Bucyrus 488 Diesel UN-A-TRAC Operation Manual A6474X253
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Bucyrus 488 Diesel UN-A-TRAC Operation Manual A6474X253

$30.00

  • Type Of Manual: Operation Manual
  • Manual ID: A6474X253
  • Number of Pages: 242
  • Size: 9.5MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 488 Diesel UN-A-TRAC
  • 1. 1. About this manual
  • 2. About this manual ………………………………………………………… 1.3
  • 3. Before starting to work………………………………………………… 1.3
  • 4. Who is this operating manual intended for? …………………… 1.3
  • 5. What is the purpose of this operating manual? ………………. 1.4
  • 6. Characters and symbols ……………………………………………… 1.5
  • 7. 2. Your safety
  • 8. Your safety …………………………………………………………………… 2.3
  • 9. Personnel………………………………………………………………….. 2.4
  • 10. Operation ……………………………………………………………… 2.4
  • 11. Installation and repair……………………………………………… 2.4
  • 12. Operating conditions…………………………………………………… 2.5
  • 13. Intended use …………………………………………………………. 2.5
  • 14. Unauthorized use…………………………………………………… 2.5
  • 15. Safety instructions………………………………………………………. 2.7
  • 16. General rules: ……………………………………………………….. 2.7
  • 17. Storage and transport …………………………………………….. 2.8
  • 18. Pre-start inspection ………………………………………………… 2.8
  • 19. Installation and start-up…………………………………………… 2.9
  • 20. Operation ……………………………………………………………… 2.9
  • 21. Stopping……………………………………………………………….2.10
  • 22. Maintenance and repair ………………………………………….2.10
  • 23. Diesel emissions ……………………………………………………2.11
  • 24. Handling of hydraulic fluids……………………………………..2.13
  • 25. Overview of the safety instructions ……………………………….2.17
  • 26. Chapter 2: Safety instructions………………………………….2.17
  • 27. Chapter 3: Storage and transport …………………………….2.17
  • 28. Chapter 4: Installation…………………………………………….2.17
  • 29. Chapter 5: Operation ……………………………………………..2.18
  • 30. Chapter 6: Technical data……………………………………….2.25
  • 31. 3. Storage and transport
  • 32. Storage and transport …………………………………………………… 3.3
  • 33. Storage …………………………………………………………………….. 3.3
  • 34. Storage of the machine and spare parts……………………. 3.3
  • 35. Transport…………………………………………………………………… 3.4
  • 36. Before transport …………………………………………………….. 3.5
  • 37. 4. Installation
  • 38. Installation……………………………………………………………………. 4.3
  • 39. Points to observe prior to installation…………………………….. 4.3
  • 40. Who is allowed to carry out installation?……………………. 4.3
  • 41. Which tools are required for installation?…………………… 4.3
  • 42. Notes on installation……………………………………………….. 4.4
  • 43. Pre-installation check list ………………………………………… 4.5
  • 44. Safety features………………………………………………………. 4.6
  • 45. 5. Operation
  • 46. Pre-operation suggestions ……………………………………………. 5.3
  • 47. Operation ……………………………………………………………………… 5.4
  • 48. How to operate the UN-A-TRAC ® ………………………………… 5.4
  • 49. Who is allowed to operate the UN-A-TRAC ® …………….. 5.4
  • 50. When can operation be started?………………………………. 5.4
  • 51. Controls and indicators ……………………………………………….. 5.5
  • 52. Operator’s compartment – right side …………………………. 5.5
  • 53. Operator’s compartment – left and center ………………….. 5.6
  • 54. Hazard zone………………………………………………………………. 5.25
  • 55. Starting procedure………………………………………………………. 5.26
  • 56. General…………………………………………………………………. 5.26
  • 57. Machine operation………………………………………………….. 5.27
  • 58. Shutdown procedure…………………………………………………… 5.29
  • 59. Towing a disabled machine …………………………………………. 5.30
  • 60. Instructions on the maintenance …………………………………… 5.31
  • 61. Important notes ……………………………………………………… 5.31
  • 62. Before maintenance ……………………………………………….. 5.31
  • 63. Critical torque values………………………………………………. 5.33
  • 64. Lubricants, fluids and capacities ………………………………. 5.33
  • 65. Specific lubrication and maintenance schedule………….. 5.34
  • 66. Specific lubrication and maintenance procedure …………….. 5.37
  • 67. Pre-shift………………………………………………………………… 5.37
