CAT Bucyrus 488D-XP Scoop General Start-up and Operating Instructions Manual - PDF DOWNLOAD

BI000968

BI000968

BI000968

________________________________________

Bucyrus Models -

UN-A-TRAC® 488D-XP

© BUCYRUS AMERICA, INC.

General Start-up and Operating Instructions Doc. No.: A6474X336

______________________________________

Bucyrus America, Inc. ______________________ 4041 Wurno Road Pulaski, VA 24301

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

Internet: www.bucyrus.com

BI000968

_______________________________________

________________________________________

This manual is intended to provide GENERAL product information for the Model 488D-XP UN-A-TRAC®. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

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 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.

© BUCYRUS AMERICA, INC.

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.

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

______________________________________

_______________________________________

BI000968

_________________________ Troubleshooting

________________________ Table of Contents

Fig. 24: Diesel safety system schematic

Table of contents Pre-start inspection..................................................................... 1 Operation .................................................................................... 2 How to operate the UN-A-TRAC® .......................................... 2 Who is allowed to operate the UN-A-TRAC®?....................... 2 When can operation be started? ........................................... 2

______________________________________

A6474X336

SSSV/00

42

Hazard Zone..............................................................................20 © BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

Controls and indicators............................................................... 3 Operator’s compartment........................................................ 3

Starting procedure .....................................................................22 Shutdown procedure .................................................................24 Towing procedure......................................................................25 Maintenance ..............................................................................28 Troubleshooting.........................................................................37 Engine fails is or difficult to start ...........................................37 Engine starts but runs unevenly or stalls..............................39 Diesel Safety System (DSS).................................................40

_______________________________________

A6474X336

SSSV/00

BI000968

Table of Contents_________________________

Troubleshooting __________________________ 

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.



Check the voltage input to the I.S. card from the alternator. It should be 13 to 14 volts DC with the engine running. 

Pin #1 on card should be positive.



If the voltage is over 15 volts, repair or replace the alternator.



If the voltage is not present, check for a tripped circuit breaker in the alternator.



If the voltage is not present at the alternator circuit breakers, repair or replace the alternator.

Check the output voltage to the lights on the I.S. card. It should be 12 volts DC. 

If not present, disconnect the two wires on the I.S. card going to the headlight switch and re-check for 12 volts. This will test any fault in the outby headlight circuit.



If the voltage is still not present, change the I.S. card.



Check the I.S. voltage on the I.S. card to the battery at terminal #TB101 - pin #1 and #2 (#1 black wire should be positive) voltage level should be 8.5 to 8.8 volts DC. If the voltage is not correct, change the I.S. card. If voltage is correct after unplugging TB101, there may be a faulty cable or battery.



All lights on status indicator box should function correctly with their respective trip device. To test prior to engine start, press the green start button.



–

Scrubber low water: green = OK; red = low water

– –

Exhaust temp switch (if used): green = OK; red = low water Engine oil pressure: red = OK prior to start; Green = OK (pressure above 35 psi) after start

–

Engine water temperature: green = OK; red = over temperature

–

Fuel on: green with button pushed prior to starting; green with engine running

If no lights work on the status indicator: 

Check for correct battery voltage (engine off: 6.5 ± 0.2 volt nominal). Also, check service machine box 3 amp breaker.



Check battery to I.S. box connection cable for damage.



Change status indicator card.

______________________________________

_______________________________________

4

41

Bucyrus - Model 488D-XP UN-A-TRAC®

Bucyrus - Model 488D-XP UN-A-TRAC®

BI000968

_________________________ Troubleshooting

______________________________ Operation

Diesel Safety System (DSS) troubleshooting

Pre-start inspection

IMPORTANT! All voltage checks should be made with a digital meter for accuracy.

Operation Read this entire guide before attempting to operate this machine.

Inspection

Open the cover of the air solenoid-transistor box (air actuator).

Read voltage on terminal #1 and #2 with engine off. The battery voltage, up to 7 volts DC, should be displayed. New battery voltage, full charge, is 6.5 ± 0.2 nominal.



Press the green start button on the status indicator. Terminals #1 and #2 should be over 4 volts and the air solenoid coil should be energized. (Note: Air pressure to fuel rack bellows 35 psi nominal.) If reading is under 4 volts, the battery is down and must be changed or block the air valve, start the machine, and charge the battery.

WARNING! The machine cannot be used with the air valve blocked because none of the safety features will shut the machine down.





After the engine starts terminals #1 and #2 should read a nominal 1.65 - 1.68 volts DC. If not, change the status indicator card.



Check the voltage from terminals #1 and #3 in the air solenoid-transistor box (air actuator). There should be 0.8 volts present with the start button pushed on with the engine running. If not, change the status indicator card.



With the voltmeter on terminal #1 to #2 in the air solenoid/transistor (air actuator) and the engine running, the battery voltage should start to increase if the battery is low and the charging system is working.



Check that the green LED is lit on the battery which indicates that the battery is charging.



If all voltages are correct but the air solenoid coil will not keep the air valve open to the fuel rack, adjustments on the air valve linkage may need to be made. the Linkage on the fuel rack may also need attention.



With the start button pushed, or engine running, the pressure switch inside the fuel solenoid I.S. box must turn on the fuel-on green LED on status indicator.

Pilot pressure regulator should be adjusted to 35 psi nominal to activate pressure switch.

