Bucyrus 488D-XP UN-A-TRAC Operation And Maintenance Manual A6474X334
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Bucyrus 488D-XP UN-A-TRAC Operation And Maintenance Manual A6474X334 - Image 5

Bucyrus 488D-XP UN-A-TRAC Operation And Maintenance Manual A6474X334

$30.00

  • Type Of Manual: Operation And Maintenance Manual
  • Manual ID: A6474X334
  • Number of Pages: 300
  • Size: 25.7MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 488D-XP 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……………………………………….2.26
  • 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 – left and center ………………….. 5.5
  • 53. Operator’s compartment – right ………………………………… 5.6
  • 54. Hazard zone………………………………………………………………. 5.21
  • 55. Starting procedure………………………………………………………. 5.22
  • 56. Shutdown procedure…………………………………………………… 5.23
  • 57. Towing a disabled machine …………………………………………. 5.25
  • 58. Instructions on the maintenance …………………………………… 5.27
  • 59. Important notes ……………………………………………………… 5.27
  • 60. Before maintenance ……………………………………………….. 5.27
  • 61. Critical torque values………………………………………………. 5.29
  • 62. Lubricants, fluids and capacities ………………………………. 5.29
  • 63. Specific lubrication and maintenance schedule………….. 5.30
  • 64. Specific lubrication and maintenance procedure …………….. 5.34
  • 65. Pre-shift………………………………………………………………… 5.34
  • 66. Every third shift ……………………………………………………… 5.37
  • 67. Weekly………………………………………………………………….. 5.43
  • 68. Every three months ………………………………………………… 5.50
  • 69. First 50 hours of service………………………………………….. 5.54
  • 70. Every 100 hours …………………………………………………….. 5.55
  • 71. Every 500 hours …………………………………………………….. 5.58
  • 72. Every 1000 hours …………………………………………………… 5.60
  • 73. Every six months……………………………………………………. 5.61
  • 74. Servicing heavy duty air filter elements …………………………. 5.62
  • 75. Diesel emissions maintenance …………………………………………. 5.66
  • 76. Introduction (emissions)………………………………………………. 5.66
  • 77. Diesel emissions ………………………………………………………… 5.67
  • 78. Diesel emissions stall test……………………………………………. 5.68
  • 79. Operational issues ……………………………………………………… 5.70
  • 80. Best practices………………………………………………………… 5.71
  • 81. Proactive attitudes………………………………………………….. 5.74
  • 82. Typical exhaust gas components………………………………….. 5.76
  • 83. Engine systems/conditions that affect diesel emissions …… 5.78
  • 84. Combustion chamber design …………………………………… 5.78
  • 85. Intake manifold system …………………………………………… 5.80
  • 86. Operating conditions that affect emissions ………………… 5.81
  • 87. Low turbocharger boost pressure …………………………….. 5.82
  • 88. High exhaust backpressure……………………………………… 5.82
  • 89. High crankcase pressure ………………………………………… 5.84
  • 90. Overview of six engine systems………………………………………. 5.85
  • 91. Intake system ……………………………………………………………. 5.86
  • 92. Dry type air cleaners ………………………………………………. 5.87
  • 93. Air induction piping…………………………………………………. 5.88
  • 94. Aftercoolers …………………………………………………………… 5.88
  • 95. Air-to-air aftercoolers………………………………………………. 5.89
  • 96. Water aftercoolers………………………………………………….. 5.89
  • 97. Intake system recommendations ……………………………… 5.90
  • 98. Servicing the intake system ………………………………………. 5.91
  • 99. Job aid checklist (Intake System) ………………………………. 5.92
  • 100. Exhaust system ………………………………………………………. 5.93
  • 101. Exhaust system recommendations…………………………….. 5.95
  • 102. Exhaust after treatment system maintenance ……………… 5.95
  • 103. Job aid checklist for exhaust system ………………………….. 5.97
  • 104. Introduction to tools used for exhaust system analysis …. 5.98
  • 105. ECOM AC+ gas analyzer……………………………………… 5.98
  • 106. UGAS software application …………………………………. 5.100
  • 107. Testing protocol…………………………………………………. 5.100
  • 108. Pre-test conditions …………………………………………….. 5.101
  • 109. Emissions testing protocol ………………………………….. 5.101
  • 110. Basic emission equipment operation ………………………… 5.102
  • 111. Undiluted diesel particulate measurement…………….. 5.102
  • 112. Measurement interpretation ………………………………… 5.104
  • 113. Analysis of particulate samples……………………………. 5.104
  • 114. Thermal optical method ……………………………………… 5.105
  • 115. ECOM AC+ gas analyzer……………………………………. 5.106
  • 116. Particulate sampling – Gilian pump ………………………. 5.106
  • 117. Intake testing…………………………………………………….. 5.107
  • 118. Intake restrictions and exhaust backpressure ……….. 5.108
  • 119. Fuel injection system ………………………………………………….. 5.109
  • 120. Injection pump or injector failure………………………………. 5.110
  • 121. Inadequate fuel supply……………………………………………. 5.110
  • 122. Incorrect injection pump or injector timing …………………. 5.111
  • 123. Advanced timing ……………………………………………………. 5.111
  • 124. Retarded timing……………………………………………………… 5.111
  • 125. Fuel system types ………………………………………………….. 5.112
  • 126. Individual unit jerk pumps ……………………………………….. 5.113
  • 127. Inline pump system ………………………………………………… 5.114
  • 128. Distributor pump system …………………………………………. 5.115