  • 68. Every third shift………………………………………………………. 5.40
  • 69. Weekly………………………………………………………………….. 5.46
  • 70. Every three months ………………………………………………… 5.52
  • 71. First 50 hours of service………………………………………….. 5.56
  • 72. Every 100 hours …………………………………………………….. 5.57
  • 73. Every 500 hours …………………………………………………….. 5.59
  • 74. Every 1000 hours …………………………………………………… 5.60
  • 75. Servicing heavy duty air filter elements …………………………. 5.61
  • 76. Diesel emissions maintenance………………………………………. 5.65
  • 77. Introduction (emissions)………………………………………………. 5.66
  • 78. Diesel emissions ………………………………………………………… 5.68
  • 79. Diesel emissions stall test……………………………………………. 5.69
  • 80. Operational issues ……………………………………………………… 5.69
  • 81. Best practices………………………………………………………… 5.70
  • 82. Proactive attitudes………………………………………………….. 5.73
  • 83. Typical exhaust gas components………………………………….. 5.75
  • 84. Carbon dioxide ………………………………………………………. 5.75
  • 85. Carbon monoxide…………………………………………………… 5.75
  • 86. Oxides of nitrogen ………………………………………………….. 5.75
  • 87. Hydrocarbons………………………………………………………… 5.75
  • 88. Particulate matter …………………………………………………… 5.76
  • 89. Oxides of sulfur ……………………………………………………… 5.76
  • 90. Smoke ………………………………………………………………….. 5.76
  • 91. Engine systems and conditions
  • 92. that affect diesel emissions………………………………………….. 5.77
  • 93. Combustion chamber design …………………………………… 5.77
  • 94. Intake manifold system …………………………………………… 5.79
  • 95. Operating conditions that affect emissions ………………… 5.80
  • 96. Low turbocharger boost pressure …………………………….. 5.81
  • 97. High exhaust backpressure……………………………………… 5.81
  • 98. High crankcase pressure ………………………………………… 5.83
  • 99. Overview of six engine systems…………………………………… 5.84
  • 100. Overview of engine introduction …………………………………… 5.84
  • 101. 1. Intake system ………………………………………………………… 5.85
  • 102. Dry type air cleaners ………………………………………………. 5.86
  • 103. Air induction piping…………………………………………………. 5.87
  • 104. Aftercoolers…………………………………………………………… 5.87
  • 105. Air-to-air aftercoolers ……………………………………………… 5.88
  • 106. Water aftercoolers………………………………………………….. 5.88
  • 107. Intake system recommendations ……………………………… 5.89
  • 108. Servicing the intake system …………………………………….. 5.90
  • 109. Job aid checklist (Intake System) …………………………….. 5.91
  • 110. 2. Exhaust system ……………………………………………………… 5.92
  • 111. Exhaust system recommendations…………………………… 5.93
  • 112. Exhaust after treatment system maintenance ……………. 5.94
  • 113. Job aid checklist for exhaust system ………………………… 5.96
  • 114. Introduction to tools used for exhaust system analysis .. 5.97
  • 115. ECOM AC+ gas analyzer……………………………………. 5.97
  • 116. UGAS software application …………………………………. 5.99
  • 117. Testing protocol…………………………………………………. 5.99
  • 118. Pre-test conditions …………………………………………….. 5.100
  • 119. Emissions testing protocol ………………………………….. 5.100
  • 120. Basic emission equipment operation ………………………… 5.101
  • 121. Undiluted diesel particulate measurement…………….. 5.101
  • 122. Measurement interpretation ………………………………… 5.103
  • 123. Analysis of particulate samples……………………………. 5.103
  • 124. Thermal optical method ……………………………………… 5.104
  • 125. Job aid checklist for exhaust system analysis tools… 5.104
  • 126. ECOM AC+ gas analyzer……………………………………. 5.105
  • 127. Particulate sampling – Gilian pump ………………………. 5.105
  • 128. Intake testing…………………………………………………….. 5.106
  • 129. Intake restrictions and exhaust backpressure ……….. 5.107
  • 130. 3. Fuel injection system ………………………………………………. 5.108
  • 131. Introduction (Fuel injection system)………………………….. 5.108
  • 132. Injection pump or injector failure………………………………. 5.109
  • 133. Inadequate fuel supply……………………………………………. 5.109
  • 134. Incorrect injection pump or injector timing …………………. 5.110
  • 135. Advanced timing ……………………………………………………. 5.110
  • 136. Retarded timing……………………………………………………… 5.110
