering lockout device (Fig. 22).

2. Sit in the operator's seat and adjust the seat position relative to the foot and hand controls.

WARNING! Be sure no one is in the hazard zone (Fig. 20) before operating any levers or pedals.

Never try to adjust the operator's seat while the machine is in motion.

Do not operate the machine with any part of your body outside the operator's compartment to prevent having body parts caught between the unit and outside objects.

3. The tape panic strip (s) may be pressed at any time to trip the machine circuit breaker, set the park brake, and to de-energize the tram and pump motors.

4. Stop button “STOP”may be pressed at any time to set the park brake, and to de-energize the tram and pump motors (Fig. 21).

______________________________________________________________ A6474X275 REV 06 5.19

Operation _______________________________________________________ Fig. 21: Control handle “J7” Press “J2”and “J7” to start pump motor.

Press “J7”to stop pump motor.

“J8” With pump motor running, press “J2”and “J8”to release park brake. Press “J8”to set park brake.

“J12” Press and hold for traction assist.

Release to stop traction assist.

“J3” Push down for stop.

“J6” Push down for  LIGHTS.

“J4” Press “J4”to activate  LIGHTS. Press “J2”and “J4”for auto lights (lights follow direction of travel).

“J10” With pump motor running and brake released, press “J2”and “J10” to activate  TRAM direction.

Press “J10”to disable  TRAM.

“J9” With pump motor running and break released, press “J2”and “J9” to activate  TRAM direction.

Press “J9”to disable  TRAM direction.

“J11” Push for diagnostics.

“J2” Push for in-position.

Machine operation Note: Refer to Fig. 21 for illustration of control handle.

WARNING! Do not attempt to operate the machine with the control handle swing arm out of position. Swing arm must be moved completely to the operator’s right and latch pin fully locked into position.

1. Turn the battery circuit breaker and/or disconnect switch (if equipped) to the “ON”position.

2. Press and hold the diagnostics button to begin on board diagnostics.

3. Hold the diagnostics button until a message is displayed on the HiPAC 10 display.

4. If the display indicates “SYSTEM OK”, continue. If any other message is displayed, turn “OFF”battery circuit breaker and/or disconnect switch (if equipped) and contact your service department.

________________________________________________________________ 5.20 SH650 VFD Roof Support Carrier

______________________________________________________ Operation 5. Release the diagnostics button and set the machine circuit breaker.

6. Test tape switch panic bars before beginning each shift, press left side tape switch and machine circuit breaker should trip. Repeat steps 1 through 5 and press right side tape switch and machine circuit breaker should trip. If machine circuit breaker fails to trip, from either tape switch, turn “OFF”battery circuit breaker and/or disconnect switch (if equipped) and contact your immediate service personnel or your Bucyrus America, Inc. service department. If both tape switch panic bars trip machine circuit breaker, repeat steps 1 through 5 and proceed to step 7.

7. Test all control handle functions before beginning each shift. Follow steps 8 through 24. If any function does not operate correctly, turn “OFF”circuit breaker (s) and disconnect switch (if equipped) and contact your service department.

8. To start the pump motor, press and hold the in-position switch and then press “PUMP START”and hold until the pump motor starts.

Release “PUMP START”and then release the in-position button.

9. To turn off the pump motor, press “STOP”or “PUMP START”.

10. To release the park brake; ■

the pump motor must be running

■

press and hold the in-position switch and the press and hold “PARK BRAKE”until the dashboard display indicates “PARK BRAKE RELEASED”

■

release “PARK BRAKE”and then the in-position switch.

11. To set the park brake and leave the pump motor running, press “PARK BRAKE”.

12. To turn off the pump motor and set the park brake, press “STOP”or “PUMP START”.

13. To activate a tramming direction; ■

the pump motor must be running

■

the park brake must be released

■

press the in-position button and hold, press either “ TRAM”or “ TRAM”to select tram direction. Hold until the dashboard display indicates direction of travel.

■

release “ TRAM”or “ TRAM”and then release the inposition button.

14. The foot pedal may now be depressed to control the machine.

______________________________________________________________ A6474X275 REV 06 5.21

Operation _______________________________________________________ WARNING! The machine is equipped with a solid state speed controller. This means that the farther the speed switch foot pedal is depressed, the faster the machine will tram.

15. To change direction of travel, press and hold the in-position button, then press and hold either “ TRAM”or “ TRAM”until the dashboard display indicates direction of travel. Release “ TRAM” or “ TRAM”and then release the in-position button.

16. Each time the direction of travel is changed, the foot pedal will require recycling through the off position.

17. To disable tramming, press “ TRAM”or “ TRAM”.

18. To leave pump motor running, set park brake, and disable tramming, press “PARK BRAKE”.

19. To disable tramming, turn off the pump motor and set the park brake, press “STOP”or “PUMP START”.

20. To activate the traction assist function, press and hold “TRACTION ASSIST”. To deactivate, release “TRACTION ASSIST”.

21. Press and release “ LIGHTS”or “ LIGHTS”to chose light direction.

22. For auto position headlights, whereas the headlights follow the direction of the selected tram direction, press and hold the in-position button, press and release “ LIGHTS”, then release the in-position button. Lights will stay in auto position until “STOP”, “ LIGHTS” or “ LIGHTS”is pressed.

23. To turn off all lights, simultaneously press and release “ LIGHTS” and “ LIGHTS”.

24. If equipped for all position headlights, whereas all headlights, front and rear are on, press and hold the in-position button, press and release “ LIGHTS”, then release the in-position button. Lights will stay in all position until “STOP”, “ LIGHTS”or “ LIGHTS”is pressed.

________________________________________________________________ 5.22 SH650 VFD Roof Support Carrier

______________________________________________________ Operation Shutdown procedure Tram the machine to its designated parking place.

Stop the machine by releasing the speed-switch foot pedal and depressing the foot brake pedal. When the speed-switch foot pedal is released, the tram (traveling) motors will stop. Applying the foot brake will stop forward (or reverse) motion. The hydraulic pump's electric motor will still be running, making a humming sound.

WARNING! If equipped with optional quick attach bucket, always check before moving the ejector blade control lever to make sure no one has any part of their body between the ejector blade and the back of the bucket.

Note: Refer to Fig. 21 for illustration of control handle.

1. If equipped with optional quick attach bucket, ensure that the ejector blade is returned to the back of the bucket. There should be no obstructions between the back of the bucket and ejector blade.

2. Before leaving the operator’ s compartment, press J3”to turn “OFF” the machine.

3. Turn “OFF”the machine circuit breaker.

4. Turn “OFF”battery circuit breaker and/or disconnect switch (if equipped) before leaving the machine area.

5. Connect the steering lockout device (Fig. 22): 

remove the steering lockout device from its storage lugs



remove the hitch pin from the end farthest from the center section



adjust turnbuckle until holes line up between the turnbuckle lug and the front section lug



insert the hitch pin into the front section lug through the turnbuckle

WARNING! Never enter the articulation area while the machine is running.

Completely shutdown the machine as outlined before connecting the steering lockout device. Failure to observe this precaution may result in injury or death.

______________________________________________________________ A6474X275 REV 06 5.23

Operation _______________________________________________________ CAUTION! This unit is equipped with a canopy. Be careful not to hit your head when entering or leaving the operator's compartment.

WARNING! In the event of an emergency, the machine may also be shutdown by striking the panic strip. When the panic strip is struck, the machine circuit breaker will trip. This disconnects the motors and applies the automatic emergency brake (s). Be prepared for the sudden stop when the panic strips are struck.

Fig. 22: Steering lockout device

Steering lock (Installed)

________________________________________________________________ 5.24 SH650 VFD Roof Support Carrier

______________________________________________________ Operation Procedures for loading and unloading the longwall roof support Loading from the long axis of the shield Note: The following illustrations for loading and unloading Longwall roof supports show a typical machine.

1. Approach from the open end of the shield (side closest to the pan line) (Fig. 23).

2. Slide the lift attachment completely under the shield and position the shield as close to the backstop of the lift attachment as possible (Fig. 25).

3. Raise the lift attachment until either the tip of the support touches the front frame on the machine or the lift is level.

NOTICE! The winch may be required to assist in pulling the support fully onto the lift plate. (See winch operation in this chapter) 4. After properly securing the shield to prevent any unplanned movement, transport the shield.

Fig. 23: Depicting approach

Unloading from the long axis of the shield 1. Lower the lift attachment until the shield touches the surface of the floor (ground).

2. Back the machine away from the shield until the lift attachment is completely clear of the shield.

______________________________________________________________ A6474X275 REV 06 5.25

Operation _______________________________________________________ Loading from the side of the shield 1. Approach from either side of the shield (Fig. 24).

If the shield is on chocks 2. Slide the lift attachment completely under the shield until the backstop of the lift attachment touches the shield.

If the shield is not on chocks, use the following procedure: 2. Slide the lift attachment about six (6) inches under the side of the shield. It may be necessary to lower the lift attachment slightly below grade to reach under the shield, starting at a point about one (1) inch from the side of the shield.

3. Raise the lift attachment until it is level.

4. After properly securing the shield to prevent any unplanned movement, transport the shield.

NOTICE! If the shield must be moved a long distance, it should be resting against the backstop of the lift. If it is not (see section above), it can be pulled back against the backstop with the winch.

Fig. 24: Approaching shield from the side

Fig. 25: Loaded shield

________________________________________________________________ 5.26 SH650 VFD Roof Support Carrier

______________________________________________________ Operation Unloading from the side of the shield 1. Lower the lift attachment until the shield touches the surface or the chocks.

2. Back the machine away from the shield until the lift attachment is completely clear of the shield.

NOTICE! If the shield is not being placed on blocks, it may be necessary to lower the lift attachment slightly below grade before the shield will begin to slide away from it.

______________________________________________________________ A6474X275 REV 06 5.27

Operation _______________________________________________________ Towing a disabled machine WARNING! It is not possible, within the scope of this guide, to anticipate all possible arrangements for towing a disabled vehicle. You must take all possible precautions to protect the operators and anyone around both vehicles from being injured. The towing vehicle and the towing device used must be strong and heavy enough to maintain control of both vehicles through all bottom conditions to be encountered at all times. Safety chains or other safety devices must be used in case of failure of the primary towing device. All operators must be alert at all times to prevent either unit from running away or running out of control during towing. The vehicle to be towed must be securely coupled to the towing vehicle before the brakes are released on the disabled unit. The operator of the towing vehicle must be in place in the towing vehicle with the brakes applied before the brakes of the disabled vehicle are released.

NOTICE! Always insure that the link used for towing a disabled machine meets all applicable regulatory standards.

1. Couple the towing vehicle securely to the disabled vehicle.

2. Turn the valve selector handle to “PUMP TO RELEASE”on the hand pump located inside the operator’ s compartment.

3. Remove pin retainers and/or pins that implemented in storing the hand pump handle.

4. Begin pumping the hand pump. The building pressure will relieve the automatic emergency/park brake system to allow the disable machine to be easily towed.

5. The automatic (emergency/park) brake is released when a minimum of 1,600 psi is indicated by the brake release gauge.

CAUTION! For long distance towing, disconnect and remove front and rear drive lines.

WARNING! At no time during towing should anyone ride in or on the vehicle being towed or stand in between the towing vehicle and the disabled vehicle.

6. Begin towing the vehicle.

7. Once the destination is reached, stop both vehicles and set the parking brake on the disabled vehicle before removing the towing devices. The disabled vehicle should be chocked in both direction at all four wheels for additional stability. The brake is set by turning the valve handle on the hand pump to “NORMAL RE-APPLY”.

WARNING! Failure to set the parking brake on the disabled vehicle before removing the towing device could allow the disabled vehicle to roll away uncontrolled.

________________________________________________________________ 5.28 SH650 VFD Roof Support Carrier

______________________________________________________ Operation Battery change procedure Two people are needed to change the battery on the machine. Since one person may step into the Hazard Zone, the other person (operating the machine) must be very careful and look each time before moving any levers or pedals. Take time now to refamiliarize yourself with the Hazard zone in this chapter.

Note: The following illustrations for the battery change procedure show a typical machine with single battery plugs.

1. Line up the battery end of the machine with the place where the battery is to be deposited (Fig. 26) (see Starting procedure in this chapter).

Fig. 26: Battery change procedure

Lift attachment

Charged battery

Discharged battery

CAUTION! The “BATTERY”change control lever should never be operated except at a battery change station or when it’s necessary to adjust the battery's terrain clearance. If the "BATTERY" change control lever is operated in a low roof area, the battery may be damaged.

WARNING! Do not move the “LIFT”attachment control lever if anyone is near enough to the lift attachment to have any part of the body underneath.

______________________________________________________________ A6474X275 REV 06 5.29

Operation _______________________________________________________ 2. Pull both battery retainer pins and store in holes provided (Fig. 27).

If difficulty is encountered in removing the retainer pins, it may be necessary to gently shake the battery up and down by using the battery “LIFT”control lever.

Fig. 27: Battery change procedure Retaining pin storage location Battery housing Retaining pin

Battery housing Retaining pin

Retaining pin storage location

3. Lower the battery completely to the surface by pushing the "BATTERY" change control lever down. The bottom of the battery should touch the surface (Fig. 28).

WARNING! Never attempt to disconnect a hydraulic hose from the battery lifting cylinders while the battery is in the up position. This could cause the battery to fall and could result in serious injury.

Fig. 28: Battery change procedure Discharged battery

4. After the battery is fully lowered, shutdown the machine (see Shutdown procedure in this chapter).

________________________________________________________________ 5.30 SH650 VFD Roof Support Carrier

______________________________________________________ Operation 5. After shutting down the machine, disconnect the discharged battery.

■

Unlock and remove the padlock (s) at the battery connector (s).

■

Grasp the threaded lock ring and rotate it counterclockwise (CCW) until the threads are disengaged and it is free to slide away from the locking lug; the lock ring is designed to move freely but not to come off the plug.

■

Grasp the plug and pull it out, until the plug is completely disconnected from the receptacle; this plug is made to fit very tightly inside the battery receptacle and should not be driven out of the receptacle, dropped, or handled roughly; if the plug (or receptacle) is damaged, it will not fit together properly.

■

Install the cap which is secured to each receptacle by a small chain; this cap is placed over the threaded receptacle and rotated in a clockwise (CW) direction until hand tight and a padlock will fit into the locking lug; the padlocks all use the same key.

6. Connect the jumper cable (s) (Fig. 29).

■

Connect the receptacle end of the jumper cable (s) to the machine plug coming out of the connection box.

■

Connect the plug end (s) of the jumper cable (s) to the fully charged battery.

■

Secure the jumper cable connections by using the threaded lock rings. These lock rings must be hand tight but do not have to be padlocked.

■

One person should hold the jumper cable (s) so they will not be damaged or be run over when the machine is moved.

Fig. 29: Battery change procedure Charged battery Jumper cable

Discharged battery

______________________________________________________________ A6474X275 REV 06 5.31

Operation _______________________________________________________ 7. Start the machine (see Starting procedure in this chapter). Gently pull away from the discharged battery while the second person holds the jumper cable away from possible damage.

8. Line the machine up with the fully charged battery. Move the machine back until the battery lift forks are fully inserted into the pockets provided on the battery (Fig. 30).

Fig. 30: Battery change procedure Charged battery Jumper cable

Battery lift forks

Discharged battery

9. Shutdown the machine (see Shutdown procedure in this chapter).

Re-insert the retainer pins on both sides of the battery along with their corresponding detent pins (Fig. 31).

10. Disconnect the jumper cable and connect the charged battery directly to the machine’ s cable. Remember to be careful with the plugs. After the plug (s) is in the receptacles, the lock ring should be rotated clockwise (CW) until hand tight. The padlock must be in the locking lug and locked for this connection to be permissible.

11. Start the machine (see Starting procedure in this chapter).

12. Raise the battery by pulling the "BATTERY" change control lever upward. Continue to hold the battery change control lever in this position until the battery is no longer resting on the surface (Fig. 31).

13. Insert retaining pins and secure.

Fig. 31: Battery change procedure Retaining pin (s)

Charged battery

________________________________________________________________ 5.32 SH650 VFD Roof Support Carrier

______________________________________________________ Operation Fig. 32: Battery plug and receptacle (typical) Locking lug

Cable to machine circuit breaker box

Receptacle

Threaded lock ring

Plug assembly

Wrench

______________________________________________________________ A6474X275 REV 06 5.33

Operation _______________________________________________________

________________________________________________________________ 5.34 SH650 VFD Roof Support Carrier

____________________________________________________ Maintenance Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine.

In particular, observe the safety instructions in chapter 2 “Your safety”.

Important notes Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the machine as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

■

Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus spare parts when replacing components.

■

All electrical work must be supervised and inspected by a certified electrician.

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this Bucyrus America, Inc. guide.

Before maintenance Please observe the following: ■

Shutdown the machine on level ground.

■

Disconnect the electrical power. Either the battery circuit breaker or the emergency manual power disconnect (if equipped) must be in the "OFF" position. If work is to be done inside the electrical controller, the battery should be disconnected. Also make sure the capacitor discharge module indicates that the capacitors are discharged before working inside the controller.

WARNING! Before performing maintenance on the machine, disconnect the electrical power. Either the battery circuit breaker or the emergency manual power disconnect (if equipped) must be in the "OFF" position. If work is to be done inside the electrical controller, the battery should be disconnected. Also make sure the capacitor discharge module indicates that the capacitors are discharged before working inside the controller. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

______________________________________________________________ A6474X275 REV 06 5.35

Maintenance_____________________________________________________ ■

Test the controls to ensure that the unit will not move.

■

Chock all four (4) wheels in each direction.

■

Connect steering lockout device.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

■

During maintenance or servicing, if drive motors are to be run, the machine must be jacked clear of the ground and securely blocked. All four wheels must be free to rotate. The center section should also be also be blocked.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

■

Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked if maintenance is to be performed with the boom in the raised position.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

WARNING! Do not lift the front or rear wheels of the machine off the surface by tilting the lift attachment down and lowering the battery, except for maintenance procedures.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■

Cleanliness can not be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

________________________________________________________________ 5.36 SH650 VFD Roof Support Carrier

____________________________________________________ Maintenance Critical torque values Torque values are expressed in lubricated thread values. Lubricated thread torque values should be used any time the bolt threads are covered with oil, grease, anti-seize or thread-locking compounds.

Table 1: Critical torque values Size Location Steering cylinder pins Tire-wheel mounting nuts Oscillating bearing Drive motor-to-gear case mounting bolts Axle mounting bolts

Grade

Lubricated

1 1/4”X 7 1/2” 3/4”X 2 3/4”

8 8

1480 - 1500 450 - 480 1340 - 1360 280 - 320

1 1/4”X 13 1/4”

8

1340 - 1360

1 1/4”nut

Center section retaining nuts

680 - 720

Lubricants, fluids and capacities Table 2: Lubricants, fluids and capacities Location

Specification

Approx. capacity

Notes

Hydraulic oil tank Gear box (reducer) Lubrication points Winch

Mobilfluid 424

50 gals. (189 L)

1

Spec. 100-6 Spec. 100-3

2.75 qts. (2.6 L) or as required As Required

3

API GL4 (140) Gear oil Peragma Grade 8 Hypoid gear oil SAE 90W Hypoid gear oil SAE 90W

2.5 gals. (2.3 L) or as required 8.4 gals. (32 L) 6.8 qts. (6.5 L)

2 2

Mobilfluid 424

Approx. 4gal. Ea.

Axle housing Planetary wheel ends Wet disc brakes

Notes: 1. With ejector blade completely retracted (if equipped with bucket).

2. The axle housing and planetary wheel end assemblies do not have a common oil source. Each assembly must be filled separately.

Make sure the level and fill hole in the planetary wheel end cover is in the proper position. Rotate the wheel end as required to bring the fill hole to either the 3 o'clock or 9 o'clock position.

When filling the axle housing and planetary wheel ends, allow enough time for the lubricant to fill the various cavities and around component parts in each assembly. Continue adding oil into each assembly until the required oil level is reached.

3.

Pump grease into fitting until old grease can be observed coming out of component.

