Cat Bucyrus 488D-XP Operation & Maintenance Manual BI620991 – PDF DOWNLOAD

Cat Bucyrus 488D-XP Operation & Maintenance Manual BI620991 – PDF DOWNLOAD

FILE DETAILS:

Cat Bucyrus 488D-XP Operation & Maintenance Manual BI620991 – PDF DOWNLOAD

Language : English
Pages : 300
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Bucyrus 488D-XP Operation & Maintenance Manual BI620991 – PDF DOWNLOAD

• The operating manual must be accessible at all times to all persons working on or with the machine.
  It should, if possible, always be avail- able at the place of operation.
• Send for a new operation manual immediately if the present manual is no longer complete or has

  become illegible.

Who is this operating manual intended for?
This operating manual is intended for those persons who work with or on the machine. Every person
working on the face or in the intersec- tion between face and entry or in the entry must read this
operating manual.
This includes persons who:
■ are in charge of transport
■ perform assembly / disassembly work
■ operate the machine
■ eliminate faults

■ perform daily routine work on the face or in the entry

■ perform maintenance work
■ perform repair work

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Cat Bucyrus 488D-XP Operation & Maintenance Manual BI620991 – PDF DOWNLOAD

1 About this manual
About this manual 1 3
Before starting to work 1 3
Who is this operating manual intended for? 1 3
What is the purpose of this operating manual? 1 4
Characters and symbols 1 5
2 Your safety
Your safety 2 3
Personnel 2 4
Operation 2 4
Installation and repair 2 4
Operating conditions 2 5
Intended use 2 5
Unauthorized use 2 5
Safety instructions 2 7
General rules 2 7
Storage and transport 2 8
Pre-start inspection 2 8
Installation and start-up 2 9
Operation 2 9
Stopping 2 10
Maintenance and repair 2 10
Diesel emissions 2 11
Handling of hydraulic fluids 2 13
Overview of the safety instructions 2 17
Chapter 2: Safety instructions 2 17
Chapter 3: Storage and transport 2 17
Chapter 4: Installation 2 17
Chapter 5: Operation 2 18
Chapter 6: Technical data 2 26
3 Storage and transport
Storage and transport 3 3
Storage 3 3
Storage of the machine and spare parts 3 3
Transport 3 4
Before transport 3 5
4 Installation
Installation 4 3
Points to observe prior to installation 4 3
Who is allowed to carry out installation? 4 3
Which tools are required for installation? 4 3
Notes on installation 4 4
Pre-installation check list 4 5
Safety features 4 6
5 Operation
Pre-operation suggestions 5 3
Operation 5 4
How to operate the UN-A-TRAC® 5 4
Who is allowed to operate the UN-A-TRAC® 5 4
When can operation be started? 5 4
Controls and indicators 5 5
Operator’s compartment – left and center 5 5
Operator’s compartment – right 5 6
Hazard zone 5 21
Starting procedure 5 22
Shutdown procedure 5 23
Towing a disabled machine 5 25
Instructions on the maintenance 5 27
Important notes 5 27
Before maintenance 5 27
Critical torque values 5 29
Lubricants, fluids and capacities 5 29
Specific lubrication and maintenance schedule 5 30
Specific lubrication and maintenance procedure 5 34
Pre-shift 5 34
Every third shift 5 37
Weekly 5 43
Every three months 5 50
First 50 hours of service 5 54
Every 100 hours 5 55
Every 500 hours 5 58
Every 1000 hours 5 60
Every six months 5 61
Servicing heavy duty air filter elements 5 62
Diesel emissions maintenance 5 66
Introduction (emissions) 5 66
Diesel emissions 5 67
Diesel emissions stall test 5 68
Operational issues 5 70
Best practices 5 71
Proactive attitudes 5 74
Typical exhaust gas components 5 76
Engine systems/conditions that affect diesel emissions 5 78
Combustion chamber design 5 78
Intake manifold system 5 80
Operating conditions that affect emissions 5 81
Low turbocharger boost pressure 5 82
High exhaust backpressure 5 82
High crankcase pressure 5 84
Overview of six engine systems 5 85
Intake system 5 86
Dry type air cleaners 5 87
