CAT Bucyrus 482 Diesel Operation Manual BI620984 – PDF DOWNLOAD

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CAT Bucyrus 482 Diesel Operation Manual BI620984 – PDF DOWNLOAD@=

FILE DETAILS:

CAT Bucyrus 482 Diesel Operation Manual BI620984 – PDF DOWNLOAD 

Language : English
Pages : 236
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

CAT Bucyrus 482 Diesel Operation Manual BI620984 – PDF DOWNLOAD 

About this manual:
This chapter provides important information making it easier for you to use this manual. You will
also be given information on the structure of the manual and the symbols and characters used.

Your safety:

This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible.

state of the art:

The machine has been manufactured in accordance with the state of the art and generally recognized
safety standards and regulations. You and others can nevertheless be exposed to dangerous situations
e.g. as a result of environmental influences, machine damage or opera- tor errors.

• Do not make any alterations or modifications which could impair the safety of the machine. All
  modifications and changes must be ap- proved by Bucyrus America, Inc.
• Use only original spare parts from Bucyrus America, Inc. Note that the use of parts from other
  manufacturers will void the guarantee.
• In addition to this operating manual be sure to also observe the respec- tive legal provisions and
  regulations in your country.

Observe the safety and accident prevention regulations:

TABLE OF CONTENTS:

CAT Bucyrus 482 Diesel Operation Manual BI620984 – 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 25
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
BI620984
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 – right side 5 5
Operator’s compartment – left and center 5 6
Hazard zone 5 23
Starting procedure 5 24
General 5 24
Machine operation 5 25
Shutdown procedure 5 27
Towing a disabled machine 5 28
Instructions on the maintenance 5 29
Important notes 5 29
Before maintenance 5 29
Critical torque values 5 31
Lubricants, fluids and capacities 5 31
Specific lubrication and maintenance schedule 5 32
Specific lubrication and maintenance procedure 5 35
Pre-shift 5 35
Every third shift 5 38
Weekly 5 43
Every three months 5 49
First 50 hours of service 5 53
Every 100 hours 5 54
Every 500 hours 5 56
Every 1000 hours 5 57
Servicing heavy duty air filter elements 5 58
Diesel emissions maintenance 5 62
Introduction (emissions) 5 62
Diesel emissions 5 63
Diesel emissions stall test 5 64
Operational issues 5 66
Tools 5 66
Best practices 5 67
Proactive attitudes 5 70
Typical exhaust gas components 5 72
Carbon dioxide 5 72
Carbon monoxide 5 72
Oxides of nitrogen 5 72
Hydrocarbons 5 72
Particulate matter 5 73
Oxides of sulfur 5 73
Smoke 5 73
Engine systems and conditions
that affect diesel emissions 5 74
Combustion chamber design 5 74
Intake manifold system 5 76
Operating conditions that affect emissions 5 77
Low turbocharger boost pressure 5 78
High exhaust backpressure 5 78
High crankcase pressure 5 80
Overview of six engine systems 5 81
Introduction 5 81
Intake system 5 82
Job aid checklist (Intake System) 5 88
Exhaust system 5 89
Introduction 5 89
Exhaust system recommendations 5 91
Exhaust after treatment system maintenance 5 91
Job aid checklist for exhaust system 5 93
Introduction to tools used for exhaust system analysis 5 94
ECOM AC+ gas analyzer 5 94
UGAS software application 5 96
Testing protocol 5 96
Pre-test conditions 5 97
Emissions testing protocol 5 97
Basic emission equipment operation 5 98
Undiluted diesel particulate measurement 5 98
Measurement interpretation 5 100
Analysis of particulate samples 5 100
Thermal optical method 5 101
Job aid checklist for exhaust system analysis tools 5 102
ECOM AC+ gas analyzer 5 102
Particulate sampling – Gilian pump 5 102
Intake testing 5 103
Intake restrictions and exhaust backpressure 5 104
Fuel injection system 5 105
Introduction (Fuel injection system) 5 105
Injection pump or injector failure 5 106
Inadequate fuel supply 5 106
Incorrect injection pump or injector timing 5 107
Advanced timing 5 107
Retarded timing 5 107
Fuel system types 5 108
Individual unit jerk pumps 5 109
Inline pump system 5 110
Distributor pump system 5 111
Cummins PT fuel system 5 111
Unit injectors 5 112
Electronically controlled fuel injection systems 5 112
Fuel injection system recommendations 5 113
Job aid checklist for fuel systems 5 114
Cooling systems 5 115
Cooling system recommendations 5 115
Cooling system maintenance 5 116
Coolant mixture 5 116
Conditioner and inhibitors 5 116
Cleaning and flushing 5 117
Troubleshooting 5 117
Thermostats 5 117
Aeration in coolant 5 117
Radiator cap relief valve 5 118
Temperature probe 5 118
Job aid checklist for cooling system) 5 119
Diesel fuel and fuel supply systems 5 120
Introduction (Diesel fuel and fuel supply systems) 5 120
Best practice recommendations 5 120
Sulfur content 5 121
Cetane number 5 121
Viscosity 5 121
Flashpoint 5 121
Fuel quality and handling recommendations 5 122
Lubrication 5 123
Lubrication recommendations 5 123
Lubrication classification 5 124
Combined service applications 5 125
Lubrication system checks 5 125
Conclusion 5 126
Diesel emissions – job aid check list 5 127
Instructions on the adjustment procedures 5 129
Main relief – primary valve bank/unloader)) pump
section 5 129
Main relief – fan pump section 5 131
Main relief – exhaust coolant pump section 5 132
Unloader valve 5 134
Relief valve – brake cooling manifold 5 136
Pressure reducing valve – HRC pilot control circuit 5 137
Troubleshooting procedures 5 139
Hydraulic system (general) 5 140
Brakes 5 142
Hydraulic cylinders 5 145
Hydraulic pump 5 146
Valves 5 148
Engine 5 149
Converter 5 153
Transmission 5 155
Fuel injector 5 156
Leaking intake system 5 157
Air intake system restriction and fuel flow 5 157
Catalyst failure 5 157
Exhaust particulate filter failure 5 157
6 Technical data
Technical data 6 3
Components of the 482 Diesel 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

Customer Support: [email protected]

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