______________________________________________________________ A6474X275 REV 06 5.37

Maintenance_____________________________________________________ Table 3: Lubrication and maintenance schedule Item

Description Every third shift

Places

Lubricant

Specification

1

Center section pivots

2

Spec. 100-3

2

Steering cylinders (rod and base end)

4

Spec. 100-3

3

Oscillating bearing

9

Spec. 100-3

4

Tilt Cylinders

4

Spec. 100-3

5

Lift cylinders

4

Spec. 100-3

6

Lift bellcrank

2

Spec. 100-3

7

Fork frame

2

Spec. 100-3

8

Battery lift cylinders

4

Spec. 100-3

9

Battery fork mount

4

Spec. 100-3

10

Battery lift bellcrank

2

Spec. 100-3

11

Battery lift link

2

Spec. 100-3

12

Accelerator assembly

2

Spec. 100-3

13

Brake pedal

1

Spec. 100-3

14

Canopy guide tubes

3

Spec. 100-3

15

Winch

3

Spec. 100-3

16

Winch guide rollers

6

Spec. 100-3

17

Front drive line

2

Spec. 100-3

18

Rear drive line

2

Spec. 100-3

19

Fasteners (Nuts, bolts and screws)

Inspect

20 21

Electrical cables, conduits and glands Hydraulic hoses and connections

Inspect Inspect

22 23

Tires (Inspect) Headlights (Inspect)

24 25 26

Reflectors and warning tags Hydraulic oil level (Check) Panic strips (Check)

4 4 Inspect 1 2

Spec. 100-12

Weekly 27

Winch oil level

28 29

Steering cylinder pins Center section pins and nuts

Inspect Inspect

30 31

Tire-wheel mounting bolts Drive motor to gear case mounting bolts

Inspect Inspect

32 33

Axle mounting bolts Oscillating bearing

Inspect Inspect

34 35

Fire suppression system Pressure filter (Main) (Inspect/change as required) Pressure filter (Secondary) (Inspect/change as required)

Inspect 1

36

1

API GL4 (140) Gear oil Peragma Grade 8

1

________________________________________________________________ 5.38 SH650 VFD Roof Support Carrier

____________________________________________________ Maintenance Table 3 (continued): Lubrication and maintenance schedule Item

Description

37

Return filter (Inspect/change as required)

1

38

Pilot filter (Inspect/change as required)

1

39

Mini in-line filter (Inspect/change as required)

4

40

Axle oil level (Check)

2

41

Planetary wheel end oil level (Check)

4

42

Wet disc brake oil level (No service required) Speed reducer (gear case) oil (Check)

4

43

Places

Lubricant

Specification

Hypoid gear oil SAE 90W Hypoid gear oil SAE 90W Cooling oil

1

Spec. 100-6

Every three months 44

Axle oil (Change)

2

45

Planetary wheel end oil (Change)

4

46

4

47

Wet disc brake oil level (No service required) Hydraulic oil (Change)

48

Tank suction strainer (Clean/change)

1

49

Pressure filter (Main) (Change)

1

50

Pressure filter (Secondary) (Change)

51

Return filter (Change)

1

52

Pilot filter (Change)

1

53

Speed reducer (gear case) oil (Change)

2

54

Winch oil (Change)

1

Hypoid gear oil SAE 90W Hypoid gear oil SAE 90W Cooling oil

1

Spec. 100-12

API GL4 (140) Gear oil Peragma Grade 8

______________________________________________________________ A6474X275 REV 06 5.39

____________________________________________________ Maintenance Fig. 33: Lubrication chart

11 9 10

22

32, 40, 44 25, 47, 37 48, 51

8

41, 42 45, 46

17, 31, 43, 53 3, 33 39 1, 29 2, 28

16, 31, 43, 53

36, 50 35, 49

38, 52 15, 27, 54 12, 13, 14 26, 34

30

16

6

5 4

7

______________________________________________________________ A6474X275 REV 06 5.40

____________________________________________________ Maintenance Specific lubrication and maintenance procedures IMPORTANT! The drive and pump motors do not require lubrication. The pump motor bearings are sealed. The drive motors have one bearing sealed and the other bearing receives lubrication from the gear case oil.

Every third shift center section pivots

steering cylinders

Lubricate the center section pivot points (2 places) with Spec. 100-3 through the grease fittings located on the side of the front frame (Fig. 34). Pump grease into the fittings until new grease can be observed coming out of the center section pins.

Lubricate the steering cylinders (4 places) with Spec. 100-3 through the grease fittings located on the rod and base end of each cylinder (Fig. 34). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 34: Center section and steering cylinders lubrication points

Center section pivot grease fitting location

Steering cylinders (2) (rod and base end) (lubricate 4 places)

oscillating bearing

Lubricate the oscillating bearing (9 places) with Spec. 100-3 through the grease fittings located around the bearing (Fig. 35). Pump grease into the fittings until new grease can be observed coming out of the

Fig. 35: Oscillating bearing lubrication points Oscillating bearing grease fitting location (lubricate 9 places)

______________________________________________________________ A6474X275 REV 06 5.41

Maintenance_____________________________________________________ tilt cylinders

Lubricate the tilt cylinders (4 places) with Spec. 100-3 through the grease fittings located on the rod and base end of each cylinder (Fig. 36). Pump grease into the fittings until new grease can be observed coming out of the pins.

lift cylinders

Lubricate the lift cylinders (4 places) with Spec. 100-3 through the grease fittings located on the rod and base end of each cylinder (Fig. 36). Pump grease into the fittings until new grease can be observed coming out of the pins.

fork frame

Lubricate the fork frame pivot (2 places) with Spec. 100-3 through the grease fittings located on the back of the frame (Fig. 36). Pump grease into the fittings until new grease can be observed coming out of the pins.

lift bellcrank

Lubricate the lift bellcrank (2 places) with Spec. 100-3 through the grease fittings located on the back of each bellcrank (Fig. 36). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 36: Lift lubrication points

Tilt cylinder grease fittings located on

Battery fork frame grease fitting located

Lift cylinder grease fittings located on

Battery bellcrank grease fitting located

________________________________________________________________ 5.42 SH650 VFD Roof Support Carrier

____________________________________________________ Maintenance battery lift cylinders

Lubricate the battery lift cylinders (4 places) with Spec. 100-3 through the grease fittings located on the rod and base end of each cylinder (Fig. 37). Pump grease into the fittings until new grease can be observed coming out of the pins.

battery fork mount

Lubricate the battery fork mount (4 places) with Spec. 100-3 through the grease fittings located on the four (4) pivot lugs (Fig. 37). Pump grease into the fittings until new grease can be observed coming out of the pins.

battery lift bellcrank (s)

Lubricate the battery lift bellcrank (s) (2 places) with Spec. 100-3 through the grease fittings located on the back of each bellcrank (Fig. 37). Pump grease into the fittings until new grease can be observed coming out of the pins.

battery lift link

Lubricate the battery lift link (2 places) with Spec. 100-3 through the grease fittings located on each side of the lift link (Fig. 37). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 37: Battery lift lubrication points

Battery fork mount grease fittings located on back 4 places

Battery lift cylinder grease fittings located on rod and base end

Battery bellcrank grease fittings location

Battery lift link grease fittings location

______________________________________________________________ A6474X275 REV 06 5.43

____________________________________________________ Maintenance accelerator pedal and linkage arm

Lubricate the accelerator pedal (2 places) and linkage arm with Spec.

100-3 through the grease fittings located on each pillow block bearing (Fig. 38). Pump grease into the fittings until new grease can be observed coming out of the bearings.

brake pedal

Lubricate the brake pedal (1 place) with Spec. 100-3 through the grease fitting located at the top of the brake pedal (Fig. 38). Pump grease into the fitting until new grease can be observed coming out of the end of the shaft.

Fig. 38: Accelerator, linkage arm, and brake pedal lubrication points

Grease fitting location for brake pedal

Linkage arm

Grease fitting located on each pillow block bearing

canopy guide tubes

Lubricate the canopy guide tubes (3 places) with Spec. 100-3 through the grease fittings located on each guide tube. Pump grease into the fittings until new grease can be observed coming out of the top of the guide tube.

winch

Lubricate the winch (Fig. 39) (3 places) with Spec. 100-3 through the grease fittings located on top of the winch. Pump grease into the fittings until new grease can be observed coming out. (Refer to the winch operation and maintenance manual included in your parts manual) Fig. 39: Winch lubrication point Grease fitting location for winch (3 places)

______________________________________________________________ A6474X275 REV 06 5.44

____________________________________________________ Maintenance winch guide rollers

Lubricate the winch guide rollers (6 places) with Spec. 100-3 through the grease fittings located on each roller (Fig. 40). Pump grease into the fittings until new grease can be observed coming out of the roller.

Fig. 40: Winch guide roller lubrication points Two rollers located inside front frame

front and rear drivelines

Lubricate the front and rear drivelines (4 places) with Spec. 100-3 through the grease fittings located on each cross bearing (Fig. 41).

Pump grease into the fittings until new grease can be observed coming out of the bearing.

Fig. 41: Front and rear driveline lubrication points (typical drive line show - actual driveline may vary)

Grease fitting Grease fitting Grease fitting Grease fitting

______________________________________________________________ A6474X275 REV 06 5.45

Maintenance_____________________________________________________ fasteners (nuts, bolts and screws)

Loose fasteners will cause premature wear and failure to machine and components. Visually inspect for loose fasteners and tighten as required.

electrical cables, conduits and glands

Visually inspect all electrical cables, conduits and glands for signs of wear or damage.

hydraulic hoses and connections

Visually inspect all hydraulic hoses and connections for signs of wear, damage or leakage.

tires

Visually inspect all tires for signs of wear or damage.

headlights

Turn on headlights and visually inspect for bulbs that need replaced or signs of damage.

reflectors and warning plates

Visually inspect the condition and readability of all warning tags, labels and reflectors for signs of wear or damage. Replace any found missing or damaged.

hydraulic oil level

Check the hydraulic oil level by looking at the sight glass located on the oil tank (Fig. 42). If the oil level is low, add oil (Spec. 100-12) via the jet fill pump until oil is visible in the sight glass.

Fig. 42: Hydraulic oil level

Sight glass

________________________________________________________________ 5.46 SH650 VFD Roof Support Carrier

____________________________________________________ Maintenance panic strips

Check the panic strips located inside the operator’ s compartment (Fig. 43). Start the machine, but do not tram. Strike the panic strips to be certain that they are operating properly, tripping the machine circuit breaker and shutting down the machine.

Fig. 43: Panic strip (s) location Panic strip

Panic strip

______________________________________________________________ A6474X275 REV 06 5.47

Maintenance_____________________________________________________ Weekly center section pins and nuts

Inspect the center section pins and nuts for looseness or wear (Fig. 44).

Tighten ( 680 - 720 ft. lbs.) where necessary and replace any worn parts.

steering cylinder pins and nuts

Inspect the steering cylinder pins and nuts for looseness or wear (Fig. 44). Tighten ( 1480 - 1500 ft. lbs.) where necessary and replace any worn parts.

Fig. 44: Center section and steering cylinder pins and nuts Inspect center section pivot pins and nuts

Inspect steering cylinder (s) fasteners (rod and base end)

winch oil level

Check the oil level in the winch (Fig. 45). Clean dirt and debris from around the check plug and remove plug. Oil level should be kept at the level of the of the plug. If oil is required, add oil (SAE 140) through the fill plug hole until oil begins to flow from the check plug hole and replace plug. Do not overfill the winch. (Refer to the winch operation and maintenance manual included in your parts manual) Fig. 45: Winch oil level Fill plug

Check plug

________________________________________________________________ 5.48 SH650 VFD Roof Support Carrier

____________________________________________________ Maintenance tire/wheel mounting bolts

Check the wheel mounting nuts (Fig. 46). The mounting nuts should be torqued to 450 - 480 ft-lbs lubricated. Use Loctite 242 on wheel mounting bolts.

Fig. 46: Tire/wheel mounting nuts Tire/wheel mounting nuts.

(Typical on all (4) wheels)

drive motor to gear case mounting bolts

Check the drive motor to gear case mounting bolts on both front and rear drive assemblies (Fig. 47). The mounting bolts should be torqued to 280 - 320 ft-lbs lubricated. Use Loctite 242 on mounting bolts.

axle mounting bolts

Check the axle mounting bolts on both front and rear axles (Fig. 47).

The mounting bolts should be torqued to 1340 - 1360 ft-lbs lubricated.

Use Loctite 242 on mounting bolts.

Fig. 47: Drive motor to gear case and axle mounting bolts (typical driveline shown, actual driveline may vary)

Axle mounting bolts Drive motor to gear case mounting bolts

______________________________________________________________ A6474X275 REV 06 5.49

Maintenance_____________________________________________________ fire suppression system

Check the fire suppression system (Fig. 48).

1. Inspect the hoses, fittings, and nozzles and replace any found damaged.

2. Check the extinguisher tank for signs of damage or corrosion. The extinguisher tank is located in the middle section of the machine.

3. Check the nozzle openings. The slot should be packed with silicone grease. If the nozzles are open or need to be repacked, the lines should be checked for blockage and blown clear before repacking them with clean silicone grease.

4. Remove the fill cap.

5. Check that the extinguisher is filled with free flowing Ansul multipurpose A, B, C dry chemical to a level not more than 3" (.75 mm) from the bottom of the fill opening.

6. Replace the fill cap, hand tight.

Fig. 48: Fire suppression system Nozzle (4 locations)

Actuator

Chemical tanks (2) Actuator Fill cap

Tank Nozzle opening

________________________________________________________________ 5.50 SH650 VFD Roof Support Carrier

____________________________________________________ Maintenance oscillating bearing mounting bolts

Check the oscillating bearing mounting bolts (Fig. 49). The mounting bolts should be torqued to 1340 - 1360 ft-lbs lubricated. Use Loctite 242 on mounting bolts.

Fig. 49: Oscillating bearing mounting bolts

Oscillating bearing mounting bolts

pressure filter (s) (main and secondary)

Inspect the pressure filter (s) (main and secondary) dirt alarm (s) (Fig. 50) located on the head of the filter. If the alarm indicates the filter element (s) is dirty, replace element (s).

return filter

Inspect the return filter dirt alarm (Fig. 50) located on the head of the filter. If the alarm indicates the filter element is dirty, replace element.

pilot filter

Inspect the pilot filter dirt alarm (Fig. 50) located on the head of the filter. If the alarm indicates the filter element is dirty, replace element.

WARNING! Due to the pilot filter being under high pressure, do not attempt to replace element until pressure has been released. To release pressure, operate any control selector handle until accumulator pressure has been depleted.

mini in-line filter

Inspect the mini in-line filter screen (Fig. 50) located inside the filter. If the screen is dirty, the screen can be cleaned. If the screen has been damaged, it must be replaced.

Fig. 50: Filter location Mini in-line filters (4)

Pilot filter

Main Pressure filter

Secondary pressure filter

Return filter

______________________________________________________________ A6474X275 REV 06 5.51

Maintenance_____________________________________________________ axle oil level

Check the axle oil level in both axles (Fig. 51).

1. Park the machine on solid level ground, clean dirt and debris from around the check/fill plug and remove the plug.

2. The oil should just barely flow from the check/fill plug hole when full.

3. Should it be necessary to add oil, add oil (Hypoid gear oil, SAE 90) through the check/fill plug hole slowly, just until it starts to flow back out. Allow sufficient time for the oil to travel throughout the axle when filling.

planetary wheel end oil level

Check the planetary wheel end oil level on each wheel end (Fig. 51).

1. Park the machine on solid level ground, clean dirt and debris from around the check/fill plug and remove the plug.

2. Make sure the check/fill plug is in the proper position. Rotate the wheel end as required until the check/fill plug is at the 3 o’ clock or 9 o’ clock position.

3. Clean dirt and debris from around the check/fill plug and remove the plug.

4. The oil should just barely flow from the check/fill plug hole when full.

5. Should it be necessary to add oil, add oil (Hypoid gear oil, SAE 90) through the check/fill plug hole slowly, just until it starts to flow back out. Allow sufficient time for the oil to travel throughout the wheel end when filling.

wet disc brake oil level

No service is required for the wet disc brake cooling oil.

Fig. 51: Axle and planetary wheel end oil level

Axle check/fill

Planetary wheel end check/fill plug

________________________________________________________________ 5.52 SH650 VFD Roof Support Carrier

____________________________________________________ Maintenance speed reducer (gear case) oil

Check the oil in both speed reducers (Fig. 52).

1. Park the machine on solid level ground, clean dirt and debris from around the dipstick.

2. Remove the dipstick from gear case and wipe clean. Insert dipstick back into gear case and remove. The oil should be level with the full line indicated on dipstick.

3. Should it be necessary to add oil, clean dirt and debris from around the fill fitting and remove fitting.

4. Should it be necessary to add oil. Add oil (Spec. 100-6) through the dipstick hole slowly, just until it reaches the full level on dipstick.

Allow sufficient time for the oil to travel throughout the speed reducer when filling.

5. Reinstall dipstick.

Fig. 52: Speed reducer (gear case) oil (typical)

Breather

Dipstick

Drain plug

______________________________________________________________ A6474X275 REV 06 5.53

Maintenance_____________________________________________________ Every three months axle oil

Change oil in both axles (Fig. 53).

1. Park the machine on solid level ground, clean dirt and debris from around the drain plug.

2. Remove drain plug and allow oil to completely drain from the axle.

3. Clean and reinstall drain plug.

4. Clean dirt and debris from around the check/fill plug and remove plug.

5. Add oil (Hypoid gear oil, SAE 90W) through the check/fill plug hole slowly, just until it starts to flow back out. Allow sufficient time for the oil to travel throughout the axle when filling.

6. Clean and reinstall check/fill plug.

planetary wheel end oil

Change oil in each planetary wheel end (Fig. 53).

1. Park the machine on solid level ground, clean dirt and debris from around the drain plug and remove the plug.

2. Make sure the check/fill and drain plugs are in the proper position.

Rotate the wheel end as required until the check/fill plug is at the 3 o’ clock or 9 o’ clock position and the drain plug is located on the bottom.

3. Remove drain plug and allow oil to completely drain from the planetary.

4. Clean and reinstall drain plug.

5. Clean dirt and debris from around the check/fill plug and remove the plug.

6. Add oil (Hypoid gear oil, SAE 90W) through the check/fill plug hole slowly, just until it starts to flow back out. Allow sufficient time for the oil to travel throughout the planetary wheel end when filling.

7. Clean and reinstall check/fill plug.

wet disc brake oil

No service is required for the wet disc brake cooling oil.

________________________________________________________________ 5.54 SH650 VFD Roof Support Carrier

____________________________________________________ Maintenance Fig. 53: Axle and planetary wheel end oil level

Axle check/fill

Axle drain plug

Planetary wheel end check/fill plug Planetary wheel end drain plug

pressure filter (s) (main and secondary)

Change the pressure filter (s) element (s) (primary and secondary) (Fig. 54). If the element (s) are extremely dirty, a more frequent interval may be required.

return filter

Change the return filter element (Fig. 54). If the element is extremely dirty, a more frequent interval may be required.

pilot filter

Change the pilot filter element (Fig. 54). If the element is extremely dirty, a more frequent interval may be required.

WARNING! Due to the pilot filter being under high pressure, do not attempt to replace element until pressure has been released. To release pressure, operate any control selector handle until accumulator Fig. 54: Filter location Mini in-line filters (4)

Pilot filter

Main Pressure filter

Secondary pressure filter

Return filter

______________________________________________________________ A6474X275 REV 06 5.55

Maintenance_____________________________________________________ speed reducer (gear case) oil

Change oil in both speed reducers (Fig. 55).

1. Park the machine on solid level ground, clean dirt and debris from around the drain plug.

2. Remove drain plug and allow oil to completely drain from the speed reducer.

3. Clean and reinstall drain plug.

4. Clean dirt and debris from around the dipstick and remove dipstick.

5. Add oil (Spec. 100-6) through the dipstick hole slowly, just until it reaches the full level indicated on dipstick. Allow sufficient time for the oil to travel throughout the speed reducer when filling.

6. Clean and reinstall dipstick.

Fig. 55: Speed reducer (gear case) oil change (typical)

Breather

Dipstick

Drain plug

________________________________________________________________ 5.56 SH650 VFD Roof Support Carrier

____________________________________________________ Maintenance winch oil

Change oil in the winch (Fig. 56). (Refer to the winch operation and maintenance manual included in your parts manual) 1. Park the machine on solid level ground, clean dirt and debris from around the drain plug.

2. Remove drain plug and allow oil to completely drain from the winch.

3. Clean and reinstall drain plug.

4. Clean dirt and debris from around the check plug and remove plug.

5. Clean dirt and debris from around the breather and remove breather.

6. Add oil (API GL4 (140) Gear oil Peragma Grade 8) through the breather hole slowly, just until it starts to flow out of the check plug hole. Allow sufficient time for the oil to travel throughout the winch when filling.

