CAT Bucyrus VT636-2 Longwall Shield Mover Operation, Maintenance Troubleshooting & Service Manual

OPERATION, PREVENTIVE MAINTENANCE, TROUBLESHOOTING AND SERVICE GUIDE MODEL VT636-2 LONGWALL SHIELD MOVER ®

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT.

P/N A6474X228 Revision 3, December 2007  BUCYRUS AMERICA 2007 ALL RIGHTS RESERVED

Bucyrus America, Inc. _______________________________________________________________ 4041 Wurno Road Telephone: 540-980-4530 Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.bucyrus.com

Bucyrus America, Inc.

TABLE OF CONTENTS Page 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 I

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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

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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.

 Bucyrus America 2007 All rights reserved.

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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.

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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.

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MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS 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.

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).

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

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MAJOR HAZARDS (CONT.) AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS 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.

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

Body parts could be crushed under battery tray.

Keep all body parts from under battery tray.

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

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

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

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

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.

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

HYDRAULIC

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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.

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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.

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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®.

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CONTROLS AND INDICATORS FIGURE 2 – OPERATOR’S COMPARTMENT FOOT BRAKE PEDAL (SEE PAGE 9)

GAUGE PANEL (SEE PAGE 10)

SPEED SWITCH (ACCELERATOR PEDAL) (SEE PAGE 11)

FIRE SUPPRESSION ACTUATOR (SEE PAGE 16)

POWER DISCONNECT (SEE PAGE 13)

WARNING GONG (SEE PAGE 18)

TAPE SWITCH (PANIC STRIP) (SEE PAGE 13)

HYDRAULIC CONTROL LEVERS (SEE PAGE 14)

CONTROL STATION (SEE PAGE 12) TAPE SWITCH (PANIC STRIP) (SEE PAGE 13)

STEERING CONTROL LEVER (SEE PAGE 16)

SEAT (SEE PAGE 20)

CIRCUIT BREAKER RESET LEVER (SEE PAGE 17)

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 9

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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. FIGURE 3 – GAUGE PANEL “EMERGENCY BRAKE” PRESSURE GAUGE

HYDRAULIC “SYSTEM PRESSURE” GAUGE

“POWER DISCONNECT” SWITCH (SEE PAGE 13)

“ACCUMULATOR” PRESSURE GAUGE

FIRE SUPPRESSION ACTUATOR (SEE PAGE 16)

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.

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E. The circuit breaker is in the "OFF" position.

F. The circuit breaker is in the "TRIPPED" position.

Before the machine is moved, the automatic emergency/park brake must be released. If not released, the machine will not tram. To release the automatic emergency/park brake, first the "CIRCUIT BREAKER" lever and the emergency manual "POWER DISCONNECT" switch must both be in the "ON" position, and the master switch must be in the "FORWARD" or "REVERSE" position. The automatic emergency/park brake is released by the "BRAKE RELEASE" push-button on the front cover panel of the control station enclosure (Figure 4, page 12). You will immediately see the “EMERGENCY BRAKE” pressure gauge on the dash panel increase to about 1850 PSI. (See NOTICE and WARNING below)

IF MACHINE IS EQUIPPED WITH OPTIONAL WET DISC AUTOMATIC PARK BRAKE, EMERGENCY BRAKE PRESSURE GAUGE INCREASES TO APPROXIMATELY 500 PSI. IF MACHINE IS EQUIPPED WITH OPTIONAL WET DISC AUTOMATIC PARK BRAKE, THE "EMERGENCY BRAKE" PRESSURE GAUGE SHOULD NOT BE ALLOWED TO EXCEED 800 PSI OR DAMAGE TO WET DISC BRAKE CAN OCCUR. SHUTDOWN THE MODEL VT636-2 IMMEDIATELY (SEE SHUTDOWN PROCEDURE, PAGE 29) AND CALL A MAINTENANCE PERSON. SHOULD THE "EMERGENCY BRAKE" PRESSURE GAUGE NOT READ THE MINIMUM 1500 PSI, SHUTDOWN THE MODEL VT636-2 IMMEDIATELY (SEE SHUTDOWN PROCEDURE, PAGE 29) AND CALL A MAINTENANCE PERSON.

SPEED SWITCH (ACCELERATOR) FOOT PEDAL This pedal, (Figure 2, page 9), operated by the right foot, is used to start the tram (traveling) motors and regulate the speed of the Model VT636-2 after the emergency manual "POWER DISCONNECT" switch is in the "ON" position and the master switch lever is in either the "FORWARD" or "REVERSE" position.

THE SPEED SWITCH (ACCELERATOR) FOOT PEDAL SHOULD NOT BE DEPRESSED AT THE SAME TIME AS THE FOOT BRAKE PEDAL. TO DO SO MAY OVERLOAD THE TRAM MOTORS AND COULD SHORTEN THEIR USEFULNESS. THE MODEL VT636-2 IS PROVIDED WITH OVERLOAD PROTECTION, BUT CONTINUED ABUSE COULD SHORTEN MOTOR LIFE. BEFORE OPERATING ANY PEDALS OR LEVERS ON THE MODEL VT636-2, ALWAYS MAKE SURE THAT NO ONE IS IN THE HAZARD ZONE (PAGE 19).

DO NOT OPERATE ANY LEVERS OR PEDALS FROM OUTSIDE THE OPERATOR'S COMPARTMENT.

PUMP START SWITCH The pump start switch is a push-button located on the front cover panel of the control station enclosure (Figure 4, page 12). If the emergency manual "POWER DISCONNECT" switch is in the "ON" position (pulled out), and the master switch is in either the "FORWARD", "REVERSE" or "PARK" position, and the pump start switch is pushed, the hydraulic pump's electric motor will operate, making a whining sound.

This is normal.

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LIGHT SWITCH LEVER The light switch (Figure 4 below), located on the side of the control station enclosure to the left of the operator's seat, turns on either one pair or the other of the headlights. Two headlights are located on the front and two headlights are located on the rear of the Model VT636-2.

MASTER SWITCH LEVER The master switch lever (Figure 4 below) is located on the side of the control station enclosure to the left of the operator. If the emergency manual “POWER DISCONNECT” switch is in the “ON” position (pulled out), and the master switch is in the “FORWARD”, “REVERSE” or “PARK” position, and the pump start push-button, located on the front of the control station is pushed, the hydraulic pump's electric motor will operate, making a whining sound. This is normal. “FORWARD” position on the master switch means that the Model VT636-2 is ready to tram forward in the direction of the lift attachment (or bucket). “REVERSE” position of the master switch means that the Model VT636-2 is ready to tram backwards. The speed switch (accelerator pedal) must be depressed before the Model VT636-2 will move in either direction.

To change the direction of travel: 1. Release the speed switch foot pedal.

2. Stop the Model VT636-2 by depressing the foot brake pedal.

3. Change the position of the master switch.

4. Release the foot brake pedal.

5. Depress the speed switch foot pedal.

FIGURE 4 – CONTROL STATION BRAKE RELEASE

“LIGHTS” “FRONT”

“REAR”

“PUMP START” SWITCH

“OFF”

“OFF” “REVERSE” “PARK”

“FORWARD”

“TRAM”

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EMERGENCY MANUAL "POWER DISCONNECT" SWITCH The emergency manual "POWER DISCONNECT" switch, (Figure 5 below), located to the right side of the dash panel, has two positions; on ("PULL"ed out) for normal operations and off ("PUSH"ed in) to disconnect the motors electrically. The emergency manual "POWER DISCONNECT" switch allows the operator to disconnect the motors by pushing only one button.

BE PREPARED FOR A SUDDEN STOP WHEN THE PANIC STRIP OR EMERGENCY MANUAL “POWER DISCONNECT” SWITCH IS STRUCK. IN AN EMERGENCY, THE OPERATOR CAN STOP THE MODEL VT636-2 BY PUSHING THE EMERGENCY MANUAL "POWER DISCONNECT" SWITCH TO THE “OFF” POSITION (PUSHED IN) AND DEPRESSING THE FOOT BRAKE PEDAL, OR BY STRIKING THE PANIC STRIP (S) AND DEPRESSING THE FOOT BRAKE PEDAL. THE EMERGENCY MANUAL "POWER DISCONNECT" SWITCH AND PANIC STRIP (S) ARE NOT INTENDED AS AN “ON”-”OFF" DEVICE FOR NORMAL OPERATION. THE MASTER SWITCH SHOULD BE MOVED TO THE “OFF” POSITION BEFORE MOVING THE EMERGENCY MANUAL “POWER DISCONNECT” SWITCH TO THE "OFF”- POSITION (SEE SHUTDOWN PROCEDURE, PAGE 29).

FIGURE 5 – EMERGENCY MANUAL “POWER DISCONNECT” SWITCH

EMERGENCY MANUAL “POWER DISCONNECT” SWITCH

TAPE SWITCH (PANIC STRIP) The two tape switches “panic strips” (Figure 2, page 9) are located on both the left and right side of the operator on top edge of the operator’s compartment. Striking either “panic switch” electrically disconnects the Model VT636-2's motors, and allows the automatic emergency/park brake to engage.

BE PREPARED FOR A SUDDEN STOP WHEN THE PANIC STRIP (S) OR EMERGENCY MANUAL “POWER DISCONNECT” SWITCH IS STRUCK.

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GENERAL HYDRAULIC CONTROL SYSTEM INFORMATION Inside of the operator's compartment to the right are six control levers. These levers control the lift forks and optional QA Lift Plate attachment or bucket in the "TILT" or the bellcrank "LIFT" position, the "WINCH", hydraulic "PTO", "BATTERY" changer cylinders by means of valves in the hydraulic system.

There is also a "SPARE" for optional equipment use. Also, to the left in the operator's compartment is the "STEERING" control lever. To the right of the operator’s seat is the optional "DIF-LOK" actuator switch (Figure 2, page 9). The hydraulic system pressure relief is set at 2250 PSI at the factory and should not be changed. Before the hydraulic system is activated, the system pressure gauge should indicate 0 PSI. After the machine is activated, the pressure should indicate no more than 2250 PSI (Figure 3, page 10).

MAKE SURE NO ONE IS IN THE HAZARD ZONE (PAGE 19) BEFORE OPERATING ANY LEVERS OR PEDALS. BECAUSE THE MODEL VT636-2 IS ARTICULATED (HINGED) IN THE CENTER, ANYONE IN THE HAZARD ZONE MAY BE SERIOUSLY INJURED IF THE UNIT IS STEERED.

IF THE HYDRAULIC “SYSTEMS PRESSURE” GAUGE (FIGURE 3, PAGE 10) SHOWS MORE THAN 2250 PSI, SHUTDOWN THE MODEL VT636-2 AND CALL A MAINTENANCE PERSON (SEE SHUTDOWN PROCEDURE, PAGE 29).

FIGURE 6 – HYDRAULIC CONTROL LEVERS “TILT” “LIFT” “WINCH”

“PTO” “BATTERY”

OPTIONAL HYDRAULIC ACCESSORY

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DO NOT MOVE THE “TILT” OR “LIFT” ATTACHMENT CONTROL LEVER IF ANYONE IS NEAR ENOUGH TO THE LIFT ATTACHMENT TO HAVE ANY PART OF THE BODY UNDERNEATH.

“TILT” LIFT FORK AND ATTACHMENT CONTROL LEVER The first control lever from the top (Figure 6, page 14) controls the forks and attachments (or optional bucket, if the Model VT636-2 is equipped with a bucket) in the tilting mode. The forks or lift attachment is hinged at the bottom and moved by two (2) hydraulic cylinders attached near the top. The "TILT" lift attachment control lever allows the operator to tilt the lift attachment up (back) or down (forward). The lift attachment control lever has three (3) positions: "DOWN," "UP," and "NEUTRAL." To tilt the lift attachment forward, push the lever to the “DOWN” position.

IF THE LIFT ATTACHMENT CONTROL LEVER IS HELD IN THE “DOWN” POSITION, THE LIFT ATTACHMENT OR BUCKET WILL CONTINUE TO LOWER UNTIL IT RAISES THE FRONT WHEELS OF THE MODEL VT636-2 OFF THE SURFACE. To tilt the lift attachment backward, pull the lever to the “UP” position.

THE LIFT ATTACHMENT LEVER WILL ALWAYS RETURN TO THE NEUTRAL POSITION WHEN RELEASED. COUNTER BALANCE VALVES ON THE CYLINDERS TRAPS FLUID IN THE CYLINDERS, HOLDING THE LIFT ATTACHMENT IN ANY DESIRED POSITION. WHEN EQUIPPED WITH AN OPTIONAL BUCKET, ALWAYS KEEP ANY OBSTRUCTION FROM BEHIND THE EJECTOR BLADE SO IT CAN RETURN COMPLETELY TO THE BACK OF THE BUCKET. BEFORE MOVING THE “EJECTOR” BLADE CONTROL LEVER, ALWAYS CHECK TO MAKE SURE NO ONE HAS ANY PART OF THEIR BODY BETWEEN THE EJECTOR BLADE AND THE BACK OF THE BUCKET.

VERTICAL “LIFT” FORK AND ATTACHMENT CONTROL LEVER The second lever from the top (Figure 6, page 14) operates the bellcrank vertical "LIFT" function. The vertical "LIFT" is used to raise the fork or attachments up or down. When the "LIFT" control lever is pulled toward the operator, the bellcrank will raise the forks and any attachments to it. When the "LIFT" control lever is pushed away from the operator, the bellcrank will lower the forks and any attachments to it.

"WINCH" CONTROL LEVER The third lever (Figure 6, page 14), located to the operator's right, controls the "WINCH" and wire rope system. When the control lever is pulled toward the operator, the winch reels in. When pushed out, the winch reels out.

THE WINCH CIRCUIT IS EQUIPPED WITH A LOAD SENSING VALVE THAT ALLOWS ROPE TO BE REELED IN AT HIGH SPEED / LOW TORQUE. AFTER A LOAD IS SENSED, THE CIRCUIT WILL AUTOMATICALLY SWITCH TO LOW SPEED / HIGH TORQUE. 15

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HYDRAULIC “PTO” The fourth lever (Figure 6, page 14), located to the operator's right, controls the hydraulic "PTO". Pulling the lever pressurizes the "B" port and pushing the lever pressurizes the "A" port.

DO NOT OPERATE THE HYDRAULIC PTO CONTINUOUSLY FOR MORE THAN 30 MINUTES AT A TIME. NEVER BLOCK OR TIE “PTO” FUNCTION TO ACTIVE POSITION.

“BATTERY” CHANGE CONTROL LEVER The fifth lever from the top (Figure 6, page 14) controls the battery changer system which is made up of two hydraulic cylinders, and a battery lift assembly. When the battery change control lever is pulled, the battery lifting mechanism raises. When pushed, the battery lifting mechanism is lowered.

The battery can be lowered to the ground for battery change without tables or pedestals of any kind or raised fully in the up position to increase frame clearance.

FOR MORE INFORMATION ON HOW TO CHANGE THE BATTERY, SEE THE BATTERY CHANGE PROCEDURE (PAGES 31 THROUGH 35). IF THE MODEL VT636-2 IS IN A LOW ROOF AREA, THE BATTERY MAY BE DAMAGED IF RAISED TOO HIGH OR DRAGGED IF LOWERED TO THE SURFACE. NEVER ATTEMPT TO DISCONNECT A HYDRAULIC HOSE FROM THE BATTERY LIFTING CYLINDERS WITH THE BATTERY IN THE “UP” POSITION. IF MAINTAINANCE IN "UP" POSITION IS EVER REQUIRED ALWAYS BLOCK THE LIFT MECHANISM UP WITH CRIB BLOCKS. NEVER ALLOW ANY PART OF THE BODY TO BE UNDER THE BATTERY IN THE RAISED POSITION. THE BATTERY COULD FALL AND WOULD RESULT IN INJURY OR DEATH.

“STEERING" CONTROL LEVER The left control lever, (Figure 2, page 9), which is also the highest control lever, is used to control the steering of the Model VT636-2. To steer left, push the steering control lever slowly away from the operator. To steer right, pull the steering control lever slowly toward the operator. If the steering control lever is jerked or moved too fast, the Model VT636-2 will jerk and move too fast to the turning limit. This fast movement is dangerous in a crowded area or a narrow space. The steering control is designed for slow movement by opening the control valve a small amount (moving the steering control lever a short distance) and for fast movement by opening the valve all the way (moving the steering control lever all the way to the limit of its travel). This steering arrangement is considered to be normal for the Model VT636-2.

FIRE SUPPRESSION ACTUATORS The fire suppression actuators (Figure 2, page 9 and Figure 7, page 17) are located to the operator's left on the dash and on the left side of the middle frame. This system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system, pull the safety pin and strike forward on the plunger on the end of the actuator. Immediately after the plunger is struck, dry chemical will be dispensed throughout the Model VT636-2. Also, there is a remote actuator located in front of the left rear wheel well of the Model VT636-2 and it too is activated by pulling the safety pin and striking downward on the plunger on the end of the actuator.

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Bucyrus America, Inc.

FIGURE 7 – FIRE SUPPRESSION ACTUATORS

CIRCUIT BREAKER RESET ARM The circuit breaker reset arm (Figure 8 below) is located at the rear of the Model VT630 in front of the battery. The circuit breaker reset arm has four (4) positions: "OFF," TRIPPED," "RESET," and "ON".

REMOTE CIRCUIT BREAKER RESET LEVER The remote circuit breaker reset lever (Figure 2, page 9) is located to the right of the operator's seat. The remote circuit reset breaker lever should be in the "OFF" or "TRIPPED" position (turned forward) before the Model VT636-2 is serviced or when the battery or plugs are being connected or disconnected.

THE CIRCUIT BREAKER TRIPS WHEN ONE OF THE FOLLOWING OCCURS: THE ELECTRICAL SYSTEM IS OVERLOADED OR SHORTED PANIC STRIP (S) IS STRUCK DISCONNECT SWITCH IS MOVED TO THE “OFF” POSITION BATTERY IS DISCONNECTED After the circuit breaker has been tripped, it will not stay in the "ON" position without first being moved to the "RESET" position, and then to the "ON" position.

FIGURE 8 – CIRCUIT BREAKER/CONNECTION BOX

RESET

17

OFF

ON

TRIPPED

Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

DIF-LOK ACTUATOR (OPERATOR SELECT) The operator controlled “DIF-LOK” actuator is a hand operated hydraulic push-button located to the right of the operator’s seat (Figure 2, page 9). When actuated, pushed in with the hand, the differential locks are engaged in both the front and rear axles. Releasing the push-button deactivates the differential lock.

THE DIF-LOK (OPERATOR SELECT) SHOULD NOT BE ENGAGED DURING SPIN-OUT OR WHILE IN A TURN OR DAMAGE TO THE AXLE CAN OCCUR.

AUTOMATIC EMERGENCY/PARK BRAKE RELEASE HAND PUMP The automatic emergency/park brake release hand pump is located to the operator's right (Figure 2, page 9). The release pump allows the automatic emergency/park brakes to be released for towing purposes when the machine is deenergized and normal brake release is not possible (see Towing Procedure, page 27).

To release the automatic emergency/park brake with the machine de-energized: A. Turn the selector valve handle to "PUMP TO RELEASE".

B. Remove the pump handle retaining pin.

C. Pump the hand pump until the “EMERGENCY BRAKE" gauge reads the minimum l500 PSI. To reset the emergency/park brake: A. Turn the selector valve handle on the "EMERGENCY BRAKE RELEASE HAND PUMP" to the "NORMAL RE-APPLY" position.

B. Push the hand pump handle down and reinstall the retainer pin.

IF MACHINE IS EQUIPPED WITH OPTIONAL WET DISC AUTOMATIC PARK BRAKE, EMERGENCY BRAKE PRESSURE GAUGE INCREASES TO APPROXIMATELY 500 PSI. IF MACHINE IS EQUIPED WITH OPTIONAL WET DISC AUTOMATIC PARK BRAKE, THE "EMERGENCY BRAKE" PRESSURE GAUGE SHOULD NOT BE ALLOWED TO EXCEED 800 PSI OR DAMAGE TO WET DISC BRAKE CAN OCCUR. SHUTDOWN THE MODEL VT636-2 IMMEDIATELY (SEE SHUTDOWN PROCEDURE, PAGE 29) AND CALL A MAINTENANCE PERSON.

WARNING GONG The warning gong (Figure 2, page 9), is located to the operator's right. It is sounded by striking the knob in the center of the gong. This warning gong should be used in accordance with the safety standards at the mine where the VERSATRAC® will be used.

THIS COMPLETES CONTROLS AND INDICATORS

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HAZARD ZONE THE HAZARD ZONE EXISTS UNLESS: A. The emergency manual “POWER DISCONNECT” switch is in the “OFF” position AND the parking brake is set OR; B. The circuit breaker is tripped AND the parking brake is set.

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STARTING PROCEDURE After reading the previous descriptions and locating each control, the operator is ready to operate the Model VT636-2. An experienced operator should monitor a new operator's indoctrination to the starting procedure.

EXCEEDING 5 MPH (8 kph) WITH THIS MACHINE WILL RESULT IN TRAM MOTOR FAILURE.

CHECK THE BATTERY CONNECTIONS AND THE BATTERY COVERS. THEY MUST BE IN PLACE AND LOCKED TO BE PERMISSIBLE (FIGURE 21, PAGE 35).

NEVER OPERATE ANY LEVERS OR PEDALS FROM OUTSIDE THE OPERATOR'S COMPARTMENT. ALL SWITCHES IN THE OPERATOR'S COMPARTMENT MUST BE IN THE “OFF” POSITION BEFORE THE BATTERY CIRCUIT BREAKER IS MOVED TO THE “ON” POSITION. THIS UNIT IS EQUIPPED WITH A CAB OR CANOPY. BE CAREFUL NOT TO HIT YOUR HEAD WHEN ENTERING OR LEAVING THE OPERATOR'S COMPARTMENT. THIS MACHINE MUST NOT BE OPERATED WITHOUT THE CANOPY IN PLACE. To operate the Model VT636-2, use the following procedure.

1. Sit in the operator's seat.

2. The Model VT636-2 is equipped with an adjustable seat that will adjust closer or farther from the foot pedals (Figure 9, page 21). If adjustment is required: A. Adjust the seat height for maximum visibility available within operating limits. The seat height is adjusted by relocating the seat mounting plate up or down using the four mounting bolts.

B. Adjust the position of the seat back to proper position.

C. Adjust the seat bottom tilt to proper position.

D. Adjust the seat position relative to the foot and hand controls.

3. Before starting the Model VT636-2, ensure that the light and master switches are in the "OFF" position.

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FIGURE 9 – SEAT ADJUSTMENT

SEAT BOTTOM ADJUSTMENT

SEAT BACK TILT ADJUSTMENT

SEAT BOTTOM TILT ADJUSTMENT

4. "PULL" the emergency manual "POWER DISCONNECT" switch to the “ON” position and turn the main circuit breaker to the “ON” position.

MAKE SURE NO ONE IS IN THE HAZARD ZONE (PAGE 19) WHILE THE CIRCUIT BREAKER AND EMERGENCY MANUAL "POWER DISCONNECT" SWITCHES ARE IN THE "ON" POSITION. 5. Move the light switch to turn on the headlights, as desired, in the direction of travel. The light switch will click when it is placed in either "ON" position.

6. Select "PARK" on the control station panel using the master switch. "FORWARD" position of the master switch means that the Model VT636-2 is ready to tram forward in the direction of the lift attachment; "REVERSE" position of the master switch means that the Model VT636-2 is ready to tram in the opposite direction. When the master switch is moved to the "PARK", "FORWARD" or "REVERSE" position, the hydraulic pump's electric motor can be started, making a whining sound.

7. Push and hold for 1 second the pump motor start button on the front cover of the control station enclosure until a whining sound is heard. The charging and unloading valve will automatically recharge the accumulator if it is below the 1440 PSI recharge level. The "ACCUMULATOR PRESSURE" gauge will indicate the moving up of the pressure until the pressure 1850 PSI is reached.

8. Check the service brake by pumping the foot brake pedal two times. The "ACCUMULATOR PRESSURE" gauge will drop incrementally with each actuation. Continue to actuate the brake pedal until the "ACCUMULATOR PRESSURE" gauge drops to a point that the charging and unloading valve 21

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Bucyrus America, Inc.

recharges it which should be about 1440 PSI - the pump motor will make a higher pitched sound as the accumulator is recharged. If the gauge does not indicate this, shutdown the Model VT636-2 (see SHUTDOWN PROCEDURE, page 29) and call a maintenance person.

If the "ACCUMULATOR PRESSURE" gauge bleeds off, call a maintenance person. Or, if it falls below 1440 PSI and does not automatically recharge, call a maintenance person.

