Cat Bucyrus 488D-XP Operation & Maintenance Manual BI000966 – PDF DOWNLOAD

Description

Cat Bucyrus 488D-XP Operation & Maintenance Manual BI000966 – PDF DOWNLOAD

FILE DETAILS:

Cat Bucyrus 488D-XP Operation & Maintenance Manual BI000966 – PDF DOWNLOAD

Language : English
Pages : 298
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Bucyrus 488D-XP Operation & Maintenance Manual BI000966 – 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.

• 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.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Cat Bucyrus 488D-XP Operation & Maintenance Manual BI000966 – 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 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
Diesel Safety System Troubleshooting 5 234
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

Customer Support: [email protected]

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]

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