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BucyrusAmerica,Inc. 4041WurnoRoad Telephone:540-980-4530 Pulaski,VA24301 Fax:540-994-3763 Internet:www.bucyrus.com OperationManual BUCYRUS VERSATRAC® Model VT650DXP Doc.No.: A6474X279 BI002303

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ThismanualisintendedtoprovideGENERALproductinformationfor theModelVT650DXPVERSATRAC®.Theillustrations,descriptions, andprocedurescontainedinthispublicationapplyonlytoTHISmachine.BucyrusAmerica,Inc.reservestherighttorevisemodelsand designswithoutpriornotice.

Thismachinewasmanufacturedundertheguidelines,procedures,and requirementsoftheU.S.FederalCoalMineHealthandSafetyAct, CodeofFederalRegulations,Title30,Chapter1,Subpart0,Part75for undergroundcoalminesandotherapplicablenon-U.S.regulatory agencystandards.

Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunitwithouttheconsentofBucyrusAmerica, Inc.andtheseregulatoryagencies,oranyrepairorreplacementof partscontrarytoBucyrusAmerica,Inc.’sinstructions,mayinvalidate theseapprovalsandrenderthisunitunsafetooperate.

StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.

Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourBucyrusAmerica,Inc.Service Representative immediately

Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylawsandisprotectedundertheU.S.CopyrightAct of1976,asamended.Thisworkisprovidedunderlicenseandthelicenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.

__________________________________________________________

BI002303

© BUCYRUSAMERICA,INC. ALLRIGHTSRESERVED

________________________________________________ Tableofcontents A6474X279 SUSV/03 ©BUCYRUSAMERICA,INC. Tableofcontents

Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual? 1.4 Charactersandsymbols 1.5

Yoursafety Yoursafety 2.3 Personnel 2.4 Operation 2.4 Installationandrepair 2.4 Operatingconditions 2.5 Intendeduse 2.5 Unauthorizeduse 2.5 Safetyinstructions 2.7 Generalrules: 2.7 Storageandtransport 2.8 Pre-startinspection 2.8 Installationandstart-up 2.9 Operation 2.9 Stopping 2.10 Maintenanceandrepair................................................. 2.10 Dieselemissions 2.11 Handlingofhydraulicfluids ........................................... 2.13 Overviewofthesafetyinstructions 2.17 Chapter2:Safetyinstructions....................................... 2.17 Chapter3:Storageandtransport 2.17 Chapter4:Installation ................................................... 2.17 Chapter5:Operation 2.18 Chapter6:Technicaldata............................................. 2.27 3. Storageandtransport Storageandtransport.............................................................3.3 Storage 3.3 Storageofthemachineandspareparts.........................3.3 Transport 3.4 Beforetransport...............................................................3.5 4. Installation Installation ...............................................................................4.3 Pointstoobservepriortoinstallation...................................4.3 Whoisallowedtocarryoutinstallation? 4.3 Whichtoolsarerequiredforinstallation?........................4.3 Notesoninstallation 4.4 Pre-installationchecklist.................................................4.5 Safetyfeatures 4.6 BI002303

5. Operation

Tableofcontents _________________________________________________ BUCYRUS – ModelVT650DXPVERSATRAC® ©BUCYRUSAMERICA,INC.

Pre-operationsuggestions.....................................................5.3 Operation 5.4 HowtooperatetheVERSATRAC® 5.4 WhoisallowedtooperatetheVERSATRAC® 5.4 Whencanoperationbestarted? 5.4 Controlsandindicators 5.5 Operator’scompartment - leftandcenter 5.5 Operator’scompartment - right 5.6 Hazardzone 5.17 Startingprocedure 5.18 Shutdownprocedure 5.19 Towingadisabledmachine 5.20 Instructionsonthemaintenance 5.23 Importantnotes 5.23 Beforemaintenance 5.23 Criticaltorquevalues.......................................................5.25 Lubricants,fluidsandcapacities 5.25 Specificlubricationandmaintenanceschedule ..............5.26 Specificlubricationandmaintenanceprocedure 5.30 Pre-shift ...........................................................................5.30 Everythirdshift 5.33 Weekly.............................................................................5.40 First50hoursofservice 5.60 Everythreemonths .........................................................5.61 Every100hours 5.66 Every500hours ..............................................................5.68 Everysixmonths 5.70 Everytwelvemonths .......................................................5.72 Servicingheavydutyairfilterelements 5.73 Dieselemissionsmaintenance..................................................5.77 Introduction(emissions) 5.77 Dieselemissions 5.77 Dieselemissionsstalltest 5.79 Operationalissues 5.81 Bestpractices 5.82 Proactiveattitudes 5.85 Typicalexhaustgascomponents 5.87 Carbondioxide 5.87 Carbonmonoxide 5.87 Oxidesofnitrogen 5.87 Hydrocarbons ..................................................................5.87 Particulatematter 5.88 Oxidesofsulfur................................................................5.88 Smoke 5.88 Enginesystemsandconditionsaffectingdieselemissions..5.89 Combustionchamberdesign 5.89 Intakemanifoldsystem....................................................5.91 Operatingconditionsthataffectemissions 5.92 Lowturbochargerboostpressure....................................5.93 Highexhaustbackpressure 5.93 BI002303