7. Clean and reinstall breather and check plug.

Fig. 56: Winch oil change Breather

Check and oil level plug

Drain plug

______________________________________________________________ A6474X275 REV 06 5.57

Maintenance_____________________________________________________ hydraulic oil tank and suction strainer

Change oil and clean or change the suction strainer in the hydraulic oil tank (Fig. 57).

1. Park the machine on solid level ground, clean dirt and debris from around the drain plug located on the back of the tank.

2. Remove drain plug or disconnect the crossover hose connection nearest the operator side of the machine and allow oil to completely drain from the tank.

3. Clean and reinstall drain plug or reconnect crossover hose..

4. Clean dirt and debris from around suction strainer access cover located on top of the tank.

5. Remove the bolts that secure the access cover.

6. Reaching down into the tank, unscrew the suction strainer and remove from tank.

7. If the strainer is not torn or damaged, it can be cleaned using kerosene and a soft brush and dried thoroughly. If strainer is damaged, it must be replaced.

8. Replace the strainer in the tank and hand tighten.

9. Replace the access cover.

10. Refill the tank with oil (Spec. 100-12).

NOTICE! Tank must be filled manually via the tank breather port until the suction strainer is fully flooded before operating the jet fill pump.

11. Start the machine and allow the hydraulic pump to run in order to purge air from the system.

12. Shutdown the machine and recheck the oil level. Add oil if necessary.

Fig. 57: Hydraulic oil and suction strainer Access cover to suction strainer

Access cover in middle frame

Sight glass

________________________________________________________________ 5.58 SH650 VFD Roof Support Carrier

_______________________________________________________________

6

Technical data

________________________________________________________________

_______________________________________________________________

________________________________________________________________

__________________________________________________Technical data

Technical data This chapter contains the most important technical data on the machine.

Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

IMPORTANT! The technical data listed in this chapter is for stock machines only.

Customer specials may not be listed.

Components Technical data sheet general

performance

Length without load lifting and battery lift forks..........approx. 24’6” with 84”lifting fork..........................................approx. 38’6” with lift plate attachment ................................approx. 39’6” Overall width with attachments and 48”tires.......................approx. 9’3” with attachments and 54”tires.......................approx. 9’11” Wheelbase ...........................................................approx. 17’2” Weight empty less battery..........................................approx. 70,000 lbs with 64-125-33 battery ...................................approx. 101,500 lbs China (with battery)........................................approx. 109,500 lbx Cab height with 20”cab and 48” tires .............................approx. 68” with 20”cab and 54” tires .............................approx. 70” Chassis height with 48”tires...................................................approx. 48” with 54”tires...................................................approx. 50” Ground clearance with 48”tires...................................................approx. 16” with 54”tires...................................................approx. 19” Inside turning radius .............................................approx. 13”7” Outside turning radius ..........................................approx. 23”8” Steering articulation..............................................100 degrees total Frame oscillation ..................................................40 degrees each way Tram speed (calculated data based on 2% rolling resistance) Level and empty on 0% grade: ......................4.1 mph Level and loaded on 0% grade: .....................3.6 mph Lift and carry capacity * Without ballast .............................................approx. 50 tons at 62” * Capacities based on 54X26 solid tire

______________________________________________________________ A6474X275 REV 06 6.3

Technical data ___________________________________________________

________________________________________________________________ 6.4 SH650 VFD Roof Support Carrier

_______________________________________________Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Set screws Table 4: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

Table 5: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

______________________________________________________________ A6474X275 REV 06 6.5

Tightening torques _______________________________________________ Table 6: FSR hex bolts (SAE 5 and 325 steel) Nominal diameter

Recommended torque setting

¼”

9 ft-lbs

5/16”

18 ft-lbs

3/8”

31 ft-lbs

7/16”

50 ft-lbs

½”

75 ft-lbs

9/16”

110 ft-lbs

5/8”

150 ft-lbs

¾”

250 ft-lbs

7/8”

378 ft-lbs

1”

583 ft-lbs

1 1/8”

782 ft-lbs

1 ¼”

1,097 ft-lbs

1 3/8”

1,461 ft-lbs

1 ½”

1,748 ft-lbs

1 ¾”

3,114 ft-lbs

2”

4,504 ft-lbs

2 ¼”

6,497 ft-lbs

2 ½”

7,144 ft-lbs

2 ¾”

12,092 ft-lbs

3”

15,744 ft-lbs

Table 7: Socket, flat, & button head cap screws (Steel only) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting 26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs 30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

________________________________________________________________ 6.6 SH650 VFD Roof Support Carrier

_______________________________________________Tightening torques Table 8: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Table 9: Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 10: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

______________________________________________________________ A6474X275 REV 06 6.7

Tightening torques _______________________________________________ Table 11: Untreated screw, black finish (Fine thread) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25

Nm

27

52

95

Ft-lbs

19

38

70

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

Table 12: Untreated screw, black finish (Fine thread, continued) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5

Nm

150

225

325

Ft-lbs

110

165

239

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

Table 13: Untreated screw, black finish (Fine thread, continued)

Property class

Torque Ma

8.8

Nm

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399

Ft-lbs 10.9 12.9

610

780

449

575

Nm

640

860

1100

Ft-lbs

472

634

811

Nm

770

1050

1300

Ft-lbs

567

774

958

________________________________________________________________ 6.8 SH650 VFD Roof Support Carrier

_______________________________________________Tightening torques Table 14: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M33 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

Table 15: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nm

36

Ft-lbs

26

42

Nm

83

132

Ft-lbs

61

97

58

Nominal diameter M18

M20

M22

121

171

230

54

89

126

169

200

275

390

530

147

202

287

390

88

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 16: Electrically zinc plated (Coarse thread, continued) Property class 5.6

8.8

10.9

12.9

Torque Ma

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

______________________________________________________________ A6474X275 REV 06 6.9

Tightening torques _______________________________________________ Table 17: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

Torque Ma Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

Recommended torque setting M8 X 1 25 18 35 25 42 30

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 18: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 19: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

________________________________________________________________ 6.10 SH650 VFD Roof Support Carrier

_______________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Use only lubrication fluids and greases approved by Bucyrus America, Inc. ! These fluids and greases have been tested at Bucyrus America, Inc. and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent.

Differently composed fluids and greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases and fluids having the same specification base but different origins.

In case of doubt, the manufacturer of the lubrication to be used should be contacted as to the compatibility of the lubrication in question.

IMPORTANT! Bucyrus America, Inc. expressly point out that the approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to use the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the machine, all used oil and lubricants should be disposed of per your local EPA standards.

______________________________________________________________ A6474X275 REV 06 6.11

Permissible media________________________________________________ Approved suppliers: Table 20: Anti-wear hydraulic oil (Spec 100-1) Supplier

Brand name

1

Amoco Oil Company

Amoco AW oil No.68

2

Gulf Oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil Company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hyldraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers

Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

________________________________________________________________ 6.12 SH650 VFD Roof Support Carrier

_______________________________________________ Permissible media Table 21: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf Oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460

6

Unocal 76

7

Shell Oil Company

8

Century Lubricating Oils, Inc.

9

Texaco Lubricants Company

Hulbest EP-7 Powergear 460 Meropa 680

10

Exxon

Spartan EP 460

11

Pennzoil

Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

608 Almosal Vari-Purpose Gear Lubricant Gear oil 460

14

Hydrotex

933 Industrial Gear Lubricant

15

Phillips

16

Miners Oil

All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680

______________________________________________________________ A6474X275 REV 06 6.13

Permissible media________________________________________________ Table 22: Extreme pressure motor bearing grease (Spec. 100-3) Supplier

Brand name

1

Amoco Oil Company

2 3 4

Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil Company Century Lubricating Oils, Inc.

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Amolith grease 2 EP Rykon Premium Grease 2 EP Gulfcrown grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Table 23: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century Oils Limited Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

________________________________________________________________ 6.14 SH650 VFD Roof Support Carrier

_______________________________________________ Permissible media Table 24: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company

5 6

Cincinnati –Vulcon Company Cities Service Oil Company

7 8

Century Oils Limited Fiske Bros. Refining Company Getty Oil Company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

9 10 11 12 13 14 15 16 17 18 19 20 21

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and Chemical Co. Pennzoil Quaker Chemical Company Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

22 23

Standard Oil Company of Ohio (Boron Sohio) Sun Oil Company Tower Oil Company

24 25

Wynn Oil Company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion fire resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR

Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant hydraulic Fluid HY-Guard

______________________________________________________________ A6474X275 REV 06 6.15

Permissible media________________________________________________ Table 25: Extreme pressure gear oil, SAE 90 (Spec. 100-6) Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf Oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil Company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

________________________________________________________________ 6.16 SH650 VFD Roof Support Carrier

_______________________________________________ Permissible media Table 26: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) Supplier Brand name 1

Amoco Oil Company

American Industrial Oil No. 68

2

Gulf Oil

Harmony 68

3

Mobil Oil Corporation

DTE Heavy –Medium

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754

6

Unocal 76

7

Shell Oil Company

Unax RX68 or Turbine Oil 68 Turbo 68

8

Century Lubricating Oils, Inc.

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

______________________________________________________________ A6474X275 REV 06 6.17

Permissible media________________________________________________ Table 27: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name 1

Amoco Oil Company

American Industrial oil No. 150

2

Gulf Oil

Harmony 150

3

Mobil Oil Corporation

DTE Oil EX. Heavy

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961

6

Unocal 76

7

Shell Oil Company

Unax RX 700 or Turbine Oil 700 Turbo 150

8

Century Lubricating Oils, Inc.

Centraulic R&O 150

9

Atlantic Richfield Company

10

Texaco Lubricants Company

Duro 600 or S-700 Regal Oil R&O 150

11

Exxon

Teresstic 150

12

Pennzoil

Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15

Conoco Inc.

Dectol R&O 76

16

Hydrotex

System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Table 28: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier Brand name 1 Amoco Oil Company Cylinder oil No. 1000 2 Mobil Oil Corporation Extra Hecla Super Cylinder Oil 3 Chevron U.S.A. Chevron Cylinder Oil W ISO 1000 4 Sun Oil Company Sun Steam Cylinder Oil 5 Unocal 76 Worm gear Lube 250 or Stevalc 6 Century Lubricating Oils, Inc. Garwal 680 7 Atlantic Richfield Company Modoc 195 8 Texaco Lubricants Company 650 T Cylinder Oil 1000 9 Exxon Cylesstic TK-1000 10 Pennzoil Cylinder Oil #1000 11 Conoco Inc. Inca Oil 1000

________________________________________________________________ 6.18 SH650 VFD Roof Support Carrier

_______________________________________________ Permissible media Table 29: Light gear oil, SAE 40 motor oil (Spec. 100-10)

1 2 3 4

Supplier Amoco Oil Company Gulf Oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil Company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 30: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 31: Multi-purpose tractor hydraulic fluid (Spec. 100-12)

1 2 3 4

Supplier Exxon / Mobil Century / Fuchs Shell Chevron

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid

5 6 7

BP Lubricants Quaker State Conoco

Tractran UTH Quaker State FCI HD Powertran Fluid

______________________________________________________________ A6474X275 REV 06 6.19

Permissible media________________________________________________ Table 32: High emulsibility extreme pressure gear oil (Spec. 100-13) 1

Supplier Fuchs

Brand name Powergear H680

Table 33: Synthetic lithium complex grease for electric motor bearings (Spec. 100-14)

1 2 3

Supplier Mobil Conoco-Phillips Shell

Brand name Mobilith SHC 100 Triton 100 Albida EMS 2

Table 34: High demulsibility extreme pressure gear oil (Spec. 100-15) 1

Supplier Conoco

Brand name GLW Gear Oil 220

________________________________________________________________ 6.20 SH650 VFD Roof Support Carrier

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7

For your information

________________________________________________________________

_______________________________________________________________

________________________________________________________________

_____________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service address Beckley, WV 351 Ragland Road Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Paonia, CO P.O. Box 566 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

______________________________________________________________ A6474X275 REV 06 7.3

Our service______________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

________________________________________________________________ 7.4 SH650 VFD Roof Support Carrier

Operation Manual Bucyrus - Battery Charger (with Optional Ground Integrity Circuitry - PA) Model - BUC-SCR 120 Series Doc. No.:

A6474X270

Bucyrus America, Inc. _________________________________________ 4041 Wurno Road Pulaski, VA

Telephone: 540-980-4530 Fax: 540-994-3763

PDF created with pdfFactory trial version www.pdffactory.com

Internet: www.bucyrus.com

___________________________________________________________

This manual is intended to provide GENERAL product information for the Model BUC-SCR 120 Series battery charger with optional ground integrity circuitry. The illustrations, descriptions and procedures contained in this publication apply only to this unit. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

Any change to the design or structure of this unit, without the consent of Bucyrus America, Inc., and applicable regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.'s instructions, may invalidate 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.

© BUCYRUS AMERICA, INC. 2008

ALL RIGHTS RESERVED

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_________________________________________________ Table of contents

Table of contents 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

© BUCYRUS AMERICA, INC.

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

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Table of contents __________________________________________________ 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

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 ........................................................ 5.13 Battery changer wiring diagram ........................................ 5.14 Instructions on the maintenance ....................................... 5.16 Important notes............................................................ 5.16 Before maintenance..................................................... 5.16 General Maintenance Procedures .................................... 5.17 Yearly.......................................................................... 5.17 Fourth Year ................................................................. 5.17 Seventh Year............................................................... 5.17 Tenth Year .................................................................. 5.17 Troubleshooting Procedures............................................. 5.18 SCR/Diode troubleshooting procedures………………...5.22

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

_________________________________________________________________ BUC-SCR 120 Series Battery Charger

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© BUCYRUS AMERICA, INC.

5. Operation

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1

About this manual

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________________________________________ Before starting to work

About this manual 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 applicable operating manual machine type

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.

© BUCYRUS AMERICA, INC.

new operation manual

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

supervisory personnel who: ■ ■

initiate and/or supervise the activities just indicated.

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Before starting to work _________________________________________ What is the purpose of this operating manual? cost-effectiveness

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the unit.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

© BUCYRUS AMERICA, INC.

service

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________________________________________ Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.

© BUCYRUS AMERICA, INC.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

■

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

F Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

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Before starting to work _________________________________________

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2

Your safety

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___________________________________________________ Personnel

Your safety This chapter provides vital information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The battery charger has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations. You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the unit. All modifications and changes must be approved by Bucyrus America, Inc.

© BUCYRUS AMERICA, INC.

Use only original spare parts from Bucyrus America, Inc. Note that the use of parts from other manufacturers will void the guarantee.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine.

■

of the Mines Inspector and

■

of the mining supervisory authorities

Please read also the operating manuals for the batteries to be charged and equipment to be operated carefully and thoroughly. Clarify any questions before starting work.

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Personnel ____________________________________________________ Personnel Operation training

The battery charger may only be operated by qualified, trained personnel.

The battery charger is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit.

Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

■

mechanics,

■

electrics and

■

operation

and must be able to prove this knowledge.

Installation and repair As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on: ■

safety components

■

the electrics

may only be carried out by service engineers from Bucyrus America, Inc. or by specially qualified personnel of the mine.

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© BUCYRUS AMERICA, INC.

You must have adequate knowledge of the

__________________________________________Operating conditions Operating conditions Intended use The battery charger has been designed and manufactured purely for recharging of mine storage batteries.

Intended uses include: ■

the recharging of mine power storage batteries that are specified on the charger nameplate

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the charger.

© BUCYRUS AMERICA, INC.

■

the recharging of other types of batteries not specified on the charger nameplate

Bucyrus America, Inc. accepts no liability for any damage resulting from any such unauthorized use.

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© BUCYRUS AMERICA, INC.

Operating conditions ___________________________________________

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___________________________________________ Safety instructions Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

personal equipment

Always wear your personal protective equipment. This also includes eye and clothing protection.

Inform your colleagues of:

© BUCYRUS AMERICA, INC.

safety equipment

■

your exact location.

■

the work you are performing.

■

the time that you will probably require.

Start the charger only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the optical start-up warnings of the unit.

symbol plates emergency stop

lock-out

cordon off working area

Observe the symbol plates on the unit.

Press the EMERGENCY STOP switch immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Lock-out and disconnect the power system while performing: ■

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for the unit.

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Safety instructions _____________________________________________

■

Save these instructions. This manual contains important safety and operating instructions. Before using this equipment, read all instructions and cautionary markings on (1) unit, (2) battery, and (3) product using the battery.

■

To reduce risk of injury and/or damage to the batteries, use only the type of batteries specified on the charger nameplate.

■

Do not expose equipment to rain or snow.

■

Do not operate equipment if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified service technician.

■

Do not disassemble this unit; take it to a qualified service technician when service or repair is required. Incorrect re-assembly may result in a risk of electric shock or fire.

■

To reduce risk of electric shock, disconnect this unit from the AC supply, batteries and loads before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

Risk of explosive gases ■

Working in the vicinity of a battery is dangerous. Batteries generate explosive gases during normal battery operation. For this reason, it is of utmost importance that each time before using this unit, you read the battery charger manual and follow the instructions.

■

To reduce risk of battery explosion, follow the instructions published by the battery manufacturer and manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary markings on all products.

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© BUCYRUS AMERICA, INC.

General precautions

___________________________________________ Safety instructions Personal precautions ■

Someone should be within range of your voice or close enough to come to your aid when you work near a battery.

■

Have plenty of fresh water and soap nearby in case the battery electrolyte contacts skin, clothing, or eyes.

■

Wear complete eye protection and clothing protection. touching eyes while working near a battery.

Avoid

■ If the battery electrolyte contacts skin or clothing, wash immediately

© BUCYRUS AMERICA, INC.

with soap and water. If the electrolyte enters the eye, immediately flood the eye with running cold water for at least ten (10) minutes and get medical attention immediately.

■

Never smoke or allow a spark or flame in vicinity of a battery.

■

Be extra cautious; DO NOT drop metal onto a battery. It might spark or short-circuit the battery or cause an explosion.

■

Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a battery. A battery can produce a short-circuit current high enough to weld these items causing severe burns.

■

NEVER charge a frozen battery.

■

Do not use battery charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause injury to person or damage to property.

Preparing to charge precautions ■

If it is necessary to remove the battery connections, make sure all loads are disconnected and unit is off, so as not to cause an arc.

■

Be sure the area around the battery is well ventilated while the battery is being charged.

■

When cleaning battery terminals, be careful to keep corrosion from coming in contact with eyes.

■

Study all the battery manufacturer’s specific precautions such as removing or not removing cell caps while charging, recommended rates of charge, and maintenance procedures.

■

Follow the battery manufacturer's recharging instructions.

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Safety instructions _____________________________________________ Charger location precautions ■

Never place this unit directly above the standard flooded battery.

Gases from the battery will corrode and damage equipment. A sealed maintenance free or valve regulated lead acid (VRLA) may be placed below this equipment.

■

Never allow the battery electrolyte to drip on this unit when reading the specific gravity or filling the battery.

■

Do not operate this unit in a closed-in area or restrict ventilation in any way.

■

Do not set any battery on top of this unit.

■

Connect and disconnect DC output cables only after setting all of this unit's switches to off position and removing AC input supply.

Do not pull on output cables when disconnecting charger from battery.

Grounding instruction ■

This battery charger should be connected to a grounded, metal, permanent wiring system; or an equipment grounding conductor should be run with circuit conductors and connected to equipmentgrounding terminal or lead on battery charger. Connections to battery should comply with all local codes and ordinances.

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© BUCYRUS AMERICA, INC.

DC connection precautions

___________________________________________ Safety instructions Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

© BUCYRUS AMERICA, INC.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.

mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

Pre-start inspection operation

Read this entire guide before attempting to operate this unit.

inspection

Inspect the unit and have any malfunctioning, broken or missing parts corrected or replaced before use.

maintenance instruction and safety tags operating area

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

Clean any foreign material from the work area.

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Safety instructions _____________________________________________ Installation and start-up environmental acceptability

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

starting procedures

Follow the starting procedure instructions in chapter 5 of this manual.

training

Operate the battery charger only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective charger.

covers

Before start-up, ensure that all covers are on the unit.

protective devices

Check that all protective devices are installed on the unit and function properly.

operating area

Clean the control panel and charging area at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

problems and malfunctions

If problems or malfunctions are encountered while operating the unit, it must be properly shutdown and the problem corrected immediately.

Maintenance and repair securing

Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration.

Secure your working area over a wide range, in order to avoid endangering other persons.

replacing components

Lock-out and disconnect power to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original Bucyrus America, Inc. spare parts.

Please refer to the spare parts lists for the order numbers

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© BUCYRUS AMERICA, INC.

