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

OPERATION AND TROUBLESHOOTING GUIDE MODEL BUCYRUS 2000 DUAL AND SINGLE MOTOR SOLID STATE CONTROLLERS

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. P/N A6474X226 Revision 1, December / 07  BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED

Bucyrus America, Inc. ________________________________________________________________ 4041 Wurno Road Telephone: 540-980-4530 Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.bucyrus.com

Bucyrus America, Inc.

TABLE OF CONTENTS DESCRIPTION

PAGE #

PREFACE ..............................................................................................................................................2 SYMBOLS AND SPECIAL NOTATIONS ..............................................................................................3 MAJOR HAZARDS................................................................................................................................5 SAFETY PRECAUTIONS AND GUIDELINES ......................................................................................6 OVERVIEW ........................................................................................................................................6 MAINTENANCE .................................................................................................................................6 INTRODUCTION ....................................................................................................................................7 BUCYRUS 2000: INNOVATIVE SPEED CONTROL BY BUCYRUS AMERICA, INC........................7 GENERAL SPECIFICATIONS.............................................................................................................12 FAIL-SAFE OPERATION WILL INCLUDE THE FOLLOWING:......................................................12 DESCRIPTION OF FEATURES ..........................................................................................................13 BUCYRUS 2000 MOTOR CONTROLLER CONSIST OF:...............................................................13 BUCYRUS 2000 MOTOR IGBT PANEL (POWER CONNECTIONS) .............................................13 MICROPROCESSOR BASED LOGIC CARD (CONTROL INPUTS) ..............................................13 CONFIGURATION JUMPER TABLE...............................................................................................15 OPTIONAL DASHBOARD DISPLAY FEATURES (SEE FIGURE 9)...............................................15 FAULT MESSAGE CHART..............................................................................................................16 OPTIONAL HAND HELD DIAGNOSTICS/CALIBRATOR UNIT......................................................18 PERSONALITY ADJUSTMENT PROCEDURE ...............................................................................19 TRACTION PERSONALITIES (CONTROLLER ADJUSTMENTS) .................................................19 TRACTION STATUS DISPLAY .......................................................................................................21 TRACTION TEST DISPLAY.............................................................................................................23 TRACTION BDI DISPLAY................................................................................................................24 ERROR CODE LEGEND (STATUS DISPLAY)................................................................................25 TROUBLESHOOTING.........................................................................................................................26 IGBT MEASUREMENTS..................................................................................................................27 INDIVIDUAL IGBT MEASUREMENTS ............................................................................................28 DIODE MEASUREMENTS ...............................................................................................................29 DIODE MEASUREMENTS ...............................................................................................................30 PANEL MEASUREMENTS ..............................................................................................................31 DRIVER MEASUREMENTS.............................................................................................................32 IGBT DUAL MOTOR PANEL, FIGURE 16 .......................................................................................34 IGBT SINGLE MOTOR PANEL,FIGURE 17 ....................................................................................35 IGBT HEAT SINK ASSEMBLY, FIGURE 18 ....................................................................................36 SINGLE MOTOR PANEL HARNESS ASSEMBLY, FIGURE 19......................................................37 DUAL MOTOR PANEL HARNESS ASSEMBLY, FIGURE 20 .........................................................38 DASHBOARD DISPLAY, FIGURE 21..............................................................................................39 DUAL "Y" HARNESS, FIGURE 22...................................................................................................40 HARNESS FOR DASHBOARD DISPLAY, FIGURE 23 ...................................................................41 CALIBRATOR UNIT, FIGURE 24.....................................................................................................42 BUCYRUS 2000 PUMP MOTOR SHUNT, FIGURE 25 ....................................................................42 BUCYRUS 2000 PANEL WIRING HARNESS, FIGURE 26 .............................................................43

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

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PREFACE This manual is intended to provide GENERAL operating and service procedures for the Bucyrus 2000 motor vehicle solid-state controller. The illustrations, descriptions and procedures contained in this publication apply only to Bucyrus 2000 motor vehicle solid-state controllers. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Bucyrus 2000 motor vehicles solid-state controller 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 Bucyrus 2000 motor vehicles solid-state controller 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 controller, 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 controller 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 controller.

While this manual attempts to anticipate the most important operations and maintenance needs for this controller, 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.

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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 POINTS IN THE TEXT MARKED WITH THIS SYMBOL DRAW YOUR ATTENTION TO IMMEDIATELY IMPENDING DANGER INCLUDING ELECTRICAL DANGERS. POSSIBLE CONSEQUENCES ARE: VERY SERIOUS INJURY, DEATH OR DEATH BY ELECTROCUTION.

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DANGER ONLY TRAINED AND/OR AUTHORIZED PERSONNEL SHOULD PERFORM MAINTENANCE ON THE CONTROLLER. FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH. FAILURE TO MAINTAIN THIS CONTROLLER IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

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MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

MOTORS AND CONTROLLER

Electrical shock could cause irreparable injury or death.

All electrical systems should be maintained by certified electricians.

The battery should be disconnected before servicing the motors or controller. When the controller cover is removed, wait for one minute for the capacitors to discharge.

BATTERY

The battery produces lethal amounts of power whether connected to the machine or charger, or not.

The battery should be maintained by qualified personnel. (Refer to Bucyrus America, Inc. "INSTALLATION, USE, MAINTENANCE, AND REPAIR OF MINE POWER STORAGE BATTERIES,” PART NUMBER A6474X26, for complete instructions).

Battery covers could fall crushing hands or arms.

Be sure cover supports are in place when working on battery.

Battery hold-down clamps could crush fingers or hands.

Keep fingers and hands away from hold-down clamps.

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.

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.

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SAFETY PRECAUTIONS AND GUIDELINES Overview Before you test, troubleshoot, service or in any other way, use this unit READ and STUDY this guide. KNOW 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 unit in congested areas.

AVOID, whenever possible, servicing or providing maintenance to the unit unless the wheels are adequately choked. If the drive motor (s) is to be run, the unit must be jacked clear of the ground and all four (4) wheels must be free to turn.

DO NOT alter the electrical settings from that indicated in this guide or as set at the factory.

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 working with electrical systems, or when welding on the unit to prevent electrical shock.

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 photographs and illustrations in this guide may show guards or covers removed for purposes of clarity. Never operate unit without all guards and covers in place.

SOME PHOTOGRAPHS OR ILLUSTRATIONS IN THIS GUIDE MAY SHOW PROTOTYPE UNITS OR UNITS WITH OPTIONAL EQUIPMENT INSTALLED THAT MAY OR MAY NOT BE ON YOUR PARTICULAR MACHINE. PRODUCTION MODELS MAY VARY IN SOME DETAIL. OPTIONAL EQUIPMENT MAY BE PURCHASED FROM BUCYRUS AMERICA, INC. CONTINUING IMPROVEMENT AND ADVANCEMENT OF PRODUCT DESIGN MAY CAUSE CHANGES TO YOUR MACHINE WHICH MAY NOT BE INCLUDED IN THIS PUBLICATION. EACH PUBLICATION IS REVIEWED AND REVISED, AS REQUIRED, TO UPDATE AND INCLUDE THE CHANGES IN LATER ADDITIONS. BUCYRUS AMERICA, INC. RESERVES THE RIGHT TO MODIFY OR MAKE CHANGES WITHIN A SPECIFIC MODEL GROUP WITHOUT NOTICE AND WITHOUT INCURRING ANY LIABILITY TO RETROFIT UNITS PREVIOUSLY SHIPPED FROM THE FACTORY. CONTACT YOUR BUCYRUS DEALER FOR MAINTENANCE THAT IS NOT COVERED IN THIS PUBLICATION. 6

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INTRODUCTION BUCYRUS 2000: Innovative Speed Control by Bucyrus America, Inc. FIGURE 1 – SIMPLIFIED BUCYRUS 2000 CIRCUIT

In the early 1970's, S&S Corporation lead 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 utilize an electromechanical "bypass" contactor to connect the motor directly to the batteries which caused more contactor problems.

In the 1980’s Bucyrus America, Inc., 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 SCR's (Silicone Controlled Rectifier) to achieve solid state direction change.

Now Bucyrus America, Inc., in conjunction with Sevcon, has developed the Bucyrus 2000 motor controller. The Bucyrus 2000 system uses IGBT’s (Insulated Gate Bipolar Transistors) 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 Bucyrus 2000 Logic Card provides complete motor control, and drives both a Diagnostic Dashboard Display along with a hand held Calibrator/Diagnostic Unit.

The IGBT switch operates so fast that it can connect and disconnect the motor in less than 1/1700 second. This is such a short time period that the dual-field motor does not have time to move. Each time the IGBT switch closes and reopens the full battery voltage is applied to the motor terminals for about 1/1700 second. This is commonly referred to as a "pulse."

The IGBT speed control works by feeding to the motor a rapid series of pulses. The number of pulses per second determines the average voltage at the motor terminals 7

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Since the windings of the motor are inductive, the current in the motor cannot change quickly.

When the IGBT switch is closed, the current builds up slowly and when the switch opens, the inductance wants to keep the current flowing. For this reason, the "flywheel" diode is provided.

Figures 3 and 4 illustrate the current paths with the switch closed in both forward (Figure 3) and reverse (Figure 4) modes.

FIGURE 2

FIGURE 3

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FIGURE 4

As seen in Figure 5, the direction of the current through the motor does not change. More important, when the switch opens, although the battery current stops, the motor current continues to flow via the "flywheel" diode. The motor current is therefore made up of two components: 1. The battery current when the IGBT switch is closed.

2. The "flywheel" current when the IGBT switch is open.

FIGURE 5

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The amount of the motor current supplied from the battery varies with the pulse frequency.

Figure 6 illustrates a typical situation at low speed. It can be seen from the illustration that the "flywheel" current, because it is flowing for a longer period, forms a larger part of the motor current than does the battery current. However, at high speeds (Figure 7), the motor current is made up of almost all battery current.

FIGURE 6

To summarize, the motor current is made up of a combination of battery current and "flywheel" current so that under all conditions the average motor current is always greater than the average battery current.

At low speeds the motor current can be several times greater than the battery current.

At high speeds, when the IGBT switch is open only for short periods before closing, the motor current is made up almost entirely of battery current.

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FIGURE 7

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Bucyrus America, Inc.

GENERAL SPECIFICATIONS The Bucyrus 2000 Motor Controller is designed to operate at 128 volts DC, 1200 Amps maximum current limit per motor and controls one or two dual-field electric motors. 

The maximum current default settings are: 800A, 1100A and 1200A



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



Traction motor current will be continuously monitored in the motor. Current limit is preset and is adjustable via the optional hand held diagnostics/calibrator unit and is password protected.

FIGURE 8 – ACCELERATOR VOLTAGE

Fail-safe operation will include the following: 

In the event of a shorted IGBT, the circuit breaker will be opened, disconnecting power from the traction motors.



Operation of the circuit breaker will always be sensed, and if faulty, drive will be inhibited.



Whenever the vehicle is power-cycled, power-up diagnostics will be executed to test the tram drive circuitry. If faulty, drive will be inhibited.

The temperature of the Bucyrus 2000 Motor Controller will be continuously monitored and if it rises above 95C the motor current will be limited to a maximum of 300 amps of motor current will be allowed.

The Bucyrus 2000 Motor Controller features a data logging capability that stores critical data into non-volatile data RAM. The stored data is displayed in the traction status display of the optional hand held diagnostics/calibrator unit.

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DESCRIPTION OF FEATURES The Bucyrus 2000 Solid State Controller incorporates a variety of independent protection systems. These improve reliability, shield the motors and controller from overload, protect the machine from inadvertent abuse by the operator, and help to protect workers from potential harm from malfunctioning equipment.

Bucyrus 2000 Motor Controller Consist of: 

Dual Motor IGBT Panel or single motor IGBT Panel or 2-single motor IGBT panels



Microprocessor Based Logic Card



Optional Dashboard Display



Optional Hand held Diagnostics/Calibrator Unit



“Y” connecting harness (used only with 2-single motor panel systems)

Bucyrus 2000 Motor IGBT Panel (Power Connections)   

Battery positive Battery negative 4 motor connections for each motor (S1, S2, A1 and A2)

(For Power Circuit Layout see Machine Wiring diagram and schematic)

Microprocessor Based Logic Card (Control Inputs)            

Input applies battery voltage to logic card (Pin 16) Proportional control accelerator, 5000 OHMS (Pins 1 and 2) Tram direction select (Pin 7) Tram direction select (Pin 8) Park brake condition (set / release) (Pin 14) Circuit breaker driver (Pin 6) Circuit breaker condition (Pin 11) Current limit default setting (Pin 12) Accelerator (FS1) input switch (Pin 4) CAN Communication Input Port for optional hand held diagnostics/calibrator unit CAN Communication Input Port for optional dashboard display Analog Input for connection to pump motor shunt to allow pump motor current measurement

The Bucyrus 2000 Microprocessor-Based Logic Card will control dual two-quadrant IGBT devices, controlled by PWM (PULSE WIDTH MODULATED) switching, providing forward and reverse direction control.

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There is an LED on the logic card which serves as an indicator of the status of the controller. The following diagnostics shall apply:   

LED on LED off 1 Flash



2 Flash



3 Flash



4 Flash



5 Flash



6 Flash



7 Flash



8 Flash

Controller operational Power-up fault – check display or calibrator. If all is blank, then replace logic.

Personality CRC EEPROM Error.

Using the hand-held calibrator, change a password to any number then recycle power – should clear, otherwise replace logic.

Procedure FAULT FS1 closed before power on ,2 Directional Fault or Current imbalance fault.

Recycle through NEUTRAL to clear.

IGBT permanently low (IGBT Short Circuit FAULT).

This includes IGBT short circuit or IGBT open circuit. This fault shuts down all modes. Recycle through NEUTRAL to clear.

Motor neither low nor high (Breaker Open FAULT).

This includes breaker open circuit or IGBT open circuit. This fault shuts down all modes. Recycle through NEUTRAL to clear.

Motor permanently high.

This includes breaker welded. This fault shuts down all modes. Recycle “KEY” to clear.

Faulty TRACTION accelerator.

This includes the accelerator greater than 15% at power on and wire-off. If wireoff occurs during active function then the motor speed will set to zero. This fault auto-clears.

Battery voltage FAULT. This includes battery below a predetermined value. Recycle through NEUTRAL to clear.

Thermal cut-back (Over-Temperature FAULT).

This includes Heatsink temperature above 95 centigrade.

AS TEMPERATURE RISES CONTROLLER WILL LIMIT REGARDLESS OF DEMAND. 

9 Flash



10 Flash



15 Flash

ABOVE 95 CENTIGRADE, THE THE CURRENT TO 300 AMPS

UVR coil over-current FAULT (Coil short circuit FAULT).

Cleared with “KEY” recycled.

Brake on FAULT Will trip Directional and FS1 are energized without releasing brake. Recycle through NEUTRAL to clear.

Current Transducer FAULT. Occurs when current output is read during power-up or if no current is read during drive above 50% demand. “KEY” recycle to clear.

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Configuration Jumper Table MAX. CURRENT CONFIG. LOGIC PIN 12 OPEN GROUND (CLOSED) OPEN

VEHICLE TYPE SINGLE MOTOR – 1200 AMP SINGLE MOTOR – 1100 AMP DUAL MOTORS 1100 AMP PER MOTOR – ADJUSTABLE TO 1200 AMP DUAL MOTORS 800 AMP PER MOTOR

GROUND (CLOSED)

OPTIONAL DASHBOARD DISPLAY FEATURES (See Figure 9)    

A battery discharge indicator An hour meter displaying tram-on hours An hour meter displaying pump-on hours A rotating display showing: 1. Battery voltage 2. Pump motor current 3. Diagnostic fault status, when applicable. Rotating display will lock on one of the following fault messages: (See Fault Message Chart, page 19)

FIGURE 9 – OPTIONAL DASHBOARD DISPLAY

BATTERY DISCHARGE FUNCTION

ROTATING DISPLAY

TRAM – ON PUMP – ON HOURS

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Fault Message Chart DASHBOARD DISPLAY “Rotating Disp.”

“Testing”

CALIBRATOR DISPLAY “OK” “Testing”

“System OK”

“System Okay”

“Over Temp.”

“Brkr Open”

“Thermal Cutback” “Breaker Open”

“Brkr Weld”

“Breaker Weld”

“UVR Coil” “Cap Fault” “Accel Flt.”

“UVR Coil” “Capacitor Fault” “Accel Flt.”

“Seq. Fault”

“Sequence Fault”

“2 Dir Fault” “Tram Fault” “Bat Low” “CRC Error”

“2 Dir Fault” “Tram Fault” “Bat Low” “CRC Error”

“IGBT s/c” “IGBT s/c” “Brake on”

“IGBT s/c” “IGBT s/c” “Brake on”

“Cur Xducer”

“Cur Xducer Flt”

“Bad Logic”

“Bad Logic”

“Bad Logic”

“Bad Logic”

“Cap Fault” “PTA Short”

“Cap Fault” “P. Up PTA Short”

“RPTA Short”

“P. Up R. PTA Short”

DESCRIPTION No fault Only visible when power-up diagnostics is running. Check connections if not clearing.

Power-up check completed, waiting to closure of Circuit Breaker Controller in thermal cut-back.

Circuit breaker failed to close. Faulty Circuit breaker, UVR, CB Auxiliary or faulty logic board.

Circuit breaker welded close. Faulty CB auxiliary switch or faulty logic will give this fault also.

UVR coil driver over-current sensed.

Caps failed to charge after power-up.

Accelerator fault sensed. Faulty accelerator (accelerator voltage 4.0v; accelerator voltage below 1.2v in NEUTRAL).

Faulty FS1 or logic board.

FS1 closed at power-up. Possible circuit breaker auxiliary switch not closing Both directional switches active.

Motor current imbalance sensed.

Battery fell below personality level.

During power-up a personality CRC error occurred. Try adjusting one of the passwords (1 or 2) then power recycle.

If not cleared replace logic board.

An IGBT short has been detected – SM. A left or right IGBT short has been detected – DM. The vehicle BRAKES are on while there is a direction and demand selected.

The controller reads current when it is first powered-up or does not read any current when demand for drive over 50%.

An internal errors has occurred in the software state machine. Faulty logic board.

Invalid status state encountered (internal error). Faulty logic board. * * * * POWER UP TEST STATUS * * * * Caps failed to change after power-up.

Single motor Block 0 point “A” short Motor short to ground or IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

Dual motor Block 0 point “A” short Motor shorted to ground or RIGHT IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

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Fault Message Chart (Continued) “LPTA Short”

“P. Up L. PTA Short”

“I. D. Fault” “Bad Logic”

“Vehicle ID Flt” “Bad Logic”

“R FWD ON”

“Tract R. FWD on”

“FWD ON”

“Tract FWD on”

“R REV ON”

“Tract R. REV on”

“REV ON”

“Tract REV on

“L FWD ON”

“Tract L. FWD on”

“L REV ON”

“Tract L. REV on”

“Drive off”

Drive 0 off Flt”:

“R FWD OFF”

“Tract R. FWD off”

“FWD OFF”

“Tract FWD off”

“R REV OFF”

“Tract R. REV off”

“REV OFF”

“Tract REV off”

“L FWD OFF”

“Tract L. FWD off”

“L REV OFF”

“Tract L. Rev off”

“BAD LOGIC”

“BAD LOGIC”

Dual motor Block 1 point “A” short Motor shorted to ground or LEFT IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

Vehicle Configuration ID invalid Diagnostic point “A” trip failed to disable UVR coil. Faulty logic board.

Diagnostic RIGHT FWD point “A” trip failed to be disabled. .

Faulty logic board, shorted motor to ground or shorted IGBT. Single motor Point “A” trip failed to disable FWD IGBT. Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic RIGHT REV point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Single motor Diagnostic REV point “A” trip failed to be disabled. Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic LEFT FWD point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic LEFT REV point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic test to enable UVR coil driver failed. Faulty logic board.

