Technical Manual
© Bucyrus All Rights Reserved
R
BI115523
BUCYRUS
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SERVICE INSTRUCTIONS
To disassemble unscrew base. Withdraw large ram plunger from R506 and both ram plungers from R2112. On the R2112 extend small ram plunger until the cap set screw is visible. Remove screw and withdraw cap. Press small ram plunger down thru large ram plunger.
To replace the packing on the small ram plunger, remove the adaptor nut with a spanner wrench. Remove spring washer, male adaptor, ram packing, and female adaptor. Clean ram plunger and remove partS. Replace female adaptor if scored. Slip the female adaptor on ram plunger and assemble the new packing one ring at a time to insure each being seated properly. Assemble male adaptor, spring washer and adaptor nut. Tighten the adaptor nut until the spring washer is compressed to one-half its original height.
Center punch the ,adaptor nut to the ram plunger to prevent it from turning loose.
To replace the packing of the large ram plunger, follow the same procedure as for the small ram plunger. Dip the small ram plunger packing in oil and carefully insert in the large ram plunger. Extend small ram plunger so that cap set screw hole is visible. Insert cap in top of small ram plunger and tighten with set screw. Dip the large ram plunger packing in oil and carefully insert the plunger into the housing. Take caution not to cut the packing when starting into the housing.
Before assembling base in housing check "0" ring. If frayed replace. Tighten base down firmly using spanner wrench.
( 0;
RAM PLUNGER -----I CARRYING HANDLE 139·9 'CROSS SECTION R506 RAM BASE R21l2-" BASE "0" RIHG J02·10A BI115523
MAINTENANCE SUGGESTIONS
Keep the ram clean and free from nicks (when the hydraulic unit is not in use, the ram or ram plunger should be retracted). Always maintain correct oil level. Use only Simplex Hydraulic Jack Oil - dewaxed - pour test minus 400 F. Never use hydraulic brake fluid.
If you are not familiar with Hydraulic Jack mechanisms, may we suggest that you write us for the name of the nearest Hydraulic Jack Service Station. Improper repairs or testing facilities are costly. Every Jack should be capable of lifting its rated capacity, and should sustain the load without lowering in excess of 1;1;" in four hours.
It is important in repairing and maintaining hydraulic units
that a dean work place and clean tools be used. Any foreign substance within a hydraulic system may make it inoperative. Special tools are available for repairing the hydraulic units.
All Simplex Jacks are inspected and tested before leaving the factory and are guaranteed against defects in material and workmanship. Any claims for adjustment are subject to our inspection and determination.
Simplex Jacks, returned to the factory for reconditioning or inspection, should be properly tagged, transportation charges prepaid, and if via freight, mark bill of lading "NOffiN-NOT ....WHEELED" to secure the lowest freight rate.
RA>4 CAl'R:<Il12·2A
guLL RAM PLlJNG;ER_"-' R2112·2
FEMALE ADAPTER R2J12·S (SMALL)
SPRING WASHER (SMALL) R2)12·J,4
R2J12·1
ADAPTER NUT R2012·7A (SMALL)
ADAPTER R2112-8 (LARGE)
"V" PACKING R2012·9 (LARGE)
CROSS SECTION R2112 RAM
ADAPTER NUT (LARGE) R2012·IOA
SASE "0" RING lOA
BASE R2112·4
X-2696
;.:112 SOCKET SET SCREW
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Oil
SERVICE INSTRUCTIONS
If pump fails to operate check oil level for all models but RP6A, stand pump on reservoir tube support and remove filler screw. If oil level is below screw hole, add oil to filler screw level. Caution. Do not fill beyond screw hole level, on Model RP6A, pump should remain in horizontal position. Remove oil fill screw (3/8 sq. hd. pipe plug). Oil level should come to bottom of hole.
Before operating RP6A Pump make sure that solid 3/8" plug is replaced by "Breather Plug."