Operation

___________________________________________ Safety instructions lifting

maintenance, repair

For raising the battery charger use only: ■

crib blocks with adequate load-holding capacity.

■

hoists, jacks or cranes with adequate load-carrying capacity.

Only persons who have and can demonstrate a special knowledge of electrics are allowed to work on the electrical system.

© BUCYRUS AMERICA, INC.

Carry out a visual inspection of all the electrical components at regular intervals. In particular check that: ■

the wiring and cables are not pinched or trapped

■

the conduits are not abnormally rigid or hard

■

the conduits are not damaged

■

he connectors are securely inserted into the sockets

■

the connections are tight

Secure wiring and cables only with the proper clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections to ensure they are tight.

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___________________________________________ Safety instructions

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_________________________________ Overview of safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and transport WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

© BUCYRUS AMERICA, INC.

Chapter 4: Installation CAUTION! Serious damage can be caused to the battery charger as a result of incorrect installation.

The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc. NOTICE! The charger was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the prestartup checks should be performed.

NOTICE! The operator must become familiar with all the safety features and their location on the machine prior to installation or operation.

NOTICE! All battery chargers are shipped from the factory with the emergency stop switch disconnected. The switch must be connected and tested by the user prior to installation. When actuated, the emergency stop switch must remove all AC power from the charger.

DANGER! Do not operate nor apply power to the battery charger with any of the covers removed. You or other personnel could be seriously injured from electrical shock.

Chapter 5: Operation DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the battery charger and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

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Overview of safety instructions __________________________________ NOTICE: The Charger must be charging the battery for 1 minute to obtain this reading; the amp hours are updated every minute. A third push of the button shows the elapsed charging time in hours/ minutes.

NOTICE: The equalize switch can also be used to start the charger even if a battery is discharged below 1.6 Vpc. Caution must be used when using this feature to start the charger because the initial battery voltage sensing is being disabled and the wrong battery could be being connected.

NOTICE: This unit is equipped with two (2) door disconnect switches and four (4) cover disconnect switches. The two access doors and the top cover of the unit must be closed to operate.

CAUTION: Make sure a battery with the correct number of cells is connected to the charger.

NOTICE: Push the red push to stop button before disconnecting the battery during a charge cycle.

WARNING! Before performing maintenance on the battery charger, disconnect the electrical power. Electrical shock can cause serious injuries or even death to you or the maintenance person.

Before troubleshooting unit, check for shipping damage. (i.e. broken wires, loose connections, etc.)

NOTICE: Blown printed circuit boards, fuses or loose printed circuit boards fuses could cause an out of phase condition. (Blowing AC input fuses) If a blown printed circuit board fuse is found, a wire on the gate lead of the SCR/Diode module could be disconnected or a defective SCR/Diode module could exist.

Chapter 6: Technical data IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

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© BUCYRUS AMERICA, INC.

NOTICE: Carefully read and adhere to all battery and battery charging instructions and safety warnings.

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3

Storage and transport

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_________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the battery charger.

Observance of the instructions and tips will increase the service life and availability of the charger. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

Components coated with temporary corrosion inhibitor are protected for approximately six months.

© BUCYRUS AMERICA, INC.

Before delivery, the charger is fully checked and adjusted from the factory. Do not make any adjustments unless the unit has been poweredup and the settings have been determined to be incorrect.

Storage of the machine and spare parts no direct exposure to sunlight

dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).

Protect the equipment and all spare parts stored outdoors against moisture and dirt, e.g. using tarpaulins.

short-term storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

long-term storage

If the equipment is to be stored more than six months, the equipment must be stored in a well ventilated, dry room. Do not store outdoors.

random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

On request, the inspection can be carried out by Bucyrus America, Inc.

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Storage and transport __________________________________________ Transport Load units; dimensions and weights Observe the transport sheets for the machine and spare parts. They contain information on: ■

Dimensions

■

Weight

■

lifting points, etc.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

Before transport temperatures below freezing

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport.

electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

Fig. 1: Battery charger lifting and pulling points

Pulling holes

Fork lift slots

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Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.

________________________________________________________________

4

Installation

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__________________________________________________ Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on: ■

the safety components

■

the electrical

© BUCYRUS AMERICA, INC.

and should only be carried out by Bucyrus America, Inc. service engineers or by specially trained personnel.

Which tools are required for installation? tool box

You will need a number of tools to be able to install the battery charger properly.

We recommend that you deposit a tool box at the battery charger that includes an assortment of mechanical and electrical tools.

The battery plugs and receptacles come with a special wrench for connecting and disconnecting battery plugs and receptacles.

In addition, various items of auxiliary equipment and machines may be required at the point of installation.

These include i.e.: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

unloading dock

■

jacks with adequate lifting capacity

CAUTION! Serious damage can be caused to the battery charger as a result of incorrect installation.

The unit should therefore only be installed under the instruction of specialists from Bucyrus America, Inc.

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Installation ____________________________________________________ Notes on installation installation plan

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

© BUCYRUS AMERICA, INC.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established

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__________________________________________________ Installation Pre-installation check list

© BUCYRUS AMERICA, INC.

NOTICE! The charger was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: ■

perform daily maintenance

■

visually inspect all electrical cables for damage

■

examine the complete charger for possible transport damage

■

verify that all instruction and safety labels are in place and legible

■

start up the charger and check for correct operation of the emergency stop switch located on the control panel

■

check all control switches to ensure all charger functions are operating properly

.

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Installation ____________________________________________________ Features

■

SCR bases control

■

automatic start/stop circuitry

■

automatic sensing of fully-charged battery

■

push to start/push to stop buttons

■

automatic twelve (12) hour override timer

■

three (3) hour timing after 80% (normal mode)

■

six (6) hour timing after 80% (equalize mode)

■

three (3) selectable current settings

■

digital display—indicates amps, volts, amp hours, elapsed time, cooling time

■

“On Charge”, “80% Complete”, “Equalize”, and “Failure” lamps

■

contact closure delay

Note:

These output adjustments are inside the unit.

See schematic

Table 1: BUC-SCR 120 Output Currents RATING IN AMPS

LOW (AH)

MED (AH)

HIGH (AH)

140

93.6 (520)

122.4 (680)

144.0 (800)

180

144 (800)

180.0 (1000)

202.5 (1125)

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The BUC-SCR 120 Series is a SCR controlled industrial battery charger for use on electric vehicle batteries. It is designed to recharge a battery of the proper amp-hour capacity in eight hours.

__________________________________________________ Installation Installation

© BUCYRUS AMERICA, INC.

The BUC-SCR 120 Series battery charger is designed to operate on a specific type of battery with a specified number of cells. The nameplate on the charger indicates the type and number of cells required. When connecting the DC output cables to the battery, be certain the positive terminal of the charger is connected to the positive battery terminal, and the negative terminal is connected to the negative of the battery. A grounding connection is also provided for complete protection. Once properly installed, the unit should automatically complete its charge cycle every time it is connected to a discharged battery. Install the unit so that the flow of air through the ventilators is vertical and not obstructed.

A terminal block is provided within the unit for the AC input connections. Before connecting the AC input cable, check the line power with that specified on the nameplate of the unit. Units with multiple AC input units have taps inside, which must be set for the proper AC setting.

(See tap card inside door (BELOW) The AC input current specified on the nameplate is for rated output.

Table 2: Voltage control taps 480V 575V CT

H2 (B)

H1 (B)

PT

2 (A)

3 (A)

Input AC breakers must be sized for the overload or current limiting point of the charger, which is 105% of the rated nameplate value.

Location ■

locate the charging station away from rain, snow, wet conditions or areas of high traffic if possible

■

Never place this unit directly above the standard flooded battery.

Gases from the battery will corrode and damage equipment. A sealed maintenance free or valve regulated lead acid (VRLA) may be placed below this equipment

■

Never allow the battery electrolyte to drip on this unit when reading the specific gravity or filling the battery

■

Do not operate this unit in a closed-in area or restrict ventilation in any way

■

Do not set any battery on top of this unit

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Installation ____________________________________________________ Safety features NOTICE! The operator must become familiar with all the safety features and their location on the charger prior to installation or operation.

Safety features include: (Reference Fig. 2) emergency stop switch

The emergency stop switch is located on the control panel of the charger. Depressing the emergency stop switch button will shutdown all charger functions immediately and remove all AC power from the charger.

Fig. 2: Emergency stop switch location Emergency stop switch

The charger is equipped with covers to reduce the possibility of personnel coming in contact with electrical components. All covers must be installed and securely fastened during operation.

DANGER! Do not operate or apply power to the battery charger with any of the covers removed. You or other personnel could be seriously injured from electrical shock.

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NOTICE! All battery chargers are shipped from the factory with the emergency stop switch disconnected. The switch must be connected and tested by the user prior to installation. When actuated, the emergency stop switch must remove all AC power from the charger.

__________________________________________________ Installation Fig. 3: Overview of the battery charger Control panel

Fork lift slots

© BUCYRUS AMERICA, INC.

Pulling holes

Charger information nameplates

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Installation ____________________________________________________

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5

Operation

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___________________________________________________ Operation

Operation This chapter contains important information on the operation and maintenance of the battery charger.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

How to operate the battery charger

© BUCYRUS AMERICA, INC.

DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the battery charger and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the battery charger?

The battery charger is only allowed to be operated by persons with adequate knowledge of the complete unit.

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

When can charging be started?

Charging must not be started until the safe condition and proper function of the complete unit has been checked and the daily maintenance operations have been carried out.

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Operation_____________________________________________________ Controls and indicators The primary controls for the battery charger are located on the front panel (Fig. 4).

Fig. 4: Battery charger controls and indicators “STOP BUTTON”

“EMERGENCY STOP BUTTON”

“STOP BUTTON”

front panel

The panel has a digital display, meter select/equalize (EQ) momentary switch, on/off switch and eight (8) LED lamps.

The digital display indicates Output Amps, Output Voltage, Ampere Hours Returned, and Elapsed Time Charging, and Cooling Time (elapsed time from end of charge).

A "Meter Select” switch and associated indicator lights allow you to read any one of the four (4) operating parameters on the digital display.

After powering up the unit and connecting the battery, the digital display indicates the output amperage of the charger. Press the "Select” switch down once and the "Output Voltage" will be displayed. Press the "Select” switch down a second time and the "Amp Hours Returned" will be displayed, a third time and the "Elapsed Time Charging" will be displayed.

NOTICE: The Charger must be charging the battery for 1 minute to obtain this reading; the amp hours are updated every minute. A third push of the button shows the elapsed charging time in hours/ minutes.

The "EQ” switch, when pressed up, allows the charger to charge six (6) additional hours after the 80% charge is reached. Batteries require one equalize cycle per week.

NOTICE: The equalize switch can also be used to start the charger even if a battery is discharged below 1.6 Vpc. Caution must be used when using this feature to start the charger because the initial battery voltage sensing is being disabled and the wrong battery could be being connected. _________________________________________________________________

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BUC-SCR 120 Series Battery Charger

© BUCYRUS AMERICA, INC.

“START BUTTON”

“START BUTTON”

___________________________________________________ Operation “ON/OFF” switch

An "ON/OFF” switch allows you to turn off the charger when disconnecting the battery during the charge cycle. (The on/off switch must be placed back to the “on” position after the battery is disconnected to activate the start function.)

“START” button (2)

Press and hold the “START” button for 20 seconds to start the charger when the following conditions are met:

“STOP” button (2)

–

the battery plug is engaged,

–

AC power is applied to the battery charger,

–

the circuit breaker is on, and

–

the “ON/OFF” switch is in the “ON” position.

The “STOP” button (s) turns the charger off but the charger remains energized.

© BUCYRUS AMERICA, INC.

The lamps are as follows: “ON CHARGE” lamp

This indicates after the charger has successfully completed the autostart cycle and the input contactor has closed.

“80% COMPLETE” lamp

This led indicator will flash when the battery voltage reaches 2.40 volts per cell. This means the battery is 80% charged. The 3 (normal) or 6 (equalize) hour timer is activated. At the end of the charge cycle this led Indicator will be on solid, the display will display Amp hours returned (when the “AMP-HRS” led is on), elapsed time of charge cycle (when the “ELAPSED TIME” led is on), and time from charge complete (cooling time, both “AMP HOUR” and “ELAPSED TIME” leds are on) “80% COMPLETE” lamp on.

equalize “EQ” lamp

This lamp indicates when the equalize mode is activated by the equalize “EQ” switch.

“FAILURE” lamp

The "FAILURE” lamp is a summary alarm. When the failure lamp illuminates, the number on the digital display indicates the type of failure.

See below:

Table 3: Failures AC voltage failure

0001

12 hour override timer time out.

0004

Wrong size battery (cells) or Low Battery Voltage - See Note**

0003

High DC current/voltage

0005

Unit will shut off within 15 minutes if a fully charged battery is connected to charger

0007

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Operation_____________________________________________________ NOTICE: To disable this feature (Reference Table 3, 007 Fault), push the Equalize “EQ” switch. The unit will start. Make sure a battery with the correct number of cells is connected to the charger.

The Model BUC-SCR 120 Series charger accomplishes its charge cycle completely automatically without the use of any moving parts except for the input AC contactor.

When using the 5-pin battery connector connect the pin labeled “C” to the battery positive at the battery end of the connector. At the charger end of the connector, connect the pin labeled “C” to pin #2 on the terminal. (The jumper bar between pins 1 and 2 must be removed when using the pin labeled “C”). To start a charge cycle - be sure the on/off switch on the timer board is in the “on” position – connect the battery, when using the 5 pin connector, the pin marked “C” will be the last pin to mate, then press the green push to start button on the charger. If for any reason the battery must be disconnected from the charger during a charge cycle, push the red, push to stop button first.

An SCR regulator controls the charge rate so that the charger puts out near maximum output current up to the gassing point of the battery, then automatically reduces the output current down to a trickle charge.

The charger provides automatic AC input line compensation up to +/10%. After the AC voltage taps are set, see INSTALLATION. The automatic compensation also eliminates charging problems that arise from a varying input line when charging continually or for two or three shift operations.

The unit is self-protecting when subjected to abnormal overloading conditions.

It should not be necessary to make any adjustments to this charger.

Because of the stability of design, the unit needs no periodic adjustment. This, along with the rugged construction and conservatively rated components, insures long life and trouble-free operation.

Should any adjustments be necessary, a factory service representative should be contacted.

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© BUCYRUS AMERICA, INC.

It is recommended that the connector used for the battery/charger connection have an auxiliary control contact. (a contact that makes last and breaks first). This contact should be wired to the battery positive on the battery side of the connector and to pin # 2 of the terminal strip on the charger side of the connector. (The jumper bar between pins 1 and 2 must be removed when using the auxiliary control contact.)

___________________________________________________ Operation The automatic start/stop feature senses the connection of a battery and determines if it is in the proper range, 1.4 volts per cell to 2.5 volts per cell, and then slowly ramps the output current up to start the charge. If the discharged battery is not the correct number of cells or if the correct battery is over discharged the unit will not start and the digital display will indicate number "0003". The charger will automatically turn off at the end of the charge cycle.

A push to stop button is provided to de-energize the charger. Be sure to push this button before disconnecting the battery during the charge cycle.

© BUCYRUS AMERICA, INC.

In the normal mode, the charger will charge the battery for 3 hours after the 80% point is reached (unless the rate program terminates the charge first) or the battery is disconnected. In the equalize mode, a 6 hour timer is initiated after the 80% point is reached.

A momentary equalize switch is provided so that equalizing may be selected to give a 6 hour charge after the 80% point is reached. Equalizing should be done once per week. This switch, when activated, will start the equalize charge mode for that cycle only. After completion of the cycle, the charger will automatically be reset to the "normal" mode.

When the 80% point is reached, the 80% charge lamp will flash at a one second rate. At this point, the timer in the SCR is set for 3 or 6 hours depending on whether or not the equalize mode is active. The charger will continue the trickle rate until the SCR control turns unit completely off. When a charging cycle is completed correctly, the 80%/ Complete light will be on solid until the battery is unplugged and the amp hours returned, elapsed charging time and elapsed time from charge complete will be displayed. Unplugging a charged (charge complete light "On") battery will place the unit back in the autostart mode.

Disconnecting the output connector while a battery is being charged is not recommended. If the battery is disconnected during a charge cycle, the control will turn off the charger, the complete light will not light, all timers will reset, and the unit will go into the autostart mode. The push to stop button must be pushed before disconnecting the battery during a charge cycle.

If the battery never reaches the 80% charge point (due to battery failure), the unit will turn off in 12 hours from the override timer. The complete light will not light. The "ON CHARGE" light will turn off, the "FAILURE" lamp will light and the display will indicate "0004." If this occurs, the unit will not autostart. The on/off switch will have to be turned off to reset the lights and turned back on to initiate the autostart mode If the AC input voltage goes off, the unit will stop and stay off until the green “START” button is pushed.

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Operation_____________________________________________________ After starting, the SCR immediately activates the 12 hour override timer. This timer is independent of battery conditions and overrides all other timing functions. The override timer will terminate the charge in the event that the rate control or the 80% timing control does not terminate the charge before the maximum time limit of 12 hours is reached.

© BUCYRUS AMERICA, INC.

The ground continuity relay is located within the battery connection box enclosure which interfaces to the charger on the ground and ground check terminals of the battery connector. If ground continuity is not detected the battery circuit breaker will not close, thus the charger will not see battery voltage and will not turn on.

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___________________________________________________ Operation Operation After the installation has been completed, the BUC-SCR 120 is ready for operation. Be sure that the battery charger is of the correct type for the battery that is to be charged. Select DC output current setting with the "C" jumper to HIGH, MED, or LOW on the terminal block. (See BUC-SCR 120 OUTPUT CURRENTS TABLE)

© BUCYRUS AMERICA, INC.

NOTICE: Carefully read and adhere to all battery and battery charging instructions and safety warnings.

To operate the charger, it is only necessary to place the on/off switch in the “ON” position and connect a battery. After the battery is connected push the push to start button. (When the battery is connected and before the start button is pushed, the timer display may indicate code 0001 AC failure). When the battery is finally connected and the push to start is pushed, after approximately a 20-second delay, the "ON CHARGE" lamp will light and the digital display will indicate a slow increase in output current. The charger will automatically start to charge the battery at some rate up to its maximum capacity depending upon the state of charge of the battery.

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Operation_____________________________________________________ Start-up procedure (Reference Fig. 5) F Check AC input voltage with that specified on the nameplate. Typical: chargers furnished with 480 volt and 575 volt power lines are dual input volt units. Taps within the unit must be set on the 480 volt setting for 480 volt power lines, and 575 volt taps for 575 volt power systems. A schematic is provided (Fig. 7) which indicates how the AC power connections must be wired. Connect the power lines to the AC input terminals and the ground wire to the ground terminal bonded to the case near the input terminals.

F A ground check wire supplied from the power center must be connected to the ground check terminal, near the input terminals.

NOTICE: This unit is equipped with two (2) door disconnect switches and four (4) cover disconnect switches. The two access doors and the top cover of the unit must be closed to operate.

F Place the on/off switch to the "ON" position. Apply AC voltage to the units input terminals. Four (4) eight's ("8888") will flash on the display.

F To select the equalize charge mode, activate the "EQUALIZE" switch on the front panel. If the equalize mode is selected, the "EQUALIZE" LED will be on.

F Connect the battery to the charger and press the “PUSH TO START” button. After a 20 second delay, which assures proper battery connection, the AC contactor should close and the on charge light should turn on. The battery charger should start to charge, showing output amps on the digital display. This completes the "Autostart” sequence. If a battery with the wrong number of cells is connected or the AC input line voltage is not present, the unit will not start and the "FAILURE" light will be on. The digital display will indicate the cause of failure. This condition will also occur if the battery being connected is discharged so deeply that the open terminal voltage will not come up to the 1.4 volts/cell required to initiate the start cycle.

NOTICE: To disable this feature push the “EQUALIZE” button.

CAUTION: Make sure a battery with the correct number of cells is connected to the charger.

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© BUCYRUS AMERICA, INC.

F The emergency stop switch must be pulled out.

___________________________________________________ Operation F When the "80% CHARGE” point is reached in the charge cycle, the "80%/COMPLETE" light will flash. There will be an additional three (3) hours (6 hours in the equalize mode) of charge after this point is reached.

© BUCYRUS AMERICA, INC.