Diagnostic RIGHT FWD point “A” trip failed to disable PWMO. Faulty logic board.

Single motor Diagnostic FWD point “A” trip failed to disable PWMO. Faulty logic board.

Diagnostic RIGHT REV point “A” trip failed to disable PWMO. Faulty logic board.

Single motor Diagnostic REV point “A” trip failed to disable PWMO. Faulty logic board.

Diagnostic LEFT FWD point “A” trip failed to disable PWM1.

Faulty logic board.

Diagnostic LEFT REV point “A” trip failed to disable PWM1.

Faulty logic board.

Internal error (Software Only) Faulty logic board.

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Optional Hand Held Diagnostics/Calibrator Unit Security Levels: 1.

2.

3.

4.

Customer level Service Level Advanced Level Engineering Level

SECURITY LEVELS 2-4 ARE ONLY ACCESSIBLE BY ENTERING THE APPROPRIATE PASSWORDS.

FIGURE 10 – OPTIONAL HAND HELD DIAGNOSTICS/CALIBRATOR UNIT RIGHT BUTTON

LEFT BUTTON

DOWN BUTTON

UP BUTTON

Connecting for Operation: 1. Turn the machine “OFF”.

2. Turn the main circuit breaker to the “OFF” position to de-energize power on machine.

3. Remove the main controller cover.

4. Connect the hand held diagnostics/calibrator unit to the CAN Communication Input Port of the logic card.

5. Turn the main circuit breaker to the “ON” position.

6. Leave the “Park Brake Set”.

The hand held diagnostics/calibrator unit is now operational.

Operation: Upon power-up of the hand held diagnostics/calibrator unit, before pressing any buttons, a top level display is visible to provide diagnostic information as follows: See list on page # 19 and 20 18

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Personality Adjustment Procedure 1. Power-up calibrator.

2. If the top level display indicates “OK”, go to step (4). If not “OK”, go to step (3).

3. Consult above diagnostic information table to determine cause of fault.

4. Press the “DOWN” button two times to access the personalities table.

5. Use the “LEFT” or “RIGHT” buttons to locate the desired personality.

6. After locating the personality, use the “+” or “-” buttons to adjust the values accordingly.

7. To go back to the top level display, press the “UP” button two times.

The following features shall be customer adjustable personalities, accessible using the Calibrator

Traction Personalities (Controller Adjustments) DISPLAY NAME

MAX CONTROLLER CURRENT

RANGE / NOTES

SECURITY LEVELS DISPLAYED

50 amps to maximum controller capacity.

ALL

ACCELERATOR DELAY

0.5 seconds to 5.0 seconds

DECELERATION DELAY

(1.0 seconds ALL VEHICLES) 1.0 seconds to 5.0 seconds

CREEP SPEED

(1.0 seconds ALL VEHICLES) 0% to 25%

MAXIMUM SPEED

(5%) 0% to 100%

PASSWORD ONE PASSWORD 2 PWM FREQUENCY ADJUST PLUG CONFIGURATION NOTE: REQUIRES POWER RECYCLE

BATTERY PROTECTION CUTOUT BATTERY PROTECTION DELAY MOTOR CURRENT LOG LEVEL

(100%) 0 – 255 characters 0 – 255 characters 0 – 255 characters (17) 0 – 1 (Internal factor) 0. RFU 1. Auto plug breaking 2. Selective plug breaking (Normal plug) (2) 50 v – 255 v

SERVICE ADVANCED ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING ALL ALL ALL ALL ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

ALL

(50v) 0.1 – 5.0 seconds

ALL

(5.0 seconds) 50 – 1200 Amps

ALL

19

SECURITY LEVELS ADJUSTABLE

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Personalities (Controller Adjustments) (Continued) PLUG CURRENT LOG LEVEL TEMPERATURE ADJUSTMENT

CLEAR DATA LOG

CLOSE CB DELAY ALLOWED

50 – 1200 Amps Compensates temperature look-up tables.

0-20 = Positive additives 21 – 40 = Negative additives 95 default (ALL VEHICLES) OFF – ON NOTE: THIS PERSONALITY CLEARS ALL OF THE DATALOG LOCATIONS IN NON-VOLATILE MEMORY. TO ENABLE THIS PERSONALITY PRESS THE “-” BUTTON. IT DISABLES ITSELF ONCE IT COMPLETES THE CLEARING TASK. FS1 MUST BE OPEN. 0 seconds (disables) to 90 seconds 45 seconds (ALL VEHICLES)

NO ACTIVITY DELAY TIMER

0 seconds (disables) to 40 minutes 0 minutes (ALL VEHICLES)

CURRENT IMBALANCE TIMER

0 seconds (disables) to 90 seconds

20

ALL

SERVICE ADVANCED ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING

ALL

SERVICE ADVANCED ENGINEERING

SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Status Display DISPLAY NAME

RANGE / NOTES

Battery Voltage Motor Voltage (S. M.) Right Motor Voltage Left Motor Voltage Motor Current (S. M.) Right Motor Current Left Motor Current S. M. Rev. IGBT Block Temp.

S. M. Fwd IGBT Block Temp.

DM Right IGBT Block Temp.

DM Left IGBT Block Temp.

IGBT Voltage (S. M.) Right IGBT Voltage Left IGBT Voltage Error Code (see error code sec.)

Number of “Key On” Hours Number of “Driving” Hours Current Calibration Factor (S. M.) Right Channel Zero Current Calibration Factor Left Channel Zero Current Calibration Factor Peak Motor Current (S. M.) Right Channel Peak Motor Current Motor Current Stored Duration High Bytes (S. M.) Right Channel Motor Current Stored Duration High Bytes (S. M.) Motor Current Stored Duration Mid Bytes (S. M.) Right Channel Motor Current Stored Duration Mid Bytes (S. M.) Motor Current Stored Duration Low Bytes (S. M.) Right Channel Motor Current Stored Duration Low Bytes (S. M.) Motor Current Stored Duration Low Bytes (S. M.) Right Channel Motor Current Stored Duration Low Bytes (S. M.)

21

SECURITY LEVELS DISPLAYED ALL ALL

SECURITY LEVELS ADJUSTABLE N/A N/A

ALL ALL

N/A N/A

ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Status Display (Continued) Peak Plugging Current (S. M.) Right Channel Peak Plugging Current Selected Plugging Current Recording Level

NOTE: CONVERT AS FOLLOWS 1. CONVERT EACH BYTE TO ITS HEX EQUIVALENT. 2. CONVERT THE (3) BTYE FIELD TO A DECIMAL AND MULTIPLY BY 3.0 MSECONDS TO OBTAIN REAL TIME.

Plugging Current Stored Duration High Bytes (S. M.) Right Channel Plugging Current Stored Duration High Bytes (S. M.) Plugging Current Stored Duration Mid Bytes (S. M.) Right Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Right Channel Plugging Current Stored Duration Low Bytes (S. M.) Peak Motor Current (S. M.) Left / Right Motor Peak Plugging Current Stored Duration High Bytes (S. M.) Left Channel Plugging Current Stored Duration High Bytes (S. M.) Plugging Current Stored Duration Mid Bytes (S. M.) Left Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Left Channel Plugging Current Stored Duration Low Bytes (S. M.) Peak Plugging Current (S. M.) Left Channel Peak Plugging Current Plugging Current Stored Duration High Bytes (S. M.) Left Channel Plugging Current Stored Duration High Bytes (S. M.) 22

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Status Display (Continued) Plugging Current Stored Duration Mid Bytes (S. M.) Left Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Left Channel Plugging Current Stored Duration Low Bytes (S. M.) SM FWD IGBT High Temperature SM REV IGBT High Temperature DM RIGHT IGBT High Temp.

DM LEFT IGBT High Temp.

SM FWD IGBT Low Temperature SM REV IGBT Low Temperature DM RIGHT IGBT Low Temp.

DM LEFT IGBT Low Temp.

Battery Voltage High Battery Voltage Low

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL ALL ALL

N/A N/A N/A

ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A

Security Level Displayed

Security Level Adjustable

ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Traction Test Display Display Name Accel. Voltage Accel. Percent Demand Forward Switch Reverse Switch FS1 Switch Configuration Jumper 1 Configuration Jumper 2 Brake Input Circuit Breaker Input Oil Temperature Oil Level Software Version

Range / Notes 0.0 V - 5.0 V 0 - 100% OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OK / HOT OK / LOW VX.XXX

23

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction BDI Display Display Name % CHANGE LEFT BDI CELLS

Range / Notes

RESET CELL LEVEL

0 - 100% 35 - 80 (64) 1.85V - 2.50V

EMPTY CELL LEVEL

(2.04V) 1.00V - 1.99V

WARNING LEVEL

(1.70V) 0% - 90%

CUTOUT LEVEL

(20%) 0% - 90%

BATTERY CALLIBRATION VOLTAGE BDI SAMPLE TIMER DISPLAY WORKING DISPLAY STATUS SELECT DASHBOARD DISPLAY STATUS

DISPLAY CONTRAST

(0%) 1.00V – 10.0V (5-VOLTS) 1.0 - 255 SECONDS 2.0 (20 SECONDS) OK LOCK / ROTATE (ROTATE) 0 - 4 (BATTERY VOLTAGE, PUMP CURRENT AND MOTOR CURRENT) BATTERY VOLTAGE (1) 0 - 127 1 (33)

24

Security Level Displayed ENGINEERING ENGINEERING

Security Level Adjustable ENGINEERING ENGINEERING

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

ENGINEERING

ENGINEERING

ENGINEERING

ENGINEERING

ADVANCED ENGINEERING ALL

ADVANCED ENGINEERING ALL

ALL

ALL

ALL

ALL

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Error Code Legend (Status Display) ERROR CODE 0 1 2

3

4

5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21

DESCRIPTION No Fault Caps failed to change after power-up Check for shorted cap Single Motor Block “0” Point “A” short Shorted IGBT or short between motor and ground Dual Motor Block “0” Point “A” short Shorted Right IGBT or short between motor and ground Dual Motor Block “0” Point “A” short Shorted Left IGBT or short between motor and ground Vehicle configuration ID invalid Diagnostic Point “A” trip failed to disable UVR Coil Replace logic assembly Diagnostic Right FWD Point “A” trip failed to disable Replace logic assembly Single Motor Point “A” trip failed to disable FWD IGBT Replace logic assembly Diagnostic Right REV Point “A” trip failed to disable Replace logic assembly Single Motor Diagnostic REV Point “A” trip failed to disable Replace logic assembly Diagnostic Left FWD Point “A” trip failed to disable Replace logic assembly Diagnostic Left REV Point “A” trip failed to disable Replace logic assembly Diagnostic test to enable UVR Coil driver failed Fault in logic assembly or faulty UVR Coil Diagnostic Right FWD Point “A” trip failed Replace logic assembly Single motor diagnostic FWD Point “A” trip failed Replace logic assembly Diagnostic Right REV Point “A” trip failed Replace logic assembly Single motor diagnostic FWD Point “A” trip failed Replace logic assembly Diagnostic Left FWD Point “A” trip failed Replace logic assembly Diagnostic Left REV Point “A” trip failed Replace logic assembly Breaker welded fault Internal error (Software Only) Replace logic assembly

25

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

TROUBLESHOOTING This section provides troubleshooting information. This guide assumes you have a working knowledge of IGBT controller servicing and that you have the following equipment.

1. Volt/Ohm Meter with Leads 2. Insulated Basic Hand Tools

WHEN WORKING INSIDE THE CONTROLLER, USE INSULATED GLOVES AND TOOLS WHERE POSSIBLE. ALL CONNECTIONS MUST BE TIGHT AND CARE MUST BE TAKEN TO PREVENT BOLTS, NUTS, WASHERS AND OTHER SMALL METAL FASTENERS FROM BEING DROPPED OR LOST INSIDE THE CONTROLLER. BEFORE STARTING ANY POWER-RELATED PERFORMANCE TESTS, THE MACHINE MUST BE JACKED AND SECURELY BLOCKED CLEAR OF THE GROUND WITH ALL FOUR (4) WHEELS FREE TO TURN.

REFER TO THE PARTS MANUAL FOR YOUR PARTICULAR MACHINE WIRING DIAGRAMS AND SCHEMATICS.

THE LOGIC UNIT CONTAINS NO USER-SERVICEABLE PARTS. OPENING THIS SEALED DEVICE WILL VOID THE WARRANTY.

26

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT and Diode Measurements Before taking readings, the following system conditions must be met: 1. Master switch or control handle in the “OFF” position.

2. Panel disconnected from and isolated from the battery (via main circuit breaker) and battery plugs being disconnected.

3. Motor leads disconnected from panel 4. After power is removed, wait for one (1) minute before making measurements to allow voltage to bleed down

IGBT Measurements (See Figure 11) If reading is 0, IGBT is shorted.

There are two IGBT’s wired in parallel; therefore, if one IGBT indicates short, it may be one or both.

FIGURE 11

27

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Individual IGBT Measurements FIGURE 12

28

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Diode Measurements FIGURE 13

29

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Diode Measurements FIGURE 14

30

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Before taking readings, the following system conditions must be met: 1. Panel mounted in vehicle 2. Main circuit breaker in the “OFF” position 3. Power “OFF” at master switch or control handle (must be off at least one minute before taking measurement)

Panel Measurements FIGURE 15

Panel Measurements Before taking readings, the following system conditions must be met: 1.

2.

3.

4.

5.

All connections attached, and power applied Main circuit breaker on Master switch or control handle in the “PARK” or “PARK BRAKE APPLIED” position Accelerator NOT depressed (FS1 open) Main line contactor open   

B+ to B-: Battery Voltage B- to AA: 50V B- to S1L, S4L, S1R, & S4R: 50V

31

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Driver Measurements The measurement of the driver on the Bucyrus America, Inc. Bucyrus 2000 Motor Controller cannot be done with a volt-ohm-meter. In order to determine whether the driver is faulty, a process of elimination is required. The LED indicates if there is “look ahead” voltage on the IGBT’s and as such does not fully indicate whether the driver is working properly or not.

The steps to follow to determine if the driver is faulty are as follows: 1. Determine if any of the IGBT’s or diodes are faulty by performing the previously illustrated tests.

2. With power applied, the master switch or control handle to the “PARK” PARK BRAKE APPLIED” position, and all motor leads connected, measure the voltage with a volt-ohm meter from “B-” to the motor connection leads, each in turn (“S1” to “B-”, “S4” to “B-”, and so on). The main line contactor must be open.

3. The reading should be less than the battery voltage, but higher than “B-” (in the range of approximately 70 volts). This voltage may vary panel to panel as there is leakage voltage through the IGBT’s and diodes.

4. If the voltage is at the same potential as “B+”, then most likely a diode is shorted.

5. If the voltage is at “B-”, then most likely an IGBT is shorted.

6. The calibrator should indicate which channel is faulty.

7. If the calibrator does not indicate which channel is faulty, the faulty component can be determined in the following manner:  Remove power from the panel, remove the motor connection leads from the panel and follow the measurements as indicated in the previous sections, or determine which channel is faulty.

8. If all the IGBT’s and diodes measure okay, the problem may be with the driver or the logic board.

32

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT PANELS

FOR REPLACEMENT PARTS AND MACHINE WIRING DIAGRAMS, PLEASE REFER TO YOUR SPARE PARTS MANUAL.

33

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT Dual Motor Panel FIGURE 16 RESISTOR ASSEMBLY BUSS BAR, B -

THERMAL STRIP AND THERMISTOR

WIRING HARNESS

BUSS BAR, B +

BUSS BAR AND CURRENT TRANSDUCER

RESISTOR ASSEMBLY HEAT SINK ASSEMBLY

BUSS BAR SHUNT ASSEMBLY

34

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT Single Motor Panel FIGURE 17 BUSS BAR CURRENT TRANSDUCER DIODE KIT

HARNESS ASSEMBLY

RESISTOR ASSEMBLY KIT

BUSS BAR ASSEMBLY KIT

BUSS BAR ASSEMBLY

DRIVER BOARD ASSEMBLY

THERMAL STRIP CAPACITOR ASSEMBLY

INSULATOR PLATE

HARNESS ASSEMBLY

COLLECTOR PLATE ASSEMBLY

DIODE KIT IGBT KIT

35

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT Heat Sink Assembly FIGURE 18

CAPACITOR ASSEMBLY

INSULATOR PLATE

IGBT KIT

COLLECTOR PLATE ASSEMBLY

COPPER SPACER DRIVER BOARD

DIODE KIT HEAT SINK

WIRING HARNESS

36

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Single Motor Panel Harness Assembly FIGURE 19

37

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Dual Motor Panel Harness Assembly FIGURE 20

38

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Dashboard Display FIGURE 21

39

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Dual “Y” Harness FIGURE 22

40

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Harness for Dashboard Display FIGURE 23

RJ11 PLUG CABLE

RJ11 PLUG CABLE

41

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Calibrator Unit FIGURE 24

Bucyrus 2000 Pump Motor Shunt FIGURE 25

42

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Bucyrus 2000 Panel Wiring Harness FIGURE 26

43

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

OPERATION, PREVENTIVE MAINTENANCE, TROUBLESHOOTING AND SERVICE GUIDE MODELS 488L and 488-6 WITH CONTROL HANDLE

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT.

P/N A6474X235 Revision 3, March 2008  BUCYRUS AMERICA, INC. 2008 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 PRE-START INSPECTION ....................................................................................................................... 7 STARTING ................................................................................................................................................ 7 OPERATING ............................................................................................................................................. 7 STOPPING ................................................................................................................................................ 8 MAINTENANCE ........................................................................................................................................ 8 INTRODUCTION........................................................................................................................................... 9 CONTROLS AND INDICATOR .................................................................................................................. 11 SERVICE BRAKE PEDAL ....................................................................................................................... 11 FIRE SUPPRESSION ACTUATORS ...................................................................................................... 12 SPEED-SWITCH (ACCELERATOR) FOOT PEDAL ............................................................................... 12 CONTROL HANDLE................................................................................................................................ 12 CIRCUIT BREAKER RESET LEVER ...................................................................................................... 14 TAPE SWITCH (PANIC STRIP) .............................................................................................................. 15 WARNING GONG ................................................................................................................................... 15 FIGURE 8 – WARNING GONG ............................................................................................................... 16 LA 2000 DASHBOARD DISPLAY (OPTIONAL) ...................................................................................... 16 GAUGE PANEL (OPTIONAL) ................................................................................................................. 16 "STEERING" CONTROL LEVER ............................................................................................................ 18 "LEFT-HAND STEERING" CONTROL LEVER ....................................................................................... 18 "BUCKET" CONTROL LEVER ................................................................................................................ 19 "EJECTOR" CONTROL LEVER .............................................................................................................. 19 "WINCH" CONTROL LEVER (OPTIONAL) ............................................................................................. 20 "2-SPEED WINCH" CONTROL ............................................................................................................... 20 “BATTERY CHANGER” CONTROL LEVER............................................................................................ 20 HYDRAULIC PTO ACTUATOR............................................................................................................... 20 BRAKE RELEASE HAND PUMP............................................................................................................. 20 STARTING PROCEDURE.......................................................................................................................... 23 TOWING A DISABLED MACHINE ............................................................................................................ 27 SHUTDOWN PROCEDURE ....................................................................................................................... 29 BATTERY CHANGE PROCEDURE (VERTICAL LIFT) ............................................................................ 31 BATTERY CHANGE PROCEDURE (GROUND LEVEL) .......................................................................... 37 GENERAL MAINTENANCE INSTRUCTIONS........................................................................................... 45 CRITICAL TORQUE VALUES ................................................................................................................... 47 I

Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

Page LUBRICANTS, FLUIDS AND CAPACITIES ..............................................................................................47 MAINTENANCE CHECK LIST ................................................................................................................... 49 PERIODIC MAINTENANCE PROCEDURES............................................................................................. 51 EVERY SHIFT ......................................................................................................................................... 51 ONCE PER WEEK................................................................................................................................... 52 ONCE PER MONTH ................................................................................................................................ 57 EVERY THREE MONTHS....................................................................................................................... 59 LUBRICANT SPECIFICATIONS................................................................................................................ 61 APPROVED SUPPLIERS ....................................................................................................................... 61 LUBRICATION CHART.............................................................................................................................. 63 ONCE PER WEEK................................................................................................................................... 63 TROUBLESHOOTING PROCEDURES ..................................................................................................... 65 HYDRAULIC SYSTEM (GENERAL)........................................................................................................ 66 BRAKES (SERVICE) WET DISC............................................................................................................. 67 BRAKES (AUTOMATIC WET DISC) ....................................................................................................... 68 CYLINDERS ............................................................................................................................................ 68 PUMPS.................................................................................................................................................... 69 RELIEF VALVES ..................................................................................................................................... 71 MAJOR MAINTENANCE PROCEDURES ................................................................................................. 73 DRIVE MOTOR/GEARBOX (SPEED REDUCER) REMOVAL AND REPLACEMENT ........................... 73 TIRE/WHEEL INSTALLATION PROCEDURE .......................................................................................... 76 TIRE/WHEEL STRESSES ...................................................................................................................... 76 WHEEL MOUNTING ARRANGEMENTS ................................................................................................ 76 PROBLEM AREAS .................................................................................................................................. 76 WHEEL MOUNTING TIPS ...................................................................................................................... 77 RECOMMENDED WHEEL MOUNTING PROCEDURES: ...................................................................... 78 PRECAUTIONS:...................................................................................................................................... 78

II

Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

PREFACE This manual is intended to provide GENERAL product information for the Model 488 Series UN-A-TRAC®.