9. If the whining sound is heard, go to step 10. If the whining sound is NOT heard, complete steps A - D below.

A. Move the master switch to the "OFF" position.

B. "PUSH" the emergency manual "POWER DISCONNECT" switch into the “OFF” position.

C. Move the light switch to the "OFF" position.

D. Check the circuit breaker; if it is in the "ON" position, call a maintenance person; if it is in the "TRIPPED" position, reset it, and repeat steps 3, 4, and 5. If the whining sound is still not heard, call a maintenance person; if it is heard, proceed to step 10.

BEFORE OPERATING ANY LEVERS OR PEDALS, MAKE SURE NO ONE IS IN THE HAZARD ZONE (PAGE 19).

10. Using the "TILT" and "LIFT" control lever, raise the fork and lift attachment to desired level so it will not drag the surface.

11. Using the "BATTERY" control lever, raise the battery up to desired level or until it is no longer on the ground.

12. Move the steering control lever slowly back and forth to get the feel of how the Model VT636-2 will steer.

13. The warning gong (Figure 2, page 9), found to the operator's right, is sounded by hitting the knob in the center of the gong. This warning gong should be used in accordance with the safety standards at the mine where the Model VT636-2 is being used.

14. While holding the foot brake pedal depressed, switch the master switch to desired direction of travel "FORWARD" or "REVERSE".

15. Release the automatic "EMERGENCY BRAKE" by pushing the "BRAKE RELEASE” push-button on the front of the control station. The "EMERGENCY BRAKE" pressure gauge indicates the required minimum 1500 PSI (Figure 3, page 10).

THE MODEL VT636-2 EMERGENCY BRAKE WILL NOT RELEASE IF THE MASTER SWITCH IS NOT IN “FORWARD” OR “REVERSE” POSITION.

SHOULD THE "EMERGENCY BRAKE" PRESSURE GAUGE NOT READ A MINIMUM OF 1500 PSI FOR DRY DISC BRAKE OR 800 PSI FOR WET DISC BRAKE, SHUTDOWN THE MODEL VT636-2 IMMEDIATELY (SEE SHUTDOWN PROCEDURE, PAGE 29), AND CALL A MAINTENANCE PERSON. 22

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16. The Model VT636-2 is now ready to tram (travel). Slowly release the foot brake pedal, and then slowly depress the speed switch foot pedal.

THIS MODEL VT636-2 HAS A SOLID STATE SPEED CONTROLLER. THIS MEANS THAT THE FARTHER THE SPEED SWITCH FOOT PEDAL IS DEPRESSED, THE FASTER THE MODEL VT636-2 WILL TRAM. 17. The Model VT636-2 can be stopped at any time in case of an emergency by moving the emergency manual “POWER DISCONNECT” switch to the “OFF” position (PUSH'ed forward) and depressing the foot brake pedal, or by striking the “panic strip” and depressing the foot brake pedal.

BE PREPARED FOR A SUDDEN STOP WHEN THE PANIC STRIP OR EMERGENCY MANUAL DISCONNECT SWITCH IS STRUCK.

THIS COMPLETES THE STARTING PROCEDURE.

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PROCEDURES FOR LOADING AND UNLOADING THE LONGWALL ROOF SUPPORT LOADING FROM THE LONG AXIS OF THE SHIELD 1. Approach from the support end of the shield (Figure 10 below).

2. Slide the lift attachment completely under the shield.

3. Raise the lift attachment until either the tip of the support touches the front frame on the Model VT636-2 or the lift is level.

THE WINCH MAY BE REQUIRED TO ASSIST IN PULLING THE SUPPORT ONTO THE LIFT PLATE. ( SEE PAGE 15 FOR “WINCH” OPERATION)

4. After properly securing the shield to prevent any unplanned movement, transport the shield.

FIGURE 10 – DEPICTING APPROACH

UNLOADING FROM THE LONG AXIS OF THE SHIELD 1. Lower the lift attachment until the shield touches the surface.

2. Back the Model VT636-2 away from the shield until the lift attachment is completely clear of the shield.

LOADING FROM THE SIDE OF THE SHIELD 1. Approach from either side of the shield (Figure 11, page 25).

2. If the shield is on chocks, slide the lift attachment completely under the shield until the backstop of the lift attachment touches the shield.

If the shield is not on chocks, use the following procedure:

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Bucyrus America, Inc.

A. Slide the lift attachment about six (6) inches under the side of the shield. It may be necessary to lower the lift attachment slightly below grade to reach under the shield, starting from a point about one inch from the side of the shield.

B. Lift the side of the shield about six (6) inches from the surface.

C. Slide the lift attachment under the shield until about six (6) inches remain between the leading edge of the lift and the side of the shield away from the Model VT636-2.

3. Raise the lift attachment until it is level.

4. After properly securing the shield to prevent any unplanned movement, transport the shield.

IF THE SHIELD MUST BE MOVED A LONG DISTANCE, IT SHOULD BE RESTING AGAINST THE BACKSTOP OF THE LIFT. IF IT IS NOT (SEE SECTION ABOVE), IT CAN BE PULLED BACK AGAINST THE BACKSTOP WITH THE WINCH. FIGURE 11 – APPROACHING SHIELD FROM THE SIDE

FIGURE 12 – LOADED CHOCK

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

UNLOADING FROM THE SIDE OF THE SHIELD 1. Lower the lift attachment until the shield touches the surface or the chocks.

2. Back the Model VT636-2 away from the shield until the lift attachment is completely clear of the shield.

IF THE SHIELD IS NOT BEING PLACED ON BLOCKS, IT MAY BE NECESSARY TO LOWER THE LIFT ATTACHMENT SLIGHTLY BELOW GRADE BEFORE THE SHIELD WILL BEGIN TO SLIDE AWAY FROM IT.

THIS COMPLETES THE PROCEDURES FOR LOADING AND UNLOADING THE LONGWALL SHIELD.

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Bucyrus America, Inc.

TOWING A DISABLED MACHINE IT IS NOT POSSIBLE, WITHIN THE SCOPE OF THIS GUIDE, TO ANTICIPATE ALL POSSIBLE ARRANGEMENTS FOR TOWING A DISABLED UNIT. BEFORE ATTEMPTING TO TOW ANY VEHICLE, YOU MUST TAKE ALL POSSIBLE PRECAUTIONS TO PROTECT THE OPERATORS AND ANY ONE AROUND BOTH VEHICLES FROM BEING INJURED BY EITHER THE TOWING VEHICLE, THE TOWING DEVICES OR THE VEHICLE BEING TOWED. THE PRIMARY TOWING DEVICE USED (CABLES, BARS, ETC.) AND THE TOWING VEHICLE (SCOOP, TRACTOR, ETC.) MUST BE STRONG AND HEAVY ENOUGH TO MAINTAIN CONTROL OF BOTH VEHICLES THROUGH ALL BOTTOM CONDITIONS TO BE ENCOUNTERED AT ALL TIMES. SAFETY CHAINS OR OTHER SAFETY DEVICES MUST BE USED IN CASE OF FAILURE OF THE PRIMARY TOWING DEVICE. ALL OPERATORS MUST BE ALERT AT ALL TIMES TO PREVENT EITHER UNIT FROM "RUNNING AWAY" OR RUNNING OUT OF CONTROL DURING TOWING. THE VEHICLE TO BE TOWED MUST BE SECURELY COUPLED TO THE TOWING VEHICLE BEFORE THE BRAKES ARE RELEASED ON THE DISABLED UNIT. THE OPERATOR OF THE TOWING VEHICLE MUST BE IN PLACE IN THE TOWING VEHICLE WITH THE BRAKES APPLIED BEFORE THE BRAKES OF THE DISABLED VEHICLE ARE RELEASED. 1. Couple the towing vehicle securely to the disabled vehicle.

2. Turn the valve selector handle (Figure 13) to “PUMP TO RELEASE” on the Emergency/Park Brake Release Hand Pump (this isolates the park brake solenoid from the circuit).

FIGURE 13 – EMERGENCY/PARK BRAKE RELEASE HAND PUMP

VALVE SELECTOR

3. Begin pumping the hand pump. The building pressure moves the shuttle valve and allows the Automatic (Park) Brake system to be pressurized.

4. The Automatic (Park) Brake is “released” when a minimum of 1500 PSI for dry disc brake or 800 PSI for wet disc brake is indicated by the Brake Release gauge.

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Bucyrus America, Inc.

FOR LONG DISTANCE TOWING, DISCONNECT AND REMOVE FRONT AND REAR DRIVE LINES. AT NO TIME DURING TOWING SHOULD ANYONE RIDE IN OR ON THE VEHICLE BEING TOWED OR STAND IN BETWEEN THE TOWING VEHICLE AND THE DISABLED VEHICLE. 5. Begin towing the vehicle.

6. Once the destination is reached, stop both vehicles and set the parking brake on the disabled vehicle before removing the towing devices. The disabled vehicle should be choked in both directions at all four wheels for additional stability. The brake is "set' by turning the valve handle on the hand-pump to “NORMAL RE-APPLY”.

FAILURE TO SET THE PARKING BRAKE ON THE DISABLED VEHICLE BEFORE REMOVING THE TOWING DEVICE COULD ALLOW THE DISABLED VEHICLE TO ROLL AWAY UNCONTROLLED.

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SHUTDOWN PROCEDURE 1. Stop the Model VT636-2 by releasing the speed switch foot pedal and depressing the foot brake pedal.

When the speed switch foot pedal is released, the tram (traveling) motors will stop. Applying the foot brake will stop forward or reverse motion. The hydraulic pump's electric motor will still be running, making a whining sound.

ALWAYS CHECK BEFORE MOVING THE EJECTOR BLADE CONTROL LEVER TO MAKE SURE NO ONE HAS ANY PART OF THEIR BODY BETWEEN THE EJECTOR BLADE AND THE BACK OF THE BUCKET. 2. If the Model VT636-2 is equipped with the optional QA bucket attachment, pull the ejector blade control lever toward the operator to move the ejector blade to the back of the bucket. There should be no obstructions behind the ejector blade.

CHECK TO BE SURE THAT NO PART OF ANYONE'S BODY IS UNDER THE LIFT ATTACHMENT BEFORE LOWERING IT TO THE SURFACE.

3. Push the lift attachment control lever to the "DOWN" position. This will lower the lift attachment to the surface.

4. Move the master switch lever to the "OFF" position. This should stop the hydraulic pump's electric motor and apply the automatic emergency/park brake.

5. Move the light switch lever to the "OFF" position to turn off the headlights.

6. Push the emergency manual "POWER DISCONNECT" switch button to the "OFF" (in) position.

7. It is now safe to leave the Model VT636-2.

BEFORE MAINTENANCE OR SERVICING ONLY 8. Connect the steering lockout device (Figure 14, page 30): A. Remove the steering lockout device from its storage lugs.

B. Remove the hitch pin from the end farthest from the center section.

C. Adjust turnbuckle until holes line up between the turnbuckle lug and the front section lug.

D. Insert the hitch pin into the front section lug through the turnbuckle.

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FIGURE 14 – STEERING LOCKOUT DEVICE STORAGE LOCATION

LOCKED LOCATION

LOCKED LOCATION

NEVER ENTER THE ARTICULATION AREA WHILE THE MODEL VT636-2 IS RUNNING. COMPLETELY SHUTDOWN THE MODEL VT636-2 AS OUTLINED BEFORE CONNECTING THE STEERING LOCKOUT DEVICE. FAILURE TO OBSERVE THIS PRECAUTION MAY RESULT IN SERIOUS INJURY OR DEATH. THE MODEL VT636-2 IS EQUIPPED WITH A CAB OR CANOPY; BE CAREFUL NOT TO HIT YOUR HEAD WHILE ENTERING OR LEAVING THE OPERATOR'S COMPARTMENT. In the event of an emergency, the Model VT636-2 may also be shutdown by striking the panic strip or the emergency "POWER DISCONNECT" switch. When the panic strip is struck, the circuit breaker will automatically trip. This action electrically disconnects the battery, shutting down the Model VT636-2 and applying the automatic emergency/park brake. Be alert for the sudden stop when the panic strip is applied.

THIS COMPLETES THE SHUTDOWN PROCEDURE.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

BATTERY CHANGE PROCEDURE Two people are needed to change the battery on the Model VT636-2. Since one person may step into the Hazard Zone (page 19) the other person (operating the Model VT636-2) must be very careful and look each time before moving any levers or pedals. Take time now to refamiliarize yourself with the Hazard Zone (page 19).

1. Line up the battery end of the Model VT636-2 with the place where the battery is to be deposited (Figure 15 below) (see STARTING PROCEDURE, page 20).

FIGURE 15 – BATTERY CHANGE PROCEDURE

CHARGED BATTERY

LIFT ATTACHMENT

DISCHARGED BATTERY

THE “BATTERY” CHANGE CONTROL LEVER SHOULD NEVER BE OPERATED EXCEPT AT A BATTERY CHANGE STATION OR WHEN IT’S NECESSARY TO ADJUST THE BATTERY'S TERRAIN CLEARANCE. IF THE "BATTERY" CHANGE CONTROL LEVER IS OPERATED IN A LOW ROOF AREA, THE BATTERY MAY BE DAMAGED.

DO NOT MOVE THE “LIFT” ATTACHMENT CONTROL LEVER IF ANYONE IS NEAR ENOUGH TO THE LIFT ATTACHMENT TO HAVE ANY PART OF THE BODY UNDERNEATH.

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2. Pull both battery retainer pins and store in holes provided (Figure 16, below). If difficulty is encountered in removing the retainer pins, it may be necessary to gently shake the battery up and down by using the battery “LIFT” control lever.

FIGURE 16 – BATTERY CHANGE PROCEDURE BATTERY HOUSING RETAINING PINS

RETAINING PIN STORAGE LOCATION

RETAINING PIN STORAGE LOCATION

BATTERY HOUSING RETAINING PINS

3. Lower the battery completely to the surface by pushing the "BATTERY" change control lever away from the operator. The bottom of the battery should touch the surface (Figure 17 below).

NEVER ATTEMPT TO DISCONNECT A HYDRAULIC HOSE FROM THE BATTERY LIFTING CYLINDERS WHILE THE BATTERY IS IN THE UP POSITION. THIS COULD CAUSE THE BATTERY TO FALL AND COULD RESULT IN SERIOUS INJURY. FIGURE 17 – BATTERY CHANGE PROCEDURE DISCHARGED BATTERY

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4. After the battery is fully lowered, shutdown the Model VT636-2 (see SHUTDOWN PROCEDURE, page 29).

5. After shutting down the Model VT636-2, disconnect the discharged battery (Figure 21, page 35): A. Unlock and remove the padlock at the battery connector.

B. Grasp the threaded lock ring and rotate it counter-clockwise (CCW) until the threads are disengaged and it is free to slide away from the locking lug; the lock ring is designed to move freely but not to come off the plug.

C. Grasp the plug and pull it out until the plug is completely disconnected from the receptacle; the plug is made to fit very tightly inside the battery receptacle and should not be driven out of the receptacle, dropped, or handled roughly; if the plug (or receptacle) is damaged, it will not fit together properly.

D. Install the cap which is secured to each receptacle on the battery by a small chain; this cap is placed over the threaded receptacle and rotated in a clockwise (CW) direction until hand tight and until a padlock will fit into the locking lug; the padlocks all use the same key.

6. Connect the jumper cable (Figure 21, page 35): A. Connect the receptacle end of the jumper cable to the Model VT636-2 plug coming out of the connection box.

B. Connect the plug end of the jumper cable to the fully charged battery.

C. Secure the jumper cable connections by using the threaded lock rings. These lock rings must be hand tight but do not have to be padlocked.

D. One person should hold the jumper cable so it will not be damaged or be run over when the Model VT636-2 is moved.

FIGURE 18 – BATTERY CHANGE PROCEDURE CHARGED BATTERY JUMPER CABLE

LIFT ATTACHMENT

DISCHARGED BATTERY

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7. Start the Model VT636-2 (see STARTING PROCEDURE, page 20). Gently pull away from the discharged battery while the second person holds the jumper cable away from possible damage.

8. Line the Model VT636-2 up with the fully charged battery. Move the machine back until the battery lift forks are fully inserted into the pockets provided on the battery (Figure 19 below).

FIGURE 19 – BATTERY CHANGE PROCEDURE CHARGED BATTERY

JUMPER CABLE

LIFT ATTACHMENT

BATTERY LIFT FORKS DISCHARGED BATTERY

9. Shutdown the Model VT636-2 (see SHUTDOWN PROCEDURE, page 29). Reinsert the retainer pins on both sides of the battery along with their corresponding detent pins (Figure 16, page 32).

10. Disconnect the jumper cable and connect the charged battery directly to the Model VT636-2's cable (Figure 21, page 35). Remember to be careful with the plugs. After the plug is in the receptacles, the lock ring should be rotated clockwise (CW) until hand tight. The padlock must be in the locking lug and locked for this connection to be permissible.

11. Start the Model VT636-2 (see STARTING PROCEDURE, page 20).

12. Raise the battery by pulling the "BATTERY" change control lever toward the operator. Continue to hold the battery change control lever in this position until the battery is no longer resting on the surface (Figure 20 below).

FIGURE 20 – BATTERY CHANGE PROCEDURE CHARGED BATTERY

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

FIGURE 21 – TYPICAL BATTERY PLUG AND RECEPTACLE CONNECTION

PAD LOCK

CABLE TO MACHINE

CAP

RECEPTACLE (THIS RECEPTACLE IS PART OF THE BATTERY)

LOCKING LUG THREADED LOCK RING

PLUG ASSEMBLY

THREADS

THIS COMPLETES THE BATTERY CHANGE PROCEDURE.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

GENERAL MAINTENANCE INSTRUCTIONS Long, reliable service and the safety of those working with the Model VT636-2 can only be ensured by conscientious periodic maintenance of the machine as outlined in this manual.

Anyone performing maintenance on this machine should be trained to operate it and must be familiar with this Bucyrus America Operation, Preventive Maintenance and Troubleshooting Manual.

All electrical work must be supervised and inspected by an MSHA-certified electrician.

BEFORE MAINTENANCE OR SERVICING A. Shutdown the Model VT636-2 on level surface (see SHUTDOWN PROCEDURE, page 29).

B. Be sure that the lift attachment and battery are resting securely on the surface.

C. Disconnect the power. Either the circuit breaker or the emergency manual disconnect switch must be in the "OFF" position.

D. Test the controls to be sure that the Model VT636-2 will not operate.

E. Chock all four (4) wheels in both directions to prevent movement.

During maintenance or servicing, if the drive motors are to be run, the Model VT636-2 must be jacked clear of the surface and securely blocked. All four (4) wheels must be free to rotate.

FIGURE 22 – BLOCKING POINTS FOR SERVICE

CLEANLINESS cannot be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified service person.

DO NOT PERFORM MAINTENANCE IN A CONGESTED AREA. DO NOT MOVE ANY HYDRAULIC CONTROL LEVER UNLESS YOU ARE CERTAIN THAT NO ONE COULD BE INJURED BY THE MACHINE’S MOVEMENT. DO NOT LIFT THE FRONT OR REAR WHEELS OF THE MODEL VT636-2 OFF THE SURFACE BY TILTING THE LIFT ATTACHMENT DOWN AND LOWERING THE BATTERY, EXCEPT FOR MAINTENANCE PROCEDURES. DO NOT DISCONNECT A HYDRAULIC CIRCUIT FROM A CYLINDER WHILE THERE IS A LOAD ON THE CYLINDER.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

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(Specific Instructions Start on Page 41) (For Lubricant Specifications, See Page 40) ITEM OR LOCATION EVERY THIRD SHIFT Grease points Hydraulic Oil Level Electrical cables and conduits; hydraulic hoses and fittings; tires and headlights Speed Reducer Oil Level Panic Strip Winch ONCE PER WEEK Axle Mounting Bolts Wheel Mounting Bolts Fire Suppression System Methane Monitor Hydraulic System Oil Filter Automatic Emergency Brake Hydraulic Oil & Suction Filter Contactors (X90 Controller only) Current Limit (X90 Controller only) Rotek Bearing ONCE PER MONTH Planetary Wheel End Brake and Axle Housing Oil Brake Cooling Sump Oil Wet Disc Park Brake EVERY THREE MONTHS Hydraulic System Pressure Steering Relief Valve Hydraulic Oil and Suction Filter Drive Motors Pump Motor YEARLY Wet Disc Park Brake

INSPECT

ADJUST

CHANGE

LUBRICATE •

• • • • • • • • • • •

• •

* * **

• •

*** •

•

*

• •

*

• • • • •

• * * •

****

* As required. ** Change after first week of service and every three months afterwards. ***Once per week or any time a drive motor, SCR or SCR panel is replaced. **** Change yearly or as required.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

MAINTENANCE CAPACITIES AND SPECIFICATIONS Drive System Drive Motors: Totally-enclosed, explosion-proof 128-volt, dual field, series wound, DC electric motor, coupled to a speed-reducing gear box.

Rating: 30 horsepower continuous 50 horsepower 1-hour rating Motor Controller: Solid state, stepless, speed control.

Rating: 1200 amps per motor Current Limit is factory set and should be adjusted any time a drive motor, solid state panel, or logic card is changed.

Drive Axles: Rigidly mounted planetary axles equipped with hydraulically power-applied, shaft speed, wet-disc brakes and optional operator selected differential lock.

Weight: 2085 lbs dry 2157 lbs wet Drivelines: 72N Series Hydraulic System Pump Motor: 128-volt, totally-enclosed, fan-cooled, explosion-proof motor.

Rating: 10 horsepower continuous 15.8 horsepower 1 - hour rating Hydraulic Pump: Single section gear pump 1 1/2" gear width Rating: 20 GPM Maximum System Pressure: 2500 PSI Filtration: Suction to Pump: 100-mesh strainer inside hydraulic oil tank.

Pressure Filter (Between pump and relief valve) 25 micron cartridge-type.

Return Line Filter (Located in top of oil tank) 25 micron cartridge-type.

Strainer screens inside brake solenoid valve and accumulator charging valve.

Hydraulic System Pressures: Main Hydraulic System Relief Steering Relief (dual, each direction)

2250 PSI (Max) 1600 PSI (Max)

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

Brake Systems Service: Hydraulically-power-applied, enclosed, shaft-speed, wet-disc brakes located between carrier and each axle wheel end.

Wet-Disc brakes sump cooled using mineral oils with an anti-chatter additive.

Emergency/Park, (Automatic): Spring applied (on) hydraulic pressure release (off) (SAHR) dry disc brake located on the front output shaft of the gear boxes.

Wet Disc Emergency/Park, (Automatic): Spring applied (on) hydraulic pressure release (off) (SAHR) dry disc brake located on the front output shaft of the gear boxes.

Brake Accumulator - 1 gallon capacity 1850 PSI normal charged pressure.

Accumulator Gas (nitrogen) pre-charge pressure 600 PSI (See page 71 for Testing & Charging Procedure).

Torque Values Torque values are expressed in lubricated and dry thread values. Lubricated thread torque values should be used anytime the bolt threads are covered with oil, grease, anti-seize or thread-locking compounds. Dry thread torque values should be used when threads are completely clean and dry.

Critical Bolt Torque Values (ft./lbs.)

Location Drive Motor to Gear Reducer Axle Mounting Bolts Wheel Mounting Nuts

Bolt Size 3/4"-16UNF Grade 5

Max Dry 285

Max Lubricated 230

7/8"-14UNF X Grade 8 3/4”-l 2NC Grade 8

640 400

525 330

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

RECOMMENDED LUBRICANTS AND CAPACITIES LOCATION

TYPE

Hydraulic Oil

Texaco Rando HD68

Gear Box

Texaco Multigear EP 8OW-90 Texaco Multigear EP 8OW-90 Texaco Multigear EP 8OW-90 Texaco TDH 1893 or Amoco 1000 or Unicol 1006 John Deere HyGard Transmission Hydraulic Oil J20A (or equivalent) Chevron SRI-2

Axle Housing Planetary Wheel Ends Wet Disc Brakes (Service) Wet Disc Brakes (Park) Electric Motor Grease Winch Multi-Purpose Grease

API GL-4 or (140W) Worm Gear OiI Peragma Grade 8 Texaco Multifak EP-1

APROXIMATE CAPACITY 40 Gallons

NOTES 1

2.75 Quarts 23 Quarts

2

3.5 Quarts Each Wheel end 3 Quarts For Each Brake

2 2

1 Cubic inch 5 Pints As Required

3

Notes: 1. With ejector blade completely retracted (if equipped with a bucket).

2. The axle housing, brake cooling sumps, and planetary wheel end assemblies do not have a common oil source. Each assembly must be filled separately.

Make sure the level and fill hole in the planetary wheel end cover is in the proper position. Rotate the wheel end as required to bring the fill hole to either the 3 o'clock or 9 o'clock position.