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

Maintenance Verify that all maintenance has been performed.

Instruction and safety tags Verify that all instruction and safety tags are in place and readable. These are as important as any other equipment on the machine.

Operator’s compartment Clean any foreign material from the operator’s compartment.

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

Remove the cover from the permissible service machine box (I.S. regulator box).

______________________________________

A6474X336

SSSV/00

40

_______________________________________

A6474X336

SSSV/00

1

© BUCYRUS AMERICA, INC.



© BUCYRUS AMERICA, INC.



BI000968

Operation _______________________________

Troubleshooting __________________________

Operation

Table 4: Engine starts but runs unevenly or stalls Problem

This manual contains important information on the operation of the machine. You must not operate this machine unless you are qualified by training and experience in its safe operation. Read the Operation and Maintenance Manual for this machine, Bucyrus America, Inc. part number A6474X278 before operating the machine.

The UN-A-TRAC® is only allowed to be operated by persons with adequate knowledge of the complete machine.

This also includes: ■

what safety devices are installed on the machine.

■

where these safety devices are located.

■

how these safety devices are to be operated.

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

How to operate the UN-A-TRAC®

Who is allowed to operate the UN-A-TRAC®?

Test, check and/or remedy

engine  Cooling air temperature rise/ hot air starts but recirculation. runs unevenly or  Incorrect valve clearance. stalls  Leaking injection line.

IMPORTANT! Before operating this machine, you must read the complete Operation and Maintenance manual supplied with your machine, part number A6474X278. This is a supplemental manual that contains basic operating procedures only.

DANGER! Incorrect operation endangers yourself and others!

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

Probable cause

 Check air temperature.  Call Bucyrus.  Check injection line.

 Injector defective.   Air in fuel system.

 Call Bucyrus.

 Fuel filter/pre-filter dirty.

 Check, clean or replace filter.

 Fuel quality not as per Operation Manual.

 Check and replace fuel.

 Fuel system not time correctly to the engine.

 Call Bucyrus.

 Fuel pressure is too low.

 Check for plugging of fuel filter or water separator. Have governor adjustments made only by qualified OEM distributor.

 Bent or broken push rod.

 Call Bucyrus.

 Defect in fuel injection valve(s) or pump(s).

 Call Bucyrus.

 Safety shutdown solenoid tripped.

 Check the reset switch, located in the engine bay.

 Check and replace fuel system.

When can operation be started?

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

______________________________________

_______________________________________

2

39

Bucyrus - Model 488D-XP UN-A-TRAC®

Bucyrus - Model 488D-XP UN-A-TRAC®

BI000968

_________________________ Troubleshooting

______________________________ Operation

Table 3: Engine fails or is difficult to start (continued)

Controls and indicators

Problem

Operator’s compartment

Probable cause

engine fails  No fuel to cylinders. or is difficult to start  Wrong fuel injection. (continued)

Test, check and/or remedy  Fill fuel tank. Prime (remove the air and/ or low quality fuel from the fuel system).

The primary controls for the machine are located in the operator’s compartment (Fig. 1 and 2).

 Call Bucyrus.

Fig. 1: Operator’s compartment - left and center

Tachometer

“PARK BRAKE”

Fire extinguisher

Fire suppression actuator

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

Gear selector

Steering control lever “START” (starter)

“RAW” exhaust

“AIR SHUTOFF VALVE”

“TREATED” exhaust

“DIESEL SAFETY SYSTEM” display

“START”

“STOP”

“ENGINE PSI” “ENGINE TEMP”

“EXH TEMP”

“AIR PSI” “EMERGENCY STOP”

“DIF-LOCK PSI”

“HORN” “TRANS TEMP” “INTAKE VACUUM”

______________________________________

A6474X336

SSSV/00

38

“EXHAUST VACUUM”

Brake pedal

Accelerator

“TRANS PSI”

_______________________________________

A6474X336

SSSV/00

3

BI000968

Operation _______________________________

Troubleshooting __________________________

Fig. 2: Operator’s compartment – right

Troubleshooting

“EMERGENCY BRAKE” pressure gauge

“ACCUMULATOR” pressure gauge

“SYSTEM PRESSURE” gauge

For complete troubleshooting information, see the Operation and Maintenance Manual, part number A6474X334.

Light switch

Table 3: Engine fails or is difficult to start Problem

Probable cause

Test, check and/or remedy

“PTO”/”EJECTOR” control lever

“EMERGENCY BRAKE RELEASE HAND PUMP”

“QA” control lever

“LIFT/TILT” control lever

Diff-lock

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

engine fails  Below starting limit temperature. or is difficult  Engine shutdown button in stop to start position (faulty solenoid).

“BRAKE OVERRIDE” valve

 Check the solenoid.

 Coolant level too low.

 Check coolant level in both reservoirs, add as necessary,

 Fuel line pressure stat.  Battery defective or discharged.

 Check pressure stat. Clean with air if necessary.   Check the battery voltage.

 Incorrect valve clearance.

 Call Bucyrus.

 Leaking injection line.

 Check injection line.

 Injector defective.

 Call Bucyrus.

 Air in fuel system.

 Check all hose connections to and from fuel tank.

 Fuel filter/prefilter dirty.

 Check, clean or replace filter.

 Incorrect engine oil SAE class or quality.

 Replace engine oil.

 Fuel quality not as per Operation Manual.