________________________________________________ Tableofcontents A6474X279 SUSV/03 ©BUCYRUSAMERICA,INC. Highcrankcasepressure 5.95 Overviewofsixenginesystems 5.96 Overviewofengineintroduction 5.96 Intakesystem 5.97 Drytypeaircleaners 5.98 Airinductionpiping..........................................................5.99 Aftercoolers 5.99 Air-to-airaftercoolers.......................................................5.100 Wateraftercoolers 5.100 Intakesystemrecommendations ....................................5.101 Servicingtheintakesystem 5.102 Jobaidchecklist(IntakeSystem)....................................5.103 Exhaustsystem 5.104 Exhaustsystemrecommendations .................................5.105 Exhaustaftertreatmentsystemmaintenance 5.106 Jobaidchecklistforexhaustsystem...............................5.108 Introductiontotoolsusedforexhaustsystemanalysis 5.109 ECOMAC+gasanalyzer...........................................5.109 UGASsoftwareapplication 5.111 Testingprotocol..........................................................5.111 Pre-testconditions 5.112 Emissionstestingprotocol 5.112 Basicemissionequipmentoperation 5.113 Undiluteddieselparticulatemeasurement 5.113 Measurementinterpretation 5.115 Analysisofparticulatesamples 5.115 Thermalopticalmethod 5.116 Jobaidchecklistforexhaustsystemanalysistools 5.116 ECOMAC+gasanalyzer 5.117 Particulatesampling - Gilianpump 5.117 Intaketesting 5.118 Intakerestrictionsandexhaustbackpressure 5.119 Fuelinjectionsystem 5.120 Introduction(Fuelinjectionsystem) 5.120 Injectionpumporinjectorfailure .....................................5.121 Inadequatefuelsupply 5.121 Incorrectinjectionpumporinjectortiming.......................5.122 Advancedtiming 5.122 Retardedtiming...............................................................5.122 Fuelsystemtypes 5.122 Individualunitjerkpumps................................................5.124 Inlinepumpsystem 5.125 Distributorpumpsystem..................................................5.126 CumminsPTfuelsystem 5.126 Unitinjectors....................................................................5.127 Electronicallycontrolledfuelinjectionsystems 5.127 Fuelinjectionsystemrecommendations 5.128 Jobaidchecklistforfuelsystems 5.129 Coolingsystems 5.130 Coolingsystemrecommendations 5.130 Coolingsystemmaintenance 5.131 Coolantmixture 5.131 Conditionerandinhibitors 5.131 Cleaningandflushing 5.132 BI002303

Tableofcontents _________________________________________________ BUCYRUS – ModelVT650DXPVERSATRAC® ©BUCYRUSAMERICA,INC. Troubleshooting 5.132 Thermostats 5.132 Aerationincoolant 5.132 Radiatorcapreliefvalve 5.133 Temperatureprobe 5.133 Jobaidchecklistforcoolingsystem)...............................5.134 Dieselfuelandfuelsupplysystems 5.135 Introduction(Dieselfuelandfuelsupplysystems)..........5.135 Bestpracticerecommendations 5.135 Sulfurcontent ..................................................................5.136 Cetanenumber 5.136 Viscosity ..........................................................................5.136 Flashpoint 5.136 Fuelqualityandhandlingrecommendations...................5.137 Lubrication 5.138 Lubricationrecommendations.........................................5.138 Lubricationclassification 5.139 Combinedserviceapplications........................................5.140 Lubricationsystemchecks 5.140 Conclusion.......................................................................5.141 Dieselemissions – jobaidchecklist 5.142 Hydraulicsystem 5.143 Adjustmentprocedures 5.145 Pressurecompensated(PC)control 5.145 Mainreliefvalve 5.146 Steeringsectionportreliefvalves 5.147 Pressurelimiter 5.147 Pressurereducingvalve 5.148 Bellcrankbi-directionalvalve 5.148 Auxiliaryreliefvalve 5.150 Dif-lokvalve 5.151 Handpumpreliefvalve 5.152 Replacementofwearparts 5.153 Tire/wheelinstallation 5.153 Axleremoval/installation..................................................5.157 Driveshaftremoval/installation 5.160 Accumulatoroperation/precharging ................................5.161 Ejectorbladeandcylinderremoval/installation 5.163 Canopy/cabremoval .......................................................5.165 Steeringcylinder 5.166 Tiltcylinder ......................................................................5.168 Liftcylinder 5.170 Brakebleedingprocedure...............................................5.172 DSTDrySystem™ 5.173 On-boardCleaningSystem™ .........................................5.173 Background 5.173 Activating 5.173 Diagnosinghighexhaustbackpressure 5.175 Proceduretoreplacetheparticulatefilter 5.177 Replacementexhaustparticulatefilters 5.178 Pre-operatinginspection 5.179 MSHArequirements 5.179 Systemrequirements 5.179 Pre-operatinginspectionchecklist 5.180 BI002303