F When the charge cycle is completed, the charge "80%/ COMPLETE" light will turn on solid and the "ON CHARGE" lamp will turn off. The display will also alternate at one second intervals between the "AMP HOURS", "CHARGE TIME" and "COOLING TIME". The "COOLING TIME" is the time since the charge cycle completed and is indicated in hours and minutes. When showing the "CHARGE TIME" the "AMP HOURS" light will be OFF and the elapsed time LED will be ON. When showing the "COOLING TIME" the "AMP HOURS" light will be ON and the elapsed time light will be ON. F If for some reason the AC input voltage fails, the "FAILURE” light will turn ON and the battery charger will turn OFF. The display will indicate number "0001". During this interval, the time registers in the SCR are held at their present count. When the AC has returned to normal, the charge cycle resumes where it left off and the failure light turns off.

F If for some reason the normal, equalize, or rate timers do not terminate the charge cycle in less than 12 hours, the override timer will time out, shut down the charger and turn on the "FAILURE" light.

The display will indicate number "0004".

F If for some reason, the unit output voltage exceeds 2.7 V/C max for 20 sec., an independent software shutdown will stop the charger.

The display will indicate number "0005." In this condition, the lamps will not update and the unit will not turn back on until the on/off switch has been toggled. The charger will reset back to the autostart mode when the battery is disconnected, or when the on/ off switch is turned "OFF” and then "ON" again.

F If a fully charged battery is connected, the charger will turn off in fifteen (15) minutes and the Code 0007. To bypass this function, push the “EQUALIZE” switch and the unit will charge the battery for up to six (6) additional hours.

NOTICE: Push the red push to stop button before disconnecting the battery during a charge cycle.

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Operation_____________________________________________________ Fig. 5: Battery charger control panel (Start-up)

“START BUTTON”

“STOP BUTTON” “ON/OFF” switch

Display screen

© BUCYRUS AMERICA, INC.

“EQ” equalize switch

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___________________________________________________ Operation Shutdown procedure (Reference Fig. 6) F Place the on/off switch to the "OFF" position.

F Press the “PUSH TO STOP BUTTON”.

F Disconnect the battery plugs and receptacles.

F Cap battery plugs and receptacles to prevent and dirt or foreign material contamination.

Fig. 6: Battery charger control panel (Shutdown)

© BUCYRUS AMERICA, INC.

“STOP BUTTON”

“ON/OFF” switch

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Operation_____________________________________________________

© BUCYRUS AMERICA, INC.

Fig. 7: Battery charger wiring diagram

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___________________________________________________ Operation

© BUCYRUS AMERICA, INC.

Fig. 7: Battery charger wiring diagram (continued)

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Maintenance __________________________________________________ Instructions on the maintenance Maintenance at regular intervals increases the operational safety and prolongs the service life of the battery charger.

In particular, observe the safety instructions in chapter 2 “Your safety”.

Important notes

■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the unit as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual.

■

Inadequate maintenance can result in battery charger damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus America, Inc. spare parts when replacing components.

■

All electrical work must be supervised and inspected by a certified electrician.

■

Anyone performing maintenance on this unit must be trained to operate it and be familiar with this Bucyrus America, Inc. guide.

Before maintenance Please observe the following: ■

Shutdown the unit.

■

Disconnect the electrical power. The power should be disconnected at the main power source.

WARNING! Before performing maintenance on the battery charger, disconnect the electrical power. Electrical shock can cause serious injuries or even death to you or the maintenance person.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■

Cleanliness can not be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede

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© BUCYRUS AMERICA, INC.

Please observe the following:

_________________________________________________ Maintenance General maintenance procedures Yearly F Blow out rectifier/inverter with a low pressure air hose.

F Make sure all connections are tight.

F Perform a visual check on all internal components.

F Check front panel meters and alarms for accuracy.

Fourth year F Repeat all the above.

F Check relay contacts for pitting or corrosion.

© BUCYRUS AMERICA, INC.

F Check capacitors for leakage.

Seventh year F Repeat all the above.

F Filter, resonating capacitors and control relays should be replaced.

Tenth year F Repeat all the above.

(Except replacing capacitors and control relays, they should be replaced every seven years.)

F Check magnetics, components and wiring for signs of excessive heat.

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Troubleshooting _______________________________________________ Troubleshooting procedures The following section lists possible problems that may be encountered with the battery charger and can aid in locating and correcting these problems.

NOTICE: Before troubleshooting unit, check for shipping damage. (i.e. broken wires, loose connections, etc.)

Problem: Blown AC input fuse

F 2. Check AC input current draw after replacing blown AC fuse.

NOTE: If AC fuse clears as soon as the AC contactor pulls in, go to STEP #5. On three (3) phase units, if the AC current is not approximately equal, check the AC voltage input to the S2A-123 printed circuit board. Connector #1, 4-5, 5-6, 6-4 should be 100 Vac. - 220 Vac. If this voltage is not there, retrace the wiring back to the SCR/Diode modules. If voltage is there, continue to step #3.

F 3. Check the AC voltage output on the S2A-123 printed circuit board, Connector #2, 4-1, 4-2, 4-3. Voltages must be approximately equal and greater than 5 Vac. If it is not greater than 5 Vac., replace the S2A-123 printed circuit board.

F 4. Connect charger to discharged battery, check output voltage and voltage across charger shunt bar. If output voltage is below 2.3 Vpc., the voltage across shunt must not exceed 135mV. If it is over 135mV, adjust pots on the printed circuit board counterclockwise which lowers the output until 97mV across the shunt bar is indicated.

© BUCYRUS AMERICA, INC.

F 1. Check AC input voltage with tap setting on power transformer and control transformer. If AC input and tap setting agree, see step #2.

Table 4: S2A-320 POT ADJUSTMENTS P3

Low start rate *

P4

Mid start rate

P6

High start rate

P8

Low finish rate

P9

Mid finish rate

P10

High finish rate

P11

Start/Finish threshold voltage

P1

High voltage clamp

* Verify the jumper selection on the AC input terminal block. If Low Start Rating is 140A and 250A/`100mV shunt is used, Adjust P3 until 140A 100mV/250A = 56 mV across the shunt bar is indicated.

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______________________________________________Troubleshooting F 5. If AC input fuse clears when the AC contactor pulls in make sure the correct AC fuses are being used, time delay fuses. If the correct AC fuses are being used, disconnect P1 connector from the FC6 printed circuit board.

F 6. Replace blown AC fuse, turn on AC power. (If fuse is good, defective S2A-320 or FC6 p.c. board.) If fuse still clears, problem is a shorted SCR/Diode module or power transformer.

F 7. Separate secondary leads from P.T. to SCR/Diode modules. If fuse still clears, problem is in the (P.T.) power transformer. If fuse is good, problem could be in the SCR/Diode module.

See SCR/Diode troubleshooting procedures section of this manual

© BUCYRUS AMERICA, INC.

NOTICE: Blown printed circuit boards, fuses or loose printed circuit boards fuses could cause an out of phase condition. (Blowing AC input fuses) If a blown printed circuit board fuse is found, a wire on the gate lead of the SCR/Diode module could be disconnected or a defective SCR/Diode module could exist.

Problem: Blown DC input fuse F 1. Make sure the correct type of fuse is being used.

F 2. Check all connections to DC fuse to be certain they are tight.

F 3. Check polarity of output cables, output connector, SCR/Diodes module and diode SD4 for shorts.

Problem: Blown control transformer fuse CTF F 1. Defective contactor (shorted coil) F 2. Control taps set wrong on control transformer H1 - H2.

F 3. Defective control transformer.

Problem: Blown control transformer fuses blown F 1. Defective S2A-320 Drive Board.

F 2. Shorted MOV. (Metal Oxide Varistor) NOTICE: Voltage across secondary of control transformer: X1 - X2 = 120Vac.

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Troubleshooting _______________________________________________ Problem: Complete “ON” but battery not charged F 1. Record all readings on digital display board before disconnecting battery. Check status of complete light.

F 2. Check battery for defective cells.

F 3. Call local Bucyrus America, Inc. representative or factory for additional information.

F 4. Possible settings on the S2A-320 control board.

Problem: Contactor does not pull in F 1. Check AC input voltage and fuses.

F 2. Check DC voltage at DC output terminals (battery connected).

F 4. If 120 Vac. is present at AC contactor coil, contactor may be defective.

Problem: Failure light on CODE 0001 or 0002 F 1. Check AC input voltage must be present.

F 2. Check taps on power and control transformer.

F 3. Check AC contactor.

F 4. Check voltages on the secondary side of the control transformer.

F 5. Loose connections on the control transformer.

F 6. Check voltages on the S2A-243 transformer board.

Problem: Failure light on CODE 0003 F 1. Check battery for correct number of cells.

F 2. Check for defective or shorted cells in battery.

F 3. Open circuit battery voltage must be above 1.6Vpc.

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F 3. Check AC voltage output on control transformer.

______________________________________________Troubleshooting Problem: Failure light on CODE 0004 F 1. Check battery for defective or shorted cells.

F 2. S2A-320 or FC6 "p.c." board may be defective.

F 3. 80% setting came on late into the charge cycle, batteries are being discharged beyond specifications.

Problem: Fuses, battery, AC voltage and taps okay, but no indication on display board

© BUCYRUS AMERICA, INC.

F 1. Defective S2A-191 board, replace board.

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Troubleshooting _______________________________________________ SCR/Diode troubleshooting procedures F 1. Disconnect power transformer secondary wire from top connection of module.

F 2. Disconnect positive bus bar from module.

F 3. Disconnect negative bus bar from module.

F 4. Disconnect 6 wires from terminal P1 on FC6 Assembly.

MAGN-A-PAK power module version

F 6. Measure resistance from top terminal of module to bottom terminal must read high resistance one way; low resistance when you reverse leads.

Hockey puk version F 5. Measure the resistance across the plates of SCR (where gate/ cathode wires are attached). Each should have high resistance on both directions.

F 6. Measure the resistance across the plates of diode. Each should have high resistance one way, low resistance the other way.

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F 5. Measure resistance from top terminal of module to center terminal must read high resistance. Reverse leads must read high resistance.

________________________________________________________________

6

Technical data

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_______________________________________________ Technical data

Technical data This chapter contains the most important technical data on the BUCSCR 120 Series battery charger. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, etc. Read this chapter through carefully and pay particular attention.

The technical data listed in this chapter is for stock units only.

Customer specials may not be listed.

Components of the BUC-SCR 120 Series battery charger

© BUCYRUS AMERICA, INC.

Technical data sheet Part number: Model number: Output: Input voltage/hz: Battery size: Overall length: Overall width: Overall height

354292 SCR 120 5/6/8 120 cell batteries 480/575/60hz 520 AH, or 680 AH, or 800 AH approx. 78” approx. 64.25” approx. 25.25”

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Technical data _________________________________________________

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___________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Set screws

© BUCYRUS AMERICA, INC.

Table 5: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

13 in-lbs

¼”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

½”

16.7 ft-lbs

Table 6: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

¼”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

½”

43 ft-lbs

5/8”

100 ft-lbs

¾”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

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Tightening torques _____________________________________________

Nominal diameter

Recommended torque setting

¼” 5/16” 3/8” 7/16” ½” 9/16” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½” 1 ¾” 2” 2 ¼” 2 ½” 2 ¾” 3”

9 ft-lbs 18 ft-lbs 31 ft-lbs 50 ft-lbs 75 ft-lbs 110 ft-lbs 150 ft-lbs 250 ft-lbs 378 ft-lbs 583 ft-lbs 782 ft-lbs 1,097 ft-lbs 1,461 ft-lbs 1,748 ft-lbs 3,114 ft-lbs 4,504 ft-lbs 6,497 ft-lbs 7,144 ft-lbs 12,092 ft-lbs 15,744 ft-lbs

Table 8: FSR hex bolts (SAE 5 and 325 steel) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

Recommended torque setting 26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs 30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

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Table 7: FSR hex bolts (SAE 5 and 325 steel)

___________________________________________ Tightening torques Table 9: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

© BUCYRUS AMERICA, INC.

Table 10: Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

M18

M20

M22

M24

Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

39 28 89 65 125 92 150 110

130 95 295 217 420 309 500 368

184 135 420 308 690 435 710 523

250 184 570 420 800 590 960 708

315 232 725 634 1020 752 1220 899

62 45 141 103 198 146 240 177

85 70 215 158 305 224 365 269

Nominal diameter

Table 11: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

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Tightening torques _____________________________________________ Table 12: Untreated screw, black finish (Fine thread) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25

Nm

27

52

95

Ft-lbs

19

38

70

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5

Nm

150

225

325

Ft-lbs

110

165

239

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

Table 14: Untreated screw, black finish (Fine thread, continued)

Property class

Torque Ma

8.8

Nm

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399

Ft-lbs 10.9 12.9

610

780

449

575

Nm

640

860

1100

Ft-lbs

472

634

811

Nm

770

1050

1300

Ft-lbs

567

774

958

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Table 13: Untreated screw, black finish (Fine thread, continued)

___________________________________________ Tightening torques Table 15: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M33 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

© BUCYRUS AMERICA, INC.

Table 16: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended Nominal diameter torque setting M12 M14 M16 M18 M20 M22

Nm

36

Ft-lbs

26

42

Nm

83

132

Ft-lbs

61

97

147

58

88

121

171

230

54

89

126

169

200

275

390

530

202

287

390

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 17: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended Nominal diameter torque setting M24 M27 M30

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

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Tightening torques _____________________________________________ Table 18: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

Torque Ma Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

Recommended torque setting M8 X 1 25 18 35 25 42 30

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 19: Electrically zinc plated (Fine thread, continued)

8.8 10.9 12.9

Torque Ma

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 20: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

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Property class

________________________________________________________________

7

For your information

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__________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

© BUCYRUS AMERICA, INC.

Service address Beckley, WV 200 George Street, Suite 4 Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA (Corporate Headquarters) 2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 Oak Hill, WV 25901

Paonia, CO P.O. Box 566 Paonia, CO 81428 719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846 Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450 Price, UT 1814 North 1500 West P.O. Box 1016 Price, UT 84501 Phone: (435) 637-3930 Fax: (435) 637-9754

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

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Our service ___________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

© BUCYRUS AMERICA, INC.

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

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INSTALLATION, USE, MAINTENANCE AND REPAIR OF MINE POWER STORAGE BATTERIES

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. P/N A6474X26 Revision 10, December / 07  BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED

Bucyrus America, Inc.

TABLE OF CONTENTS Page 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

I

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

II

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

PREFACE This manual is intended to provide GENERAL product information for Bucyrus America, Inc. mine power storage batteries. The illustrations, descriptions and procedures contained in this publication apply only to Bucyrus America, Inc. mine power storage batteries. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Bucyrus America, Inc. mine power storage battery 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, the battery 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 the battery, 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 the battery 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 battery.

While this manual attempts to anticipate the most important operations and maintenance needs for this battery, 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 liability.

 Bucyrus America, Inc. All rights reserved.

1

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

2

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

SYMBOLS AND SPECIAL NOTATIONS Throughout this manual there are specific notations that are either UPPERCASE BOLD, UNDERLINED or ITALICIZED for the primary purpose of emphasis. Please pay special attention to such statements as they regard safety or critical maintenance installation information.

You will also see the following:

NOTICE: THIS NOTATION DENOTES A REFERENCE TO PREVIOUSLY STATED INSTRUCTIONS.

IMPORTANT: THIS SYMBOL DENOTES THAT SPECIAL ATTENTION MUST BE ADHERED TO IN THE ATTACHED STATEMENT.

CAUTION: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A CUT, BRUISE OR ABRASION.

WARNING: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A LOST TIME ACCIDENT.

DANGER: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A SERIOUS INJURY OR FATALITY.

3

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

DANGER ONLY TRAINED AUTHORIZED PERSONNEL SHOULD OPERATE OR PERFORM MAINTENANCE ON THE BATTERY. FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH. FAILURE TO OPERATE OR MAINTAIN THIS BATTERY IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

4

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

ENTIRE BATTERY

Mine service batteries can weigh several thousand pounds and could cause severe injury or death should the battery fall on persons or body parts

Batteries must be resting securely in a machine, on battery tables, or platforms capable of supporting the weight while performing maintenance or service on battery.

ELECTRICAL

Electrical shock could cause death or serious injury. The battery produces lethal amounts of current whether connected to a machine or not.

Batteries should be maintained and serviced by qualified personnel.

The battery should be disconnected before servicing.

EXPLOSIVE GASES

Batteries produce explosive gases that could be ignited causing burns or explosions.

Batteries should be well vented before servicing, particularly if welding or burning on the battery.

Batteries should be maintained by qualified personnel.

CORROSIVE ACIDS

Batteries contain strong acid that could cause severe burns if spilled or splashed on body parts or in the eyes.

Protective clothing, gloves, and eyewear must be worn when working on batteries. Batteries should be maintained by qualified personnel.

COVERS

Battery covers could fall, crushing hands, arms, or fingers.

Battery covers must be secured with the cover supported when working under the covers.

5

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

6

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

SAFETY PRECAUTIONS AND GUIDELINES OVERVIEW Before you install, maintain or repair a mine service battery READ and STUDY this guide. KNOW how to safely use the battery and what you must do for safe maintenance.

ALWAYS wear or use the proper safety items required for your personal protection.

If you have ANY QUESTIONS about the safe use or maintenance of this unit: ASK YOUR SUPERVISOR - NEVER GUESS - ALWAYS CHECK

MAINTENANCE AVOID, whenever possible, servicing, cleaning or examining the battery in congested areas.

ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Manual for the proper location and part number of decals and plates.

DISCONNECT the battery when servicing or when welding on the battery.

BE SURE the battery area is well ventilated (clear of fumes) when it is necessary to connect battery charger. Fumes from the battery could ignite by a spark and explode.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Chapter 4 of this guide is dedicated to safety procedures that MUST be followed when using or servicing lead-acid batteries. It is important that you read and understand the procedures outlined in this guide, particularly those in Chapter 4.

7

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

CHAPTER 1 - INTRODUCTION Section I. General 1-1. Scope This guide contains information concerning the theory, construction, installation, use, maintenance, repair, and hazards of lead-acid storage batteries used to power mine tractors, scoops, locomotives, and coal haulers.

1-2. Forms, Records and Reports The following form will be used by personnel responsible for the receipt, storage, operation, charging, and maintenance of lead-acid storage batteries. a. Monthly Storage Battery Record - The Monthly Storage Battery Record is to be used to record the services performed on motive power batteries. This record should be prepared and maintained by the using operator and should accompany the battery at all times. (See Figure 1 for a typical "Monthly Storage Battery Report" form.)

FIGURE 1 – MONTHLY STORAGE BATTERY RECORD

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Section II. Definitions 1-3. Standards Those definitions referenced throughout this manual generally agree with accepted industry standards.

For a more complete listing of "Definitions for Lead-Acid Industrial Storage Batteries" see NEMA Standards publication No. 1B 1-1971.

Copies of NEMA standards may be obtained at nominal cost by writing to: National Electrical Manufacturers Association, Department of Engineering and Safety Regulations, 2101 L Street, N.W. Washington, D.C. 20037.

Section III. Description and Construction 1-4. Battery Mine power lead-acid batteries for electric vehicles typically consist of of: (1) a steel tray into which the cells are assembled; (2) a battery terminal connector; and (3) other components necessary to secure and protect the cells and provide the necessary electrical interconnections. a. Battery Identification and Data - The essential information necessary for proper care of an industrial motive power battery appears on the battery, either stamped into one of the intercell connectors or on a name plate affixed to the tray. This information usually includes the manufacturer's name and model, number of plates per cell, battery capacity, battery voltage, serial number, suggested charging rate, and fully charged specific gravity of electrolyte.

If vital information is missing, or is no longer legible, such information can be obtained by contacting your nearest BUCYRUS AMERICA, INC. representative.

Some manufacturers list, as a part of the model or type designation, the rated ampere-hour capacity of a single positive plate, such as "SS75". As an alternate means of determining rated battery capacity, this number should be multiplied by the total number of positive plates in one cell. To find the number of positive plates in a cell, subtract one from the total number of plates and divide by two. To find the capacity of a battery designated "SS75-19," therefore: 19 - 1 = 18; 18 divided by 2 = 9; 9 x 75 = 675 Ah battery capacity. b. Cell Arrangement - The individual cells, which contain the energy generating components of the battery, may be arranged slightly differently for various types of equipment. The cells of all motive power batteries are, however, always connected in series to produce the required voltage. Cell and battery capacity, which is the available ampere-hours or watt-hours, is a function of the total number and size of plates within each cell. Voltage, though, is the same for all cells regardless of size. Each lead-acid cell yields a nominal 2 volts. c. Connector Arrangement - Connections between cells are made by intercell connectors which may be lead-coated copper straps or be cast of solid lead. These connections are always welded, in proper sequence, by the application of heat to the terminals of the cells. Energy from the battery is drawn off by terminal cables which extend beyond the steel tray wall and are in turn permanently joined to the battery terminal connector.