The illustrations, descriptions and procedures contained in this publication apply only to this Model 488 UN-A-TRAC®. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Model 488 UN-A-TRAC® was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U. S. regulatory agency standards.

At the completion of the manufacturing process, this Model 488 UN-A-TRAC® was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this Model 488 UN-A-TRAC®, without the consent of Bucyrus America, Inc., and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America's instructions, may invalidate these approvals and render this Model 488 UN-A-TRAC® unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this Model 488 UN-A-TRAC®.

While this manual attempts to anticipate the most important operations and maintenance needs for this Model 488 UN-A-TRAC®, unforeseen circumstances may arise that

have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America 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. 2008 All rights reserved.

Bucyrus America, Inc.

2

Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

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 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

DANGER ONLY TRAINED AUTHORIZED PERSONNEL SHOULD OPERATE OR PERFORM MAINTENANCE ON THE MODEL 488 SERIES UN-A-TRAC®.

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 488 SERIES UN-A-TRAC® IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

4

Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

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 MACHINE

Movement of machine can run over or crush body parts between machine and other objects and cause irreparable injury or death.

Keep alI people out of Hazard Zone (page 21). Use extreme caution when moving machine. The machine should be properly shutdown (see page 29) before the operator leaves the operator's compartment.

OPERATOR'S AREA

Operation of machine with head, arms, or hands outside of operator's compartment could cause irreparable injury or death if body parts strike or are crushed between machine and outside objects.

Keep head, arms, hands, inside operator's compartment at alI times.

BUCKET

Ejector blade being returned could cause irreparable injury or death if body parts or persons are crushed between ejector blade and the back of the bucket.

Keep alI hands, arms, legs, feet and persons out from between the ejector blade and the back of the bucket. The machine must be properly shutdown for service (see page 29).

CENTER SECTION (ARTICULATION POINT)

Machine could be steered crushing persons, hands, feet, or legs in the articulation area.

Keep alI persons, hands, feet, legs, out of articulation area and off the top and out from under the machine. Machine should be properly shutdown (page 29) before servicing. The machine must also be blocked under the battery end, bucket, and center section.

The steering lock (page 30) must be installed when working in or around the center section.

UNDERNEATH DURING SERVICE

Machine raised for service could fall and crush persons or body parts underneath.

If machine must be raised for service, it must be securely blocked so that all wheels may safely turn (see maintenance page 45).

5

Keep the machine’s protective canopy securely in place at all times.

Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

MAJOR HAZARDS (CONT.) AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

ELECTRICAL (BATTERY, CONTROLLER, MOTORS, ETC.)

Electrical shock could cause irreparable injury or death.

The electrical system should be maintained by certified electricians.

The battery should be disconnected before servicing the motors or controller. When the controller cover is removed, allow one minute for the capacitors to discharge.

BATTERY

The battery produces lethal amounts of power whether connected to the machine or not.

The battery should be maintained by qualified personnel. (Refer to Bucyrus America, Inc. "INSTALLATION, USE, MAINTENANCE, AND REPAIR OF MINE POWER STORAGE BATTERIES,” PART NUMBER A6474X26, for complete instructions).

Battery covers could fall crushing hands or arms.

Be sure cover supports are in place when working on battery.

Body parts could be crushed under battery tray.

Keep all body parts from under battery tray.

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 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.

If part of a hydraulic circuit is removed while there is a load on a cylinder in the circuit, the cylinder could drop the load.

Securely block or remove any load from the cylinder before disconnecting the hose or circuit.

HYDRAULIC

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SAFETY PRECAUTIONS AND GUIDELINES OVERVIEW Before you operate, maintain or in any other way, use this unit READ and STUDY this guide. KNOW how to safely use the unit's controls 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

PRE-START INSPECTION Read this entire guide BEFORE attempting to operate this unit. You should be familiar with the controls and their functions before the unit is energized.

INSPECT your machine by doing a pre-operational inspection. Have any malfunctioning, broken or missing parts corrected or replaced before use.

VERIFY that all maintenance has been performed.

VERIFY that all the instruction and safety labels 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 Model 488 Series UN-A-TRAC® was shipped from the factory equipped with a protective canopy.

This canopy MUST be securely in place before operating the unit.

STARTING DO NOT operate any levers or pedals from outside the operator's compartment to keep the machine from hitting you or other personnel.

FOLLOW the instructions in the STARTING PROCEDURES section of this guide (page 23).

DO NOT operate any levers or pedals if anyone is in the Hazard Zone (page 21).

BE familiar with the operation of the tape switches and be prepared for the sudden stop when the tape switches are struck.

OPERATING ALWAYS make sure that no person or obstruction is in your line of travel BEFORE starting the unit into motion or in the articulation area when steering the unit.

NEVER climb onto, or climb 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 objects outside.

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

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

ALWAYS look in all directions BEFORE changing your direction of travel. The warning gong should be sounded when changing directions.

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

If problems or equipment malfunctions are encountered while operating the unit, it must be properly shutdown (see page 29) and the problem repaired. Continuing to use malfunctioning equipment can not only be unsafe for the operator and other personnel, but can lead to further damage to the unit as well.

STOPPING DO NOT leave the operator's compartment with the unit running. ALWAYS properly shutdown the unit (page 29) before leaving the operator's compartment.

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 wheels in both directions whenever possible.

MAINTENANCE 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 adequately chocked to prevent accidental movement of the unit.

DO NOT alter the electrical or hydraulic settings from that indicated in this operation guide or as set at the factory.

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 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 by a spark and explode.

ALWAYS connect the steering lockout device before performing maintenance.

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 may show guards or cover panels removed for purposes of clarity. Never operate unit without guards and cover panels in place.

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INTRODUCTION

FIGURE 1 – MODEL 488L UN-A-TRAC®

FIGURE 2 - MODEL 488-6 UN-A-TRAC®

The Bucyrus America, Inc. Model 488 Series UN-A-TRAC® can be one of the most useful and safe machines found underground today, IF IT IS OPERATED CORRECTLY BY A PROPERLY TRAINED OPERATOR. Before operating the Model 488 Series UN-A-TRAC®, study the illustration (Figure 3, page 11) to become familiar with the controls and read the description of each control. If a word is in quotation marks and capital letters, such as "OFF" or "ON," that word is found as a label on the UN-A-TRAC®.

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CONTROLS AND INDICATOR FIGURE 3 – OPERATOR’S COMPARTMENT CONTROL HANDLE & LEFT HAND STEERING (SEE PAGES 12 & 18)

TAPE SWITCH (PANIC STRIP) (SEE PAGE 15)

GAUGE PANEL (SEE PAGE 16)

CIRCUIT BREAKER RESET (SEE PAGE 14)

SPEED-SWITCH (ACCELERATOR) (SEE PAGE 12) FIRE SUPPRESSION ACTUATOR (SEE PAGE 12) BUC 2000 DISPLAY (SEE PAGE 16)

SEAT

BRAKE RELEASE HAND PUMP (NOT SHOWN) (SEE PAGE 20)

SERVICE BRAKE PEDAL (SEE PAGE 11)

HYDRAULIC CONTROL PANEL (SEE PAGE 18)

NOTE: LOCATION OF CONTROLS MAY VARY.

BEFORE OPERATING ANY LEVERS OR PEDALS ON THE UN-A-TRAC® ALWAYS MAKE SURE NO ONE IS IN THE HAZARD ZONE (PAGE 21). DO NOT OPERATE ANY LEVERS OR PEDALS FROM OUTSIDE THE OPERATOR'S COMPARTMENT.

SERVICE BRAKE PEDAL The service brake pedal (Figure 3) is a foot-operated pedal located in front of and to the left of the operator and is used to apply the service brake. The service brake pedal works similarly to an automobile brake pedal. The pedal is normally operated by the left foot. The braking system of the Model 488 Series is wet-disc brakes located in the drive axles.

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FIGURE 4 – FIRE SUPPRESSION ACTUATOR (TYPICAL)

PLUNGER

PIN CO2 CARTRIDGE (BOMB)

FIRE SUPPRESSION ACTUATORS The two fire suppression (remote) actuators (Figure 3, page 11 and Figure 4, page 12) are located to the operator's right or left in the operator's compartment and on the rear frame of the machine opposite the operator. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the fire suppression system from either of the two 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.

SPEED-SWITCH (ACCELERATOR) FOOT PEDAL This speed switch foot pedal (Figure 3, page 11), operated by the right foot, is used to start the tram (traveling) motor and regulate the speed of the UN-A-TRAC®.

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 MOTOR AND COULD SHORTEN ITS USEFULNESS. THE UN-A-TRAC® IS PROVIDED WITH OVERLOAD PROTECTION, BUT CONTINUED ABUSE CAN SHORTEN MOTOR LIFE.

CONTROL HANDLE FOR MORE DETAILED CONTROL HANDLE OPERATING INSTRUCTIONS, SEE STARTING PROCEDURES PAGE 23.

The control handle (Figure 5), located to the left of the operator has a group of switches that control the following: “TRACTION ASSIST” Press down for Traction Assist.

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

“PARK BRAKE” (Automatic) To release park brake, (pump motor must be running) press in-position trigger down and hold. Then press “PARK BRAKE” button until the dashboard display indicates “PARK BRAKE RELEASED”.

Release “PARK BRAKE” button, then release in-position trigger. 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” button or “PUMP MOTOR” button.

The Automatic Emergency/Park Brake is a Spring Applied / Hydraulically Released (SAHR) park brake caliper mounted on the output shaft of the tram motor gearbox. The automatic park brake release switch is located on the control handle (Figure 5).

Anytime one of the following occurs, the electric motor is immediately disconnected and the brake is automatically applied and brings the vehicle to a stop within 5 seconds.

A. either of the panic tape switches/bar is struck or; B. the “STOP” button or “PUMP MOTOR” button is depressed on the control handle or; C. the “PARK BRAKE” button is depressed on the control handle or; D. the optional emergency manual “POWER DISCONNECT” switch (if equipped) is in the “OFF” position or; E. the circuit breaker is in the “OFF” position or; F. the circuit breaker is in the “TRIPPED” position.

BEFORE THE MACHINE IS MOVED THE AUTOMATIC EMERGENCY/PARK BRAKE MUST BE RELEASED. “TRAM Õ or Ö” To activate a tramming direction; A. The pump motor must be running.

B. The park brake must be released.

C. Press in-position down and hold, press either “TRAM Õ” for tram direction or “TRAM Ö” for tram direction, hold until the dashboard display indicates direction of travel.

D. Release “TRAM” Õ or “TRAM” Ö depending on direction selected and then release in-position trigger.

E. To disable tramming, press either “TRAM” button and release.

“LIGHTS Õ or Ö” To activate “LIGHTS” press either “LIGHTS Õ” for light direction or “LIGHTS Ö” for light direction. For auto position headlights, whereas the headlights follow the direction of the selected tram direction, press in-position trigger down and hold, press “LIGHTS Õ” release “LIGHTS Õ”, then release inposition trigger. Lights will stay in auto position until “STOP”, “LIGHTS Õ” or “LIGHTS Ö” is pressed.

To turn all lights off, press “LIGHTS Õ” and “LIGHTS Ö” simultaneously and release simultaneously.

“DIAGNOSTICS” Push up for machine diagnostics.

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FIGURE 5 – CONTROL HANDLE “PUMP MOTOR”

“PARK BRAKE”

“STOP” “TRACTION ASSIST”

“LIGHTS” (BATTERY END)

“LIGHTS” (BUCKET END)

“TRAM” (BATTERY DIRECTION)

“TRAM” (BUCKET DIRECTION)

DIAGNOSTICS

IN-P0SITION

CIRCUIT BREAKER RESET LEVER BEFORE ATTEMPTING TO TURN ON THE CIRCUIT BREAKER, PULL UP THE DIAGNOSTICS TRIGGER AND HOLD UNTIL A MESSAGE IS DISPLAYED ON THE DISPLAY SCREEN. IF “SYSTEM OKAY” MESSAGE IS DISPLAYED, THE CIRCUIT BREAKER CAN BE TURNED ON. IF ANY OTHER MESSAGE IS DIAPLAYED, CONTACT YOUR LOCAL BUCYRUS AMERICA, INC. SERVICE DEPARTMENT. The circuit breaker reset lever (Figure 3, page 11 and Figure 6), located in front of and to the right of the operator is used to reset the connection box (batteries) breaker when it has tripped. This circuit breaker is located in the connection box in the rear section of the UN-A-TRAC®. If the breaker has tripped, the reset lever must be moved to the "RESET” position first; pull up on the diagnostics trigger and check display screen for “SYSTEM OKAY” message; then move reset lever to the "ON” position.

THE CIRCUIT BREAKER DE-ENERGIZES THE ELECTRICAL CONTROLLER AND MOTORS. HOWEVER, ELECTRICAL POWER IS STILL PRESENT INSIDE THE CONNECTION BOX TO THE CIRCUIT BREAKER. IF THE CIRCUIT BREAKER INSIDE THE CONNECTION BOX REQUIRES SERVICE, THE BATTERY PLUGS MUST BE DISCONNECTED FROM THE BATTERIES.

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

THE CIRCUIT BREAKER SHOULD BE IN THE “OFF” POSITION AND THE PARKING BRAKE SET BEFORE THE OPERATOR LEAVES THE OPERATOR’S SEAT. IN AN EMERGENCY, THE OPERATOR CAN STOP THE UN-A-TRAC®

BY STRIKING THE TAPE SWITCH, WHICH TRIPS THE CIRCUIT BREAKER. THE UNIT CAN ALSO BE STOPPED BY MOVING THE CIRCUIT BREAKER LEVER TO THE “OFF” POSITION. FIGURE 6 – CIRCUIT BREAKER RESET LEVER

TAPE SWITCH (PANIC STRIP) The UN-A-TRAC® is equipped with two (2) tape switches (Figure 7) 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 tape switches are used to break the control circuit and trip the circuit breaker only in emergency situations, stopping all motors. Striking with a small amount of force will actuate either tape switch.

FIGURE 7 – TAPE SWITCHES (PANIC STRIP)

TAPE SWITCH (RIGHT) TAPE SWITCH (LEFT)

WARNING GONG The warning gong (Figure 8) 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 UN-A-TRAC® will be used.

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FIGURE 8 – WARNING GONG WARNING GONG

BUC 2000 DASHBOARD DISPLAY The Optional BUC 2000 display (Figure 3, page 11) is located in front of and to the right of the operator’s seat.

Features include:

• • • •

Battery discharge indicator Hour meter displaying tram-on hours Hour meter displaying pump-on hours Rotating display showing: 1.

2.

3.

4.

Battery voltage Pump motor current Diagnostic fault status Tram motor current FOR MORE DETAILED INSTRUCTIONS ON THE BUC 2000 DISPLAY REFER TO YOUR “MODEL BUC 2000 SOLID-STATE TROUBLESHOOTING GUIDE”.

GAUGE PANEL (OPTIONAL) The gauge panel (Figure 9) is located directly in front of the operator’s seat. It has two (2) gauges, one (1) for dif-lok (tractive assist) pressure and one (1) for brake pressure. During operation the gauges should read as listed in the table below.

GAUGE PANEL AXLE ASSEMBLY John Deere Meritor

DIF-LOK PRESSURE 600 psi Max (41 bar) 1000 psi Max (69 bar)

BRAKE PRESSURE (When Applied) 400 psi Max (28 bar) 1200 psi Max (83 bar)

SHOULD THE DIF-LOK OR BRAKE PRESSURE EXCEED THE MAXIMUM READING AS LISTED ABOVE, SHUTDOWN THE UN-A-TRAC® AND CALL A MAINTENANCE PERSON (SEE PAGE 29 FOR SHUTDOWN PROCEDURE).

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FIGURE 9 – GAUGE PANEL

DIF-LOK PRESSURE

BRAKE PRESSURE

GENERAL HYDRAULIC CONTROL SYSTEM INFORMATION In the operator's compartment located to the right of the operator’s seat is a group of control levers and gauges (Figure 10). These levers control the steering, bucket position, ejector blade position, winch operation and battery changer system by means of a hydraulic valve bank located behind the panel to the operator's right. The gauges include emergency brake, accumulator, and system pressure. The hydraulic system pressure relief valve is set at the factory at 2000 psi (138 bar), and should not be changed. Should the "SYSTEM PRESSURE" gauge (Figure 10) read more than 2250 psi (155 bar), SHUTDOWN the Model 488-6 and call a maintenance person (see page 29 for Shutdown Procedure).

HYDRAULIC CONTROL PANEL GAUGES GAUGE PRESSURE READING Emergency Brake 1500 – 1800 psi (103 –124 bar) Accumulator 1500 – 1875 psi (103 – 129 bar) System Pressure 2250 psi (155 bar)

SHOULD EITHER GAUGE SHOW ABOVE OR BELOW THE PRESSURES LISTED ABOVE, SHUTDOWN THE UN-A-TRAC® AND CALL A MAINTENANCE PERSON (SEE PAGE 29 FOR SHUTDOWN PROCEDURE).

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FIGURE 10 – HYDRAULIC CONTROL PANEL

EMERGENCY BRAKE

STEERING LEVER

BUCKET LEVER

ACCUMULATOR

EJECTOR LEVER

PTO / WINCH LEVER SYSTEM PRESSURE

BATTERY LEVER

"STEERING" CONTROL LEVER The steering control Lever (Figure 10) is used to steer the UN-A-TRAC®. 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.

"LEFT-HAND STEERING" CONTROL LEVER The optional left-hand steering control Lever (Figure 11) is used to steer the UN-A-TRAC®. 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.

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FIGURE 11 – “LEFT-HAND STEERING” CONTROL LEVER

LEFT-HAND STEERING CONTROL LEVER

"BUCKET" CONTROL LEVER The "BUCKET” control lever (Figure 10) is used to control the position of the bucket. When the "BUCKET" control lever is pulled to the right, toward the operator, the front end of the bucket will move up, toward the roof. When the "BUCKET" control lever is pushed to the left, away from the operator, the bucket will move down, toward the bottom. If the bucket control lever is held in the "DOWN" position, the bucket will continue to lower until the front wheels of the unit are raised off the ground. The "FLOAT” position of the "BUCKET" control lever will allow the bucket to lower to the ground and follow the contour of the mine bottom using the weight of the bucket. This can be useful when doing clean-up work.

