BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationandMaintenance Manual BUCYRUSUN-A-TRAC® Model 488D-XPwithSEMS2 Doc.No.: A6474X373 BI000944
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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 A6474X373 REV1 ©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............................................. 2.26
Storageandtransport Storageandtransport.............................................................3.3 Storage 3.3 Storageofthemachineandspareparts.........................3.3 Transport 3.4 Beforetransport...............................................................3.5
Installation Installation ...............................................................................4.3 Pointstoobservepriortoinstallation...................................4.3 Whoisallowedtocarryoutinstallation? 4.3 Whichtoolsarerequiredforinstallation?........................4.3 Notesoninstallation 4.4 Pre-installationchecklist.................................................4.5 Safetyfeatures 4.6 BI000944
2.
3.
4.
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 Enginemonitoringsystem 5.21 Hazardzone 5.29 Startingprocedure 5.30 Shutdownprocedure 5.31 Towingadisabledmachine 5.33 Instructionsonthemaintenance 5.35 Importantnotes 5.35 Beforemaintenance ........................................................5.35 Criticaltorquevalues 5.37 Lubricants,fluidsandcapacities......................................5.37 Specificlubricationandmaintenanceschedule 5.38 Specificlubricationandmaintenanceprocedure..................5.42 Pre-shift 5.42 Everythirdshift................................................................5.45 Weekly 5.51 Everythreemonths .........................................................5.58 First50hoursofservice 5.62 Every100hours ..............................................................5.63 Every500hours 5.64 Every1000hours ............................................................5.68 Everysixmonths 5.69 Servicingheavydutyairfilterelements................................5.70 Dieselemissionsmaintenance 5.74 Introduction(emissions) 5.74 Dieselemissions 5.75 Dieselemissionsstalltest 5.76 Operationalissues 5.78 Bestpractices 5.79 Proactiveattitudes 5.82 Typicalexhaustgascomponents 5.84 Enginesystems/conditionsthataffectdieselemissions 5.86 Combustionchamberdesign 5.86 Intakemanifoldsystem....................................................5.88 Operatingconditionsthataffectemissions 5.89 Lowturbochargerboostpressure....................................5.90 Highexhaustbackpressure 5.90 Highcrankcasepressure.................................................5.92 Overviewofsixenginesystems 5.93 Intakesystem ......................................................................5.94 Drytypeaircleaners 5.95 Airinductionpiping ..........................................................5.96 Aftercoolers 5.96 Air-to-airaftercoolers.......................................................5.97 Wateraftercoolers 5.97 BI000944
________________________________________________ Tableofcontents A6474X373 REV1 ©BUCYRUSAMERICA,INC. Servicingtheintakesystem 5.99 Jobaidchecklist(IntakeSystem) 5.100 Exhaustsystem 5.101 Exhaustsystemrecommendations 5.102 Exhaustaftertreatmentsystemmaintenance 5.102 Jobaidchecklistforexhaustsystem...............................5.105 Introductiontotoolsusedforexhaustsystemanalysis 5.106 ECOMAC+gasanalyzer...........................................5.106 UGASsoftwareapplication 5.108 Testingprotocol..........................................................5.108 Pre-testconditions 5.109 Emissionstestingprotocol..........................................5.109 Basicemissionequipmentoperation 5.110 Undiluteddieselparticulatemeasurement.................5.110 Measurementinterpretation 5.112 Analysisofparticulatesamples..................................5.112 Thermalopticalmethod 5.113 ECOMAC+gasanalyzer...........................................5.114 Particulatesampling - Gilianpump 5.114 Intaketesting..............................................................5.115 Intakerestrictionsandexhaustbackpressure 5.116 Fuelinjectionsystem 5.117 Injectionpumporinjectorfailure 5.118 Inadequatefuelsupply 5.118 Incorrectinjectionpumporinjectortiming 5.119 Advancedtiming 5.119 Retardedtiming 5.119 Fuelsystemtypes 5.120 Individualunitjerkpumps 5.121 Inlinepumpsystem 5.122 Distributorpumpsystem 