“LIFT/TILT” control lever

 Check temperature.

  Remove the fuel from the fuel tank, install a new fuel filter element, refill with correct grade, clean fuel.

 Low air pressure.

 Recharge air tank through quick disconnect fitting to 120 psi min.

 Starter pressure regulator set too low.

 Reset regulator to 6 bar (90 psi).

 Air starter piston sticking.

 Check air piston for free operation.

 Slow cranking speed.

 Low air pressure or regulator setting (see above).

 No fuel in the housing for the fuel injection pumps.    Dirty or broken fuel lines.

 Fill the housing for the fuel injection pumps with fuel via the priming pump.

Remove the air with the bleed valve.  Clean or install new fuel lines as necessary.

______________________________________

_______________________________________

4

37

Bucyrus - Model 488D-XP UN-A-TRAC®

Bucyrus - Model 488D-XP UN-A-TRAC®

BI000968

____________________________ Maintenance

______________________________ Operation

Fig. 23: Lubrication and maintenance chart, continued

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.

Fire suppression The machine is equipped with a fire suppression system (Fig. 3) that can be actuated either automatically or manually.

15

© BUCYRUS AMERICA, INC.

33, 42, 53

28

The machine is also equipped with two (2) fire suppression (remote) actuators. One is located to the operator’s left inside the operator’s compartment and the other is located on opposite side of the machine on the rear frame in the fuel filter compartment. This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two (2) actuators, pull the safety pin and strike downward on the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The engine will shut down when the fire suppression system is activated. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated. Refer to the Ansul fire suppression users manual for complete operating instructions.

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

Fig. 3: Fire suppression locator (typical) Actuator

Fire extinguisher Actuator

______________________________________

A6474X336

SSSV/00

36

_______________________________________

A6474X336

SSSV/00

5

© BUCYRUS AMERICA, INC.

A wire circuit is routed throughout the machine. When exposed to fire, the circuit will initiate a fire detection condition and the fire suppression will discharge.

BI000968

Operation _______________________________

Maintenance _____________________________

“EMERGENCY PARK BRAKE RELEASE HAND PUMP”

Fig. 23: Lubrication and maintenance chart

The automatic emergency brakes are spring-applied (on), pressure-release (off) internal wet disc brakes located on each wheel end. The automatic (park) brake is normally released using the "PARK BRAKE" lever located in front and to the left of the operator (see instructions for “PARK BRAKE” later in this chapter). Should hydraulic system failure occur, the automatic (park) brake can be released using the manual brake release hand pump (Fig. 4).

To release the automatic emergency/park brakes with the machine de-energized proceed as follows:

13



Turn the selector valve handle on the hand pump to the “PUMP TO RELEASE” position.



Remove the pump handle retaining ring.



Pump the hand pump until the “EMERGENCY BRAKE” pressure gauge reads a minimum of 1,500 psi.

To reset the automatic emergency/park brakes proceed as follows: 

Turn the selector valve handle on the hand pump to the “NORMAL RE-APPLY” position.



Push the hand pump handle down and reinstall the retainer pin.

12 18

38, 39, 40 57, 58, 59

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

WARNING! The machine must be chocked at all four (4) wheels before releasing the automatic emergency/park brakes with the hand pump. The machine could run away out of control and cause damage to the machine or injury or death the operator or other persons.

16, 17

11, 36

9, 32

10, 31

6

Fig. 4: Brake release hand pump Brake release hand pump

29, 55, 56

Selector valve handle

8 4, 62

64, 67 3, 16 5, 68 65, 66

7 63

5, 68

______________________________________

_______________________________________

6

35

Bucyrus - Model 488D-XP UN-A-TRAC®

Bucyrus - Model 488D-XP UN-A-TRAC®

BI000968

____________________________ Maintenance

______________________________ Operation

Table 2 continued: Lubrication and maintenance

“SYSTEM PRESSURE” gauge

53

Planetary wheel end oil (Change)

4

54

Wet disc brake wear indicator (Check) Hydraulic oil (Change)

4

Tank suction strainer (Clean/ change) Pressure filter (Change) Return filter (Change) Auxiliary pump pressure filter (Inspect/change as required) Winch oil (Change) (Optional)

1

55 56 57 58 59 60

Places

Lubricant

2

Hypoid gear oil SAE 90W Hypoid gear oil SAE 90W

1

1

1st 50 Hours of service Engine oil and filter

Change

62 63 64

Every 100 hours of service Engine air cleaner Radiator Engine oil and filter

Change Clean Change

67 68

69 70 71 72

Fuel pre-filter Fuel final filter Every 500 hours of service Converter/transmission filter Radiator coolant

Change Change

Scrubber heat exchanger Every 1000 hours of service Scrubber heat exchanger Every 6 months Power system permissibility: intake system Power system permissibility: shutdown circuit testing

Inspect

SSSV/00

The hydraulic system pressure relief valve (Fig. 5) is set at the factory at 2,500 psi, and should not be changed. Should the “SYSTEM PRESSURE” gauge read more than 2,650 psi, shut down the machine and call a maintenance person.

Spec. 10012

Clean Change

API GL4 (140) Gear oil Peragma Grade 8 10W40 API CF/ 4

10W40 API CF/ 4

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

“ACCUMULATOR” gauge WARNING! If the “ACCUMULATOR” pressure drops below 1,900 psi, shutdown the machine (see Shutdown procedure in this chapter) and call a maintenance person.