Pump Piston (See Figure 1)
Oil leakage around pump piston at pump gland indicates a worn or torn piston cup. To install a new piston cup, remove handle socket (RP5-6) and withdraw pump piston (RP5-l3) until the piston head is about an inch above the P'1l mph 0 us in g (RP5-l). Loosen pump gland (RP5-9) and complete withdrawal of pump piston. Remove the pump packing (RP5-l0) and the male adapter (RP5-11). Clean piston chamber (both small and large diameters) thoroughly. Remove pump piston cup (RP5-l3D) and pump piston cup washer (RP5-13E). Assemble replacement cup, , leather washer, brass washer and nut. Remove pump
,piston "0" ring (RP5-13C) from large diameter. Slip , the pump gland, pump packing, and male adapter over the large diameter of the pump piston and then assemble the replacement "0" ring on RP5 only. Dip the piston in oil and carefully insert into the housing until both piston diameters are in their respective chambers. Lower the male adapter onto its counterbored shoulder and carefully insert packing rings one at a time. Be sure the first ring is seated on the male adapter and that each other ring is seated on the one below. Thread down pump gland until it touches the packing rings (do not tighten). Center punch the ends of the thread to prevent the pump gland from working loose. Assemble handle socket.
Pump Valves (See Figures 1 & 3)
Should the pump fail to supply pressure or should the pump piston be under pressure at all times, the pump valves need a cleaning. To clean, open release valve (RP3-4). Remove valve seal screw (3HJ-2l) and valve seal (3HJ-24). With valve screw hole down, strike base of pump on bench so that balls and springs fallout of valve chamber. Inspect and clean valve chamber thoroughly. Do not nick or mar finish of valve seats. Clean pump valve balls and springs carefully in solvent. Do not stretch the springs. Replace rusted or corroded balls. To reassemble insert small ball, then small spring, then large ball \ large spring; using the valve seal inserting tool '(3ID-50), assemble the new pump valve seal, and
finally, the valve seal screw.
This cleaning should be carried out in the pump valve circuits of both the small and the large diameter piston. If the valves fail to operate after the cleaning, it may be necessary to reseat the bails. Remove the springs and tap each ballUghtly on its respective seat using the 1/4" ball seating tool (RP3-52) for the small ball and the 3/8" ball seating tool (RP3-5l) for the large ball. Remove the balls to insure against sticking. Reassemble pump valve as before.
Release Valve (See Figure 2)
A ram will fail to lift or hold a load if the pump release valve is dirty. Remove release screw (RP3-4), release screw gland (RP3-5), 'release valve packing (303A-40A) and release valve ball. Clean and inspect valve seat and release screw. A slight depression in the end of the screw is not harmful. Burred screws should be replaced. Reseat the release ball using the 1/4" ballseating tool (RP3-52) and insert the release valve using the valve packing inserting tool (303A-60). Reassemble release screw.
Safety By-Pass Valve (See Figure 2)
If a ram fails to lift or hold a load after the release valve and pump valves have been checked, the safety by-pass valve may be dirty. Remove valve seal screw (3HJ-21), valve seal (3HJ-24), and using the knurled socket wrench (RP3-50) remove th e safety valve screw (RP3-7B). With hole down tap pump housing to
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L--i I I 2
RP5-12 (S"dORT) RP5-6A (LONG)
NUT
RP5-9 RP5-10 RP5-11
Figure I Section Showing P=p Piston and Pwnp Valve for Small Dia.nleter of P=p Piston
BI115523
remove safety valve spring (RP3-7A), safety valve needle (RP6-7C) and ball. (RP5 has ball, RP6 and RP6A have needle point.) Clean and inspect ball seat. If seat is marred, reseat by lightly tapping ball on the seat. RemovE' ba U to insure against sticking. Reassemble safety valve ball, spring plunger, spring and screw. Connect a pressure gauge calibrated in psi to the pump high pressure outlet. Tighten the safety valve screw a turn, close the release valve, and stroke the pump piston until the gauge reaches a ma..ximum reading. Repeat this sequence of opera'tions until the gauge records a maximum reading of 12,500 psi. Reassemble valve seal and valve seal screw and remove gauge.
large Diameter Pump Piston By-Pass Valve on Models RP6 & 6A (See Figure 2)
On models RP6 and RP6A remove high speed by-pass valve assembly clean and inspect ball seat, lightly tap ball if seat is marred, replace parts. No resetting is necessary. Setting screw RP6-'18A must be turned in until it bottoms; this automatically sets bypass to the proper setting.
