CAT Bucyrus VT636-2 LONGWALL SHIELD MOVER OPERATION, MAINTENANCE, TROUBLESHOOTING & SERVICE Manual

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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.

SYMBOLS AND SPECIAL NOTATIONS

Throughout this manual there are specific notations that are either UPPERCASE BOLD, UNDERLINED or ITALICIZED for the primary purpose of emphasis Please pay special attention to such statements as they regard safety or critical maintenance installation information.

You will also see the following:

NOTICE: THIS NOTATION DENOTES A REFERENCE TO PREVIOUSLY STATED INSTRUCTIONS

IMPORTANT: THIS SYMBOL DENOTES THAT SPECIAL ATTENTION MUST BE ADHERED TO IN THE ATTACHED STATEMENT.

CAUTION: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A CUT, BRUISE OR ABRASION.

WARNING: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A LOST TIME ACCIDENT.

DANGER: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A SERIOUS INJURY OR FATALITY.

DANGER

ONLY TRAINED AUTHORIZED PERSONNEL SHOULD OPERATE OR PERFORM MAINTENANCE ON THE MODEL VT636-2 VERSATRAC®.

FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH.

FAILURE TO OPERATE OR MAINTAIN THIS VT636-2 VERSATRAC® IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

MAJOR HAZARDS

AREA HAZARD SAFEGUARDS WHERE HAZARD CAN OCCUR WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

HOW TO AVOID THE HAZARD

ENTIRE MACHINE

Movement of machine can run over or crush body parts between machine and other objects and cause irreparable injury or death.

Keep all people out of Hazard Zone (page 19). Use extreme caution when moving machine. The machine should be properly shutdown (see page 29) before the operator leaves the operator's compartment.

OPERATOR'S AREA

Operation of machine with head, arms, or hands outside of operator's compartment could cause irreparable injury or death if body parts strike or are crushed between machine and outside objects.

Keep head, arms, hands, inside operator's compartment at alI times.

Keep the machine’s protective canopy securely in place at all times.

LIFT ATTACHMENT (OR OPTIONAL BUCKET)

Lift plate could be lowered onto feet. Ejector blade of optional bucket could be returned and cause irreparable injury or death if body parts or persons are crushed between ejector blade and the back of the bucket.

Keep alI hands, arms, legs, feet and persons out of way and from between the ejector blade and the back of the bucket. The machine must be properly shutdown for service (see page 29).

CENTER SECTION (ARTICULATION POINT)

Machine could be steered crushing persons, hands, feet, or legs in the articulation area.

Keep all persons, hands, feet, legs, out of articulation area and off the top and out from under the machine. Machine should be properly shutdown (page 29) before servicing. The machine must also be blocked under the battery end, bucket or lift plate, and center section.

The steering lock (page 29) must be installed when working in or around the center section.

UNDERNEATH DURING SERVICE

Machine raised for service could fall and crush persons or body parts underneath.

If machine must be raised for service, it must be securely blocked so that all wheels may safely turn (see maintenance, page 36).

MAJOR HAZARDS (CONT.)

AREA HAZARD SAFEGUARDS WHERE HAZARD CAN OCCUR WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

HOW TO AVOID THE HAZARD

ELECTRICAL (BATTERY, CONTROLLER, MOTORS, ETC.)

Electrical shock could cause irreparable injury or death.

The electrical system should be maintained by certified electricians. The battery should be disconnected before servicing the motors or controller. When the controller cover is removed, allow one minute for the capacitors to discharge.

BATTERY The battery produces lethal amounts of power whether connected to the machine or not.

The battery should be maintained by qualified personnel. (Refer to Bucyrus America "INSTALLATION, USE, MAINTENANCE, AND REPAIR OF MINE POWER STORAGE BATTERIES,” PART NUMBER A6474X26, for complete instructions).

Battery covers could fall crushing hands or arms.

Body parts could be crushed under battery tray.

Batteries produce explosive gases that could be ignited causing burns or explosions.

Batteries contain strong acid that could cause severe burns if spilled or splashed on body parts or in the eyes.

HYDRAULIC If part of a hydraulic circuit is removed while there is a load on a cylinder in the circuit, the cylinder could drop the load.

Be sure cover supports are in place when working on battery.

Keep all body parts from under battery tray.

Batteries should be well vented before servicing particularly if welding or burning on the battery.

Protective clothing, gloves, and eyewear must be worn when working on batteries.

Securely block or remove any load from the cylinder before disconnecting the hose or circuit.

SAFETY PRECAUTIONS AND GUIDELINES OVERVIEW

Before you operate, maintain or in any other way, use this unitREAD 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.

NEVER carry passengers, this will prevent any passenger (s) from being thrown off or crushed between the machine and outside objects.

ALWAYS look in all directions BEFORE changing your direction of travel. The warning gong should be sounded when changing directions.

ALWAYS follow all safety rules of each particular mine when operating the machine.

If problems or equipment malfunctions are encountered while operating the unit, it must be properly shutdown (see page 29) and the problem repaired. Continuing to use malfunctioning equipment can not only be unsafe for the operator and other personnel, but can lead to further damage to the unit as well.

