CAT Bucyrus VT636-2 Longwall Shield Mover VERSATRAC Operation, Preventive Maintenance Troubleshooting & Service Guide Manual PN A6474X228

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CAT Bucyrus VT636-2 Longwall Shield Mover VERSATRAC Operation, Preventive Maintenance Troubleshooting & Service Guide Manual PN A6474X228 – PDF DOWNLOAD

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CAT Bucyrus VT636-2 Longwall Shield Mover VERSATRAC Operation, Preventive Maintenance Troubleshooting & Service Guide Manual PN A6474X228 – PDF DOWNLOAD

Language : English
Pages : 247
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT Bucyrus VT636-2 Longwall Shield Mover VERSATRAC Operation, Preventive Maintenance Troubleshooting & Service Guide Manual PN A6474X228 – PDF DOWNLOAD

1.CAT Bucyrus VT636-2 Longwall Shield Mover VERSATRAC Operation, Preventive Maintenance Troubleshooting & Service Guide Manual PN A6474X228

PREFACE 1
SYMBOLS AND SPECIAL NOTATIONS 2
MAJOR HAZARDS 4
SAFETY PRECAUTIONS AND GUIDELINES 6
OVERVIEW 6
PRE-START INSPECTION 6
STARTING 6
OPERATING 6
STOPPING 7
MAINTENANCE 7
INTRODUCTION 8
CONTROLS AND INDICATORS 9
FOOT BRAKE PEDAL 9
AUTOMATIC EMERGENCY/PARK BRAKE RELEASE 10
SPEED SWITCH (ACCELERATOR) FOOT PEDAL 11
PUMP START SWITCH 11
LIGHT SWITCH LEVER 12
MASTER SWITCH LEVER 12
EMERGENCY MANUAL “POWER DISCONNECT” SWITCH 13
TAPE SWITCH (PANIC STRIP) 13
GENERAL HYDRAULIC CONTROL SYSTEM INFORMATION 14
“TILT” LIFT FORK AND ATTACHMENT CONTROL LEVER 15
VERTICAL “LIFT” FORK AND ATTACHMENT CONTROL LEVER 15
“WINCH” CONTROL LEVER 15
HYDRAULIC “PTO” 16
“BATTERY” CHANGE CONTROL LEVER 16
“STEERING” CONTROL LEVER 16
FIRE SUPPRESSION ACTUATORS 16
CIRCUIT BREAKER RESET ARM 17
REMOTE CIRCUIT BREAKER RESET LEVER 17
DIF-LOK ACTUATOR (OPERATOR SELECT) 18
AUTOMATIC EMERGENCY/PARK BRAKE RELEASE HAND PUMP 18
WARNING GONG 18
STARTING PROCEDURE 20
PROCEDURES FOR LOADING AND UNLOADING THE LONGWALL ROOF SUPPORT 24
LOADING FROM THE LONG AXIS OF THE SHIELD 24
UNLOADING FROM THE LONG AXIS OF THE SHIELD 24
LOADING FROM THE SIDE OF THE SHIELD 24
TOWING A DISABLED MACHINE 27
SHUTDOWN PROCEDURE 29
Bucyrus America, Inc
Revised 12 – 07
MODEL VT636-2 VERSATRAC®
II
BEFORE MAINTENANCE OR SERVICING ONLY 29
BATTERY CHANGE PROCEDURE 31
GENERAL MAINTENANCE INSTRUCTIONS 36
BEFORE MAINTENANCE OR SERVICING 36
MAINTENANCE CAPACITIES AND SPECIFICATIONS 38
RECOMMENDED LUBRICANTS AND CAPACITIES 40
PERIODIC MAINTENANCE PROCEDURES 41
EVERY THIRD SHIFT 41
ONCE PER WEEK 43
ONCE PER MONTH 48
EVERY THREE MONTHS 50
EVERY THREE MONTHS 51
YEARLY 56
GREASE LUBRICATION CHART 57
EVERY THIRD SHIFT 57
EVERY THREE MONTHS 57
TIRE/WHEEL INSTALLATION PROCEDURE 62
TIRE/WHEEL STRESSES 62
WHEEL MOUNTING ARRANGEMENTS 62
PROBLEM AREAS 63
WHEEL MOUNTING TIPS 63
RECOMMENDED WHEEL MOUNTING PROCEDURES 64
PRECAUTIONS 64
TROUBLESHOOTING PROCEDURES 65
HYDRAULIC SYSTEM (GENERAL) 66
BRAKES 69
HYDRAULIC CYLINDERS 72
HYDRAULIC PUMP 73
MAJOR MAINTENANCE PROCEDURES 76
HYDRAULIC OIL FILL PROCEDURE 76
BRAKE BLEEDING PROCEDURE 77
CONTACTOR TIP REPLACEMENT 78
DRIVE MOTOR/GEAR BOX REMOVAL AND INSTALLATION 79
ACCUMULATOR OPERATION AND PRECHARGING PROCEDURE 81