When filling the axle housing and planetary wheel ends, allow enough time for the lubricant to fill the various cavities and around component parts in each assembly. Continue adding oil into each assembly until the required oil level is reached.

3. Pump grease into fitting until old grease can be observed coming out of component.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

PERIODIC MAINTENANCE PROCEDURES EVERY THIRD SHIFT DO NOT ALLOW WATER TO ENTER THE ELECTRICAL CONTROLLER AT ANY TIME. EXCEPT DURING SERVICE OR MAINTENANCE, THE CONTROLLER COVER SHOULD BE IN PLACE AND SECURE. DO NOT SPRAY WATER DIRECTLY ONTO TAPE SWITCHES; THIS COULD SHORT OUT THE CIRCUIT. 1. Wash the Model VT636-2 and clean any foreign material from the operator's compartment, and make a general inspection of the machine.

2. Lubricate the Model VT636-2 at the points marked on the lubrication chart (Figure 44, page 58) with heavy-duty multi-purpose grease (for Lubricant Specifications, see page 40).

3. Check the hydraulic oil level by looking at the sight glass on the end of the oil tank (Figure 23 below) (for Lubricant Specifications, see page 40).

FIGURE 23 – HYDRAULIC OIL TANK SIGHT GLASS

4. Check the oil level in both front and rear speed reducer gear boxes (Figure 24 below) (for Lubricant Specifications, see page 40).

FIGURE 24 – SPEED REDUCER GEAR BOX OIL LEVEL FILLER PLUG

SPEED REDUCER GEAR BOX

HORIZONTAL OIL LEVEL PLUG

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

5. Check the oil level in the winch and lubricate the grease fitting located on the top right side of the winch (Figure 25 below) (for Lubricant Specifications, see page 40).

FIGURE 25 – WINCH

FILLER PLUG

GREASE FITTING

DRAIN

HORIZONTAL OIL LEVEL PLUG

6. Check the tires visually for signs of wear. The Model VT636-2 is equipped with either Solid Rubber or PERMAFOAM filled tires and do not require inflation.

7. lnspect all electrical cables and hydraulic hoses and fittings for signs of wear or leakage.

8. Check the headlights to assure they are working properly and are not damaged.

9. Check the tape switch “Panic Strip” (Figure 2, page 9). Start the Model VT636 but do not tram. Strike the tape switch to be certain that it is operating properly, tripping the circuit breaker and shutting down the Model VT636-2.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

ONCE PER WEEK 1. Check the axle mounting bolts (Figure 26 below). The 7/8" NF grade 8 axle mounting bolts should be torqued to 640 ft-lb. if dry and 525 ft-lb. if wet.

FIGURE 26 – AXLE MOUNTING BOLTS

AXLE MOUNTING BOLTS

FRONT AXLE ASSEMBLY

AXLE MOUNTING BOLTS

AXLE MOUNTING BOLTS

REAR AXLE ASSEMBLY

AXLE MOUNTING BOLTS

2. Check the wheel mounting nuts (Figure 27 below). The 3/4" NF mounting nuts should be torqued to maximum 400 ft-lb. if dry and 330 ft-lb. if wet.

FIGURE 27 – WHEEL MOUNTING NUTS WHEEL MOUNTING NUTS, WITH HEX THREAD PROTECTORS

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

3. If installed, check the methane monitor alarm-light circuits and the machine power cut-off relay. The circuit breaker and the emergency manual “POWER DISCONNECT” switch lever must be in the "ON" position.

4. Check the fire suppression system (Figure 28 below).

A. Check the hoses, fittings, and nozzles for signs of mechanical damage and cuts.

B. Check the extinguisher(s) for signs of damage or corrosion.

C. Check the nozzle openings. The slot should be packed with silicone grease. If the nozzles are open or need to be repacked, the lines should be checked for blockage and blown clean before repacking the nozzles with clean silicone grease.

D. Remove the fill cap.

E. Check that the extinguisher is filled with free-flowing, Ansul multi-purpose A,B,C dry chemical to a Ievel not more than 3" from the bottom of the fiII opening.

F. Replace the fill cap, hand tight.

IF ANY PART OF THE FIRE SUPPRESSION IS BROKEN OR OTHERWISE INOPERATIVE, SHUTDOWN THE MODEL VT636-2 (FOR SHUTDOWN PROCEDURE, SEE PAGE 29) AND CALL A SERVICE PERSON. FIGURE 28 – FIRE SUPPRESSION TANK AND NOZZLES

NOZZLE OPENING

FILL CAP TANK

TYPICAL FIRE SUPPRESSION TANK LOCATION

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

5. Check the Automatic Emergency/Park Brake lining wear indicator. (See Figure 29 for spring brake and Figure 30 for wet disc brake) A. Park the machine in a level working area. Chock the machine to prevent any unplanned movement.

B. Install the steering lockout device per procedure (see page 29).

C. To gain access to the brake caliper, remove the forward cover from the middle frame section of the Model VT636-2 or reach through the center section above the driveline.

If equipped with spring brake: (See Figure 29) D. Feel around the center of the brake housing for the wear indicator. The wear indicator is about a 1/2” in diameter round rod and should be protruding from the brake housing up to 3/8” with new brake pads and needs replacing when the wear indicator is flush with the brake housing.

If equipped with wet disc brake: (See Figure 30) D. Feel around the top of the brake house for the wear indicator. The wear indicator is about a 3/4” in diameter round rod and should be inset from the brake housing up to 1/8” with new brake pads and needs replacing when the wear indicator is flush with the brake housing.

FIGURE 29 – SPRING BRAKE LINING WEAR INDICATOR CHECK AUTOMATIC EMERGENCY/PARK BRAKE

GREASE FITTING

WEAR INDICATOR

BRAKE DISC BRAKE LINING

FIGURE 30 – WET DISC BRAKE LINING WEAR INDICATOR CHECK

WEAR INDICATOR

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

6. Check the system pressure line filter's color-coded pop-up style dirt alarm (Figure 31 below) and replace the filter element weekly or more frequently if unordinary dirty or dusty conditions exist.

A. The filter indicator has two positions: IN, (“O.K.”) for normal operation; OUT, (CHANGE) indicating the filter is clogged and hydraulic oil is by-passing the filter.

B. If the indicator is OUT (with the pump motor running), the filter element must be changed. To change the filter element, stop the pump motor and rotate the filter element housing counter clockwise (CCW) until the threads disengage. Remove the old element and replace with a new one.

C. Replace the filter housing.

FIGURE 31 – SYSTEM PRESSURE LINE FILTER AND DIRT ALARM

HOUSING POP-UP DIRT ALARM

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

7. Inspect the contactor tips inside the electrical controller. If the tips are burned, pitted, or black in color they should be replaced (Figure 32 below).

FIGURE 32 – CONTACTOR TIP INSPECTION

MOVING TIP

MOVING TIP

STATIONARY TIP STATIONARY TIP

PUMP CONTACTOR

MAIN CONTACTOR

BEFORE REMOVING THE CONTROLLER COVER, REMOVE POWER FROM THE SYSTEM BY UNPLUGGING THE BATTERY. WHEN THE COVER IS REMOVED, WAIT ONE MINUTE FOR THE CAPACITORS TO FULLY DISCHARGE BEFORE WORKING INSIDE THE CONTROLLER. 8. Check the current limit setting. (For procedure and adjustments, refer to your LA 2000 Troubleshooting Guide) 9. Inspect rotek bearing (Figure 33) for loose or broken bolts. If loose or broken bolts are found, replace and torque to 350 – 400 lb-ft.

FIGURE 33 – ROTEK BEARING Torque to 350 – 400 lb-ft Use Loctite 242

Torque to 350 – 400 lb-ft Use Loctite 242

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

ONCE PER MONTH 1. Check the oil level in the two (2) axles (Figures 34, 35, 36 and 37) (for oil specifications, see page 40).

THE AXLE HOUSING, PLANETARY WHEEL ENDS, AND BRAKE ASSEMBLIES DO NOT HAVE A COMMON OIL/COOLANT LEVEL. THE BEST MEANS TO FILL WITH OIL IS ACCOMPLISHED BY FILLING THROUGH EACH WHEEL END, (FIGURES 35 AND 37), EACH BRAKE ASSEMBLY (FIGURE 38), AND THE HOUSING OR DRIVE UNIT (FIGURES 34 AND 37).

MAKE SURE THE LEVEL AND FILL HOLES IN THE PLANETARY WHEEL END COVERS ARE IN THE PROPER POSITION. REFER TO THE INFORMATION CAST INTO THE COVERS AND ROTATE THE WHEEL END AS REQUIRED. WHEN FILLING THE AXLE HOUSING, PLANETARY WHEEL ENDS OR BRAKES ALLOW ENOUGH TIME FOR THE LUBRICANT TO FLOW THROUGH THE VARIOUS CAVITIES AND AROUND COMPONENT PARTS IN EACH ASSEMBLY. FIGURE 34 – AXLE HOUSING (REAR AXLE)

OIL LEVEL CHECK PLUG

DRAIN

FIGURE 35 – WHEEL END (REAR AXLE)

HORIZONTAL OIL FILL LOCATION

DRAIN

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

FIGURE 36 – BRAKE HOUSING (REAR AXLE) OIL FILL LOCATION

OIL FILL LOCATION

DRAIN LOCATION

DRAIN LOCATION

FIGURE 37 – CHECK POINTS (FRONT AXLE) OIL LEVEL CHECK PLUG

OIL LEVEL DRAIN PLUG SERVICE BRAKE BLEEDER

WHEEL END FILL/CHECK PLUG

SERVICE BRAKE DRAIN

49

WHEEL END DRAIN PLUG

Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

2. If equipped with wet disc park brake, check the oil level by removing the oil fill level plug (Figure 38 below). If the oil level is below this port, add oil through the upper fill port until the oil is even with the oil level port. (For Lubricant Specifications, see page 40)

FIGURE 38 – WET DISC BRAKE PARK BRAKE FILL PORT

OIL FILL LEVEL PLUG

DRAIN

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

EVERY THREE MONTHS 1. Lubricate the points marked on the lubrication chart (Figure 44, page 58) (For Lubricant Specifications, see page 40).

2. Inspect the drive motors (Figure 39 below).

A. Be sure that the circuit breaker lever is in the "OFF" position.

B. Remove the appropriate covers from the front Model VT636-2.

C. Remove the inspection cover from the motor.

D. Inspect the windings, commutator, brushes, armature, and terminal leads.

(1) Windings should be dry and free of dust, grease, oil, and dirt.

(2) The commutator should be clean and smooth with a medium polish and a light brown color.

(3) Brushes and brush holders should be clean so that the brushes are free to move in the holders.

Brushes should be replaced before wear permits the rivets to score the commutator.

(4) The armature and field leads should be undamaged.

(5) Terminal leads should be tight.

E. Check that the assembly screws, bolts, and nuts are tight.

F. Replace the inspection cover being sure that the flanges are clean.

G. Replace the covers on the Model VT636-2.

THE DRIVE MOTORS OF THE MODEL VT636-2 DO NOT REQUIRE PERIODIC LUBRICATION. THE BEARING IN THE SPEED REDUCER (GEAR BOX) END IS LUBRICATED BY OIL FROM THE SPEED REDUCER AND THE BEARING ON THE OPPOSITE END IS SEALED. FIGURE 39 – DRIVE MOTOR INSPECTION

INSPECTION COVER

ROCKER RING LOCK SCREWS REDUCER GEAR BOX

BRUSHES AND BRUSH HOLDERS

DRIVE MOTOR

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

3. Inspect the pump motor (Figure 40 below).

A. Be sure that the circuit breaker is in the "OFF" position.

B. Remove the cover from the rear section of the Model VT636-2.

C. Remove the inspection cover from the motor.

D. Inspect the windings, commutator, brushes armature, and terminal leads.

(1) Windings should be dry and free of dust, grease, oil, and dirt.

(2) The commutator should be clean and smooth with a medium polish and a light brown color.

(3) Brushes and brush holders should be clean so that the brushes are free to move in the holders.

Brushes should be replaced before wear permits the rivets to score the commutator.

(4) The armature and field leads should be undamaged.

(5) Terminal leads should be tight.

E. Check that the assembly screws, bolts, and nuts are tight.

F. Replace the inspection covers being sure that the flanges are clean.

G. Replace the cover on the rear section of the Model VT636-2.

FIGURE 40 – PUMP MOTOR INSPECTION PUMP MOTOR INSPECTION COVER

ROCKER RING LOCK SCREWS

BRUSHES AND BRUSH HOLDERS

PUMP

4. Change the hydraulic oil and hydraulic oil strainer (Figure 41, page 53).

A. Remove the plug at the end of the hydraulic oil tank and allow the tank to drain completely.

B. Remove the cover plate in the end of the oil tank just above the drain plug.

C. Unscrew the strainer counter-clockwise (CCW) and pull out through the end cover opening.

D. Replace the strainer or thoroughly clean the old strainer with kerosene and a soft brush. Dry the cleaned filter with air before replacing it in the tank.

E. Replace the strainer in the tank and tighten.

F. Replace the gasket, end plate and tighten the plug in the bottom of the hydraulic oil tank.

G. Refill the hydraulic oil tank to the proper level (see Hydraulic Oil Fill Procedure, page 76) (for Lubricant Specifications, see page 40).

H. Start the Model VT636-2 (see Starting Procedure, page 20) and allow the hydraulic pump to run in order to remove air from the system.

I. Shutdown the Model VT636-2 (see SHUTDOWN PROCEDURE, page 29) and recheck the hydraulic oil level (Figure 23, page 41). Add oil if necessary.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

FIGURE 41 – HYDRAULIC OIL TANK BREATHER HYDRAULIC OIL TANK

FILTER

OIL SIGHT GAUGE

GASKET

COVER PLATE

STRAINER DRAIN PLUG

THE AUTOMATIC BRAKE MUST BE ON AND THE PUMP MOTOR “OFF” WHILE PERFORMING MAINTENANCE TO THE UNIT. DO NOT DEPRESS THE SPEED SWITCH DURING THIS TIME OR THE UNIT WILL MOVE. ALL AUXILIARY HYDRAULIC DEVICES MUST BE DISCONNECTED FROM THE PTO. IT IS RECOMMENDED THAT ALL OF THE RELIEF PRESSURES BE CHECKED ADJUSTED AT THE SAME TIME. THE STEERING VALVE ADJUSTMENTS ARE ON THE VALVE BANK IN THE OPERATOR'S COMPARTMENT WHILE THE SYSTEM PRESSURE RELIEF VALVE IS LOCATED ON THE BACK OF THE OIL TANK. 5. Check (and adjust if necessary) the main Hydraulic System pressure: A. Remove the cover behind the hydraulic oil tank located on the front frame section.

B. Pull the "PTO" lever toward the operator.

C. Continue to hold the "PTO" lever pulled toward the operator and read the pressure indicated by the "SYSTEM PRESSURE" gauge (Figure 3, page 10).

D. Normal hydraulic system pressure relief is set at the factory at 2250 PSI. If the pressure indicated on the "SYSTEM PRESSURE" gauge is not 2250 PSI, adjust as follows: (1) Loosen the relief valve locknut located on the relief valve (Figure 42, page 54).

(2) While holding the “PTO” lever toward the operator turn the adjustment screw until the "SYSTEM PRESSURE" gauge indicates 2250 PSI. (3) Tighten the locknut and replace the cover.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

DO NOT ADJUST THE HYDRAULIC SYSTEM PRESSURE TO MORE THAN 2250 PSI. FIGURE 42 – SYSTEM PRESSURE RELIEF VALVE ADJUSTMENT

RELIEF VALVE (ADJUST TO 2250 PSI)

IN ORDER TO CHECK AND ADJUST THE STEERING SYSTEM RELIEF PRESSURE, IT IS NECESSARY TO STEER THE MODEL VT636-2 TO THE TURNING LIMIT IN BOTH DIRECTIONS. CARE MUST BE TAKEN TO AVOID HAVING ANYONE OR ANY PART OF YOUR BODY IN THE ARTICULATION AREA WHILE THE UNIT IS BEING STEERED. ALL ADJUSTMENTS TO THE STEERING SYSTEM RELIEF PRESSURE MUST BE MADE FROM INSIDE THE OPERATOR'S COMPARTMENT AND NOT FROM OUTSIDE THE UNIT. 6. Check (and adjust if necessary) the Steering System relief pressure: A. Steer the unit to the turning limit in either direction and read the pressure indicated on the "SYSTEM PRESSURE" gauge (Figure 3, page 10).

B. Normal steering system relief pressure is set at the factory at 1600 PSI. If the pressure indicated on the "SYSTEM PRESSURE" gauge is not 1600 PSI in one or both directions, adjust the pressure as follows: C. Remove the cover over the hydraulic valve bank.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

D. The steering relief has two (2) adjustment screws, one for steering to the right and one for steering to the left. To adjust the steering relief pressure: (1) For a right turn, (Figure 42) hold the "STEERING" control lever pulled toward the operator.

Loosen the 1 1/8” jam nut and adjust the relief valve with a flat screwdriver until the pressure indicated on the "SYSTEM PRESSURE" gauge reads 1600 PSI. Once the gauge indicates 1600 PSI tighten the jam nut.

(2)

For a left turn, (Figure 43) hold the "STEERING" control lever pushed away from the operator.

Loosen the 1 1/8” jam nut and adjust the relief valve with a flat screwdriver until the pressure indicated on the "SYSTEM PRESSURE" gauge reads 1600 PSI. Once the gauge indicates 1600 PSI tighten the jam nut.

E. Replace the cover over the valve bank.

FIGURE 43 – STEERING SYSTEM RELIEF VALVE ADJUSTMENT

RELIEF VALVE (ADJUST TO 1600 PSI)

RELIEF VALVE (ADJUST TO 1600 PSI)

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

YEARLY 1. If equipped with wet disc park brake, drain and refill with proper oil. See page 50 for oil check and fill procedure.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

GREASE LUBRICATION CHART The following points should be lubricated at the grease fittings with heavy-duty, multi-purpose grease except where another lubricant is specified. Clean all excess grease and oil from the Model VT636-2 after completing maintenance procedures.

EVERY THIRD SHIFT Detail Number 1 2 3 4 8 9 10 11 12 13 14 15

Location Roll guide assembly Tilt lift cylinders rod and pivot end (left & right) Bellcrank lift cylinders rod and pivot end (left & right) Steering cylinders rod and base end (left & right) Foot pedal pivot bearings Pivot plates Grease block (Rotek bearing) Drive assembly (Front) Drive assembly (Rear) Winch Battery lift Hydraulic cab

Total Number of Fittings 4 grease fittings 4 grease fittings 4 grease fittings 4 grease fittings 3 grease fittings 2 grease fittings 10 grease fittings 4 grease fittings 4 grease fittings 1 grease fitting 10 grease fittings 6 grease fittings

EVERY THREE MONTHS Detail Number 5 6 7

Location Circuit breaker reset Iever Operator compartment control levers Control Station

57

Total Number of Fittings 1 grease fitting 9 grease fittings 1 grease fitting

Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

FIGURE 44 – LUBRICATION CHART (SHEET 1)

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FIGURE 44 – LUBRICATION CHART (SHEET 2)

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FIGURE 44 – LUBRICATION CHART (SHEET 3)

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FIGURE 44 – LUBRICATION CHART (SHEET 4)

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

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TIRE/WHEEL INSTALLATION PROCEDURE

The following installation procedures are for general guidance when installing a tirelwheel assembly on most underground mining machines. Any use made of the advisory information contained herein is entirely within the control and discretion of the user and is wholly voluntary.

MIXING PARTS OF DIFFERENT DESIGN OR FROM A VARIETY OF SOURCES FOR WHEELS WITH PNEUMATIC TIRES COULD CAUSE SEVERE INJURY OR DEATH.

TIRE/WHEEL STRESSES Rubber tired underground mining machinery is routinely subject to severe abuse due to the conditions in which it is operated. Whether a primary haulage or utility/support vehicle, all are subject to extreme shock, vibration, temperature change and various other loads and stresses that cause maintenance problems. One such problem is found in tire/wheel assemblies.

Many maintenance personnel view installing a tire/wheel assembly on a machine as a relatively simple task. However, if a few simple rules on proper installation are not followed, unnecessary difficulties may be experienced. Tires act like shock absorbers on haulage and support vehicles, transferring cushioned loads to the wheels. Even after proper installation, periodic checks need to be made to insure that tire/wheel assemblies do not loosen, causing wheel studs to break or damaging the mounting bolt pattern.

WHEEL MOUNTING ARRANGEMENTS Various mounting arrangements between the wheel and hub or wheel end are used by manufacturers.

One of the more common is the taper-lock. This arrangement requires a taper on both wheel and hub where the mating surfaces of the taper carry the loads. Incomplete seating of the taper will allow the wheel to loosen, resulting in stud or bolt shear and possible tire/wheel damage.

Another mounting arrangement is based on holding a very close pilot fit where the tolerance between the wheel and hub is very tight, requiring a clamp-load force to hold the wheel securely in place. If the wheel studs or bolts are allowed to loosen, the load will be transmitted to them, resulting in sheared studs or bolts.

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Bucyrus America, Inc.

PROBLEM AREAS Periodic wheel inspection is critical to the life cycle of a tire/wheel assembly. A fractured wheel, broken bolt pattern and missing or broken wheel studs are all contributors to tire/wheel failures. Problems in these areas occur as the result of repeated cyclical loading as the tire/wheel unit rotates during machine travel. Haulage vehicles loaded unevenly, downhill hauls with high speed turns, or operating a vehicle with one tire of a dual assembly damaged or flat are some examples of conditions that produce damaging high stresses in wheel assemblies. Also, the effects of corrosion or poorly fitted mating parts can produce surface irregularities that result in cracks and ultimate failure of a wheel.

A most common problem with tire/wheel installations is the incorrect tightening of wheel bolts or studs.

Threaded fasteners perform there function of holding things together better when torque control is used in their tightening. Using an accurate torque wrench correctly is the best and most practical way of securing fasteners, although torque value charts are available as a reference guide to proper tightening, OEM specifications should always be followed when tightening fasteners. However, proper torque values are of little benefit if certain other factors are not considered.

WHEEL MOUNTING TIPS All fasteners should be examined before use. Any fastener that is worn, bent or has damaged threads should be replaced. Fastener threads should also be lightly coated with a protective substance, such as residual oils, wax or loctite, because any oxidation or rust will upset the torque-to-tension relationship.

Mating surface conditions should also be considered. The tightening surface under the bolt or nut should be carefully inspected. A fastener, when tightened against a softer material, will gall under these conditions, and much of the applied torque may be lost through head friction. It is very important when using higher strength fasteners to have a smooth, even surface under the bolt head. In some cases, hard flat washers and most lock washers will provide a good tightening surface.

Another area of concern is cleanliness. AlI mating surfaces should be free of rust, dirt, oil, paint, etc.

Also no paint of any kind should exist between a fastener and wheel disc surface. Any form of contamination between these surfaces will most likely lead to serious wheel problems.

FIGURE 45 – TORQUE PATTERNS

WHEN TORQUING ANY WHEEL BOLT PATTERN, ALWAYS TORQUE IN A TRIANGULAR PATTERN.

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Bucyrus America, Inc.

RECOMMENDED WHEEL MOUNTING PROCEDURES 1. All steel mating surfaces must be free and clean of any dirt, corrosion, paint, etc. These areas include wheel/hub tapers and disc faces. NO PAINT should be present under bolt heads or nuts.

2. Fasteners should be in proper condition. Any fastener with damage, such as corrosion, bending or worn threads, should be replaced. Replace all broken wheel studs.

3. After positioning the wheel on the hub, tighten nuts down evenly. tightening sequence as shown in the diagrams.

Triangulate the bolt pattern

4. After operating the machine for a short period of time, check the wheel-mounting bolts or nuts for proper torque.

NOTE: Wheel bolts or nuts “seat in” during normal vehicle operation. Therefore, it is necessary to repeat torquing procedures as necessary to seat the wheel to the hub. Planned periodic checks will help maintain correct torque values. All bolts and nuts, regardless of type, should be regularly checked for tightness.

PRECAUTIONS Do not install or remove tire/wheel assemblies from a machine without proper training.

Check wheel components periodically for cracks or broken parts. damaged or severely rusted components. When in doubt replace.

Replace all cracked, badly worn,

Do not, under any circumstances, attempt to rework, weld, heat or braze any wheel components that are cracked, broken or damaged. Replace such components with new OEM parts of the correct size and type.

Mixing wheel parts of different design or from a variety of sources is potentially dangerous.

Replace broken studs and each unbroken stud next to the broken one.

Replace all damaged wheel studs or bolts.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

TROUBLESHOOTING PROCEDURES The following section lists possible problems encountered when servicing the Model VT636-2 and can aid in locating and correcting these problems.

This section covers basic hydraulic components, with each listed in a trouble-cause-remedy format.

