BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com ServiceTechnician TroubleshootingGuide Bucyrus UN-A-TRAC® Model 488Dwith Deutz1013Engine Doc.No.: A6474X302 FORBUCYRUSINTERNALUSEONLY BI000928
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Thismanualisintendedtoprovidetroubleshootinginformationforthe Model488DUN-A-TRAC®.Theillustrations,descriptionsandprocedurescontainedinthispublicationapplyonlytoTHISmachine.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 A6474X302 VSSV/0 ©BUCYRUSAMERICA,INC. Tableofcontents
Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisguideintendedfor? 1.3 Whatisthepurposeofthisguide? ...................................... 1.3 Charactersandsymbols 1.4
Yoursafety Yoursafety 2.3 Personnel 2.4 Operation 2.4 Installationandrepair...................................................... 2.4 Operatingconditions 2.5 Intendeduse 2.5 Unauthorizeduse 2.5 Safetyinstructions 2.6 Stopping 2.7 Maintenanceandrepair 2.7 Dieselemissions 2.8 Handlingofhydraulicfluids 2.10
Operationandtroubleshooting Pre-operationsuggestions 3.3 Operationguidelines 3.4 Hydraulicinformation 3.5 Controlsandindicators 3.6 Hazardzone 3.10 Troubleshootingprocedures 3.11 Hydraulic 3.12 General 3.13 Brakes 3.18 Cylinders 3.20 Pumps 3.21 Valves...........................................................................3.23 Powerpack 3.24 Engine,Deutz1013......................................................3.25 Converter 3.37 Transmission................................................................3.39 Fuelinjectors 3.40 Leakingintakesystem..................................................3.42 Airintakerestrictionandfuelflow 3.42 Catalystfailure..............................................................3.42 Exhaustparticulatefilterfailure 3.43 Generaltroubleshootingnotesandprocedures...........3.46 Heavydutyfilterelements 3.50 BI000928
1.
2.
3.
Tableofcontents _________________________________________________ BUCYRUS – Model488DIESELUN-A-TRAC ® ©BUCYRUSAMERICA,INC. Controller,LOFAEP250 3.52 LEDs 3.52 General 3.55 Fuelrun/stopsolenoid 3.57 Preheat 3.58 Controlsystem..............................................................3.59 Powerbox 3.60 4. Technicaldata Componentsofthe488DieselUN-A-TRAC® ..........................4.3 Tighteningtorques 4.5 Lubricationfluidsandgreases................................................. 4.11 5. Foryourinformation Serviceaddress 5.3 Rebuildfacilityaddress.............................................................5.4 BI000928
_______________________________________________________________ 1 Aboutthismanual BI000928
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machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Thistroubleshootingguideisintendedfor:
BucyrusModel488DUN-A-TRAC®
SerialNo.:N/A
andisonlypermittedtobeusedforequipmentofthistype.
operationmanual safety
Thismanualisatroubleshootingguideonly.ForacompleteOperation andMaintenanceManual,seemanualpartnumberA6474X253.
Whoisthisguideintendedfor?
ThistroubleshootingguideisintendedforBucyrusservicepersonnel.
Whatisthepurposeofthisguide?
Thisguideisintendedtoprovidetroubleshootinginformationandproceduresforthe488DUN-A-TRAC®.
Observetheinformationgivenandfollowtheproceduralinstructions. Followallfederal,mine,andBucyrussafetystandards.
_______________________________________ Beforestartingtowork A6474X302 VSSV/0 1.3 ©BUCYRUSAMERICA,INC.
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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 ________________________________________ 1.4 BUCYRUS – 488DIESELUN-A-TRAC ® ©BUCYRUSAMERICA,INC.
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2 Yoursafety
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furtheroperatingmanuals
Yoursafety
Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Themachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. Youandotherscanneverthelessbeexposedtodangeroussituations asaresultofenvironmentalinfluences,machinedamage,oroperator errors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.AllmodificationsandchangesmustbeapprovedbyBucyrusAmerica,Inc.
UseonlyoriginalsparepartsfromBucyrusAmerica,Inc.Notethatthe useofpartsfromothermanufacturerswillvoidthewarranty.
Inadditiontothistroubleshootingguide,youshouldbefamiliarwiththe completeOperationandMaintenanceManual(partnumber A6474X253).
Observethesafetyandaccidentpreventionregulations:
■ ofthemine,
■ ofthemineinspector,and
■ oftheminingsupervisoryauthorities
Pleasereadalsotheoperatingmanualsofthecomponentsrequiredfor operation,e.g.ofgearboxes,dieselmotors,etc.,carefullyandthoroughly.Clarifyanyquestions before beginningtotroubleshootthemachine.
_________________________________________________ YourSafety A6474X302 VSSV/0 2.3
©BUCYRUSAMERICA,INC.
stateoftheart
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Personnel
Operation
Themachinemayonlybeoperatedbyqualified,trainedpersonnelwho canprovideproofofhavingbeentrainedonthisunit.Readingofthe operationmanual,especiallythechapteronsafety,shallconstitutea partofthistraining.
Youmusthaveadequateknowledgeofthe
■ mechanics,
■ hydraulics,and
■ controlengineering andmustbeabletoprovethisknowledge.
Installationandrepair
Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.
Installationandrepairworkon:
■ safetycomponents(pressurereliefvalves,extinguishers,etc.)
■ theelectrics(controllers,etc.)
■ thehydraulics(controls,cylinders,etc.)
■ dieselengines(engines,exhaustsystem,etc.)
mayonlybecarriedoutbyServiceEngineersfromBucyrusAmerica, Inc.orbyspeciallyqualifiedpersonnelofthemine.
Personnel ___________________________________________________ 2.4 BUCYRUS –
©BUCYRUSAMERICA,INC
488DIESELUN-A-TRAC ®
training BI000928
Operatingconditions
Intendeduse
Intendedusesinclude:
■ thetransportofmaterials
■ useduringcleanupandutilitywork.
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.
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Operatingconditions
2.5
©BUCYRUSAMERICA,INC.
BUCYRUS– 488DIESELUN-A-TRAC ®
BI000928
• 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
