PDF Operation Manual CAT Bucyrus 488-6 & 488L UN-A-TRAC - 2 MB
This operation manual provides essential information for the safe and efficient use of the CAT Bucyrus 488-6 and 488L UN-A-TRAC systems.
It details the machine's controls, operational procedures, safety warnings, and daily maintenance checks.
Familiarizing yourself with this manual is the first step toward maximizing productivity and ensuring the longevity of your equipment.
It is a critical resource for all operators and site supervisors.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
Operation Manual
Bucyrus - UN-A-TRAC®
Models - 488L and 488-6
Doc. No.: A6474X235
Bucyrus America, Inc. ________________________________________
4041 Wurno Road Telephone: 540-980-4530
Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.bucyrus.com
--- Page 3 ---
_______________________________________________________________
2 Your safety
________________________________________________________________
--- Page 4 ---
___________________________________________ 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.
© BUCYRUS AMERICA, INC.
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.
______________________________________________________________
A6474X235 SVVI/07 2.11
--- Page 5 ---
________________________________ Overview of safety instructions
WARNING!
Power must be removed by unplugging the battery plugs before
servicing the motor.
WARNING!
Mixing parts of different designs or from a variety of sources for
wheels with pneumatic tires could cause severe injury or death.
Chapter 6: Technical data
IMPORTANT!
Due to the application of fasteners being subject to great stresses
and heavy or extreme vibration, it is imperative that all bolts be
applied with an adequate amount of torque. For this reason this
list of recommended torque settings for different types and sizes
of fasteners used has been compiled. The tightening torques
stated in the spare parts lists have to be observed, as well, for in-
stallation and maintenance.
NOTICE!
Use only lubrication fluids and greases approved by Bucyrus
© BUCYRUS AMERICA, INC.
America, Inc. ! These fluids and greases have been tested at Bu-
cyrus America, Inc. and guarantee reliable operation of the me-
chanical and hydraulic functions of the machine.
IMPORTANT!
The lubrication fluids and greases listed in the same table can be
mixed. Other products may only be used if the supplier can guar-
antee that they are equivalent. Differently composed fluids and
greases must not be mixed as this may change the consistency,
i.e. the mixture can become thinner so that the lubrication effect is
not sufficient. It may also be dangerous to use lubricating
greases and fluids having the same specification base but differ-
ent origins. In case of doubt, the manufacturer of the lubrication
to be used should be contacted as to the compatibility of the lubri-
cation in question.
IMPORTANT!
Bucyrus America, Inc. expressly point out that the approval of the
listed products relates only to the pure technical use in our me-
chanical and hydraulic systems. The responsibility for the con-
stituents used in the hydraulic concentrates lies solely with the
respective manufacturer.
NOTICE!
When performing maintenance on the machine, all used oil and
lubricants should be disposed of per your local EPA standards.
______________________________________________________________
A6474X235 SVVI/07 2.21
--- Page 6 ---
__________________________________________________Installation
Installation
Points to observe prior to installation
Who is allowed to carry out installation?
Installation is only allowed to be carried out by personnel having re-
ceived adequate training to perform this task.
Work on:
the safety components (pressure relief valves, fire extinguishing equip-
ment etc.),
the electrical equipment (control units, signaling devices, etc.), and
the hydraulic equipment (cylinders, directional control valves, hoses
etc.)
© BUCYRUS AMERICA, INC.
should only be carried out by Bucyrus America, Inc. service engineers
or by specially trained personnel.
Which tools are required for installation?
tool box No special tools are required to put the UN-A-TRAC® into service.
The battery plugs and receptacles come with a special wrench for con-
necting and disconnecting battery plugs and receptacles.
Various items of auxiliary equipment and machines may be required at
the point of installation. These include:
■ hoists with adequate lifting capacity
■ means of attachment with adequate lifting capacity
■ unloading dock
■ jacks with adequate lifting capacity
______________________________________________________________
A6474X235 SVVI/07 4.3
--- Page 7 ---
___________________________________________________Operation
Fig. 9: Operator’s compartment with control station
Left hand steering Emergency
Tape switch Gauge panel Circuit breaker reset
(optional) disconnect
(panic strip)
Control station
BUC2000
display
Fire suppression
Speed switch
actuator
(accelerator)
© BUCYRUS AMERICA, INC.
Seat
Hydraulic control
Dif-lok (optional) Service brake pedal Brake release hand
panel
pump (not shown)
Note:
Typical operator’s compartment shown, location of controls may vary.
WARNING!
Before operating any levers or pedals on the UN-A-TRAC® always
make sure no one is in the hazard zone (see Hazard zone in this
chapter). Do not operate any levers or pedals from outside the
operator's compartment.
______________________________________________________________
A6474X235 SVVI/07 5.5
--- Page 8 ---
___________________________________________________Operation
Operator’s compartment - control handle model only
“CIRCUIT BREAKER RESET” lever The “CIRCUIT BREAKER RESET” lever (Fig. 18), 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 pulled all the way out to the
"RESET” position first and then pushed in to the "ON” position.
