BI002298-11(EN-US)
A6474X278
March2013
Operationand Maintenance Manual
SAFETY.CAT.COM
SU488DScoop
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ThismanualisintendedtoprovideGENERALproductinformationfor theSU488D Scoop.Theillustrations,descriptionsandprocedures containedinthispublicationapplyonlytoTHISmachine.Caterpillar reservestherighttorevisemodelsanddesignswithoutpriornotice.
ThisSU488D wasmanufacturedundertheguidelines,proceduresand requirementsoftheU.S.FederalCoalMineHealthandSafetyAct, CodeofFederalRegulations,Title30,Chapter1,Subpart0,Part75for undergroundcoalmines,andotherapplicablenon-U.S.regulatory agencystandards.
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.
© CATERPILLAR2012 ALLRIGHTSRESERVED
__________________________________________________________ BI002298-11(EN-US)
_________________________________________________ Tableofcontents A6474X278 REV11 BI002298-11(EN-US) 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
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
1.
2.
3.
5. Operation
Tableofcontents _________________________________________________ SU488DScoop BI002298-11(EN-US)
Pre-operationsuggestions ........................................................5.3 Operation 5.4 HowtooperatetheScoop....................................................5.4 WhoisallowedtooperatetheScoop 5.4 Whencanoperationbestarted? 5.4 Controlsandindicators 5.5 Operator’scompartment - leftandcenter........................5.5 Operator’scompartment - right 5.6 Enginemonitoringsystem 5.22 Secondaryshutdownsystem(optional) 5.30 Hazardzone 5.32 Startingprocedure 5.33 Shutdownprocedure 5.35 Towingadisabledmachine 5.37 Instructionsonthemaintenance 5.39 Importantnotes.....................................................................5.39 Beforemaintenance 5.39 Criticaltorquevalues 5.41 Lubricants,fluidsandcapacities 5.41 Specificlubricationandmaintenanceschedule ...................5.42 Specificlubricationandmaintenanceprocedure 5.46 Pre-shift ...........................................................................5.46 Everythirdshift 5.49 Weekly.............................................................................5.55 Everythreemonths 5.62 First50hoursofservice ..................................................5.66 Every100hours 5.67 Every500hours ..............................................................5.10 Every1000hours 5.72 Everysixmonths .............................................................5.73 Servicingheavydutyairfilterelements 5.74 Dieselemissionsmaintenance(reference) 5.78 Replacementofwearparts 5.145 Tire/Wheelinstallation 5.145 Axles 5.149 Driveshaft 5.152 Accumulatoroperationandprecharging 5.153 Ejectorbladeandcylinder 5.155 Canopy/Cab 5.157 Steeringcylinder 5.158 Tiltcylinder 5.161 Liftcylinder 5.162 Brakebleedingprocedure 5.164 Instructionsontheadjustmentprocedures 5.165 Mainrelief - primary(mainimplement)pumpsection..........5.165 Mainrelief - auxiliarypumpsection 5.166 Unloadingvalve....................................................................5.167 Reliefvalve - brakecoolingmanifold 5.168 Pressurereducingvalve - HRCpilotcontrolcircuit..............5.169 MSHAchecklists 5.171
_________________________________________________ Tableofcontents A6474X278 REV11
Troubleshootingprocedures 5.217 Hydraulicsystem(general) 5.218 Brakes 5.221 Hydrauliccylinders 5.223 Hydraulicpump 5.224 Valves................................................................................5.226 Engine 5.227 Converter 5.237 Transmission 5.239 Fuelinjector.......................................................................5.240 Compressor 5.240 Leakingintakesystem.......................................................5.242 Airintakesystemrestrictionandfuelflow 5.242 Catalystfailure...................................................................5.242 Exhaustparticulatefilterfailure 5.243 DieselSafetySystemTroubleshooting.............................5.244
BI002298-11(EN-US)
Technicaldata Technicaldata 6.3 Componentsofthe488D-XP 6.3 Technicaldata......................................................................6.3 Tighteningtorques 6.5 Permissibledata................................................................. 6.11 Lubricationfluidsandgreases 6.11
6.