STOPPING

DO NOT leave the operator's compartment with the unit running. ALWAYS properly shutdown the unit (page 29) before leaving the operator's compartment.

ALWAYS park the unit on solid, level ground. If this is not possible, park the unit at a right angle to the slope to prevent accidental movement of the machine.

Use proper flags, warnings or barriers when parking in areas of traffic. Chock all four wheels in both directions whenever possible.

MAINTENANCE

AVOID, whenever possible, servicing, cleaning or examining the machine in congested areas.

AVOID, whenever possible, servicing or providing maintenance to the unit unless the wheels are adequately chocked to prevent accidental movement of the unit.

DO NOT alter the electrical or hydraulic settings from that indicated in this operation guide or as set at the factory.

ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Manual for the proper location and part number of decals and plates.

DISCONNECT the battery when working with the electrical system, or when welding on the unit to prevent electrical shock.

BE SURE the battery area is well ventilated (clear of fumes) when it is necessary to connect battery charger. Fumes from the battery could ignite by a spark and explode.

ALWAYS connect the steering lockout device before performing maintenance.

ALWAYS follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Some illustrations in this manual may show guards or cover panels removed for purposes of clarity. Never operate unit without guards and cover panels in place.

INTRODUCTION

FIGURE 1 – MODEL VT636-2 VERSATRAC®

The Bucyrus America Model VT636-2 VERSATRAC® can be one of the most useful and safe machines found underground today, IF IT IS OPERATED CORRECTLY BY A PROPERLY TRAINED OPERATOR.

Before operating the Model VT636-2 VERSATRAC®, study the illustration (Figure 2, page 9) to become familiar with the controls and read the description of each control. If a word is in quotation marks and capital letters, such as "OFF" or "ON," that word is found as a label on the VERSATRAC®.

MODEL VT636-2 VERSATRAC®

CONTROLS AND INDICATORS

FOOT BRAKE PEDAL (SEE PAGE 9)

FIRE SUPPRESSION ACTUATOR (SEE PAGE 16)

GAUGE PANEL (SEE PAGE 10)

SPEED SWITCH (ACCELERATOR PEDAL) (SEE PAGE 11)

POWER DISCONNECT (SEE PAGE 13)

WARNING GONG (SEE PAGE 18)

TAPE SWITCH (PANIC STRIP) (SEE PAGE 13)

CONTROL STATION (SEE PAGE 12)

STEERING CONTROL LEVER (SEE PAGE 16)

HYDRAULIC CONTROL LEVERS (SEE PAGE 14)

TAPE SWITCH (PANIC STRIP) (SEE PAGE 13)

CIRCUIT BREAKER RESET LEVER (SEE PAGE 17)

SEAT (SEE PAGE 20)

AUTOMATIC EMERGENCY BRAKE RELEASE HAND PUMP (SEE PAGE 18)

DIF-LOK ACTUATOR (OPERATOR SELECT) (SEE PAGE 18)

BEFORE OPERATING ANY LEVERS OR PEDALS ON THE VERSATRAC® ALWAYS MAKE SURE NO ONE IS IN THE HAZARD ZONE (PAGE 19). DO NOT OPERATE ANY LEVERS OR PEDALS FROM OUTSIDE THE OPERATOR'S COMPARTMENT.

FOOT BRAKE PEDAL

The foot brake pedal (Figure 2) is a foot-operated pedal located in front of, and to the left of the operator. The foot brake pedal works similarly to an automobile brake pedal and is normally operated by the left foot. When the Model VT636-2 is first activated, pressure will begin to build up in the brake system

FIGURE 2 – OPERATOR’S COMPARTMENT

accumulator. Once the accumulator-charging valve closes, the brake “ACCUMULATOR” gauge should indicate 1850 PSI (Figure 3 below). When the brakes have been applied enough times to drop the pressure to 1440 PSI, the brake valve should open, allowing pressure to build back up to 1850 PSI. An accumulator in the system allows for approximately three stops should hydraulic pressure to the system malfunction.

IF THE BRAKE ACCUMULATOR PRESSURE DROPS BELOW 1440 PSI, SHUTDOWN THE VERSATRAC® (SEE SHUTDOWN PROCEDURE, PAGE 29) AND CALL A MAINTENANCE PERSON.

“EMERGENCY BRAKE” PRESSURE GAUGE

“ACCUMULATOR” PRESSURE GAUGE

FIRE SUPPRESSION ACTUATOR (SEE PAGE 16)

HYDRAULIC “SYSTEM PRESSURE” GAUGE

“POWER DISCONNECT” SWITCH (SEE PAGE 13)

AUTOMATIC EMERGENCY/PARK BRAKE RELEASE

The automatic emergency/park brake is a spring-applied, pressure-release brake caliper mounted onto the gearbox of the gear motor. The dry disk is mounted on the front output shaft of the gear motor. Any of the following conditions will apply the automatic emergency/park brake:

A. The red tape switch “panic strip” is struck, tripping the circuit breaker.

B. The master switch is in the "OFF" position.

C. The master switch is in the "PARK" position.

D. The emergency manual "POWER DISCONNECT" switch is in the “OFF” position by having been "PUSH"ed in.

FIGURE 3 – GAUGE PANEL

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