2.CAT BUCYRUS MINE POWER STORAGE BATTERIES INSTALLATION, USE, MAINTENANCE & REPAIR MANUAL PN A6474X26

PREFACE 1
SYMBOLS AND SPECIAL NOTATIONS 3
MAJOR HAZARDS 5
SAFETY PRECAUTIONS AND GUIDELINES 7
OVERVIEW 7
MAINTENANCE 7
CHAPTER 1 – INTRODUCTION 8
SECTION I GENERAL 8
SECTION II DEFINITIONS 9
SECTION III DESCRIPTION AND CONSTRUCTION 9
SECTION IV PRINCIPLES OF OPERATION 13
CHAPTER 2 – INSTALLATION, USE, AND MAINTENANCE 16
SECTION I PREPARATION FOR USE 16
SECTION II ROUTINE MAINTENANCE 20
CHAPTER 3 – FIELD SERVICING AND REPAIR 25
SECTION I TROUBLESHOOTING 25
SECTION II REPAIRING BATTERIES 26
CHAPTER 4 – HEALTH AND SAFETY 35
SECTION I BATTERY HAZARDS 35
SECTION II SAFETY PROCEDURES 35
CHAPTER 5 – STORAGE AND SHIPMEMT 39

3.CAT BUCYRUS LA5, LA6, LA8, LA10, LA12 & LA14 OPERATION, PREVENTIVE MAINTENANCE, TROUBLESHOOTING, PARTS & SERVICE GUIDE MANUAL A6474X193

PREFACE 1
SYMBOLS AND SPECIAL NOTATIONS 3
MAJOR HAZARDS 5
SAFETY PRECAUTIONS AND GUIDELINES 7
OVERVIEW 7
LOCATION 7
PRE-START 7
STARTING 7
MAINTENANCE 8
PERSONAL PRECAUTIONS 8
THEORY OF OPERATION FERRORESONANT DESIGN 11
INTRODUCTION 13
GENERAL 13
RATINGS AND SPECIFICATIONS 15
OUTPUT RATINGS 15
INPUT RATINGS 15
TYPICAL ELECTRICAL SPECIFICATIONS 15
STANDARD FEATURES 16
OPTIONAL GROUND INTEGRITY 16
ENVIRONMENTAL RATINGS 17
INSTALLATION INFORMATION 19
MINIMUMWIRE SIZES 19
ELECTRICAL CONNECTIONS & FIELDWIRING 19
OPERATION 21
START UP (ELECTRONIC TIMER) 21
ADJUSTMENTS 21
CIRCUIT OPERATION 21
TROUBLESHOOTING 23
GENERAL INSPECTION 23
SERVICE INFORMATION 23
SYMPTOMS AND CAUSES 24
GROUND AND SHORT CIRCUIT TEST 24
TROUBLESHOOTING AND REPLACING POWER SILICON DIODES 25
CHECKING CAPACITORS 25
BATTERY CHARGER REPLACEMENT PARTS 27
491868X3 LA-14 BATTERY CHARGER 480/575 VOLT, 60 HZ 28
491868X4 LA-14 BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 29
491868X5 LA-14-MT BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 30
491868X7 LA-12 BATTERY CHARGER 480/575 VOLT, 60 HZ 31
Bucyrus America, Inc
Revised 12 – 07
MINE POWER II STORAGE BATTERIES
491868X8 LA-12 BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 32
491868X10 LA-10 BATTERY CHARGER 480/575 VOLT, 60 HZ 33
491868X12 LA-8 BATTERY CHARGER 480/575 VOLT, 60 HZ 35
491868X14 LA-8 BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 36
491868X15 LA-6 BATTERY CHARGER 480/575 VOLT, 60 HZ 37
491868X16 LA-6 BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 38
491868X17 LA-5 BATTERY CHARGER 480/575 VOLT, 60 HZ 39
491868X18 LA-5 BATTERY CHARGER 480/575 VOLT, 60 HZ (PA KIT) 40

