BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationManual BUCYRUS - UN-A-TRAC ® Model - 482DIESEL Doc.No.: A6474X272 BI620984
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ThismanualisintendedtoprovideGENERALproductinformationfor theModel482DIESELUN-A-TRAC ®.Theillustrations,descriptions andprocedurescontainedinthispublicationapplyonlytoTHISmachine.BucyrusAmerica,Inc.reservestherighttorevisemodelsand designswithoutpriornotice.
ThisUN-A-TRAC ® wasmanufacturedundertheguidelines,procedures andrequirementsoftheU.S.FederalCoalMineHealthandSafetyAct, CodeofFederalRegulations,Title30,Chapter1,Subpart0,Part75for undergroundcoalmines,andotherapplicablenon-U.S.regulatory agencystandards.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofBucyrusAmerica, Inc.andtheseregulatoryagencies,oranyrepairorreplacementof partscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidate theseapprovalsandrenderthisunitunsafetooperate.
StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusAmerica,Inc.Service Representative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
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BI620984
© BUCYRUSAMERICA,INC. ALLRIGHTSRESERVED
________________________________________________ Tableofcontents A6474X272 REV2 ©BUCYRUSAMERICA,INC.
Tableofcontents
Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual? 1.4 Charactersandsymbols 1.5
1.
Yoursafety Yoursafety 2.3 Personnel 2.4 Operation 2.4 Installationandrepair 2.4 Operatingconditions 2.5 Intendeduse 2.5 Unauthorizeduse 2.5 Safetyinstructions 2.7 Generalrules: 2.7 Storageandtransport 2.8 Pre-startinspection 2.8 Installationandstart-up 2.9 Operation 2.9 Stopping 2.10 Maintenanceandrepair................................................. 2.10 Dieselemissions 2.11 Handlingofhydraulicfluids ........................................... 2.13 Overviewofthesafetyinstructions 2.17 Chapter2:Safetyinstructions....................................... 2.17 Chapter3:Storageandtransport 2.17 Chapter4:Installation ................................................... 2.17 Chapter5:Operation 2.18 Chapter6:Technicaldata............................................. 2.25
Storageandtransport Storageandtransport.............................................................3.3 Storage 3.3 Storageofthemachineandspareparts.........................3.3 Transport 3.4 Beforetransport...............................................................3.5 4. Installation Installation ...............................................................................4.3 Pointstoobservepriortoinstallation...................................4.3 Whoisallowedtocarryoutinstallation? 4.3 Whichtoolsarerequiredforinstallation?........................4.3 Notesoninstallation 4.4 Pre-installationchecklist.................................................4.5 Safetyfeatures 4.6 BI620984
2.
3.
5. Operation
Tableofcontents _________________________________________________ BUCYRUS – Model482DIESELUN-A-TRAC ® ©BUCYRUSAMERICA,INC.
Pre-operationsuggestions.....................................................5.3 Operation 5.4 HowtooperatetheUN-A-TRAC ® 5.4 WhoisallowedtooperatetheUN-A-TRAC ® 5.4 Whencanoperationbestarted? 5.4 Controlsandindicators 5.5 Operator’scompartment - rightside 5.5 Operator’scompartment - leftandcenter 5.6 Hazardzone 5.23 Startingprocedure 5.24 General 5.24 Machineoperation 5.25 Shutdownprocedure 5.27 Towingadisabledmachine 5.28 Instructionsonthemaintenance 5.29 Importantnotes................................................................5.29 Beforemaintenance 5.29 Criticaltorquevalues.......................................................5.31 Lubricants,fluidsandcapacities 5.31 Specificlubricationandmaintenanceschedule ..............5.32 Specificlubricationandmaintenanceprocedure 5.35 Pre-shift ...........................................................................5.35 Everythirdshift 5.38 Weekly.............................................................................5.43 Everythreemonths 5.49 First50hoursofservice..................................................5.53 Every100hours 5.54 Every500hours ..............................................................5.56 Every1000hours 5.57 Servicingheavydutyairfilterelements................................5.58 Dieselemissionsmaintenance 5.62 Introduction(emissions) 5.62 Dieselemissions 5.63 Dieselemissionsstalltest 5.64 Operationalissues 5.66 Tools 5.66 Bestpractices 5.67 Proactiveattitudes 5.70 Typicalexhaustgascomponents 5.72 Carbondioxide 5.72 Carbonmonoxide ............................................................5.72 Oxidesofnitrogen 5.72 Hydrocarbons ..................................................................5.72 Particulatematter 5.73 Oxidesofsulfur................................................................5.73 Smoke 5.73 Enginesystemsandconditions thataffectdieselemissions 5.74 Combustionchamberdesign...........................................5.74 Intakemanifoldsystem 5.76 Operatingconditionsthataffectemissions......................5.77 Lowturbochargerboostpressure 5.78 Highexhaustbackpressure.............................................5.78 BI620984