________________________________________________ Tableofcontents A6474X279 SUSV/03 ©BUCYRUSAMERICA,INC. Operatinginstructions 5.181 Background....................................................................5.181 Startingtheengine 5.181 Startingacoldengine(afterextendedparking) ............5.182 Automaticsafetyshutdownfeatures 5.183 Manualshutdownfeatures ............................................5.184 Excessiveidling 5.184 Operatingrecommendations .........................................5.184 Stoppingtheengineandparkingthemachine 5.185 CarbonMonoxide(CO)samplingprocedure .......................5.186 Background 5.186 Reasonsformonitoringengine-outCOemissions........5.187 ReasonsformonitoringtreatedCOemissions(opt) 5.187 PermanentlyinstalledCOsamplingports .....................5.188 COsamplingprocedure 5.189 COsamplinginstruments 5.190 Maintenanceforflameproofports 5.191 COsamplingrecordkeeping(sampleform) 5.192 Coolingsystemfillingprocedure 5.193 Safetyshutdownsystem 5.194 Systemdescription(pneumaticsystem) 5.194 Startingthesystem 5.195 Manualsystemshutdown 5.195 Manualemergencyshutdown 5.195 Automatictemperatureshutdownfeature 5.195 Automaticlowoilpressureshutdownfeature 5.196 MSHAdocumentation 5.197 Machinepermissibility(drawing624309) 5.197 Powerpackagepermissibility(drawingM255-001-01)........5.205 Electricpackagepermissibility(drawingM261-008-01) 5.217 Generalarrangement(drawing624312)..............................5.222 Electricalschematic(drawingM261-003-01) 5.224 Electricalinstallation(drawingM261-010-01)......................5.225 Alternatorinstallation(drawingM250-107-01) 5.226 Startingcircuit - Cummins8.3(drawingM250-012-01) .......5.227 Coolingsystem(drawingM250-008-01) 5.228 Waterinjectionsystem,pneumatic(drawingM265-006-01)5.229 COmonitoringports(drawingM250-006-01) 5.230 Shutdownsystem(drawingM250-007-01) ..........................5.231 Fuelsystem,C8.3(drawing624310) 5.232 Operator’scompartment(drawing624311) .........................5.233 Troubleshootingprocedures 5.235 Hydraulicsystem(general) 5.236 Brakes 5.239 Hydrauliccylinders 5.240 Hydraulicpump 5.242 Valves 5.244 Engine 5.245 Converter 5.256 Transmission 5.258 Fuelinjector 5.259 Compressor 5.259 Leakingintakesystem 5.261 Airintakesystemrestrictionandfuelflow............................5.261 Catalystfailure 5.261 Exhaustparticulatefilterfailure............................................5.261 BI002303

Tableofcontents _________________________________________________ BUCYRUS – ModelVT650DXPVERSATRAC® ©BUCYRUSAMERICA,INC. 6. Technicaldata Technicaldata .........................................................................6.3 ComponentsoftheVT650DPermissibleVERSATRAC® 6.3 Technicaldata 6.3 Tighteningtorques 6.4 Permissibledata 6.11 Lubricationfluidsandgreases 6.11 7. Foryourinformation Foryourinformation...............................................................7.3 Ourservice...........................................................................7.3 Serviceaddress 7.3 Rebuildfacilityaddress ...................................................7.4 BI002303

_______________________________________________________________ Aboutthismanual BI002303

_______________________________________________________________ BI002303

applicableoperatingmanual machinetype

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.

Beforestartingtowork

Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.

Thisoperatingmanualisintendedfor:

BUCYRUS – ModelVT650DPermissibleVERSATRAC®

SerialNo.:N/A

andisonlypermittedtobeusedforequipmentofthistype.

Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.

Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.

Whoisthisoperatingmanualintendedfor?

Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthemachine.Everypersonworkingonthefaceorintheintersectionbetweenfaceandentryorintheentrymustreadthisoperating manual.

Thisincludespersonswho:

■ areinchargeoftransport

■ performassembly/disassemblywork

■ operatethemachine

■ eliminatefaults

■ performdailyroutineworkonthefaceorintheentry

■ performmaintenancework

■ performrepairwork

andsupervisorypersonnelwho:

■ initiateand/or

■ supervisetheactivitiesjustindicated.

________________________________________Beforestartingtowork A6474X279 SUSV/03 1.3 ©BUCYRUSAMERICA,INC.

BI002303

newoperationmanual

cost-effectiveness

Whatisthepurposeofthisoperatingmanual?

Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothemachine.

Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.

service safety

Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.

Readthechapter“Yoursafety”withspecialattention.Thechaptercontainsimportantinformationindicatingpossiblehazards.Observethe informationgivenandfollowtheproceduralinstructions.

BI002303

Charactersandsymbolsused

Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.

Trytomemorizethesymbolsandtheirmeanings.

DANGER!

Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.

WARNING!

Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.

CAUTION!

Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.

NOTICE!

Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.

IMPORTANT!

Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.

■ Itemsinlistsaremarkedwithbullets.

– Pointsinsub-listsaremarkedwithalongdashatthestart oftheline.

 Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.

BI002303

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL