Cat Bucyrus 488D-XP Operation Manual BI377605 – PDF DOWNLOAD

Page 1

Technical Manual

© Bucyrus All Rights Reserved
R
BI377605
BUCYRUS

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BUCYRUS V‘41°

OPERATION AND MAINTENANCE MANUALS

BUCYRUS - UN-A-TRAC ®

Model - 488

Serial Number - 4036

BUCYRUS AMERICA, INC.
I BI377605

Table of Contents

BUCYRUS AMERICA, INC.
Technical Manuals 488D Operation and Maintenance Section 3 1012 and 1013 Deutz Engine Operation Manual Section 4 1013 Deutz Engine Spare Parts Manual Section 5 Ansul Fire Extinguisher Manual Section 6 Dana Converter Service Manual Section 7 Dana Torque Converter Manual Section 8 Clark Hurth Ring Gear Manual Section 9 Clark Hurth Maintenance and Service Manual Section 10 Dana Transmission Service Manual Section 11 Mico Throttle Control Installation and Service Instructions Section 12 Kessler Axle Service Manual Section 13 Air Filter Service Section 14 2 BI377605

BUCYRUS AMERICA, INC.

Our service

If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service address

Beckley, WV

351 Ragland Road

Beckley, WV 25801

Phone: (304) 256-5927

Fax: (304) 256-5928

Duffield, VA

P.O. Box 847

243 Fraley Avenue

Duffield, VA 24244

Phone: (276) 431-7000

Fax: (276) 431-2464

Carrier Mills, IL

9580 State Route 13 West

Carrier Mills, IL 62917

Phone: (618) 982-9000

Fax: (618) 982-9912

Paonia, CO

P.O. Box 566

Paonia, CO 81428

719 Second Street

Paonia, CO 81428

Phone: (970) 527-3151

Fax: (970) 527-6846

Pulaski, VA

4041 Wurno Road

Pulaski, VA 24301

Phone: 540-980-4530

Fax: 540-980-6211

Craig, CO

400 Mack Lane

Craig, CO 81625

Phone: (970) 824-3249

Fax: (970) 824-8851

Houston, PA (Corporate Headquarters)

2045 West Pike Street

Houston, PA 15342

Phone: (724) 743-1200

Fax: (724) 743-1201

Oak Hill, WV

P.O. Box 60

Oak Hill, WV 25901

843 Lochgelly Road

Oak Hill, WV 25901

Phone: (304) 469-3302

Fax: (304) 465-0450

Price, UT

1814 North 1500 West

P.O. Box 1016

Price, UT 84501

Phone: (435) 637-3930

Fax: (435) 637-9754

Washington, PA 255 Berry Road

Washington, PA 15301

Phone: (724) 743-1200

Fax: (724) 228-2177

3
BI377605

BUCYRUS AMERICA, INC.

Rebuild facility address

Huntington, UT Norris City, IL

P.O. Box 1190 635 Illinois Highway 1

Route 10, 1Mile North Norris City, IL 62869

Huntington, UT 84528

Phone: (435) 687-9831

Fax: (435) 687-2522

Pearisburg, VA

P.O. Box 463

222 Industrial Park Drive

Pearisburg, VA 24134

Phone: (540) 921-2111

Fax: (540) 921-2711

Phone: (618) 378-3441

Fax: (618) 378-3106

4 BI377605

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BI377605
ANN.. BUCYRUS Nj4174"1® Operation Manual BUCYRUS UN-A-TRAC® Model 488D-XP Doc. No.: A6474X278 Bucyrus America, Inc. 4041 Wurno Road Telephone: 540-980-4530 Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.bucyrus.com BI377605

This manual is intended to provide GENERAL product information for the Model 488D-XP UN-A-TRAC®, The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice,

This UN-A-TRAC® was manufactured under the guidelines, procedures and requirements of the U, S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U.S. regulatory agency standards.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.'s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable, Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

® BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED BI377605

Table of contents

Table of contents

1. About this manual

2. Your safety

3. Storage and transport

About this manual 1.3 Before starting to work 1.3 Who is this operating manual intended for? 1.3 What is the purpose of this operating manual? 1.4 Characters and symbols 1.5
Your safety 2.3 Personnel 2.4 Operation 2.4 Installation and repair 2.4 Operating conditions 2.5 Intended use 2.5 Unauthorized use 2,5 Safety instructions 2.7 General rules 2.7 Storage and transport 2.8 Pre-start inspection 2.8 Installation and start-up 2.9 Operation 2.9 Stopping 2,10 Maintenance and repair 2.10 Diesel emissions 2.11 Handling of hydraulic fluids 2.13 Overview of the safety instructions 2.17 Chapter 2: Safety instructions 2.17 Chapter 3: Storage and transport 2.17 Chapter 4: Installation 2.17 Chapter 5: Operation 2.18 Chapter 6: Technical data 2.26
Storage and transport 3.3 Storage 3.3 Storage of the machine and spare parts 3.3 Transport 3.4 Before transport 3.5 4. Installation Installation 4.3 Points to observe prior to installation 4.3 Who is allowed to carry out installation? 4.3 Which tools are required for installation? 4.3 Notes on installation 4.4 Pre-installation check list 4,5 Safety features 4.6 © BU CYRU S AMERIC A, INC.
A6474X278 VLSV/04 BI377605

5. Operation

Pre-operation suggestions 5.3 Operation 5,4 How to operate the UN-A-TRAC® 5,4 Who is allowed to operate the UN-A-TRAC® 5.4 When can operation be started? 5.4 Controls and indicators 5.5 Operator's compartment - left and center 5.5 Operator's compartment - right 5.6 Hazard zone 5.21 Starting procedure 5.22 Shutdown procedure 5.23 Towing a disabled machine 5.25 Instructions on the maintenance 5.27 Important notes 5.27 Before maintenance 5,27 Critical torque values 5.29 Lubricants, fluids and capacities 5.29 Specific lubrication and maintenance schedule 5,30 Specific lubrication and maintenance procedure 5.34 Pre-shift 5.34 Every third shift 5.37 Weekly 5.43 Every three months 5.50 First 50 hours of service 5.54 Every 100 hours 5.55 Every 500 hours 5.58 Every 1000 hours 5.60 Every six months 5.61 Servicing heavy duty air filter elements 5.62 Diesel emissions maintenance 5.66 Introduction (emissions) 5.66 Diesel emissions 5.67 Diesel emissions stall test 5.68 Operational issues 5.70 Best practices 5.71 Proactive attitudes 5.74 Typical exhaust gas components 5.76 Engine systems/conditions that affect diesel emissions 5.78 Combustion chamber design 5.78 Intake manifold system 5.80 Operating conditions that affect emissions 5.81 Low turbocharger boost pressure 5.82 High exhaust backpressure 5.82 High crankcase pressure 5.84 Overview of six engine systems 5.85 Intake system 5.86 Dry type air cleaners 5.87 Air induction piping 5,88 Aftercoolers 5.88 Air-to-air aftercoolers 5.89 Water aftercoolers 5.89 Intake system recommendations 5.90 © BUCYRUS AMERICA, INC.
Table of contents
BI377605
BUCYRUS - Model 488D-XP UN-A-TRAC®

• 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
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C) BU CYRUS AMERIC A, INC.
Servicing the intake system 5.91 Job aid checklist (Intake System) 5.92 Exhaust system 5.93 Exhaust system recommendations 5.95 Exhaust after treatment system maintenance 5.95 Job aid checklist for exhaust system 5.97 Introduction to tools used for exhaust system analysis 5.98 ECOM AC+ gas analyzer 5.98 UGAS software application 5.100 Testing protocol 5.100 Pre-test conditions 5.101 Emissions testing protocol 5.101 Basic emission equipment operation 5.102 Undiluted diesel particulate measurement 5.102 Measurement interpretation 5.104 Analysis of particulate samples 5.104 Thermal optical method 5.105 ECOM AC+ gas analyzer 5.106 Particulate sampling - Gilian pump 5.106 Intake testing 5.107 Intake restrictions and exhaust backpressure 5.108 Fuel injection system 5.109 Injection pump or injector failure 5,110 Inadequate fuel supply 5,110 Incorrect injection pump or injector timing 5,111 Advanced timing 5.111 Retarded timing 5.111 Fuel system types 5.112 Individual unit jerk pumps 5.113 Inline pump system 5.114 Distributor pump system 5.115 Cummins PT fuel system 5.115 Unit injectors 5.116 Electronically controlled fuel injection systems 5.116 Fuel injection system recommendations 5.117 Job aid checklist for fuel systems 5.118 Cooling systems 5.119 Cooling system recommendations 5.119 Cooling system maintenance 5.120 Coolant mixture 5.120 Conditioner and inhibitors 5.120 Cleaning and flushing 5.121 Troubleshooting 5.121 Thermostats 5.121 Aeration in coolant 5.121 Radiator cap relief valve 5.122 Temperature probe 5.122 Job aid checklist for cooling system) 5.123 Diesel fuel and fuel supply systems 5.124 Best practice recommendations 5.124 Sulfur content 5.125 Cetane number 5.125 Viscosity 5.125 Flashpoint 5.125 Fuel quality and handling recommendations 5.126 A6474X278 VLSV/04
Table of contents
BI377605

