Manual SU488DN SAFETY.CAT.COM BI001974 A6474X253 May2012
Operationand Maintenance
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ThismanualisintendedtoprovideGENERALproductinformation.The illustrations,descriptionsandprocedurescontainedinthispublication applyonlytoTHISmachine.Caterpillarreservestherighttorevise modelsanddesignswithoutpriornotice.
Thismachinewasmanufacturedundertheguidelines,proceduresand requirementsoftheappropriateregulatoryagencies.
Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofCaterpillarand theseregulatoryagencies,oranyrepairorreplacementofpartscontrarytotheinstructions,mayinvalidatetheseapprovalsandrenderthis unitunsafetooperate.
StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourservicerepresentative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
__________________________________________________________ BI001974
© CATERPILLAR2012 ALLRIGHTSRESERVED
_________________________________________________ Tableofcontents A6474X253 REV05 BI001974 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
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
2.
3.
5. Operation
Tableofcontents _________________________________________________ SU488DNNScoop BI001974
Pre-operationsuggestions.....................................................5.3 Operation..................................................................................5.4 Howtooperatethescoop ...................................................5.4 Whoisallowedtooperatethescoop 5.4 Whencanoperationbestarted? 5.4 Controlsandindicators 5.5 Operator’scompartment - rightside................................5.5 Operator’scompartment - leftandcenter 5.6 Hazardzone 5.25 Startingprocedure 5.26 General 5.26 Machineoperation 5.27 Shutdownprocedure 5.29 Towingadisabledmachine 5.30 Instructionsonthemaintenance 5.31 Importantnotes................................................................5.31 Beforemaintenance 5.31 Criticaltorquevalues 5.33 Lubricants,fluidsandcapacities 5.33 Specificlubricationandmaintenanceschedule ..............5.34 Specificlubricationandmaintenanceprocedure 5.37 Pre-shift ...........................................................................5.37 Everythirdshift 5.40 Weekly.............................................................................5.46 Everythreemonths 5.52 First50hoursofservice ..................................................5.56 Every100hours 5.57 Every500hours ..............................................................5.59 Every1000hours 5.60 Servicingheavydutyairfilterelements................................5.61 Dieselemissionsmaintenance 5.65 Introduction(emissions) 5.66 Dieselemissions 5.68 Dieselemissionsstalltest 5.69 Operationalissues 5.69 Bestpractices 5.70 Proactiveattitudes 5.73 Typicalexhaustgascomponents 5.75 Carbondioxide 5.75 Carbonmonoxide 5.75 Oxidesofnitrogen 5.75 Hydrocarbons 5.75 Particulatematter 5.76 Oxidesofsulfur 5.76 Smoke..............................................................................5.76 Enginesystemsandconditions thataffectdieselemissions ..................................................5.77 Combustionchamberdesign 5.77 Intakemanifoldsystem....................................................5.79 Operatingconditionsthataffectemissions 5.80 Lowturbochargerboostpressure....................................5.81 Highexhaustbackpressure 5.81
_________________________________________________ Tableofcontents A6474X253 REV05 BI001974 Highcrankcasepressure 5.83 Overviewofsixenginesystems 5.84 Overviewofengineintroduction 5.84 1.Intakesystem 5.85 Drytypeaircleaners 5.86 Airinductionpiping..........................................................5.87 Aftercoolers 5.87 Air-to-airaftercoolers 5.88 Wateraftercoolers 5.88 Intakesystemrecommendations ....................................5.89 Servicingtheintakesystem 5.90 Jobaidchecklist(IntakeSystem)....................................5.91 2.Exhaustsystem 5.92 Exhaustsystemrecommendations .................................5.93 Exhaustaftertreatmentsystemmaintenance 5.94 Jobaidchecklistforexhaustsystem...............................5.96 Introductiontotoolsusedforexhaustsystemanalysis 5.97 ECOMAC+gasanalyzer...........................................5.97 UGASsoftwareapplication 5.99 Testingprotocol..........................................................5.99 Pre-testconditions 5.100 Emissionstestingprotocol 5.100 Basicemissionequipmentoperation 5.101 Undiluteddieselparticulatemeasurement.................5.101 Measurementinterpretation 5.103 Analysisofparticulatesamples 5.103 Thermalopticalmethod 5.104 Jobaidchecklistforexhaustsystemanalysistools 5.104 ECOMAC+gasanalyzer 5.105 Particulatesampling - Gilianpump 5.105 Intaketesting 5.106 Intakerestrictionsandexhaustbackpressure 5.107 3.Fuelinjectionsystem 5.108 Introduction(Fuelinjectionsystem) 5.108 Injectionpumporinjectorfailure .....................................5.109 Inadequatefuelsupply 5.109 Incorrectinjectionpumporinjectortiming.......................5.110 Advancedtiming 5.110 Retardedtiming...............................................................5.110 Fuelsystemtypes 5.110 Individualunitjerkpumps................................................5.112 Inlinepumpsystem 5.113 Distributorpumpsystem..................................................5.114 CumminsPTfuelsystem 5.114 Unitinjectors....................................................................5.115 Electronicallycontrolledfuelinjectionsystems 5.115 Fuelinjectionsystemrecommendations.........................5.116 Jobaidchecklistforfuelsystems 5.117 4.Coolingsystems...............................................................5.118 Coolingsystemrecommendations 5.118 Coolingsystemmaintenance 5.119 Coolantmixture 5.119 Conditionerandinhibitors 5.119 Cleaningandflushing 5.120
6. Technicaldata
Tableofcontents _________________________________________________ SU488DNNScoop BI001974 Troubleshooting 5.120 Thermostats 5.120 Aerationincoolant 5.120 Radiatorcapreliefvalve 5.121 Temperatureprobe 5.121 Jobaidchecklistforcoolingsystem)...............................5.122 5.Dieselfuelandfuelsupplysystems 5.123 Introduction(Dieselfuelandfuelsupplysystems) 5.123 Bestpracticerecommendations 5.123 Sulfurcontent...................................................................5.124 Cetanenumber 5.124 Viscosity...........................................................................5.124 Flashpoint 5.124 Fuelqualityandhandlingrecommendations...................5.125 6.Lubrication 5.126 Lubricationrecommendations .........................................5.126 Lubricationclassification 5.127 Combinedserviceapplications........................................5.128 Lubricationsystemchecks 5.128 Conclusion .......................................................................5.129 Dieselemissions –jobaidchecklist 5.130 Instructionsontheadjustmentprocedures 5.131 Mainrelief - primary(mainimplement)pumpsection 5.131 Mainrelief - accumulatorpumpsection...........................5.132 Unloadervalve 5.133 Reliefvalve - brakecoolingmanifold 5.134 Pressurereducingvalve - HRCpilotcontrolcircuit 5.135 Troubleshootingprocedures 5.137 Hydraulicsystem(general) 5.138 Brakes 5.141 Hydrauliccylinders 5.143 Hydraulicpump 5.144 Valves 5.146 Engine 5.147 Converter.........................................................................5.151 Transmission 5.153 Fuelinjector.....................................................................5.154 Leakingintakesystem 5.155 Airintakesystemrestrictionandfuelflow.......................5.155 Catalystfailure 5.155 Exhaustparticulatefilterfailure .......................................5.156
Technicaldata 6.3 Componentsofthe488DieselScoop 6.3 Technicaldata ......................................................................6.3 Tighteningtorques 6.11 Permissibledata................................................................. 6.17 Lubricationfluidsandgreases 6.17
_________________________________________________ Tableofcontents A6474X253 REV05 BI001974 7. Foryourinformation Foryourinformation...............................................................7.3 Ourservice 7.3 Serviceaddress...............................................................7.3 Rebuildfacilityaddress 7.4
Tableofcontents _________________________________________________ SU488DNNScoop BI001974
_______________________________________________________________ 1 Aboutthismanual BI001974
_______________________________________________________________ BI001974
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