Issuu

BI002297-03(EN-US)

A6474X373

June2012

Operationand Maintenance Manual

SAFETY.CAT.COM

SU488D-XPScoop

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ThismanualisintendedtoprovideGENERALproductinformationfor theModelSU488D-XPScoop.Theillustrations,descriptionsandprocedurescontainedinthispublicationapplyonlytoTHISmachine.Caterpillarreservestherighttorevisemodelsanddesignswithoutprior notice.

Thisscoopwasmanufacturedundertheguidelines,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.

__________________________________________________________ BI002297-03(EN-US)

© CATERPILLAR2012 ALLRIGHTSRESERVED

_________________________________________________ Tableofcontents A6474X373 REV3 BI002297-03(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

5. Operation

Tableofcontents _________________________________________________ SU488D-XPScoop BI002297-03(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 5.21 Hazardzone 5.29 Startingprocedure 5.30 Shutdownprocedure 5.31 Towingadisabledmachine 5.33 Instructionsonthemaintenance 5.35 Importantnotes 5.35 Beforemaintenance ........................................................5.35 Criticaltorquevalues 5.37 Lubricants,fluidsandcapacities 5.37 Specificlubricationandmaintenanceschedule 5.38 Specificlubricationandmaintenanceprocedure..................5.42 Pre-shift 5.42 Everythirdshift................................................................5.45 Weekly 5.51 Everythreemonths .........................................................5.58 First50hoursofservice 5.62 Every100hours ..............................................................5.63 Every500hours 5.64 Every1000hours ............................................................5.68 Everysixmonths 5.69 Servicingheavydutyairfilterelements................................5.70 Dieselemissionsmaintenance(generalinformation) 5.74 Replacementofwearparts 5.141 Tire/Wheelinstallation 5.141 Axles 5.145 Driveshaft 5.148 Accumulatoroperationandprecharging 5.149 Ejectorbladeandcylinder 5.151 Canopy/Cab 5.153 Steeringcylinder 5.154 Tiltcylinder 5.157 Liftcylinder 5.158 Brakebleedingprocedure 5.160 Instructionsontheadjustmentprocedures 5.161 Mainrelief - primary(mainimplement)pumpsection 5.161 Mainrelief - auxiliarypumpsection.................................5.162 Unloadingvalve 5.163 Reliefvalve - brakecoolingmanifold...............................5.164 Pressurereducingvalve - HRCpilotcontrolcircuit 5.165

_________________________________________________ Tableofcontents A6474X373 REV3

MSHAdocumentation 5.167 Factoryinspectionform 5.167 Generalarrangement 5.170 Fuelsystem 5.171 Hydraulicsystem 5.172 Safety/shutdownsystem ......................................................5.174 Pneumaticcircuit 5.176 Operator’scompartment 5.177 Approvaltag 5.178 Machinechecklist.................................................................5.179 Powersystemchecklist 5.187 Electricalassembly...............................................................5.207 Electricalchecklist 5.208 Troubleshootingprocedures.......................................................5.209 Hydraulicsystem(general) 5.210 Brakes..................................................................................5.213 Hydrauliccylinders 5.214 Hydraulicpump ....................................................................5.216 Valves 5.218 Engine ..................................................................................5.219 Converter 5.229 Transmission 5.231 Fuelinjector 5.232 Compressor..........................................................................5.232 Leakingintakesystem 5.234 Airintakesystemrestrictionandfuelflow 5.234 Catalystfailure 5.234 Exhaustparticulatefilterfailure 5.235 Enginemonitoringsystem 5.236 6. Technicaldata Technicaldata 6.3 ComponentsoftheSU488D-XP 6.3 Technicaldata 6.3 Tighteningtorques 6.5 Permissibledata 6.11 Lubricationfluidsandgreases 6.11 7. Foryourinformation Foryourinformation...............................................................7.3 Ourservice 7.3 Serviceaddress...............................................................7.3 Rebuildfacilityaddress 7.4

BI002297-03(EN-US)

Tableofcontents _________________________________________________ SU488D-XPScoop BI002297-03(EN-US)

_______________________________________________________________ 1 Aboutthismanual BI002297-03(EN-US)

_______________________________________________________________ BI002297-03(EN-US)

applicableoperatingmanual machinetype

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.

Beforestartingtowork

Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.

Thisoperatingmanualisintendedfor:

ModelSU488Diesel-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 A6474X373 REV3 1.3 BI002297-03(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 SU488D-XPScoop BI002297-03(EN-US)

• Thank you very much for reading the preview of the manual.

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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 yourworkfasterand,moreimportantly,safer.

___________________________________________ Beforestartingtowork A6474X373 REV3 1.5 BI002297-03(EN-US)

Beforestartingtowork____________________________________________ 1.6 SU488D-XPScoop BI002297-03(EN-US)

_______________________________________________________________ 2 Yoursafety BI002297-03(EN-US)

_______________________________________________________________ BI002297-03(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 A6474X373 REV3 2.3 BI002297-03(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.)

mayonlybecarriedoutbyserviceengineersorspeciallyqualifiedpersonnelofthemine.

Personnel _______________________________________________________ 2.4 SU488D-XPScoop BI002297-03(EN-US)

training

Operatingconditions

Intendeduse

Intendedusesinclude:

■ thetransportofmaterialsand/or

■ useduringcleanupandutilitywork.

Unauthorizeduse

Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththemachine.

■ thetransportofpersons

Themanufactureracceptsnoliabilityforanydamageresultingfrom anysuchunauthorizeduse.

_____________________________________________Operatingconditions A6474X373 REV3 2.5 BI002297-03(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