Air induction piping 5 88
Aftercoolers 5 88
Air-to-air aftercoolers 5 89
Water aftercoolers 5 89
Intake system recommendations 5 90
Servicing the intake system 5 91
Job aid checklist (Intake System) 5 92
Exhaust system 5 93
Exhaust system recommendations 5 95
Exhaust after treatment system maintenance 5 95
Job aid checklist for exhaust system 5 97
Introduction to tools used for exhaust system analysis 5 98
ECOM AC+ gas analyzer 5 98
UGAS software application 5 100
Testing protocol 5 100
Pre-test conditions 5 101
Emissions testing protocol 5 101
Basic emission equipment operation 5 102
Undiluted diesel particulate measurement 5 102
Measurement interpretation 5 104
Analysis of particulate samples 5 104
Thermal optical method 5 105
ECOM AC+ gas analyzer 5 106
Particulate sampling – Gilian pump 5 106
Intake testing 5 107
Intake restrictions and exhaust backpressure 5 108
Fuel injection system 5 109
Injection pump or injector failure 5 110
Inadequate fuel supply 5 110
Incorrect injection pump or injector timing 5 111
Advanced timing 5 111
Retarded timing 5 111
Fuel system types 5 112
Individual unit jerk pumps 5 113
Inline pump system 5 114
Distributor pump system 5 115
Cummins PT fuel system 5 115
Unit injectors 5 116
Electronically controlled fuel injection systems 5 116
Fuel injection system recommendations 5 117
Job aid checklist for fuel systems 5 118
Cooling systems 5 119
Cooling system recommendations 5 119
Cooling system maintenance 5 120
Coolant mixture 5 120
Conditioner and inhibitors 5 120
Cleaning and flushing 5 121
Troubleshooting 5 121
Thermostats 5 121
Aeration in coolant 5 121
Radiator cap relief valve 5 122
Temperature probe 5 122
Job aid checklist for cooling system) 5 123
Diesel fuel and fuel supply systems 5 124
Best practice recommendations 5 124
Sulfur content 5 125
Cetane number 5 125
Viscosity 5 125
Flashpoint 5 125
Fuel quality and handling recommendations 5 126
Lubrication 5 127
Lubrication recommendations 5 127
Lubrication classification 5 128
Combined service applications 5 129
Lubrication system checks 5 129
Conclusion 5 130
Diesel emissions – job aid check list 5 131
Replacement of wear parts 5 133
Tire/Wheel installation 5 133
Axles 5 137
Drive shaft 5 140
Accumulator operation and precharging 5 141
Ejector blade and cylinder 5 143
Canopy/Cab 5 145
Steering cylinder 5 146
Tilt cylinder 5 159
Lift cylinder 5 150
Brake bleeding procedure 5 152
Instructions on the adjustment procedures 5 153
Main relief – primary (main implement) pump section 5 153
Main relief – auxiliary pump section 5 154
Unloading valve 5 155
Relief valve – brake cooling manifold 5 156
Pressure reducing valve – HRC pilot control circuit 5 157
MSHA documentation 5 159
Machine/Electrical checklist (drawing 607214) 5 159
Power system checklist (drawing 606348) 5 169
Certification statement (drawing 607742) 5 191
Certification statement (drawing 607858) 5 192
General arrangement (drawing 607215) 5 193
Hydraulic system (drawing 607217) 5 194
Electrical diagram (drawing 561G518) 5 195
Electronic shutdown assembly (drawing 561G508) 5 196
Inspection for permissibility form (drawing 561A509) 5 197
Troubleshooting procedures 5 199
Hydraulic system (general) 5 200
Brakes 5 203
Hydraulic cylinders 5 205
Hydraulic pump 5 206
Valves 5 208
Engine 5 209
Converter 5 219
Transmission 5 221
Fuel injector 5 222
Compressor 5 222
Leaking intake system 5 224
Air intake system restriction and fuel flow 5 224
Catalyst failure 5 224
Exhaust particulate filter failure 5 225
Diesel Safety System Troubleshooting 5 226
6 Technical data
Technical data 6 3
Components of the 488D-XP UN-A-TRAC 6 3
Technical data 6 3
Tightening torques 6 5
Permissible data 6 11
Lubrication fluids and greases 6 11
7 For your information
For your information 7 3
Our service 7 3
Service address 7 3
Rebuild facility address 7 4

VIDEO PREVIEW OF THE MANUAL:

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