Technical Manual
© Bucyrus All Rights Reserved
R
BI377672
BUCYRUS
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OPERATION AND MAINTENANCE MANUALS
BUCYRUS — UN-A-TRAC ®
Model — 488
Serial Number - 4037
BUCYRUS AMERICA, INC.
BUCYRUS NV®
1 BI377672
BUCYRUS AMERICA, INC.
Technical Manuals 488 Operation and Maintenance Section 5 Model Bucyrus 2000 Troubleshooting Guide Section 6 Battery Charger Troubleshooting Guide Section 7 Battery Maintenance Manual Section 8 Battery Charging and Maintenance Instructions Section 9 Battery Automatic Watering System Instructions Section 10 2 BI377672
Table of Contents
BUCYRUS AMERICA, INC.
Our service
If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.
Service address
Beckley, WV
200 George Street, Suite 4
Beckley, WV 25801
Phone: (304) 256-5927
Fax: (304) 256-5928
Duffield, VA
P.O. Box 847
6808 Fraley Avenue
Duffield, VA 24244
Phone: (276) 431-7000
Fax: (276) 431-2464
Carrier Mills, IL
9580 State Route 13 West
Carrier Mills, IL 62917
Phone: (618) 982-9000
Fax: (618) 982-9912
Paonia, CO
P.O. Box 566
Paonia, CO 81428
719 Second Street
Paonia, CO 81428
Phone: (970) 527-3151
Fax: (970) 527-6846
Pulaski, VA 4041 Wurno Road
Pulaski, VA 24301
Phone: 540-980-4530
Fax: 540-980-6211
Craig, CO 400 Mack Lane
Craig, CO 81625
Phone: (970) 824-3249
Fax: (970) 824-8851
Houston, PA
(Corporate Headquarters)
2045 West Pike Street
Houston, PA 15342
Phone: (724) 743-1200
Fax: (724) 743-1201
Oak Hill, WV
P.O. Box 60
Oak Hill, WV 25901
843 Lochgelly Road
Oak Hill, WV 25901
Phone: (304) 469-3302
Fax: (304) 465-0450
Price, UT
1814 North 1500 West
P.O. Box 1016
Price, UT 84501
Phone: (435) 637-3930
Fax: (435) 637-9754
Washington, PA 255 Berry Road
Washington, PA 15301
Phone: (724) 743-1200
Fax: (724) 228-2177
3 BI377672
BUCYRUS AMERICA, INC.
Rebuild facility address
Huntington, UT
P.O. Box 1190
Route 10, 1Mile North
Huntington, UT 84528
Phone: (435) 687-9831
Fax: (435) 687-2522
Pearisburg, VA
P.O. Box 463
222 Industrial Park Drive
Pearisburg, VA 24134
Phone: (540) 921-2111
Fax: (540) 921-2711
Norris City, IL
635 Illinois Highway 1
Norris City, IL 62869
Phone: (618) 378-3441
Fax: (618) 378-3106
4 BI377672
BUCYRUS N444'41® 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 BI377672
This manual is intended to provide GENERAL product information for the Model 488-6 and 488L UN-A-TRAC®. The illustrations, descriptions and procedures contained in this publication apply only to THESE machines. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.
This 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 unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of 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 this unit unsafe to operate.
Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.
While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America. Inc. Service Representative immediately.
This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.
la BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED BI377672
Table of contents
1. About this manual
2. Your safety
3. Storage and transport
contents A6474X235 VTVI/05
Table of
About this manual 1.3 Before starting to work 1.3 Who is this operating manual intended for? 1.3 What is the purpose of this operating manual? 1.4 Characters and symbols 1.5
Your safety 2.3 Personnel 2.4 Operation 2.4 Installation and repair 2.4 Operating conditions 2.5 Intended use 2.5 Unauthorized use 2.5 Safety instructions 2.7 General rules: 2.7 Storage and transport 2.8 Pre-start inspection 2.8 Installation and start-up 2.9 Operation 2.9 Stopping 2.10 Maintenance and repair 2.10 Overview of the safety instructions 2.15 Chapter 3: Storage and transport 2.15 Chapter 4: Installation 2.15 Chapter 5: Operation 2.16 Chapter 6: Technical data 2.21
Storage and transport 3.3 Storage 3.3 Storage of the machine and spare parts 3.3 Transport 3.4 Load units, dimensions, and weights 3.4 Before transport 3.5
Installation 4,3 Points to observe prior to installation 4.3 Who is allowed to carry out installation? 4.3 Which tools are required for installation? 4.3 Notes on installation 4.4 Pre-installation check list 4.5 Safety features 4.6 O BU CYRUS AMERI CA, INC. BI377672
4. Installation
5. Operation
6. Technical data
7. For your information
Operation 5.3 How to operate the UN-A-TRAC® 5.3 Who is allowed to operate the UN-A-TRAC® 5.3 When can operation be started? 5.3 Controls and indicators 5.4 Operator's compartment - common 5.6 Operator's compartment with control handle 5.12 Operator's compartment with control station 5.15 Hazard zone 5.17 Starting procedure with control handle 5.18 Machine operation with control handle 5.19 Shutdown procedure with control handle 5.22 Starting procedure with control station 5.24 Shutdown procedure with control station 5.27 Towing a disabled machine 5.28 Battery change procedure 5.29 Instructions on the maintenance 5.35 Important notes 5.35 Before maintenance 5.35 Critical torque values 5.37 Lubricants, fluids and capacities 5.37 Specific lubrication and maintenance instructions 5.41 Every shift 5.41 Weekly 5.42 Monthly 5.53 Every three months 5.54 Major maintenance 5.61 Drive motor/gearbox removal and replacement 5.61 Tire/wheel installation procedure 5.63 Troubleshooting procedures 5.67 Hydraulic system (general) 5.68 Brakes 5.71 Hydraulic cylinders 5.73 Hydraulic pump 5.74 Valves 5.76
Technical data 6.3 Tightening torques 6.5 Permissible data 6.11 Lubrication fluids and greases 6.11
For your information 7.3 Our service 7.3 Service address 7.3 Rebuild facility address 7.4 ti g C) BUC YRIJS AMERIC A, INC.
Table of contents
BI377672
Bucyrus - Models 488L and 488-6 UN-A-TRACe
II Aboutthismanual
BI377672
applicable operating manual
machine type
Before starting to work
About this manual
This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.
Before starting to work
Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.
This operating manual is intended for:
Bucyrus Model 488-6 UN-A-TRAC® Model 488L UN-A-TRAC®
Serial No.: N/A
and is only permitted to be used for equipment of this type.
new operation manual
The operating manual must be accessible at all times to all persons working on or with the machine. It should, if possible, always be available at the place of operation.
Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.
Who is this operating manual intended for?
This operating manual is intended for those persons who work with or on the machine. Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.
This includes persons who:
▪ are in charge of transport
■ perform assembly / disassembly work
■ operate the machine
■ eliminate faults
■ perform daily routine work on the face or in the entry
■ perform maintenance work
■ perform repair work
supervisory personnel who:
■ initiate and/or
■ supervise the activities just indicated.
© BU CYRUS AMERI CA, INC.
A6474X235 VTVI/05 1.3 BI377672
Before starting to work
cost-effectiveness
What is the purpose of this operating manual?
This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.
Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.
service If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled "For your information".
safety Read the chapter "For your safety" with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions,
IA Bucyrus — Models 488L and 488-6 UN-A-TRAC® C) BUC YRUS AMERICA, INC BI377672
Before starting to work
Characters and symbols used
The following characters and symbols are used for safety instructions and important information in the operating manual.
Try to memorize the symbols and their meanings.
DANGER!
Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.
WARNINGI
These points contain information on dangerous situations. Possible consequences are: very serious injury or even death.
CAUTION!
This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.
NOTICE!
Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.
IMPORTANT!
Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you, They do not warn about harmful or dangerous situations.
■ Items in lists are marked with bullets.
— Points in sub-lists are marked with a long dash at the start of the line.
Points in text marked in this way describe individual operations. Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.
© BUCY RUS AME RICA, IN C. A6474X235 VTV!/05 1.5 BI377672
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL