PDF Operation & Maintenance Manual Caterpillar SU488D Scoop - 2 MB
This is the complete operation and maintenance manual for the Caterpillar SU488D Scoop.
It's a critical guide for operators and service personnel working with this underground mining loader.
The manual covers all aspects of safe operation, control functions, and detailed maintenance schedules to ensure machine reliability and longevity.
Adhering to the procedures in this document is essential for maintaining productivity and safety in demanding mining environments.
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A6474X253
June 2012
Operation and
Maintenance
Manual
SU488D Scoop
SAFETY.CAT.COM
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________________________________________Before starting to work
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.
Before starting to work
applicable operating manual Take care to ensure that the operating manual available to you is appli-
cable for the type of equipment or machine used.
machine type This operating manual is intended for:
Model, SU488 D Scoop
Serial No.: N/A
and is only permitted to be used for equipment of this type.
new operation manual The operating manual must be accessible at all times to all persons
working on or with the machine.
It should, if possible, always be available 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 intersection between face
and entry or in the entry must read this operating manual.
This includes persons who:
■ are in charge of transport
■ prepare the rise heading
■ 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
supervisory personnel who:
■ initiate and/or
■ supervise the activities just indicated.
______________________________________________________________
A6474X253 Rev 2 1.3
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___________________________________________ Safety instructions
Safety instructions
General rules:
general Always work with full concentration.
Familiarize yourself with your working environment.
noise emissions Always wear your personal protective equipment. This also includes
ear protectors as the noise emitted by other equipment in the area may
at times exceed 85 db(A).
Inform your colleagues of:
■ your exact location.
■ the work you are performing.
■ the time that you will probably require.
safety equipment Start the machine only when it is in a good and safe operating condition
and all protective devices, cover plates, etc. are correctly installed.
Observe the acoustic and optical start-up warnings of the machine.
symbol plates Observe the symbol plates on the machine.
cordon off working area Cordon off your working area widely for the machine.
moving parts Never allow parts of your body to come between parts which could
move, such as e.g.:
■ bucket
■ pivot points
■ ejector
steering lockout Connect the steering lockout device before performing maintenance or
repairs on the machine.
______________________________________________________________
A6474X253 Rev 2 2.7
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_________________________________Overview of safety instructions
Overview of the safety instructions
This is a summary of all the safety instructions which have to be ob-
served in the following chapters. This summary is intended only to give
you an overview of all the instructions. In some cases, there is no logi-
cal relationship between the individual instructions.
Chapter 2: Safety Instructions
NOTICE!
The fuel buffalo enables the fuel to remain clean during transition
to fuel tank
Keep the tank topped off to minimize the moisture buildup in the
tank
Excessive intake restriction causes significant increase in carbon
monoxide and soot emissions—restriction (>50”WG)
When increased carbon monoxide and black smoke are detected,
the intake air cleaner may need to be replaced
A mostly blocked intake system can lead to carbon monoxide in-
creases of 50-250% and increases in smoke
Chapter 3: Storage and transport
Instructions on the storage of concentrates for hydraulic fluids can be
found, if required, in chapter 6 in this operating manual.
IMPORTANT!
Take care to insure that new supplies are stored separately from
existing stock and that removal takes place on the “first in, first
out” principle.
Additional information on the dimensions and weights can be found in
chapter 6 in this operating manual.
WARNING!
Use only load handling devices complying with the technical and
legal regulations for the transport of loads.
You could be seriously injured or even killed by falling loads.
Use only suitable load handling devices.
Chapter 4: Installation
CAUTION!
Serious damage can be caused to the scoop as a result of incor-
rect installation.
The unit should therefore only be installed under the instruction of
specialists.
______________________________________________________________
A6474X253 Rev 2 2.17
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_______________________________________________________________
3 Storage and transport
________________________________________________________________
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__________________________________________________ Installation
Pre-installation check list
NOTICE!
The machine was inspected prior to shipment from the factory to
ensure proper functioning and installation of all components.
However, to ensure that no transit damage has occurred, the fol-
lowing pre-startup checks should be performed:
■ perform daily maintenance
■ visually inspect all hydraulic hoses and electrical cables for dam-
age
■ clean any foreign material from the operator’s compartment
■ if equipped with bucket, clean any foreign material from behind the
ejector blade
■ check safety provisions for operational condition on fire suppres-
sion system
■ check that all covers and guards are in place and secure
■ check that all tags and instruction labels are in place and secure
■ check that operator’s canopy is secure and in place
■ start the machine and allow the hydraulic system to warm up for
five (5) to ten (10) minutes
■ check hydraulic system pressures (refer to the hydraulic schematic
supplied for your particular machine for pressure settings)
■ Check all engine gauges in the operator’s comportment to ensure
all systems are functioning properly
______________________________________________________________
A6474X253 Rev 2 4.5
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___________________________________________________ Operation
Controls and indicators
Operator’s compartment – right side
The primary controls for the machine are located in the operator’s com-
partment (Fig.10).
