Bucyrus 650D XP Versatrac Operation Manual A6474X279
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Bucyrus 650D XP Versatrac Operation Manual A6474X279

$30.00

  • Type Of Manual: Operation Manual
  • Manual ID: A6474X279
  • Number of Pages: 340
  • Size: 25.8MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 650D XP Versatrac
  • 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……………………………………….2.27
  • 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 VERSATRAC®……………………………….. 5.4
  • 49. Who is allowed to operate the VERSATRAC®……………. 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………………………………………………………………. 5.16
  • 55. Starting procedure………………………………………………………. 5.17
  • 56. Shutdown procedure…………………………………………………… 5.18
  • 57. Towing a disabled machine …………………………………………. 5.19
  • 58. Instructions on the maintenance …………………………………… 5.21
  • 59. Important notes ……………………………………………………… 5.21
  • 60. Before maintenance ……………………………………………….. 5.21
  • 61. Critical torque values………………………………………………. 5.23
  • 62. Lubricants, fluids and capacities ………………………………. 5.23
  • 63. Specific lubrication and maintenance schedule………….. 5.24
  • 64. Specific lubrication and maintenance procedure …………….. 5.28
  • 65. Pre-shift………………………………………………………………… 5.28
  • 66. Every third shift ……………………………………………………… 5.31
  • 67. Weekly………………………………………………………………….. 5.38
  • 68. First 50 hours of service………………………………………….. 5.58
  • 69. Every three months ………………………………………………… 5.59
  • 70. Every 100 hours …………………………………………………….. 5.64
  • 71. Every 500 hours …………………………………………………….. 5.66
  • 72. Every six months……………………………………………………. 5.68
  • 73. Every twelve months ………………………………………………. 5.70
  • 74. Servicing heavy duty air filter elements …………………………. 5.71
  • 75. Diesel emissions maintenance …………………………………………. 5.75
  • 76. Introduction (emissions)………………………………………………. 5.75
  • 77. Diesel emissions ………………………………………………………… 5.75
  • 78. Diesel emissions stall test……………………………………………. 5.77
  • 79. Operational issues ……………………………………………………… 5.79
  • 80. Best practices…………………………………………………………….. 5.80
  • 81. Proactive attitudes………………………………………………………. 5.83
  • 82. Typical exhaust gas components………………………………….. 5.85
  • 83. Carbon dioxide ………………………………………………………. 5.85
  • 84. Carbon monoxide…………………………………………………… 5.85
  • 85. Oxides of nitrogen ………………………………………………….. 5.85
  • 86. Hydrocarbons………………………………………………………… 5.85
  • 87. Particulate matter …………………………………………………… 5.86
  • 88. Oxides of sulfur ……………………………………………………… 5.86
  • 89. Smoke ………………………………………………………………….. 5.86
  • 90. Engine systems and conditions
  • 91. that affect diesel emissions………………………………………….. 5.87
  • 92. Combustion chamber design …………………………………… 5.87
  • 93. Intake manifold system …………………………………………… 5.89
  • 94. Operating conditions that affect emissions ………………… 5.90
  • 95. Low turbocharger boost pressure …………………………….. 5.91
  • 96. High exhaust backpressure……………………………………… 5.91
  • 97. High crankcase pressure ………………………………………… 5.93
  • 98. Overview of six engine systems………………………………………. 5.94
  • 99. Overview of engine introduction …………………………………… 5.94
  • 100. Intake system ……………………………………………………………. 5.95
  • 101. Dry type air cleaners………………………………………………. 5.96
  • 102. Air induction piping…………………………………………………. 5.97
  • 103. Aftercoolers…………………………………………………………… 5.97
  • 104. Air-to-air aftercoolers ……………………………………………… 5.98
  • 105. Water aftercoolers………………………………………………….. 5.98
  • 106. Intake system recommendations ……………………………… 5.99
  • 107. Servicing the intake system …………………………………….. 5.100
  • 108. Job aid checklist (Intake System) …………………………….. 5.101
  • 109. Exhaust system …………………………………………………………. 5.102
  • 110. Exhaust system recommendations…………………………… 5.103
  • 111. Exhaust after treatment system maintenance ……………. 5.104
  • 112. Job aid checklist for exhaust system ………………………… 5.106
  • 113. Introduction to tools used for exhaust system analysis .. 5.107
  • 114. ECOM AC+ gas analyzer……………………………………. 5.107
  • 115. UGAS software application …………………………………. 5.109
  • 116. Testing protocol…………………………………………………. 5.109
  • 117. Pre-test conditions …………………………………………….. 5.110
  • 118. Emissions testing protocol ………………………………….. 5.110
  • 119. Basic emission equipment operation ………………………… 5.111
  • 120. Undiluted diesel particulate measurement…………….. 5.111
  • 121. Measurement interpretation ………………………………… 5.113
  • 122. Analysis of particulate samples……………………………. 5.113
  • 123. Thermal optical method ……………………………………… 5.114
  • 124. Job aid checklist for exhaust system analysis tools… 5.114
  • 125. ECOM AC+ gas analyzer……………………………………. 5.115
  • 126. Particulate sampling – Gilian pump ………………………. 5.115
  • 127. Intake testing…………………………………………………….. 5.116
  • 128. Intake restrictions and exhaust backpressure ……….. 5.117
  • 129. Fuel injection system ………………………………………………….. 5.118
  • 130. Introduction (Fuel injection system) ………………………….. 5.118
  • 131. Injection pump or injector failure………………………………. 5.119
  • 132. Inadequate fuel supply……………………………………………. 5.119
  • 133. Incorrect injection pump or injector timing …………………. 5.120
  • 134. Advanced timing ……………………………………………………. 5.120
  • 135. Retarded timing……………………………………………………… 5.120
  • 136. Fuel system types ………………………………………………….. 5.120
  • 137. Individual unit jerk pumps ……………………………………….. 5.122
  • 138. Inline pump system ………………………………………………… 5.123
  • 139. Distributor pump system …………………………………………. 5.124
  • 140. Cummins PT fuel system………………………………………… 5.124
  • 141. Unit injectors …………………………………………………………. 5.125
  • 142. Electronically controlled fuel injection systems…………… 5.125
  • 143. Fuel injection system recommendations……………………. 5.126
  • 144. Job aid checklist for fuel systems …………………………….. 5.127
  • 145. Cooling systems…………………………………………………………. 5.128
  • 146. Cooling system recommendations……………………………. 5.128
  • 147. Cooling system maintenance…………………………………… 5.129
  • 148. Coolant mixture……………………………………………………… 5.129
  • 149. Conditioner and inhibitors ……………………………………….. 5.129
  • 150. Cleaning and flushing …………………………………………….. 5.130
  • 151. Troubleshooting …………………………………………………….. 5.130
  • 152. Thermostats ………………………………………………………….. 5.130
  • 153. Aeration in coolant …………………………………………………. 5.130
  • 154. Radiator cap relief valve …………………………………………. 5.131
  • 155. Temperature probe ………………………………………………… 5.131
  • 156. Job aid checklist for cooling system) ………………………… 5.132
  • 157. Diesel fuel and fuel supply systems ……………………………… 5.133
  • 158. Introduction (Diesel fuel and fuel supply systems) ……… 5.133
  • 159. Best practice recommendations……………………………….. 5.133
  • 160. Sulfur content………………………………………………………… 5.134
  • 161. Cetane number ……………………………………………………… 5.134
  • 162. Viscosity……………………………………………………………….. 5.134
  • 163. Flashpoint……………………………………………………………… 5.134
  • 164. Fuel quality and handling recommendations ……………… 5.135
  • 165. Lubrication ………………………………………………………………… 5.136
  • 166. Lubrication recommendations………………………………….. 5.136
  • 167. Lubrication classification …………………………………………. 5.137
  • 168. Combined service applications ………………………………… 5.138
  • 169. Lubrication system checks………………………………………. 5.138
  • 170. Conclusion…………………………………………………………….. 5.139
  • 171. Diesel emissions – job aid check list …………………………….. 5.140
  • 172. Hydraulic system………………………………………………………… 5.141
  • 173. Adjustment procedures……………………………………………….. 5.143
  • 174. Pressure compensated (PC) control…………………………. 5.143
  • 175. Main relief valve …………………………………………………….. 5.144
  • 176. Steering section port relief valves…………………………….. 5.145
  • 177. Pressure limiter ……………………………………………………… 5.145
  • 178. Pressure reducing valve …………………………………………. 5.146
  • 179. Bell crank bi-directional valve ………………………………….. 5.146
  • 180. Auxiliary relief valve ……………………………………………….. 5.148
  • 181. Dif-lok valve…………………………………………………………… 5.149
  • 182. Hand pump relief valve …………………………………………… 5.150
  • 183. Replacement of wear parts………………………………………….. 5.151
  • 184. Tire/wheel installation …………………………………………….. 5.151
  • 185. Axle removal/installation …………………………………………. 5.155
  • 186. Drive shaft removal/installation………………………………… 5.158
  • 187. Accumulator operation/precharging………………………….. 5.159
  • 188. Ejector blade and cylinder removal/installation…………… 5.161
  • 189. Canopy/cab removal ………………………………………………. 5.163
  • 190. Steering cylinder ……………………………………………………. 5.164
  • 191. Tilt cylinder……………………………………………………………. 5.166
  • 192. Lift cylinder……………………………………………………………. 5.168
  • 193. Brake bleeding procedure……………………………………….. 5.170
  • 194. DST Dry System™……………………………………………………… 5.171
  • 195. On-board Cleaning System™ ………………………………….. 5.171
  • 196. Background ………………………………………………………. 5.171
  • 197. Activating………………………………………………………….. 5.171
  • 198. Diagnosing high exhaust backpressure………………… 5.173