  • 137. Fuel system types ………………………………………………….. 5.110
  • 138. Individual unit jerk pumps ……………………………………….. 5.112
  • 139. Inline pump system ………………………………………………… 5.113
  • 140. Distributor pump system …………………………………………. 5.114
  • 141. Cummins PT fuel system………………………………………… 5.114
  • 142. Unit injectors …………………………………………………………. 5.115
  • 143. Electronically controlled fuel injection systems…………… 5.115
  • 144. Fuel injection system recommendations……………………. 5.116
  • 145. Job aid checklist for fuel systems …………………………….. 5.117
  • 146. 4. Cooling systems……………………………………………………… 5.118
  • 147. Cooling system recommendations……………………………. 5.118
  • 148. Cooling system maintenance…………………………………… 5.119
  • 149. Coolant mixture……………………………………………………… 5.119
  • 150. Conditioner and inhibitors ……………………………………….. 5.119
  • 151. Cleaning and flushing …………………………………………….. 5.120
  • 152. Troubleshooting …………………………………………………….. 5.120
  • 153. Thermostats ………………………………………………………….. 5.120
  • 154. Aeration in coolant …………………………………………………. 5.120
  • 155. Radiator cap relief valve………………………………………….. 5.121
  • 156. Temperature probe ………………………………………………… 5.121
  • 157. Job aid checklist for cooling system) ………………………… 5.122
  • 158. 5. Diesel fuel and fuel supply systems ………………………….. 5.123
  • 159. Introduction (Diesel fuel and fuel supply systems)………. 5.123
  • 160. Best practice recommendations……………………………….. 5.123
  • 161. Sulfur content ………………………………………………………… 5.124
  • 162. Cetane number………………………………………………………. 5.124
  • 163. Viscosity ……………………………………………………………….. 5.124
  • 164. Flashpoint……………………………………………………………… 5.124
  • 165. Fuel quality and handling recommendations ……………… 5.125
  • 166. 6. Lubrication……………………………………………………………… 5.126
  • 167. Lubrication recommendations………………………………….. 5.126
  • 168. Lubrication classification …………………………………………. 5.127
  • 169. Combined service applications ………………………………… 5.128
  • 170. Lubrication system checks………………………………………. 5.128
  • 171. Conclusion…………………………………………………………….. 5.129
  • 172. Diesel emissions – job aid check list……………………………… 5.130
  • 173. Instructions on the adjustment procedures…………………….. 5.131
  • 174. Main relief – primary (main implement) pump section….. 5.131
  • 175. Main relief – accumulator pump section …………………….. 5.132
  • 176. Unloader valve ………………………………………………………. 5.133
  • 177. Relief valve – brake cooling manifold ………………………… 5.134
  • 178. Pressure reducing valve – HRC pilot control circuit……… 5.135
  • 179. Troubleshooting procedures ………………………………………… 5.137
  • 180. Hydraulic system (general) ……………………………………… 5.138
  • 181. Brakes ………………………………………………………………….. 5.141
  • 182. Hydraulic cylinders …………………………………………………. 5.143
  • 183. Hydraulic pump ……………………………………………………… 5.144
  • 184. Valves…………………………………………………………………… 5.146
  • 185. Engine ………………………………………………………………….. 5.147
  • 186. Converter………………………………………………………………. 5.151
  • 187. Transmission…………………………………………………………. 5.153
  • 188. Fuel injector…………………………………………………………… 5.154
  • 189. Leaking intake system…………………………………………….. 5.155
  • 190. Air intake system restriction and fuel flow………………….. 5.155
  • 191. Catalyst failure……………………………………………………….. 5.155
  • 192. Exhaust particulate filter failure………………………………… 5.156
  • 193. 6. Technical data
  • 194. Technical data ………………………………………………………………. 6.3
  • 195. Components of the 488 Diesel UN-A-TRAC…………………… 6.3
  • 196. Technical data……………………………………………………………. 6.3
  • 197. Tightening torques ……………………………………………………… 6.11
  • 198. Permissible data………………………………………………………… 6.17
  • 199. Lubrication fluids and greases ………………………………… 6.17
  • 200. 7. For your information
  • 201. For your information …………………………………………………….. 7.3
  • 202. Our service………………………………………………………………… 7.3
  • 203. Service address …………………………………………………….. 7.3
  • 204. Rebuild facility address…………………………………………… 7.4
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