Fig. 10: Operator’s compartment – right side 2 Speed Winch
Fire Suppression
Operation
Warning Gong
Dif-lok
Winch/ PTO
Diverter Valve
Winch/ PTO Accumulator
Pressure
System
Pressure
Fire Ejector
Seat Extinguisher
Bucket tilt
Emergency
Brake Pressure
Brake Release
Bucket lift
Hand pump
Note: QA Lock
Typical operator’s compartment shown, location of controls may vary.
______________________________________________________________
A6474X253 Rev 2 5.5
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___________________________________________________ Operation
Fig. 19: Operator’s compartment
Intake Restriction
Emergency/Parking Vacuum Gauge
Exhaust Pressure
Brake
Throttle Reservoir Dif-lok Pressure Brake Pressure
LOFA EP250 series The EP250 series control systems (Fig. 20) are a very flexible platform
control panel for diesel engine control, monitoring, and protection, featuring LOFA’s
powerful First Fault Diagnostics (FFD). After pinpointing the initial fail-
ure, FFD stores it in memory and alerts the end user via a single bright
LED. FFD monitors battery charge, low oil pressure, high temperature,
overspeed and up to three additional contact closure inputs. The field
programmable, expandable microprocessor-based solid-state design
uses high-power semiconductors instead of outdated electromechanical
relays to ensure reliable high-current switching.
Some of the EP250 programmable features include:
■ automatic preheat duration
■ afterglow duration
■ failure indication with shutdown or indication only
■ over-speed shutdown
■ normally open or normally closed shutdown switches
The standard system includes a 12 inch wiring harness terminating into
a sealed weatherproof plug. This durable connection performs well in
harsh environments and provides efficient installation of custom plug-
and-play engine harnesses as well as standard harness extensions.
WARNING!
When replacement parts are required, LOFA Industries recom-
mends using replacement parts supplied by LOFA or parts with
equivalent specifications. Failure to heed this warning can lead to
premature failure, product damage, personal injury or death.
Improper operation, maintenance or repair of this product can be
dangerous and may result in injury or death.
______________________________________________________________
A6474X253 Rev 2 5.15
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___________________________________________________ Operation
Hazard zone
Fig. 28: Hazard zone
______________________________________________________________
A6474X253 Rev 2 5.25
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________________________________________________ Maintenance
Table 3: Lubrication and maintenance schedule (continued)
Item Description Places Lubricant Specification
38 Pressure filter (Main) 1
(Inspect/change as required)
39 Return filter 1
(Inspect/change as required)
40 Axle oil level (Check) 2 Hypoid gear oil
SAE 90W
41 Planetary wheel end oil level (Check) 4 Hypoid gear oil
SAE 90W
42 Wet disc brake oil level 4 Cooling oil
(No service required)
Every three months
43 Axle oil (Change) 2 Hypoid gear oil
SAE 90W
44 Planetary wheel end oil (Change) 4 Hypoid gear oil
SAE 90W
45 Wet disc brake oil level 4 Cooling oil
(No service required)
46 Hydraulic oil (Change) 1 Mobilfluid 424 Spec. 100-12
47 Tank suction strainer (Clean/change) 1
48 Pressure filter (Change) 1
49 Return filter (Change) 1
50 Winch oil (Change) (Optional) 1 API GL4 (140) Gear oil
Peragma Grade 8
1st 50 Hours of service
51 Engine oil and filter Change 10W40 API CF/ 4
Every 100 hours of service
52 Engine air cleaner Change
53 Radiator Clean
54 Engine oil and filter Change 10W40 API CF/ 4
55 Fuel pre-filter Change
56 Fuel final filter Change
Every 500 hours of service
57 Converter/transmission filter Clean
58 Radiator coolant Change Avia Antifreeze Extra
Glysantin G 48
DEA radiator anti-
freeze
Shell GlycoShell
59 Scrubber heat exchanger Inspect
Every 1000 hours of service
60 Scrubber heat exchanger Clean
______________________________________________________________
A6474X253 Rev 2 5.35
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________________________________________________ Maintenance
fasteners Loose fasteners will cause premature wear and failure to machine and
(nuts, bolts and screws) components. Visually inspect for loose fasteners and tighten as
required.
electrical cables, Visually inspect all electrical cables, conduits and glands for signs of
conduits and glands wear or damage.
hydraulic hoses and Visually inspect all hydraulic hoses and connections for signs of wear,
connections damage or leakage.
tires Visually inspect all tires for signs of wear or damage.
hydraulic oil level Check the hydraulic oil level by looking at the sight glass located on the
oil tank (Fig. 43). If the oil level is low, add oil (Spec. 100-12) via the jet
fill pump until oil is visible in the sight glass.