“EMERGENCY BRAKE” gauge WARNING! If the “BRAKE” pressure drops below 1,800 psi, shutdown the machine (see Shutdown procedure in this chapter) and call a maintenance person.

Fig. 5: Pressure gauges “EMERGENCY BRAKE” pressure gauge

1. Avia Antifreeze Extra 2. Glysantin G 48 DEA radiator antifreeze 3. Shell Glyco

“ACCUMULATOR” pressure gauge

“SYSTEM PRESSURE” gauge

Clean

______________________________________

A6474X336

Located to the right of the operator’s seat are three (3) pressure gauges (Fig. 5) that provide the operator with a continuous reading of the “ACCUMULATOR”, “SYSTEM” and “BRAKE” pressures.

1 1

61

65 66

Spec.

34

_______________________________________

A6474X336

SSSV/00

7

© BUCYRUS AMERICA, INC.

52

Description Every three months Axle oil (Change)

© BUCYRUS AMERICA, INC.

Item

BI000968

Operation _______________________________

Maintenance _____________________________

“2 SPEED WINCH OPERATION” (if equipped)

Table 2 continued: Lubrication and maintenance

The “2 SPEED WINCH OPERATION” valve (if equipped) allows the operator to speed up or slow down the speed of the winch. To increase the speed of the winch, pull the handle out and to decrease the speed of the winch, push the handle in.

Item 30

Differential lock

31 32 33 34

WARNING! Operation of differential locks may cause overloading of drive line parts. Special attention is necessary. Operate differential locks only in difficult ground condition (sand, gravel, mud). The differential lock button should only be actuated at a stand still and under no circumstances when wheels are spinning.

Fig. 6: Differential lock

35 36 37 38 © BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

The operator controlled differential lock actuator (Fig. 6) is located in front and to the left of the operator, beside the brake pedal. When actuated (knob pushed in), the differential locks are engaged in both the front and rear axles. To release the differential lock, pull out on the knob.

39 40 41 42 43 44 45 46 47 48 49

Differential lock

50 51

Description Weekly Winch oil level (Optional)

Places

Lubricant

1

Steering cylinder pins Center section pins and nuts Tire-wheel mounting bolts Engine, converter, and transmission Mounting bolts Axle mounting bolts Oscillating bearing Fire suppression system Pressure filter (Main) (Inspect/change as required) Return filter (Inspect/change as required) Auxiliary pump pressure filter (Inspect/change as required) Axle oil level (Check)

Inspect Inspect Inspect Inspect

API GL4 (140) Gear oil Peragma Grade 8

Planetary wheel end oil level (Check) Wet disc brake wear indicator (Check) Power system permissibility: intake system Power system permissibility: exhaust system Power system permissibility: shutdown circuit testing Machine/electrical system permissibility: fuel system Machine/electrical system permissibility: braking system Machine/electrical system permissibility: electrical lighting system Machine/electrical system permissibility: miscellaneous Carbon monoxide (CO) sampling

4

Spec.

Inspect Inspect Inspect 1 1 1 2

Hypoid gear oil SAE 90W Hypoid gear oil SAE 90W

4

______________________________________

_______________________________________

8

33

Bucyrus - Model 488D-XP UN-A-TRAC®

Bucyrus - Model 488D-XP UN-A-TRAC®

BI000968

____________________________ Maintenance

______________________________ Operation

Table 2: Lubrication and maintenance schedule

“PTO”/“EJECTOR” control lever

4 Inspect Check

4 5

Engine air cleaner Radiator coolant level

Check Check

6

Transmission/Converter oil level

Check

7 8

Soot Filter (Replace as necessary) Fuel level

Inspect Check

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Every third shift Center section pivots Steering cylinders (rod and base end) Oscillating bearing Tilt cylinders (2 cylinders) Lift cylinder (1 cylinder) Ejector cylinder (2 cylinders) Lift arm attachment pins (4 pins) Accelerator assembly Brake pedal Canopy guide tubes Winch (Optional) Front drive line Rear drive line Middle drive line Converter drive line Flange bearing (front drive line) Fasteners (Nuts, bolts and screws) Electrical cables, conduits and glands Hydraulic hoses and connections Tires (Inspect) Hydraulic oil level (Check)

Places

Lubricant

10W40 API CF/ 4 1. Avia Antifreeze Extra 2. Glysantin G 48 DEA radiator antifreeze 3. Shell Glycol SAE 20W CAT TO-4 Allison C4

WARNING! 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.

Low sulfur diesel fuel

2 4

Spec. 100-3 Spec. 100-3

9 4 2 4 4 2 1 3 3 3 3 3 3 1 Inspect Inspect

Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3

Inspect 4 1

Spec. 100-12

______________________________________

A6474X336

SSSV/00

The “EJECTOR” lever (Fig. 7) 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 to the right (“OUT”), the ejector blade moves toward the front of the bucket (extend.) When the ejector lever is pushed to the left (“IN”), the ejector blade moves toward the back of the bucket (retract.) When the ejector blade is not being used, it should be resting in the retracted position.

Spec.

32

When forks are attached, the “EJECTOR” lever will move the forks in and out. When the lever is pushed to the right, the forks will spread. When the lever is pushed to the left, the forks will move in.