  • 199. Procedure to replace the particulate filter ……………… 5.175
  • 200. Replacement exhaust particulate filters………………… 5.176
  • 201. Pre-operating inspection…………………………………………. 5.177
  • 202. MSHA requirements…………………………………………… 5.177
  • 203. System requirements …………………………………………. 5.177
  • 204. Pre-operating inspection checklist ……………………….. 5.178
  • 205. Operating instructions…………………………………………………. 5.179
  • 206. Background …………………………………………………………. 5.179
  • 207. Starting the engine ……………………………………………….. 5.179
  • 208. Starting a cold engine (after extended parking) ………… 5.180
  • 209. Automatic safety shutdown features ……………………….. 5.181
  • 210. Manual shutdown features …………………………………….. 5.182
  • 211. Excessive idling……………………………………………………. 5.182
  • 212. Operating recommendations………………………………….. 5.182
  • 213. Stopping the engine and parking the machine………….. 5.183
  • 214. Carbon Monoxide (CO) sampling procedure………………….. 5.184
  • 215. Background …………………………………………………………. 5.184
  • 216. Reasons for monitoring engine-out CO emissions ……. 5.185
  • 217. Reasons for monitoring treated CO emissions (opt)….. 5.185
  • 218. Permanently installed CO sampling ports ………………… 5.186
  • 219. CO sampling procedure ………………………………………… 5.187
  • 220. CO sampling instruments………………………………………. 5.188
  • 221. Maintenance for flameproof ports …………………………… 5.189
  • 222. CO sampling recordkeeping (sample form) ……………… 5.190
  • 223. Cooling system filling procedure…………………………………… 5.191
  • 224. Safety shutdown system……………………………………………… 5.192
  • 225. System description (pneumatic system) ………………….. 5.192
  • 226. Starting the system……………………………………………….. 5.193
  • 227. Manual system shutdown………………………………………. 5.193
  • 228. Manual emergency shutdown ………………………………… 5.193
  • 229. Automatic temperature shutdown feature ………………… 5.193
  • 230. Automatic low oil pressure shutdown feature……………. 5.194
  • 231. MSHA documentation ………………………………………………………. 5.195
  • 232. Machine permissibility (drawing 624309) ………………………. 5.195
  • 233. Power package permissibility (drawing M255-001-01)…….. 5.203
  • 234. Electric package permissibility (drawing M261-008-01) …… 5.215
  • 235. General arrangement (drawing 624312) ……………………….. 5.220
  • 236. Electrical schematic (drawing M261-003-01) …………………. 5.222
  • 237. Electrical installation (drawing M261-010-01)…………………. 5.223
  • 238. Alternator installation (drawing M250-107-01)………………… 5.224
  • 239. Starting circuit – Cummins 8.3 (drawing M250-012-01)……. 5.225
  • 240. Cooling system (drawing M250-008-01)………………………… 5.226
  • 241. Water injection system, pneumatic (drawing M265-006-01) 5.227
  • 242. CO monitoring ports (drawing M250-006-01) …………………. 5.228
  • 243. Shutdown system (drawing M250-007-01)…………………….. 5.229
  • 244. Fuel system, C8.3 (drawing 624310)…………………………….. 5.230
  • 245. Operator’s compartment (drawing 624311)……………………. 5.231
  • 246. Troubleshooting procedures………………………………………………. 5.233
  • 247. Hydraulic system (general) ………………………………………….. 5.234
  • 248. Brakes………………………………………………………………………. 5.237
  • 249. Hydraulic cylinders……………………………………………………… 5.239
  • 250. Hydraulic pump………………………………………………………….. 5.240
  • 251. Valves ………………………………………………………………………. 5.242
  • 252. Engine………………………………………………………………………. 5.243
  • 253. Converter ………………………………………………………………….. 5.254
  • 254. Transmission……………………………………………………………… 5.256
  • 255. Fuel injector ………………………………………………………………. 5.257
  • 256. Compressor ………………………………………………………………. 5.257
  • 257. Leaking intake system ………………………………………………… 5.259
  • 258. Air intake system restriction and fuel flow ……………………… 5.259
  • 259. Catalyst failure …………………………………………………………… 5.259
  • 260. Exhaust particulate filter failure…………………………………….. 5.259
  • 261. 6. Technical data
  • 262. Technical data………………………………………………………………. 6.3
  • 263. Components of the 650D Permissible VERSATRAC®…….. 6.3
  • 264. Technical data……………………………………………………………. 6.3
  • 265. Tightening torques ……………………………………………………… 6.4
  • 266. Permissible data ……………………………………………………….. 6.11
  • 267. Lubrication fluids and greases ………………………………… 6.11
  • 268. 7. For your information
  • 269. For your information …………………………………………………….. 7.3
  • 270. Our service………………………………………………………………… 7.3
  • 271. Service address …………………………………………………….. 7.3
  • 272. Rebuild facility address …………………………………………… 7.4
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