For electrical instructions, troubleshooting, and maintenance procedures, refer to the BUCYRUS AMERICA “Dual Motor Controller Solid-State Troubleshooting Guide”.

SOME PROCEDURES MUST BE CARRIED OUT WITH THE COVER OF THE ELECTRICAL CONTROLLER REMOVED AND SOME PROCEDURES REQUIRE THE CONTROLLER TO BE ENERGIZED DURING THE TESTS. IT IS EXTREMELY IMPORTANT THAT YOU TAKE ALL NECESSARY PRECAUTIONS TO PREVENT ACCIDENTAL ELECTRICAL SHOCK WHILE WORKING WITHIN THE CONTROLLER. AN MSHA-CERTIFIED ELECTRICIAN MUST SUPERVISE AND INSPECT ALL WORK PERFORMED. For maintenance procedures and tests that DO NOT require the controller to be energized, these precautions include: A. Before removing the controller cover, remove power from the system by unplugging the battery.

B. When the cover is removed, wait one minute for the capacitors to discharge before working inside the controller. To insure that the capacitors are discharged, connect an insulated 100-ohm, 10-watt resistor between the center buss bar and the outer buss bar of the capacitor bank and hold for 30 seconds.

C. Use insulated gloves and tools where possible.

D. All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: A. At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be turned to the “OFF” position and the capacitor bank discharged (see above). Once the circuit breaker is in the “OFF” position and the capacitor bank discharged, adjustments or parts replacements can be made.

B. Use insulated gloves and tools where possible.

C. All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

NEVER DISCONNECT A HYDRAULIC HOSE IF THE CIRCUIT IS PRESSURIZED OR THERE IS A LOAD ON THE CIRCUIT. IF A HOSE IS DISCONNECTED WHILE THE CYLINDER IS SUPPORTING A LOAD, THE LOAD WILL FALL.

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Bucyrus America, Inc.

HYDRAULIC SYSTEM (GENERAL) TROUBLE, SYMPTOM OR CONDITION DIRTY OIL

FOAMING OIL

MOISTURE IN OIL

OVERHEATING OF SYSTEM

PROBABLE CAUSE

TEST, CHECK AND/OR REMEDY

1. Components not properly cleaned after servicing.

1. Disassemble components and reclean parts.

2. Air breather Ieft off.

2. Replace breather.

3. Hose lines not properly covered while servicing machine.

3. Clean hose Iines after servicing.

4. Filter elements not replaced at proper intervals or when indicated.

4. Replace elements at proper intervals.

1. Return of tank lines not below fluid level. Check oil level.

1. Replace broken hoses or lines.

2. Oil contaminated with incompatible foreign matter.

2. Drain out oil and replace with clean oil.

3. Suction leak to pump aerating oil.

3. Replace or tighten fittings and Iines.

1. Soluble oil solution splashing into poorly gasketed tanks or fill holes left open.

1. Drain out and refiII with clean oil. Check fill pipes to see if they are properly closed.

2. Moisture in cans or used replacement oil.

2. Replace with new cans of oil.

3. Extreme temperature differential in certain geographical locations

3. Replace with recommended oil for correct temperature range.

1. Fluid viscosity too high.

1. Check fluid specs.

2. Excessive slippage or internal leakage past pump or cylinders.

2. Fluid viscosity too low.

3. Improper air circulation around reservoir.

3. Check to see if the area around the reservoir is clear.

4. System relief valve set too high or too low.

4. Reset the relief valve to specifications.

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Bucyrus America, Inc.

TROUBLE, SYMPTOM OR CONDITION

PROBABLE CAUSE

FOREIGN MATTER SOURCES IN THE CIRCUIT

1. Sealing compound (pipe dope, teflon tape).

1. Clean or replace seals.

2. Burrs inside piping components.

2. Disassemble piping components and remove any burrs.

3. Tag ends of packing coming loose.

3. Remove old packing and replace with new.

4. Lines left unprotected and dirty, repaired components.

4. Drain and replace oil.

5. Repair parts not properly protected while stored.

5. Clean parts thoroughly before installation.

1. Leaking accumulator Iines or fittings.

1. Check lines and fittings for leaks and correct.

2. Accumulator gas charge too low.

2. Check accumulator gas charge.

3. Accumulator gas charge too high.

3. Check accumulator.

4. Line to accumulator plugged.

4. Replace line.

1. No oil or low oil level in tank.

1. Check oil level.

2. Defective or worn pump (pump doesn't deliver full flow or pressure).

2. Check pump pressure and flow.

3. Defective system relief valve (valve leaking or has low setting so full flow and pressure are not available).

3. Check relief valve.

4. Defective charging valve.

4. Replace valve.

1. Pump worn (not delivering full flow or pressure).

1. Check pump pressure and flow.

2. Relief valve defective (valve leaking so that full flow and pressure not available).

2. Check relief valve.

3. Defective charging valve.

3. Replace charging valve.

ACCUMULATOR CHARGING CYCLE REPEATS FREQUENTLY WHEN ACCUMULATOR IS NOT NORMALLY BEING DISCHARGED IN SERVICE

ACCUMULATOR STARTS TO CHARGE BUT DOESN'T REACH HIGH LIMIT

NO STEERING OR INADEQUATE STEERING WHEN ACCUMULATOR IS CHARGING BUT STEERING SATISFACTORY WHEN ACCUMULATOR IS NOT CHARGING

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

TROUBLE, SYMPTOM OR CONDITION

PROBABLE CAUSE

ACCUMULATOR CHARGING TIME TOO LONG

1. No oil or low oil level in tank.

TEST, CHECK AND/OR REMEDY 1. Check oil level.

2. Check vaIve setting.

2. Relief valve setting too low.

3. Check pump.

3. Pump worn or defective and not delivering full flow or pressure.

4. Remove charging valve.

4. Defective charging valve.

ACCUMULATOR FAILS TO START CHARGING

1. No oil or low oil level in tank.

2. Worn or defective pump.

1. Check oiI level.

2. Check pump pressure and flow.

3. Check relief valve setting.

3. Defective relief valve.

4. Replace charging vaIve. 4. Defective charging valve.

VERY RAPID CYCLING OF CHARGING VALVE

1. Accumulator gas charge too low.

1. Check gas charge.

2. Accumulator gas charge too high.

2. Check gas charge.

3. No gas charge in accumulator.

3. Check gas charge.

4. Defective charging valve.

4. Replace charging valve.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

BRAKES TROUBLE, SYMPTOM OR CONDITION BRAKE SLOW TO APPLY

BRAKES WON'T RELEASE

INSUFFICIENT BRAKES

BRAKES WILL NOT RELEASE COMPLETELY

PROBABLE CAUSE 1. No gas charge in accumulator.

TEST, CHECK AND/OR REMEDY 1. Check gas charge.

2. Defective brakes.

2. Check brakes.

3. Hydraulic lines or fittings leaking.

3. Check for leaks and repair.

4. Pedal linkage out of adjustment.

4. Adjust Iinkage.

5. Damaged hydraulic brake lines.

5. Check lines for dents that restrict flow of oiI.

1. Pedal linkage out of adjustment or binding.

1. Check for proper adjustment and binding.

2. Defective brakes.

2. Check brakes.

3. Defective brake valve.

3. Replace brake valve.

1. No oil or low level in tank.

1. Check oil level in tank.

2. Pedal linkage out of adjustment.

2. Adjust linkage.

3. Brake line mashed.

3. Check Iines and replace.

4. No gas charge in accumulator.

4. Check gas charge.

5. Defective brakes.

5. Check brakes.

6. Brake valve defective.

6. Replace valve.

1. Defective brakes.

1. Check brakes.

2. Pedal Iinkage out of adjustment.

2. Adjust pedal linkage.

3. Air in brakes.

3. Bleed brakes.

4. Defective brake valve.

4. Replace brake valve.

5. Back pressure on return line too high.

5. Remove restriction.

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Bucyrus America, Inc.

TROUBLE, SYMPTOM OR CONDITION EXCESSIVE BRAKING

NO BRAKES

PROBABLE CAUSE

TEST, CHECK AND/OR REMEDY

1. Defective brakes.

1. Check brakes.

2. Defective brake valve.

2. Replace brake valve.

1. No oil in hydraulic system.

1. Check oil level in tank.

2. Pedal Iinkage out of adjustment.

2. Adjust pedal linkage.

3. Broken or mashed brake line.

3. Check Iines for breaks or mashed condition.

4. Defective system relief valve. 4. Check pressure in pressure Iine to vaIve. 5. Worn pump.

5. Check pressure in pressure Iine to vaIve.

6. Defective or worn brakes.

6. Check brakes.

7. Defective brake valve.

1. Insufficient pressure.

7. Replace brake valve.

1. Check lines.

2. Accumulator not fully recharged.

2. Recharge accumulator.

1. Defective ball valve in charging valve.

1. Replace ball valve.

2. Defective guide in charging valve.

2. Replace guide.

3. Seal leaking in charging valve.

3. Replace seal.

4. Guide sticking in plug due to contamination.

4. Remove and clean the guides.

INSUFFICIENT BRAKES

1. Broken pressure regulating spring.

1. Replace pressure regulating spring.

BRAKES WON'T RELEASE

1. Defective ball valve in charging valve.

1. Replace ball valve.

2. Piston and washer binding in charging valve.

2. Replace piston and washer.

PARKING BRAKES WILL NOT RELEASE COMPLETELY EXCESSIVE ACCUMULATOR LEAKAGE WHEN BRAKES ARE NOT BEING USED

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Bucyrus America, Inc.

TROUBLE, SYMPTOM OR CONDITION

PROBABLE CAUSE

EXCESSIVE ACCUMULATOR LEAKAGE WHEN BRAKES ARE APPLIED

1. Defective seat on piston in charging.

1. Replace seat.

2. Seal leaking.

2. Replace seal.

3. Defective ball valve.

3. Replace ball valve.

4. Guide sticking in plug due to contamination.

4. Remove and clean guide.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

HYDRAULIC CYLINDERS TROUBLE, SYMPTOM OR CONDITION CYLINDER DRIFTS

1. Piston seal leak.

TEST, CHECK AND/OR REMEDY 1. Replace seals.

2. Other circuit leaks.

2. Correct leaks.

1. Pressure too Iow.

1. Check pressure at cylinder to make circuit requirements.

2. Piston seal leak.

2. Replace seals.

3. Piston rod broken at piston end.

3. Disassemble and replace piston rod.

4. Contamination in hydraulic system resulting in scored cylinder bore.

4. Disassemble and replace necessary parts.

ERRATIC OR CHATTER IN OPERATION

1. Excessive friction due to misalignment.

1. Correct cylinder to load alignment.

EXCESSIVE OR RAPID PISTON SEAL WEAR

1. Excessive high back pressure due to over adjustment.

1. Correct pressure adjustment.

CYLINDER BODY SEAL LEAK

1. Excessive pressure.

1. Reduce pressure to rated limits.

2. Seal is pinched or extruded.

2. Replace cylinder body seal.

3. Seal deterioration (soft or gummy).

3. Check compatibility of seal material with operating fluid.

Replace oil.

THE PISTON IS LEAKING

1. Dirt has scored the piston or the rod.

1. Replace rod.

THE PISTON FREEZES TO THE TUBE

1. Scoring in the piston.

1. Replace.

PACKING AND GASKET LEAKS DEVELOP

1. Excessive heat.

1. Replace packing and gasket.

CYLINDER FAILS TO MOVE THE LOAD WHEN ACTUATED

PROBABLE CAUSE

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Bucyrus America, Inc.

HYDRAULIC PUMP TROUBLE, SYMPTOM OR CONDITION

PROBABLE CAUSE

PUMP MAKES EXCESSIVE NOISE

1. Vacuum leaks in suction line.

1. Check for leaks in fittings or damaged suction lines.

2. Vacuum leaks in the pump shaft seal.

2. Check pump.

3. Poor alignment with drive mechanism.

3. Align pump and pump motor.

4. Incorrect fluid in system.

4. Check fluid specs.

5. Relief valve set too high.

5. Check relief pressure.

6. Seal deterioration (hard or loss of elasticity).

6. Replace seal.

7. Seal deterioration (loss of radial squeeze due to flat spots or wear on O.D. or I. D.).

7. Replace seal.

1. Torn or worn seaIs.

1. Replace seal.

2. Gland bearing worn.

2. Replace gland and seals.

3. Seal deterioration (soft or gummy).

3. Replace seal.

4.Seal deterioration (hard or loss of elasticity).

4. Replace seal.

5. Seal deterioration (flat spots on I. D.).

5. Replace seal.

6. Aeration of fluid in reservoir.

6. Correct air leak.

7. Worn or damaged gears and housing.

7. Replace gears and housing.

8. Worn or faulty bearing.

8. Replace faulty bearing.

9. Reversed rotation.

9. Check pump motor wiring.

10. PIugged or restricted suction Iine or suction strainer.

10. Clean by removing the plugged area.

11. Plugged reservoir filter breather.

11. Clean reservoir. Clean breather.

SEAL LEAK

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

TROUBLE, SYMPTOM OR CONDITION

PUMP FAILURE TO DELIVER OIL

OIL LEAKAGE AROUND PUMP

PROBABLE CAUSE 12. Oil viscosity too high or operating temperature too low.

TEST, CHECK AND/OR REMEDY 12. Replace with recommended oil.

13. Air leak in suction line or fittings.

13. Replace lines or fittings if badly worn.

14. Loose or worn pump parts.

14. Replace worn pump parts.

15. Air leak at pump shaft seal.

15. Replace pump shaft seals.

16. Oil level too low and drawing air in through inlet pipe opening.

16. Check oil level.

17. Air bubbles in intake oil.

17. Check oil level and tighten any loose fittings.

18. Pump housing bolts loose or not properly torqued.

18. Tighten the housing bolts, and re-torque bolts.

1. Low oiI Ievel in reservoir.

1. Fill to proper level.

2. Oil intake hose suction strainer plugged.

2. Clean or replace strainer.

3. Air leak in suction line and preventing priming.

3. Tighten or replace suction lines.

4. Pump shaft turning too slowly.

4. Gears are worn and need replacing.

5. Oil viscosity too high.

5. Replace with recommended oil.

6. Wrong shaft rotation.

6. Check pump motor wiring.

7. Pump shaft or parts broken.

7. Replace shaft or broken parts.

8. Dirt in pump.

8. Clean pump.

1. Shaft seal worn.

1. Replace seals.

2. Head of oil on suction hose connection leaking.

2. Tighten bolts. Tighten or replace connections.

3. Pump housing bolts loose or improperly torqued.

3. Tighten bolts.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

TROUBLE, SYMPTOM OR CONDITION

PROBABLE CAUSE

TEST, CHECK AND/OR REMEDY

1. Abrasive dirt in hydraulic oil being circulated through the system.

1. Replace oil with clean hydraulic oil.

2. OiI viscosity too Iow.

2. Replace with recommended oil.

3. System pressure exceeding pump rating.

3. Relief valve out of adjustment.

4. Pump misalignment.

4. Realign pump.

1. Seizure due to lack of oil.

1. Check oiI level.

2. Excessive system pressure above maximum pump rating.

2. Relief vaIve out of adjustment.

3. Excessive torquing to housing bolts.

3. Loosen bolts and then retorque.

4. Solid matter being drawn in from reservoir and wedged in pump.

4. Remove and clean clogged area.

THE OPERATING PRESSURE CANNOT BE CHANGED

1. Valve spring broken.

1. Replace the spring.

2. Open valve in the system.

2. Find and close open valve.

THE VALVE PISTON STICKS

1. Dirt in the system.

1. Remove the valve and clean it thoroughly; flush the system as necessary.

CERTAIN PASSAGES ARE BLOCKED OR PRESSURE FLUCTUATES

1. Dirt in the system.

1. Remove the valve and clean it thoroughly; flush the system as necessary.

THE PRESSURE FLUCTUATES, AND THERE IS EXTREME NOISE IN THE VALVE

1. Air in the system.

1. Check for leaks.

2. Pressure or volume too high.

2. Adjust the pressure or volume.

THE VALVE LEAKS INTERNALLY

1. Valve piston and body worn.

1. Replace the vaIve.

EXCESSIVE LEAKAGE OR STICKING PISTONS OCCURS

1. Valve excessively hot.

1. Remove the valve and clean it thoroughly; flush the system.

2. Dirt in the system.

2. Replace oil.

EXCESSIVE PUMP WEAR

PUMP PARTS INSIDE THE HOUSING ARE BROKEN

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

MAJOR MAINTENANCE PROCEDURES HYDRAULIC OIL FILL PROCEDURE DO NOT ALLOW THE HYDRAULIC OIL LEVEL TO FALL BELOW THE MIDPOINT OF THE SIGHT GAUGE DURING OPERATION.

The standard oil fill system on the Model VT636-2 uses a manual handpump located on the middle frame section. Through a series of hoses and fittings, the oil is pumped into the tank through the low pressure return oil filter located on top of the oil tank. Monitor the oil level with the sight gauge provided in the end of the tank. The gauge is located on the left rear side of the front frame section (Figure 46 below).

1. Remove the 1/2-13UNC bolt holding down the cover over the oil fill handpump located on the left side of the middle frame section.

2. Pull out the hose that is attached to the oil fill hand pump on one end and loose on the other.

3. Remove the plug in the end of the hose.

4. Insert the loose end of the hose into the oil container and secure.

5. Flip the latch holding the handpump handle down back out of the way.

6. While watching the sight gauge, pump the oil into the tank until it reaches at least within 1/2” of the top of the gauge (Figure 46 below).

7. When the tank is full, remove the hose from the oil container.

8. Wipe off the excess oil, replace the plug in the end of the hose and store the hose back in the cavity provided for it.

9. Replace the handpump hold-down clip.

10. Bolt the cover back down.

FIGURE 46 – HYDRAULIC OIL FILL PROCEDURE HANDPUMP LOCATION

SIGHT GAUGE

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

BRAKE BLEEDING PROCEDURE THESE PROCEDURES REQUIRE 2 PERSONS. ONE SHOULD SIT IN THE OPERATOR'S SEAT AND THE OTHER WORK AT EACH WHEEL END. TO PREVENT POSSIBLE MOVEMENT DURING THE BLEEDING PROCEDURES, THE UNIT SHOULD BE CHOCKED ON ALL FOUR (4) WHEELS IN BOTH DIRECTIONS. SERVICE BRAKES: 1. Locate the bleeder port for the (4) service brakes on each brake housing (Figure 47 below).

2. With the unit running, have the operator apply pressure to the foot brake pedal (Figure 2, page 9).

3. While the operator continues to hold the brake pedal, loosen the bleeder port on (1) service brake and allow hydraulic fluid to escape until the pressure drops enough to activate the accumulator charging valve (the pump motor will make a higher pitched sound).

4. Close the bleeder port and release the service brake foot pedal.

5. Allow the accumulator to recharge and repeat steps 1 through 4 for the other (3) brakes, one at a time.

6. Clean up all spilled fluid.

7. Check and refill (if necessary) the hydraulic oil level (See page 76).

FIGURE 47 – SERVICE BRAKE BLEEDING PROCEDURE

BLEEDER

TYPICAL 4 PLACES

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

CONTACTOR TIP REPLACEMENT BEFORE REMOVING THE CONTROLLER COVER, REMOVE POWER FROM THE SYSTEM BY UNPLUGGING THE BATTERY. WHEN THE COVER IS REMOVED, WAIT ONE MINUTE FOR THE CAPACITORS TO FULLY DISCHARGE BEFORE WORKING INSIDE THE CONTROLLER. 1. Insure electrical power is off and capacitors are discharged (See page 65).

2. Change the stationary contactor tips (Figure 48 below): A. Remove the bolt that holds the old tip in place and remove the old tip.

B. Position the new tip in place and replace the bolt. Check the placement of the tip to insure that it is correctly positioned and the bolt is tight.

C. Repeat for all stationary tips.

THE BOLTS USED TO FASTEN THE STATIONARY CONTACTOR TIPS IN PLACE ARE SPECIALLY SIZED TO PREVENT THE CONTACTOR TIP FROM GROUNDING TO THE CONTACTOR COIL. IF REPLACEMENT BECOMES NECESSARY, IT IS IMPORTANT TO USE BOLTS AND WASHERS IDENTICAL TO THE ORIGINAL ONES. ALL CONNECTIONS MUST BE TIGHT BEFORE THE UNIT IS PUT BACK INTO SERVICE. 3. Check for grounding between the stationary tips and either terminal of the contactor coil by using a volt/ohm meter set on R x 1. Correct any shorts if found.

4. Change the moving contactor tips (Figure 48 below).

A. Remove the two (2) nuts that secure the tip and remove the old tip.

B. Position the new tip and secure with new nuts. Check the placement of the tip to insure that it is correctly positioned and the nuts are tight.

C. Repeat for all moving tips.

FIGURE 48 – CONTACTOR TIP INSPECTION AND REPLACEMENT

MOVING TIP

MOVING TIP

STATIONARY TIP STATIONARY TIP

PUMP CONTACTOR

MAIN CONTACTOR

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

DRIVE MOTOR/GEAR BOX REMOVAL AND INSTALLATION DRIVE MOTOR REMOVAL:

ELECTRICAL POWER MUST BE REMOVED BY DISCONNECTING THE BATTERY PLUG BEFORE SERVICING THE MOTORS. 1. Remove the motor inspection cover and disconnect the power cables to the motor. Unpack the motor gland and completely remove the wiring and conduit from the motor.

2. Attach a crane or hoist, capable of lifting the motor, to the eyebolt on top of the motor and take up any slack in hoist chain.

3. Remove the four (4) bolts that attach the motor to the gear box. Cover the gear box opening to prevent foreign matter from entering the gear box.

4. Lift the motor out of the unit.

DRIVE MOTOR INSTALLATION: 1. Verify that motor pinion gear is installed.

2. Clean all mating surfaces (motor and gear box).

3. Lower motor into unit and align bolt holes.

4. Bolt motor onto gear box turning pinion gear as necessary to align gears.

5. Torque bolts to 170 ft-lb. (Lubricated threads) 285 ft-lb. (Dry threads) 6. Reconnect cable leads.

7. Replace inspection cover.

8. Check the current limit setting. (For procedure and adjustments, refer to your LA 2000 Troubleshooting Guide)

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

DRIVE MOTOR AND GEAR BOX REMOVAL:

ELECTRICAL POWER MUST BE REMOVED BY DISCONNECTING THE BATTERY PLUG BEFORE SERVICING THE MOTORS. 1. Remove the motor inspection cover and disconnect the power cables to the motor. Unpack the motor gland and completely, remove the wiring and conduit from the motor.

2. Remove the drive shafts from both sides of the gear box and slide the drive shafts away from the gear box.

3. Attach a crane or hoist, capable of lifting the motor and gear box and take up any slack in the hoist chain.

4. Remove the bolts that attach the gear box to the frame.

5. Lift the motor/gear box out of the unit.

MOTOR/GEAR BOX REPLACEMENT: 1. Attach motor to gear box and torque bolts to 170 ft-lb. (lubricated threads) 285 ft-lb (dry threads).

2. Hoist motor/gear box to its location in the frame.

3. Bolt the motor/gear box to the frame.

4. Replace the drive shafts on to the gear box.

5. Check the gear box oil level before operating the unit (Figure 24, page 41).

6. Check the current limit setting. (For procedure and adjustments, refer to your LA 2000 Troubleshooting Guide)

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

Bucyrus America, Inc.

ACCUMULATOR OPERATION AND PRECHARGING PROCEDURE OPERATION: The accumulator used in the Model VT636-2's braking system is a hydro-pneumatic bladder accumulator working essentially as a fluid pressure storage chamber. Incompressible fluid (hydraulic oil) is stored against a compressible force of gas (nitrogen) to act as a secondary source of pressure.

The flexible rubber bladder in the accumulator shell is precharged to 600 PSI with nitrogen gas. If the fluid pressure in the accumulator is less than 600 PSI, the accumulator charging valve opens, allowing the hydraulic pump to force hydraulic oil into the fluid chamber of the accumulator. As fluid is forced into the chamber, the nitrogen gas in the bladder compresses until the gas pressure becomes equal to the system pressure. At 1850 PSI the accumulator charging valve closes until the fluid pressure has dropped back to below 1440 PSI. PRECHARGING & RECHARGING: (Figure 48, page 81)

DO NOT DISCONNECT ANY HOSES IN THE BRAKE SYSTEM UNTIL ALL PRESSURE HAS BEEN RELIEVED AND THE “ACCUMULATOR” GAUGE INDICATES "0” PRESSURE. 1. Mount hose assembly gland nut on pressure regulator. Use "oil pumped or dry nitrogen" which is commercially available.

DO NOT USE OXYGEN OR ANY GAS OTHER THAN NITROGEN. 2. Attach swivel connector of hose assembly to gas valve. Hand tighten sufficiently to compress gasket swivel connector in order to prevent gas leakage.