4.CAT BUCYRUS BUCYRUS 2000 DUAL AND SINGLE MOTOR SOLID STATE CONTROLLERS OPERATION & TROUBLESHOOTING GUIDE MANUAL PN A6474X226

PREFACE 2
SYMBOLS AND SPECIAL NOTATIONS 3
MAJOR HAZARDS 5
SAFETY PRECAUTIONS AND GUIDELINES 6
OVERVIEW 6
MAINTENANCE 6
INTRODUCTION 7
BUCYRUS 2000: INNOVATIVE SPEED CONTROL BY BUCYRUS AMERICA, INC 7
GENERAL SPECIFICATIONS 12
FAIL-SAFE OPERATION WILL INCLUDE THE FOLLOWING: 12
DESCRIPTION OF FEATURES 13
BUCYRUS 2000 MOTOR CONTROLLER CONSIST OF: 13
BUCYRUS 2000 MOTOR IGBT PANEL (POWER CONNECTIONS) 13
MICROPROCESSOR BASED LOGIC CARD (CONTROL INPUTS) 13
CONFIGURATION JUMPER TABLE 15
OPTIONAL DASHBOARD DISPLAY FEATURES (SEE FIGURE 9) 15
FAULT MESSAGE CHART 16
OPTIONAL HAND HELD DIAGNOSTICS/CALIBRATOR UNIT 18
PERSONALITY ADJUSTMENT PROCEDURE 19
TRACTION PERSONALITIES (CONTROLLER ADJUSTMENTS) 19
TRACTION STATUS DISPLAY 21
TRACTION TEST DISPLAY 23
TRACTION BDI DISPLAY 24
ERROR CODE LEGEND (STATUS DISPLAY) 25
TROUBLESHOOTING 26
IGBTMEASUREMENTS 27
INDIVIDUAL IGBT MEASUREMENTS 28
DIODEMEASUREMENTS 29
DIODEMEASUREMENTS 30
PANEL MEASUREMENTS 31
DRIVER MEASUREMENTS 32
IGBT DUAL MOTOR PANEL, FIGURE 16 34
IGBT SINGLEMOTOR PANEL,FIGURE 17 35
IGBT HEAT SINK ASSEMBLY, FIGURE 18 36
SINGLE MOTOR PANEL HARNESS ASSEMBLY, FIGURE 19 37
DUAL MOTOR PANEL HARNESS ASSEMBLY, FIGURE 20 38
DASHBOARD DISPLAY, FIGURE 21 39
DUAL “Y” HARNESS, FIGURE 22 40
HARNESS FOR DASHBOARD DISPLAY, FIGURE 23 41
CALIBRATOR UNIT, FIGURE 24 42
BUCYRUS 2000 PUMPMOTOR SHUNT, FIGURE 25 42
BUCYRUS 2000 PANELWIRING HARNESS, FIGURE 26 43

DESCRIPTION:

CAT Bucyrus VT636-2 Longwall Shield Mover VERSATRAC Operation, Preventive Maintenance Troubleshooting & Service Guide Manual PN A6474X228 – PDF DOWNLOAD

1.CAT Bucyrus VT636-2 Longwall Shield Mover VERSATRAC Operation, Preventive Maintenance Troubleshooting & Service Guide Manual PN A6474X228
2.CAT BUCYRUS MINE POWER STORAGE BATTERIES INSTALLATION, USE, MAINTENANCE & REPAIR MANUAL PN A6474X26
3.CAT BUCYRUS LA5, LA6, LA8, LA10, LA12 & LA14 OPERATION, PREVENTIVE MAINTENANCE, TROUBLESHOOTING, PARTS & SERVICE GUIDE MANUAL A6474X193
4.CAT BUCYRUS BUCYRUS 2000 DUAL AND SINGLE MOTOR SOLID STATE CONTROLLERS OPERATION & TROUBLESHOOTING GUIDE MANUAL PN A6474X226