HOLDING THE "BUCKET" CONTROL LEVER IN THE DOWN POSITION CAN RAISE THE FRONT END OF THE MACHINE OFF THE GROUND AND COULD CAUSE THE TOP OF THE MACHINE TO STRIKE THE ROOF OF THE MINE, CRUSHING PERSONS OR BODY PARTS IN BETWEEN. MAKE SURE THAT NO ONE IS IN THE HAZARD ZONE (PAGE 21) BEFORE MOVING ANY LEVERS OR PEDALS. WHEN THE UNIT IS TO BE SHUTDOWN, THE BUCKET SHOULD BE LOWERED TO THE GROUND TO PREVENT ACCIDENTAL MOVEMENT OF THE BUCKET. IF THE "BUCKET" CONTROL LEVER IS MOVED WHEN THE UNIT IS SHUTDOWN, THE BUCKET COULD DROP, EVEN IF ALL OTHER LEVERS AND PEDALS ARE IN THE "OFF" POSITION.

"EJECTOR" CONTROL LEVER The "EJECTOR" lever (Figure 10) operates the ejector blade located in the bucket. The ejector blade pushes out everything in its path, emptying the bucket. When the "EJECTOR" lever is pushed away from the operator ("OUT”), the ejector blade should move toward the front of the bucket (extend.) When the "EJECTOR" lever is pulled toward the operator, the ejector blade should move toward the back of the bucket (retract). When the ejector blade is not being used, it should be resting in the retracted position.

BEFORE MOVING THE "EJECTOR" CONTROL LEVER, VERIFY THAT NO ONE HAS ANY PART OF HIS BODY BETWEEN THE EJECTOR BLADE AND THE BACK OF THE BUCKET. ALSO KEEP ANY OBSTRUCTIONS FROM BEHIND THE EJECTOR BLADE SO IT CAN RETURN COMPLETELY TO THE BACK OF THE BUCKET.

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"WINCH" CONTROL LEVER (OPTIONAL) The "WINCH” control lever (Figure 10) controls the flow of hydraulic oil to the winch. When the control lever is pushed away from the operator the winch will pay out cable. Pulling the control lever toward the operator will reel in the cable.

"2-SPEED WINCH" CONTROL The "2-SPEED WINCH” control lever, located in the floor and to the right of the operator is used to control the speed of the winch. Pulling the lever toward the operator allows the winch to operate at high speed for rewinding cable. Pushing the lever away from the operator allows the winch to operate at slow speed for winching a load.

THE "BATTERY CHANGER" LEVER SHOULD ONLY BE OPERATED AT A BATTERY CHANGE STATION. THE BATTERY MAY BE DAMAGED IF ACCIDENTALLY RAISED IN A LOW ROOF AREA.

“BATTERY CHANGER” CONTROL LEVER The "BATTERY" lever (Figure 10) controls the battery changing system, which is made up of two hydraulic cylinders (battery lifting cylinders), one on each side of the batteries. When the "BATTERY” control lever is pulled toward the operator, the battery-lifting cylinders will raise the batteries. Pushing the handle away from the operator will lower the batteries.

THE BATTERIES CANNOT BE CHANGED ON UN-A-TRAC®’S THAT HAVE VERTICAL LIFT BATTERY CHANGING IF THE BATTERIES ARE NOT LEVEL WHEN IN THE RAISED POSITION. FOR MORE INFORMATION ON HOW TO CHANGE THE BATTERIES SEE THE BATTERY CHANGE PROCEDURE (PAGES 31 THROUGH 42).

NEVER ATTEMPT TO DISCONNECT A HYDRAULIC HOSE FROM THE BATTERY LIFTING CYLINDERS WITH THE BATTERY IN THE "UP" POSITION. THIS WOULD ALLOW THE BATTERY TO FALL AND COULD RESULT IN INJURY.

HYDRAULIC PTO ACTUATOR The hydraulic PTO actuator (Figure 10), located to the right of the operator is used to engage the hydraulic PTO. Shifting the control lever either up or down will engage the hydraulic PTO system.

BRAKE RELEASE HAND PUMP The automatic emergency brakes are spring-applied (on), pressure-release (off) brakes located in the driveline. The automatic (park) brake is normally released using the "PARK BRAKE" release switch (see "PARK BRAKE”, page 13). Should hydraulic system failure occur, the automatic (park) brake can be released using the manual brake release hand pump. To release the brakes using the hand pump, turn the hand pump selector valve to the set position. Pump the hand pump until the brake release valve indicates the required minimum 1500 psi (103 bar).

THIS COMPLETES CONTROLS AND INDICATORS.

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FIGURE 12 – HAZARD ZONE

THE HAZARD ZONE EXISTS UNLESS: A. The battery plug is disconnected from the battery, OR; B. The machine circuit breaker is in the “OFF” or “TRIPPED” position.

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STARTING PROCEDURE After reading the previous descriptions and locating each control, the operator is ready to operate the UN-A-TRAC®. An experienced operator should monitor a new operator's indoctrination to the starting procedure.

USE CAUTION WHEN TRAVELING DOWN GRADE, EXCEEDING 5 MPH (8 kph) WITH THIS MACHINE WILL RESULT IN TRAM MOTOR FAILURE.

CHECK THE BATTERY CONNECTIONS AND THE BATTERY COVERS. THEY MUST BE IN PLACE AND LOCKED TO BE PERMISSIBLE (FIGURE 34, PAGE 43).

NEVER OPERATE ANY LEVERS OR PEDALS FROM OUTSIDE THE OPERATOR'S COMPARTMENT. 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 (Figure 14, page 30).

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

BE SURE NO ONE IS IN THE HAZARD ZONE (PAGE 21) BEFORE OPERATING ANY LEVERS OR PEDALS. NEVER TRY TO ADJUST THE OPERATOR'S SEAT WHILE THE UN-A-TRAC® IS IN MOTION. DO NOT OPERATE THE UN-A-TRAC® WITH ANY PART OF YOUR BODY OUTSIDE THE OPERATOR'S COMPARTMENT TO PREVENT HAVING BODY PARTS CAUGHT BETWEEN THE UNIT AND OUTSIDE OBJECTS. BE SURE NO ONE IS IN THE HAZARD ZONE (PAGE 21) BEFORE OPERATING ANY LEVERS OR PEDALS. 3. The tape switch panic bars 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.

Note: Refer to Figure 13 for illustration of control handle.

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FIGURE 13 – 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 DOWN FOR TRACTION ASSIST.

“J3” PUSH DOWN FOR STOP

“J4” PRESS “J4” TO ACTIVATE Õ LIGHTS. PRESS “J2” AND “J4” FOR AUTO LIGHTS. AUTO LIGHTS FOLLOW DIRECTION OF TRAVEL.

“J6” PUSH DOWN FOR Ö LIGHTS. “J10” WITH PUMP MOTOR RUNNING AND BRAKE RELEASED PRESS “J2” AND “J10” TO ACTIVATE Ö TRAM DIRECTION. PRESS “J10” TO DISABLE Ö TRAM DIRECTION.

“J9” WITH PUMP MOTOR RUNNING AND BRAKE RELEASED PRESS “J2” AND “J9” TO ACTIVATE Õ TRAM DIRECTION. PRESS “J9” TO DISABLE Õ TRAM DIRECTION.

“J2” PUSH DOWN FOR IN-POSITION

“J11” PUSH UP FOR DIAGNOSTICS

4. Stop button “J3” may be pressed at any time to set the park brake, and to de-energize the tram and pump motors.

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

2. Press “J11” to begin on board diagnostics.

3. Hold “J11” until a message is displayed on the LA2000 display.

4. If the display indicates “SYSTEM OKAY” continue to step 5, if any other message is displayed, turn “OFF” battery circuit breaker and/or disconnect switch (if equipped) and contact Bucyrus America, Inc. service department.

5. Release “J11” and set 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 Bucyrus America service department.

If both tape switch panic bars trip machine circuit breaker, repeat steps 1 through 5 and proceed to step 7.

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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 Bucyrus America service department.

8. To start the pump motor, press “J2” and hold. Then press “J7” and hold until the pump motor starts.

Release “J7” and then release “J2”.

9. To turn off the pump motor, press “J3” or “J7”.

10. To release the park brake; A. The pump motor must be running.

B. Press “J2” and hold, press “J8” and hold until the dashboard display indicates “PARK BRAKE RELEASED”.

C. Release “J8” and then “J2”.

11. To set the park brake and leave the pump motor running, press “J8”.

12. To turn “OFF” the pump motor and set the park brake, press “J3” or “J7”.

13. To activate a tramming direction; A. The pump motor must be running.

B. The park brake must be released.

C. Press “J2” and hold, press either “J9” for Õ tram direction or “J10” for Ö tram direction, hold until the dashboard display indicates direction of travel.

D. Release “J9” or “J10” depending on direction selected and then release “J2”.

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

THE UN-A-TRAC® IS EQUIPPED WITH A SOLID STATE SPEED CONTROLLER. THIS MEANS THAT THE FARTHER THE SPEED SWITCH FOOT PEDAL IS DEPRESSED, THE FASTER THE UN-A-TRAC® WILL TRAM. 15. To change direction of travel, press “J2” and hold, then press either “J9” or “J10” and hold until the dashboard display indicates direction of travel. Then release “J9” or “J10” depending on direction selected and then release “J2”.

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

17. To disable tramming, press ”J9” or “J10”.

18. To leave pump motor running, set park brake, and disable tramming, press “J8”.

19. To disable tramming, turn off the pump motor and set the park brake, press “J3” or “J7”.

20. If equipped, to activate the optional traction assist function, press “J12”.

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Bucyrus America, Inc.

THE TRACTIVE ASSIST CAN BE USED AS NECESSARY. HOWEVER, BATTERY LIFE WILL BE PROLONGED IF THE TRACTIVE ASSIST IS ALLOWED TO REMAIN DISENGAGED WHEN POSSIBLE. 21. Press “J4” then release “J4” for Õ direction lights.

22. Press “J6” then release “J6” for Ö direction lights.

23. For auto position headlights, whereas the headlights follow the direction of the selected tram direction, press “J2” and hold, press “J4” release “J4”, then release “J2”. Lights will stay in auto position until “J3”, “J4” or “J6” is pressed.

24. To turn off all lights, press “J4” and “J6” simultaneously and then release both “J4” and “J6” simultaneously.

THIS COMPLETES THE STARTING PROCEDURE.

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Bucyrus America, Inc.

TOWING A DISABLED MACHINE IT IS NOT POSSIBLE, WITHIN THE SCOPE OF THIS GUIDE, TO ANTICIPATE ALL POSSIBLE ARRANGEMENTS FOR TOWING A DISABLED UNIT. BEFORE ATTEMPTING TO TOW ANY VEHICLE, YOU MUST TAKE ALL POSSIBLE PRECAUTIONS TO PROTECT THE OPERATORS AND ANY ONE AROUND BOTH VEHICLES FROM BEING INJURED BY EITHER THE TOWING VEHICLE, THE TOWING DEVICES OR THE VEHICLE BEING TOWED. THE PRIMARY TOWING DEVICE USED (CABLES, BARS, ETC.) AND THE TOWING VEHICLE (SCOOP, TRACTOR, ETC.) 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. 1. Couple the towing vehicle securely to the disabled vehicle.

2. Close the valve to tank circuit that is on the hand pump. This isolates the park brake solenoid from the circuit.

3. Begin pumping the hand pump. The building pressure moves the shuttle valve and allows the Automatic (Park) Brake system to be pressurized.

4. The Automatic (Park) Brake is "released" as indicated by the Brake Release gauge.

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. 5. Begin towing the vehicle.

6. 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 choked in both directions at all four wheels for additional stability. The brake is "set' by opening the valve on the hand-pump.

FAILURE TO SET THE PARKING BRAKE ON THE DISABLED VEHICLE BEFORE REMOVING THE TOWING DEVICE COULD ALLOW THE DISABLED VEHICLE TO ROLL AWAY UNCONTROLLED.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

SHUTDOWN PROCEDURE 1. Tram the UN-A-TRAC® to its designated parking place.

2. Stop the UN-A-TRAC® 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 whining sound.

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. 3. Pull the ejector blade control lever toward the operator to move the ejector blade to the back of the bucket. There should be no obstructions between the ejector blade and the back of the bucket.

Note: Refer to Figure 13 for illustration of control handle.

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

5. Turn “OFF” the machine circuit breaker.

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

8. Connect the steering lockout device (Figure 14): A. Remove the steering lockout device from its storage lugs.

B. Remove the hitch pin from the end farthest from the center section.

C. Adjust turnbuckle until holes line up between the turnbuckle lug and the front section lug.

D. Insert the hitch pin into the front section lug through the turnbuckle.

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. THIS UNIT IS EQUIPPED WITH A CANOPY. BE CAREFUL NOT TO HIT YOUR HEAD WHEN ENTERING OR LEAVING THE OPERATOR'S COMPARTMENT.

IN THE EVENT OF AN EMERGENCY, THE UN-A-TRAC® 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. BE PREPARED FOR THE SUDDEN STOP WHEN THE PANIC STRIPS ARE STRUCK.

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Bucyrus America, Inc.

FIGURE 14 – STEERING LOCKOUT DEVICE

HITCH PIN

STEERING LOCK (SHOWN IN LOCKED POSITION)

STEERING LOCK (SHOWN IN STORED POSITION)

IF THE MACHINE HYDRAULIC SYSTEM IS DISABLED AND THE AUTOMATIC (PARK) BRAKE HAS BEEN RELEASED USING THE BRAKE HAND PUMP, THE SELECTOR VALVE ON THE HAND PUMP MUST BE RETURNED TO THE SET POSITION TO SET THE AUTOMATIC BRAKE. IF THE AUTOMATIC (PARK) BRAKE IS NOT RE-SET AFTER BEING RELEASED WITH THE HAND PUMP, THE MACHINE COULD MOVE OR ROLL OFF, CAUSING INJURY TO PERSONS AROUND THE MACHINE OR OTHER OBJECTS. THIS COMPLETES THE SHUTDOWN PROCEDURE.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

BATTERY CHANGE PROCEDURE (VERTICAL LIFT) Two people are needed to change the battery in the UN-A-TRAC®. Since one person may step into the Hazard Zone, the other person (operating the UN-A-TRAC®) must be very careful and look each time before moving any levers or pedals. Take time now to refamiliarize yourself with the Hazard Zone (page 21).

The battery table must be placed on level ground and the tires fully inflated to130 psi (9 bar).

1. Line up the battery end of the UN-A-TRAC® with an empty battery table (Figure 15) (see Starting Procedure, page 23).

FIGURE 15 – BATTERY CHANGE PROCEDURE (VERTICAL LIFT) CHARGED BATTERY

BATTERY TABLE

DISCHARGED BATTERY

BATTERY TABLE

BATTERY TRAY

CIRCUIT BREAKER

THE "BATTERY" LEVER SHOULD NEVER BE OPERATED EXCEPT AT A BATTERY CHANGE STATION. IF THE "BATTERY" LEVER IS OPERATED IN A LOW ROOF AREA, THE BATTERIES MAY BE DAMAGED. NEVER ATTEMPT TO DISCONNECT A HYDRAULIC HOSE FROM THE BATTERY LIFTING CYLINDERS WHILE THE BATTERIES ARE IN THE UP POSITION. THIS WOULD ALLOW THE BATTERIES TO FALL AND COULD RESULT IN SERIOUS INJURY. TO SERVICE THE BATTERY LIFTING CYLINDERS, THE BATTERIES MUST BE RESTING SECURELY ON A BATTERY CHANGE TABLE.

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Bucyrus America, Inc.

2. Raise the battery tray completely by pulling the "BATTERY" lever. The battery should remain level as it rises. The bottom of the battery tray should rise above the top of the battery table (Figure 16). If the battery is level, go to Step 3. If one side of the battery tray goes up faster than the other side, lower the battery tray by pushing the “BATTERY” lever and continue to hold the lever in this position for one-half to one minute after the battery is seated. Try to raise the battery again. If difficulty in raising the battery level is still encountered, SHUTDOWN the UN-A-TRAC® and call a maintenance person. The battery cannot be changed if it is not level when in the raised position.

FIGURE 16 – BATTERY CHANGE PROCEDURE (VERTICAL LIFT) EMPTY BATTERY TABLE

DISCHARGED BATTERY

BATTERY LIFTING CYLINDER ROD

3. After the battery tray is fully raised, tram the UN-A-TRAC® backward until the battery is positioned completely over the battery change table (Figure 17).

FIGURE 17 – BATTERY CHANGE PROCEDURE (VERTICAL LIFT) DISCHARGED BATTERY

BATTERY LIFTING CYLINDER ROD

BATTERY TABLE

CONTACT POINT

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Bucyrus America, Inc.

4. Lower the battery tray on to the battery table by pushing the “BATTERY” lever away from the operator and holding the lever until the battery lifting cylinder rods are completely retracted (Figure 18).

FIGURE 18 – BATTERY CHANGE PROCEDURE (VERTICAL LIFT) BATTERY TABLE

DISCHARGED BATTERY

5. SHUTDOWN the UN-A-TRAC® (see Shutdown Procedure, page 29).

6. After shutting down the UN-A-TRAC®, disconnect the discharged battery: A. Move the battery circuit breaker to the "OFF" position.

B. Unlock and remove the padlock or other approved locking device at the battery connectors (Figure 34).

C. 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.

D. 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.

E. 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.

7. Connect the jumper cable: A. Connect the receptacle end of the jumper cable to the UN-A-TRAC® and connect the plug end of the jumper cable to the fully charged battery (Figure 19).

B. 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 so it will not be damaged or run over when the UN-A-TRAC® is moved.

8. Start the UN-A-TRAC® (see Starting Procedure, page 23).

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FIGURE 19 – BATTERY CHANGE PROCEDURE (VERTICAL LIFT) JUMPER CABLES

BATTERY TABLE

CHARGED BATTERY

DISCHARGED BATTERY

BATTERY TABLE

9. Line up the UN-A-TRAC® with the charged battery (Figure 20) with the cylinders in the DOWN position. Move the machine until the battery is in position over the battery lifting cylinders (Figure 21).

FIGURE 20 – BATTERY CHANGE PROCEDURE (VERTICAL LIFT) CHARGED BATTERY

JUMPER CABLES

DISCHARGED BATTERY

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Bucyrus America, Inc.

FIGURE 21 – BATTERY CHANGE PROCEDURE (VERTICAL LIFT)

BATTERY TABLE

CHARGED BATTERY

10. SHUTDOWN the UN-A-TRAC® (see Shutdown Procedure, page 29).

11. Disconnect the jumper cable and connect the charged battery directly to the UN-A-TRAC®'s cable.

Remember to be careful with the plug and to line up the connector prongs when inserting the plug.

After the plug is in the receptacle, the lock ring should be rotated clockwise (CW) until hand tight. The padlock or approved locking device must be in the locking lug and locked for this connection to be permissible.

12. Start the UN-A-TRAC® (see Starting Procedure, page 23).

13. Raise the battery by pulling the “BATTERY” lever. Continue to hold the “BATTERY” lever in this position until the battery is no longer resting on the battery table (Figure 22).

IF THE BATTERY IS NOT COMPLETELY LOWERED BEFORE THE UN-ATRAC® LEAVES THE BATTERY CHANGE STATION, THE BATTERY MAY FALL OFF OR HIT THE ROOF AND BE DAMAGED. FIGURE 22 – BATTERY CHANGE PROCEDURE (VERTICAL LIFT)

BATTERY TABLE

BATTERY LIFTING CYLINDER ROD

CHARGED BATTERY

CONTACT POINT

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

14. Move the UN-A-TRAC® forward to clear the battery table (Figure 23).

FIGURE 23 – BATTERY CHANGE PROCEDURE (VERTICAL LIFT) EMPTY BATTERY TABLE

CHARGED BATTERY

BATTERY LIFTING CYLINDER ROD

15. Lower the battery by pushing the “BATTERY” lever. Continue to hold the “BATTERY” lever in this position until the battery lifting cylinder rods are completely retracted (Figure 24).