3. Precharge bladder slowly to about 10 PSIG before completely tightening the valve stem nut. Use a second wrench on the valve stem flats to react the torque applied to the stem nut.

4. Proceed to inflate accumulator to predetermined pressure (600 PSI) by slowly opening the pressure regulator valve on nitrogen cylinder, closing it occasionally to allow needle on pressure gauge to stabilize (thus giving accurate reading of precharge pressure). When correct precharge has been reached, close pressure regulator valve on nitrogen cylinder securely.

D0 NOT EXCEED 800 PSI PRECHARGE PRESSURE.

5. Bleeder valve can be used to let out any gas pressure in excess of desired precharge.

6. Replace dynaseal and valve guard.

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Bucyrus America, Inc.

FIGURE 48 – PRECHARGING AND RECHARGING ACCUMULATOR

PRESSURE GAUGE

CAP

ACCUMULATOR

FOR RECHARGING ONLY.

Exhaust all hydraulic pressure from the system. Remove valve guard and dynaseal (Figure 49 above).

Then, follow "Precharging bladder" steps 1 through 6, page 81.

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Revised 12 - 07 MODEL VT636-2 VERSATRAC®

OPERATION AND TROUBLESHOOTING GUIDE MODEL BUCYRUS 2000 DUAL AND SINGLE MOTOR SOLID STATE CONTROLLERS

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. P/N A6474X226 Revision 1, December / 07  BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED

Bucyrus America, Inc. ________________________________________________________________ 4041 Wurno Road Telephone: 540-980-4530 Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.bucyrus.com

Bucyrus America, Inc.

TABLE OF CONTENTS DESCRIPTION

PAGE #

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 IGBT MEASUREMENTS..................................................................................................................27 INDIVIDUAL IGBT MEASUREMENTS ............................................................................................28 DIODE MEASUREMENTS ...............................................................................................................29 DIODE MEASUREMENTS ...............................................................................................................30 PANEL MEASUREMENTS ..............................................................................................................31 DRIVER MEASUREMENTS.............................................................................................................32 IGBT DUAL MOTOR PANEL, FIGURE 16 .......................................................................................34 IGBT SINGLE MOTOR 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 PUMP MOTOR SHUNT, FIGURE 25 ....................................................................42 BUCYRUS 2000 PANEL WIRING HARNESS, FIGURE 26 .............................................................43

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

PREFACE This manual is intended to provide GENERAL operating and service procedures for the Bucyrus 2000 motor vehicle solid-state controller. The illustrations, descriptions and procedures contained in this publication apply only to Bucyrus 2000 motor vehicle solid-state controllers. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Bucyrus 2000 motor vehicles solid-state controller 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, the Bucyrus 2000 motor vehicles solid-state controller 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 the controller, without the consent of Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render the controller 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 controller.

While this manual attempts to anticipate the most important operations and maintenance needs for this controller, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. 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.

 Bucyrus America, Inc. All rights reserved.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

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 POINTS IN THE TEXT MARKED WITH THIS SYMBOL DRAW YOUR ATTENTION TO IMMEDIATELY IMPENDING DANGER INCLUDING ELECTRICAL DANGERS. POSSIBLE CONSEQUENCES ARE: VERY SERIOUS INJURY, DEATH OR DEATH BY ELECTROCUTION.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

DANGER ONLY TRAINED AND/OR AUTHORIZED PERSONNEL SHOULD PERFORM MAINTENANCE ON THE CONTROLLER. FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH. FAILURE TO MAINTAIN THIS CONTROLLER IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

MOTORS AND CONTROLLER

Electrical shock could cause irreparable injury or death.

All electrical systems should be maintained by certified electricians.

The battery should be disconnected before servicing the motors or controller. When the controller cover is removed, wait for one minute for the capacitors to discharge.

BATTERY

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

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

Battery covers could fall crushing hands or arms.

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

Battery hold-down clamps could crush fingers or hands.

Keep fingers and hands away from hold-down clamps.

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

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

Batteries should be maintained by qualified personnel.

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

Protective clothing, gloves, and eyewear must be worn when working on batteries. Batteries should be maintained by qualified personnel.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

SAFETY PRECAUTIONS AND GUIDELINES Overview Before you test, troubleshoot, service or in any other way, use this unit READ and STUDY this guide. KNOW 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 Maintenance AVOID, whenever possible, servicing, cleaning or examining the unit in congested areas.

AVOID, whenever possible, servicing or providing maintenance to the unit unless the wheels are adequately choked. If the drive motor (s) is to be run, the unit must be jacked clear of the ground and all four (4) wheels must be free to turn.

DO NOT alter the electrical settings from that indicated in this 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 electrical systems, or when welding on the unit to prevent electrical shock.

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 photographs and illustrations in this guide may show guards or covers removed for purposes of clarity. Never operate unit without all guards and covers in place.

SOME PHOTOGRAPHS OR ILLUSTRATIONS IN THIS GUIDE MAY SHOW PROTOTYPE UNITS OR UNITS WITH OPTIONAL EQUIPMENT INSTALLED THAT MAY OR MAY NOT BE ON YOUR PARTICULAR MACHINE. PRODUCTION MODELS MAY VARY IN SOME DETAIL. OPTIONAL EQUIPMENT MAY BE PURCHASED FROM BUCYRUS AMERICA, INC. CONTINUING IMPROVEMENT AND ADVANCEMENT OF PRODUCT DESIGN MAY CAUSE CHANGES TO YOUR MACHINE WHICH MAY NOT BE INCLUDED IN THIS PUBLICATION. EACH PUBLICATION IS REVIEWED AND REVISED, AS REQUIRED, TO UPDATE AND INCLUDE THE CHANGES IN LATER ADDITIONS. BUCYRUS AMERICA, INC. RESERVES THE RIGHT TO MODIFY OR MAKE CHANGES WITHIN A SPECIFIC MODEL GROUP WITHOUT NOTICE AND WITHOUT INCURRING ANY LIABILITY TO RETROFIT UNITS PREVIOUSLY SHIPPED FROM THE FACTORY. CONTACT YOUR BUCYRUS DEALER FOR MAINTENANCE THAT IS NOT COVERED IN THIS PUBLICATION. 6

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

INTRODUCTION BUCYRUS 2000: Innovative Speed Control by Bucyrus America, Inc. FIGURE 1 – SIMPLIFIED BUCYRUS 2000 CIRCUIT

In the early 1970's, S&S Corporation lead the way in mining innovation with the introduction of Solid State speed controls for battery-powered underground mining equipment. Solid State controls increased the range and reliability of the battery powered vehicles along with providing smooth, stepless acceleration. Even with solid state speed control, direction change was achieved with the use of electromechanical contactors. These contactors provided an endless source of maintenance problems and consumed excessive amounts of valuable controller-box space. Also, most solid state controllers of the past utilize an electromechanical "bypass" contactor to connect the motor directly to the batteries which caused more contactor problems.

In the 1980’s Bucyrus America, Inc., in conjunction with Sevcon, developed a contactorless motor controller (X90) to be used exclusively on Bucyrus equipment. The X90 system used a dual-field motor in combination with SCR's (Silicone Controlled Rectifier) to achieve solid state direction change.

Now Bucyrus America, Inc., in conjunction with Sevcon, has developed the Bucyrus 2000 motor controller. The Bucyrus 2000 system uses IGBT’s (Insulated Gate Bipolar Transistors) to achieve motor control and direction change. Unlike an SCR, an IGBT is turned ON and OFF via a gating electronic signal. This eliminated commutating capacitor banks and coils. The microprocessor based Bucyrus 2000 Logic Card provides complete motor control, and drives both a Diagnostic Dashboard Display along with a hand held Calibrator/Diagnostic Unit.

The IGBT switch operates so fast that it can connect and disconnect the motor in less than 1/1700 second. This is such a short time period that the dual-field motor does not have time to move. Each time the IGBT switch closes and reopens the full battery voltage is applied to the motor terminals for about 1/1700 second. This is commonly referred to as a "pulse."

The IGBT speed control works by feeding to the motor a rapid series of pulses. The number of pulses per second determines the average voltage at the motor terminals 7

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Since the windings of the motor are inductive, the current in the motor cannot change quickly.

When the IGBT switch is closed, the current builds up slowly and when the switch opens, the inductance wants to keep the current flowing. For this reason, the "flywheel" diode is provided.

Figures 3 and 4 illustrate the current paths with the switch closed in both forward (Figure 3) and reverse (Figure 4) modes.

FIGURE 2

FIGURE 3

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

FIGURE 4

As seen in Figure 5, the direction of the current through the motor does not change. More important, when the switch opens, although the battery current stops, the motor current continues to flow via the "flywheel" diode. The motor current is therefore made up of two components: 1. The battery current when the IGBT switch is closed.

2. The "flywheel" current when the IGBT switch is open.

FIGURE 5

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

The amount of the motor current supplied from the battery varies with the pulse frequency.

Figure 6 illustrates a typical situation at low speed. It can be seen from the illustration that the "flywheel" current, because it is flowing for a longer period, forms a larger part of the motor current than does the battery current. However, at high speeds (Figure 7), the motor current is made up of almost all battery current.

FIGURE 6

To summarize, the motor current is made up of a combination of battery current and "flywheel" current so that under all conditions the average motor current is always greater than the average battery current.

At low speeds the motor current can be several times greater than the battery current.

At high speeds, when the IGBT switch is open only for short periods before closing, the motor current is made up almost entirely of battery current.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

FIGURE 7

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

GENERAL SPECIFICATIONS The Bucyrus 2000 Motor Controller is designed to operate at 128 volts DC, 1200 Amps maximum current limit per motor and controls one or two dual-field electric motors. 

The maximum current default settings are: 800A, 1100A and 1200A



Traction functions operate at a speed that is directly proportional to the accelerator (FS1) demand. (See Figure 8)



Traction motor current will be continuously monitored in the motor. Current limit is preset and is adjustable via the optional hand held diagnostics/calibrator unit and is password protected.

FIGURE 8 – ACCELERATOR VOLTAGE

Fail-safe operation will include the following: 

In the event of a shorted IGBT, the circuit breaker will be opened, disconnecting power from the traction motors.



Operation of the circuit breaker will always be sensed, and if faulty, drive will be inhibited.



Whenever the vehicle is power-cycled, power-up diagnostics will be executed to test the tram drive circuitry. If faulty, drive will be inhibited.

The temperature of the Bucyrus 2000 Motor Controller will be continuously monitored and if it rises above 95C the motor current will be limited to a maximum of 300 amps of motor current will be allowed.

The Bucyrus 2000 Motor Controller features a data logging capability that stores critical data into non-volatile data RAM. The stored data is displayed in the traction status display of the optional hand held diagnostics/calibrator unit.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

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DESCRIPTION OF FEATURES The Bucyrus 2000 Solid State Controller incorporates a variety of independent protection systems. These improve reliability, shield the motors and controller from overload, protect the machine from inadvertent abuse by the operator, and help to protect workers from potential harm from malfunctioning equipment.

Bucyrus 2000 Motor Controller Consist of: 

Dual Motor IGBT Panel or single motor IGBT Panel or 2-single motor IGBT panels



Microprocessor Based Logic Card



Optional Dashboard Display



Optional Hand held Diagnostics/Calibrator Unit



“Y” connecting harness (used only with 2-single motor panel systems)

Bucyrus 2000 Motor IGBT Panel (Power Connections)   

Battery positive Battery negative 4 motor connections for each motor (S1, S2, A1 and A2)

(For Power Circuit Layout see Machine Wiring diagram and schematic)

Microprocessor Based Logic Card (Control Inputs)            

Input applies battery voltage to logic card (Pin 16) Proportional control accelerator, 5000 OHMS (Pins 1 and 2) Tram direction select (Pin 7) Tram direction select (Pin 8) Park brake condition (set / release) (Pin 14) Circuit breaker driver (Pin 6) Circuit breaker condition (Pin 11) Current limit default setting (Pin 12) Accelerator (FS1) input switch (Pin 4) CAN Communication Input Port for optional hand held diagnostics/calibrator unit CAN Communication Input Port for optional dashboard display Analog Input for connection to pump motor shunt to allow pump motor current measurement

The Bucyrus 2000 Microprocessor-Based Logic Card will control dual two-quadrant IGBT devices, controlled by PWM (PULSE WIDTH MODULATED) switching, providing forward and reverse direction control.

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Bucyrus America, Inc.

There is an LED on the logic card which serves as an indicator of the status of the controller. The following diagnostics shall apply:   

LED on LED off 1 Flash



2 Flash



3 Flash



4 Flash



5 Flash



6 Flash



7 Flash



8 Flash

Controller operational Power-up fault – check display or calibrator. If all is blank, then replace logic.

Personality CRC EEPROM Error.

Using the hand-held calibrator, change a password to any number then recycle power – should clear, otherwise replace logic.

Procedure FAULT FS1 closed before power on ,2 Directional Fault or Current imbalance fault.

Recycle through NEUTRAL to clear.

IGBT permanently low (IGBT Short Circuit FAULT).

This includes IGBT short circuit or IGBT open circuit. This fault shuts down all modes. Recycle through NEUTRAL to clear.

Motor neither low nor high (Breaker Open FAULT).

This includes breaker open circuit or IGBT open circuit. This fault shuts down all modes. Recycle through NEUTRAL to clear.

Motor permanently high.

This includes breaker welded. This fault shuts down all modes. Recycle “KEY” to clear.

Faulty TRACTION accelerator.

This includes the accelerator greater than 15% at power on and wire-off. If wireoff occurs during active function then the motor speed will set to zero. This fault auto-clears.

Battery voltage FAULT. This includes battery below a predetermined value. Recycle through NEUTRAL to clear.

Thermal cut-back (Over-Temperature FAULT).

This includes Heatsink temperature above 95 centigrade.

AS TEMPERATURE RISES CONTROLLER WILL LIMIT REGARDLESS OF DEMAND. 

9 Flash



10 Flash



15 Flash

ABOVE 95 CENTIGRADE, THE THE CURRENT TO 300 AMPS

UVR coil over-current FAULT (Coil short circuit FAULT).

Cleared with “KEY” recycled.

Brake on FAULT Will trip Directional and FS1 are energized without releasing brake. Recycle through NEUTRAL to clear.

Current Transducer FAULT. Occurs when current output is read during power-up or if no current is read during drive above 50% demand. “KEY” recycle to clear.

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Configuration Jumper Table MAX. CURRENT CONFIG. LOGIC PIN 12 OPEN GROUND (CLOSED) OPEN

VEHICLE TYPE SINGLE MOTOR – 1200 AMP SINGLE MOTOR – 1100 AMP DUAL MOTORS 1100 AMP PER MOTOR – ADJUSTABLE TO 1200 AMP DUAL MOTORS 800 AMP PER MOTOR

GROUND (CLOSED)

OPTIONAL DASHBOARD DISPLAY FEATURES (See Figure 9)    

A battery discharge indicator An hour meter displaying tram-on hours An hour meter displaying pump-on hours A rotating display showing: 1. Battery voltage 2. Pump motor current 3. Diagnostic fault status, when applicable. Rotating display will lock on one of the following fault messages: (See Fault Message Chart, page 19)

FIGURE 9 – OPTIONAL DASHBOARD DISPLAY

BATTERY DISCHARGE FUNCTION

ROTATING DISPLAY

TRAM – ON PUMP – ON HOURS

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Fault Message Chart DASHBOARD DISPLAY “Rotating Disp.”

“Testing”

CALIBRATOR DISPLAY “OK” “Testing”

“System OK”

“System Okay”

“Over Temp.”

“Brkr Open”

“Thermal Cutback” “Breaker Open”

“Brkr Weld”

“Breaker Weld”

“UVR Coil” “Cap Fault” “Accel Flt.”

“UVR Coil” “Capacitor Fault” “Accel Flt.”

“Seq. Fault”

“Sequence Fault”

“2 Dir Fault” “Tram Fault” “Bat Low” “CRC Error”

“2 Dir Fault” “Tram Fault” “Bat Low” “CRC Error”

“IGBT s/c” “IGBT s/c” “Brake on”

“IGBT s/c” “IGBT s/c” “Brake on”

“Cur Xducer”

“Cur Xducer Flt”

“Bad Logic”

“Bad Logic”

“Bad Logic”

“Bad Logic”

“Cap Fault” “PTA Short”

“Cap Fault” “P. Up PTA Short”

“RPTA Short”

“P. Up R. PTA Short”

DESCRIPTION No fault Only visible when power-up diagnostics is running. Check connections if not clearing.

Power-up check completed, waiting to closure of Circuit Breaker Controller in thermal cut-back.

Circuit breaker failed to close. Faulty Circuit breaker, UVR, CB Auxiliary or faulty logic board.

Circuit breaker welded close. Faulty CB auxiliary switch or faulty logic will give this fault also.

UVR coil driver over-current sensed.

Caps failed to charge after power-up.

Accelerator fault sensed. Faulty accelerator (accelerator voltage 4.0v; accelerator voltage below 1.2v in NEUTRAL).

Faulty FS1 or logic board.

FS1 closed at power-up. Possible circuit breaker auxiliary switch not closing Both directional switches active.

Motor current imbalance sensed.

Battery fell below personality level.

During power-up a personality CRC error occurred. Try adjusting one of the passwords (1 or 2) then power recycle.

If not cleared replace logic board.

An IGBT short has been detected – SM. A left or right IGBT short has been detected – DM. The vehicle BRAKES are on while there is a direction and demand selected.

The controller reads current when it is first powered-up or does not read any current when demand for drive over 50%.

An internal errors has occurred in the software state machine. Faulty logic board.

Invalid status state encountered (internal error). Faulty logic board. * * * * POWER UP TEST STATUS * * * * Caps failed to change after power-up.

Single motor Block 0 point “A” short Motor short to ground or IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

Dual motor Block 0 point “A” short Motor shorted to ground or RIGHT IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

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Fault Message Chart (Continued) “LPTA Short”

“P. Up L. PTA Short”

“I. D. Fault” “Bad Logic”

“Vehicle ID Flt” “Bad Logic”

“R FWD ON”

“Tract R. FWD on”

“FWD ON”

“Tract FWD on”

“R REV ON”

“Tract R. REV on”

“REV ON”

“Tract REV on

“L FWD ON”

“Tract L. FWD on”

“L REV ON”

“Tract L. REV on”

“Drive off”

Drive 0 off Flt”:

“R FWD OFF”

“Tract R. FWD off”

“FWD OFF”

“Tract FWD off”

“R REV OFF”

“Tract R. REV off”

“REV OFF”

“Tract REV off”

“L FWD OFF”

“Tract L. FWD off”

“L REV OFF”

“Tract L. Rev off”

“BAD LOGIC”

“BAD LOGIC”

Dual motor Block 1 point “A” short Motor shorted to ground or LEFT IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

Vehicle Configuration ID invalid Diagnostic point “A” trip failed to disable UVR coil. Faulty logic board.

Diagnostic RIGHT FWD point “A” trip failed to be disabled. .

Faulty logic board, shorted motor to ground or shorted IGBT. Single motor Point “A” trip failed to disable FWD IGBT. Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic RIGHT REV point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Single motor Diagnostic REV point “A” trip failed to be disabled. Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic LEFT FWD point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic LEFT REV point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic test to enable UVR coil driver failed. Faulty logic board.

Diagnostic RIGHT FWD point “A” trip failed to disable PWMO. Faulty logic board.

Single motor Diagnostic FWD point “A” trip failed to disable PWMO. Faulty logic board.

Diagnostic RIGHT REV point “A” trip failed to disable PWMO. Faulty logic board.

Single motor Diagnostic REV point “A” trip failed to disable PWMO. Faulty logic board.

Diagnostic LEFT FWD point “A” trip failed to disable PWM1.

Faulty logic board.

Diagnostic LEFT REV point “A” trip failed to disable PWM1.

Faulty logic board.

Internal error (Software Only) Faulty logic board.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Optional Hand Held Diagnostics/Calibrator Unit Security Levels: 1.

2.

3.

4.

Customer level Service Level Advanced Level Engineering Level

SECURITY LEVELS 2-4 ARE ONLY ACCESSIBLE BY ENTERING THE APPROPRIATE PASSWORDS.

FIGURE 10 – OPTIONAL HAND HELD DIAGNOSTICS/CALIBRATOR UNIT RIGHT BUTTON

LEFT BUTTON

DOWN BUTTON

UP BUTTON

Connecting for Operation: 1. Turn the machine “OFF”.

2. Turn the main circuit breaker to the “OFF” position to de-energize power on machine.

3. Remove the main controller cover.

4. Connect the hand held diagnostics/calibrator unit to the CAN Communication Input Port of the logic card.

5. Turn the main circuit breaker to the “ON” position.

6. Leave the “Park Brake Set”.

The hand held diagnostics/calibrator unit is now operational.

Operation: Upon power-up of the hand held diagnostics/calibrator unit, before pressing any buttons, a top level display is visible to provide diagnostic information as follows: See list on page # 19 and 20 18

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Personality Adjustment Procedure 1. Power-up calibrator.

2. If the top level display indicates “OK”, go to step (4). If not “OK”, go to step (3).

3. Consult above diagnostic information table to determine cause of fault.

4. Press the “DOWN” button two times to access the personalities table.

5. Use the “LEFT” or “RIGHT” buttons to locate the desired personality.

6. After locating the personality, use the “+” or “-” buttons to adjust the values accordingly.

7. To go back to the top level display, press the “UP” button two times.

The following features shall be customer adjustable personalities, accessible using the Calibrator

Traction Personalities (Controller Adjustments) DISPLAY NAME

MAX CONTROLLER CURRENT

RANGE / NOTES

SECURITY LEVELS DISPLAYED

50 amps to maximum controller capacity.

ALL

ACCELERATOR DELAY

0.5 seconds to 5.0 seconds

DECELERATION DELAY

(1.0 seconds ALL VEHICLES) 1.0 seconds to 5.0 seconds

CREEP SPEED

(1.0 seconds ALL VEHICLES) 0% to 25%

MAXIMUM SPEED

(5%) 0% to 100%

PASSWORD ONE PASSWORD 2 PWM FREQUENCY ADJUST PLUG CONFIGURATION NOTE: REQUIRES POWER RECYCLE

BATTERY PROTECTION CUTOUT BATTERY PROTECTION DELAY MOTOR CURRENT LOG LEVEL

(100%) 0 – 255 characters 0 – 255 characters 0 – 255 characters (17) 0 – 1 (Internal factor) 0. RFU 1. Auto plug breaking 2. Selective plug breaking (Normal plug) (2) 50 v – 255 v

SERVICE ADVANCED ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING ALL ALL ALL ALL ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

ALL

(50v) 0.1 – 5.0 seconds

ALL

(5.0 seconds) 50 – 1200 Amps

ALL

19

SECURITY LEVELS ADJUSTABLE

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Personalities (Controller Adjustments) (Continued) PLUG CURRENT LOG LEVEL TEMPERATURE ADJUSTMENT

CLEAR DATA LOG

CLOSE CB DELAY ALLOWED

50 – 1200 Amps Compensates temperature look-up tables.

0-20 = Positive additives 21 – 40 = Negative additives 95 default (ALL VEHICLES) OFF – ON NOTE: THIS PERSONALITY CLEARS ALL OF THE DATALOG LOCATIONS IN NON-VOLATILE MEMORY. TO ENABLE THIS PERSONALITY PRESS THE “-” BUTTON. IT DISABLES ITSELF ONCE IT COMPLETES THE CLEARING TASK. FS1 MUST BE OPEN. 0 seconds (disables) to 90 seconds 45 seconds (ALL VEHICLES)

NO ACTIVITY DELAY TIMER

0 seconds (disables) to 40 minutes 0 minutes (ALL VEHICLES)

CURRENT IMBALANCE TIMER

0 seconds (disables) to 90 seconds

20

ALL

SERVICE ADVANCED ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING

ALL

SERVICE ADVANCED ENGINEERING

SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Status Display DISPLAY NAME

RANGE / NOTES

Battery Voltage Motor Voltage (S. M.) Right Motor Voltage Left Motor Voltage Motor Current (S. M.) Right Motor Current Left Motor Current S. M. Rev. IGBT Block Temp.

S. M. Fwd IGBT Block Temp.

DM Right IGBT Block Temp.

DM Left IGBT Block Temp.

IGBT Voltage (S. M.) Right IGBT Voltage Left IGBT Voltage Error Code (see error code sec.)