  • 129. Cummins PT fuel system………………………………………… 5.115
  • 130. Unit injectors …………………………………………………………. 5.116
  • 131. Electronically controlled fuel injection systems…………… 5.116
  • 132. Fuel injection system recommendations……………………. 5.117
  • 133. Job aid checklist for fuel systems …………………………….. 5.118
  • 134. Cooling systems…………………………………………………………. 5.119
  • 135. Cooling system recommendations……………………………. 5.119
  • 136. Cooling system maintenance…………………………………… 5.120
  • 137. Coolant mixture……………………………………………………… 5.120
  • 138. Conditioner and inhibitors ……………………………………….. 5.120
  • 139. Cleaning and flushing …………………………………………….. 5.121
  • 140. Troubleshooting …………………………………………………….. 5.121
  • 141. Thermostats ………………………………………………………….. 5.121
  • 142. Aeration in coolant …………………………………………………. 5.121
  • 143. Radiator cap relief valve …………………………………………. 5.122
  • 144. Temperature probe ………………………………………………… 5.122
  • 145. Job aid checklist for cooling system) ………………………… 5.123
  • 146. Diesel fuel and fuel supply systems ……………………………… 5.124
  • 147. Best practice recommendations ………………………………. 5.124
  • 148. Sulfur content………………………………………………………… 5.125
  • 149. Cetane number ……………………………………………………… 5.125
  • 150. Viscosity……………………………………………………………….. 5.125
  • 151. Flashpoint……………………………………………………………… 5.125
  • 152. Fuel quality and handling recommendations ……………… 5.126
  • 153. Lubrication…………………………………………………………………. 5.127
  • 154. Lubrication recommendations………………………………….. 5.127
  • 155. Lubrication classification …………………………………………. 5.128
  • 156. Combined service applications ………………………………… 5.129
  • 157. Lubrication system checks ………………………………………. 5.129
  • 158. Conclusion ………………………………………………………………… 5.130
  • 159. Diesel emissions – job aid check list……………………………… 5.131
  • 160. Replacement of wear parts ………………………………………….. 5.133
  • 161. Tire/Wheel installation…………………………………………….. 5.133
  • 162. Axles…………………………………………………………………….. 5.137
  • 163. Drive shaft …………………………………………………………….. 5.140
  • 164. Accumulator operation and precharging ……………………. 5.141
  • 165. Ejector blade and cylinder……………………………………….. 5.143
  • 166. Canopy/Cab ………………………………………………………….. 5.145
  • 167. Steering cylinder ……………………………………………………. 5.146
  • 168. Tilt cylinder ……………………………………………………………. 5.159
  • 169. Lift cylinder ……………………………………………………………. 5.150
  • 170. Brake bleeding procedure……………………………………….. 5.152
  • 171. Instructions on the adjustment procedures…………………….. 5.153
  • 172. Main relief – primary (main implement) pump section….. 5.153
  • 173. Main relief – auxiliary pump section…………………………… 5.154
  • 174. Unloading valve……………………………………………………… 5.155
  • 175. Relief valve – brake cooling manifold ………………………… 5.156
  • 176. Pressure reducing valve – HRC pilot control circuit……… 5.157
  • 177. MSHA documentation …………………………………………………. 5.159
  • 178. Machine/Electrical checklist (drawing 607214) …………… 5.159
  • 179. Power system checklist (drawing 606348) …………………….. 5.169
  • 180. Certification statement (drawing 607742) ………………………. 5.191
  • 181. Certification statement (drawing 607858) ………………….. 5.192
  • 182. General arrangement (drawing 607215)……………………. 5.193
  • 183. Hydraulic system (drawing 607217)………………………….. 5.194
  • 184. Electrical diagram (drawing 561G518)………………………. 5.195
  • 185. Electronic shutdown assembly (drawing 561G508)…….. 5.196
  • 186. Inspection for permissibility form (drawing 561A509) ….. 5.197
  • 187. Troubleshooting procedures ………………………………………… 5.199
  • 188. Hydraulic system (general) ……………………………………… 5.200
  • 189. Brakes ………………………………………………………………….. 5.203
  • 190. Hydraulic cylinders …………………………………………………. 5.205
  • 191. Hydraulic pump ……………………………………………………… 5.206
  • 192. Valves…………………………………………………………………… 5.208
  • 193. Engine ………………………………………………………………….. 5.209
  • 194. Converter………………………………………………………………. 5.219
  • 195. Transmission…………………………………………………………. 5.221
  • 196. Fuel injector…………………………………………………………… 5.222
  • 197. Compressor…………………………………………………………… 5.222
  • 198. Leaking intake system…………………………………………….. 5.224
  • 199. Air intake system restriction and fuel flow………………….. 5.224
  • 200. Catalyst failure ………………………………………………………. 5.224
  • 201. Exhaust particulate filter failure………………………………… 5.225
  • 202. Diesel Safety System Troubleshooting ……………………… 5.226
  • 203. 6. Technical data
  • 204. Technical data ……………………………………………………………….. 6.3
  • 205. Components of the 488D-XP UN-A-TRAC……………………. 6.3
  • 206. Technical data……………………………………………………………. 6.3
  • 207. Tightening torques ……………………………………………………… 6.5
  • 208. Permissible data ……………………………………………………….. 6.11
  • 209. Lubrication fluids and greases ………………………………… 6.11
  • 210. 7. For your information
  • 211. For your information …………………………………………………….. 7.3
  • 212. Our service………………………………………………………………… 7.3
  • 213. Service address …………………………………………………….. 7.3
  • 214. Rebuild facility address…………………………………………… 7.4
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