1-5. Cell

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This is the basic unit of any battery. It is a galvanic cell which produces electrical energy when connected to an electrical load and, after being discharged, may be restored to its original fully charged condition. It has a nominal voltage of 2 volts and consists of an element, from which the energy is derived, and the electrolyte; both are contained by an impact resistant, molded plastic jar. The element is prevented from contacting the bottom of the jar by means of a high impact bridge, which consists of a series of support ribs. These ribs provide sediment space below the bottom of the element to accommodate particles of active material, shed by the positive plates during normal operation of the battery. (See Figure 2.)

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FIGURE 2 – TYPICAL BUCYRUS AMERICA, INC. CELL

Cover - With lead insert bushing prevents leakage and voltage to ground.

Vent Cap – Quarter turn bayonet type simplifies watering and inspection.

Post - Special alloy for increased strength and conductivity.

Separator Guard – White in color to increase visibility for fast electrolyte check.

Post Plate Strap - Extra heavy to insure a permanent connection between post and plates.

Negative Plate – Designed to compliment positive plate performance.

Positive Grid - A non-porous lead alloy casting, designed for maximum current carrying capacity, capable of many years of service.

Vertical Mat - Laminated construction compromised of uniformly spaced fine glass tape that imbed into the active material and an interwoven glass fiber mat wrapped vertically around the positive plate insuring optimum active material retention.

Horizontal Mat - Made of glass fibers with an insoluble binder.

Breaks up gas bubbles and increases positive plate insulation.

Active Material - Specially formulated and uniformly applied under rigid laboratory control to insure maximum efficiency throughout long battery life.

Retainer and Bottom Shield - A high porosity perforated envelop that encases positive plate and glass mats to prevent shorts and insure maximum performance and life.

Jar - Molded of high-impact material to remain leak free under rough treatment.

Separator - Deep channeled, microporous, impervious to heat, acid and corrosion: provides insulation between positive and negative plates while allowing the free flow of electrolyte throughout the cell.

Bridge - Provides firm element support and ample sediment space.

Bucyrus America, Inc. mine batteries incorporate every feature required by today’s mines. They are designed by engineering technology and built by master battery craftsmen according to strict quality control guidelines. DBT America Inc. batteries are the finest available to meet today’s mining requirements, and our precision construction provides new equipment performance throughout a long life.

The top of each cell is fitted with a molded rubber plastic cover sealed to the jar at the edges. A vent or filler cap is located in the center of the cover. This vent permits the escape of hydrogen and oxygen while the cells are gassing and, when removed, provides an opening through which water may be added 11

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to the cell. The positive and negative terminal posts, which are part of the element, fit through openings in the cover. Prior to being connected together, cells are placed so that the positive terminal of one cell is adjacent to the negative terminal of the next. This arrangement permits a conveniently made series connection. a. Element - The element of the cell consists of one group each of positive and negative plates meshed together. The plates are insulated from each other by separators which are inserted between all plates. A plastic element protector is positioned on top of the separators. This prevents mechanical damage to the element and aids in preventing electrical shorts which occur when particles of active material bridge the space between plates. Terminal posts are welded to each group and are used to electrically connect one cell to another. b. Group - This is an assembly of plates of like polarity connected in parallel by welding to a common strap or busbar. A cell must contain one positive and one negative group. The negative group always has one more plate than the positive group. One or more terminal posts are welded to each. c. Plates - The plates (also called "electrodes") are either positive or negative and consist of a cast lead alloy grid and active material. The grid provides support to the active material and becomes the primary electrical conductor. The active materials result from the addition of chemicals to lead oxides which are converted, by electrochemical processing, to lead dioxide in the positive and to sponge lead in the negative.

(1) Pasted type - The grid of the pasted plate consists of horizontal and vertical or diagonal cast lead conducting members within a rectangular cast frame. A slurry of active material is pasted or squeezed into the voids, and the surfaces are then covered by porous glass and plastic retainers to prevent the loss of active material. d. Electrolyte - The element within the jar is immersed in an electrolyte, which is a solution of sulfuric acid and "pure" water. This permits the necessary chemical reaction to occur and provides a conducting medium in which the flow of electric current takes place. The electrolyte in a fully charged cell normally has a specific gravity of between 1.280 and 1.295 at 77 degrees F. As a cell discharges, the specific gravity decreases. Measurement of this specific gravity, by means of a hydrometer, indicates the state of charge of a cell. To save time in determining- this state of charge for the battery, a pilot cell or cells may be chosen; a pilot cell is a selected cell(s) whose condition is assumed to be representative of the condition of the entire battery. e. Separators - Separators are made from microporous plastic, which is resistant to heat and acid.

Separators provide mechanical and electrical insulation between positive and negative plates, but are porous enough to permit passage of electrolyte. The grooved or ribbed side of the separator is placed toward the positive plate to allow a free flow of electrolyte to the active material. The flat side faces the negative plate to contain the sponge lead. f. Positive Plate Retainers - Pasted type plate retainers are added, after pasting, typically by wrapping the plate first with fibrous-type glass tape or mats and then by a perforated plastic envelope complete with bottom boot or by other suitable filtering systems. All types of retainers act to prevent the escape of positive active material during normal use. Retainers are not needed on negative plates.

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Section IV. Principles of Operation 1-6. Fundamentals of Cycling A cycle is a discharge followed by a charge. During the charge, the electrical energy supplied by the charger causes an electromechanical reaction within the battery. This restores the active materials to a fully charged condition. a. The Fully Charged Cell or Battery - The positive and negative plates (electrodes) are separated from each other and immersed in electrolyte. In the fully charged condition, the active material of the positive plate is lead dioxide and that of the negative plate is sponge lead. The electrolyte is a solution of sulfuric acid and water that normally varies in a specific gravity from 1.280 to 1.295. The combination produces a voltage of approximately 2 volts on open circuit. This voltage potential results from the fundamental characteristic of a storage battery which dictates that when two electrodes of dissimilar metals are immersed in suitable electrolyte, and a circuit is closed between the two, electrons begin to flow. A fully charged cell should normally have an on-charge voltage of from 2.45 to 2.70 volts when charging at the finish rate. b. The Discharging Cell or Battery - While a battery is being discharged or used, lead dioxide and sponge lead combine with sulfuric acid to form lead sulfate within both plates. This action causes the specific gravity of the electrolyte to decrease. As the discharge progresses, individual cell and battery voltages decline, generally in direct proportion to the rate of discharge. c. The Discharged Cell or Battery - As the depth of discharge increases, more sulphuric acid is removed from the electrolyte so the specific gravity decreases and may drop below 1.100 as it approaches the specific gravity of water. Almost all of the active material of both positive and negative plates is converted to lead sulfate, and an effective electromechanical reaction is no longer possible.

At this point the battery has reached its discharge limit. d. The Charging Cell or Battery - The charging action begins when the terminals of the battery are connected to an external source of direct current. The electromechanical reaction is reversed and the positive plates, negative plates, and electrolyte start returning to their original charged condition.

Charging causes the battery voltage to rise as active materials are restored. A cell being charged may have a voltage of from 2.12 to 2.70 volts depending upon charging rate and time. e. General - Storage batteries do not actually store electrical energy; instead, they accept the electrical energy delivered to them during charging and convert it into chemical energy. During discharging, this chemical energy is reconverted into electrical energy to be used as needed.

To obtain the best performance and life from a mine power storage battery, it should usually be charged after each shift of use or whenever the specific gravity of the electrolyte falls below 1.240. It is very important that proper ventilation be provided during charging to make certain that (1) the hydrogen gas, given off toward the end of the charging process is dissipated (see Chapter 4), and (2) that individual cell electrolyte temperatures, during normal operations, do not exceed 110 degrees F. 1-7. Ampere-Hour Capacity The electrical capability of a storage battery is usually expressed in ampere-hours. The ampere-hour capacity is the number of ampere-hours which can be delivered under specified conditions of temperature, rate of discharge, and final voltage. Basically, ampere-hours are determined by multiplying the number of amperes which the battery will deliver by the number of hours during which the current is flowing. Total cell or battery capacity then is determined by the size and number of plates which make up

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the element. Due to the variety of job requirements, batteries are produced with many different sizes of cells.

1-8. Voltage With reference specifically to storage batteries, many "voltage" conditions have been recognized. The most important of these are: a. Open Circuit Voltage - This is the voltage of a cell or battery at the terminals, when no current is flowing. The nominal open circuit voltage of an individual fully charged cell is 2 volts. This is true regardless of cell size. The voltage of a 64 cell lead-acid battery is stated, therefore, as 128 volts. b. Initial Voltage - The initial voltage of a cell or battery is the closed circuit voltage at the beginning of a discharge. It is usually taken after current has been flowing for a sufficient period of time for the rate of change of the voltage to become practically constant, usually a matter of minutes. c. Average Voltage - The average voltage of the cell or battery is the average value of the voltage during the period of charge or discharge. d. Final Voltage - The final or cut-off voltage of a cell or battery is the prescribed voltage at which the discharge is considered complete. It is usually chosen so that the useful capacity of the battery is realized without subjecting it to harmful overdischarging. Final voltage will vary with the rate of discharge, cell temperature, and the type of service, but for mine power applications it is considered to be 1.70 volts per cell.

Inital voltage, average voltage, and final voltage are monitored when conducting test discharges.

1-9. Rated Capacity The rated capacity of a storage battery is the number of ampere-hours or watt-hours which it is capable of delivering when fully charged and under specified conditions of temperature, rate of discharge, final voltage, and specific gravity. United States industry standards for mine power batteries always specify this to be at the 6 hour rate of discharge. The total capacity available from a battery is greatest at low rates of discharge over a long period of time. Discharging at high current rates reduces the total ampere-hours available.

1-10. Sulfation Sulfation occurs when conditions within the cell cause sufficient accumulation of abnormal lead sulfate at both the positive and negative plates, permanently affecting the normal chemical reactions. Habitual overdischarging below final voltage, prolonged operation in an undercharged condition, and extended stand periods while in a discharged state are major causes of sulfation. A servicing schedule should be followed to provide frequent monitoring and adequate charging. See Chapter 3, Section 1, for methods of restoring a sulfated battery.

1-11. Operating Cycle An operating cycle of a storage battery is the discharge during use and subsequent charge to restore its initial condition.

1-12. Service Life The service life of a storage battery is the period during which it provides useful power while being discharged. It is usually expressed as the time period, or number of cycles, which elapses before the ampere-hour capacity falls below 80% of its rated value. To obtain maximum service life, it is 14

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recommended that a battery be restricted to one full cycle per 24 hour day or fewer than 300 cycles per year. Other factors which most often adversely influence service life are: 1. Abnormally high or low electrolyte temperatures.

2. Frequent overdischarging.

3. Failure to add water regularly.

4. Frequent overcharging.

5. Poor, or high, resistance, connections or contacts.

6. Adding too much water.

1-13. Effect of Temperature The normal operating characteristics of a storage battery are modified by unusually low or high cell temperatures. a. Low Temperature - Available battery power is reduced by low temperature because electrolyte viscosity and resistance is increased and diffusion throughout the pores of the active material is retarded. For example, a fully charged battery (1.280 to 1.295 specific gravity at 77 degrees F.), when its electrolyte temperature is about 32 degrees F., will deliver only 75% of the capacity which would be available at normal room temperature. This drops to 40% at 0 degrees F. The electrolyte could freeze if a discharged battery were exposed to very cold temperatures for several hours. (See Table 1 for freezing points of various electrolyte concentrations.)

In addition to the discharge-related problems, the charge acceptance of a lead-acid battery is impaired when electrolyte temperatures drop below 60 degrees F. As a result, batteries should always be kept fully charged, especially in cold weather. They should be heated, even during operation or storage, if exposure is severe enough to cause the temperature of the electrolyte to approach 32 degrees F. b. High Temperatures - Although high temperatures (up to 110 degrees F.) do not cause a reduction in available capacity, battery operation is adversely affected. Because most chemical reactions are accelerated at high temperatures, the rate of corrosion of the positive grid is increased and the active material is shed more rapidly. Even electrolyte temperatures above 90 degrees F. will cause some reduction in service life and should be avoided whenever possible. Cell temperatures should never be allowed to exceed 110 degrees F.

TABLE 1 FREEZING POINTS OF VARIOUS ELECTROLYTE CONCENTRATIONS State of Charge-Approximate (Percent)

Specific Gravity

Freezing Point (Degrees Fahrenheit)

100 75 50 25 10

1.280 1.250 1.220 1.160 1.130

-95 -62 -31 +1 +10

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CHAPTER 2 – INSTALLATION, USE, AND MAINTENANCE Section I. Preparation for Use 2-1. Establishing Requirements The number of batteries required for service depends primarily upon the number of 8-hour shifts in effect. Normally, for operation on a single-shift basis, the minimum number of batteries required will be the same as the number of items of operating equipment and the batteries need not be removed from the unit for charging. For operation on a 2- or 3-shift basis, the minimum number of batteries required will be twice the number of items of operating equipment and it will, therefore, be necessary to exchange discharged batteries for charged batteries at the end of each work shift. Whenever possible, it is recommended that more than the minimum number of batteries be available for multiple-shift operation, providing at least an 8-hour cooling period after charging. In an emergency, any one battery can be used for two 8-hour shifts during a 24-hour period, but this procedure, repeated regularly, will probably cause high electrolyte temperatures and could seriously affect service life. Therefore, where 3-shift operation is normal, 3 batteries will be required per item of equipment.

2-2. Unpacking Upon Receipt 1. It is important first to examine the exterior of the packing for wet spots on bottom or sides which may indicate leaking jars. Inspect also for physical damage to battery package because the battery could be affected as well. Report any damage to your supervisor.

2. Make certain that the package is right side up, with skid mounts resting firmly on floor.

3. Use a forklift truck or crane of sufficient capacity to remove the packaged battery from the truck or freight car. If a crane is employed, be sure the sling is secured against the bottom of the skid and not around the skid mounts.

LIFTING DEVICES USED TO MOVE BATTERIES MUST BE CAPABLE OF CARRYING THE WEIGHT STAMPED ON THE BATTERY CASE. KEEP ALL PERSONS AND BODY PARTS FROM UNDER THE BATTERIES WHEN THEY ARE LIFTED. 4. Move the crated battery to the uncrating area and remove packaging, including any wrapping or other protection provided to the battery terminal cable connectors.

5. Inspect battery and report any damage to your supervisor.

6. Use a properly insulated lifting beam of adequate capacity to lift the battery, by means of an overhead hoist, from the battery skid.

2-3. Handling Batteries When lifting batteries, always use a device which exerts a vertical pull on the lifting eye or tab. If a chain must be used, it should be in combination with a lifting beam with provision for adjusting lifting hook centers to the exact length of the tray. Any method of lifting which tends to "squeeze" or "stretch" the battery tray may distort it and could damage jars or disturb cell seals. A piece of rubber sheet or other insulating material, temporarily laid on the battery while lifting, will prevent any possible short circuits from chains or hooks. As an additional precaution against accidental shorting, the lifting beam hooks should be electrically insulated from each other.

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2-4. Preparing Batteries for Use a. See Table 2 for proportions of sulfuric acid and water to make electrolyte.

TABLE 2 Note: Sulfuric Acid of 1.400 Specific Gravity Specific Gravity Required

Parts Water Required

1.375 1.365 1.355 1.350 1.340 1.330 1.325 1.315 1.310 1.300 1.290 1.285 1.280 1.275 1.270 1.260 1.255 1.250 1.245 1.240 1.230 1.225 1.220 1.215 1.210 1.205 1.200

.075 .11 .14 .16 .20 .24 .27 .31 .33 .38 .43 .46 .49 .53 .56 .63 .67 .70 .74 .78 .85 .905 .96 1.00 1.05 1.11 1.16

Parts Acid Required 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

b. Charged and Wet Batteries - Charged and wet batteries are shipped with cells filled and fully charged. Prepare these batteries for use as follows:

PROPER EYE AND BODY PROTECTION MUST BE WORN AT ALL TIMES WHEN SERVICING THE BATTERIES TO PREVENT ELECTRICAL SHOCK AND CONTACT WITH THE BATTERY ACID. CLEAN AND NEUTRALIZE ANY ACID SPILLS IMMEDIATELY. 1. Examine battery to see if electrolyte has been accidentally spilled. If so, clean and neutralize any spillage with a cloth that has been dipped in a soda solution. Rinse area with clear water.

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2. Remove vent caps and check the electrolyte level in each cell. Take and record the specific gravity reading, electrolyte temperature, and individual open circuit voltage of each cell. Note any irregularities.

3. Check to make sure that all cells are properly connected and that terminal connections are tight. If there are irregularities in the electrolyte levels or specific gravity readings, or if the battery has been in storage for more than 30 days, it should be given a freshening charge (see Paragraph 2-10d).

4. Recheck electrolyte levels after charging and after gassing has stopped. Again take and record specific gravity readings and electrolyte temperatures. If irregularities in electrolyte specific gravity readings still exist, they should be adjusted as described in Paragraph 3-12.

2-5. General Economical and dependable performance from a storage battery depends, to a great extent, upon proper charging. Faulty charging causes a decrease in battery service life and dissatisfaction with its performance. The selection of suitable charging equipment and methods is as important as the application of the correct battery. A mine battery installation is completely satisfactory only when the unit, battery, and charger operate as a smoothly functioning team. This text on chargers is for general information and guidance only. If specific data is required on a particular type of charger, contact the nearest sales representative.

When preparing a battery to be charged, make certain that all points of contact between the charger and the battery are clean to assure good conductivity. Also make certain that the positive terminal of the battery is connected to the positive terminal of the charger and, correspondingly, negative of battery to negative of charger.

PERMANENT DAMAGE TO THE BATTERY OR CHARGER MAY RESULT IF THE BATTERY IS CONNECTED INCORRECTLY. 2-6. Charging Principles Charging, as applied to a storage battery, is the conversion of electrical energy into chemical energy within the cell or battery. This restores the active materials and is accomplished by maintaining a unidirectional current to the battery in the opposite direction to that during discharge. When a cell or battery is said to be charged it is understood to mean fully charged. The type of battery, service condition, time available for charging, and the variation in battery voltages will strongly influence which charging method is best for a particular situation. Normally lead-acid batteries are recharged in 8 hours following a full discharge. However, they can be recharged within other time periods when desirable. A deeply discharged battery will absorb high current rates when the voltage is low. As the charge progresses, the voltage steadily increases until it reaches gassing voltage, approximately 2.37 volts per cell at 77 degrees F. At this point, battery chargers normally reduce charging rates automatically and taper to finishing rates which are used to complete the charge. The battery is fully charged when nearly all of the active material has been converted and when the specific gravity of the electrolyte and cell voltage have reached their maximum or constant values (corrected for temperature), as indicated by similar readings over a two or three hour period.

Batteries used in mine power applications are cycled - they are either being charged or discharged. In most circumstances, batteries are charged after each shift of use, so they are cycled many times during their lifetime. Incorrect charging for only a few cycles will do little harm, but if repeated day after day, the battery's service life will be seriously shortened.

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2-7. Charging Rates Proper charging means charging the battery sufficiently without overcharging, overheating, or excessive gassing. The charge is usually started at high amperage which is known as the starting rate.

Later during the charge, this rate of current flow is reduced to what is called the finishing rate. It is suggested that this finishing rate should not exceed 5 amperes per 100 ampere-hours of rated battery capacity. The starting rate may be as much as four to five times higher than the finishing rate.

Lead-acid batteries should be charged for a sufficient length of time and at a rate which will put back into the battery the same number of ampere-hours removed on discharge, plus approximately 10% additional which is an acceptable, and in fact desirable, overcharge. The specific amount of overcharge depends upon the temperature, age, and history of the battery. In general, it is more harmful to excessively overcharge an older battery, or one which is operating at high temperature, than a new battery or one operating consistently at room temperature. Any charge rate is permissible which does not produce excessive gassing or cell temperatures greater than 110 degrees F. 2-8. Control of Gassing Gassing is the evolution of gases from one or more of the electrodes during electrolysis. It is a natural phenomenon which takes place when a battery on charge can no longer accept all of the current being applied to it. Gassing is evidenced by bubbling of the electrolyte. The gases liberated are oxygen (evolved at the positive plates) and hydrogen (evolved at the negatives).