Number of “Key On” Hours Number of “Driving” Hours Current Calibration Factor (S. M.) Right Channel Zero Current Calibration Factor Left Channel Zero Current Calibration Factor Peak Motor Current (S. M.) Right Channel Peak Motor Current Motor Current Stored Duration High Bytes (S. M.) Right Channel Motor Current Stored Duration High Bytes (S. M.) Motor Current Stored Duration Mid Bytes (S. M.) Right Channel Motor Current Stored Duration Mid Bytes (S. M.) Motor Current Stored Duration Low Bytes (S. M.) Right Channel Motor Current Stored Duration Low Bytes (S. M.) Motor Current Stored Duration Low Bytes (S. M.) Right Channel Motor Current Stored Duration Low Bytes (S. M.)

21

SECURITY LEVELS DISPLAYED ALL ALL

SECURITY LEVELS ADJUSTABLE N/A N/A

ALL ALL

N/A N/A

ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Status Display (Continued) Peak Plugging Current (S. M.) Right Channel Peak Plugging Current Selected Plugging Current Recording Level

NOTE: CONVERT AS FOLLOWS 1. CONVERT EACH BYTE TO ITS HEX EQUIVALENT. 2. CONVERT THE (3) BTYE FIELD TO A DECIMAL AND MULTIPLY BY 3.0 MSECONDS TO OBTAIN REAL TIME.

Plugging Current Stored Duration High Bytes (S. M.) Right Channel Plugging Current Stored Duration High Bytes (S. M.) Plugging Current Stored Duration Mid Bytes (S. M.) Right Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Right Channel Plugging Current Stored Duration Low Bytes (S. M.) Peak Motor Current (S. M.) Left / Right Motor Peak Plugging Current Stored Duration High Bytes (S. M.) Left Channel Plugging Current Stored Duration High Bytes (S. M.) Plugging Current Stored Duration Mid Bytes (S. M.) Left Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Left Channel Plugging Current Stored Duration Low Bytes (S. M.) Peak Plugging Current (S. M.) Left Channel Peak Plugging Current Plugging Current Stored Duration High Bytes (S. M.) Left Channel Plugging Current Stored Duration High Bytes (S. M.) 22

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction Status Display (Continued) Plugging Current Stored Duration Mid Bytes (S. M.) Left Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Left Channel Plugging Current Stored Duration Low Bytes (S. M.) SM FWD IGBT High Temperature SM REV IGBT High Temperature DM RIGHT IGBT High Temp.

DM LEFT IGBT High Temp.

SM FWD IGBT Low Temperature SM REV IGBT Low Temperature DM RIGHT IGBT Low Temp.

DM LEFT IGBT Low Temp.

Battery Voltage High Battery Voltage Low

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL ALL ALL

N/A N/A N/A

ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A

Security Level Displayed

Security Level Adjustable

ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Traction Test Display Display Name Accel. Voltage Accel. Percent Demand Forward Switch Reverse Switch FS1 Switch Configuration Jumper 1 Configuration Jumper 2 Brake Input Circuit Breaker Input Oil Temperature Oil Level Software Version

Range / Notes 0.0 V - 5.0 V 0 - 100% OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OK / HOT OK / LOW VX.XXX

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Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Traction BDI Display Display Name % CHANGE LEFT BDI CELLS

Range / Notes

RESET CELL LEVEL

0 - 100% 35 - 80 (64) 1.85V - 2.50V

EMPTY CELL LEVEL

(2.04V) 1.00V - 1.99V

WARNING LEVEL

(1.70V) 0% - 90%

CUTOUT LEVEL

(20%) 0% - 90%

BATTERY CALLIBRATION VOLTAGE BDI SAMPLE TIMER DISPLAY WORKING DISPLAY STATUS SELECT DASHBOARD DISPLAY STATUS

DISPLAY CONTRAST

(0%) 1.00V – 10.0V (5-VOLTS) 1.0 - 255 SECONDS 2.0 (20 SECONDS) OK LOCK / ROTATE (ROTATE) 0 - 4 (BATTERY VOLTAGE, PUMP CURRENT AND MOTOR CURRENT) BATTERY VOLTAGE (1) 0 - 127 1 (33)

24

Security Level Displayed ENGINEERING ENGINEERING

Security Level Adjustable ENGINEERING ENGINEERING

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

ENGINEERING

ENGINEERING

ENGINEERING

ENGINEERING

ADVANCED ENGINEERING ALL

ADVANCED ENGINEERING ALL

ALL

ALL

ALL

ALL

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Error Code Legend (Status Display) ERROR CODE 0 1 2

3

4

5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21

DESCRIPTION No Fault Caps failed to change after power-up Check for shorted cap Single Motor Block “0” Point “A” short Shorted IGBT or short between motor and ground Dual Motor Block “0” Point “A” short Shorted Right IGBT or short between motor and ground Dual Motor Block “0” Point “A” short Shorted Left IGBT or short between motor and ground Vehicle configuration ID invalid Diagnostic Point “A” trip failed to disable UVR Coil Replace logic assembly Diagnostic Right FWD Point “A” trip failed to disable Replace logic assembly Single Motor Point “A” trip failed to disable FWD IGBT Replace logic assembly Diagnostic Right REV Point “A” trip failed to disable Replace logic assembly Single Motor Diagnostic REV Point “A” trip failed to disable Replace logic assembly Diagnostic Left FWD Point “A” trip failed to disable Replace logic assembly Diagnostic Left REV Point “A” trip failed to disable Replace logic assembly Diagnostic test to enable UVR Coil driver failed Fault in logic assembly or faulty UVR Coil Diagnostic Right FWD Point “A” trip failed Replace logic assembly Single motor diagnostic FWD Point “A” trip failed Replace logic assembly Diagnostic Right REV Point “A” trip failed Replace logic assembly Single motor diagnostic FWD Point “A” trip failed Replace logic assembly Diagnostic Left FWD Point “A” trip failed Replace logic assembly Diagnostic Left REV Point “A” trip failed Replace logic assembly Breaker welded fault Internal error (Software Only) Replace logic assembly

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Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

TROUBLESHOOTING This section provides troubleshooting information. This guide assumes you have a working knowledge of IGBT controller servicing and that you have the following equipment.

1. Volt/Ohm Meter with Leads 2. Insulated Basic Hand Tools

WHEN WORKING INSIDE THE CONTROLLER, USE INSULATED GLOVES AND TOOLS WHERE POSSIBLE. ALL CONNECTIONS MUST BE TIGHT AND CARE MUST BE TAKEN TO PREVENT BOLTS, NUTS, WASHERS AND OTHER SMALL METAL FASTENERS FROM BEING DROPPED OR LOST INSIDE THE CONTROLLER. BEFORE STARTING ANY POWER-RELATED PERFORMANCE TESTS, THE MACHINE MUST BE JACKED AND SECURELY BLOCKED CLEAR OF THE GROUND WITH ALL FOUR (4) WHEELS FREE TO TURN.

REFER TO THE PARTS MANUAL FOR YOUR PARTICULAR MACHINE WIRING DIAGRAMS AND SCHEMATICS.

THE LOGIC UNIT CONTAINS NO USER-SERVICEABLE PARTS. OPENING THIS SEALED DEVICE WILL VOID THE WARRANTY.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT and Diode Measurements Before taking readings, the following system conditions must be met: 1. Master switch or control handle in the “OFF” position.

2. Panel disconnected from and isolated from the battery (via main circuit breaker) and battery plugs being disconnected.

3. Motor leads disconnected from panel 4. After power is removed, wait for one (1) minute before making measurements to allow voltage to bleed down

IGBT Measurements (See Figure 11) If reading is 0, IGBT is shorted.

There are two IGBT’s wired in parallel; therefore, if one IGBT indicates short, it may be one or both.

FIGURE 11

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Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Individual IGBT Measurements FIGURE 12

28

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Diode Measurements FIGURE 13

29

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Diode Measurements FIGURE 14

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Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Before taking readings, the following system conditions must be met: 1. Panel mounted in vehicle 2. Main circuit breaker in the “OFF” position 3. Power “OFF” at master switch or control handle (must be off at least one minute before taking measurement)

Panel Measurements FIGURE 15

Panel Measurements Before taking readings, the following system conditions must be met: 1.

2.

3.

4.

5.

All connections attached, and power applied Main circuit breaker on Master switch or control handle in the “PARK” or “PARK BRAKE APPLIED” position Accelerator NOT depressed (FS1 open) Main line contactor open   

B+ to B-: Battery Voltage B- to AA: 50V B- to S1L, S4L, S1R, & S4R: 50V

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Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Driver Measurements The measurement of the driver on the Bucyrus America, Inc. Bucyrus 2000 Motor Controller cannot be done with a volt-ohm-meter. In order to determine whether the driver is faulty, a process of elimination is required. The LED indicates if there is “look ahead” voltage on the IGBT’s and as such does not fully indicate whether the driver is working properly or not.

The steps to follow to determine if the driver is faulty are as follows: 1. Determine if any of the IGBT’s or diodes are faulty by performing the previously illustrated tests.

2. With power applied, the master switch or control handle to the “PARK” PARK BRAKE APPLIED” position, and all motor leads connected, measure the voltage with a volt-ohm meter from “B-” to the motor connection leads, each in turn (“S1” to “B-”, “S4” to “B-”, and so on). The main line contactor must be open.

3. The reading should be less than the battery voltage, but higher than “B-” (in the range of approximately 70 volts). This voltage may vary panel to panel as there is leakage voltage through the IGBT’s and diodes.

4. If the voltage is at the same potential as “B+”, then most likely a diode is shorted.

5. If the voltage is at “B-”, then most likely an IGBT is shorted.

6. The calibrator should indicate which channel is faulty.

7. If the calibrator does not indicate which channel is faulty, the faulty component can be determined in the following manner:  Remove power from the panel, remove the motor connection leads from the panel and follow the measurements as indicated in the previous sections, or determine which channel is faulty.

8. If all the IGBT’s and diodes measure okay, the problem may be with the driver or the logic board.

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MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT PANELS

FOR REPLACEMENT PARTS AND MACHINE WIRING DIAGRAMS, PLEASE REFER TO YOUR SPARE PARTS MANUAL.

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Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT Dual Motor Panel FIGURE 16 RESISTOR ASSEMBLY BUSS BAR, B -

THERMAL STRIP AND THERMISTOR

WIRING HARNESS

BUSS BAR, B +

BUSS BAR AND CURRENT TRANSDUCER

RESISTOR ASSEMBLY HEAT SINK ASSEMBLY

BUSS BAR SHUNT ASSEMBLY

34

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT Single Motor Panel FIGURE 17 BUSS BAR CURRENT TRANSDUCER DIODE KIT

HARNESS ASSEMBLY

RESISTOR ASSEMBLY KIT

BUSS BAR ASSEMBLY KIT

BUSS BAR ASSEMBLY

DRIVER BOARD ASSEMBLY

THERMAL STRIP CAPACITOR ASSEMBLY

INSULATOR PLATE

HARNESS ASSEMBLY

COLLECTOR PLATE ASSEMBLY

DIODE KIT IGBT KIT

35

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

IGBT Heat Sink Assembly FIGURE 18

CAPACITOR ASSEMBLY

INSULATOR PLATE

IGBT KIT

COLLECTOR PLATE ASSEMBLY

COPPER SPACER DRIVER BOARD

DIODE KIT HEAT SINK

WIRING HARNESS

36

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Single Motor Panel Harness Assembly FIGURE 19

37

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Dual Motor Panel Harness Assembly FIGURE 20

38

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Dashboard Display FIGURE 21

39

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Dual “Y” Harness FIGURE 22

40

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Harness for Dashboard Display FIGURE 23

RJ11 PLUG CABLE

RJ11 PLUG CABLE

41

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Calibrator Unit FIGURE 24

Bucyrus 2000 Pump Motor Shunt FIGURE 25

42

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

Bucyrus America, Inc.

Bucyrus 2000 Panel Wiring Harness FIGURE 26

43

Revised 12 – 07

MODEL BUCYRUS 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

INSTALLATION, USE, MAINTENANCE AND REPAIR OF MINE POWER STORAGE BATTERIES

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. P/N A6474X26 Revision 10, December / 07  BUCYRUS AMERICA, INC. ALL RIGHTS RESERVED

Bucyrus America, Inc.

TABLE OF CONTENTS Page 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

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Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

II

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

PREFACE This manual is intended to provide GENERAL product information for Bucyrus America, Inc. mine power storage batteries. The illustrations, descriptions and procedures contained in this publication apply only to Bucyrus America, Inc. mine power storage batteries. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.

This Bucyrus America, Inc. mine power storage battery 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, the battery 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 the battery, without the consent of Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render the battery 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 battery.

While this manual attempts to anticipate the most important operations and maintenance needs for this battery, unforeseen circumstances may arise that have not been

addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. 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.

 Bucyrus America, Inc. All rights reserved.

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Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

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Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

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.

3

Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

DANGER ONLY TRAINED AUTHORIZED PERSONNEL SHOULD OPERATE OR PERFORM MAINTENANCE ON THE BATTERY. 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 BATTERY IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

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Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

ENTIRE BATTERY

Mine service batteries can weigh several thousand pounds and could cause severe injury or death should the battery fall on persons or body parts

Batteries must be resting securely in a machine, on battery tables, or platforms capable of supporting the weight while performing maintenance or service on battery.

ELECTRICAL

Electrical shock could cause death or serious injury. The battery produces lethal amounts of current whether connected to a machine or not.

Batteries should be maintained and serviced by qualified personnel.

The battery should be disconnected before servicing.

EXPLOSIVE GASES

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

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

Batteries should be maintained by qualified personnel.

CORROSIVE ACIDS

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

Protective clothing, gloves, and eyewear must be worn when working on batteries. Batteries should be maintained by qualified personnel.

COVERS

Battery covers could fall, crushing hands, arms, or fingers.

Battery covers must be secured with the cover supported when working under the covers.

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Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

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Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

SAFETY PRECAUTIONS AND GUIDELINES OVERVIEW Before you install, maintain or repair a mine service battery READ and STUDY this guide. KNOW how to safely use the battery 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

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

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 servicing or when welding on the battery.

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.

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

Chapter 4 of this guide is dedicated to safety procedures that MUST be followed when using or servicing lead-acid batteries. It is important that you read and understand the procedures outlined in this guide, particularly those in Chapter 4.

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CHAPTER 1 - INTRODUCTION Section I. General 1-1. Scope This guide contains information concerning the theory, construction, installation, use, maintenance, repair, and hazards of lead-acid storage batteries used to power mine tractors, scoops, locomotives, and coal haulers.

1-2. Forms, Records and Reports The following form will be used by personnel responsible for the receipt, storage, operation, charging, and maintenance of lead-acid storage batteries. a. Monthly Storage Battery Record - The Monthly Storage Battery Record is to be used to record the services performed on motive power batteries. This record should be prepared and maintained by the using operator and should accompany the battery at all times. (See Figure 1 for a typical "Monthly Storage Battery Report" form.)

FIGURE 1 – MONTHLY STORAGE BATTERY RECORD

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Section II. Definitions 1-3. Standards Those definitions referenced throughout this manual generally agree with accepted industry standards.

For a more complete listing of "Definitions for Lead-Acid Industrial Storage Batteries" see NEMA Standards publication No. 1B 1-1971.

Copies of NEMA standards may be obtained at nominal cost by writing to: National Electrical Manufacturers Association, Department of Engineering and Safety Regulations, 2101 L Street, N.W. Washington, D.C. 20037.

Section III. Description and Construction 1-4. Battery Mine power lead-acid batteries for electric vehicles typically consist of of: (1) a steel tray into which the cells are assembled; (2) a battery terminal connector; and (3) other components necessary to secure and protect the cells and provide the necessary electrical interconnections. a. Battery Identification and Data - The essential information necessary for proper care of an industrial motive power battery appears on the battery, either stamped into one of the intercell connectors or on a name plate affixed to the tray. This information usually includes the manufacturer's name and model, number of plates per cell, battery capacity, battery voltage, serial number, suggested charging rate, and fully charged specific gravity of electrolyte.

If vital information is missing, or is no longer legible, such information can be obtained by contacting your nearest BUCYRUS AMERICA, INC. representative.

Some manufacturers list, as a part of the model or type designation, the rated ampere-hour capacity of a single positive plate, such as "SS75". As an alternate means of determining rated battery capacity, this number should be multiplied by the total number of positive plates in one cell. To find the number of positive plates in a cell, subtract one from the total number of plates and divide by two. To find the capacity of a battery designated "SS75-19," therefore: 19 - 1 = 18; 18 divided by 2 = 9; 9 x 75 = 675 Ah battery capacity. b. Cell Arrangement - The individual cells, which contain the energy generating components of the battery, may be arranged slightly differently for various types of equipment. The cells of all motive power batteries are, however, always connected in series to produce the required voltage. Cell and battery capacity, which is the available ampere-hours or watt-hours, is a function of the total number and size of plates within each cell. Voltage, though, is the same for all cells regardless of size. Each lead-acid cell yields a nominal 2 volts. c. Connector Arrangement - Connections between cells are made by intercell connectors which may be lead-coated copper straps or be cast of solid lead. These connections are always welded, in proper sequence, by the application of heat to the terminals of the cells. Energy from the battery is drawn off by terminal cables which extend beyond the steel tray wall and are in turn permanently joined to the battery terminal connector.

1-5. Cell

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This is the basic unit of any battery. It is a galvanic cell which produces electrical energy when connected to an electrical load and, after being discharged, may be restored to its original fully charged condition. It has a nominal voltage of 2 volts and consists of an element, from which the energy is derived, and the electrolyte; both are contained by an impact resistant, molded plastic jar. The element is prevented from contacting the bottom of the jar by means of a high impact bridge, which consists of a series of support ribs. These ribs provide sediment space below the bottom of the element to accommodate particles of active material, shed by the positive plates during normal operation of the battery. (See Figure 2.)

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FIGURE 2 – TYPICAL BUCYRUS AMERICA, INC. CELL

Cover - With lead insert bushing prevents leakage and voltage to ground.

Vent Cap – Quarter turn bayonet type simplifies watering and inspection.

Post - Special alloy for increased strength and conductivity.

Separator Guard – White in color to increase visibility for fast electrolyte check.

Post Plate Strap - Extra heavy to insure a permanent connection between post and plates.

Negative Plate – Designed to compliment positive plate performance.

Positive Grid - A non-porous lead alloy casting, designed for maximum current carrying capacity, capable of many years of service.

Vertical Mat - Laminated construction compromised of uniformly spaced fine glass tape that imbed into the active material and an interwoven glass fiber mat wrapped vertically around the positive plate insuring optimum active material retention.

Horizontal Mat - Made of glass fibers with an insoluble binder.

Breaks up gas bubbles and increases positive plate insulation.

Active Material - Specially formulated and uniformly applied under rigid laboratory control to insure maximum efficiency throughout long battery life.

Retainer and Bottom Shield - A high porosity perforated envelop that encases positive plate and glass mats to prevent shorts and insure maximum performance and life.

Jar - Molded of high-impact material to remain leak free under rough treatment.

Separator - Deep channeled, microporous, impervious to heat, acid and corrosion: provides insulation between positive and negative plates while allowing the free flow of electrolyte throughout the cell.

Bridge - Provides firm element support and ample sediment space.

Bucyrus America, Inc. mine batteries incorporate every feature required by today’s mines. They are designed by engineering technology and built by master battery craftsmen according to strict quality control guidelines. DBT America Inc. batteries are the finest available to meet today’s mining requirements, and our precision construction provides new equipment performance throughout a long life.

The top of each cell is fitted with a molded rubber plastic cover sealed to the jar at the edges. A vent or filler cap is located in the center of the cover. This vent permits the escape of hydrogen and oxygen while the cells are gassing and, when removed, provides an opening through which water may be added 11

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to the cell. The positive and negative terminal posts, which are part of the element, fit through openings in the cover. Prior to being connected together, cells are placed so that the positive terminal of one cell is adjacent to the negative terminal of the next. This arrangement permits a conveniently made series connection. a. Element - The element of the cell consists of one group each of positive and negative plates meshed together. The plates are insulated from each other by separators which are inserted between all plates. A plastic element protector is positioned on top of the separators. This prevents mechanical damage to the element and aids in preventing electrical shorts which occur when particles of active material bridge the space between plates. Terminal posts are welded to each group and are used to electrically connect one cell to another. b. Group - This is an assembly of plates of like polarity connected in parallel by welding to a common strap or busbar. A cell must contain one positive and one negative group. The negative group always has one more plate than the positive group. One or more terminal posts are welded to each. c. Plates - The plates (also called "electrodes") are either positive or negative and consist of a cast lead alloy grid and active material. The grid provides support to the active material and becomes the primary electrical conductor. The active materials result from the addition of chemicals to lead oxides which are converted, by electrochemical processing, to lead dioxide in the positive and to sponge lead in the negative.

(1) Pasted type - The grid of the pasted plate consists of horizontal and vertical or diagonal cast lead conducting members within a rectangular cast frame. A slurry of active material is pasted or squeezed into the voids, and the surfaces are then covered by porous glass and plastic retainers to prevent the loss of active material. d. Electrolyte - The element within the jar is immersed in an electrolyte, which is a solution of sulfuric acid and "pure" water. This permits the necessary chemical reaction to occur and provides a conducting medium in which the flow of electric current takes place. The electrolyte in a fully charged cell normally has a specific gravity of between 1.280 and 1.295 at 77 degrees F. As a cell discharges, the specific gravity decreases. Measurement of this specific gravity, by means of a hydrometer, indicates the state of charge of a cell. To save time in determining- this state of charge for the battery, a pilot cell or cells may be chosen; a pilot cell is a selected cell(s) whose condition is assumed to be representative of the condition of the entire battery. e. Separators - Separators are made from microporous plastic, which is resistant to heat and acid.

Separators provide mechanical and electrical insulation between positive and negative plates, but are porous enough to permit passage of electrolyte. The grooved or ribbed side of the separator is placed toward the positive plate to allow a free flow of electrolyte to the active material. The flat side faces the negative plate to contain the sponge lead. f. Positive Plate Retainers - Pasted type plate retainers are added, after pasting, typically by wrapping the plate first with fibrous-type glass tape or mats and then by a perforated plastic envelope complete with bottom boot or by other suitable filtering systems. All types of retainers act to prevent the escape of positive active material during normal use. Retainers are not needed on negative plates.

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Section IV. Principles of Operation 1-6. Fundamentals of Cycling A cycle is a discharge followed by a charge. During the charge, the electrical energy supplied by the charger causes an electromechanical reaction within the battery. This restores the active materials to a fully charged condition. a. The Fully Charged Cell or Battery - The positive and negative plates (electrodes) are separated from each other and immersed in electrolyte. In the fully charged condition, the active material of the positive plate is lead dioxide and that of the negative plate is sponge lead. The electrolyte is a solution of sulfuric acid and water that normally varies in a specific gravity from 1.280 to 1.295. The combination produces a voltage of approximately 2 volts on open circuit. This voltage potential results from the fundamental characteristic of a storage battery which dictates that when two electrodes of dissimilar metals are immersed in suitable electrolyte, and a circuit is closed between the two, electrons begin to flow. A fully charged cell should normally have an on-charge voltage of from 2.45 to 2.70 volts when charging at the finish rate. b. The Discharging Cell or Battery - While a battery is being discharged or used, lead dioxide and sponge lead combine with sulfuric acid to form lead sulfate within both plates. This action causes the specific gravity of the electrolyte to decrease. As the discharge progresses, individual cell and battery voltages decline, generally in direct proportion to the rate of discharge. c. The Discharged Cell or Battery - As the depth of discharge increases, more sulphuric acid is removed from the electrolyte so the specific gravity decreases and may drop below 1.100 as it approaches the specific gravity of water. Almost all of the active material of both positive and negative plates is converted to lead sulfate, and an effective electromechanical reaction is no longer possible.

At this point the battery has reached its discharge limit. d. The Charging Cell or Battery - The charging action begins when the terminals of the battery are connected to an external source of direct current. The electromechanical reaction is reversed and the positive plates, negative plates, and electrolyte start returning to their original charged condition.

Charging causes the battery voltage to rise as active materials are restored. A cell being charged may have a voltage of from 2.12 to 2.70 volts depending upon charging rate and time. e. General - Storage batteries do not actually store electrical energy; instead, they accept the electrical energy delivered to them during charging and convert it into chemical energy. During discharging, this chemical energy is reconverted into electrical energy to be used as needed.

To obtain the best performance and life from a mine power storage battery, it should usually be charged after each shift of use or whenever the specific gravity of the electrolyte falls below 1.240. It is very important that proper ventilation be provided during charging to make certain that (1) the hydrogen gas, given off toward the end of the charging process is dissipated (see Chapter 4), and (2) that individual cell electrolyte temperatures, during normal operations, do not exceed 110 degrees F. 1-7. Ampere-Hour Capacity The electrical capability of a storage battery is usually expressed in ampere-hours. The ampere-hour capacity is the number of ampere-hours which can be delivered under specified conditions of temperature, rate of discharge, and final voltage. Basically, ampere-hours are determined by multiplying the number of amperes which the battery will deliver by the number of hours during which the current is flowing. Total cell or battery capacity then is determined by the size and number of plates which make up

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the element. Due to the variety of job requirements, batteries are produced with many different sizes of cells.