3HJ -23B (1/4'1
303A-39B /16" BALL)
6-18B 6-18A
BY-PASS VALVE FOR LARGE. DIAMETER· OF PUMP PISTON
MAINTENANCE INSTRUCTIONS
large Diameter Pump Piston By-Pass Valve on Model RPS (See Figure 3)
If the ram does not raise faster under no loading or light loading than it does under heavier loading, the large diameter pump piston by-pass valve is dirty. Remove parts, clean and inspect ball seats as explained above. Remove valve seal screw (3HJ-21), valve seal (3HJ-24), and the springs and balls from the small diameter pump valve hole. Reassemble large ball, large spring, valve seal and valve screw, leaving out small ball and spring. Connect a pressure gauge to the high pressure outlet. Reassemble by-pass valve ball, spring plunger, spring and screw. Following the same sequence of operations as for the overload valve, set the by-pass valve to a maximum pressure of 900 psi. Reassemble valve seal and valve seal screw and remove gauge. Reassemble small ball and small spring in the small diameter pump valve hole.
Keep all parts clean and free from nicks (when the hydraulic unit is not in use, the ram or ram plunger should be retracted). Always maintain correct oil level. Use only Simplex Hydraulic Jack Oil- dewaxed - pour test mmus 40°F. Never use hydraulic brake fluid.
If you are not familiar with Hydraulic. Jack mechanism, may we suggest that you write us for the name of the nearest Hydraulic Jack Service Station. Improper repairs or testing facilities are costly. Every Jack should be capable of lifting its rated capacity, and should sustain the load withoutlowering In excess of 1/8" in four hours.
It is important in repairing and maintaining hydraulic units that a clean work place and clean tools be used. Any foreign substance within a hydraulic system may make it inoperative. Special tools are available { repairing the hydraulic units. 6
x- 2 9b
RP3-4 RP3-5 303A-40A RI0Z-10B (5/16") SAFETY BY-PASS VALVE 3HJ-21 3H.T -24 RP3-7B 0.::-,.::..---- RP6-7G
Figure .2 Section Showing Release Valve and Safety By-Pass Valve
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Figure 3 Section Showing Pump Valve and By-Pass Valve for Large Dia:meter of Pump Piston
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'.' BI115523
• ® for 'IIIe'lgell,Flexible Couplings with Fully-Crowned Teeth
AMERIGEAR SERIES F
Standard Flanged - Sleeve
Flexible Coupling
AMERIGEAR SERIES C
Standard Continuous- Sleeve Flexible Coupling X2226
C i
A
BI115523
SHAFT '( SIZES 100 - 107 INSTALLATION -LUBRICATION ....--LUIlE PLUG BAS Ie SEAL \'5:(IlOLT" INSTALLATION, LUBRICATIOr( (For Standard Series F SIZES 100-107 BI115523
t:,;;::; ,::,.' .• { ::." ." holes so that ." : ',', flange boltscanb'':;'used to separate. sleeves. For sizes' , 108 and hirger bolt sehl retainers to··sleeves.
MAINTENANCE
,
',:,', The Arrieiig'ear F 3 til 5 years' befcirerecommended dillassel:i1b,ly
re-iubri;;;;'tion:
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,'Remove both D..ysehl lube Iilugs and add grease .. ? in sufficient alnoruit to'"rverflowwith lubricant holes in hcirizOntllipcisiticin.'Iristalllubeplugs and seat securely.
For\iertichl.'couplings;h!moveone Dryseal plug in each " coupling hhlf prope under '
hub seal to assure. complete \\:/' >.,' ,
, .:- Step' togollnstalled andhibricatedin :', ancewith·theinstrUctions, yolirAmerigear Series F :' Coupling is prepared fora long life of dependable, low , _.:-v'._ _. ':."
'To remove flange' fasteners, se:para1te ,.slc!ev and larger), slide >and geai:teeth R·c!asIseJrnl?le; .'a,'or'hna· .: ". '.
'::Ifproper'alignment 'of shafts h assured '., b6thlube add grease with lubric;u;.t holes' in horizontal position:F.0r reCOlnn'eIlde:d quantities, see next page.
