PDF Operation Manual CAT SU488 L SU488 Scoop - 1 MB
This operation manual is the essential guide for the safe and efficient use of the CAT SU488 L and SU488 Scoops.
It covers all operating controls, safety procedures, and routine maintenance checks.
Operators must be familiar with the contents of this manual to prevent accidents and maximize productivity in underground mining environments.
This document is a key part of any operator training program.
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A6474X235
June 2012
Operation
Manual
SU488 L and SU488 Scoop
A6474X235 (Operation)
SAFETY.CAT.COM
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_______________________________________________________________
2 Your safety
________________________________________________________________
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_______________________________________________Safety instructions
maintenance, repair Only persons who have and can demonstrate a special knowledge of
hydraulics are allowed to work on the hydraulic system.
Avoid, whenever possible, servicing, cleaning or examining the ma-
chine in congested areas.
Avoid, whenever possible, servicing or providing maintenance to the
unit unless the wheels are chocked and steering lockout device is con-
nected to prevent accidental movement of the unit.
Do not alter the electrical or hydraulic settings from that indicated in this
manual or as set at the factory.
Always replace damaged or lost decals and metal instruction plates.
Disconnect the battery when working with the electrical system, or
when welding on the unit to prevent electrical shock.
Be sure the battery area is well ventilated (clear of fumes) when it is
necessary to connect battery charger. Fumes from the battery could
ignite from a spark and explode.
Always follow all safety procedures of each particular mine when per-
forming maintenance.
It is important that any procedure not specifically recommended in this
guide be thoroughly evaluated from the standpoint of safety before it is
implemented.
Some illustrations in this manual show guards or cover panels removed
for purposes of clarity. Never operate unit without guards or cover pan-
els in place.
Carry out a visual inspection of all the hydraulic components at regular
intervals. In particular check that:
■ the hoses are not pinched or trapped,
■ the hoses have no bubbles or blisters,
■ the hose or outer sheathes of the hose are not abnormally rigid or
hard,
■ the outer sheath of the hoses is not damaged,
■ the connectors are securely inserted into the sockets, and
■ the connections are leak-tight.
Ensure that no dirt enters the hydraulic system during repair work. Dirt
in the hydraulic system can cause serious damage in the whole system!
Flush out the hydraulic lines thoroughly before connecting.
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A6474X235 REV 11 2.11
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_______________________________________________________________
4 Installation
________________________________________________________________
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_______________________________________________________________
5 Operation
________________________________________________________________
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______________________________________________________ Operation
Fig. 14: Hydraulic control system (with vertical lift and/or QDS)
“DIVERSION VALVE” “ACCUMULATOR” “SYSTEM
PRESSURE”
“EMERGENCY BRAKE”
“STEERING”lever
(standard)
“EJECTOR”lever
“TILT”lever
“PTO/BATT”lever
“LIFT”lever
“QDS”lever
(optional)
Hydraulic control panel (with vertical lift and/or QDS)
The hydraulic control panel (Fig. 14), located to the left of the operator,
has a group of switches that control the following:
IMPORTANT!
For more detailed control handle operating instructions, see Start-
ing procedures in this chapter.
“STEERING” The “STEERING”control lever is used to steer the machine. To steer
left while moving forward (right when moving in reverse), push the
steering control lever slowly away from the operator. To turn right while
moving forward (left when moving in reverse), pull the steering control
lever slowly toward the operator.
“TILT” The “TILT”control lever is used to control the forks and/or the quick
attach bucket. This control lever allows the operator to tilt the forks or
bucket either forward or back. To tilt the attachment down, push the
lever away from the operator. To tilt the attachment up, pull the lever
towards the operator.
“LIFT” The “LIFT”control lever is used to raise or lower the forks and/or the
quick attach bucket. To lower the attachment, push the lever away
from the operator. To raise the attachment, pull the lever towards the
operator.
______________________________________________________________
A6474X235 REV 11 5.11
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______________________________________________________ Operation
Starting procedure with control handle
After reading the previous descriptions and locating each control, the
operator is ready to operate the machine. An experienced operator
should monitor a new operator's indoctrination to the starting proce-
dure.
CAUTION!
Use caution when traveling down grade, exceeding 5 mph (8 kph)
with this machine will result in tram motor failure.
WARNING!
Check the battery connections and the battery covers. They must
be in place and locked to be permissible.
WARNING!