The same lever is used to control both front and rear “PTO” functions. To operate the front PTO, the bucket/forks must be disconnected. See the hydraulic schematic in the Bucyrus parts book for your machine for PTO operation.

WARNING! The rear PTO circuit is not isolated from the ejector/fork circuit. Operating the rear PTO with the bucket or forks attached will result in movement of the ejector blade or the forks. It is strongly recommended that the bucket/forks be disconnected before operating the rear PTO. “TILT/LIFT” control lever The “TILT/LIFT” control lever (Fig. 7) the attachment. To lower the attachment, push the lever toward the operator (left). To raise the attachment, push the lever up away from the operator (right). To tilt the attachment down, push the lever up (towards the front of the machine). To tilt the attachment up, pull the lever back (towards the rear of the machine.)

WARNING! Holding the “LIFT” 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 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 attachment. If the “LIFT” or “TILT” control lever is moved when the unit is shutdown, the attachment could drop, even if all other levers and pedals are in the off position.

_______________________________________

A6474X336

SSSV/00

9

© BUCYRUS AMERICA, INC.

1 2 3

Description Pre-shift Headlights (Inspect) Reflectors and warning tags Engine oil level

© BUCYRUS AMERICA, INC.

Item

BI000968

Operation _______________________________

Maintenance _____________________________

“QA” control lever (optional)

Lubricants, fluids and capacities

The “QA” control lever (Fig. 7) provides the operator with a means of quick attachment of the bucket or forks. Push the lever down to “LOCK” the attachment system and push the lever up to “UNLOCK” and disengage the system.

Table 1: Lubricants, fluids and capacities Location

Specification

Approximate capacity

Notes

“WINCH/PTO SELECTOR” (if winch equipped)

Hydraulic oil tank

Spec. 100-12

70 gals. (189 liters)

1

The “WINCH/PTO SELECTOR” controls a diverter valve that directs flow to either the winch or the PTO. Pull selector up to activate the winch and push the selector down to activate the PTO.

Lubrication points

Spec. 100-3

As Required

3

API GL4 (140) Gear oil Peragma Grade 8 Hypoid gear oil SAE 90W Hypoid gear oil SAE 90W Cooling oil

2.5 gals. (2.3 liters) or as required

Approximately 4 gals. Ea.

Low sulfur

30 gals.

Winch

The optional "PTO/WINCH" control lever is used to control either the winch or the hydraulic PTO, depending on the position of the diverter valve. When the “WINCH/PTO SELECTOR” is pushed down, the "PTO/WINCH" control lever operates the PTO. When the control lever is moved to the left by the operator, the “B” port is pressurized. Moving the handle to the right pressurize the “A” port.

CAUTION! Do not operate the “PTO” system continuously for more than 30 minutes at a time. Never block or tie the “PTO” function to active position.

Operating the PTO for longer than thirty minutes will result in excessive heat in the hydraulic system, accelerating breakdown of the hydraulic fluid and causing hydraulic component failure.

When the “WINCH/PTO SELECTOR” is pulled up, the "PTO/WINCH" control lever operates the winch. When the control lever is pulled to the left, the winch reels in. When the control lever is pushed to the right, the winch reels out.

Fig. 7: Control lever locations

“EJECTOR”/”PTO” control lever

Axle housing Planetary wheel ends © BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

“PTO/WINCH” (if equipped)

Wet disc brakes Diesel fuel

8.4 gals. (32 liters)

2

6.8 qts. (6.5 liters)

2

Notes: 1. With ejector blade completely retracted (if equipped with bucket).

2.

The axle housing and planetary wheel end assemblies do not have a common oil source. Each assembly must be filled separately.

Make sure the level and fill hole in the planetary wheel end cover is in the proper position. Rotate the wheel end as required to bring the fill hole to either the 3 o'clock or 9 o'clock position.

When filling the axle housing and planetary wheel ends, allow enough time for the lubricant to fill the various cavities and around component parts in each assembly.

Continue adding oil into each assembly until the required oil level is reached.

“LIFT/TILT” control lever “QA” lock lever

______________________________________

_______________________________________

10

31

Bucyrus - Model 488D-XP UN-A-TRAC®

Bucyrus - Model 488D-XP UN-A-TRAC®

BI000968

____________________________ Maintenance

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

During maintenance or servicing, if drive shafts are to be run, the machine must be jacked clear of the ground and securely blocked. All four wheels must be free to rotate. The center section should also be blocked.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

WARNING! Do not lift the front wheels of the UN-A-TRAC ® off the surface by tilting the lift attachment down except for maintenance procedures.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

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

■

The service brake pedal (Fig. 8) is a foot operated pedal located in front of the operator and is situated for actuation by the operator’s left foot. Service brake actuation is a reverse modulating (de-modulating) process which reduces the pressure supplied to the HRSA (Hydraulic Released Spring Applied) brakes as the pedal is depressed.

Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked if maintenance is to be performed with the boom in the raised position.

Brake system operating pressure is regulated to a maximum limit of 1,850 psi and is achieved via internal controls within the brake pedal valves themselves (not adjustable).

Accelerator pedal © BUCYRUS AMERICA, INC.

■

Brake pedal (service)

The speed of the vehicle within a selected range is controlled by the accelerator pedal (Fig. 8). The final speed of the vehicle is dependent upon both the accelerator pedal and the speed selector lever.