MAINTENANCE and C Flexible Couplings)
t: c STRAIGHT EDGE HUB SEPARATION Size F FS 100 'IB '/64 101 'IB '/64 101',4 'IB '/64 101'/2 'Is 5/32 102 '/8 5f32 102'12 '/'6 '1'6 103 '/'6 '/,6 103';' 'A 7/32 104 'A '/,6 104'/2 5/16 1l/J2 105 '/'6 11/32 105 '12 '/'6 106 '/,6 13hz 107 % ';' 108 % '/2 109 1;2 9/,6 110 '/2 % 111 '/2 % 112 Y2 % 113 % 'A 114 % % 115 % % OR FEELER GAGE
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INSTRUCTIONS HUB SEPARATION STRAIGHT EDGE Size C CS 100 YB 'IB 101 'IB 'IB 101',1" 'IB 'IB lOW2 I Va 'IB 102 I 'IB 'IB 102Y2 I 'I,. '1'6 103 'I,. ';\. 103'/2 'A 'A 104 '14 '/4 104Y2 '/,6 '/'6 105 '/,6 '/'6 105'/2 5/16 5/'6 106 5/,6 ,/,. 107 % % 108 %109 '/2110 'h111 'h112 '/2113 %114 %115 %APERED OR FEELER GAGE MAINTENANCE SERIES CS BI115523
Amerlgellr RECOMMENDED LUBRICANTS
A grease lubricant which is stable and will not centrifuge is normally used with Amerigear Couplings. The following lubricants are provided as general recommendations only equivalents may also be used. The listing is not intended to be complete or necessarily current due to continuous research and improvements by the various manufacturers.
RECOMMENDED QUANTITIES SERIES
SERIES C, CM, CA
For Series CS, CMS, CAS, use "2 the quantities recommended.
LUBRICANT TYPES OF OPERATING CONDITIONS MANUFACTURER GENERAL MOIST OR WET HIGH TORQUE 150° - 300" F TEMP. American Oil Co. Rykon Grease No. lEP Rykon Grease No. 1EP Rykon Grease No.lEP Rykon Grease No. lEP Atlantic Refining Co. Lubricant 52 T. 52 Lubricant 52 Lubricant 52 Brooks Oil Co. Leadolene 375-Light Klingfast 310 Cities Service Oil Co. Trojan Grease l:0jan Grease Trojan Grease Trojan Grease H-l or HA-l H-l or HA-l HEP-l or HB-31 HB-22 or HA-2 Continental Oil Co. Conoco Super Lube ConocoSuperLube Conoeo EP or Conolith No.1 Fiske Bros. Refining Co. 630-AA Lubriplate 630-AA Lubriplate 630-AA Lubriplate Gulf Oil Co. Gulf XXX Lubricant Gulf XXX Lubricant GulfcrownGrease Gulfcrown Grease No.1 No.1 EP No.2 EPNo.2 Houghton & Co. Cosmolube Z Cosmolube Z CosmoTube ZEP Cosmolube 102 Humble Oil & Refining Co. Andok B Nebula EPO Pen-O-Led EP 350 Nebula EPO Kendall Refining Co. Kenlube L-421 Kenlube L-421 Kenlube L-424 Kenlube M-621 Keystone 81 Light 81 Light Moly 5110 Light Moly 5110 Light Mobil Oil Co. Sovarex Grease L-O Sovarex Grease L-O Sovarex Grease L-O Sovar-ex Grease L-O i>ennzoil Co. TTM Multi-Purpose TTM Multi-Purpose TTM Multi-Purpose TTM Multi-Purpose Pure Oil Co. POCOHT-EP No.2 POCO HT-EP No.2 POCO HT-EP No.2 POCO HT-EP No.2 Quaker "LL" Chassis Grease "LL" Chassis Grease "LL" Chassis Grease "LL" Chassis Grease Richfield Oil Co. Rocolube ZMP Rocolube ZMP Track Roll EP Grease Thermo Shell Oil Co. Alvania EP Grease 1 or 2 Alvania EP Grease 1 or 2 Alvania EP Grease 1 or 2 Alvania EP Grease 1 or 2 Sinclair Refining Co. Litholine Multi-Purpose Litholine Multi-Purpose Pennant EP No.2 Heavy Duty Bearing Grease No.2 Sun Oil Co. Sunaplex 991 EP or SunapJex 991 EP or Sunaplex 991 EP or Sunaplex 991 EP or Prestige 741 EP Prestige 741 EP .prestige 141 EP Prestige 741 EP Standard Oil Co. of Calol Industrial Calol Industrial Calol EP Roller California Medium Medium Grease -IXStandard Oil Co. of Ohio Sohitran 2 Sohitran 2 uvuu-,.,." EPl Factolube 350 Texaco Inc. Marfak 1 Marfak 1 Marfak HD EP2 Marfak 3 Tidewater Oil Co. Veedol Alitho 20 Veedol Alitho 20 Veedol Alitho 20 Veedol A1itho 20 Union Oil Co. of Calif. Unoba A-O Unoba A-lor A-2 Unoba A-2 Waverly Oil Works Co. Torque Lubricant A Torque Lubricant A