Never operate any levers or pedals from outside the operator's
compartment. All switches in the operator’s compartment must
be in the “OFF”position before the battery circuit breaker is
moved to the “ON”position.
WARNING!
This unit is equipped with a cab or canopy. Be careful not to hit
your head when entering or leaving the operator's compartment.
This machine must not be operated without the canopy in place.
General
1. Disconnect the steering lockout device (Fig. 25).
2. Sit in the operator's seat and adjust the seat position relative to
the foot and hand controls.
WARNING!
Be sure no one is in the Hazard zone (Fig. 23) before operating
any levers or pedals.
Never try to adjust the operator's seat while the machine is in mo-
tion.
Do not operate the machine with any part of your body outside the
operator's compartment to prevent having body parts caught be-
tween the unit and outside objects.
3. The tape panic strip (s) may be pressed at any time to trip the
machine circuit breaker, set the park brake, and to de-energize
the tram and pump motors.
4. Stop button “J3”may be pressed at any time to set the park
brake, and to de-energize the tram and pump motors (Fig. 24).
______________________________________________________________
A6474X235 REV 11 5.21
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______________________________________________________ Operation
Towing a disabled machine
WARNING!
It is not possible, within the scope of this guide, to anticipate all
possible arrangements for towing a disabled vehicle, you must
take all possible precautions to protect the operators and anyone
around both vehicles from being injured by either the towing vehi-
cle, the towing device used (cables, bars, etc.) and the towing ve-
hicle (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 run-
ning 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 re-
leased.
Couple the towing vehicle securely to the disabled vehicle.
Close the valve to tank circuit that is on the hand pump to isolate
the park brake solenoid from the circuit.
Begin pumping the hand pump. The building pressure moves the
shuttle valve and allows the Automatic (Park) Brake system to be
pressurized.
The Automatic (Park) Brake is released as indicated by the Brake
Release gauge.
CAUTION!
For long distance towing, disconnect and remove front and rear
drive lines.
WARNING!
At no time during towing should anyone ride in or on the vehicle
being towed or stand in between the towing vehicle and the dis-
abled vehicle.
Begin towing the vehicle.
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 direction
at all four wheels for additional stability. The brake is set by turning
the valve handle on the hand pump to “NORMAL RE-APPLY”.
WARNING!
Failure to set the parking brake on the disabled vehicle before re-
moving the towing device could allow the disabled vehicle to roll
away uncontrolled.
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A6474X235 REV 11 5.31
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______________________________________________________ Operation
Connect the jumper cable:
Connect the receptacle end of the jumper cable to the machine
and connect the plug end of the jumper cable to the fully charged
battery (Fig. 39).
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 machine is moved.
Start the machine (see Starting procedure in this chapter).
Fig. 39: Battery change procedure (vertical lift)
Battery
table Jumper cables
Charged
battery
Discharged
battery
Battery
table
______________________________________________________________
A6474X235 REV 11 5.41
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____________________________________________________ Maintenance
Specific lubrication and maintenance procedures
Every shift
electrical cables and conduits Inspect all electrical cables, conduits, hydraulic hoses, fittings, tires,
hydraulic hoses and fittings and headlights for signs of wear or damage. Repair or replace any
tires and headlights damaged item.
warning tags and reflectors Visually inspect the condition and readability of all warning tags, labels,
and reflectors. Replace all that are found missing or damaged.
tape switches (panic bars) Check the tape switches (panic bars) located inside the operator’s
compartment (Fig. 46). Start the machine but do not tram. Strike the
tape switch: the machine circuit breaker should trip and the machine
should shut down. Repeat with the other tape switch.
Fig. 46: Tape switch (panic strip) location
Tape switch
Tape switch
hydraulic oil level Check the hydraulic oil level by looking at the sight glass located on the
oil tank (Fig. 47). If the oil level is low, add oil:
(Spec. 100-1, if equipped with John Deere or Axle Tech axles)
(Spec. 100-12, if equipped with Kessler axles)
Fig. 47: Hydraulic oil level
Brake cooling fluid
Fill cap
tank (Standard -
Kessler, Optional-
Axle Tech)
Sight glass
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A6474X235 REV 11 5.51
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____________________________________________________ Maintenance
Fig. 64: Axle oil level (John Deere)
Breather
Brake inspection
port
Brake inspection
port
Oil level
fill/check plug
Oil level fill/check plug
speed reducer (gear case) oil Check the oil in both speed reducers (Fig. 65).
