BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationManual BucyrusUN-A-TRAC® Model488Dwith2013Engine Doc.No.: A6474X304 BI620988
• 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
ThismanualisintendedtoprovideGENERALproductinformationfor theModel488DLHDUN-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.
__________________________________________________________
BI620988
© BUCYRUSAMERICA,INC. ALLRIGHTSRESERVED
________________________________________________ Tableofcontents A6474X304 SSVI/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..............................................2.25
Storageandtransport Storageandtransport 3.3 Storage 3.3 Storageofthemachineandspareparts......................... 3.3 Transport 3.5 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 BI620988
1.
2.
3.
4.
5. Operation
Tableofcontents _________________________________________________ Bucyrus – Model488DUN-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 - rightside ...............................5.5 Operator’scompartment - leftandcenter 5.6 Hazardzone 5.21 Startingprocedure 5.22 Shutdownprocedure 5.24 Towingadisabledmachine 5.25 Instructionsonthemaintenance 5.27 Importantnotes 5.27 Beforemaintenance 5.27 Criticaltorquevalues.......................................................5.29 Lubricants,fluidsandcapacities 5.29 Specificlubricationandmaintenanceschedule 5.30 Specificlubricationandmaintenanceprocedure 5.33 Pre-shift...........................................................................5.33 Everythirdshift 5.35 Weekly.............................................................................5.39 Everythreemonths 5.45 First50hoursofservice..................................................5.49 Every100hours 5.50 Every500hours..............................................................5.53 Generaldieselinformation 5.55 Servicingheavydutyairfilterelements ...............................5.55 Dieselemissionsmaintenance 5.59 Introduction(emissions) ................................................5.59 Dieselemissions 5.60 Dieselemissionsstalltest 5.61 Operationalissues 5.64 Bestpractices 5.65 Proactiveattitudes 5.68 Typicalexhaustgascomponents 5.70 Carbondioxide 5.70 Carbonmonoxide 5.70 Oxidesofnitrogen 5.70 Hydrocarbons 5.70 Particulatematter 5.71 Oxidesofsulfur 5.71 Smoke 5.71 Enginesystemsandconditionsaffectingemissions 5.72 Combustionchamberdesign ..................................5.72 Intakemanifoldsystem 5.74 Operatingconditions...............................................5.75 Lowturbochargerboostpressure 5.76 Highexhaustbackpressure ....................................5.76 Highcrankcasepressure 5.78 BI620988
________________________________________________ Tableofcontents A6474X304 SSVI/00 ©BUCYRUSAMERICA,INC. Overviewofsixenginesystems 5.79 Overviewofengineintroduction 5.79 Intakesystem 5.80 Exhaustsystem 5.87 Fuelinjectionsystem 5.103 Coolingsystems............................................................ 5.113 Dieselfuelandfuelsupplysystems 5.118 Lubrication 5.121 Dieselemissions – jobaidchecklist 5.125 Instructionsontheadjustmentprocedures ................................ 5.127 Mainrelief - primary(mainimplement)pumpsection 5.127 Mainrelief - accumulatorpumpsection............................... 5.128 Fanrelief - fandrivepumpsection 5.129 Unloadervalve..................................................................... 5.129 Reliefvalve - brakecoolingmanifold 5.131 Pressurereducingvalve - HRCpilotcontrolcircuit............. 5.132 Mainrelief 5.134 Workportreliefs................................................................... 5.135 Troubleshootingprocedures 5.137 Hydraulicsystem(general).................................................. 5.138 Brakes 5.140 Hydrauliccylinders 5.142 Hydraulicpump 5.143 Valves .................................................................................. 5.145 Engine 5.146 Converter 5.150 Transmission 5.152 Fuelinjector 5.153 Leakingintakesystem 5.154 Airintakesystemrestrictionandfuelflow 5.154 Catalystfailure 5.154 Exhaustparticulatefilterfailure 5.154 EMR3faultcodes 5.155 Electricalsystem(general) 5.177 Preheat ................................................................................ 5.178 Powerbox 5.179
Technicaldata Technicaldata......................................................................... 6.3 Componentsofthe488DieselUN-A-TRAC 6.3 Technicaldata 6.3 Tighteningtorques 6.11 Permissibledata 6.17 Lubricationfluidsandgreases 6.17
Foryourinformation Foryourinformation 7.3 Ourservice 7.3 Serviceaddress 7.3 Rebuildfacilityaddress 7.4 BI620988
6.
7.
Tableofcontents _________________________________________________ Bucyrus –
® ©BUCYRUSAMERICA,INC. BI620988
Model488DUN-A-TRAC
_______________________________________________________________ 1 Aboutthismanual BI620988
________________________________________________________________ BI620988
applicableoperatingmanual machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
BucyrusModel488DLHDUN-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
supervisorypersonnelwho:
■ initiateand/orsupervisetheactivitiesjustindicated.
_______________________________________ Beforestartingtowork A6474X304 SSVI/00 1.3 ©BUCYRUSAMERICA,INC.
BI620988
cost-effectiveness
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
service safety
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Beforestartingtowork ________________________________________ 1.4 Bucyrus – 488DUN-A-TRAC® ©BUCYRUSAMERICA,INC.
BI620988
• 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
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 A6474X304 SSVI/00 1.5 ©BUCYRUSAMERICA,INC.
BI620988
Beforestartingtowork ________________________________________ 1.6 Bucyrus – 488DUN-A-TRAC® ©BUCYRUSAMERICA,INC. BI620988
_______________________________________________________________
BI620988
2 Yoursafety
________________________________________________________________ BI620988
furtheroperatingmanuals
Yoursafety
Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Themachinehasbeenmanufacturedinaccordancewiththestateof theartandgenerallyrecognizedsafetystandardsandregulations. Youandotherscanneverthelessbeexposedtodangeroussituations, forexample,asaresultofenvironmentalinfluences,machinedamage, oroperatorerrors.
Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.AllmodificationsandchangesmustbeapprovedbyBucyrusAmerica,Inc.
UseonlyoriginalsparepartsfromBucyrusAmerica,Inc.Notethatthe useofpartsfromothermanufacturerswillvoidtheguarantee.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations:
■ ofthemine,
■ ofthemineinspector,and
■ oftheminingsupervisoryauthorities
Pleasereadalsotheoperatingmanualsofthecomponentsrequiredfor operation,e.g.ofgearboxes,dieselmotors,etc.,carefullyandthoroughly.Clarifyanyquestions before startingwork.
_________________________________________________ YourSafety A6474X304 SSVI/00 2.3
©BUCYRUSAMERICA,INC.
stateoftheart
BI620988
Personnel
Operation
Themachinemayonlybeoperatedbyqualified,trainedpersonnel.
Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho 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 ___________________________________________________
©BUCYRUSAMERICA,INC
2.4 Bucyrus – 488DUN-A-TRAC®
training BI620988
Operatingconditions
Intendeduse
Intendedusesinclude:
■ thetransportofmaterials
■ useduringcleanupandutilitywork.
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
BucyrusAmerica,Inc.acceptsnoliabilityforanydamageresulting fromanysuchunauthorizeduse.
_________________________________________ Operatingconditions A6474X304 SSVI/00 2.5 ©BUCYRUSAMERICA,INC.
BI620988
• 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