The point at which significant gassing begins is determined by voltage, but the amount of gas depends upon the portion of the charging current that is not being absorbed by the battery. Normally, noticeable gassing will begin when the voltage exceeds 2.30 volts per cell. At 2.40 volts per cell, gassing will be normal; at 2.50, it will be rapid. The amperage at which gassing becomes excessive depends primarily upon the state of charge and electrolyte temperatures. As the battery approaches full charge, it is necessary to reduce the charging rate to a point at which excessive gassing is prevented. This safe rate is the finishing rate or below. When proper charging equipment is used, the tapering of the charging current to the finishing rate is achieved automatically.

2-9. Charging Methods and Equipment The modern storage battery, used with a properly designed, modern, automatic charger, needs only normal water additions, occasional cleaning, and regular checking of both charger adjustment and battery condition to provide long, dependable service.

There are two recommended methods for the normal charging of motive power batteries: a. Modified Constant Voltage (potential) Method - The modified constant voltage method, in which the tapering of the charging rate is accomplished gradually, requires a source of direct current with a constant bus voltage of approximately 2.63 volts for each cell. This is for an 8-hour charge. Proper series resistance in the output circuit inherently provides the correct starting rate and assures that the rate will automatically be reduced, as the charge progresses, to the recommended finish rate. The constant voltage source may be either a motor-driven generator or rectifier. b. Taper Method - The taper method can be used with either generator or rectifier type equipment. The charger is designed to provide the correct charge rate during a constantly tapering charge. This is accomplished by coordinating the rising battery voltage with the design characteristics of the charger.

The shape of the current-taper curve will vary with different types of equipment, but the result is essentially the same. Solid state chargers are available which deliver as much current as the battery can accept, up to maximum charger output, and then taper the input sharply, when cells begin to gas, to keep finish rates low. These chargers do not require adjustment.

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2-10. Types of Charge a. Normal Charge - The two generally recommended types of normal or routine charges, following a deep discharge, are: (1) modified constant voltage charge, and (2) taper charge. b. Boost Charge (Quick Charge) - A boost charge of a storage battery is a partial charge, usuallly at a high rate for a short period. Such a charge is given in an emergency when it is believed that the amperehour capacity of the battery may be less than normal and insufficient to complete a planned period of work. A boost charge may also be used when it is not possible to give a battery one of the recommended types of normal charge. c. Equalizing Charge - An equalizing charge of a storage battery is a prolonged charge, usually at the finishing rate or less, to correct any inequalities of voltage or specific gravity which may have developed between cells during service. It consists of following a normal charge with an extended charge of 4 hours at a rate no higher than the finishing rate. In mine power applications, a battery should receive an equalizing charge weekly. d. Freshening Charge - A freshening charge of a storage battery is a charge given to batteries in storage or during inactive periods to replace losses due to self-discharge and to assure that every cell is periodically brought to a fully charged state.

2-11. Charging Precautions 1. When connecting the battery to the charger always connect positive (+) to positive and negative (-) to negative terminals.

2. Always recharge the battery as soon as possible after discharging.

3. Keep vent caps tightly in place while the battery is being charged, except when servicing the cell or when taking specific gravity or temperature readings.

4. Make sure that battery and charger voltages and ampere-hour ratings match when preparing to charge batteries.

5. Make certain that charging area is well ventilated.

6. Prohibit smoking and open flames in charging area.

7. Do not allow tools or other metal objects to contact intercell connectors.

8. Observe safety and health practices defined in Chapter 4, Section 11. It is especially important, while preparing for charging, to take the following precautions: (1) Wear protective gear provided and know the location of fresh water for emergency purposes.

(2) Use proper mechanical equipment to move or lift batteries.

(3) Provide acceptable fire extinguishing equipment.

Section II. Routine Maintenance 2-12. General

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The modern industrial battery is designed and built to give an average of 1500 cycles of charge and discharge during its life, depending upon the application and the operating environment. The exact length of the service life will depend, to a great extent, upon the care the battery receives. The following maintenance procedures, carried out at the proper time, will do much to prolong the life of the battery and provide efficient, satisfactory service.

PROPER PROTECTIVE CLOTHING AND EQUIPMENT MUST BE USED WHEN SERVICING BATTERIES TO PROTECT AGAINST ELECTRICAL SHOCK AND BATTERY ACID. BATTERIES, CHARGERS AND RELATED ELECTRICAL EQUIPMENT SHOULD ONLY BE SERVICED BY QUALIFIED, PROPERLY TRAINED PERSONNEL. 2-13. Charger Adjustment Make sure that the charger adjustment, for control of charging rates and cut-off, are correct. This will ensure that the batteries are properly charged with no excessive overcharge. Batteries that are overcharged regularly will need water more often, and cell temperatures usually will be higher than normal. If either condition is evident, adjust the charge rate downward, in those chargers which have provision for adjustment, so it is between a normal finish rate and one-half normal finish rate.

2-14. Cleaning a Battery Inspect the battery at least once each month to make certain the terminal connections are tight.

Remove dirt or electrolyte accumulation from the tops of the cells. Wash weekly with clean water. Using a solution of baking soda and water (one pound of baking soda to one gallon of water), neutralize any acid which may be collected at cell or battery terminals to keep them free from corrosion.

Use the solution until all fizzing stops. Work the solution under the connectors. To remove all traces of soda solution and loose dirt, rinse the battery down with clear water from a low pressure hose.

Whenever the battery top is being cleaned or rinsed, vent caps must be tightly in place.

2-15. Adding Water A certain amount of water loss in cells is normal and it should be replaced with "pure" tap water or distilled water. In some geographical areas, tap water may contain chemicals or other impurities harmful to batteries. The NEMA recommendation for battery replacement water lists the following maximum allowable impurities (parts per million): Total Solids Chlorides as CI Nitrates as NO 3 Iron as Fe

350 PPM 25 PPM 10 PPM 4 PPM

DBT AMERICA INC. PROVIDES WATER ANALYSIS SERVICE. A MINIMUM OF ONE QUART IS REQUIRED. CONSULT YOUR SALES REPRESENTATIVE.

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Check the height of the electrolyte at least weekly and if water is needed, add just enough to bring the electrolyte to proper level. Do not overfill. Batteries should be watered only when discharged and only cover plastic plate with holes - never any higher.

Add water often enough to prevent the electrolyte level from dropping below the perforated separator protector. Ideally, a watering schedule should be established. This schedule should assure adequate watering while taking into consideration those factors which control water consumption, such as (1) frequency of charging, (2) water storage capacity of the specific cell type, and (3) age and condition of the battery.

2-16. Taking Hydrometer Readings 1. With the tip of the hydrometer immersed in the electrolyte, squeeze the syringe bulb and then slowly release it, drawing into the cylinder or barrel just enough electrolyte to permit the hydrometer float to ride free. The float stem must not touch the side of the cylinder nor the top of the syringe. If the float stem touches the upper area of the syringe, too much electrolyte has been drawn up; if the float still rests on the bottom, too little electrolyte has been drawn up. (See Figure 3.)

2. Read the hydrometer float scale with your eye at the same level as the electrolyte. The reading should be taken at the surface of the liquid, disregarding any slight curvature. This reading will be the specific gravity uncorrected for temperature. (See Table 3 for correction factors.)

3. Return all electrolyte to cell.

2-17. Record Keeping Facilities with more than just a few batteries will find that records of battery cycles, maintenance, and repair are indispensable for an effective battery maintenance program. In addition to those monthly records which require the posting of data each time a battery is charged, the following procedure will be helpful: 1. Establish a battery identification system giving each battery a code number. A multiple-digit system is suggested.

2. Record specific gravity of the pilot cell or cells before and after each charge. Pilot cells should be selected from those nearest the center of the battery and identified by differently colored vent caps.

They should be representative of the balance of the cells in the battery.

3. Record the number of cycles on a cumulative basis plus maintenance and repair information. Note any irregularities. The use of a "Battery Cycle and Maintenance Record" form is recommended. If variations in specific gravity readings exceed 20 points (.020) and on-charge voltage, after an equalizing charge, varies by more than .15 volts, contact your DBT AMERICA INC. service representative.

4. When the battery is new, and on at least an annual basis thereafter, read and record the specific gravity and open circuit voltage for all cells of the battery.

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FIGURE 3 – TAKING HYDROMETER READINGS

TABLE 3 SPECIFIC GRAVITY TEMPERATURE CORRECTION CHART Electrolyte Temperature (Degrees Centigrade)

Electrolyte Temperature (Degrees Fahrenheit)

Point Correction

110 107 104 101 98 95 92 89 86 83 80 77 74 71 68 65 62 59 56 53 50 47 44 41 38 35 32

230 221 218 212 209 203 198 194 185 180 176 171 167 158 152 149 140 135 131 128 122 118 113 104 99 95 86

+11 +10 +9 +8 +7 +6 +5 +4 +3 +2 +1 No Correction -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15

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CHAPTER 3 – FIELD SERVICING AND REPAIR Section I. Troubleshooting 3-1. General In addition to the required routine maintenance described in Chapter 2, Section III, storage batteries may, at some time during their service life, require more extensive or unusual care. Such care should be given as soon as it has been determined that a problem exists or that trouble may be developing. This section deals with the means of identifying existing or impending problems and offers possible solutions.

The Troubleshooting Chart, Table 4, defines the most common problems which could occur during a battery's lifetime. If the suggested operational remedies are ineffective, it may be assumed that there is an internal problem and it will be necessary to disassemble the cell or cells to inspect the elements and sediment well. If the cause of the problem can only be corrected by completely replacing cells or the battery, this information should be reported to the person in authority.

3-2. Restoring a Sulfated Battery Continued undercharging a battery, even to a small degree, leads to excessive "sulfation." The same is true of batteries which have been left standing in an uncharged state for an extended period. High temperatures rapidly accelerate sulfation when batteries are left standing in a partially charged condition.

The cells of a sulfated battery will give low specific gravity and voltage readings. The battery will not become fully charged after a single normal charging when sulfation has taken place over a prolonged period.

If the sulfation has not progressed too far, it may be possible to restore the battery to a serviceable condition by using the following special procedures: 1. Thoroughly clean the battery. (See Paragraph 2-14.)

2. Bring the electrolyte level up to a point which is just visible over the separator-protector by adding approved water.

3. Put the battery on charge at the prescribed finishing rate until the rated ampere-hour capacity has been returned to the battery. Record the voltage and specific gravity readings. Correct the specific gravity readings for temperature by using Table 3. If the temperature at any time during these procedures exceeds 110 degrees F., stop the charge and allow the battery to cool to 90 degrees F. or below before continuing. Charge the battery until the specific gravity shows no change during a 4 hour period while taking hourly readings. With automatic charging equipment, the battery may have to be placed on equalizing charge two or three times. If a battery is badly sulfated, the specific gravity may rise only 30 to 40 points (.030 to .040) during the first charge.

4. Place the battery into service and discharge it to a fully discharged condition.

5. Charge the battery again until the specific gravity shows no change during a 4 hour period.

6. Repeat the cycling process until the specific gravity rises to within 30 points of a normal fully charged battery, then place the battery back in routine service. Even though specific gravities may be lower than normal, they should not vary much from cell to cell. If they do, problems other than sulfation may be present. If the spread between the highest and the lowest gravity reading is 50 points or more, refer to the Troubleshooting Chart for help in identifying the problem. If the battery still has not responded to treatment, it should be replaced.

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3-3. Correcting Excessive Self-Discharge While a storage battery is in a charged state, a local electrochemical reaction takes place within the cells, which causes very gradual discharging. This reaction is known as self-discharge. A small amount is quite normal in mine power batteries where grids are made from antimonial lead. The rate of selfdischarge is temperature-related and increases significantly as temperatures rise. Table 4 shows the relationship between temperature and loss of specific gravity. The normal rate at 77 degrees F. to 80 degrees F. is a loss in specific gravity of about one point (.001) per day. This becomes of concern only when a wet battery is to be stored for weeks at a time. It can be ignored as a factor in normal battery operation.

It is possible, however, particularly during the latter stages of a battery's life, for the rate of discharge to become much greater and even limit the battery's duty cycle. Excessive self-discharge may be caused by defective separators or plates which have become shorted at the edges. Edge shorting is usually caused by loss of positive active material which can fill the sediment well or build up on the top or sides of the plates and eventually bridge the space between the positives and negatives. If a shorted condition seems likely, the element should be pulled for examination and the defective separator replaced, shorts cleared, or cells replaced. Usually, if the sediment well is full, salvage is impractical.

3-4. Test Discharge A capacity test is sometimes desirable to determine a battery's actual discharge capability as compared to its 6-hour rated capacity.

This can be a significant diagnostic tool when equipment does not operate as expected and it can help determine when the battery should be replaced. When a battery consistently delivers less than 80% of its rated ampere-hour capacity, either some cells are substandard or the battery has reached the end of its useful life and should be replaced.

A test discharge is performed by discharging a fully charged battery at a fixed rate under carefully controlled test conditions.

Section II. Repairing Batteries 3-5. General Storage batteries which have been damaged or which contain defective cells may, if the rebuilding cost and time are justified, be restored to a serviceable condition.

It is important to check a battery thoroughly if it has been involved in an accident or if it is believed to be defective. A neglected battery will continue to deteriorate even when not in use. Usually rebuilding is justified if the majority of the cells are in good condition.

This section explains how to remove cells from a battery and how to repair them if they are to be salvaged. Some special tools and parts will be required, depending upon the work to be done.

Reference will be made to the use of such special devices but they will not be further identified in this manual. Each manufacturer identifies all tools, accessories, and replacement parts by an appropriate part number. Use this number when making reference to them.

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Before starting any repairs, remove all vent caps from cells to be repaired as well as from all surrounding cells. The space above the electrolyte must be cleared of hydrogen gas before proceeding with repairs. Introduce a low volume air stream (volume and force equal to that produced by fanning each cell with a stiff piece of cardboard or other suitable nonconducting material) into each cell for at least 30 seconds. Be very careful when using air so that the electrolyte is not splashed out of the cell. Do not blow breath into cells. Wear protective face shield or goggles, rubber gloves, and apron. After cells have been purged, cover all vent openings with several layers of water-dampened cloth before starting repairs.

3-7. Removing lntercell Connectors Special intercell connector drills are designed to cut the bond between the cell post and the connector while permitting the post to remain for later rebuilding. The drills come in different sizes. When using them, be careful to cut only as deep as necessary, usually 1/4" to 3/8". Make certain vent plugs are in place. During drilling, try to center on the cover bushing and make sure any lead curl produced does not short across other connectors. After drilling, the intercell connectors can be lifted off with a pair of pliers.

3-8. Removing a Complete Cell After removing connectors as described in Paragraph 3-7, isolate the cell from adjacent cells. This may require cutting of compound or removal of spacers. Use a long spatula or similar tool to free the cell from top to bottom. When the jar walls are free, the cell can be lifted from the battery tray. All cells are heavy so a suitable lifting device, such as an electric hoist, is recommended. Threaded post clamps or cell pullers are available which can be burned or clamped to the posts, and used to pull the cell. Use a non-conducting bar between the loops of the post clamps and hook the hoist to this bar.

After removing the cell, neutralize any acid in the tray with a soda solution and clean up the residue.

When a cell or element is being pulled, it is advisable to have on hand both a replacement jar and a cover in the event that either of the original parts are damaged in the process.

If a wet and charged cell has been pulled and allowed to stand unsupported, the jar walls may bulge and permit the electrolyte level to drop. Do not attempt to adjust electrolyte levels until cells have been reinstalled in the battery.

TABLE 4 TEMPERATURE EFFECT ON BATTERY SELF-DISCHARGE Temperature (Degrees Fahrenheit)

Loss of Specific Gravity Per Day

120 100 80 50

.004 .003 .001 .0005

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TABLE 5 STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

BATTERY OVERHEATS DURING CHARGE

1. Malfunctioning charging equipment.

1. Replace or repair defective charger parts (timer, voltage sensitive relay, control board, etc.)

2. Charging equipment out of adjustment.

2. Adjust start or finish charging rates.

3. Defective or weak cell(s).

3. Replace or repair problem cell(s).

4. Battery worn out and beyond economical repair.

4. Replace battery.

5. High resistance connection within battery.

5. Check for hot wires, cells, intercell connectors, charging plugs, etc. Repair or replace defective component(s).

6. Low electrolyte level.

6. Add water; Just cover separator protector when discharged.

7.Battery charged in the vehicle with battery compartment closed or the tray cover closed.

7. Open the compartment during charge or charge the battery out of the unit with the tray cover opened.

8. Battery over 100 degrees F. when placed on charge.

8. Allow battery to cool below 90 degrees F. before charging.

1. See causes 3 through 8 above.

1. See remedies 3 through 8 above.

2. Worn out bearings, brakes dragging, or other vehicle problem causing high current draw.

2. Repair or replace defective unit problems.

3. Over discharge of battery.

3. a. Require drivers to return battery for recharge when vehicle begins to slow down.

BATTERY OVERHEATS DURING DISCHARGE

b. Put more batteries into service.

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TABLE 5 (Continued) STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

BATTERY NOT COMPLETING FULL WORK SHIFT

1. Battery not fully charged before placed into operation.

1. See that battery has reached full charge specific gravity before placing into operation.

2. Weak, leaking, or defective cell(s) in battery.

2. Repair or replace cell(s) or battery.

3. Grounds or shorts in the battery.

3. Remove grounds or shorts.

4. Battery worn out and beyond economical repair.

4. Replace battery with equal or higher capacity battery.

5. Battery too small for job.

5. a. Replace battery with one having higher capacity. b. Purchase extra batteries (with higher capacity if possible) and change them more frequently.

LOW ELECTROLYTE

6. Electrical or mechanical problem.

6. Troubleshoot vehicle and repair.

1. Cracked or broken jar(s).

1. Replace jar(s) and adjust gravity.

2. Cell missed when watered.

2. More careful attention when watering.

3. Defective or weak cell(s).

3. Repair or replace cell(s)

4. Frequent overcharge.

4. See items 1 and 2 in “Battery Overheats During Charge.”

5. Battery not regularly watered.

5. Water battery regularly.

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TABLE 5 (Continued) STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

UNEQUAL CELL VOLTAGES

1. Grounds in battery.

1. Clean battery.

2. There is a “tap” off the battery for auxiliary equipment (radio, light, etc.)

2. a. Use dropping resistor instead of tap. b. Equalize battery regularly.

3. Battery sluggish due to lack of work.

3. Give battery a deep discharge and equalizing charge.

4. Leaking cell or cover.

4. Replace jar or cover and adjust gravity.

5. Defective or weak cell(s).

5. Repair or replace defective cell(s)

6. Battery worn out beyond economical repair.

6. Replace the battery.

7. Acid loss in few cells by tipping battery over.

7. Adjust specific gravity.

3-9. Removing an Element If the jar is known to be serviceable, it may not be necessary to remove the complete cell. Usually only the element, complete with cover, has to be pulled. This can only be done, however, on those batteries containing a compound type cover-to-jar seal. On these, after removing connectors, draw a warm putty knife through the sealing compound close to the inside jar wall. Use a threaded post clamp or cell puller and hoist to raise the element, with cover in place, first to drain position, and then up and out of the jar.

When pulling an element from a cell which has been removed from a battery, use jar hold-down clamps.

Some batteries are furnished with permanent seals between the cover and jar. With these, if a defect occurs, the complete cell must be pulled and cover-to-jar seal cut or sawed to permit removal of the element. In doing so, both jar and cover must be replaced and resealed in accordance with the correct instructions.

When removing an element, lift it halfway out of the jar and hold it at this position until most of the electrolyte has drained off. Then raise the element to clear the top of the jar. Do not, unless absolutely necessary, expose an element to air longer than five minutes. Oxygen in the air combines with the active material in the negative plates, causing them to oxidize and heat. If the exposure persists, negatives will 30

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discharge. While the element is out of the jar, check the sediment well in the bottom of the jar. If it is full of shed material, the cell probably will have to be replaced.

Plate and separator edges may be inspected while the element is suspended above the jar. A more thorough inspection of separators, plate insulation, grids, and active materials may be indicated. If so, lay the element on its side on a clean non-metallic surface. The plates should be at right angles to the table surface so the element can be fanned slightly to permit the removal of separators. Always on negative side.

When reinstalling separators, make certain that the flat side of the separator is against the negative plate and the ribbed side is facing the positive. They should be pushed up until they are flush with the bottom of the element and they should project equally on each side of the plates.

Before installing an element in a previously used jar, wash out any sediment which may have accumulated in the bottom of the jar and clean all compound from around the inside of the top edge.

Clamp the element, if necessary, when reinstalling it in the jar. Make certain that the element is entering the jar properly and that the plates are at right angles to the plate support ribs in the bottom.