1-8. Voltage With reference specifically to storage batteries, many "voltage" conditions have been recognized. The most important of these are: a. Open Circuit Voltage - This is the voltage of a cell or battery at the terminals, when no current is flowing. The nominal open circuit voltage of an individual fully charged cell is 2 volts. This is true regardless of cell size. The voltage of a 64 cell lead-acid battery is stated, therefore, as 128 volts. b. Initial Voltage - The initial voltage of a cell or battery is the closed circuit voltage at the beginning of a discharge. It is usually taken after current has been flowing for a sufficient period of time for the rate of change of the voltage to become practically constant, usually a matter of minutes. c. Average Voltage - The average voltage of the cell or battery is the average value of the voltage during the period of charge or discharge. d. Final Voltage - The final or cut-off voltage of a cell or battery is the prescribed voltage at which the discharge is considered complete. It is usually chosen so that the useful capacity of the battery is realized without subjecting it to harmful overdischarging. Final voltage will vary with the rate of discharge, cell temperature, and the type of service, but for mine power applications it is considered to be 1.70 volts per cell.

Inital voltage, average voltage, and final voltage are monitored when conducting test discharges.

1-9. Rated Capacity The rated capacity of a storage battery is the number of ampere-hours or watt-hours which it is capable of delivering when fully charged and under specified conditions of temperature, rate of discharge, final voltage, and specific gravity. United States industry standards for mine power batteries always specify this to be at the 6 hour rate of discharge. The total capacity available from a battery is greatest at low rates of discharge over a long period of time. Discharging at high current rates reduces the total ampere-hours available.

1-10. Sulfation Sulfation occurs when conditions within the cell cause sufficient accumulation of abnormal lead sulfate at both the positive and negative plates, permanently affecting the normal chemical reactions. Habitual overdischarging below final voltage, prolonged operation in an undercharged condition, and extended stand periods while in a discharged state are major causes of sulfation. A servicing schedule should be followed to provide frequent monitoring and adequate charging. See Chapter 3, Section 1, for methods of restoring a sulfated battery.

1-11. Operating Cycle An operating cycle of a storage battery is the discharge during use and subsequent charge to restore its initial condition.

1-12. Service Life The service life of a storage battery is the period during which it provides useful power while being discharged. It is usually expressed as the time period, or number of cycles, which elapses before the ampere-hour capacity falls below 80% of its rated value. To obtain maximum service life, it is 14

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recommended that a battery be restricted to one full cycle per 24 hour day or fewer than 300 cycles per year. Other factors which most often adversely influence service life are: 1. Abnormally high or low electrolyte temperatures.

2. Frequent overdischarging.

3. Failure to add water regularly.

4. Frequent overcharging.

5. Poor, or high, resistance, connections or contacts.

6. Adding too much water.

1-13. Effect of Temperature The normal operating characteristics of a storage battery are modified by unusually low or high cell temperatures. a. Low Temperature - Available battery power is reduced by low temperature because electrolyte viscosity and resistance is increased and diffusion throughout the pores of the active material is retarded. For example, a fully charged battery (1.280 to 1.295 specific gravity at 77 degrees F.), when its electrolyte temperature is about 32 degrees F., will deliver only 75% of the capacity which would be available at normal room temperature. This drops to 40% at 0 degrees F. The electrolyte could freeze if a discharged battery were exposed to very cold temperatures for several hours. (See Table 1 for freezing points of various electrolyte concentrations.)

In addition to the discharge-related problems, the charge acceptance of a lead-acid battery is impaired when electrolyte temperatures drop below 60 degrees F. As a result, batteries should always be kept fully charged, especially in cold weather. They should be heated, even during operation or storage, if exposure is severe enough to cause the temperature of the electrolyte to approach 32 degrees F. b. High Temperatures - Although high temperatures (up to 110 degrees F.) do not cause a reduction in available capacity, battery operation is adversely affected. Because most chemical reactions are accelerated at high temperatures, the rate of corrosion of the positive grid is increased and the active material is shed more rapidly. Even electrolyte temperatures above 90 degrees F. will cause some reduction in service life and should be avoided whenever possible. Cell temperatures should never be allowed to exceed 110 degrees F.

TABLE 1 FREEZING POINTS OF VARIOUS ELECTROLYTE CONCENTRATIONS State of Charge-Approximate (Percent)

Specific Gravity

Freezing Point (Degrees Fahrenheit)

100 75 50 25 10

1.280 1.250 1.220 1.160 1.130

-95 -62 -31 +1 +10

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CHAPTER 2 – INSTALLATION, USE, AND MAINTENANCE Section I. Preparation for Use 2-1. Establishing Requirements The number of batteries required for service depends primarily upon the number of 8-hour shifts in effect. Normally, for operation on a single-shift basis, the minimum number of batteries required will be the same as the number of items of operating equipment and the batteries need not be removed from the unit for charging. For operation on a 2- or 3-shift basis, the minimum number of batteries required will be twice the number of items of operating equipment and it will, therefore, be necessary to exchange discharged batteries for charged batteries at the end of each work shift. Whenever possible, it is recommended that more than the minimum number of batteries be available for multiple-shift operation, providing at least an 8-hour cooling period after charging. In an emergency, any one battery can be used for two 8-hour shifts during a 24-hour period, but this procedure, repeated regularly, will probably cause high electrolyte temperatures and could seriously affect service life. Therefore, where 3-shift operation is normal, 3 batteries will be required per item of equipment.

2-2. Unpacking Upon Receipt 1. It is important first to examine the exterior of the packing for wet spots on bottom or sides which may indicate leaking jars. Inspect also for physical damage to battery package because the battery could be affected as well. Report any damage to your supervisor.

2. Make certain that the package is right side up, with skid mounts resting firmly on floor.

3. Use a forklift truck or crane of sufficient capacity to remove the packaged battery from the truck or freight car. If a crane is employed, be sure the sling is secured against the bottom of the skid and not around the skid mounts.

LIFTING DEVICES USED TO MOVE BATTERIES MUST BE CAPABLE OF CARRYING THE WEIGHT STAMPED ON THE BATTERY CASE. KEEP ALL PERSONS AND BODY PARTS FROM UNDER THE BATTERIES WHEN THEY ARE LIFTED. 4. Move the crated battery to the uncrating area and remove packaging, including any wrapping or other protection provided to the battery terminal cable connectors.

5. Inspect battery and report any damage to your supervisor.

6. Use a properly insulated lifting beam of adequate capacity to lift the battery, by means of an overhead hoist, from the battery skid.

2-3. Handling Batteries When lifting batteries, always use a device which exerts a vertical pull on the lifting eye or tab. If a chain must be used, it should be in combination with a lifting beam with provision for adjusting lifting hook centers to the exact length of the tray. Any method of lifting which tends to "squeeze" or "stretch" the battery tray may distort it and could damage jars or disturb cell seals. A piece of rubber sheet or other insulating material, temporarily laid on the battery while lifting, will prevent any possible short circuits from chains or hooks. As an additional precaution against accidental shorting, the lifting beam hooks should be electrically insulated from each other.

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2-4. Preparing Batteries for Use a. See Table 2 for proportions of sulfuric acid and water to make electrolyte.

TABLE 2 Note: Sulfuric Acid of 1.400 Specific Gravity Specific Gravity Required

Parts Water Required

1.375 1.365 1.355 1.350 1.340 1.330 1.325 1.315 1.310 1.300 1.290 1.285 1.280 1.275 1.270 1.260 1.255 1.250 1.245 1.240 1.230 1.225 1.220 1.215 1.210 1.205 1.200

.075 .11 .14 .16 .20 .24 .27 .31 .33 .38 .43 .46 .49 .53 .56 .63 .67 .70 .74 .78 .85 .905 .96 1.00 1.05 1.11 1.16

Parts Acid Required 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

b. Charged and Wet Batteries - Charged and wet batteries are shipped with cells filled and fully charged. Prepare these batteries for use as follows:

PROPER EYE AND BODY PROTECTION MUST BE WORN AT ALL TIMES WHEN SERVICING THE BATTERIES TO PREVENT ELECTRICAL SHOCK AND CONTACT WITH THE BATTERY ACID. CLEAN AND NEUTRALIZE ANY ACID SPILLS IMMEDIATELY. 1. Examine battery to see if electrolyte has been accidentally spilled. If so, clean and neutralize any spillage with a cloth that has been dipped in a soda solution. Rinse area with clear water.

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2. Remove vent caps and check the electrolyte level in each cell. Take and record the specific gravity reading, electrolyte temperature, and individual open circuit voltage of each cell. Note any irregularities.

3. Check to make sure that all cells are properly connected and that terminal connections are tight. If there are irregularities in the electrolyte levels or specific gravity readings, or if the battery has been in storage for more than 30 days, it should be given a freshening charge (see Paragraph 2-10d).

4. Recheck electrolyte levels after charging and after gassing has stopped. Again take and record specific gravity readings and electrolyte temperatures. If irregularities in electrolyte specific gravity readings still exist, they should be adjusted as described in Paragraph 3-12.

2-5. General Economical and dependable performance from a storage battery depends, to a great extent, upon proper charging. Faulty charging causes a decrease in battery service life and dissatisfaction with its performance. The selection of suitable charging equipment and methods is as important as the application of the correct battery. A mine battery installation is completely satisfactory only when the unit, battery, and charger operate as a smoothly functioning team. This text on chargers is for general information and guidance only. If specific data is required on a particular type of charger, contact the nearest sales representative.

When preparing a battery to be charged, make certain that all points of contact between the charger and the battery are clean to assure good conductivity. Also make certain that the positive terminal of the battery is connected to the positive terminal of the charger and, correspondingly, negative of battery to negative of charger.

PERMANENT DAMAGE TO THE BATTERY OR CHARGER MAY RESULT IF THE BATTERY IS CONNECTED INCORRECTLY. 2-6. Charging Principles Charging, as applied to a storage battery, is the conversion of electrical energy into chemical energy within the cell or battery. This restores the active materials and is accomplished by maintaining a unidirectional current to the battery in the opposite direction to that during discharge. When a cell or battery is said to be charged it is understood to mean fully charged. The type of battery, service condition, time available for charging, and the variation in battery voltages will strongly influence which charging method is best for a particular situation. Normally lead-acid batteries are recharged in 8 hours following a full discharge. However, they can be recharged within other time periods when desirable. A deeply discharged battery will absorb high current rates when the voltage is low. As the charge progresses, the voltage steadily increases until it reaches gassing voltage, approximately 2.37 volts per cell at 77 degrees F. At this point, battery chargers normally reduce charging rates automatically and taper to finishing rates which are used to complete the charge. The battery is fully charged when nearly all of the active material has been converted and when the specific gravity of the electrolyte and cell voltage have reached their maximum or constant values (corrected for temperature), as indicated by similar readings over a two or three hour period.

Batteries used in mine power applications are cycled - they are either being charged or discharged. In most circumstances, batteries are charged after each shift of use, so they are cycled many times during their lifetime. Incorrect charging for only a few cycles will do little harm, but if repeated day after day, the battery's service life will be seriously shortened.

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2-7. Charging Rates Proper charging means charging the battery sufficiently without overcharging, overheating, or excessive gassing. The charge is usually started at high amperage which is known as the starting rate.

Later during the charge, this rate of current flow is reduced to what is called the finishing rate. It is suggested that this finishing rate should not exceed 5 amperes per 100 ampere-hours of rated battery capacity. The starting rate may be as much as four to five times higher than the finishing rate.

Lead-acid batteries should be charged for a sufficient length of time and at a rate which will put back into the battery the same number of ampere-hours removed on discharge, plus approximately 10% additional which is an acceptable, and in fact desirable, overcharge. The specific amount of overcharge depends upon the temperature, age, and history of the battery. In general, it is more harmful to excessively overcharge an older battery, or one which is operating at high temperature, than a new battery or one operating consistently at room temperature. Any charge rate is permissible which does not produce excessive gassing or cell temperatures greater than 110 degrees F. 2-8. Control of Gassing Gassing is the evolution of gases from one or more of the electrodes during electrolysis. It is a natural phenomenon which takes place when a battery on charge can no longer accept all of the current being applied to it. Gassing is evidenced by bubbling of the electrolyte. The gases liberated are oxygen (evolved at the positive plates) and hydrogen (evolved at the negatives).

The point at which significant gassing begins is determined by voltage, but the amount of gas depends upon the portion of the charging current that is not being absorbed by the battery. Normally, noticeable gassing will begin when the voltage exceeds 2.30 volts per cell. At 2.40 volts per cell, gassing will be normal; at 2.50, it will be rapid. The amperage at which gassing becomes excessive depends primarily upon the state of charge and electrolyte temperatures. As the battery approaches full charge, it is necessary to reduce the charging rate to a point at which excessive gassing is prevented. This safe rate is the finishing rate or below. When proper charging equipment is used, the tapering of the charging current to the finishing rate is achieved automatically.

2-9. Charging Methods and Equipment The modern storage battery, used with a properly designed, modern, automatic charger, needs only normal water additions, occasional cleaning, and regular checking of both charger adjustment and battery condition to provide long, dependable service.

There are two recommended methods for the normal charging of motive power batteries: a. Modified Constant Voltage (potential) Method - The modified constant voltage method, in which the tapering of the charging rate is accomplished gradually, requires a source of direct current with a constant bus voltage of approximately 2.63 volts for each cell. This is for an 8-hour charge. Proper series resistance in the output circuit inherently provides the correct starting rate and assures that the rate will automatically be reduced, as the charge progresses, to the recommended finish rate. The constant voltage source may be either a motor-driven generator or rectifier. b. Taper Method - The taper method can be used with either generator or rectifier type equipment. The charger is designed to provide the correct charge rate during a constantly tapering charge. This is accomplished by coordinating the rising battery voltage with the design characteristics of the charger.

The shape of the current-taper curve will vary with different types of equipment, but the result is essentially the same. Solid state chargers are available which deliver as much current as the battery can accept, up to maximum charger output, and then taper the input sharply, when cells begin to gas, to keep finish rates low. These chargers do not require adjustment.

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2-10. Types of Charge a. Normal Charge - The two generally recommended types of normal or routine charges, following a deep discharge, are: (1) modified constant voltage charge, and (2) taper charge. b. Boost Charge (Quick Charge) - A boost charge of a storage battery is a partial charge, usuallly at a high rate for a short period. Such a charge is given in an emergency when it is believed that the amperehour capacity of the battery may be less than normal and insufficient to complete a planned period of work. A boost charge may also be used when it is not possible to give a battery one of the recommended types of normal charge. c. Equalizing Charge - An equalizing charge of a storage battery is a prolonged charge, usually at the finishing rate or less, to correct any inequalities of voltage or specific gravity which may have developed between cells during service. It consists of following a normal charge with an extended charge of 4 hours at a rate no higher than the finishing rate. In mine power applications, a battery should receive an equalizing charge weekly. d. Freshening Charge - A freshening charge of a storage battery is a charge given to batteries in storage or during inactive periods to replace losses due to self-discharge and to assure that every cell is periodically brought to a fully charged state.

2-11. Charging Precautions 1. When connecting the battery to the charger always connect positive (+) to positive and negative (-) to negative terminals.

2. Always recharge the battery as soon as possible after discharging.

3. Keep vent caps tightly in place while the battery is being charged, except when servicing the cell or when taking specific gravity or temperature readings.

4. Make sure that battery and charger voltages and ampere-hour ratings match when preparing to charge batteries.

5. Make certain that charging area is well ventilated.

6. Prohibit smoking and open flames in charging area.

7. Do not allow tools or other metal objects to contact intercell connectors.

8. Observe safety and health practices defined in Chapter 4, Section 11. It is especially important, while preparing for charging, to take the following precautions: (1) Wear protective gear provided and know the location of fresh water for emergency purposes.

(2) Use proper mechanical equipment to move or lift batteries.

(3) Provide acceptable fire extinguishing equipment.

Section II. Routine Maintenance 2-12. General

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The modern industrial battery is designed and built to give an average of 1500 cycles of charge and discharge during its life, depending upon the application and the operating environment. The exact length of the service life will depend, to a great extent, upon the care the battery receives. The following maintenance procedures, carried out at the proper time, will do much to prolong the life of the battery and provide efficient, satisfactory service.

PROPER PROTECTIVE CLOTHING AND EQUIPMENT MUST BE USED WHEN SERVICING BATTERIES TO PROTECT AGAINST ELECTRICAL SHOCK AND BATTERY ACID. BATTERIES, CHARGERS AND RELATED ELECTRICAL EQUIPMENT SHOULD ONLY BE SERVICED BY QUALIFIED, PROPERLY TRAINED PERSONNEL. 2-13. Charger Adjustment Make sure that the charger adjustment, for control of charging rates and cut-off, are correct. This will ensure that the batteries are properly charged with no excessive overcharge. Batteries that are overcharged regularly will need water more often, and cell temperatures usually will be higher than normal. If either condition is evident, adjust the charge rate downward, in those chargers which have provision for adjustment, so it is between a normal finish rate and one-half normal finish rate.

2-14. Cleaning a Battery Inspect the battery at least once each month to make certain the terminal connections are tight.

Remove dirt or electrolyte accumulation from the tops of the cells. Wash weekly with clean water. Using a solution of baking soda and water (one pound of baking soda to one gallon of water), neutralize any acid which may be collected at cell or battery terminals to keep them free from corrosion.

Use the solution until all fizzing stops. Work the solution under the connectors. To remove all traces of soda solution and loose dirt, rinse the battery down with clear water from a low pressure hose.

Whenever the battery top is being cleaned or rinsed, vent caps must be tightly in place.

2-15. Adding Water A certain amount of water loss in cells is normal and it should be replaced with "pure" tap water or distilled water. In some geographical areas, tap water may contain chemicals or other impurities harmful to batteries. The NEMA recommendation for battery replacement water lists the following maximum allowable impurities (parts per million): Total Solids Chlorides as CI Nitrates as NO 3 Iron as Fe

350 PPM 25 PPM 10 PPM 4 PPM

DBT AMERICA INC. PROVIDES WATER ANALYSIS SERVICE. A MINIMUM OF ONE QUART IS REQUIRED. CONSULT YOUR SALES REPRESENTATIVE.

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Check the height of the electrolyte at least weekly and if water is needed, add just enough to bring the electrolyte to proper level. Do not overfill. Batteries should be watered only when discharged and only cover plastic plate with holes - never any higher.

Add water often enough to prevent the electrolyte level from dropping below the perforated separator protector. Ideally, a watering schedule should be established. This schedule should assure adequate watering while taking into consideration those factors which control water consumption, such as (1) frequency of charging, (2) water storage capacity of the specific cell type, and (3) age and condition of the battery.

2-16. Taking Hydrometer Readings 1. With the tip of the hydrometer immersed in the electrolyte, squeeze the syringe bulb and then slowly release it, drawing into the cylinder or barrel just enough electrolyte to permit the hydrometer float to ride free. The float stem must not touch the side of the cylinder nor the top of the syringe. If the float stem touches the upper area of the syringe, too much electrolyte has been drawn up; if the float still rests on the bottom, too little electrolyte has been drawn up. (See Figure 3.)

2. Read the hydrometer float scale with your eye at the same level as the electrolyte. The reading should be taken at the surface of the liquid, disregarding any slight curvature. This reading will be the specific gravity uncorrected for temperature. (See Table 3 for correction factors.)

3. Return all electrolyte to cell.

2-17. Record Keeping Facilities with more than just a few batteries will find that records of battery cycles, maintenance, and repair are indispensable for an effective battery maintenance program. In addition to those monthly records which require the posting of data each time a battery is charged, the following procedure will be helpful: 1. Establish a battery identification system giving each battery a code number. A multiple-digit system is suggested.

2. Record specific gravity of the pilot cell or cells before and after each charge. Pilot cells should be selected from those nearest the center of the battery and identified by differently colored vent caps.

They should be representative of the balance of the cells in the battery.

3. Record the number of cycles on a cumulative basis plus maintenance and repair information. Note any irregularities. The use of a "Battery Cycle and Maintenance Record" form is recommended. If variations in specific gravity readings exceed 20 points (.020) and on-charge voltage, after an equalizing charge, varies by more than .15 volts, contact your DBT AMERICA INC. service representative.

4. When the battery is new, and on at least an annual basis thereafter, read and record the specific gravity and open circuit voltage for all cells of the battery.

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FIGURE 3 – TAKING HYDROMETER READINGS

TABLE 3 SPECIFIC GRAVITY TEMPERATURE CORRECTION CHART Electrolyte Temperature (Degrees Centigrade)

Electrolyte Temperature (Degrees Fahrenheit)

Point Correction

110 107 104 101 98 95 92 89 86 83 80 77 74 71 68 65 62 59 56 53 50 47 44 41 38 35 32

230 221 218 212 209 203 198 194 185 180 176 171 167 158 152 149 140 135 131 128 122 118 113 104 99 95 86

+11 +10 +9 +8 +7 +6 +5 +4 +3 +2 +1 No Correction -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15

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CHAPTER 3 – FIELD SERVICING AND REPAIR Section I. Troubleshooting 3-1. General In addition to the required routine maintenance described in Chapter 2, Section III, storage batteries may, at some time during their service life, require more extensive or unusual care. Such care should be given as soon as it has been determined that a problem exists or that trouble may be developing. This section deals with the means of identifying existing or impending problems and offers possible solutions.

The Troubleshooting Chart, Table 4, defines the most common problems which could occur during a battery's lifetime. If the suggested operational remedies are ineffective, it may be assumed that there is an internal problem and it will be necessary to disassemble the cell or cells to inspect the elements and sediment well. If the cause of the problem can only be corrected by completely replacing cells or the battery, this information should be reported to the person in authority.

3-2. Restoring a Sulfated Battery Continued undercharging a battery, even to a small degree, leads to excessive "sulfation." The same is true of batteries which have been left standing in an uncharged state for an extended period. High temperatures rapidly accelerate sulfation when batteries are left standing in a partially charged condition.

The cells of a sulfated battery will give low specific gravity and voltage readings. The battery will not become fully charged after a single normal charging when sulfation has taken place over a prolonged period.

If the sulfation has not progressed too far, it may be possible to restore the battery to a serviceable condition by using the following special procedures: 1. Thoroughly clean the battery. (See Paragraph 2-14.)

2. Bring the electrolyte level up to a point which is just visible over the separator-protector by adding approved water.

3. Put the battery on charge at the prescribed finishing rate until the rated ampere-hour capacity has been returned to the battery. Record the voltage and specific gravity readings. Correct the specific gravity readings for temperature by using Table 3. If the temperature at any time during these procedures exceeds 110 degrees F., stop the charge and allow the battery to cool to 90 degrees F. or below before continuing. Charge the battery until the specific gravity shows no change during a 4 hour period while taking hourly readings. With automatic charging equipment, the battery may have to be placed on equalizing charge two or three times. If a battery is badly sulfated, the specific gravity may rise only 30 to 40 points (.030 to .040) during the first charge.

4. Place the battery into service and discharge it to a fully discharged condition.

5. Charge the battery again until the specific gravity shows no change during a 4 hour period.

6. Repeat the cycling process until the specific gravity rises to within 30 points of a normal fully charged battery, then place the battery back in routine service. Even though specific gravities may be lower than normal, they should not vary much from cell to cell. If they do, problems other than sulfation may be present. If the spread between the highest and the lowest gravity reading is 50 points or more, refer to the Troubleshooting Chart for help in identifying the problem. If the battery still has not responded to treatment, it should be replaced.

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3-3. Correcting Excessive Self-Discharge While a storage battery is in a charged state, a local electrochemical reaction takes place within the cells, which causes very gradual discharging. This reaction is known as self-discharge. A small amount is quite normal in mine power batteries where grids are made from antimonial lead. The rate of selfdischarge is temperature-related and increases significantly as temperatures rise. Table 4 shows the relationship between temperature and loss of specific gravity. The normal rate at 77 degrees F. to 80 degrees F. is a loss in specific gravity of about one point (.001) per day. This becomes of concern only when a wet battery is to be stored for weeks at a time. It can be ignored as a factor in normal battery operation.

It is possible, however, particularly during the latter stages of a battery's life, for the rate of discharge to become much greater and even limit the battery's duty cycle. Excessive self-discharge may be caused by defective separators or plates which have become shorted at the edges. Edge shorting is usually caused by loss of positive active material which can fill the sediment well or build up on the top or sides of the plates and eventually bridge the space between the positives and negatives. If a shorted condition seems likely, the element should be pulled for examination and the defective separator replaced, shorts cleared, or cells replaced. Usually, if the sediment well is full, salvage is impractical.

3-4. Test Discharge A capacity test is sometimes desirable to determine a battery's actual discharge capability as compared to its 6-hour rated capacity.