________________________________________________ Tableofcontents A6474X272 REV2 ©BUCYRUSAMERICA,INC. Highcrankcasepressure 5.80 Overviewofsixenginesystems 5.81 Introduction 5.81 Intakesystem 5.82 Jobaidchecklist(IntakeSystem) 5.88 Exhaustsystem ................................................................5.89 Introduction 5.89 Exhaustsystemrecommendations ................................5.91 Exhaustaftertreatmentsystemmaintenance 5.91 Jobaidchecklistforexhaustsystem..............................5.93 Introductiontotoolsusedforexhaustsystemanalysis 5.94 ECOMAC+gasanalyzer...........................................5.94 UGASsoftwareapplication 5.96 Testingprotocol..........................................................5.96 Pre-testconditions 5.97 Emissionstestingprotocol..........................................5.97 Basicemissionequipmentoperation 5.98 Undiluteddieselparticulatemeasurement.................5.98 Measurementinterpretation 5.100 Analysisofparticulatesamples..................................5.100 Thermalopticalmethod 5.101 Jobaidchecklistforexhaustsystemanalysistools 5.102 ECOMAC+gasanalyzer 5.102 Particulatesampling - Gilianpump 5.102 Intaketesting 5.103 Intakerestrictionsandexhaustbackpressure 5.104 Fuelinjectionsystem 5.105 Introduction(Fuelinjectionsystem) 5.105 Injectionpumporinjectorfailure 5.106 Inadequatefuelsupply 5.106 Incorrectinjectionpumporinjectortiming 5.107 Advancedtiming 5.107 Retardedtiming 5.107 Fuelsystemtypes 5.108 Individualunitjerkpumps...............................................5.109 Inlinepumpsystem 5.110 Distributorpumpsystem.................................................5.111 CumminsPTfuelsystem 5.111 Unitinjectors...................................................................5.112 Electronicallycontrolledfuelinjectionsystems 5.112 Fuelinjectionsystemrecommendations........................5.113 Jobaidchecklistforfuelsystems 5.114 Coolingsystems.................................................................5.115 Coolingsystemrecommendations 5.115 Coolingsystemmaintenance.........................................5.116 Coolantmixture 5.116 Conditionerandinhibitors 5.116 Cleaningandflushing 5.117 Troubleshooting 5.117 Thermostats 5.117 Aerationincoolant 5.117 Radiatorcapreliefvalve 5.118 Temperatureprobe 5.118 Jobaidchecklistforcoolingsystem) 5.119 BI620984
Tableofcontents _________________________________________________ BUCYRUS – Model482DIESELUN-A-TRAC ® ©BUCYRUSAMERICA,INC. Dieselfuelandfuelsupplysystems 5.120 Introduction(Dieselfuelandfuelsupplysystems) 5.120 Bestpracticerecommendations 5.120 Sulfurcontent 5.121 Cetanenumber 5.121 Viscosity..........................................................................5.121 Flashpoint 5.121 Fuelqualityandhandlingrecommendations..................5.122 Lubrication 5.123 Lubricationrecommendations ........................................5.123 Lubricationclassification 5.124 Combinedserviceapplications.......................................5.125 Lubricationsystemchecks 5.125 Conclusion......................................................................5.126 Dieselemissions – jobaidchecklist 5.127 Instructionsontheadjustmentprocedures ..........................5.129 Mainrelief - primaryvalvebank/unloader))pump section .............................................................................5.129 Mainrelief - fanpumpsection 5.131 Mainrelief - exhaustcoolantpumpsection.....................5.132 Unloadervalve 5.134 Reliefvalve - brakecoolingmanifold 5.136 Pressurereducingvalve - HRCpilotcontrolcircuit 5.137 Troubleshootingprocedures 5.139 Hydraulicsystem(general) 5.140 Brakes 5.142 Hydrauliccylinders 5.145 Hydraulicpump 5.146 Valves 5.148 Engine 5.149 Converter 5.153 Transmission 5.155 Fuelinjector 5.156 Leakingintakesystem 5.157 Airintakesystemrestrictionandfuelflow .......................5.157 Catalystfailure 5.157 Exhaustparticulatefilterfailure .......................................5.157 6. Technicaldata Technicaldata .........................................................................6.3 Componentsofthe482DieselUN-A-TRAC 6.3 Technicaldata......................................................................6.3 Tighteningtorques 6.5 Permissibledata................................................................. 6.11 Lubricationfluidsandgreases 6.11 7. Foryourinformation Foryourinformation...............................................................7.3 Ourservice 7.3 Serviceaddress 7.3 Rebuildfacilityaddress....................................................7.4 BI620984
_______________________________________________________________ Aboutthismanual BI620984
_______________________________________________________________ BI620984
applicableoperatingmanual machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BUCYRUS – Model482DIESELUN-A-TRAC ®
SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine. Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.
Everypersonworkingonthefaceorintheintersectionbetweenface andentryorintheentrymustreadthisoperatingmanual.
Thisincludespersonswho:
■ areinchargeoftransport
■ preparetheriseheading
■ performassembly/disassemblywork
■ operatethemachine
■ eliminatefaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/or
■ supervisetheactivitiesjustindicated.
________________________________________Beforestartingtowork A6474X272 REV2 1.3 ©BUCYRUSAMERICA,INC.
BI620984
newoperationmanual
cost-effectiveness
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
service safety
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Beforestartingtowork ________________________________________ 1.4 BUCYRUS – 482DIESELUN-A-TRAC ® ©BUCYRUSAMERICA,INC.
BI620984
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER!
Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING!
Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE!
Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.
IMPORTANT!
Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestart oftheline.
Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.
________________________________________Beforestartingtowork A6474X272 REV2 1.5 ©BUCYRUSAMERICA,INC.
BI620984
Beforestartingtowork ________________________________________ 1.6 BUCYRUS – 482DIESELUN-A-TRAC ® ©BUCYRUSAMERICA,INC. BI620984
_______________________________________________________________
BI620984
Yoursafety
• 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