Foryourinformation Foryourinformation...............................................................7.3 Ourservice 7.3 Serviceaddress 7.3 Rebuildfacilityaddress 7.4
7.
Tableofcontents _________________________________________________ SU488DScoop BI002298-11(EN-US)
_______________________________________________________________ 1 Aboutthismanual BI002298-11(EN-US)
_______________________________________________________________ BI002298-11(EN-US)
applicableoperatingmanual machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.
Thisoperatingmanualisintendedfor:
SU488Diesel-XPScoop 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 A6474X278 REV11 1.3 BI002298-11(EN-US)
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 SU488DScoop BI002298-11(EN-US)
• 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
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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 yourworkfasterand,moreimportantly,safer.
____________________________________________Beforestartingtowork A6474X278 REV11 1.5 BI002298-11(EN-US)
Beforestartingtowork____________________________________________ 1.6 SU488DScoop BI002298-11(EN-US)
_______________________________________________________________ 2 Yoursafety BI002298-11(EN-US)
_______________________________________________________________ BI002298-11(EN-US)
stateoftheart
Yoursafety
Thischapterprovidesvitalinformationforyoursafety.Payspecialattentiontothischapter.Thesafetyinstructionsandrulesofprocedure willhelpyoutoavoidhazardoussituationsandtoperformthenecessaryworkassafelyaspossible.
Themachinehasbeenmanufacturedinaccordancewithstateofthe artandgenerallyrecognizedsafetystandardsandregulations.You andotherscanneverthelessbeexposedtodangeroussituationsasa resultofenvironmentalinfluences,machinedamageoroperatorerrors. Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.Allmodificationsandchangesmustbeapproved.
Useonlyoriginalspareparts.Notethattheuseofpartsfromother manufacturerswillvoidtheguarantee.
Inadditiontothisoperatingmanualbesuretoalsoobservetherespectivelegalprovisionsandregulationsinyourcountry.
Observethesafetyandaccidentpreventionregulations:
■ ofthemine,
■ ofthemineinspector,and
■ oftheminingsupervisoryauthorities.
furtheroperatingmanuals
Pleasereadtheoperatingmanualsofthecomponentsrequiredforoperation,e.g.gearboxes,dieselengines,etc.,carefullyandthoroughly. Clarifyanyquestions before startingwork.
_____________________________________________________ YourSafety A6474X278 REV11 2.3 BI002298-11(EN-US)
Personnel
Operation
Themachinemayonlybeoperatedbyqualified,trainedpersonnel.
Themachineisonlyallowedtobeoperatedbyqualifiedpersonnelwho canprovideproofofhavingbeentrainedonthisunit.Readingofthe operationmanual,especiallythechapteronsafety,shallconstitutea partofthistraining.
Youmusthaveadequateknowledgeofthe
■ mechanics,
■ pneumatics,
■ hydraulics,and
■ controlengineering
andmustbeabletoprovethisknowledge.
Installationandrepair
Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.
Installationandrepairworkon:
■ safetycomponents(pressurereliefvalves,extinguishers,etc.)
■ theelectrics(controllers,etc.)
■ thehydraulics(controls,cylinders,etc.)
■ pneumatics(aircompressor,valves,etc.)
■ dieselsystem(engines,exhaustsystem,etc.)
mayonlybecarriedoutbyserviceengineersorbyspeciallyqualified personnelofthemine.
Personnel _______________________________________________________ 2.4 SU88D-XPScoop BI002298-11(EN-US)
training
Operatingconditions
Intendeduse
Intendedusesinclude:
■ thetransportofmaterialsand/or
■ useduringcleanupandutilitywork.
Unauthorizeduse
Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.
■ thetransportofpersons
Themanufactureracceptsnoliabilityforanydamageresultingfrom anysuchunauthorizeduse.
_____________________________________________Operatingconditions A6474X278 REV11 2.5 BI002298-11(EN-US)
• 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