FIGURE 24 – BATTERY CHANGE PROCEDURE (VERTICAL LIFT)

THIS COMPLETES THE VERTICAL LIFT BATTERY CHANGE PROCEDURE.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

BATTERY CHANGE PROCEDURE (GROUND LEVEL) Two people are needed to change the battery in the UN-A-TRAC®. Since one person may step into the Hazard Zone, the other person (operating the UN-A-TRAC®) must be very careful and look each time before moving any levers or pedals. Take time now to refamiliarize yourself with the Hazard Zone (page 21).

1. Line up the battery end of the UN-A-TRAC® with the place where the battery is to be deposited (Figure 25) (see Starting Procedure, page 23).

FIGURE 25 – BATTERY CHANGE PROCEDURE (GROUND LEVEL)

CHARGED BATTERY

JUMPER CABLES

DISCHARGED BATTERY

THE "BATTERY" CHANGE CONTROL LEVER SHOULD NEVER BE OPERATED EXCEPT AT A BATTERY CHANGE STATION OR WHEN ITS 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. 2. Unlatch both battery Iatch pins before placing the battery on the ground (Figure 26). If difficulty is encountered in unlatching the latch pins, it may be necessary to gently shake the battery up and down by using the battery "LIFT” control lever.

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Bucyrus America, Inc.

FIGURE 26 – BATTERY CHANGE PROCEDURE (GROUND LEVEL)

BATTERY LATCH PIN

BATTERY LATCH PIN

LATCH PIN SHOWN IN LOCKED POSITION

LATCH PIN SHOWN IN RAISED POSITION

LATCH PIN SHOWN IN UNLOCKED POSITION

3. Lower the battery completely to the surface by pushing the "BATTERY” change control lever away from the operator. The bottom of the battery should touch the surface (Figure 27).

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. FIGURE 27 – BATTERY CHANGE PROCEDURE (GROUND LEVEL) DISCHARGED BATTERY

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Bucyrus America, Inc.

4. After the battery is fully lowered, shutdown-the UN-A-TRAC® (see Shutdown Procedure, page 23).

5. After shutting down the UN-A-TRAC®, disconnect the discharged battery (Figure 34, page 43): A. Unlock and remove the padlock or approved locking device at the battery connector.

B. 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 to not come off the plug.

C. Grasp the plug and pull it out until the plug is completely disconnected from the receptacle; the 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.

D. Install the cap which is secured to a receptacle on the battery by a small chain; this cap is placed over the threaded receptacle and rotated in a clockwise (CW) direction until hand tight and until a padlock will fit into the locking lug; the padlocks all use the same key.

6. Connect the jumper cable: A. Connect the receptacle end of the jumper cable to the plug coming out of the connection box on the UN-A-TRAC® (Figure 28).

B. Connect the plug end of the jumper cable to the fully charged battery.

C. 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.

D. One person should hold the jumper cable so it will not be damaged or be run over when the UN-ATRAC® is moved.

FIGURE 28 – BATTERY CHANGE PROCEDURE (GROUND LEVEL) DISCHARGED BATTERY

CHARGED BATTERY

JUMPER CABLES

7. Start the UN-A-TRAC® (see Starting Procedure, page 23). Gently pull away from the discharged battery while the second person holds the jumper cable away from possible damage (Figure 29).

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

FIGURE 29 – BATTERY CHANGE PROCEDURE (GROUND LEVEL) CHARGED BATTERY

JUMPER CABLES

DISCHARGED BATTERY

8. Line the UN-A-TRAC® up with the fully charged battery. Move the machine back until the lift arms are aligned with the sides of the battery (Figures 30 and 31).

FIGURE 30 – BATTERY CHANGE PROCEDURE (GROUND LEVEL) CHARGED BATTERY

JUMPER CABLES

DISCHARGED BATTERY

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

FIGURE 31 – BATTERY CHANGE PROCEDURE (GROUND LEVEL) CHARGED BATTERY

JUMPER CABLES

DISCHARGED BATTERY

9. Raise the battery to the carry position by pulling the "BATTERY" change control lever toward the operator (Figure 32).

FIGURE 32 – BATTERY CHANGE PROCEDURE (GROUND LEVEL)

CHARGED BATTERY

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

10. Reinsert the latch pins on both sides of the battery (Figure 33). If difficulty is encountered in latching the latch pins, it may be necessary to gently shake the battery up and down by using the battery "LIFT” control lever. Shutdown the UN-A-TRAC® (see Shutdown Procedure, page 29).

FIGURE 33 – BATTERY CHANGE PROCEDURE (GROUND LEVEL)

LATCH PIN SHOWN IN LOCKED POSITION

11. Disconnect the jumper cable and connect the charged battery directly to the UN-A-TRAC®'s cable (Figure 34, page 43). Remember to be careful with the plugs. After the plug is in the receptacle, the lock ring should be rotated clockwise (CW) until hand tight. The padlock or approved locking device must be in the locking lug and locked for this connection to be permissible.

12. Start the UN-A-TRAC® (see Starting Procedure, page 23).

THIS COMPLETES THE GROUND LEVEL BATTERY CHANGE PROCEDURE.

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FIGURE 34 – BATTERY PLUG AND RECEPTACLE ASSEMBLY (TYPICAL)

PAD LOCK OR APPROVED LOCKING

CABLE TO MACHINE

CAP

LOCKING LUG RECEPTACLE (THIS RECEPTACLE IS PART OF THE BATTERY)

THREADED LOCK RING

PLUG ASSEMBLY THREADS

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

GENERAL MAINTENANCE INSTRUCTIONS Long reliable service and the safety of those working with this UN-A-TRAC® can only be ensured by conscientious periodic maintenance of the machine.

Anyone performing maintenance on this machine should be trained to operate it and must be familiar with this BUCYRUS AMERICA, INC. Guide.

All electrical work must be supervised and inspected by a MSHA certified electrician.

BEFORE MAINTENANCE OR SERVICING: A. SHUTDOWN the UN-A-TRAC® on level ground (see Shutdown Procedure, page 29).

B. Disconnect the electrical power. The circuit breaker must be in the "OFF" position and the batteries should be disconnected. Also, allow a minimum of one minute for the capacitors to discharge before performing maintenance or working inside the controller.

C. Test the controls to be sure that the UN-A-TRAC® will not operate.

D. Chock all four (4) wheels in both directions.

E. Connect the steering lockout device.

During maintenance or servicing, if the drive motor is to be run, the UN-A-TRAC® must be jacked clear of the ground and securely blocked. All four wheels must be free to rotate.

DO NOT perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity. The maintenance area should be as clean as possible.

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified service person.

CLEANLINESS cannot 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.

DO NOT MOVE ANY HYDRAULIC CONTROL LEVER UNLESS YOU ARE CERTAIN THAT NO ONE COULD BE HURT BY THE MACHINE’S MOVEMENT. DO NOT DISCONNECT A HYDRAULIC CIRCUIT FROM A CYLINDER WHILE THERE IS A LOAD ON THE CYLINDER. DISCONNECT THE BATTERIES BEFORE WORKING ON ANY PART OF THE ELECTRICAL SYSTEM.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

CRITICAL TORQUE VALUES Torque values are expressed in lubricated and dry 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. Dry thread torque values should be used when threads are completely clean and dry.

CRITICAL BOLT TORQUE VALUES (ft./lbs.) (m-n) LOCATION

BOLT SIZE

GRADE

DRY

LUBRICATED

Steering Cylinder Pins Tire-Wheel Mounting Bolts (John Deere Axle) Tire-Wheel Mounting Bolts (Meritor Axle) Tire-Wheel Mounting Bolts (Kessler) Drive Motor-to-Gearbox Mounting Bolts

7/8 NC 3/4-16UNF X 2-1/2” 9/16 NC X 2-1/4” M16 X 1.5 X 60

Grade 8 Grade 8

N/A 390 (529 m-n) 160 (217 m-n) 232

460 300 (407 m-n) 120 (163 m-n) 217

285 (387 m-n)

170 (231 m-n)

Grade 8 Class 10.9

3/4NC X 2-3/4”

Grade 5

LUBRICANTS, FLUIDS AND CAPACITIES LOCATION

TYPE OF LUBRICANT

APPROXIMATE CAPACITY

NOTES

Hydraulic Oil

Spec. 100-1 (John Deere or Meritor) Spec. 100-12 (Kessler) Spec. 100-6 Spec. 100-6 Spec. 100-6

40 Gallons (151.5 l) As Required As Required As Required Each Wheel end As Required For Each Brake

1

Speed Reducer (Gearbox) Axle Housing (Meritor) (Kessler) Planetary Wheel Ends (Meritor) (Kessler) Wet Disc Brakes (Meritor) (Kessler) John Deere Axle Winch SROIB Park Brake Wet Disc Brake (PT Tech) Multi-Purpose Grease

Spec. 100-12 John Deere Hy-Gard Oil API GL-4 or (140) Worm Gear Oil Peragma Grade 8 SROIB Oil Spec. 100-1 Spec. 100-3

2 2 2

20 Qt. (18.9 l) 5 pints (2.36 l)

5

2 Qt. (1.89 l) As Required As Required

4 3

Notes: 1. With ejector blade completely retracted.

2. The axle housing, brake cooling sumps, 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.

4. If the SROIB brake is used as a service brake, sump oil capacity is 4 qt (3.78 l).

5. When bleeding brakes, bleed both ports at the same time.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

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MAINTENANCE CHECK LIST (For Specific Instructions see page 51).

(For Lubricant Specifications see page 61).

ITEM OR LOCATION

INSPECT

EVERY SHIFT Electrical Cables and Conduits; Hydraulic Hoses and Fittings; Tires; Headlights; Warning Tags; Reflectors; Hydraulic Oil Level Tape Switches

ADJUST

CHANGE

LUBRICATE

•

• •

ONCE PER WEEK Grease Points Center Section Pins and Nuts Fire Suppression System Steering Cylinder Pins and Nuts Hydraulic System Oil Filter Wheel Mounting Bolts (First Week Of service) Speed Reducer (Gearbox) Oil Axle Oil Level Drive Shafts Wet Disc Brake Fluid Level SROIB Brake Winch

A/R

• • • • •

A/R •

• • • • • •

ONCE PER MONTH Drive Motor Pump Motor Wheel Bolts

• • •

EVERY THREE MONTHS Hydraulic System Pressure Hydraulic Oil Suction Filter

• •

A/R A/R A/R

A/R

• •

A/R - Perform service as required.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

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PERIODIC MAINTENANCE PROCEDURES EVERY SHIFT DO NOT ALLOW WATER TO ENTER THE ELECTRICAL CONTROLLER AT ANY TIME. EXCEPT DURING SERVICE OR MAINTENANCE, THE CONTROLLER COVER SHOULD BE IN PLACE AND SECURED. 1. Wash down the UN-A-TRAC® and remove all foreign material from the operator's compartment.

2. Inspect all electrical cables, conduits, hydraulic hoses, fittings, tires and headlights for signs of wear or damage. Repair or replace any found damaged.

3. Visually inspect the condition and readability of all warning tags, labels and reflectors. Replace any found missing or damaged.

4. Check the tape switches. Start the UN-A-TRAC®, but do not tram. Strike the tape switches to be certain that they are operating properly, tripping the machine circuit breaker and shutting down the UNA-TRAC®.

5. Check the hydraulic oil level by looking at the sight glass located on the oil tank (Figure 35).

A. If the hydraulic oil level is low, add hydraulic oil to the tank with the hand refill pump.

For Fluid Specifications see page 61: (Spec. 100-1, if equipped with Meritor or John Deere axles) (Spec. 100-12, if equipped with Kessler axles)

FIGURE 35 – HYDRAULIC OIL TANK SIGHT GLASS

SIGHT GLASS

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ONCE PER WEEK 1. Lubricate the UN-A-TRAC® at the points marked on the lubrication chart (Figure 48) with heavy-duty, multi-purpose grease (for Lubricant Specifications see page 61).

2. Check steering cylinder and center section pins and nuts for looseness or wear. necessary. Replace excessively worn parts.

Tighten where

3. Check the fire suppression system.

A. Inspect the hoses, fittings, and nozzles and replace any found damaged.

B. Check the extinguisher tank (Figure 36) for signs of damage or corrosion. The extinguisher tank is located in the rear section of the machine.

C. 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, D. Remove the fill cap (Figure 36).

E. Check that the extinguisher is filled with free flowing Ansul multi-purpose A, B, C dry chemical to a level not more than 3" (.75 mm) from the bottom of the fill opening.

F. Replace the fill cap, hand tight.

FIGURE 36 – FIRE SUPPRESSION TANK AND NOZZLES TYPICAL FIRE SUPPRESSION TANK LOCATION

FILL CAP

NOZZLE OPENING TANK

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

4. Check the wheel mounting bolts (Figure 37). The mounting bolts should be torqued daily for the first two days of operation and weekly afterwards (See page 47 for Torque Values). Also, if equipped with pneumatic tires, check tire pressure. The tires should be inflated to 130 psi (9 bar).

FIGURE 37 – WHEEL MOUNTING BOLTS (John Deere Axle Shown)

WHEEL LUG

5. Check the oil level in the speed reducer (gearbox).

A. Remove the check plug from the speed reducer (gearbox) (Figure 38). The oil level should be kept at the level of the check plug.

B. Should it be necessary to add oil, add oil (Spec. 100-6) through the fill plug hole slowly until oil flows from the check plug hole. Do not overfill the speed reducer.

C. Replace the check and fill plug.

FIGURE 38 – SPEED REDUCER (GEARBOX) OIL LEVEL

FILL PLUG

DRAIN PLUG

53

CHECK PLUG

Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

6. Check the oil levels of both drive axles. (If equipped with John Deere axles, see Figure 41).

A. Park the UN-A-TRAC® on solid level ground and remove the oil level/fill plugs (Figure 39), B. 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 hole to either the 3 o’clock or 9 o’clock position.

B. The oil should just barely flow out from these holes when full.

C. Should it be necessary to add oil, add the oil through the level/fill plug hole slowly, just until it starts to run back out. Allow time for the oil to travel throughout the axle when filling.

7. Check the oil levels of both wet disc brakes.

A. Park the UN-A-TRAC® on solid level ground and remove the oil level/fill plugs (Figure 39 or 40).

B. Should it be necessary to add oil, add oil (Spec. 100-12) through the level/fill plug hole slowly, just until it starts to run back out. Allow time for the oil to travel throughout the wet disc brake when filling.

FIGURE 39 – AXLE AND WET DISC BRAKE FILL POINTS (Meritor) Bleeder

Fill plug Breather

Oil level plug

Fill plug

Fill/check plug

Fill/check plug

FIGURE 40 – AXLE AND WET DISC BRAKE FILL POINTS (Kessler) Bleeder

Brake pressure

Oil level fill/check plug

Drain

Breather

Brake coolant in

Oil level fill/check plug

Brake coolant out

Wear indicator Oil level drain plug

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

FIGURE 41 – JOHN DEERE AXLE BREATHER BRAKE INSPECTION PORT

BRAKE INSPECTION PORT

OIL LEVEL FILL / CHECK PLUG OIL LEVEL FILL / CHECK PLUG

8. If equipped, check oil level in the emergency/park brake (See Figure 42 for SROIB brake and Figure 43 for PT Tech brake).

A. Park the UN-A-TRAC® on solid level ground and remove the oil level/fill plug.

B. Should it be necessary to add oil, add the oil through the level/fill plug hole slowly? Add oil until oil level reaches oil level fill point. Allow time for the oil to travel throughout the wet disc brake when filling. (For Oil Specifications, see page 47)

FOR MORE DETAILED INFORMATION ON THE SROIB WET DISC BRAKE, REFER TO THE BUCYRUS AMERICA, INC. "SROIB BRAKE INSTALLATION AND MAINTENANCE GUIDE,” PART NUMBER A6474X204, AVAILABLE FROM BUCYRUS AMERICA, INC. FIGURE 42 – SROIB WET DISC BRAKE

OIL FILL / CHECK PLUG

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

FIGURE 43 – PT TECH WET DISC BRAKE BLEEDER

OIL FILL PLUG

OIL LEVEL CHECK PLUG

DRAIN PLUG

9. Check the oil level in the winch and lubricate the grease fitting located on the top right side of the winch (Figure 43).

FIGURE 44 – WINCH FILLER PLUG

GREASE FITTING

HORIZONTAL OIL LEVEL PLUG

DRAIN

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

ONCE PER MONTH 1. Inspect the drive motor (Figure 45).

A. Be sure that the machine circuit breaker lever is in the "OFF" position.

B. Remove the inspection covers.

C. Inspect the windings, commutators, brushes, armature, and terminal leads.

1. Windings should be dry and free of dust, grease, oil, and dirt.

2. The commutator should be clean and smooth with a medium polish and a light brown color.

3. Brushes and brush holders should be clean so that the brushes are free to move in the holders and are properly seated. Brushes should be replaced before wear permits the rivets to score the commutator. (See replacement procedure below) 4. The armature and field leads should be undamaged.

5. Terminal leads should be tight.

D. Replace the inspection plate being sure it is securely tightened.

THE DRIVE AND PUMP MOTORS DO NOT REQUIRE PERIODIC LUBRICATION. THE PUMP MOTOR BEARINGS ARE SEALED. THE DRIVE MOTORS HAVE ONE BEARING SEALED AND THE OTHER BEARING RECEIVES LUBRICATION FROM THE GEARCASE OIL. FIGURE 45 – ROCKER RING AND BRUSHES INSPECTION COVER

ROCKER RING

BRUSHES AND BRUSH HOLDERS

ROCKER RING LOCK SCREWS

2. Drive Motor Brush Replacement (if necessary): A. Remove power from the unit by moving the machine or battery circuit breaker lever to "OFF" or by unplugging the battery.

B. Remove inspection cover (Figure 45).

C. Mark the brush holder (rocker ring) neutral setting by scratching or painting two aligning marks, one on the brush holder (rocker ring) and one on the motor end bell.

D. Loosen (BUT DO NOT REMOVE COMPLETELY) the two rocker ring lock screws.

E. Rotate the rocker ring until one of the brushes comes up on top. Disconnect the brush lead and remove the old brush. Replace the old brush with a new one and reconnect the lead wire.

F. Repeat this procedure until all the old brushes have been replaced.

G. Rotate the rocker ring until the neutral marks are aligned.

H. Retighten the two lock screws.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

I. Replace the inspection cover.

3. Inspect the pump motor (Figure 45).

A. Remove the cover from the right rear section of the UN-A-TRAC®.

B. Be sure that the machine circuit breaker lever is in the "OFF" position.

C. Remove the inspection cover (Figure 45).

D. Inspect the windings, commutator, brushes, armature, and terminal leads.

1. Windings should be dry and free of dust, grease, oil, and dirt.

2. The commutator should be clean and smooth with a medium polish and a light brown color.

3. Brushes and brush holders should be clean so that the brushes are free to move in the holders and are properly seated. Brushes should be replaced before the rivets score the commutator.

4. The armature and field leads should be undamaged.

5. Terminal leads should be tight.

E. Replace the inspection cover.

4. Pump Motor Brush Replacement.

A. Remove the inspection cover (Figure 45) from the motor.

B. Mark the brush holder (rocker ring) neutral setting by scratching or painting two aligning marks, one on the brush holder (rocker ring) and one on the motor end bell.

C. Loosen (BUT DO NOT REMOVE COMPLETELY) the two rocker ring lock screws.

D. Rotate the rocker ring until one of the brushes comes up on top. Disconnect the brush lead and remove the old brush. Replace the old brush with a new one and reconnect the lead wire.