PREFACE:

• This manual is intended to provide GENERAL product information for the Model
  VT636-2 VERSATRAC®. The illustrations, descriptions and procedures
  contained in this publication apply only to this Model VT636-2 VERSATRAC®.
  Bucyrus America reserves the right to revise models and designs without prior
  notice.
• This Model VT636-2 VERSATRAC® was manufactured under the guidelines,
  procedures and requirements of the U. S. Federal Coal Mine Health and Safety
  Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for
  underground coal mines, and other applicable non-U. S. regulatory agency
  standards.
• At the completion of the manufacturing process, this Model VT636-2
  VERSATRAC® was issued the appropriate approval numbers and nameplates
  indicating it met the technical requirements of these regulatory agencies. Any
  change to the design or structure of this Model VT636-2 VERSATRAC®, without
  the consent of Bucyrus America, and these regulatory agencies, or any repair or
  replacement of parts contrary to Bucyrus America’s instructions, may invalidate
  these approvals and render this Model VT636-2 VERSATRAC® unsafe to
  operate.
• Strict compliance with all Federal and State Mining laws, regulations and
  practices regarding the safe operation and maintenance of underground mining
  equipment and strict adherence to the instructions in this manual is necessary for
  the personal safety of those working on or around this Model VT636-2
  VERSATRAC®.
• While this manual attempts to anticipate the most important operations and maintenance
  needs for this Model VT636-2 VERSATRAC®, unforeseen circumstances may arise
  that have not been addressed in this manual. If any concerns or questions arise,
  please contact your Bucyrus America Service Representative immediately.
• This work contains information protected under trade secret and other intellectual
  property laws, and is protected under the U. S. Copyright Act of 1976, as
  amended. This work is provided under license and the license is nontransferable.
• Distribution and access is limited only to authorized personnel.
• Disclosure, reproduction, distribution or unauthorized use may be a violation of
  federal and state laws and may subject the unauthorized user to criminal liability.

SAFETY PRECAUTIONS AND GUIDELINES:
OVERVIEW:
Before you operate, maintain or in any other way, use this unit –
READ and STUDY this guide. KNOW how to safely use the unit’s controls and what you must do for safe
maintenance.
ALWAYS wear or use the proper safety items required for your personal protection.
If you have ANY QUESTIONS about the safe use or maintenance of this unit:
ASK YOUR SUPERVISOR – NEVER GUESS – ALWAYS CHECK
PRE-START INSPECTION:
Read this entire guide BEFORE attempting to operate this unit. You should be familiar with the controls
and their functions before the unit is energized.
INSPECT your machine by doing a pre-operational inspection. Have any malfunctioning, broken or
missing parts corrected or replaced before use.
VERIFY that all maintenance has been performed.
VERIFY that all the instruction and safety labels are in place and readable. These are as important as
any other equipment on the machine.
CLEAN any foreign material from the operator’s compartment.
THIS Model VT636-2 VERSATRAC® was shipped from the factory equipped with a protective canopy.
This canopy MUST be securely in place before operating the unit.
STARTING:
DO NOT operate any levers or pedals from outside the operator’s compartment to keep the machine from
hitting you or other personnel.
FOLLOW the instructions in the STARTING PROCEDURES section of this guide (page 20).
DO NOT operate any levers or pedals if anyone is in the Hazard Zone (page 19).
BE familiar with the operation of the tape switches and be prepared for the sudden stop when the tape
switches are struck.
OPERATING:
ALWAYS make sure that no person or obstruction is in your line of travel BEFORE starting the unit into
motion or in the articulation area when steering the unit.
NEVER climb onto, or climb out of the machine while it is in motion.
DO NOT operate the machine with any part of your body outside of the operator’s compartment in order
to prevent body parts from being crushed between the machine and objects outside.
USE extreme caution and be observant when working in close quarters or in congested or blind-travel
areas. The warning gong should be sounded to alert personnel of your movement.

Customer Support: [email protected]

S.V