The right pedal is the accelerator pedal (throttle), controlling the engine speed, while the left pedal controls the vehicle brakes - just like an automobile.

The accelerator pedal works like the accelerator of a car. Pushing the pedal down accelerates the vehicle, and releasing the pedal allows the vehicle to decelerate through the torque converter.

Fig. 8: Brake and accelerator pedal locations

Cleanliness can not be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

______________________________________

A6474X336

SSSV/00

30

Brake Accelerator _______________________________________

A6474X336

SSSV/00

11

© BUCYRUS AMERICA, INC.

■

______________________________ Operation

BI000968

Operation _______________________________

Maintenance _____________________________

“PARK BRAKE”

Instructions on the maintenance

The “PARK BRAKE” (Fig. 9), which is the same as the emergency brake, has two positions: on and off. Pushing the lever forward, away from the operator puts the brake in the on position (brake must be on to start the engine). Pulling the lever towards the operator puts the brake in the off position. In the on position, the brake is immediately engaged under any circumstances. In the off position, the brake is automatically applied only when the engine is stopped. Note that the parking brake is automatically applied, regardless of lever position, whenever the engine is stopped.

Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine.

In particular, observe the safety instructions in chapter 2 “Your safety”.

Important notes Please observe the following:

DANGER! Never leave the vehicle with the engine running and the parking brake disengaged.

■

In order to avoid individual components not being serviced or being inadequately serviced during maintenance work on the machine, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using the operation manual (part number A6474X278) and the manuals of the other components (located in the parts book).

■

Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work.

■

Use only original Bucyrus America, Inc. spare parts when replacing components.

■

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

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this Bucyrus America, Inc. guide.

The brake override valve (Fig. 9) is used to stall test the machine. Holding in the valve while the “PARK BRAKE” is set will cause the “PARK BRAKE” to be bypassed, allowing the machine to go in gear. This valve is used to test machine performance only.

Fig. 9: Brake override valve “PARK BRAKE”

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

Brake override valve

Before maintenance Please observe the following: “BRAKE OVERRIDE” valve

■

Shutdown the machine on level ground.

■

Test the controls to ensure that the unit will not move.

■

Chock all four (4) wheels in each direction.

■

Connect steering lockout device.

WARNING! Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

______________________________________

_______________________________________

12

29

Bucyrus - Model 488D-XP UN-A-TRAC®

Bucyrus - Model 488D-XP UN-A-TRAC®

BI000968

________________________ Towing procedure

______________________________ Operation

IMPORTANT! In states with specific towing regulations, follow the regulations without deviation. A Bucyrus America, Inc. specific tow bar is available for purchase and is designed to be used with the Un-a-trac specifically.

“TOTAL INTAKE VACUUM” The “TOTAL INTAKE VACUUM” gauge (Fig. 10) monitors the inlet vacuum pressure and gives a visual indication if the air inlet filter needs cleaning or replacement. The maximum restriction is 25” of water.

WARNING! Failure to set the parking brake on the disabled vehicle before removing the towing device could allow the disabled vehicle to roll away uncontrolled.

“EXHAUST BACK PRESSURE” This gauge (Fig. 10) displays the back-pressure, in inches of water, across the hydraulic or dry filter. Check the exhaust pressure at high idle with the engine in neutral. If the needle exceeds 60” of water, then maintenance is required.

Fig. 10: Gauges

______________________________________

A6474X336

SSSV/00

28

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

“TOTAL INTAKE VACUUM”

“EXHAUST BACK PRESSURE”

_______________________________________

A6474X336

SSSV/00

13

BI000968

Operation _______________________________

Towing procedure ________________________

“DIESEL SAFETY SYSTEM” display

Towing a disabled machine

The “DIESEL SAFETY SYSTEM” display (Fig. 11) monitors the engine status and can be used as an aid in troubleshooting. When the system is operating under normal conditions, the indicator lights will be green. If the exhaust temperature, engine oil pressure, or engine temperature go out of their normal operating parameters, the machine will shutdown. When the start button is pressed in after shutdown, the indicator light for the cause of the shutdown will be red (for example, high exhaust temperature). If the fire suppression system is activated, the indicator light above the label “FIRE” will turn red.

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 vehicle, the 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.

There is a green “START” button on the face of the display. This button must be held in as part of the normal startup procedure (see Startup procedure in this chapter). The red “STOP” button on the face of the display is used to shut the machine down (see Shutdown procedure in this chapter).

Indicator lights

“STOP” button “START” button

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

Fig. 11: “DIESEL SAFETY SYSTEM” display



Couple the towing vehicle securely to the disabled vehicle.

 Turn the valve selector handle on the disabled vehicle to “PUMP TO RELEASE” on the Emergency/Park Brake Release Hand Pump located inside the operator’s compartment (this isolates 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. 

Engine RPM “TACHOMETER”

The Automatic (Park) Brake is released when a minimum of 1,500 psi is indicated by the Brake Release gauge.

CAUTION! For long distance towing, disconnect and remove front and rear drive lines.

The engine rpm “TACHOMETER” (Fig. 12) is mounted on the frame outside and to the left of the operator’s compartment. It indicates engine RPM using a mechanical drive cable and adapter from the engine drive pulley.

WARNING! At no time during towing should anyone ride in or on the vehicle being towed or stand in between the towing vehicle and the disabled vehicle.