Table of contents

Lubrication 5.127 Lubrication recommendations 5.127 Lubrication classification 5.128 Combined service applications 5.129 Lubrication system checks 5.129 Conclusion 5.130 Diesel emissions -job aid check list 5.131 Replacement of wear parts 5.133 Tire/Wheel installation 5.133 Axles 5.137 Drive shaft 5.140 Accumulator operation and precharging 5.141 Ejector blade and cylinder 5.143 Canopy/Cab 5.145 Steering cylinder 5.146 Tilt cylinder 5.159 Lift cylinder 5,150 Brake bleeding procedure 5,152 Instructions on the adjustment procedures 5,153 Main relief - primary (main implement) pump section 5.153 Main relief - auxiliary pump section 5.154 Unloading valve 5.155 Relief valve - brake cooling manifold 5.156 Pressure reducing valve - HRC pilot control circuit 5.157 MSHA documentation 5.159 Machine/Electrical checklist (drawing 607214) 5.159 Power system checklist (drawing 606348) 5.169 Certification statement (drawing 607742) 5.191 Certification statement (drawing 607858) 5.192 General arrangement (drawing 607215) 5.193 Hydraulic system (drawing 607217) 5,194 Electrical diagram (drawing 561G518) 5.195 Electronic shutdown assembly (drawing 561G508) 5,196 Inspection for permissibility form (drawing 561A509) 5.197 Troubleshooting procedures 5.199 Hydraulic system (general) 5.200 Brakes 5.203 Hydraulic cylinders 5.205 Hydraulic pump 5.206 Valves 5.208 Engine 5.209 Converter 5.220 Transmission 5.222 Fuel injector 5.223 Compressor 5,223 Leaking intake system 5.225 Air intake system restriction and fuel flow 5,225 Catalyst failure 5,225 Exhaust particulate filter failure 5.226 Diesel Safety System Troubleshooting 5.227 0 BU CYRUS AME RICA, INC.
BI377605
BUCYRUS -- Model 488D-XP UN-A-TRAC®
0 BU CY RU S AMERIC A, INC A6474X278 VLSV/04 Table of contents 6. Technical data 9 Technical data 6.3 Components of the 488D-XP UN-A-TRAC 6.3 Technical data 6.3 Tightening torques 6,5 Permissible data 6.11 Lubrication fluids and greases 6.11
For your information For your information 7.3 Our service 7.3 Service address 7.3 Rebuild facility address 7.4BI377605
7.
© BUCYRUS AMERICA, IN C.
Table of contents
BI377605
BUCYRUS — Model 488D-XP UN-A-TRAC®
1
BI377605
About this manual

applicable operating manual

Before starting to work

About this manual

This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

machine type This operating manual is intended for:

BUCYRUS Model 488 Diesel-XP UN-A-TRACe Serial No.: N/A

and is only permitted to be used for equipment of this type.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine. It should, if possible, always be available at the place of operation.

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the machine. Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who:

m are in charge of transport

am perform assembly / disassembly work

• operate the machine

• eliminate faults

• perform daily routine work on the face or in the entry

• perform maintenance work

• perform repair work

and supervisory personnel who:

• initiate and/or

• supervise the activities just indicated.

Q BU CY RU S AMERICA, INC.
A6474X278 VLSV/04 1.3 BI377605

Before starting to work cost-effectiveness

What is the purpose of this operating manual?

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled "For your information".

Read the chapter "Your safety" with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

service safety
1.4
© BUCYRUS AMERICA, INC. BI377605
BUCYRUS — 488D-XP UN-A-TRAC®

• 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

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