When installing an element with a cell cover attached, use a putty knife to guide the lip of the cover past the top edges of the jar.

3-10. Replacing Cell in Battery Cells from which the elements were pulled, or which had damaged jars replaced, should be given an equalizing charge and acid should be adjusted immediately followinging repair before they are returned to service. (See Paragraphs 2-10c and 3-12.)

Before lowering a cell into a battery tray, be sure that it is correctly positioned relative to adjoining cells to which it is to be connected. Cells must be connected in series with the positive side of one cell connected to the negative side of the adjacent cell.

When the problem has been corrected and the cell is returned to the battery tray, the cover must be resealed to the jar. With the exception of those cells which contain a permanent jar-to-cover seal, a special asphalt type sealing compound is used for this purpose. Heat the compound until it melts, but do not let the temperature get above 400°F. Pack any large openings between cover lip and jar wall with cold compound and then pour the hot compound into the sealing groove in two steps. First pour the groove full and soft flame with a torch to improve the adhesion; then fill and flame again. Allow compound to cool and trim excess.

After sealing, pressure test cells for 10 seconds at a maximum of 1.5 psi and reinstall intercell connectors by welding or "burning" them to the terminal posts. A small hot flame is recommended such as is available from a standard commercial burning torch using natural gas and oxygen or propane and oxygen. Carbon burning outfits are also acceptable.

ALWAYS BE SURE THE CELLS ARE PURGED OF GAS, AS EXPLAINED IN PARAGRAPH 3-6, BEFORE USING AN OPEN FLAME OR BURNING ARC ON TOP OF THE BATTERY. 3-11. Replacing a Cell Cover The specific methods used to seal cell covers to both the jar and the terminal posts are as follows:

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a. Sealing Compound and Lead Bushing Design - Probably the most commonly used system, an asphalt type compound is applied to seal the cover to both rubber and plastic jars. Lead bushings, molded into the cover as inserts, are welded or "burned" to the terminal posts to prevent electrolyte leakage around the posts. When replacing a cover of this type, first cut the compound with a warm putty knife. Cut the full depth of the cover adjacent to the jar wall from corner to corner on each of the four sides. Since reuse of covers which have been removed from the element is not recommended, use a post trimmer to cut off the post extensions above the cover. Break the lead bond between post and lead insert by driving the cover down approximately 1/32". The lead insert mold placed over the post and tapped with a hammer serves this purpose. Insert a hook through the vent opening and lift the cover off. Remove all sealing compound adhering to jar wall and neutralize these surfaces and upper portion of all terminal posts, using a cloth moistened with a soda solution. Thoroughly dry all of the neutralized surfaces. Install the new cover, complete cover-to-jar seal, and reburn cell connectors as described in Paragraph 3-10. b. Epoxy Seal and Seal Nut Design - This is one of the newer systems which employs an epoxy or permanent, hard seal between cover and jar. To disassemble a cell of this design requires that the jar be cut and that both jar and cover be replaced. When reassembling with a new jar and cover, it is very important to adhere to the following procedure to obtain an effective seal: 1. Epoxy can be used only on rubber jars and covers.

2. Thoroughly clean cover and jar sealing areas first with xylol (xylene), then with isopropyl alcohol; use a separate cleaning cloth for each.

3. Caulk bottom of seal groove with glass cord. Tamp corners in. Make overlap small. Do not use warm compound with epoxy.

4. Use special epoxy sealant as recommended by the battery manufacturer. Follow instructions provided.

5. Apply epoxy in two pours. Make second pour within two hours after first pour. Fill to top of jar. Do not overfill.

6. Pressure test seal after three hours or more from time of final pouring. Pressure test to 1.5 psi for 10 seconds. d. Heat Bonded Plastic Cover-to-Jar Seal and Lead Bushing Design - This is the newest of the sealing systems used with motive power batteries. To disassemble a cell of this design also requires that the jar be cut and both jar and cover be replaced. The seal between jar and cover is, in effect, a plastic weld. It can only be used with jars and covers made from identical plastic molding material.

Since special techniques must be used when resealing these covers, the battery manufacturer recommends that these cover-to-jar seals not be repaired in the field. Manufacturers' instructions request that such repairs be made in their service stations only.

3-12. Adjusting Specific Gravity of Electrolyte Fully charged cells usually operate at a specific gravity between 1.280 and 1.295. Normally it should never be necessary to adjust the gravity, but upsets, jar breakage, additions of too much water, and careless use of hydrometer can result in electrolyte loss and possible reductions of battery capacity. Lost electrolyte must be replaced but only after it has been determined that charging will not restore the gravity to normal when at the recommended level.

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Therefore a cell or battery should first be given an equalizing charge as described in Paragraph 2-10c.

Never make a gravity adjustment on a cell which does not gas vigorously while on charge.

If, after the equalizing charge, the specific gravity of any cell, corrected for temperature, is lower than normal, it should be adjusted in the following manner: 1. Put battery back on charge at the finish rate until cells are actively gassing to provide proper mixing.

2. Remove electrolyte from the low reading cells until level reaches separator protector.

3. Slowly add 1.400 specific gravity sulfuric acid to the cell while it is still gassing.

4. Wait 15 to 20 minutes for the added acid to become thoroughly mixed, then read the specific gravity. If it is still low, repeat the process until gravity is normal. As a guide, every 1/4" of electrolyte that has been removed and replaced by 1.400 acid will cause the specific gravity to rise 4 to 5 points (.004 to .005).

If the corrected specific gravity of any cell is higher than normal, proceed as follows: 1. While the battery is gassing on charge, withdraw from the cell a small amount of electrolyte and replace with approved water.

2. Repeat, if necessary, at 20 to 30 minute intervals until the desired reading is obtained. Every 1/4" of electrolyte which is replaced with water will cause the specific gravity of the cell electrolyte to drop 4 to 5 points (.004 to .005).

NEVER ADD ACID WITH A SPECIFIC GRAVITY HIGHER THAN 1.400.

STRONGER ACID COULD PERMANENTLY DAMAGE THE CELL. WHEN MIXING OR CUTTING ACID, ALWAYS ADD THE ACID TO THE WATER. NEVER POUR WATER INTO ACID. A VIOLENT REACTION COULD RESULT WHICH MIGHT CAUSE PERSONAL INJURY. WHEN WORKING WITH ACID, ALWAYS USE A FACE SHIELD OR GOGGLES, RUBBER GLOVES, AND AN ACID RESISTANT APRON.

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CHAPTER 4 – HEALTH AND SAFETY Section I. Battery Hazards 4-1. General A lead-acid battery can be very useful, safe source of electrical power. While installing, using, maintaining, or repairing a motive power battery, opportunities exist, however, for exposure to potentially dangerous situations. This section identifies those hazards which could result from improper handling or use.

4-2. Hazards a. A sulfuric acid solution is used as the electrolyte in lead-acid batteries and has a concentration of approximately 37% by weight of sulfuric acid in water. In this diluted state, it is not as hazardous as strong or concentrated sulfuric acid, but it acts as an oxidizing agent and can burn the skin or eyes and destroy clothing made of many common materials such as cotton or rayon. b. An explosive mixture of hydrogen and oxygen is produced in a lead-acid battery while it is being charged. The gases can combine explosively if a spark or flame is present to ignite them. Because hydrogen is so light, it normally rises and diffuses into the air before it can concentrate in any explosive mixture. If it accumulates into gas pockets, as can occur within a cell, it might explode if ignited. c. Electricity is produced by the batteries on discharge and, while most persons cannot "feel" voltages below 35 to 40 volts, all mine power batteries should be regarded as potentially dangerous. A lead-acid battery is capable of discharging at extremely high rates and, under conditions of direct shorting, can cause damage and serious injury. d. The weight of these heavy batteries can easily cause painful strains or crushed hands or feet if improperly lifted or handled. Batteries can be damaged if dropped. The average mine power battery weighs more than one ton, so proper equipment must be provided when changing or handling batteries. e. Burns can result from contact with molten lead or hot compound while repairing a battery. Lead can splash when intercell connectors are being reburned and hot compound can be spilled when resealing covers to jars. The protective gear provided, if worn, will prevent such burns.

Section II. Safety Procedures 4-3. Federal Standards In 1970, Congress passed the Occupational Safety and Health Act (OSHA). This act established the minimal acceptable standards for safe and healthful working conditions. The safety procedures suggested in this manual have been compiled from standards developed over the years by professional and technical organizations and by battery manufacturers and users. Experience has shown them to be the most effective safety standards. In all cases, they exceed the minimum standards of OSHA for personal safety and include procedures for safeguarding equipment as well.

The safety procedures have been grouped by functional area of most logical application or need.

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4-4. Safety Procedures While Handling Batteries 1. Lift batteries with mechanical equipment, such as an overhead hoist, crane or lift truck. A properly insulated lifting beam, of adequate capacity, should always be used with overhead lifting equipment. Do not use chains attached to a hoist at a single central point forming a triangle. This procedure is unsafe and could damage the steel tray.

2. Always wear safety shoes and safety glasses.

3. Tools, chains, and other metallic objects should be kept away from the top of uncovered batteries to prevent possible short circuits.

4. Battery operated equipment should be properly positioned with switch off, brake set, and battery unplugged when changing batteries or charging them while in the equipment.

5 Personnel who work around batteries should not wear jewelry made from a conductive material.

Metal items can short circuit a battery and could cause severe burns.

6. Only trained and authorized personnel should be permitted to change or charge batteries.

7. Reinstalled batteries should be properly positioned and secured in the unit. Before installing a new or different battery, check both the unit nameplate and battery service weight to make sure that the proper weight battery is being used. A battery of the wrong weight could change the center of gravity and cause equipment to upset.

4-5. Safety Procedures While Charging Batteries 1. Specific areas should be designated for charging batteries.

2. Charging areas should be adequately ventilated. The actual amount of ventilation will depend upon such factors as number and size of batteries being charged at the same time, room size, ceiling height and air-tightness of the building. Hydrogen concentrations above 4% can be explosive.

3. Smoking, open flames, and sparks should all be prohibited in the charging area. Post placards "Hydrogen," "Flammable Gas,” “ No Smoking," and "No Open Flames."

4. Facilities should be provided for flushing and neutralizing spilled electrolyte, for fire protection (including hand-operated fire extinguishers), and for protecting charging equipment from damage by units.

5. Fresh water should always be available in case electrolyte is splashed on skin, clothing, or into eyes. The kinds of equipment available for eye-wash and acid neutralization vary widely. A squeeze bottle containing a buffering solution for relief of acid burns should be located in the immediate work area. These should be clearly identified and readily accessible.

6. Before connecting a battery to, or disconnecting it from, a charger, the charger should be turned off.

Live leads can cause arcing and pitting of battery connector contact surfaces.

7. Make sure that all electrical connections are tight and mechanically sound to prevent any arcing or loss of power.

8. Wear a face shield or goggles, rubber gloves, apron, and boots when checking, filling, charging, or repairing batteries during periods of possible exposure to acid or electrolyte.

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9. When charging an enclosed or covered battery, always keep the battery tray cover, or compartment cover, open during the charging period. This will help to keep the battery cool and disperse the gases.

10. Keep vent caps in place at all times except while servicing or repairing cells. This minimizes the loss of electrolyte and prevents foreign matter from entering the cells.

11. Shut off and disconnect both input and output connections to the charger before charging equipment.

4-6. Safety Procedures While Handling Acids 1. The splashing of acid Into the eyes Is the most dangerous condition which can be encountered while handling sulfuric acid or electrolyte. If this should happen, the eyes should immediately be gently flooded with clean, fresh, running water for at least 15 minutes, followed as quickly as possible with a physician's examination. If the person is wearing contact lenses, they should be removed before rinsing the eyes.

DO NOT USE A BUFFERING OR NEUTRALIZING AGENT IN THE EYES WITHOUT MEDICAL APPROVAL. 2. Acid or electrolyte splashed onto the skin should be washed off under running water. Battery electrolyte will usually only cause irritation of the skin; if a burn develops, it should be treated medically.

3. When electrolyte is splashed on clothing, use a weak solution of bicarbonate of soda, as soon as possible, to neutralize the acid.

4. A carboy tilter or safety siphon should be provided for handling acid from a carboy container. Use the protective box when moving a carboy. Store acid in a cool place out of the direct rays of the sun. Use only glass, rubber containers, lead, or acid-resistant plastic containers when storing acid or electrolyte.

5. When mixing acid to prepare electrolyte, always pour the acid slowly into the water and stir constantly to mix well. Never pour water Into acid. Never use sulfuric acid solutions which are over 1.400 specific gravity.

6. Apply a neutralizing solution, such as bicarbonate of soda and water, when acid is spilled on floor.

Clean up affected area promptly. A mixture of one pound of soda to one gallon of water is recommended.

4-7. Safety Procedures While Servicing or Repairing Batteries.

1. Disconnect the battery from the unit when servicing or repairing either the battery or the equipment.

Also make certain the battery is disconnected from the charger before handling or repairing the battery.

2. Before repairing a battery, remove all of the vent caps and blow out each cell with a low pressure air hose to remove any residual gas. Use only a gentle stream of air to avoid splashing electrolyte.

Do not blow breath Into cells.

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Bucyrus America, Inc.

3. Open or "break" the circuit before repairing damaged or dirty terminal plugs or receptacles connected to a battery by removing and insulating one terminal lead at a time.

4. When melting sealing compound in preparation for resealing cells, be careful not to puncture the top section of unmelted compound with a screw driver or other pointed object. A build-up of pressure from the melted compound in the bottom could cause liquid compound to squirt and inflict a severe burn. Do not allow compound to ignite by overheating. Compound becomes workable at 400 to 425 degrees F. 5. Check batteries frequently for acid leakage or signs of corrosion.

6. Use insulated tools whenever possible when working on batteries. If possible, also cover the terminals and connectors of a battery with a sheet of plywood or other insulating material to prevent short circuits.

7. When taking specific gravity readings, use a face shield or goggles and read the hydrometer with your eye at about the same level as the electrolyte. Return all electrolyte to the cell.

38

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

CHAPTER 5 – STORAGE AND SHIPMEMT 5-1. General Follow these guidelines for those occasions when batteries must be stored, in either a wet or dry state, and for possible reshipment to other areas.

5-2. Storage Methods a. Charged and Wet Batteries - Lead acid batteries may be stored in a charged and wet (filled with electrolyte) condition when necessary for periods of up to several months. During such periods they should be stored in a clean, cool, dry, and well ventilated location away from radiators, hot air ducts, or other sources of heat, and protected from exposure to direct sunlight. Before being stored, the battery should be fully charged and the electrolyte brought to the proper level. Any leads should be disconnected or insulated to prevent accidental discharge. The top of the battery should be protected from dust, foreign matter, and moisture. Do not attempt to dismantle the battery.

If the average storage temperature is 80 degrees F. or higher, the specific gravity of the electrolyte should be checked at least monthly. If below 80 degrees F., check gravities at least every two months.

Whenever the specific gravity, corrected to 80 degrees F., falls to 1.240 or below, the battery should be given a freshening charge as described in Paragraph 2-10d. A freshening charge is also recommended just before returning a battery to service. b. Charged and Dry Batteries - New batteries are often supplied charged and dry (without electrolyte).

Batteries in this condition can remain in storage, unattended, for a period of at least two years. They should be stored in a cool, dry place with vent caps tightly closed. Average temperatures should not exceed 80 degrees F. Batteries should not be stored near radiators, hot air ducts, or other sources of heat, and should be protected from exposure to direct sunlight. The top of the battery should be protected from dust, foreign matter, and moisture. Charged and dry batteries when removed from storage should be activated as described in Paragraph 2-4a.

5-3. Shipment a. Charged and Wet Batteries - Depots or using organizations may make shipments of motive power batteries in a charged and wet condition if intended for use within a period of 90 days. The battery service weight is usually stamped into the steel tray near one of the lifting holes.

Before crating a wet battery for shipment, it should be given a freshening charge as described in Paragraph 2-10d. A tag should be attached to both the battery and the crate showing the date of the last charge and the specific gravity of the electrolyte at the completion of the charge. Make certain that the battery is properly protected when crated. The receiving organization should be alerted also to the need for a freshening charge before the battery is put into service. b. Charged and Dry Batteries - Depots will normally make domestic and export shipments of new batteries which usually will be in a charged and dry condition. Batteries, and the accompanying electrolyte in separate carboys, which are intended for export shipment must be packaged in accordance with approved methods.

WHENEVER BATTERIES ARE REGULATIONS WILL APPLY. 39

SHIPPED

BY

COMMON

CARRIER,

ICC

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

40

Revised 12 – 07 MINE POWER STORAGE BATTERIES

BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS ALWAYS WEAR SAFETY GLASSES AND PROTECTIVE CLOTHING WHEN SERVICING BATTERIES. NEUTRALIZE ANY ACID SPILLS IMMEDATELY. IF ACID CONTACTS ANY PART OF THE BODY, FLUSH IMMEDATELY WITH RUNNING WATER AND SEEK MEDICAL ATTENTION. CARE SHOULD BE TAKEN AT ALL TIMES TO AVOID ELECTRICAL SHOCK FROM THE BATTERY OR CHARGER. THE CHARGER MUST BE TURNED OFF BEFORE CONNECTING OR DISCONNECTING THE LEAD(S) TO THE BATTERY. I.

CHARGING A.

Tray covers should be open during charge.

B.

Be sure charger switch is in “OFF” position.

C.

Check plugs and receptacles to be sure they are clean and in good condition. Connect the charger to the battery.

NEVER CONNECT OR DISCONNECT THE BATTERY AND CHARGER UNLESS THE CHARGER IS TURNED OFF. DAMAGE TO THE PLUGS AND RECEPTACLES WILL OCCUR. ALSO AN ARC WILL BE DRAWN THAT COULD BE A SAFETY HAZARD. D.

Turn switch “ON”, and press “START” to start daily charge. Check ammeter to be sure battery is charging and charger is operating correctly.

E.

Charger is fully automatic and will stop charging when it recognizes a fully charged battery in approximately 8 hours.

F.

Full charge specific gravity reading should be 1.280 to 1.295. Higher readings will result due to low water levels. Do not over water battery as lost acid will result in less work per charge and shorten battery life.

ALL SPECIFIC GRAVITY READINGS ARE BASED ON BATTERY TEMPERATURE OF 25 DEGREES C.

II.

III.

IV.

EQUALIZING CHARGE A.

After the daily 8-hour charge is complete, turn switch “ON” and press “START” (If equipped) for an equalizing charge once per week.

B.

When equalizing charge is completed and automatic electronic timer has turned charger off, read specific gravity of each cell and record. If variations of 10 or 20 points of specific gravity are recorded, call a Bucyrus America, Inc. Technician. If cells show variations of 0.1 or more, call a Bucyrus America, Inc. Technician.

OPERATING INSTRUCTIONS A.

Do not charge or operate in service if temperature of battery reaches 46 degrees C. High temperatures are a result of improper charger adjustments, high discharge rates, over discharging, short cycling, and low water levels.

B.

Keep plugs and receptacles clean and adjusted for tension. If plug is hot, it is not making good contact. Remember the battery has current at all times. Be careful when working on plugs and receptacles.

C.

Vent caps should only be removed to check water level, temperature, and specific gravity, or to add water. Be sure they are in place and tight at all times.

D.

Do not weld, grind or allow sparks or allow flame near battery. Do not allow tools or any other metal to be laid on connector of battery.

E.

Never add anything to the battery except approved water.

F.

Never add acid to battery.

WATERING A.

Add approved water to 1/4” (6.35 mm) below vent well only at the end of charge.

Filling to this level before charging will cause acid overflow. Acid attacks external battery parts. Any acid loss from the battery will result in power loss and shortened life.

B.

Replace vent caps securely.

6.35 mm .63 mm

V.

CLEANING A.

Wash battery at least weekly using soda and water, then rinse with plain water 1 lb. (0.45 kg) soda to 1 gal. (3.78 l) water mixture). Vent caps should be in place when washing battery.

B.

Dirty batteries create grounds, reduce work time, increase battery cost, and shorten life. Correctly charged, watered, and cleaned batteries give longer work time per shift per charge, reduced cost, and longer life.

BUCYRUS AMERICA, INC. HAS COMPLETE SERVICE FOR BATTERIES AND CHARGERS AT YOUR MINE SITE. WE ALSO HAVE COMPLETE BATTERY REBUILD CENTERS FOR QUICK TURNARROUND ON BATTERY AND CHARGER REBUILDS.

P/N A6474X61 Revised 12 – 07 BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS