BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationandMaintenance Manual BUCYRUSUN-A-TRAC® Model 488D-XP Doc.No.: A6474X334 BI000967
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ThismanualisintendedtoprovideGENERALproductinformationfor theModel488D-XP UN-A-TRAC®.Theillustrations,descriptionsand procedurescontainedinthispublicationapplyonlytoTHISmachine. BucyrusAmerica,Inc.reservestherighttorevisemodelsanddesigns withoutpriornotice.
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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© BUCYRUSAMERICA,INC. ALLRIGHTSRESERVED
________________________________________________ Tableofcontents A6474X334 SVSV/00 ©BUCYRUSAMERICA,INC. Tableofcontents
Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual? 1.4 Charactersandsymbols 1.5
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..............................................2.26
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 BI000967
1.
2.
3.
5. Operation
Tableofcontents _________________________________________________ BUCYRUS – Model488D-XPUN-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 - leftandcenter 5.5 Operator’scompartment - right 5.6 Hazardzone 5.21 Startingprocedure 5.22 Shutdownprocedure 5.23 Towingadisabledmachine 5.25 Instructionsonthemaintenance 5.27 Importantnotes 5.27 Beforemaintenance 5.27 Criticaltorquevalues.......................................................5.29 Lubricants,fluidsandcapacities 5.29 Specificlubricationandmaintenanceschedule..............5.30 Specificlubricationandmaintenanceprocedure 5.34 Pre-shift...........................................................................5.34 Everythirdshift 5.37 Weekly.............................................................................5.43 Everythreemonths 5.50 First50hoursofservice..................................................5.54 Every100hours 5.55 Every500hours..............................................................5.58 Every1000hours 5.60 Everysixmonths.............................................................5.61 Servicingheavydutyairfilterelements 5.62 Dieselemissionsmaintenance .................................................5.66 Introduction(emissions) 5.66 Dieselemissions 5.67 Dieselemissionsstalltest 5.68 Operationalissues 5.70 Bestpractices 5.71 Proactiveattitudes 5.74 Typicalexhaustgascomponents 5.76 Enginesystems/conditionsthataffectdieselemissions 5.78 Combustionchamberdesign 5.78 Intakemanifoldsystem 5.80 Operatingconditionsthataffectemissions .....................5.81 Lowturbochargerboostpressure 5.82 Highexhaustbackpressure.............................................5.82 Highcrankcasepressure 5.84 Overviewofsixenginesystems..............................................5.85 Intakesystem 5.86 Drytypeaircleaners .......................................................5.87 Airinductionpiping 5.88 Aftercoolers.....................................................................5.88 Air-to-airaftercoolers 5.89 Wateraftercoolers...........................................................5.89 Intakesystemrecommendations 5.90 BI000967
________________________________________________ Tableofcontents A6474X334 SVSV/00 ©BUCYRUSAMERICA,INC. Servicingtheintakesystem 5.91 Jobaidchecklist(IntakeSystem) 5.92 Exhaustsystem 5.93 Exhaustsystemrecommendations 5.95 Exhaustaftertreatmentsystemmaintenance 5.95 Jobaidchecklistforexhaustsystem ................................5.97 Introductiontotoolsusedforexhaustsystemanalysis 5.98 ECOMAC+gasanalyzer.............................................5.98 UGASsoftwareapplication 5.100 Testingprotocol.......................................................... 5.100 Pre-testconditions 5.101 Emissionstestingprotocol ......................................... 5.101 Basicemissionequipmentoperation 5.102 Undiluteddieselparticulatemeasurement................. 5.102 Measurementinterpretation 5.104 Analysisofparticulatesamples.................................. 5.104 Thermalopticalmethod 5.105 ECOMAC+gasanalyzer........................................... 5.106 Particulatesampling - Gilianpump 5.106 Intaketesting.............................................................. 5.107 Intakerestrictionsandexhaustbackpressure 5.108 Fuelinjectionsystem 5.109 Injectionpumporinjectorfailure 5.110 Inadequatefuelsupply 5.110 Incorrectinjectionpumporinjectortiming 5.111 Advancedtiming 5.111 Retardedtiming 5.111 Fuelsystemtypes 5.112 Individualunitjerkpumps 5.113 Inlinepumpsystem 5.114 Distributorpumpsystem 5.115 CumminsPTfuelsystem 5.115 Unitinjectors 5.116 Electronicallycontrolledfuelinjectionsystems 5.116 Fuelinjectionsystemrecommendations......................... 5.117 Jobaidchecklistforfuelsystems 5.118 Coolingsystems................................................................... 5.119 Coolingsystemrecommendations 5.119 Coolingsystemmaintenance.......................................... 