Fig. 12: “TACHOMETER”

“TACHOMETER”



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 chocked in both direction at all four wheels for additional stability. The brake is set by turning the valve handle on the hand pump to “NORMAL RE-APPLY”.

______________________________________

_______________________________________

14

27

Bucyrus - Model 488D-XP UN-A-TRAC®

Bucyrus - Model 488D-XP UN-A-TRAC®

BI000968

_____________________ Shutdown procedure

______________________________ Operation

Fig. 22: Steering lockout device (typical)

Engine hour meter (optional)

Steering lockout device (stored location)

The engine hour meter (optional), displays elapsed operating time in engine-hours of the diesel engine.

“TRANSMISSION TEMPERATURE” gauge The “TRANSMISSION TEMPERATURE” gauge (Fig. 13) displays the oil temperature in the transmission in degrees Fahrenheit. Maximum safe temperature is about 225°F (107° C).

“ENGINE OIL PRESSURE” gauge

Steering lockout device (installed location)

“ENGINE TEMPERATURE” gauge The “ENGINE TEMPERATURE” gauge (Fig. 13) measures the temperature of the coolant in the diesel engine. Maximum engine temperature is 200 °F. If the temperature goes above the safe operating limit, the engine will shutdown.

“AIR PRESSURE” gauge The “AIR PRESSURE” gauge (Fig. 13) measure the air pressure in the pneumatic system. Minimum operating pressure is 120 psi and maximum operating pressure is 150 psi.

“TRANSMISSION PRESSURE” gauge The “TRANSMISSION PRESSURE” gauge (Fig. 13) measures transmission oil pressure.

The minimum transmission oil pressure should be 160 psi.

“DIF-LOCK PSI” gauge The “DIF-LOCK PSI” gauge (Fig. 13) should not exceed 600 psi (41 bar) (John Deere axle) or 150 psi (10 bar) when the differential locks are engaged.

WARNING! Should the dif-lock pressure exceed the maximum reading as listed above, shutdown the machine and call maintenance.

______________________________________

A6474X336

SSSV/00

26

_______________________________________

A6474X336

SSSV/00

15

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

The “ENGINE OIL PRESSURE” gauge (Fig. 13) measures oil pressure with a resistance sender on the engine referenced to ground. The minimum oil pressure should be 20 psi.

If the pressure drops below 20 psi, the engine will shutdown.

BI000968

Operation _______________________________

Shutdown procedure ______________________

Fig. 13: Gauge panel

Shutdown procedure

“ENGINE PSI”

“ENGINE TEMP”

 

“AIR PSI”

Tram the machine to its designated parking place.



Stop the machine by releasing the speed-switch foot pedal and depressing the foot brake pedal. Applying the foot brake will stop forward (or reverse) motion.



Return the shift lever (Fig. 20) to “NEUTRAL”.



Apply the parking brake (Fig. 20).

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

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

“TRANS PSI”

“TRANS TEMP”



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



Press the red “STOP” button on the “DIESEL SAFETY SYSTEM” display (Fig. 20).



Close the “AIR SHUTOFF VALVE” (Fig. 20).



Connect the steering lockout device (Fig. 22): 

remove the steering lockout device from its storage lugs



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



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



insert the hitch pin into the front section lug through the turnbuckle WARNING! Never enter the articulation area while the machine is running. Completely shutdown the machine as outlined before connecting the steering lockout device. Failure to observe this precaution may result in injury or death.

“DIF-LOK PSI”

______________________________________

_______________________________________

16

25

Bucyrus - Model 488D-XP UN-A-TRAC®

Bucyrus - Model 488D-XP UN-A-TRAC®

BI000968

Starting procedure________________________

______________________________ Operation

Fig. 21: Fuel on/off valve, water separator, and primer

“AIR SHUTOFF VALVE” The “AIR SHUTOFF VALVE” (Fig. 14) is used to shut off air supply to the main control valve for servicing purposes.

“RAW” exhaust sampling port The “RAW” exhaust (Fig. 14) is a port where a meter can be connected to analyze the composition of the untreated exhaust.

“TREATED” exhaust sampling port The “TREATED” exhaust (Fig. 14) is a port where a meter can be connected to analyze the composition of treated exhaust.

© BUCYRUS AMERICA, INC.

Fuel primer

The optional “EXH TEMP” gauge is used to monitor the exhaust temperature. If the exhaust temperature exceeds 300° F, the machine must be shut down immediately.

Fig. 14: “AIR SHUTOFF VALVE”, “EXH TEMP” gauge, and sampling ports “EXH TEMP” gauge

Fuel on/off valve

Check bowl for water - drain as necessary

Fuel/water separator

______________________________________ 24

Bucyrus - Model 488D-XP UN-A-TRAC®

“RAW” exhaust sampling port

“TREATED” exhaust sampling port

“AIR SHUTOFF VALVE”

_______________________________________

A6474X336

SSSV/00

17

© BUCYRUS AMERICA, INC.

“EXH TEMP” (optional)

BI000968

_______________________ Starting procedure  

“HORN” The “HORN” button (Fig. 15) is used to sound the air horns. Follow all applicable laws

Push in the green “START” button (Fig. 20) on the “DIESEL SAFETY SYSTEM” display. 

The safety system is equipped with a low oil pressure shutdown. While depressed, the “START” button acts as an override. The button must be depressed until oil pressure builds above 20 psi to ensure that the engine will continue to run.