Fig. 43: Hydraulic oil level
Access cover to
suction strainer
Access cover both
sides of frame
Sight glass
______________________________________________________________
A6474X253 Rev 2 5.45
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________________________________________________ Maintenance
main pressure filter Change the pressure filter element (Fig. 55). If the element is extremely
dirty, a more frequent interval may be required.
return filter Change the return filter element (Fig. 55). If the element is extremely
dirty, a more frequent interval may be required.
pilot filter Change the pilot filter element (Fig. 55). If the element is extremely
dirty, a more frequent interval may be required.
Fig. 55: Filter location
Main
Pilot Return
Pressure
filter filter
filter
winch oil Change oil in the winch (Fig. 56). (Refer to the winch operation and
maintenance manual included in your parts manual)
Park the scoop on solid level ground, clean dirt and debris from
around the drain plug.
Remove drain plug and allow oil to completely drain from the winch.
Clean and reinstall drain plug.
Clean dirt and debris from around the check plug and remove plug.
Clean dirt and debris from around the breather and remove
breather.
Add oil (API GL4 (140) Gear oil Peragma Grade 8) through the
breather hole slowly, just until it starts to flow out of the check plug
hole. Allow sufficient time for the oil to travel throughout the winch
when filling.
Clean and reinstall breather and check plug.
______________________________________________________________
A6474X253 Rev 2 5.55
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________________________________________________ Maintenance
Diesel emissions maintenance
Introduction
This section of this manual was prepared with the intent to provide me-
chanics and operators of diesel engine equipment with a set of guide-
lines for an introduction to the maintenance of diesel emission systems.
With the continuing increase in environmental and health concerns,
there has been growing trend to cut down on the release of any unnec-
essary exhaust gas pollutants into the environment. Regulations are in
place limiting the maximum pollutant concentrations in diesel engine
exhaust gas. Furthermore, sufficient ventilation must be provided in or-
der to ensure that pollutant levels in the working environment don't ex-
ceed Threshold Limit Values (TLV). This manual has been developed to
address these issues from a maintenance perspective. To better under-
stand the relationship between engine maintenance and engine emis-
sions, it's important to know the factors which affect the formation of the
exhaust gas components.
Experience has shown that emission characteristics remain constant
during the life of the diesel engines, providing that maintenance is per-
formed in accordance with manufacturers' recommendations. Improper
or insufficient maintenance will have a negative effect on the combus-
tion process and lead to accelerated wear of engine components result-
ing in an increase in emissions. This usually occurs before a decrease
in performance becomes noticeable.
The traditional approach towards maintenance operations was to look
at it as an expensive exercise not yielding any direct benefit. A piece of
equipment will be repaired if and when it fails, not before. This type of
approach doesn't make sense from an economical standpoint. Timely
maintenance extends the life of the equipment, increases the machine's
availability for production, and reduces operating cost. Purchasing and
operational cost calculations can easily prove the benefits of timely pre-
ventive maintenance.
An improved strategy toward diesel engine maintenance requires not
only a firm commitment from management and planners, but an imple-
mentable set of best practices that mechanics can adopt into their eve-
ryday routine. This guide provides the foundation from which the main-
tainers of diesel engines can build a system that best suits the needs of
their equipment.
The following guide is divided into two categories of equal importance.
Part I (Operational Issues) targets the practices of both mechanics and
operators concerning diesel engines. The system specific section (Part
II) targets the six primary engine systems outlined in previous research
and expands on improved practices that address the needs of today's
engine technologies.
______________________________________________________________
A6474X253 Rev 2 5.65
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________________________________________________ Maintenance
Typical exhaust gas components:
carbon dioxide (C02) Although this gas is non-poisonous, it may still be considered a prob-
lem, especially if it is produced in large enough quantities to displace
oxygen in the working environment
carbon monoxide (CO) CO is the result of the incomplete combustion of the fuel, caused by
localized insufficiencies of oxygen (rich fuel/air ratio). Quenching of the
reaction by cold combustion chamber walls also increases the CO lev-
els. (Example: cold engine operating temperatures) CO gas is a color-
less, odorless, and tasteless gas. Inhalation of as little as 0.3% by vol-
ume can cause death within 30 minutes. For this reason, it is important
never to allow the engine to run in enclosed spaces such as a closed
garage without good ventilation. Increased CO concentrations may be
the result of poor mixture formation caused by a defective injection sys-
tem, injectors with defective spray characteristics, or engine over-
fuelling.