E. Repeat this procedure until all the old brushes have been replaced.

F. Rotate the rocker ring until the neutral marks are aligned.

G. Retighten the two lock screws.

H. Replace the inspection cover.

5. Motor Brush Neutral Adjustment IS not recommended (if necessary): A. Remove the motor leads from the controller or disconnect the leads in such a way that 2A2 and 2S2 can be connected to a 12-volt, DC power source.

B. Remove the inspection cover (Figure 44) from the motor.

C. Loosen (BUT DO NOT COMPLETELY REMOVE) the rocker ring lock screws.

D. Apply 12 volts DC to motor leads A1 and A2.

E. If the motor turns, rotate the rocker ring in the direction opposite motor rotation until the motor rotation stops.

F. Tighten the rocker ring lock screws.

G. Replace the inspection cover (Figure 45).

H. Reconnect the leads from the motor to the controller.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

EVERY THREE MONTHS 1. Check (and adjust if necessary) the main Hydraulic System pressure (Figure 46):

BEFORE MOVING THE "EJECTOR" CONTROL LEVER, ALWAYS CHECK TO MAKE SURE NO ONE HAS ANY PART OF HIS BODY BETWEEN THE EJECTOR BLADE AND THE BACK OF THE BUCKET. A. Pull the "EJECTOR" lever toward the operator until the ejector blade has completely returned to the back of the bucket.

B. Continue to hold the "EJECTOR" lever pulled toward the operator and read the pressure indicated by the "SYSTEM PRESSURE" gauge (Figure 10).

A. Normal hydraulic system pressure is set at the factory at 2250 psi (155 bar). If the pressure indicated on the "SYSTEM PRESSURE" gauge is not 2250 psi (155 bar), adjust per hydraulic schematic.

DO NOT ADJUST THE HYDRAULIC SYSTEM PRESSURE TO MORE THAN 2250 psi (155 bar).

FIGURE 46 – HYDRAULIC VALVE BANK

OUTLET STEERING (1700 psi) (117 bar) BUCKET EJECTOR WINCH BATTERY CHANGER OUTLET MAIN RELIEF 2500 PSI PRESET (172 bar)

NOTE: The UN-A-TRAC® is equipped with two relief valves.

1. The relief valve at the pump is to be set at 2250 psi (155 bar).

2. The back-up relief in the valve bank is to be set at 2500 psi (172 bar).

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

2. Clean or change the suction strainer inside the hydraulic oil tank (Figure 47).

A. Clean all dirt and debris from around the hydraulic oil tank cap.

B. Remove the bolts that hold the hydraulic oil tank cap on the top of the tank.

C. Reaching down into the oil tank, unscrew the suction strainer and remove it from the tank.

D. If the strainer is not torn or damaged, it can be cleaned using kerosene and a soft brush and dried thoroughly. If the strainer is damaged, it must be replaced.

E. Replace the strainer in the tank and tighten hand-tight.

F. Replace the cap assembly.

G. Refill the oil tank to the proper level.

(Spec. 100-1, if equipped with Meritor or John Deere axles) (Spec. 100-12, if equipped with Kessler axles)

FIGURE 47 – HYDRAULIC OIL TANK AND SUCTION STRAINER SIGHT GLASS

CAP ASSEMBLY

SUCTION STRAINER

4. Change the oil in the speed reducer (gearbox).

A. Remove the drain plug and allow the oil to drain.

B. Replace the drain plug and refill with oil to the proper level (see Oil Level Procedures, page 53).

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

LUBRICANT SPECIFICATIONS APPROVED SUPPLIERS SPEC. 100-1 - ANTI-WEAR HYDRAULIC OIL ASTM GRADE 315 SUPPLIER

BRAND NAME

SUPPLIER

BRAND NAME

1. AMOCO OIL CO.

AMOCO AW OIL NO. 68

2. GULF OIL 3. MOBIL OIL CORP.

HARMONY 68 AW MOBIL DTE-16

10. TEXACO LUBRICANTS CO. 11. EXXON 12. PENNZOIL

TEXACO RANDO OIL HD 68 NUTO H 68 PENNZBELL AW 68 HYDRAULIC OIL

4. CHEVRON U.S.A.

CHEVRON HYDRAULIC OIL AW ISO 68

13. STANDARD OIL CO. STD. OIL CO.OF OHIO BORON OIL CO BP OIL INC.

5. SUN OIL'COMPANY

SUNVIS 868

6. UNOCAL76

UNAX AW 68

14. LUBRICATION ENGINEERS 15. CONOCO INC.

7. SHELL OIL COMPANY

SHELL HYDRAULIC OIL #33 HULDRAULIC AW 68 CENTRAULIC AW 68

16. HYDROTEX

SUPER HYDRAULIC OIL 68 SYSTEMS 5K 68

17. PHILLIPS

MAGINUS A OILS 81350

DURO AW S-315 OIL

18. MINERS OIL

HYDRAULIC OIL 68AW

8. CENTURY LUBRICATING OILS, INC. 9. ATLANTIC RICHFIELD CO.

INDUSTRON 53 INDUSTRON 53 ENERGOL HLP-C68 6120 MONOLEC HYD. OIL

SPEC. 100-3 - EXTREME PRESSURE BEARING GREASE NLGI GRADE #2 1. AMOCO OIL CO 2. GULF OIL 3. MOBIL OIL CORP. 4. CHEVRON U.S.A. 5. SUN OIL COMPANY

6. UNOCAL 76 7. SHELL OIL COMPANY 8. CENTURY LUBRICATING OILS, INC.

AMOLITH GREASE 2 EP RYKON PREMIUM GREASE 2 EP GULFCROWN GREASE EP#2 MOBILUX EP-2

9. TEXACO, LUBRICANTS CO.

TEXACO MULTIFAK EP 2

10. EXXON

LIDOK EP 2

11. PENNZOIL

CHEVRON DURA-LITH GREASE EP-2 NLGI 2 SUN PRESTIGE 742EP

12. LUBRICATION ENGINEERS 13. CONOCO INC.

MULTIPLEX EP2 ALVANIA EP-2 HULLITH EP2 MULTIPURPOSE GREASE OR REPLEX 2 OR UNIWRL 2 OR UNIWRL EMB OR HULLITH GP 2 OR HULLITH EP 2

14. HYDROTEX 15. PHILLIPS 16. ATLANTIC RICHFIELD

PENNLITH EP 712 GREASE 3752 ALMAGARD VARIPURPOSE LUBRICANT EP CONOLITH GREASE NO. 2 OR SUPER STA GREASE NO. 2 LC-65 HYPLEX PHILUBE EP GREASE LITHOLINE H EP-2 GREASE

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

SPEC. 100-6 - EXTREME PRESSURE GEAR OIL (SAE 90) SUPPLIER

BRAND NAME

SUPPLIER

BRAND NAME

1. AMOCO OIL CO.

AMOCO AW PREMAGEAR EP 320

10. TEXACO LUBRICANTS CO.

2. GULF OIL 3. MOBIL OIL CORP.

EP LUBRICANT HD 320 MOBIL GEAR 632

11. EXXON 12. PENNZOIL

4. CHEVRON U.S.A.

CHEVRON GEAR COMPOUND EP ISO 320

13. LUBRICATION ENGINEERS

5. SUN OIL'COMPANY 6. UNOCAL76

SUNEP 320 EXTRA DUTY NL GEAR LUBE 6EP OMALA 75

14. CONOCO INC. 15. HYDROTEX

HULBEST EP-6

17. MINERS OIL

MEROPA 320 or TEXACO MULTIGEAR EP 80W-90 SPARTAN EP 320 SUPER MAXOL EP 220 GEAR LUBE or PEN GEAR #320 605 ALMASOL VARIPURPOSE GEAR LUBRICANT GEAR OIL 320 932 INDUSTRIAL GEAR LUBE PHILUBE ALL PURPOSE GEAR OIL 85W-90 GEAR OIL EP220

PENNANT NL S-1000

18. CITIES SERVICE

7. SHELL OIL COMPANY 8. CENTURY LUBRICATING OILS, INC. 9. ATLANTIC RICHFIELD CO.

16. PHILLIPS

CITGO EP COMPOUND 110

SPEC. 100-7 - HYDRAULIC AND GENERAL PURPOSE OIL HEAVY / R & O INHIBITED SUPPLIER

BRAND NAME

SUPPLIER

BRAND NAME

1. AMOCO OIL CO.

AMERICAN INDUSTRIAL OIL NO. 68 HARMONY 68 DTE HEAVY-MEDIUM CHEVRON TURBINE OIL ISO 68 or CHEVRON MACHINE OIL R&O ISO 68 SUNVIS 754

10. TEXACO LUBRICANTS CO. 11. EXXON 12. PENNZOIL 13. LUBRICATION ENGINEERS

REGAL OIL R & O N-68 or TDH 1893 TERESSTIC 68 PENNZBELL RO 68 6120 MONOLEC TURBINE OIL

14. CONOCO INC.

UNAX RX 68 or TURBINE OIL 68 TURBO 68 CENTRAULIC R & O 68

15. HYDROTEX

DECTOL R & O 68 or TURBINE OIL 68 SYSTEM 1, SYSTEM 5K 68 MAGNUS OILS 700 HYDRAULIC OIL AW68

DURO 5.315

18. CITIES SERVICE

2. GULF OIL 3. MOBIL OIL CORP. 4. CHEVRON U.S.A.

5. SUN OIL COMPANY 6. UNOCAL76 7. SHELL OIL COMPANY 8. CENTURY LUBRICATING OILS, INC. 9. ATLANTIC RICHFIELD CO.

16. PHILLIPS 17. MINERS OIL

CITGO PACEMAKER A/W68

SPEC. 100-12 – MULTI PURPOSE TRACTOR HYDRAULIC FLUID SUPPLIER

BRAND NAME

SUPPLIER

BRAND NAME

1. EXXON / MOBIL 2. CENTURY / FUCHS 3. SHELL 4. CHEVRON

MOBILFLUID 424 MULTITRAN DONAX TD TRACTOR HYDRAULIC FLUID

5. BP LUBRICANTS 6. QUAKER STATE 7. CONOCO

TRACTRAN UTH QUAKER STATE FCI HD POWERTRAN FLUID

62

Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

The following lubricants are recommended for use in the UN-A-TRAC®. Other lubricants with equivalent specifications may be used.

Hydraulic Oil (John Deere or Meritor) Hydraulic Oil (Kessler) Heavy-Duty, Multi-Purpose Grease Speed Reducer (Gearbox) Oil Axle Oil (Meritor or Kessler) Axle Oil (John Deere) Wet Disc Brakes (Meritor or Kessler) SROIB Park Brake

Recommended Lubricant Texaco Rando HD68

Specification Spec 100-1

Mobilfluid 424

Spec 100-12

Texaco EP 1 Texaco EP-90 Gear Oil Texaco EP-90 Gear Oil John Deere Hy-Gard Oil Mobilfluid 424

Spec 100-3 Spec 100-6 Spec 100-6 -------Spec 100-12

SROIB Oil

--------

LUBRICATION CHART CLEAN ALL EXCESS OIL AND GREASE FROM THE UN-A-TRAC® AFTER COMPLETING MAINTENANCE PROCEDURES.

ONCE PER WEEK The following points should be lubricated at the grease fittings with heavy-duty, multi purpose grease.

SYMBOL

LOCATION

•

1. Bucket Pivot Pins (2 Places)

•

2. Bucket Lift Cylinders (Rod End)

•

3. Bucket Lift Cylinders (Base End)

•

4. Steering Cylinders (Rod End)

•

5. Steering Cylinders (Base End)

•

6. Automatic (Park) brake Caliper

•

7. Drive Line Universal Joints

•

8. Drive Line Slip Joints

•

9. Control Levers

•

10. Foot Pedals

•

11. Central Lubrication Fitting Block

•

12. Center Section Assembly

•

13. Winch 63

Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

FIGURE 48 – MAINTENANCE AND LUBRICATION POINTS

64

Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

TROUBLESHOOTING PROCEDURES The following section lists possible problems encountered when servicing the UN-A-TRAC® and can aid in locating and correcting these problems.

For electrical instructions, troubleshooting, and maintenance procedures, refer to the BUCYRUS AMERICA, INC. "Model BUC 2000 Solid-State Troubleshooting Guide,” available from your BUCYRUS AMERICA, INC. dealer.

THE FOLLOWING PROCEDURES MUST BE CARRIED OUT WITH THE COVER OF THE ELECTRICAL CONTROLLER REMOVED AND SOME PROCEDURES REQUIRE THE CONTROLLER TO BE ENERGIZED DURING THE TESTS. IT IS EXTREMELY IMPORTANT THAT YOU TAKE ALL NECESSARY PRECAUTIONS TO PREVENT ACCIDENTAL ELECTRICAL SHOCK WHILE WORKING WITHIN THE CONTROLLER. AN MSHACERTIFIED ELECTRICIAN MUST SUPERVISE AND INSPECT ALL WORK PERFORMED. For maintenance procedures and tests that DO NOT require the controller to be energized, these precautions include: B. Before removing the controller cover, remove electrical power from the system by turning the circuit breaker to the “OFF” position and unplugging the battery connectors.

B. Use insulated gloves and tools where possible.

C. When the power or cover is removed, allow a minimum of one minute for the capacitors to discharge before working inside the controller. To insure that the capacitors are discharged, connect an insulated 100-ohm, 10-watt resistor across the capacitor assembly and hold for 30 seconds. Repeat for both (2) capacitor assemblies.

D. All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: A. At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be turned to the "OFF" position and the capacitor banks discharged (see above.) Once the circuit breaker is in the "OFF" position and the capacitor banks discharged, adjustments or parts replacements can be made.

B. Use insulated gloves and tools where possible.

C. All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

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 LIFT CYLINDER IS SUPPORTING THE BATTERY, THE BATTERY WILL FALL.

65

Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

HYDRAULIC SYSTEM (GENERAL) TROUBLE, SYMPTOM OR CONDITION DIRTY OIL

FOAMING OIL

MOISTURE IN OIL

OVERHEATING OF SYSTEM

PROBABLE CAUSE

TEST, CHECK AND/OR REMEDY

1. Components not properly cleaned after servicing.

1. Disassemble components and reclean parts.

2. Air breather Ieft off.

2. Replace breather.

3. Hose lines not properly covered while servicing machine.

3. Clean hose Iines after servicing.

4. Filter elements not replaced at proper, intervals or when indicated.

4. Replace elements at proper intervals with new filters.

1. Return of tank lines not below fluid level. Check oil level.

1. Replace broken hoses or lines.

2. Oil contaminated with incompatible foreign matter.

2. Drain out oil and replace with clean oil.

3. Suction leak to pump aerating oil.

3. Replace or tighten fittings and Iines.

1.Soluble oil solution splashing into poorly gasketed tanks or fill holes left open.

1. Drain out and refill with clean oil. Check fill pipes to see if they are properly closed.

2. Moisture in cans or used replacement oil.

2. Replace with new cans of oil.

3. Extreme temperature differential in certain geographical locations.

3. Replace with recommended oil for correct temperature range.

1. Fluid viscosity too high.

1. Check fluid specs.

2. Excessive slippage or internal leakage past pump or cylinders.

2. Fluid viscosity too low.

3. Improper air circulation around reservoir.

3. Check to see if the area around the reservoir is clear.

4. System relief valve set too high.

4. Reset the relief valve to specifications.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

HYDRAULIC SYSTEM (GENERAL) (CONT.) TROUBLE, SYMPTOM OR CONDITION

PROBABLE CAUSE

TEST, CHECK AND/OR REMEDY

FOREIGN MATTER SOURCES IN THE CIRCUIT

1. Sealing compound (pipe dope, teflon tape).

1. Clean or replace seals.

2. Burrs inside piping components.

2. Disassemble piping components and remove any burrs.

3. Tag ends of packing coming loose.

3. Remove old packing and replace with new.

4. Lines left unprotected and dirty, repaired components.

4. Drain and replace oil.

5. Repair parts not properly protected while stored.

5. Clean parts thoroughly before installation.

BRAKES (SERVICE) WET DISC INSUFFICIENT BRAKING

1. No gas charge in accumulator.

1. Check gas charge.

2. Defective brakes.

2. Check brakes.

3. Hydraulic lines or fittings leaking.

3. Check for leaks and repair.

4. Pedal linkage out of adjustment.

4. Adjust linkage.

5. Damaged hydraulic brake lines.

5. Check lines for dents that restrict flow.

6. Air in brake system.

6. Bleed brakes.

7. Brake seal or o-ring failure.

7. Replace seal or o-ring.

8. No oil or low oil level in tank.

8. Bring oil up to proper level.

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Revised 03 – 08 MODEL 488L AND 488-6 SERIES UN-A-TRAC®

Bucyrus America, Inc.

BRAKES (AUTOMATIC WET DISC) 1. Insufficient hydraulic pressure.

1. Check hydraulic circuit.

2. Hydraulic lines or fitting damage.

2. Repair lines or fitting.

3. Solenoid coil bad.

3. Replace solenoid coil.

4. Solenoid plunger won’t seat.

4. Check for dirt or contamination in system.

5. Blown o-ring in piston housing.

5. Replace o-ring.

1. Blocked or crushed hydraulic line.

1. Replace hydraulic line.

2. Brake pads worn or broken.

2. Replace brake pads.

1. Piston seal leak.

1. Replace seals.

2. Other circuit leaks.

2. Correct leaks.

1. Pressure too Iow.

1. Check pressure at cylinder to make circuit requirements.

2. Piston seal leak.

2. Replace seals.

3. Piston rod broken at piston end.

3. Disassemble and replace piston rod.

4. Contamination in hydraulic system resulting in scored cylinder bore.

4. Disassemble and replace necessary parts.

ERRATIC OR CHATTER IN OPERATION

1. Excessive friction due to misalignment.

1. Correct cylinder to load alignment.

EXCESSIVE OR RAPID PISTON SEAL WEAR

1. Excessive high back pressure due to over adjustment.

1. Correct pressure adjustment.

BRAKES WON’T RELEASE

BRAKE WON’T SET

CYLINDERS CYLINDER DRIFTS

CYLINDER FAILS TO MOVE THE LOAD WHEN ACTUATED

68

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Bucyrus America, Inc.

CYLINDERS (CONT.) TROUBLE, SYMPTOM OR CONDITION

PROBABLE CAUSE

TEST, CHECK AND/OR REMEDY

1. Excessive pressure.

1. Reduce pressure to rated limits.

2. Seal is pinched or extruded.

2. Replace cylinder body seal.

3. Seal deterioration (soft or gummy).

3. Check compatibility of seal material with operating fluid.

Replace oil.

THE PISTON IS LEAKING

1. Dirt has scored the piston or the rod.

1. Replace rod.

THE PISTON FREEZES TO THE TUBE

1. Scoring in the piston.

1. Replace.

PACKING AND GASKET LEAKS DEVELOP

1. Excessive heat.

1. Replace packing and gasket.

1. Vacuum leaks in suction line.

1. Check for leaks in fittings or damaged suction lines.

CYLINDER BODY SEAL LEAK

PUMPS PUMP MAKES EXCESSIVE NOISE

2. Vacuum leaks in the pump shaft seal.

SEAL LEAK

2. Check pump.

3. Poor alignment with drive mechanism.

3. Align pump and pump motor.

4. Incorrect fluid in system.

4. Check fluid specs.

5. Relief valve set too high.

5. Check relief pressure.

6. Seal deterioration (hard or loss of elasticity).

6. Replace seal.

7.Seal deterioration (loss of radial squeeze due to flat spots or wear on O.D. or I. D.).