5.120 Coolantmixture 5.120 Conditionerandinhibitors............................................... 5.120 Cleaningandflushing 5.121 Troubleshooting .............................................................. 5.121 Thermostats 5.121 Aerationincoolant.......................................................... 5.121 Radiatorcapreliefvalve 5.122 Temperatureprobe 5.122 Jobaidchecklistforcoolingsystem) 5.123 Dieselfuelandfuelsupplysystems 5.124 Bestpracticerecommendations 5.124 Sulfurcontent 5.125 Cetanenumber 5.125 Viscosity 5.125 Flashpoint 5.125 Fuelqualityandhandlingrecommendations 5.126 BI000967
Tableofcontents _________________________________________________ BUCYRUS – Model488D-XPUN-A-TRAC® ©BUCYRUSAMERICA,INC. Lubrication 5.127 Lubricationrecommendations 5.127 Lubricationclassification 5.128 Combinedserviceapplications 5.129 Lubricationsystemchecks 5.129 Conclusion ...........................................................................5.130 Dieselemissions – jobaidchecklist 5.131 Replacementofwearparts..................................................5.133 Tire/Wheelinstallation 5.133 Axles................................................................................5.137 Driveshaft 5.140 Accumulatoroperationandprecharging.........................5.141 Ejectorbladeandcylinder 5.143 Canopy/Cab ....................................................................5.145 Steeringcylinder 5.146 Tiltcylinder......................................................................5.159 Liftcylinder 5.150 Brakebleedingprocedure...............................................5.152 Instructionsontheadjustmentprocedures 5.153 Mainrelief - primary(mainimplement)pumpsection.....5.153 Mainrelief - auxiliarypumpsection 5.154 Unloadingvalve 5.155 Reliefvalve - brakecoolingmanifold 5.156 Pressurereducingvalve - HRCpilotcontrolcircuit 5.157 MSHAdocumentation 5.159 Machine/Electricalchecklist(drawing607214) 5.159 Powersystemchecklist(drawing606348) 5.169 Certificationstatement(drawing607742) 5.191 Certificationstatement(drawing607858) 5.192 Generalarrangement(drawing607215) 5.193 Hydraulicsystem(drawing607217) 5.194 Electricaldiagram(drawing561G518) 5.195 Electronicshutdownassembly(drawing561G508) 5.196 Inspectionforpermissibilityform(drawing561A509) 5.197 Troubleshootingprocedures ................................................5.199 Hydraulicsystem(general) 5.200 Brakes.............................................................................5.203 Hydrauliccylinders 5.205 Hydraulicpump ...............................................................5.206 Valves 5.208 Engine.............................................................................5.209 Converter 5.219 Transmission...................................................................5.221 Fuelinjector 5.222 Compressor.....................................................................5.222 Leakingintakesystem 5.224 Airintakesystemrestrictionandfuelflow 5.224 Catalystfailure 5.224 Exhaustparticulatefilterfailure 5.225 DieselSafetySystemTroubleshooting 5.226 BI000967
________________________________________________ Tableofcontents A6474X334 SVSV/00 ©BUCYRUSAMERICA,INC. 6. Technicaldata Technicaldata 6.3 Componentsofthe488D-XPUN-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 BI000967
Tableofcontents _________________________________________________ BUCYRUS – Model488D-XPUN-A-TRAC® ©BUCYRUSAMERICA,INC. BI000967
_______________________________________________________________ Aboutthismanual BI000967
________________________________________________________________ BI000967
applicableoperatingmanual machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BUCYRUSModel488Diesel-XPUN-A-TRAC®
SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.
Thisincludespersonswho:
■ areinchargeoftransport
■ performassembly/disassemblywork
■ operatethemachine
■ eliminatefaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
andsupervisorypersonnelwho:
■ initiateand/or
■ supervisetheactivitiesjustindicated.
________________________________________Beforestartingtowork A6474X334 SVSV/00 1.3 ©BUCYRUSAMERICA,INC.
newoperationmanual BI000967
cost-effectiveness
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
service safety
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Yoursafety”withspecialattention.Thechaptercontainsimportantinformationindicatingpossiblehazards.Observethe informationgivenandfollowtheproceduralinstructions.
Beforestartingtowork ________________________________________ 1.4 BUCYRUS – 488D-XPUN-A-TRAC® ©BUCYRUSAMERICA,INC.
BI000967
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 yourworkfasterand,moreimportantly,safer.
________________________________________Beforestartingtowork A6474X334 SVSV/00 1.5 ©BUCYRUSAMERICA,INC.
BI000967
• 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