Park the machine on solid level ground.
Remove the check plug from the speed reducer (gearbox). The oil
level should be kept at the level of the check plug.
Should it be necessary to add oil, add the oil (Spec. 100-6)
through the fill plug hole slowly until oil flows from the check plug
hole. Do not overfill speed reducer.
Replaced the check and fill plugs.
Fig. 65: Speed reducer (gear case) oil
Fill plug
Check plug
Drain plug
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A6474X235 REV 11 5.61
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_______________________________________________Major Maintenance
Drive motor/gearbox (speed reducer) removal and re-
placement
WARNING!
Power must be removed by unplugging the battery plugs before
servicing the motor.
Fig. 77: Drive train components
Front axle assembly
Speed reducer
Drive motor
Front drive shaft
Bearing carrier
Middle drive shaft
Rear drive shaft
Rear axle assembly
The following procedures reference Fig. 77.
Drive motor
Remove the motor inspection cover and disconnect the power ca-
bles to the motor. Unpack the motor gland and completely remove
the wiring and conduit from the motor.
Attach a crane or hoist, capable of lifting the motor, to the eyebolt
on top of the motor and take up any slack in hoist chain.
Remove the four (4) bolts that attach the motor to the gearbox.
Lift the motor out of the unit.
Cover the reducer opening to prevent foreign matter from entering
the gearbox.
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A6474X235 REV 11 5.71
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_________________________________________________ Troubleshooting
Brakes
Table 6: Brakes troubleshooting
Trouble, symptom or cause Probable cause Test, check and/or remedy
brakes slow to apply No gas charge in accumulator. Check gas charge.
Defective brakes. Check brakes.
Hydraulic lines or fittings leak- Check for leaks and repair.
ing.
Pedal linkage out of adjustment. Adjust Iinkage.
Damaged hydraulic brake lines. Check lines for dents that re-
strict flow of oiI.
brakes won’t release Pedal linkage out of adjustment Check for proper adjustment
or binding. and binding.
Defective brakes. Check brakes .
Defective brake valve. Replace brake valve.
insufficient brakes No oil or low level in tank. Check oil level in tank.
Pedal linkage out of adjustment. Adjust linkage.
Brake line mashed. Check Iines and replace.
No gas charge in accumulator. Check gas charge.
Defective brakes. Check brakes.
Brake valve defective. Replace valve.
brakes will not release Defective brakes. Check brakes.
completely
Pedal linkage out of adjustment. Adjust pedal linkage.
Air in brakes. Bleed brakes.
Defective brake valve. Replace brake valve.
Back pressure on return line too Remove restriction.
high.
excessive braking Defective brakes. Check brakes.
Defective brake valve. Replace brake valve.
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A6474X235 REV 11 5.81
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_______________________________________________Tightening torques
Tightening torques
IMPORTANT!
Due to the application of fasteners being subject to great stresses
and heavy or extreme vibration, it is imperative that all bolts be
applied with an adequate amount of torque. For this reason this
list of recommended torque settings for different types and sizes
of fasteners used has been compiled.
The tightening torques stated in the spare parts lists have to be
observed, as well, for installation and maintenance.
Set screws
Table 10: Set screws (Socket long-lok)
Nominal diameter Recommended torque setting
#6 6 in-lbs
#8 9 in-lbs
#10 13 in-lbs
¼” 30 in-lbs
5/16” 5 ft-lbs
3/8” 8 ft-lbs
7/16” 11 ft-lbs
½” 16.7 ft-lbs
Table 11: Set screws (Socket standard steel)
Nominal diameter Recommended torque setting
#6 9 in-lbs
#8 16 in-lbs
#10 30 in-lbs
¼” 6 ft-lbs
5/16” 12 ft-lbs
3/8” 18 ft-lbs
7/16” 29 ft-lbs
½” 43 ft-lbs
5/8” 100 ft-lbs
¾” 146 ft-lbs
7/8” 199 ft-lbs
1” 262 ft-lbs
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A6474X235 REV 11 6.5
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_______________________________________________ Permissible media
Table 22: Invert emulsion hydraulic fluid (Spec. 100-5)
Supplier Brand name
1 Unocal 76 FR Fluid
2 Conoco Inc. FR Hydraulic Fluid
3 Atlantic Richfield Company Duro FR-HD
4 Brooks Oil Company Brooks Fire Resistant Hydraulic
Fluid B
5 Cincinnati –Vulcon Company Vulcon FR Fluid #1
6 Cities Service Oil Company Citgo Pacemaker Invert FR
Fluid
7 Century Oils Limited Aquacent Light
8 Fiske Bros. Refining Com- Lubriplate HO-Retard
pany
9 Getty Oil Company Veedol Auburn FRH
(Veedol, Tidewater)
10 Gulf Oil Company FR Fluid
11 E.F. Houghton Houghto-Safe 5046
Houghto-Safe 5046W
12 Century Lubricating Oils Hulsafe 600
13 Imperial Oil and Grease Astrol 587
14 Mobil Oil Corporation Pyrogard D
15 National Oil and Chemical Erifon 1, 2, and 3
Co.