7. Replace seal.

1. Torn or worn seals.

1. Replace seal.

2. Gland bearing worn.

2. Replace gland and seals.

3. Seal deterioration (soft or gummy).

3. Replace seal.

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PUMPS (CONT.) TROUBLE, SYMPTOM OR CONDITION SEAL LEAK (Continued)

PUMP FAILURE TO DELIVER OIL

PROBABLE CAUSE

TEST, CHECK AND/OR REMEDY

8. Worn or faulty bearing.

8. Replace faulty bearing.

9. Reversed rotation.

9. Check pump motor wiring.

10. PIugged or restricted suction Iine or suction strainer.

10. Clean by removing the plugged area.

11. Plugged reservoir filter breather.

11. Clean reservoir. Clean breather.

12. Oil viscosity too high or operating temperature too low.

12. Replace with recommended oil.

13. Air leak in suction line or fittings.

13. Replace lines or fittings if badly worn.

14. Loose or worn pump parts.

14. Replace worn pump parts.

15. Air leak at pump shaft seal.

15. Replace pump shaft seals.

16. Oil level too low and drawing air in through inlet pipe opening.

16. Check oil level.

17. Air bubbles in intake oil.

17. Check oil level and tighten any loose fittings.

18. Pump housing bolts loose or not properly torqued.

18. Tighten the housing bolts, and re-torque bolts.

1. Low oil Ievel in reservoir.

1. Check oil level.

2. Oil intake hose suction strainer plugged.

2. Clean or replace strainer.

3. Air leak in suction line and preventing priming.

3. Tighten or replace suction lines.

4. Pump shaft turning too slowly.

4. Gears are worn and need replacing.

5. Oil viscosity too high.

5. Replace with recommended oil.

6. Wrong shaft rotation.

6. Check pump motor wiring.

7. Pump shaft or parts broken.

7. Replace shaft or broken parts.

8. Dirt in pump.

8. Clean pump.

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PUMPS (CONT.) TROUBLE, SYMPTOM OR CONDITION

PROBABLE CAUSE

TEST, CHECK AND/OR REMEDY

1. Shaft seal worn.

1. Replace seals.

2. Head of oil on suction hose connection leaking.

2. Tighten bolts. Tighten or replace connections.

3. Pump housing bolts loose or improperly torqued.

3. Tighten bolts.

1. Abrasive dirt in hydraulic oil being circulated through the system.

1. Replace oil with clean hydraulic oil.

2. OiI viscosity too Iow.

2. Replace with recommended oil.

3. System pressure exceeding pump rating.

3. Relief valve out of adjustment.

4. Pump misalignment.

4. Realign pump.

1. Seizure due to lack of oil.

1. Check oil level.

2. Excessive system pressure above maximum pump rating.

2. Relief valve out of adjustment.

3. Excessive torquing to housing bolts.

3. Loosen bolts and then retorque.

4. Solid matter being drawn in from reservoir and wedged in pump.

4. Remove and clean clogged area.

THE OPERATING PRESSURE CANNOT BE CHANGED

1. Valve spring broken.

1. Replace the spring.

2. Open valve in the system.

2. Find and close open valve.

THE VALVE PISTON STICKS

1. Dirt in the system.

1. Remove the valve and clean it thoroughly; flush the system as necessary.

CERTAIN PASSAGES ARE BLOCKED OR PRESSURE FLUCTUATES

1. Dirt in the system.

1. Remove the valve and clean it thoroughly; flush the system as necessary.

OIL LEAKAGE AROUND PUMP

EXCESSIVE PUMP WEAR

PUMP PARTS INSIDE THE HOUSING ARE BROKEN

RELIEF VALVES

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RELIEF VALVES (CONT.) TROUBLE, SYMPTOM OR CONDITION

PROBABLE CAUSE

TEST, CHECK AND/OR REMEDY

THE PRESSURE FLUCTUATES, AND THERE IS EXTREME NOISE IN THE VALVE

1. Air in the system.

1. Check for leaks.

2. Pressure or volume too high.

2. Adjust the pressure or volume.

THE VALVE LEAKS INTERNALLY

1. Valve piston and body worn.

1. Replace the valve.

EXCESSIVE LEAKAGE OR STICKING PISTONS OCCURS

1. Valve excessively hot.

1. Remove the valve and clean it thoroughly; flush the system.

2. Dirt in the system.

2. Replace oil.

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MAJOR MAINTENANCE PROCEDURES DRIVE MOTOR/GEARBOX (SPEED REDUCER) REMOVAL AND REPLACEMENT POWER MUST BE REMOVED BY UNPLUGGING THE BATTERY PLUGS BEFORE SERVICING THE MOTORS. FIGURE 49 – DRIVE TRAIN COMPONENTS FRONT AXLE ASSEMBLY

DRIVE MOTOR

SPEED REDUCER

FRONT DRIVE SHAFT BEARING CARRIER MIDDLE DRIVE SHAFT REAR DRIVE SHAFT REAR AXLE ASSEMBLY

1. Drive Motor: A. Remove the motor inspection cover (Figure 49) and disconnect the power cables to the motor.

Unpack the motor gland and completely remove the wiring and conduit from the motor.

B. Attach a crane or hoist, capable of lifting the motor, to the eyebolt (Figure 49) on top of the motor and take up any slack in hoist chain.

C. Remove the four (4) bolts that attach the motor to the gearbox.

D. Lift the motor out of the unit.

E. Cover the reducer opening to prevent foreign matter from entering the gearbox.

2. Drive Motor Replacement: Verify that motor pinion gear is installed.

B. Clean all mating surfaces (motor and gearbox.)

C. Lower motor into unit and align bolt holes.

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D. Bolt motor onto gearbox, turning pinion gear as necessary to align gears.

E. Torque bolts to 240 ft./lbs. (325 m-n) (Lubricated threads) 400 ft./lbs. (543 m-n) (Dry threads) F. Reconnect cable leads.

G. Replace inspection cover.

3. Drive Motor and Gearbox Removal: A. Remove the motor inspection cover and disconnect the power cables to the motor. Unpack the motor gland and completely remove the wiring and conduit from the motor.

B. Disconnect the drive shafts from both sides of the gearbox.

C. Tag and disconnect the brake lines from the brake calipers on the gearbox.

D. Attach a crane or hoist, capable of lifting the motor and gearbox and take up any slack in the hoist chain.

E. Remove the bolts that attach the gearbox to the frame.

F. Lift the motor/gearbox out of the unit.

4. Motor/gearbox Replacement: A. Attach motor to gearbox and torque bolts to 240 ft./lbs. (325 m-n) (lubricated threads) 400 ft./lbs (543 m-n) (dry threads).

B. Clean all mating surfaces (gearbox and frame) thoroughly.

C. Hoist motor/gearbox close to its location in the frame.

D. Align the gearbox mounting feet with the holes in the frame and tighten bolts. Torque the mounting bolts to 240 ft./lbs. (325 m-n) (lubricated threads) 400 ft/lbs. (543 m-n) (dry threads).

E. Connect the drive shafts to the gearbox.

F. Connect the brake hoses to the proper calipers and bleed the service brake.

G. Check all oil levels before operating the unit.

H. Bleed the automatic brake.

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TIRE/WHEEL INSTALLATION PROCEDURE

The following installation procedures are for general guidance when installing a tirelwheel assembly on most underground mining machines. Any use made of the advisory information contained herein is entirely within the control and discretion of the user and is wholly voluntary.

MIXING PARTS OF DIFFERENT DESIGN OR FROM A VARIETY OF SOURCES FOR WHEELS WITH PNEUMATIC TIRES COULD CAUSE SEVERE INJURY OR DEATH.

TIRE/WHEEL STRESSES Rubber tired underground mining machinery is routinely subject to severe abuse due to the conditions in which it is operated. Whether a primary haulage or utility/support vehicle, all are subject to extreme shock, vibration, temperature change and various other loads and stresses that cause maintenance problems. One such problem is found in tire/wheel assemblies.

Many maintenance personnel view installing a tire/wheel assembly on a machine as a relatively simple task. However, if a few simple rules on proper installation are not followed, unnecessary difficulties may be experienced. Tires act like shock absorbers on haulage and support vehicles, transferring cushioned loads to the wheels. Even after proper installation, periodic checks need to be made to insure that tire/wheel assemblies do not loosen, causing wheel studs to break or damaging the mounting bolt pattern.

WHEEL MOUNTING ARRANGEMENTS Various mounting arrangements between the wheel and hub or wheel end are used by manufacturers.

One of the more common is the taper-lock. This arrangement requires a taper on both wheel and hub where the mating surfaces of the taper carry the loads. Incomplete seating of the taper will allow the wheel to loosen, resulting in stud or bolt shear and possible tire/wheel damage.

Another mounting arrangement is based on holding a very close pilot fit where the tolerance between the wheel and hub is very tight, requiring a clamp-load force to hold the wheel securely in place. If the wheel studs or bolts are allowed to loosen, the load will be transmitted to them, resulting in sheared studs or bolts.

PROBLEM AREAS Periodic wheel inspection is critical to the life cycle of a tire/wheel assembly. A fractured wheel, broken bolt pattern and missing or broken wheel studs are all contributors to tire/wheel failures. Problems in these areas occur as the result of repeated cyclical loading as the tire/wheel unit rotates during machine travel. Haulage vehicles loaded unevenly, downhill hauls with high speed turns, or operating a vehicle with one tire of a dual assembly damaged or flat are some examples of conditions that produce damaging high stresses in wheel assemblies. Also, the effects of corroding or poorly fitted mating parts can produce surface irregularities that result in cracks and ultimate failure of a wheel.

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A most common problem with tire/wheel installations is the incorrect tightening of wheel bolts or studs.

Threaded fasteners perform there function of holding things together better when torque control is used in their tightening. Using an accurate torque wrench correctly is the best and most practical way of securing fasteners, Although torque value charts are available as a reference guide to proper tightening, OEM specifications should always be followed when tightening fasteners. However, proper torque values are of little benefit if certain other factors are not considered.

WHEEL MOUNTING TIPS All fasteners should be examined before use. Any fastener that is worn, bent or has damaged threads should be replaced. Fastener threads should also be lightly coated with a protective substance, such as residual oils, wax or loctite, because any oxidation or rust will upset the torque-to-tension relationship.

Mating surface conditions should also be considered. The tightening surface under the bolt or nut should be carefully inspected. A fastener, when tightened against a softer material, will gall under these conditions, and much of the applied torque may be lost through head friction. It is very important when using higher strength fasteners to have a smooth, even surface under the bolt head. In some cases, hard flat washers and most lockwashers will provide a good tightening surface.

Another area of concern is cleanliness. AlI mating surfaces should be free of rust, dirt, oil, paint, etc.

Also no paint of any kind should exist between a fastener and wheel disc surface. Any form of contamination between these surfaces will most likely lead to serious wheel problems.

FIGURE 50 – WHEEL TORQUING PATTERN

WHEN TORQUING ANY WHEEL BOLT PATTERN, ALWAYS TORQUE IN A TRIANGULAR PATTERN.

FIGURE 51 –TORQUE PATTERNS

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RECOMMENDED WHEEL MOUNTING PROCEDURES: 1. All steel mating surfaces must be free and clean of any dirt, corrosion, paint, etc. These areas include wheel/hub tapers and disc faces. NO PAINT should be present under bolt heads or nuts.

2. Fasteners should be in proper condition. Any fastener with damage, such as corrosion, bending or worn threads, should be replaced. Replace all broken wheel studs.

3. After positioning the wheel on the hub, tighten nuts down eveningly. Triangulate the bolt pattern tightening sequence as shown in the diagrams.

4. After operating the machine for a short period of time, check the wheel-mounting bolts or nuts for proper torque.

NOTE: Wheel bolts or nuts “seat in” during normal vehicle operation. Therefore, it is necessary to repeat torquing procedures as necessary to seat the wheel to the hub. Planned periodic checks will help maintain correct torque values. All bolts and nuts, regardless of type, should be regularly checked for tightness.

PRECAUTIONS: Do not install or remove tire/wheel assemblies from a machine without proper training.

Check wheel components periodically for cracks or broken parts. damaged or severely rusted components. When in doubt replace.

Replace all cracked, badly worn,

Do not, under any circumstances, attempt to rework, weld, heat or braze any wheel components that are cracked, broken or damaged. Replace such components with new OEM parts of the correct size and type.

Mixing wheel parts of different design or from a variety of sources is potentially dangerous.

Replace broken studs and each unbroken stud next to the broken one.

Replace all damaged wheel studs or bolts.

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

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. P/N A6474X230 Revision 1, December / 07  BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED

Bucyrus America, Inc. ________________________________________________________________ 4041 Wurno Road Telephone: 540-980-4530 Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.bucyrus.com

Bucyrus America, Inc.

TABLE OF CONTENTS Page PREFACE ............................................................................................................................................... 1 SYMBOLS AND SPECIAL NOTATIONS ................................................................................................ 2 MAJOR HAZARDS ................................................................................................................................. 4 SAFETY PRECAUTIONS AND GUIDELINES ......................................................................................... 5 OVERVIEW............................................................................................................................................. 5 LOCATION ............................................................................................................................................. 5 PRE-START ........................................................................................................................................... 5 MAINTENANCE ....................................................................................................................................... 6 THEORY OF OPERATION FERRORESONANT DESIGN....................................................................... 8 INTRODUCTION ..................................................................................................................................... 9 GENERAL .............................................................................................................................................. 9 GENERAL INFORMATION ................................................................................................................... 10 RECEIVING INSTRUCTIONS ............................................................................................................... 10 HANDLING ........................................................................................................................................... 10 NOMENCLATURE PLATES ................................................................................................................. 10 ADJUSTMENTS ................................................................................................................................... 10 SPARE PARTS..................................................................................................................................... 10 RATINGS AND SPECIFICATIONS ....................................................................................................... 11 OUTPUT RATINGS ................................................................................................................................ 11 INPUT RATINGS .................................................................................................................................... 11 TYPICAL ELECTRICAL SPECIFICATIONS ................................................................................................... 11 STANDARD FEATURES .......................................................................................................................... 12 OPTIONAL GROUND INTEGRITY .............................................................................................................. 12 ENVIRONMENTAL RATINGS .................................................................................................................... 13 INSTALLATION INFORMATION........................................................................................................... 14 MINIMUM W IRE SIZES ........................................................................................................................... 14 ELECTRICAL CONNECTIONS & FIELD W IRING ........................................................................................... 14 OPERATION ......................................................................................................................................... 16 START UP (ELECTRONIC TIMER) ............................................................................................................ 16 ADJUSTMENTS ..................................................................................................................................... 17 CIRCUIT OPERATION............................................................................................................................. 17 TROUBLESHOOTING .......................................................................................................................... 18 GENERAL INSPECTION .......................................................................................................................... 18 SERVICE INFORMATION ......................................................................................................................... 18 I

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SYMPTOMS AND CAUSES ...................................................................................................................... 19 GROUND AND SHORT CIRCUIT TEST ....................................................................................................... 19 TROUBLESHOOTING AND REPLACING POWER SILICON DIODES .................................................................. 20 CHECKING CAPACITORS........................................................................................................................ 20

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PREFACE This manual is intended to provide GENERAL product information for Bucyrus Series Battery Chargers.

The illustrations, descriptions and procedures contained in this publication apply only to Bucyrus Series Battery Chargers.

Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Bucyrus Series Battery Charger 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 charger 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 charger, 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 charger 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 charger.

While this manual attempts to anticipate the most important operations and maintenance needs for this charger, 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.

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.

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DANGER ONLY TRAINED AUTHORIZED PERSONNEL SHOULD OPERATE OR PERFORM MAINTENANCE ON THE CHARGER. 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 CHARGER IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

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MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

ELECTRICAL (A.C. Input, Charger, Battery)

Electrical shock could cause irreparable injury or death.

All electrical systems should be maintained by certified electricians.

The a.c. input and charger plug should be disconnected before servicing the charger.

Charging a battery of a size different than that shown on the charger nameplate could cause the battery to burst, or cause damage to the battery or charger.

Chargers should be matched to the size batteries in use at each particular mine.

The battery produces lethal amounts of power whether connected to the machine or charger, or not.

The battery should be maintained by qualified personnel. (Refer to Bucyrus America, Inc. "INSTALLATION, USE, MAINTENANCE, AND REPAIR OF MINE POWER STORAGE BATTERIES,” PART NUMBER A6474X26, for complete instructions).

Battery covers could fall crushing hands or arms.

Be sure cover supports are in place when working on battery.

Battery hold-down clamps could crush fingers.

Keep fingers away from hold-down clamps.

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.

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.

BATTERY

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SAFETY PRECAUTIONS AND GUIDELINES Overview Before using this equipment, read all instructions and cautionary markings on (1) unit, (2) battery, and (3) product using the battery.

READ and STUDY this guide. KNOW how to safely use the unit's controls and what you must do for safe operation and 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

Location LOCATE the charging station away from rain, snow, wet conditions or areas of high traffic when possible.

NEVER place this unit directly above a battery. equipment.

Gases from the battery will corrode and damage

NEVER allow the battery electrolyte to drop 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 anyway.

DO NOT set a battery on top of this unit

Pre-Start Read this entire guide BEFORE attempting to operate this unit. You should be familiar with the controls and their functions before the unit is energized.

DO NOT operate this equipment if it has received a sharp blow been dropped, or otherwise damaged in any way; take it to a qualified service technician.

INSPECT the charger by doing a pre-operational inspection. Have any broken or missing parts corrected or replaced before use.

VERIFY that all maintenance has been performed.

VERIFY that all the instruction and safety labels are in place and readable. These are as important as any other equipment on the machine.

CLEAN any foreign material from inside the charger cabinet.

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Starting ALWAYS follow all safety rules of each particular mine when operating the charger.

If problems or equipment malfunctions are encountered while operating the unit, it must be properly shutdown and the problem repaired. Continuing to use malfunctioning equipment can not only be unsafe for the operator and other personnel but can lead to further damage to the unit as well.

Before using this equipment, read all instructions and cautionary markings on the charger and the battery.

Maintenance AVOID, whenever possible, servicing, cleaning or examining the charger in congested areas.

DO NOT alter the electrical settings from that indicated in this operation guide or as set at the factory.

DO NOT disassemble this unit; take it to a qualified service technician if service or repair is required.

Incorrect reassemble may result in a risk of electric shock or fire.

ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Section for the proper location and part number of decals and plates.

DISCONNECT the battery when working with electrical systems, or when welding on the unit to prevent electrical shock.

To help reduce risk of electric shock, disconnect this unit from the AC power supply and batteries before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

BE SURE the battery area is well ventilated (clear of fumes) when it is connected to the battery charger or when working on or around the battery with sparks or flames. 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.

USE ONLY THE NUMBER AND TYPE OF BATTERIES SPECIFIED ON NAMEPLATE. ATTEMPTING TO CHARGE OTHER TYPES OF BATTERIES COULD CAUSE THE BATTERY TO BURST, CAUSING PERSONAL INJURY OR DAMAGE. BATTERIES PRODUCE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF THE UTMOST IMPORTANCE THAT EACH TIME BEFORE USING THIS UNIT, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY. To reduce risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of any other equipment you intend to use in the vicinity of the battery.

Review cautionary marking on all products.

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Personal Precautions Have someone 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. Avoid touching eyes while working near a battery.

If the battery electrolyte contacts skin or clothing, wash immediately 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.

Avoid dropping metal tools onto a battery. It might spark or short circuit the battery or other electric parts that could 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 a ring or the like to metal, causing a severe burn.

NEVER charge a frozen battery.

If it is necessary to remove the battery connections, always remove the grounded terminal from the battery first. 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 the eyes.

Study all the battery manufacturer's specific precautions such as do not remove cell caps while charging, recommended rates of charge, and maintenance procedures.

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THEORY OF OPERATION FERRORESONANT DESIGN The transformer in a ferroresonant design is non-linear. Its secondary is operated in saturation while the primary is operated in the linear region of the B-H curve.

A magnetic shunt is used to separate the primary and secondary fluxes, which are at different levels.

This non-linear operation means that the transformer no longer obeys the turn’s ratio laws of the linear transformer. That is, the secondary voltage is no longer a function of the turns ratio times the primary voltage. This means that changes in the primary voltage do not directly affect the secondary voltage value.

The secondary voltage is proportional to the voltage across the resonating winding only. The voltage of the resonating winding is affected by the amount of magnetic coupling to the primary, and by careful selection of magnetic shunts and capacitor values. Thus a battery charging curve can be established.

The charging curve is essentially fixed and can only be altered by changes in the transformer design.

Under short circuit conditions, the amount of primary to secondary magnetic coupling determines the value of the output current limit.

Rectifiers are added to convert the output of this A.C. regulator into D.C. The ferroresonant circuit requires a good grade of capacitor in the resonating circuit to improve reliability and a careful design of the transformer. That is the principle of the ferroresonant design.

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INTRODUCTION The Bucyrus America, Inc. Series Charger can be one of the most useful and safe machines found underground today, IF IT IS OPERATED CORRECTLY BY A PROPERLY TRAINED OPERATOR. Before operating the Bucyrus Series Charger, study the illustrations to become familiar with the controls and read the description of each control.

General The Bucyrus Series Mine Battery Charger combines reliable, rugged components with unmatched circuit simplicity.

The ferroresonant design of the Bucyrus Series Charger eliminates the need for complicated control circuits and lowers the parts count.

Three major components make up the circuit of the Bucyrus Series Charger; a ferroresonant step down transformer; silicon rectifiers, and timer.

The magnetics are designed with an extra margin of capacity and have a Class H (180 degrees C) rating.

Cores and windings are insulated with Class H Nomex material. The DuPont Nomex system uses a modified polyester baking varnish for further protection. This assures continued operation under the most severe, damp and dirty conditions present in the mine.

The full wave rectifier includes conservatively rated silicon diodes and surge suppressers to provide a reliable d. c. output.

The Bucyrus Series Charger regulates the d. c. output voltage to produce the proper charging curves for the battery. Its charge rate is dependent on the state of charge of your battery. A.C. line voltage compensation prevents any drift from the d. c. charging curve because of surges or drops in voltage.

Basic design eliminates the need for voltage sensitive relays.

The Bucyrus Series a Charger automatically limits the output of the charger to approximately 125% of its rating. This prevents battery overheating, fuse blowing and assures long life for both battery and charger.

The Bucyrus Series Charger is a completely automatic constant voltage charger. Each Bucyrus Series Charger is designed to operate on a specific type of battery with a specified number of cells.

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GENERAL INFORMATION TO ENSURE SAFE INSTALLATION AND OPERATION, THE INFORMATION GIVEN IN THIS INSTRUCTION MANUAL SHOULD BE READ AND UNDERSTOOD BEFORE INSTALLING OR USING THE EQUIPMENT.

RECEIVING INSTRUCTIONS Unpacking and Inspection: Examine the shipping crate upon arrival. If there is obvious damage, describe on the receiving documents. Within a few days after delivery, the equipment should be uncrated and carefully inspected for hidden damages. When removing packaging material, be careful not to discard any equipment, parts, or manuals

HANDLING EQUIPMENT CAN BE VERY HEAVY, AND TOP HEAVY. USE ADEQUATE MANPOWER OR EQUIPMENT FOR HANDLING. UNTIL THE EQUIPMENT IS SECURELY MOUNTED, CARE MUST BE USED TO PREVENT THE EQUIPMENT FROM BEING ACCIDENTALLY TIPPED OVER.

NOMENCLATURE PLATES Each Bucyrus Series Charger shipped is identified by part number on the nomenclature plate.

ADJUSTMENTS All equipment is shipped from the factory fully checked and adjusted. Do not make any adjustments unless the equipment has been powered-up and the settings have been determined to be incorrect.

SPARE PARTS To minimize downtime during installation or normal service, it is advisable to purchase spare fuses, circuit boards and other recommended components. Please refer to the parts manual for parts numbers. It is recommended that spare fuses be ordered for all systems.

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RATINGS AND SPECIFICATIONS Output Ratings D.C. Voltage The Bucyrus Series Mine Chargers are factory set to finish at approximately 2.5 volts/per cell for lead acid batteries. The chargers are available in 32 cell (64 volt) or 64 cell (128 volt) output.

Output Current (Refer to table 1).

Regulation The charge rate is dependent on the state of charge of the battery. Automatic a.c. line voltage compensation regulates the d.c. output and maintains the charging curve.

INPUT CURRENT AND BATTERY CAPACITIES

CHARGER MODEL 5 6 8 10 12 14

APPROX. AC CURRENT DRAW (3-PHASE) 480VAC / 575VAC 26 - 22 32 - 27 41 - 34 52 - 44 61 - 51 70 - 59

BATTERY AMPEREHOUR CHARGING CAPACITY 495 550 - 680 750 - 850 1000 - 1050 1200 - 1210 1375 - 1500

OUTPUT RATING 90 AMPS 110 AMPS 140 AMPS 180 AMPS 210 AMPS 240 AMPS

TABLE 1 Input Ratings A.C. VOLTAGE Taps are provided for various three phase a. c. input voltages with an a. c. input voltage range of +/10% of nominal. (See unit schematic for details) Input Frequency Range 57 to 63 Hz. (60 HZ nominal)

Typical Electrical Specifications (Refer to TABLE 1)

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Standard Features Input Protection A. A.C. fuses on each input leg.

B. A.C. contactor to disconnect the unit from the a.c. line.

C. A.C. fuse in one leg of control transformer.

Meters Digital Volt/Amp Meter – Standard (See OPERATION section) Output Protection A. D.C. output fuse.

B. Current limiting automatically limits the d. c. output current of the charger to approximately 125% of its rating..

Electronic Timer 8 hour timer with auto start/stop feature on battery connection. (See OPERATION section) Mounting Low profile mine case with skids.

Optional Ground Integrity The Automatic Mine Recharger is designed to operate on a specific type of battery with a specified number of cells. The nameplate on the charger indicates the type of battery, number of cells, and the a.c. input voltage.

To energize the unit with optional ground integrity, the following procedure should be used: 1. Check a. c. input voltage with that specified on the nameplate. i.e.: chargers furnished with 480 volt and 575 volt power lines, are dual input 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 with the unit which indicates how the a.c. power connections must be wired. Connect the power lines to the a.c. input terminals, the ground wire to the ground terminal bonded to the case near the input terminals.

2. A ground check wire supplied from the power center must be connected to terminal 3R, near the input terminals.

3. The battery, with a 4 wire plug, must be connected to the unit’s output in order to energize the unit.

4. Ground integrity must be made on all systems to energize the unit. If the case ground is more than 5 ohms, the unit will not energize.

5. The emergency stop switch must be pulled out.

6. Push in the green button. The unit should energize, and 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, and charge the battery to full charge, then shutdown to a trickle charge-preserving-charge.

The charger will continue the trickle rate until the timer turns the unit completely off.

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THIS UNIT IS EQUIPED WITH TWO (2) DOOR DISCONNECT SWITCHES AND ONE (1) COVER DISCONNECT SWITCH. THE TWO ACCESS DOORS AND THE TOP COVER OF THE UNIT MUST BE CLOSED FOR THE UNIT TO OPERATE. If the unit fails to energize: 1. Check a. c. power on all three phases.

2. Check to make sure voltage taps are wired properly.

3. Check a. c. and d. c. fuses.

4. Make sure battery is connected to unit’s output.

5. Check for ground integrity. This can be done by putting a jumper from ground bus #2 to terminal 1R or 2R on two circuit chargers. If unit starts when jumpered, ground integrity is the problem. (Disconnect the jumper after check) 6. Check emergency stop switch. It must be pulled out.

7. Check all ground connections.

8. Start button must be depressed to energize the unit. (Listen for click of control relay) If a second battery is added on two circuit chargers, the start button, again must be depressed.

9. Check all disconnect switches - doors and top must be closed.

Environmental Ratings Operating Ambient Temperatures Operation - 0 - 50 C (32 - 122 F)

Storage - -40 to +85 C (-40 to + 185 F)

Humidity This rectifier is capable of operating in an ambient relative humidity range of 0-95% (non-condensing).

Ventilation The unit should be placed so that the ventilating openings are not blocked and air entering the cabinet does not exceed 50 C (122 F).

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INSTALLATION INFORMATION Minimum Wire Sizes Table 2 lists the a.c. input and the d.c. output minimum wire size requirements. At distances exceeding 10 ft., the d.c. wire size should be chosen to keep the voltage difference between the units d.c. output terminals and the battery at less than 1/2 volt when the unit is fully loaded.

FUSE SIZE 1 3 4 5 6 10 15 20 25 30 35 40 45 50 60 70 80 90 100 110 125 130

WIRE SIZE REQUIREMENT CUSTOMER CONNECTION #14 #14 #14 #14 #14 #14 #12 #12 #10 #10 #8 #8 #8 #8 #6 #6 #4 #4 #4 #2 #2 #2

EQUIPMENT GROUNDING CONDUCTOR MINIMUM #14 #14 #14 #14 #14 #14 #12 #12 #12 #10 #10 #10 #10 #10 #10 #8 #8 #8 #8 #6 #6 #6

FUSE SIZE 150 175 200 225 250 300 350 400 450 500 600 700 800 1000 1200 1600 2000 2500 3000 4000 5000 6000

WIRE SIZE REQUIREMENT CUSTOMER CONNECTION #1 #1/0 #2/0 #2/0 #4/0 250-MCM 350-MCM 400-MCM 500-MCM 600-MCM 900-MCM 1500-MCM 2/500-MCM 2/800-MCM 2/1000-MCM 2/2000-MCM

EQUIPMENT GROUNDING CONDUCTOR MINIMUM #6 #6 #6 #4 #4 #4 #2 #2 #2 #2 #1 1/0 1/0 4/0 4/0 4/0 250-MCM 350-MCM 400-MCM 500-MCM 700-MCM 800-MCM

TABLE 2 Electrical Connections & Field Wiring Terminal blocks are provided for connecting the a.c. input and d.c. output. A ground wire must be connected to the unit's case ground.

A.C. Input Make sure that the input source is the same voltage and frequency as that which is marked on the nameplate of the rectifier.

The a.c. input current, specified on the nameplate, is for (nominal) output. A.C. line fuses or breakers must be sized for the overload or current limit point of the charger which is 130% of the nameplate value.

An adequate earth ground lead should be connected to the terminal marked "GROUND" or "GND" on the rectifier terminal board or case.

Be sure the transformer taps are set for the correct a.c. input. (see Figure 1, page 15).

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FIGURE 1 – TRANSFORMER TAP CONNECTIONS

D.C. Output Make sure that the battery which is being connected to the rectifier matches the cell type and number of cells that is marked on the rectifier nameplate.

OBSERVE PROPER POLARITY! The negative wire from the battery must be connected to the terminal marked "NEGATIVE" or "NEG" and the positive wire from the battery must be connected, to the terminal marked "POSITIVE" or "POS" on the rectifier.

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OPERATION Start Up (Electronic Timer) A. With the a.c. input connected to the charger, turn the ON/OFF switch to the "ON" position.

B. Connect the battery to the charger. After a 20 second delay, which assures proper battery connection, the input contactor will close. The battery charger will start to charge and the "ON CHARGE" light will turn on. This completes the "Auto start" sequence.

The display will read, OUTPUT AMPS, push the select switch down once and the display will read D.C. VOLTAGE, a second push the display will read AMP/HOURS RETURNED and a third push the display will read ELAPSED TIME. Push the select switch UP and the unit will equalize the battery.

C. When the "80% CHARGE" point is reached in the charge cycle, the "80%" light will turn on and a three (3) hour timer will start. (If in the equalize mode, the unit will operate for six (6) hours after 80% light turns on.)

D. When the charge cycle is complete, normally 6 to 8 hours, the charge "COMPLETE" light will turn on.

E. If for some reason the a. c. input voltage fails, the battery charger will turn off. During this interval the time registers in the auto timer is held at the present count. When the a. c. has returned to normal, the charge cycle resumes where it left off.

TURN THE ON/OFF SWITCH TO THE "OFF" POSITION WHEN DISCONNECTING THE BATTERY DURING THE CHARGE CYCLE TO PREVENT ARCING AT THE D. C. CONNECTOR. FAILURE TO COMPLY WITH THE ABOVE WILL RESULT IN DAMAGE TO THE BATTERY AND CHARGER CONNECTORS. F. Fault Codes *Code 1 - Low or no a.c. input voltage *Code 2 - N/A *Code 3 - Wrong size battery/deeply discharged battery, open terminal voltage below 1.4pc

TO DISABLE THIS FEATURE, PUSH THE EQUALIZE BUTTON. THE UNIT WILL START.

MAKE SURE A BATTERY WITH THE CORRECT NUMBER OF CELLS IS CONNECTED TO THE CHARGER. *Code 4 - 12 Hour overrides timer, unit will automatically turn off in 12 hours after being connected to a battery *Code 5 - N/A *Code 6 - Possible shorted cells – Battery voltage decreases while battery is charging *Code 7 - Unit will turn OFF within 15 minutes if a fully charged battery is connected to charger

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Adjustments The Bucyrus Series is a completely automatic constant voltage charger. Each is designed to operate on a specific type of battery with a specified number of cells. THE UNIT IS FACTORY SET AT 2.5 VOLTS PER CELL (V.P.C.).

Circuit Operation The Bucyrus Series Ferroresonant Mine battery charger has three basic components; a ferroresonant step down transformer, silicon rectifiers (diodes) and electronic timer.

The regulating action of the unit is caused by the current developed in the resonant winding of the power transformer. The resonating capacitor along with the resonant winding of the transformer form a tuned circuit which establishes the correct core saturation point and in turn regulates the unit's output.

The transformer also steps down the a.c. input voltage to the proper voltage to charge the battery. It also provides isolation from the input to the output.

The silicon diodes convert the a.c. output from the secondary of the transformer to the d.c. voltage needed to charge the battery.

The automatic timer senses the connection of the battery and turns the unit on, the timer will allow the charger to charge the battery for a period of time (maximum 12 hours), then turns the charger off. It will also turn the charger off when the battery is disconnected.

FIGURE 2 – CHARGER CONTROLS

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TROUBLESHOOTING Troubleshooting should be performed only by trained service personnel or experienced electricians.

HAZARDOUS A.C. AND D.C. VOLTAGES ARE PRESENT WITHIN THE CHARGER’S CABINET. Equipment: The only equipment required is a multimeter (volt-ohm meter).

General Inspection On servicing new equipment, before setting up any complicated testing or jumping to any conclusions, give the unit a general inspection. Check the following: 1. Check d.c. output cables, connections, battery type, and number of battery cells with rectifier rating.

2. Check unit specifications with customer order.

3. Check input connections, input voltage and a.c. line breaker size.

4. Check for shipping damage, loose connections, broken wires, etc.

5. Certain failures can be caused by defective batteries and customer loads; make sure batteries and loads are free from defects.

6. Check all safety switches.

IF THE PROBLEM IS FOUND TO BE LOCATED IN THE PRINTED CIRCUIT BOARDS, THE BOARD SHOULD BE REPLACED. NO ATTEMPT SHOULD BE MADE TO REPAIR CIRCUIT BOARDS IN THE FIELD.

Service Information Information you should have when calling in for troubleshooting assistance: 1. Equipment model number and serial number.

2. The actual a.c. input voltage.

3. The d.c. output voltage with and without the battery.

4. Result of the check of a.c. input fuse and d.c. output fuse.

5. The actual d.c. output current and voltage when measured with battery connected to rectifier.

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Symptoms and Causes SYMPTOM

POSSIBLE CAUSE

REMEDY

OPEN A.C. FUSE

1. Wrong a.c. input voltage.

1. Correct input voltage.

2.The a.c. input taps on power transformer set incorrectly. (See schematic wiring diagram)

2. Set input taps correctly.

3. An a.c. to d. c. short or a.c. to d.c. short to ground. (See Ground Short Circuit Test, below).

3. Correct shorts.

4. Shorted power transformer.

4. Replace transformer.

5. Check for shorted power diodes (SD1). (See page 20)

5. Replace defective diodes.

6. Check for shorted coil on d.c. contactor or defective control transformer.

6. Replace contactor or transformer.

1. Shorted power diode.

1. Replace as required.

2. Shorted battery cells.

2. Repair battery.

3. Shorted output cables.

3. Repair or replace cables.

4. Shorted capacitors.

(See page 20)

4. Replace capacitors.

1. Shorted power diode.

1. Replace as required.

2. Shorted capacitor.

2. Replace capacitor.

1.Check a.c. input fuses.

1. Replace fuse(s).

2. Check power diodes.

(See diode troubleshooting procedure, page 20)

2. Replace diode(s).

OPEN D.C. FUSE

OPEN SECONDARY FUSE

CHARGER OPERATES BUT OUTPUT VOLTAGE IS LOW

Ground and Short Circuit Test A simple ohmmeter check can be performed to check the unit for a short to ground, primary to secondary breakdown, a.c.-d.c. short, or d.c. ground. Before installation of a new unit, the above checks should be made before installing. If a short of this type is suspected on a unit in service, check as follows: 1. Disconnect a.c. input power to the unit. Disconnect the d.c. battery and loads from the rectifier.

2. Set ohmmeter scale on ohms scale RX100.

3. Measure from one terminal of the input to one terminal of the output. Meter should not indicate. If the meter reads full scale deflection, this indicates an ac-dc short.

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During shipping, an a.c. wire may rub against the d.c. lugs, terminals, etc. and cause a short.

These problems may be eliminated by very carefully inspecting the wiring to make certain the a.c. wires are not touching the d.c. wiring. If no wires are touching, then it is possible that the primary and secondary of the transformer is shorted. Disconnect the secondary of the transformer from the diodes. Measure with ohmmeter from input terminal to one of the isolated secondary leads. If there is an ohmmeter indication, there is an insulation breakdown between primary and secondary windings. The transformer should be replaced.

4. Check the input terminals to ground and check the output terminals ground. If the meter indicates full scale deflection, a wire is touching a metal part of the unit. Look for wires that are near any metal part and inspect for possible breakdown caused by shipping. The heatsink of the diodes and the control unit are insulated from ground through the mounting legs.

Troubleshooting and Replacing Power Silicon Diodes If a portable multimeter is used, set the switches on "ohms", "d.c.", and " Rx1 " scale.

1. Isolate one end of the diode by disconnecting the wires attached to the nipple (or pigtail) end of the diode (only one end of the diode must be disconnected).

2. Clip one lead of the ohmmeter to the anode lead of the diode. Clip the other ohmmeter lead to the cathode.

3. Note the ohmmeter reading. Then reverse the leads to the diode. Again, note the ohmmeter reading. If the diode is good, the meter will indicate a high resistance in one direction, and a low resistance with the leads reversed. If the diode is shorted, the meter will read full scale, or zero ("O") resistance with the leads in either direction. If the diode is "open", the ohmmeter needle will not indicate or it will show infinite resistance in either direction, indicating an open circuit.

4 All diodes must be checked in the event that more than one diode is defective.

5. If the diode is defective, remove it from the heatsink. Clean and smooth the heatsink surface, then using an electrically conductive grease, apply to the new diode and replace it in the heatsink.

Checking Capacitors When checking capacitors, be sure all power is turned off and the battery is disconnected.

Momentarily short circuit the capacitor leads to assure complete discharge. Connect the meter test leads to the capacitor leads or terminals and observe indicated resistance.

A good capacitor will indicate an initial low resistance and gradually increase as the capacitor charges.

The final resistance of a good capacitor is usually several hundred thousand ohms approaching a megohm.

Initial high resistance approaching infinity indicates an open capacitor.

Initial and continued low resistance readings indicate a shorted capacitor.

When ordering replacement parts, drawings, or schematics, always give model number, serial number and a.c. input voltage.

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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

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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.

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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.

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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.

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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.

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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.

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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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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.

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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,

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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