5.123 CumminsPTfuelsystem 5.123 Unitinjectors 5.124 Electronicallycontrolledfuelinjectionsystems 5.124 Fuelinjectionsystemrecommendations.........................5.125 Jobaidchecklistforfuelsystems 5.126 Coolingsystems...................................................................5.127 Coolingsystemrecommendations 5.127 Coolingsystemmaintenance..........................................5.128 Coolantmixture 5.128 Conditionerandinhibitors................................................5.128 Cleaningandflushing 5.129 Troubleshooting...............................................................5.129 Thermostats 5.129 Aerationincoolant...........................................................5.129 Radiatorcapreliefvalve 5.130 Temperatureprobe 5.130 Jobaidchecklistforcoolingsystem) 5.131 Dieselfuelandfuelsupplysystems 5.132 Bestpracticerecommendations 5.132 Sulfurcontent 5.133 Cetanenumber 5.133 Viscosity 5.133 Flashpoint 5.133 Fuelqualityandhandlingrecommendations 5.134 BI000944
Tableofcontents _________________________________________________ BUCYRUS –
® ©BUCYRUSAMERICA,INC. Lubrication 5.135 Lubricationrecommendations 5.135 Lubricationclassification 5.136 Combinedserviceapplications 5.137 Lubricationsystemchecks 5.137 Conclusion............................................................................5.139 Dieselemissions – jobaidchecklist 5.139 Replacementofwearparts ..................................................5.141 Tire/Wheelinstallation 5.141 Axles................................................................................5.145 Driveshaft 5.148 Accumulatoroperationandprecharging .........................5.149 Ejectorbladeandcylinder 5.151 Canopy/Cab.....................................................................5.153 Steeringcylinder 5.154 Tiltcylinder.......................................................................5.157 Liftcylinder 5.158 Brakebleedingprocedure ...............................................5.160 Instructionsontheadjustmentprocedures 5.161 Mainrelief - primary(mainimplement)pumpsection .....5.161 Mainrelief - auxiliarypumpsection 5.162 Unloadingvalve 5.163 Reliefvalve - brakecoolingmanifold 5.164 Pressurereducingvalve - HRCpilotcontrolcircuit 5.165 MSHAdocumentation 5.167 Machine/Electricalchecklist(drawing607214) 5.167 Powersystemchecklist(drawing606348) 5.177 Certificationstatement(drawing607742) 5.199 Certificationstatement(drawing607858) 5.200 Generalarrangement(drawing607215) 5.201 Hydraulicsystem(drawing607217) 5.202 Electricaldiagram(drawing561G518) 5.203 Electronicshutdownassembly(drawing561G508) 5.204 Inspectionforpermissibilityform(drawing561A509) 5.205 Troubleshootingprocedures.................................................5.207 Hydraulicsystem(general) 5.208 Brakes..............................................................................5.211 Hydrauliccylinders 5.212 Hydraulicpump................................................................5.214 Valves 5.216 Engine..............................................................................5.217 Converter 5.227 Transmission ...................................................................5.229 Fuelinjector 5.230 Compressor.....................................................................5.230 Leakingintakesystem 5.232 Airintakesystemrestrictionandfuelflow 5.232 Catalystfailure 5.232 Exhaustparticulatefilterfailure 5.233 Enginemonitoringsystem 5.234 BI000944
Model488D-XPUN-A-TRAC
________________________________________________ Tableofcontents A6474X373 REV1 ©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 BI000944
Tableofcontents _________________________________________________ BUCYRUS – Model488D-XPUN-A-TRAC® ©BUCYRUSAMERICA,INC. BI000944
_______________________________________________________________ Aboutthismanual BI000944
_______________________________________________________________ BI000944
applicableoperatingmanual machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BUCYRUSModel488Diesel-XPUN-A-TRAC® SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
newoperationmanual
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 A6474X373 REV1 1.3 ©BUCYRUSAMERICA,INC.
BI000944
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.
BI000944
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 A6474X373 REV1 1.5 ©BUCYRUSAMERICA,INC.
BI000944
• 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