This can be a significant diagnostic tool when equipment does not operate as expected and it can help determine when the battery should be replaced. When a battery consistently delivers less than 80% of its rated ampere-hour capacity, either some cells are substandard or the battery has reached the end of its useful life and should be replaced.

A test discharge is performed by discharging a fully charged battery at a fixed rate under carefully controlled test conditions.

Section II. Repairing Batteries 3-5. General Storage batteries which have been damaged or which contain defective cells may, if the rebuilding cost and time are justified, be restored to a serviceable condition.

It is important to check a battery thoroughly if it has been involved in an accident or if it is believed to be defective. A neglected battery will continue to deteriorate even when not in use. Usually rebuilding is justified if the majority of the cells are in good condition.

This section explains how to remove cells from a battery and how to repair them if they are to be salvaged. Some special tools and parts will be required, depending upon the work to be done.

Reference will be made to the use of such special devices but they will not be further identified in this manual. Each manufacturer identifies all tools, accessories, and replacement parts by an appropriate part number. Use this number when making reference to them.

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Before starting any repairs, remove all vent caps from cells to be repaired as well as from all surrounding cells. The space above the electrolyte must be cleared of hydrogen gas before proceeding with repairs. Introduce a low volume air stream (volume and force equal to that produced by fanning each cell with a stiff piece of cardboard or other suitable nonconducting material) into each cell for at least 30 seconds. Be very careful when using air so that the electrolyte is not splashed out of the cell. Do not blow breath into cells. Wear protective face shield or goggles, rubber gloves, and apron. After cells have been purged, cover all vent openings with several layers of water-dampened cloth before starting repairs.

3-7. Removing lntercell Connectors Special intercell connector drills are designed to cut the bond between the cell post and the connector while permitting the post to remain for later rebuilding. The drills come in different sizes. When using them, be careful to cut only as deep as necessary, usually 1/4" to 3/8". Make certain vent plugs are in place. During drilling, try to center on the cover bushing and make sure any lead curl produced does not short across other connectors. After drilling, the intercell connectors can be lifted off with a pair of pliers.

3-8. Removing a Complete Cell After removing connectors as described in Paragraph 3-7, isolate the cell from adjacent cells. This may require cutting of compound or removal of spacers. Use a long spatula or similar tool to free the cell from top to bottom. When the jar walls are free, the cell can be lifted from the battery tray. All cells are heavy so a suitable lifting device, such as an electric hoist, is recommended. Threaded post clamps or cell pullers are available which can be burned or clamped to the posts, and used to pull the cell. Use a non-conducting bar between the loops of the post clamps and hook the hoist to this bar.

After removing the cell, neutralize any acid in the tray with a soda solution and clean up the residue.

When a cell or element is being pulled, it is advisable to have on hand both a replacement jar and a cover in the event that either of the original parts are damaged in the process.

If a wet and charged cell has been pulled and allowed to stand unsupported, the jar walls may bulge and permit the electrolyte level to drop. Do not attempt to adjust electrolyte levels until cells have been reinstalled in the battery.

TABLE 4 TEMPERATURE EFFECT ON BATTERY SELF-DISCHARGE Temperature (Degrees Fahrenheit)

Loss of Specific Gravity Per Day

120 100 80 50

.004 .003 .001 .0005

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TABLE 5 STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

BATTERY OVERHEATS DURING CHARGE

1. Malfunctioning charging equipment.

1. Replace or repair defective charger parts (timer, voltage sensitive relay, control board, etc.)

2. Charging equipment out of adjustment.

2. Adjust start or finish charging rates.

3. Defective or weak cell(s).

3. Replace or repair problem cell(s).

4. Battery worn out and beyond economical repair.

4. Replace battery.

5. High resistance connection within battery.

5. Check for hot wires, cells, intercell connectors, charging plugs, etc. Repair or replace defective component(s).

6. Low electrolyte level.

6. Add water; Just cover separator protector when discharged.

7.Battery charged in the vehicle with battery compartment closed or the tray cover closed.

7. Open the compartment during charge or charge the battery out of the unit with the tray cover opened.

8. Battery over 100 degrees F. when placed on charge.

8. Allow battery to cool below 90 degrees F. before charging.

1. See causes 3 through 8 above.

1. See remedies 3 through 8 above.

2. Worn out bearings, brakes dragging, or other vehicle problem causing high current draw.

2. Repair or replace defective unit problems.

3. Over discharge of battery.

3. a. Require drivers to return battery for recharge when vehicle begins to slow down.

BATTERY OVERHEATS DURING DISCHARGE

b. Put more batteries into service.

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TABLE 5 (Continued) STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

BATTERY NOT COMPLETING FULL WORK SHIFT

1. Battery not fully charged before placed into operation.

1. See that battery has reached full charge specific gravity before placing into operation.

2. Weak, leaking, or defective cell(s) in battery.

2. Repair or replace cell(s) or battery.

3. Grounds or shorts in the battery.

3. Remove grounds or shorts.

4. Battery worn out and beyond economical repair.

4. Replace battery with equal or higher capacity battery.

5. Battery too small for job.

5. a. Replace battery with one having higher capacity. b. Purchase extra batteries (with higher capacity if possible) and change them more frequently.

LOW ELECTROLYTE

6. Electrical or mechanical problem.

6. Troubleshoot vehicle and repair.

1. Cracked or broken jar(s).

1. Replace jar(s) and adjust gravity.

2. Cell missed when watered.

2. More careful attention when watering.

3. Defective or weak cell(s).

3. Repair or replace cell(s)

4. Frequent overcharge.

4. See items 1 and 2 in “Battery Overheats During Charge.”

5. Battery not regularly watered.

5. Water battery regularly.

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TABLE 5 (Continued) STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

UNEQUAL CELL VOLTAGES

1. Grounds in battery.

1. Clean battery.

2. There is a “tap” off the battery for auxiliary equipment (radio, light, etc.)

2. a. Use dropping resistor instead of tap. b. Equalize battery regularly.

3. Battery sluggish due to lack of work.

3. Give battery a deep discharge and equalizing charge.

4. Leaking cell or cover.

4. Replace jar or cover and adjust gravity.

5. Defective or weak cell(s).

5. Repair or replace defective cell(s)

6. Battery worn out beyond economical repair.

6. Replace the battery.

7. Acid loss in few cells by tipping battery over.

7. Adjust specific gravity.

3-9. Removing an Element If the jar is known to be serviceable, it may not be necessary to remove the complete cell. Usually only the element, complete with cover, has to be pulled. This can only be done, however, on those batteries containing a compound type cover-to-jar seal. On these, after removing connectors, draw a warm putty knife through the sealing compound close to the inside jar wall. Use a threaded post clamp or cell puller and hoist to raise the element, with cover in place, first to drain position, and then up and out of the jar.

When pulling an element from a cell which has been removed from a battery, use jar hold-down clamps.

Some batteries are furnished with permanent seals between the cover and jar. With these, if a defect occurs, the complete cell must be pulled and cover-to-jar seal cut or sawed to permit removal of the element. In doing so, both jar and cover must be replaced and resealed in accordance with the correct instructions.

When removing an element, lift it halfway out of the jar and hold it at this position until most of the electrolyte has drained off. Then raise the element to clear the top of the jar. Do not, unless absolutely necessary, expose an element to air longer than five minutes. Oxygen in the air combines with the active material in the negative plates, causing them to oxidize and heat. If the exposure persists, negatives will 30

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discharge. While the element is out of the jar, check the sediment well in the bottom of the jar. If it is full of shed material, the cell probably will have to be replaced.

Plate and separator edges may be inspected while the element is suspended above the jar. A more thorough inspection of separators, plate insulation, grids, and active materials may be indicated. If so, lay the element on its side on a clean non-metallic surface. The plates should be at right angles to the table surface so the element can be fanned slightly to permit the removal of separators. Always on negative side.

When reinstalling separators, make certain that the flat side of the separator is against the negative plate and the ribbed side is facing the positive. They should be pushed up until they are flush with the bottom of the element and they should project equally on each side of the plates.

Before installing an element in a previously used jar, wash out any sediment which may have accumulated in the bottom of the jar and clean all compound from around the inside of the top edge.

Clamp the element, if necessary, when reinstalling it in the jar. Make certain that the element is entering the jar properly and that the plates are at right angles to the plate support ribs in the bottom.

When installing an element with a cell cover attached, use a putty knife to guide the lip of the cover past the top edges of the jar.

3-10. Replacing Cell in Battery Cells from which the elements were pulled, or which had damaged jars replaced, should be given an equalizing charge and acid should be adjusted immediately followinging repair before they are returned to service. (See Paragraphs 2-10c and 3-12.)

Before lowering a cell into a battery tray, be sure that it is correctly positioned relative to adjoining cells to which it is to be connected. Cells must be connected in series with the positive side of one cell connected to the negative side of the adjacent cell.

When the problem has been corrected and the cell is returned to the battery tray, the cover must be resealed to the jar. With the exception of those cells which contain a permanent jar-to-cover seal, a special asphalt type sealing compound is used for this purpose. Heat the compound until it melts, but do not let the temperature get above 400°F. Pack any large openings between cover lip and jar wall with cold compound and then pour the hot compound into the sealing groove in two steps. First pour the groove full and soft flame with a torch to improve the adhesion; then fill and flame again. Allow compound to cool and trim excess.

After sealing, pressure test cells for 10 seconds at a maximum of 1.5 psi and reinstall intercell connectors by welding or "burning" them to the terminal posts. A small hot flame is recommended such as is available from a standard commercial burning torch using natural gas and oxygen or propane and oxygen. Carbon burning outfits are also acceptable.

ALWAYS BE SURE THE CELLS ARE PURGED OF GAS, AS EXPLAINED IN PARAGRAPH 3-6, BEFORE USING AN OPEN FLAME OR BURNING ARC ON TOP OF THE BATTERY. 3-11. Replacing a Cell Cover The specific methods used to seal cell covers to both the jar and the terminal posts are as follows:

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a. Sealing Compound and Lead Bushing Design - Probably the most commonly used system, an asphalt type compound is applied to seal the cover to both rubber and plastic jars. Lead bushings, molded into the cover as inserts, are welded or "burned" to the terminal posts to prevent electrolyte leakage around the posts. When replacing a cover of this type, first cut the compound with a warm putty knife. Cut the full depth of the cover adjacent to the jar wall from corner to corner on each of the four sides. Since reuse of covers which have been removed from the element is not recommended, use a post trimmer to cut off the post extensions above the cover. Break the lead bond between post and lead insert by driving the cover down approximately 1/32". The lead insert mold placed over the post and tapped with a hammer serves this purpose. Insert a hook through the vent opening and lift the cover off. Remove all sealing compound adhering to jar wall and neutralize these surfaces and upper portion of all terminal posts, using a cloth moistened with a soda solution. Thoroughly dry all of the neutralized surfaces. Install the new cover, complete cover-to-jar seal, and reburn cell connectors as described in Paragraph 3-10. b. Epoxy Seal and Seal Nut Design - This is one of the newer systems which employs an epoxy or permanent, hard seal between cover and jar. To disassemble a cell of this design requires that the jar be cut and that both jar and cover be replaced. When reassembling with a new jar and cover, it is very important to adhere to the following procedure to obtain an effective seal: 1. Epoxy can be used only on rubber jars and covers.

2. Thoroughly clean cover and jar sealing areas first with xylol (xylene), then with isopropyl alcohol; use a separate cleaning cloth for each.

3. Caulk bottom of seal groove with glass cord. Tamp corners in. Make overlap small. Do not use warm compound with epoxy.

4. Use special epoxy sealant as recommended by the battery manufacturer. Follow instructions provided.

5. Apply epoxy in two pours. Make second pour within two hours after first pour. Fill to top of jar. Do not overfill.

6. Pressure test seal after three hours or more from time of final pouring. Pressure test to 1.5 psi for 10 seconds. d. Heat Bonded Plastic Cover-to-Jar Seal and Lead Bushing Design - This is the newest of the sealing systems used with motive power batteries. To disassemble a cell of this design also requires that the jar be cut and both jar and cover be replaced. The seal between jar and cover is, in effect, a plastic weld. It can only be used with jars and covers made from identical plastic molding material.

Since special techniques must be used when resealing these covers, the battery manufacturer recommends that these cover-to-jar seals not be repaired in the field. Manufacturers' instructions request that such repairs be made in their service stations only.

3-12. Adjusting Specific Gravity of Electrolyte Fully charged cells usually operate at a specific gravity between 1.280 and 1.295. Normally it should never be necessary to adjust the gravity, but upsets, jar breakage, additions of too much water, and careless use of hydrometer can result in electrolyte loss and possible reductions of battery capacity. Lost electrolyte must be replaced but only after it has been determined that charging will not restore the gravity to normal when at the recommended level.

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Therefore a cell or battery should first be given an equalizing charge as described in Paragraph 2-10c.

Never make a gravity adjustment on a cell which does not gas vigorously while on charge.

If, after the equalizing charge, the specific gravity of any cell, corrected for temperature, is lower than normal, it should be adjusted in the following manner: 1. Put battery back on charge at the finish rate until cells are actively gassing to provide proper mixing.

2. Remove electrolyte from the low reading cells until level reaches separator protector.

3. Slowly add 1.400 specific gravity sulfuric acid to the cell while it is still gassing.

4. Wait 15 to 20 minutes for the added acid to become thoroughly mixed, then read the specific gravity. If it is still low, repeat the process until gravity is normal. As a guide, every 1/4" of electrolyte that has been removed and replaced by 1.400 acid will cause the specific gravity to rise 4 to 5 points (.004 to .005).

If the corrected specific gravity of any cell is higher than normal, proceed as follows: 1. While the battery is gassing on charge, withdraw from the cell a small amount of electrolyte and replace with approved water.

2. Repeat, if necessary, at 20 to 30 minute intervals until the desired reading is obtained. Every 1/4" of electrolyte which is replaced with water will cause the specific gravity of the cell electrolyte to drop 4 to 5 points (.004 to .005).

NEVER ADD ACID WITH A SPECIFIC GRAVITY HIGHER THAN 1.400.

STRONGER ACID COULD PERMANENTLY DAMAGE THE CELL. WHEN MIXING OR CUTTING ACID, ALWAYS ADD THE ACID TO THE WATER. NEVER POUR WATER INTO ACID. A VIOLENT REACTION COULD RESULT WHICH MIGHT CAUSE PERSONAL INJURY. WHEN WORKING WITH ACID, ALWAYS USE A FACE SHIELD OR GOGGLES, RUBBER GLOVES, AND AN ACID RESISTANT APRON.

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CHAPTER 4 – HEALTH AND SAFETY Section I. Battery Hazards 4-1. General A lead-acid battery can be very useful, safe source of electrical power. While installing, using, maintaining, or repairing a motive power battery, opportunities exist, however, for exposure to potentially dangerous situations. This section identifies those hazards which could result from improper handling or use.

4-2. Hazards a. A sulfuric acid solution is used as the electrolyte in lead-acid batteries and has a concentration of approximately 37% by weight of sulfuric acid in water. In this diluted state, it is not as hazardous as strong or concentrated sulfuric acid, but it acts as an oxidizing agent and can burn the skin or eyes and destroy clothing made of many common materials such as cotton or rayon. b. An explosive mixture of hydrogen and oxygen is produced in a lead-acid battery while it is being charged. The gases can combine explosively if a spark or flame is present to ignite them. Because hydrogen is so light, it normally rises and diffuses into the air before it can concentrate in any explosive mixture. If it accumulates into gas pockets, as can occur within a cell, it might explode if ignited. c. Electricity is produced by the batteries on discharge and, while most persons cannot "feel" voltages below 35 to 40 volts, all mine power batteries should be regarded as potentially dangerous. A lead-acid battery is capable of discharging at extremely high rates and, under conditions of direct shorting, can cause damage and serious injury. d. The weight of these heavy batteries can easily cause painful strains or crushed hands or feet if improperly lifted or handled. Batteries can be damaged if dropped. The average mine power battery weighs more than one ton, so proper equipment must be provided when changing or handling batteries. e. Burns can result from contact with molten lead or hot compound while repairing a battery. Lead can splash when intercell connectors are being reburned and hot compound can be spilled when resealing covers to jars. The protective gear provided, if worn, will prevent such burns.

Section II. Safety Procedures 4-3. Federal Standards In 1970, Congress passed the Occupational Safety and Health Act (OSHA). This act established the minimal acceptable standards for safe and healthful working conditions. The safety procedures suggested in this manual have been compiled from standards developed over the years by professional and technical organizations and by battery manufacturers and users. Experience has shown them to be the most effective safety standards. In all cases, they exceed the minimum standards of OSHA for personal safety and include procedures for safeguarding equipment as well.

The safety procedures have been grouped by functional area of most logical application or need.

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4-4. Safety Procedures While Handling Batteries 1. Lift batteries with mechanical equipment, such as an overhead hoist, crane or lift truck. A properly insulated lifting beam, of adequate capacity, should always be used with overhead lifting equipment. Do not use chains attached to a hoist at a single central point forming a triangle. This procedure is unsafe and could damage the steel tray.

2. Always wear safety shoes and safety glasses.

3. Tools, chains, and other metallic objects should be kept away from the top of uncovered batteries to prevent possible short circuits.

4. Battery operated equipment should be properly positioned with switch off, brake set, and battery unplugged when changing batteries or charging them while in the equipment.

5 Personnel who work around batteries should not wear jewelry made from a conductive material.

Metal items can short circuit a battery and could cause severe burns.

6. Only trained and authorized personnel should be permitted to change or charge batteries.

7. Reinstalled batteries should be properly positioned and secured in the unit. Before installing a new or different battery, check both the unit nameplate and battery service weight to make sure that the proper weight battery is being used. A battery of the wrong weight could change the center of gravity and cause equipment to upset.

4-5. Safety Procedures While Charging Batteries 1. Specific areas should be designated for charging batteries.

2. Charging areas should be adequately ventilated. The actual amount of ventilation will depend upon such factors as number and size of batteries being charged at the same time, room size, ceiling height and air-tightness of the building. Hydrogen concentrations above 4% can be explosive.

3. Smoking, open flames, and sparks should all be prohibited in the charging area. Post placards "Hydrogen," "Flammable Gas,” “ No Smoking," and "No Open Flames."

4. Facilities should be provided for flushing and neutralizing spilled electrolyte, for fire protection (including hand-operated fire extinguishers), and for protecting charging equipment from damage by units.

5. Fresh water should always be available in case electrolyte is splashed on skin, clothing, or into eyes. The kinds of equipment available for eye-wash and acid neutralization vary widely. A squeeze bottle containing a buffering solution for relief of acid burns should be located in the immediate work area. These should be clearly identified and readily accessible.

6. Before connecting a battery to, or disconnecting it from, a charger, the charger should be turned off.

Live leads can cause arcing and pitting of battery connector contact surfaces.

7. Make sure that all electrical connections are tight and mechanically sound to prevent any arcing or loss of power.

8. Wear a face shield or goggles, rubber gloves, apron, and boots when checking, filling, charging, or repairing batteries during periods of possible exposure to acid or electrolyte.

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9. When charging an enclosed or covered battery, always keep the battery tray cover, or compartment cover, open during the charging period. This will help to keep the battery cool and disperse the gases.

10. Keep vent caps in place at all times except while servicing or repairing cells. This minimizes the loss of electrolyte and prevents foreign matter from entering the cells.

11. Shut off and disconnect both input and output connections to the charger before charging equipment.

4-6. Safety Procedures While Handling Acids 1. The splashing of acid Into the eyes Is the most dangerous condition which can be encountered while handling sulfuric acid or electrolyte. If this should happen, the eyes should immediately be gently flooded with clean, fresh, running water for at least 15 minutes, followed as quickly as possible with a physician's examination. If the person is wearing contact lenses, they should be removed before rinsing the eyes.

DO NOT USE A BUFFERING OR NEUTRALIZING AGENT IN THE EYES WITHOUT MEDICAL APPROVAL. 2. Acid or electrolyte splashed onto the skin should be washed off under running water. Battery electrolyte will usually only cause irritation of the skin; if a burn develops, it should be treated medically.

3. When electrolyte is splashed on clothing, use a weak solution of bicarbonate of soda, as soon as possible, to neutralize the acid.

4. A carboy tilter or safety siphon should be provided for handling acid from a carboy container. Use the protective box when moving a carboy. Store acid in a cool place out of the direct rays of the sun. Use only glass, rubber containers, lead, or acid-resistant plastic containers when storing acid or electrolyte.

5. When mixing acid to prepare electrolyte, always pour the acid slowly into the water and stir constantly to mix well. Never pour water Into acid. Never use sulfuric acid solutions which are over 1.400 specific gravity.

6. Apply a neutralizing solution, such as bicarbonate of soda and water, when acid is spilled on floor.

Clean up affected area promptly. A mixture of one pound of soda to one gallon of water is recommended.

4-7. Safety Procedures While Servicing or Repairing Batteries.

1. Disconnect the battery from the unit when servicing or repairing either the battery or the equipment.

Also make certain the battery is disconnected from the charger before handling or repairing the battery.

2. Before repairing a battery, remove all of the vent caps and blow out each cell with a low pressure air hose to remove any residual gas. Use only a gentle stream of air to avoid splashing electrolyte.

Do not blow breath Into cells.

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3. Open or "break" the circuit before repairing damaged or dirty terminal plugs or receptacles connected to a battery by removing and insulating one terminal lead at a time.

4. When melting sealing compound in preparation for resealing cells, be careful not to puncture the top section of unmelted compound with a screw driver or other pointed object. A build-up of pressure from the melted compound in the bottom could cause liquid compound to squirt and inflict a severe burn. Do not allow compound to ignite by overheating. Compound becomes workable at 400 to 425 degrees F. 5. Check batteries frequently for acid leakage or signs of corrosion.

6. Use insulated tools whenever possible when working on batteries. If possible, also cover the terminals and connectors of a battery with a sheet of plywood or other insulating material to prevent short circuits.

7. When taking specific gravity readings, use a face shield or goggles and read the hydrometer with your eye at about the same level as the electrolyte. Return all electrolyte to the cell.

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CHAPTER 5 – STORAGE AND SHIPMEMT 5-1. General Follow these guidelines for those occasions when batteries must be stored, in either a wet or dry state, and for possible reshipment to other areas.

5-2. Storage Methods a. Charged and Wet Batteries - Lead acid batteries may be stored in a charged and wet (filled with electrolyte) condition when necessary for periods of up to several months. During such periods they should be stored in a clean, cool, dry, and well ventilated location away from radiators, hot air ducts, or other sources of heat, and protected from exposure to direct sunlight. Before being stored, the battery should be fully charged and the electrolyte brought to the proper level. Any leads should be disconnected or insulated to prevent accidental discharge. The top of the battery should be protected from dust, foreign matter, and moisture. Do not attempt to dismantle the battery.

If the average storage temperature is 80 degrees F. or higher, the specific gravity of the electrolyte should be checked at least monthly. If below 80 degrees F., check gravities at least every two months.

Whenever the specific gravity, corrected to 80 degrees F., falls to 1.240 or below, the battery should be given a freshening charge as described in Paragraph 2-10d. A freshening charge is also recommended just before returning a battery to service. b. Charged and Dry Batteries - New batteries are often supplied charged and dry (without electrolyte).

Batteries in this condition can remain in storage, unattended, for a period of at least two years. They should be stored in a cool, dry place with vent caps tightly closed. Average temperatures should not exceed 80 degrees F. Batteries should not be stored near radiators, hot air ducts, or other sources of heat, and should be protected from exposure to direct sunlight. The top of the battery should be protected from dust, foreign matter, and moisture. Charged and dry batteries when removed from storage should be activated as described in Paragraph 2-4a.

5-3. Shipment a. Charged and Wet Batteries - Depots or using organizations may make shipments of motive power batteries in a charged and wet condition if intended for use within a period of 90 days. The battery service weight is usually stamped into the steel tray near one of the lifting holes.

Before crating a wet battery for shipment, it should be given a freshening charge as described in Paragraph 2-10d. A tag should be attached to both the battery and the crate showing the date of the last charge and the specific gravity of the electrolyte at the completion of the charge. Make certain that the battery is properly protected when crated. The receiving organization should be alerted also to the need for a freshening charge before the battery is put into service. b. Charged and Dry Batteries - Depots will normally make domestic and export shipments of new batteries which usually will be in a charged and dry condition. Batteries, and the accompanying electrolyte in separate carboys, which are intended for export shipment must be packaged in accordance with approved methods.

WHENEVER BATTERIES ARE REGULATIONS WILL APPLY. 39

SHIPPED

BY

COMMON

CARRIER,

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Revised 12 – 07 MINE POWER STORAGE BATTERIES

Bucyrus America, Inc.

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Revised 12 – 07 MINE POWER STORAGE BATTERIES