Fig. 18: “CIRCUIT BREAKER RESET” lever
© BUCYRUS AMERICA, INC.
“CIRCUIT BREAKER RESET” lever
WARNING!
The circuit breaker de-energizes the electrical controller and mo-
tors. However, electrical power is still present inside the connec-
tion box to the circuit breaker. If the circuit breaker inside the
connection box requires service, the battery plugs must be dis-
connected from the batteries.
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 moving the master switch to the "OFF" position
and then moving the circuit breaker to the "OFF" position.
WARNING!
The circuit breaker should be in the “OFF” position and the park-
ing 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 (panic bar), which trips the circuit breaker. The ma-
chine can also be stopped by moving the circuit breaker lever to
the “OFF” position.
Control handle
IMPORTANT!
For more detailed control handle operating instructions, see Start-
ing procedures in this chapter.
The control handle (Fig. 19) located to the left of the operator has a
group of switches that control the following:
“TRACTION ASSIST” Press down for Traction Assist.
______________________________________________________________
A6474X235 SVVI/07 5.15
--- Page 9 ---
___________________________________________________Operation
Shutdown procedure with control handle
Tram the UN-A-TRAC® to its designated parking place.
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.
1. If equipped with optional quick attach bucket, ensure that the
bucket (or other attachment) is lowered to the surface and ejec-
tor blade is returned to the back of the bucket. There should
be no obstructions between the back of the bucket and ejector
blade.
WARNING!
If equipped with optional quick attach bucket or other attachment,
ensure that the bucket or attachment is lowered to the surface and
ejector blade is returned to the back of the bucket. Always check
before moving the ejector blade control lever to make sure no one
© BUCYRUS AMERICA, INC.
has any part of their body between the ejector blade and the back
of the bucket.
Note: Refer to Fig. 24 for illustration of control handle.
2. Before leaving the operator’s compartment, press J3” to turn
“OFF” the machine.
3. Turn “OFF” the machine circuit breaker.
4. Turn “OFF” battery circuit breaker and/or disconnect switch (if
equipped) before leaving the machine area.
5. Connect the steering lockout device (Fig. 25):
■ remove the steering lockout device from its storage lugs
■ remove the hitch pin from the end farthest from the center
section
■ adjust turnbuckle until holes line up between the turnbuckle
lug and the front section lug
■ insert the hitch pin into the front section lug through the
turnbuckle
WARNING!
Never enter the articulation area while the machine is running.
Completely shutdown the machine as outlined before connecting
the steering lockout device. Failure to observe this precaution
may result in injury or death.
______________________________________________________________
A6474X235 SVVI/07 5.25
--- Page 10 ---
___________________________________________________Operation
Start the UN-A-TRAC® (see Starting Procedure in this manual).
Gently pull away from the discharged battery while the second per-
son holds the jumper cable away from possible damage (Fig. 30).
Fig 30: Battery changing procedure (ground level)
Charged battery Jumper cables
Discharged battery
© BUCYRUS AMERICA, INC.
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 (Fig. 30 and 31).
Fig. 31: Battery changing procedure (ground level)
Jumper cables
Charged battery
Discharged battery
______________________________________________________________
A6474X235 SVVI/07 5.35
--- Page 11 ---
________________________________________________ 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. 36). Start the machine but do not tram. Strike the
tape switch: the machine circuit breaker should trip and the UN-A-
TRAC® should shut down. Repeat with the other tape switch.
Fig. 36: Tape switch (panic strip) location
Tape switch
© BUCYRUS AMERICA, INC.
Tape switch
hydraulic oil level Check the hydraulic oil level by looking at the sight glass located on the
oil tank (Fig. 37). 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. 37: Hydraulic oil level
Brake cooling fluid
Fill cap
tank (Standard -
Kessler, Optional-
Axle Tech)
Sight glass
______________________________________________________________
A6474X235 SVVI/07 5.45
--- Page 12 ---
________________________________________________ Maintenance
Fig. 54: 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. 55).
© BUCYRUS AMERICA, INC.
Park the UN-A-TRAC® 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. 55: Speed reducer (gear case) oil
Fill plug
Check plug
Drain plug
______________________________________________________________
A6474X235 SVVI/07 5.55
--- Page 13 ---
___________________________________________ 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. 67: Drive train components
Front axle assembly
Speed reducer
Drive motor
© BUCYRUS AMERICA, INC.
Front drive shaft
Bearing carrier
Middle drive shaft
Rear drive shaft
Rear axle assembly
The following procedures reference Fig. 67.
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.
______________________________________________________________
A6474X235 SVVI/07 5.65
--- Page 14 ---
_____________________________________________ 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.
© BUCYRUS AMERICA, INC.
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.