All lights on the “DIESEL SAFETY SYSTEM” except for the “ENGINE OIL PSI” must be green for the engine to start.

and mine safety regulations for sounding the horn.

“START” The “START” (Fig. 15) is used in the start up of the machine (see Starting procedure in this chapter). 

“EMERGENCY STOP”

© BUCYRUS AMERICA, INC.

The “EMERGENCY STOP” button (Fig. 15) is used to shut the machine down in an emergency situation. After pushing this button, the air inlet to the engine (Fig. 16) has to be manually reset. This button is not for normal shutdown of the machine. For normal shutdown, see the Shutdown procedure in this chapter.

Press the air “STARTER” button (Fig. 20) until the engine fires. 

Short button actuations should be all that is necessary for the engine to catch.

Long duration button depressions will allow large amounts of air to escape and will result in low air tank volume. Low air tank volume will result in fewer available start cycles. © BUCYRUS AMERICA, INC.

Operation _______________________________

Fig. 19: Operator compartment controls

Fig. 15: “HORN”, “STARTER”, and “EMERGENCY STOP” “EMERGENCY STOP”

“PARK BRAKE”

“START”

“HORN”

Fig. 16: “EMERGENCY STOP” reset location “EMERGENCY STOP” reset location

“START” (starter)

“START”

“AIR SHUT-OFF VALVE”

______________________________________ 18

Gear selector

Bucyrus - Model 488D-XP UN-A-TRAC®

_______________________________________

A6474X336

SSSV/00

23

BI000968

Starting procedure________________________

______________________________ Operation

Starting procedure

Steering control lever

WARNING! The vehicle should be stored and protected from temperatures below 40° F. Temperatures below 32° F can cause damage to pneumatic controls, fuel systems, exhaust components, and emission control devices.,

© BUCYRUS AMERICA, INC.

WARNING! Never operate any levers or pedals from outside the operator's compartment.

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.



Check all fluid levels.



Turn the master air valve, “AIR SHUTOFF VALVE”, (Fig. 20) on.



Turn fuel on (Fig. 21).



Check water separator and bleed off as necessary (Fig. 21).



Prime the fuel system (Fig. 21):



If, during priming, the actuator fails to become resistant to continued pumping or the primer bulb feels spongy, stop and determine the cause. Air may be entering the system or the fuel pressure stat may be stuck open, prohibiting the build up of pressure necessary for start-up.

If the pressure stat is stuck open, take it out and clean it with air, then reinstall.

Prime the fuel system again.



Ensure that the park brake release knob (Fig. 20) is in the “SET” position.



Ensure that the transmission gear selector (Fig. 20) is in the “NEUTRAL START” position.

IMPORTANT! The starting circuit will not be complete if the gear selector is not in “NEUTRAL START” position and the parking brake is not in the appropriate position. The machine will not start if these conditions are not met.

______________________________________ 22

Gear selector lever A single shift lever (Fig. 17) selects the following gears: ■

REVERSE 4th GEAR

■

FORWARD 4th GEAR

■

REVERSE 3rd GEAR

■

FORWARD 3rd GEAR

■

REVERSE 2nd GEAR

■

FORWARD 2nd GEAR

■

REVERSE 1st GEAR

■

FORWARD 1st GEAR

■

NEUTRAL

■

NEUTRAL START

The shift lever is operated by the driver’s left hand. This lever must be in NEUTRAL START (selector lever push forward in neutral position) for the engine to start.

To start the machine:



The steering control lever (Fig. 17) located by the gear selector to the left of the operator, is used to steer the machine. To steer left when moving forward (toward the bucket), move the steering lever away from the operator. To steer right when moving forward, move the lever toward the operator.

Bucyrus - Model 488D-XP UN-A-TRAC®

Remember to always engage FORWARD or REVERSE with the engine idling. It is not necessary to start off in low gear and constant operation in higher gears in low grade conditions is permitted.

Never lug or drag the engine RPM’s down in high gear when working the vehicle on a grade. Whenever the machine is traveling below walking speed and is still pulling a load, shift into LOW. A recommended shift point should be around 1750 ± 50 RPM. Speed range shifting (LOW-INTERMEDIATE-HIGH) may be made under full power. This will not hurt the transmission, but letting up on the throttle will provide the operator a smoother ride.

Fig. 17: Steering control and speed selector Gear selector lever

Steering control lever

_______________________________________

A6474X336

SSSV/00

19

© BUCYRUS AMERICA, INC.

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 procedure.

BI000968

Operation _______________________________

______________________________ Operation

Light switch

Fig. 19: Hazard zone

The machine is equipped with a light switch (Fig. 18) that is used to deenergize all power to the front and rear headlights. Location may vary.

© BUCYRUS AMERICA, INC.

© BUCYRUS AMERICA, INC.

Fig. 18: Light switch

Hazard zone The hazard zone (Fig. 19) exists unless: 

All air is drained from the pneumatic system.

WARNING! Do not position body parts under any raised portion of the machine (ex. forks, bucket). If the elevated portion of the machine falls, serious injury or death may result.

GVW ...................................... 80,000 lbs Maximum capacity ................. 12 tons Maximum grade ..................... 22 %

______________________________________ 20

Bucyrus - Model 488D-XP UN-A-TRAC®

_______________________________________

A6474X336

SSSV/00

21