CAT BUCYRUS 488D-XP Operation and Maintenance Manual BI000965 – PDF DOWNLOAD

Description

CAT BUCYRUS 488D-XP Operation and Maintenance Manual BI000965 – PDF DOWNLOAD

FILE DETAILS:

CAT BUCYRUS 488D-XP Operation and Maintenance Manual BI000965 – PDF DOWNLOAD

Language : English
Pages : 56
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

CAT BUCYRUS 488D-XP Operation and Maintenance Manual BI000965 – 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
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
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 29
Starting procedure 5 30
Shutdown procedure 5 32
Towing a disabled machine 5 34
Instructions on the maintenance 5 35
Important notes 5 35
Before maintenance 5 35
Critical torque values 5 37
Lubricants, fluids and capacities 5 37
Specific lubrication and maintenance schedule 5 38
Specific lubrication and maintenance procedure 5 42
Pre-shift 5 42
Every third shift 5 46
Weekly 5 51
Every three months 5 58
First 50 hours of service 5 63
Every 100 hours 5 64
Every 500 hours 5 67
Every 1000 hours 5 69
Every six months 5 69
Servicing heavy duty air filter elements 5 70
Diesel emissions maintenance 5 74
Introduction (emissions) 5 74
Diesel emissions 5 75
Diesel emissions stall test 5 76
Operational issues 5 78
Best practices 5 79
Proactive attitudes 5 82
Typical exhaust gas components 5 84
Engine systems/conditions that affect diesel emissions 5 86
Combustion chamber design 5 86
Intake manifold system 5 88
Operating conditions that affect emissions 5 89
Low turbocharger boost pressure 5 90
High exhaust backpressure 5 90
High crankcase pressure 5 92
Overview of six engine systems 5 93
Intake system 5 94
Dry type air cleaners 5 95
Air induction piping 5 96
Aftercoolers 5 96
Air-to-air aftercoolers 5 97
Water aftercoolers 5 97
Intake system recommendations 5 98
Servicing the intake system 5 99
Job aid checklist (Intake System) 5 100
Exhaust system 5 101
Exhaust system recommendations 5 103
Exhaust after treatment system maintenance 5 103
Job aid checklist for exhaust system 5 105
Introduction to tools used for exhaust system analysis 5 106
ECOM AC+ gas analyzer 5 106
UGAS software application 5 108
Testing protocol 5 108
Pre-test conditions 5 109
Emissions testing protocol 5 109
Basic emission equipment operation 5 111
Undiluted diesel particulate measurement 5 111
Measurement interpretation 5 112
Analysis of particulate samples 5 112
Thermal optical method 5 113
ECOM AC+ gas analyzer 5 114
Particulate sampling – Gilian pump 5 114
Intake testing 5 115
Intake restrictions and exhaust backpressure 5 116
Fuel injection system 5 117
Injection pump or injector failure 5 118
Inadequate fuel supply 5 118
Incorrect injection pump or injector timing 5 119
Advanced timing 5 119
Retarded timing 5 119
Fuel system types 5 120
Individual unit jerk pumps 5 121
Inline pump system 5 122
Distributor pump system 5 123
Cummins PT fuel system 5 123
Unit injectors 5 124
Electronically controlled fuel injection systems 5 124
Fuel injection system recommendations 5 125
Job aid checklist for fuel systems 5 126
Cooling systems 5 127
Cooling system recommendations 5 127
Cooling system maintenance 5 128
Coolant mixture 5 128
Conditioner and inhibitors 5 128
Cleaning and flushing 5 129
Troubleshooting 5 129
Thermostats 5 129
Aeration in coolant 5 129
Radiator cap relief valve 5 130
Temperature probe 5 130
Job aid checklist for cooling system) 5 131
Diesel fuel and fuel supply systems 5 132
Best practice recommendations 5 132
Sulfur content 5 133
Cetane number 5 133
Viscosity 5 133
Flashpoint 5 133
Fuel quality and handling recommendations 5 134
Lubrication 5 135
Lubrication recommendations 5 135
Lubrication classification 5 136
Combined service applications 5 137
Lubrication system checks 5 137
Conclusion 5 138
Diesel emissions – job aid check list 5 139
Replacement of wear parts 5 141
Tire/Wheel installation 5 141
Axles 5 145
Drive shaft 5 148
Accumulator operation and precharging 5 149
Ejector blade and cylinder 5 151
Canopy/Cab 5 153
Steering cylinder 5 154
Tilt cylinder 5 157
Lift cylinder 5 158
Brake bleeding procedure 5 160
Instructions on the adjustment procedures 5 161
Main relief – primary (main implement) pump section 5 161
Main relief – auxiliary pump section 5 162
Unloading valve 5 163
Relief valve – brake cooling manifold 5 164
Pressure reducing valve – HRC pilot control circuit 5 165
MSHA documentation 5 177
Machine/Electrical checklist (drawing 607214) 5 177
Power system checklist (drawing 606348) 5 187
Certification statement (drawing 607742) 5 199
Certification statement (drawing 607858) 5 200
General arrangement (drawing 607215) 5 201
Hydraulic system (drawing 607217) 5 202
Electrical diagram (drawing 561G518) 5 203
Electronic shutdown assembly (drawing 561G508) 5 204
Inspection for permissibility form (drawing 561A509) 5 205
Troubleshooting procedures 5 207
Hydraulic system (general) 5 208
Brakes 5 211
Hydraulic cylinders 5 212
Hydraulic pump 5 214
Valves 5 216
Engine 5 217
Converter 5 227
Transmission 5 228
Fuel injector 5 230
Compressor 5 230
Leaking intake system 5 232
Air intake system restriction and fuel flow 5 232
Catalyst failure 5 232
Exhaust particulate filter failure 5 233
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

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M