oxides of nitrogen (NOx) The formation of NOx is dependent on the temperatures during the
combustion process, the concentrations of the components nitrogen
(N2) and oxygen (02) and the time available for them to react with each
other. NO and NO2 are generally lumped together and referred to as
oxides of nitrogen (NOx). A rise in the combustion temperature in-
creases the NO concentrations in the exhaust gas In a diesel engine,
the combustion process forms only NO, a small portion of which oxi-
dizes to N02 at lower temperatures and in the presence of 02. The sum
of NO and N02 is called NOx. These gases belong to two different
classes. Nitrogen monoxide (NO) is a colorless, odorless, and tasteless
gas that is rapidly converted into nitrogen dioxide (NO2) in the presence
of oxygen - O2. Advanced injection timing can cause an increase of NO
in the exhaust gas. Measures which decrease the NO concentrations,
such as low compression ratio or retarded injection timing, also tend to
decrease the efficiency of the combustion process. This can result in
increased fuel consumption and higher CO and HC concentrations in
the exhaust.
hydrocarbons (HC) HC in exhaust gases is usually from very small quantities of unburned
diesel fuel and engine lubricating oil. Since the measurement of con-
centrations of different hydrocarbons involves the use of sophisticated
instrumentation, only total HC is usually measured and reported. In the
presence of nitrogen oxide and sunlight, hydrocarbons form sub-
stances, which irritate the mucous membranes. Some hydrocarbons
are cancer-causing. Incomplete combustion in a diesel engine produces
unburned hydrocarbons. Increased HC levels in the exhaust gas are
found when an diesel engine suffers from high oil consumption, a de-
fective injection system, rich fuel/air ratio, or quenching of the combus-
tion process in the proximity of the cold combustion chamber walls.
______________________________________________________________
A6474X253 Rev 2 5.75
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________________________________________________ Maintenance
1. Intake system:
Introduction
The intake system (Fig. 72, Fig. 73 and Fig. 74) on a diesel engine
must provide an adequate supply of clean air for good combustion at all
operating speeds, loads, and operating conditions. As much as 1500
cubic feet of air per minute or more may be required. This depends on
engine size and horsepower. On naturally aspirated (non-turbocharged)
and turbocharged engines, air is as important to good operation as the
quality of the fuel used. Lack of adequate airflow to an engine can result
in high emissions along with poor performance
Contaminated air can quickly wear out a diesel engine - a condition of-
ten referred to as "dusting". This condition is particularly noticeable
when an engine has been overhauled, and after a short period in ser-
vice, compression and power losses are noticeable.
Tests conducted by major diesel engine manufacturers have shown
that as little as two tablespoons of dirt can dust out an engine within a
very short time. Unfiltered air contains small particles of dirt and abra-
sive material that are not always visible to the naked eye.
Intake air can also be contaminated by partially burned fuel. Some of it
washes down the cylinder wall and can dilute lubrication oil. Some of
the unburned fuel dries up and sticks to pistons, rings, and valves as
well as fouling up the small orifices in the injector tip, resulting in higher
emissions. Nothing wears out a diesel engine faster than contaminated
air entering the intake system. The dirt and oil mixture acts as an abra-
sive lapping compound. On the cylinder walls it proves to be disas-
trous. Imagine how the continuous rubbing action of the piston rings
against the liner surface contaminated with abrasive dirt in the oil
quickly accelerates wear.
Fig. 72: A two-stage intake system
______________________________________________________________
A6474X253 Rev 2 5.85
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________________________________________________ Maintenance
To effectively maintain diesel oxidation catalysts the
following points should be adhered to:
■ Perform emissions measurements on a regular basis to calculate
CO (Carbon Monoxide) conversion efficiency. Refer to section with
procedure on emission testing. Efficiency should be between 65%
and 95%.
■ Use exhaust backpressure for monitoring purifier condition.
Establish a baseline value for each engine series with a new or
clean purifier. Maintenance checks should not exceed 3 inches of
water above baseline value. Backpressures exceeding this indicate
need for service.
■ Clean catalytic purifiers using compressed air, steam cleaning, and
fuel. After blowing out and washing with steam, soak the purifier in
a clean container of diesel fuel for at least 2 hours to loosen and
dissolve hard carbon build-up. After soaking, re-steam and blow out
with compressed air.
■ When blowing out purifiers with compressed air, ensure the safety
of yourself and others with adequate ventilation to avoid exposure
to airborne soot.
To effectively maintain diesel particulate filters the fol-
lowing points should be adhered to: