Cat SU488 DN Scoop Operation and Maintenance Manual A6474X253 – PDF DOWNLOAD
FILE DETAILS:
Cat SU488 DN Scoop Operation and Maintenance Manual A6474X253 – PDF DOWNLOAD
Language : English
Pages :236
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Cat SU488 DN Scoop Operation and Maintenance Manual A6474X253 – PDF DOWNLOAD
Table of contents
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
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 scoop 5 4
Who is allowed to operate the scoop 5 4
When can operation be started? 5 4
Controls and indicators 5 5
Operator’s compartment – right side 5 5
Operator’s compartment – left and center 5 6
Hazard zone 5 25
Starting procedure 5 26
General 5 26
Machine operation 5 27
Shutdown procedure 5 29
Towing a disabled machine 5 30
Instructions on the maintenance 5 31
Important notes 5 31
Before maintenance 5 31
Critical torque values 5 33
Lubricants, fluids and capacities 5 33
Specific lubrication and maintenance schedule 5 34
Specific lubrication and maintenance procedure 5 37
Pre-shift 5 37
Every third shift 5 40
Weekly 5 46
Every three months 5 52
First 50 hours of service 5 56
Every 100 hours 5 57
Every 500 hours 5 59
Every 1000 hours 5 60
Servicing heavy duty air filter elements 5 61
Diesel emissions maintenance 5 65
Introduction (emissions) 5 66
Diesel emissions 5 68
Diesel emissions stall test 5 69
Operational issues 5 69
Best practices 5 70
Proactive attitudes 5 73
Typical exhaust gas components 5 75
Carbon dioxide 5 75
Carbon monoxide 5 75
Oxides of nitrogen 5 75
Hydrocarbons 5 75
Particulate matter 5 76
Oxides of sulfur 5 76
Smoke 5 76
Engine systems and conditions
that affect diesel emissions 5 77
Combustion chamber design 5 77
Intake manifold system 5 79
Operating conditions that affect emissions 5 80
Low turbocharger boost pressure 5 81
High exhaust backpressure 5 81
High crankcase pressure 5 83
Overview of six engine systems 5 84
Overview of engine introduction 5 84
1 Intake system 5 85
Dry type air cleaners 5 86
Air induction piping 5 87
Aftercoolers 5 87
Air-to-air aftercoolers 5 88
Water aftercoolers 5 88
Intake system recommendations 5 89
Servicing the intake system 5 90
Job aid checklist (Intake System) 5 91
2 Exhaust system 5 92
Exhaust system recommendations 5 93
Exhaust after treatment system maintenance 5 94
Job aid checklist for exhaust system 5 96
Introduction to tools used for exhaust system analysis 5 97
ECOM AC+ gas analyzer 5 97
UGAS software application 5 99
Testing protocol 5 99
Pre-test conditions 5 100
Emissions testing protocol 5 100
Basic emission equipment operation 5 101
Undiluted diesel particulate measurement 5 101
Measurement interpretation 5 103
Analysis of particulate samples 5 103
Thermal optical method 5 104
Job aid checklist for exhaust system analysis tools 5 104
ECOM AC+ gas analyzer 5 105
Particulate sampling – Gilian pump 5 105
Intake testing 5 106
Intake restrictions and exhaust backpressure 5 107
3 Fuel injection system 5 108
Introduction (Fuel injection system) 5 108
Injection pump or injector failure 5 109
Inadequate fuel supply 5 109
Incorrect injection pump or injector timing 5 110
Advanced timing 5 110
Retarded timing 5 110
Fuel system types 5 110
Individual unit jerk pumps 5 112
Inline pump system 5 113
Distributor pump system 5 114
Cummins PT fuel system 5 114
Unit injectors 5 115
Electronically controlled fuel injection systems 5 115
Fuel injection system recommendations 5 116
Job aid checklist for fuel systems 5 117
4 Cooling systems 5 118
Cooling system recommendations 5 118
Cooling system maintenance 5 119
Coolant mixture 5 119
Conditioner and inhibitors 5 119
Cleaning and flushing 5 120
Troubleshooting 5 120
Thermostats 5 120
Aeration in coolant 5 120
Radiator cap relief valve 5 121
Temperature probe 5 121
Job aid checklist for cooling system) 5 122
5 Diesel fuel and fuel supply systems 5 123
Introduction (Diesel fuel and fuel supply systems) 5 123
Best practice recommendations 5 123
Sulfur content 5 124
Cetane number 5 124
Viscosity 5 124
Flashpoint 5 124
Fuel quality and handling recommendations 5 125
6 Lubrication 5 126
Lubrication recommendations 5 126
Lubrication classification 5 127
Combined service applications 5 128
Lubrication system checks 5 128
Conclusion 5 129
Diesel emissions –job aid check list 5 130
Instructions on the adjustment procedures 5 131
Main relief – primary (main implement) pump section 5 131
Main relief – accumulator pump section 5 132
Unloader valve 5 133
Relief valve – brake cooling manifold 5 134
Pressure reducing valve – HRC pilot control circuit 5 135
Troubleshooting procedures 5 137
Hydraulic system (general) 5 138
Brakes 5 141
Hydraulic cylinders 5 143
Hydraulic pump 5 144
Valves 5 146
Engine 5 147
Converter 5 151
Transmission 5 153
Fuel injector 5 154
Leaking intake system 5 155
Air intake system restriction and fuel flow 5 155
Catalyst failure 5 155
Exhaust particulate filter failure 5 156
6 Technical data
Technical data 6 3
Components of the 488 Diesel Scoop 6 3
Technical data 6 3
Tightening torques 6 11
Permissible data 6 17
Lubrication fluids and greases 6 17
7 For your information
For your information 7 3
Our service 7 3
Service address 7 3
Rebuild facility address 7 4
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