16 Pennzoil Maxmul FRP/G
17 Quaker Chemical Company Quintolubric 958 Series
Quintolubric 958 Series
18 Henery E. Sanson and Sons Hydra-Mul Premium Emulsion
MFGE Company Fluid
19 Southwest Grease and Oil Invert Emulsion Fire Resistant
Company, Inc. Hydraulic Fluid
20 Southwest Petroleum Corp. Swepco Fire Resistant Hydrau-
lic oil #718
21 Standard Oil Company of Staysol FR
Ohio
(Boron Sohio)
22 Sun Oil Company Sunsafe F
23 Tower Oil Company Safoil Anti-Wear Hydraulic Fluid
24 Wynn Oil Company Hydra-Safe Heavy Medium
25 Lubrication Engineers 6455 Monolec Fire Resistant
Hydraulic Fluid
26 Hydrotex HY-Guard
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A6474X235 REV 11 6.15
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BI001458-05
A6474X226
March 2012
Operation and
Troubleshooting Manual
Model BUC2000
Dual and Single Motor Solid State Controller
SAFETY.CAT.COM
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BI001458-05
_______________________________________________________________
2 Your safety
________________________________________________________________
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BI001458-05
_______________________________________________________Operation
Operation
This chapter contains important information on the operation and trou-
bleshooting of the model BUC2000 Dual and Single Motor Controller.
Read this chapter carefully and thoroughly. In particular, observe the
safety instructions in Chapter 2 “Your safety”.
History
In the early 1970's, the introduction of solid state speed controls for
battery-powered underground mining equipment led the way in mining
innovation. 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 contac-
tors provided an endless source of maintenance problems and con-
sumed excessive amounts of valuable controller-box space. Also,
most solid state controllers of the past utilized an electromechanical
"bypass" contactor to connect the motor directly to the batteries which
caused more contactor problems.
In the 1980’ s, contactorless motor controller (X90) was developed to be
used exclusively on Cat underground mining equipment. The X90 sys-
tem used a dual-field motor in combination with SCRs (Silicone Con-
trolled Rectifier) to achieve solid state direction change.
Today, a BUC2000 motor controller has been developed. The
BUC2000 system uses IGBTs (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
BUC2000 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 re-
ferred to as a "pulse." (Fig. 1)
The IGBT speed control works by feeding to the motor a rapid series of
pulses. The number of pulses per second determines the average volt-
age at the motor terminals. (Fig. 2)
_____________________________________________________________ _
A6474X226 REV 05 3.3
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BI001458-05
_______________________________________________________Operation
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 Controller operational
LED off Power-up fault –check display or calibrator. If all is blank, then
replace logic. Check control wiring. possible shorted driver
board, UVR, or “W”relay.
1 Flash Personality CRC EEPROM Error.
Using the hand-held calibrator, change a password to any num-
ber then recycle power –should clear, otherwise replace logic.
2 Flash Procedure FAULT
FS1 closed before power on or 2 Directional Fault. Recycle FS1
through neutral to clear.
3 Flash IGBT permanently low (IGBT Short Circuit FAULT).
This includes IGBT short circuit or IGBT open circuit. This fault
shuts down all modes. Recycle FS1 through neutral to clear.
4 Flash Motor neither low nor high (Breaker Open FAULT).
This includes breaker open circuit or IGBT open circuit. This
fault shuts down all modes. Recycle FS1 through neutral to
clear.
5 Flash Motor permanently high. (Breaker welded FAULT)
This includes breaker welded. This fault shuts down all modes.