F, FM, FA F or Series FS, FMS, F AS, use !/z the quantities recommended. 1-66-5 (4) Page SiX<! 101 10!}i 10IH 102 r-i02H 103 103y'; 104 I 106 107 108 109 110 III 112 113 114 115 Weighl .66 oz. 1.0 2.3 5.1 7.3 13 lIb. 1.6 1.9 1-:-", ;:) 5.8 11 19 24 30 44 50 60 80 90 Volume 1/20 pt. 1/15 1/5 % ;!"i % l;i131 I hi qts. 2 1.5 gal. 2.3 2.8 3.5 5.3 6.0 7.2 9.5 10.7
Size Weight Volume 101 .66 oz. 1/20 pt. 10131 .75 1/20 1.4 1/10 102 2.9 Y5 I02H 4.1 :Y3 103 7 .!1 103H 9 % 104 1.1 Ibs. ni I04!1 1.2 1:Y3 105 1.15 1 qt. 10SH 2.2, 106 2.7 1Y2 107 6 3H' 10 1.1 gal. 109 12 1.5 110 16 1.9 III 26 3.1 112 129 3.5 113 35 4.3 114 49 5.9 115 56 6.8 ( BI115523
These instructions have been prepared to assist the operator or electrician in charge of maintenance of the machine, to adjust and care for the electrical equipment properly. The various items of electrical equipment used on Bucyrus-Erie machines are the products of reputable electrical manufacturing concerns adapted to service on excavating equipment. Included in the instructions originally furnished with the machine are a ntnnber of bulletins furnished by the manufacturer of the electrical equipment which describe the various items and give the recommended adjustment and maintenance procedr.lre. Such instructions must be carefully followed if satisfac· tory operation of the electrical equipment is to be obtained.
Most Bucyrus-Erie electrically-operated machines may be placed in one of two classifications. Small electric machines are usually powered with a single induction motor in the position., and serving the same purpose, as the combustion engine of the standard fricl ion machine. Machines of larger size are generally of the Ward-Leonard (variable voltage generator) control type. Most machines of this type have a single induction (or synchronous) motor driving .three direct-current generators (two on draglines) _ A separate, constant voltage exciter ge::era tor furnishes the control field curre:1t for the generators and excitation for the .shunt motors_ The circuit of each is connected directly to the armature circuit of '" heavy-duTY direct-current motor without anv switches or other control equi?:-:::ent in the ci:-· The speed, as well as direction of ;-o;:a:io:1 of each :-:1otor, is regulated by a:1 individual co:;troller a: the operator's position.
Use Approved Cable and Install It Properly
Power is carried to electric machines by a flexible, rubber-covered cable especially developed by cable manufacturers for excavating service. This cable is the "life line" of the machine and must be p:-operly installed and carefully handled to ensure continuous service and minimum hazard.
Remember that the cable carries the full voltage of the supply line and must be handled carefully. Protect the cable from falling rocks or other damage. Do not let the cable rest in pools of water or become buried under sailor stones. Handle the cable with extreme caution, taking care that it is not dragged around corners or over sharp stones. Coiling the cable in a figure eight permits laying out or taking in cable .....-ithout subjecting it to sharp bends. There are several methods for installing the cable. The best one to use· is dependent on iocal power conditions and safety rules. Full of installation should be discussed with your power company but the foilOWIng points must be observed to ensure maximum safety.
The. cable used should be provided with some of ground connection such as a fourth ductor. three individual grot:nd ",>ires, woven copper br-aid sheath around each conductor, or som·e combination of the above. Whichever ground c0n11ection is used must be kept continuous, and whenever the cable is spliced, a cardully soldered connection in the ground connection must also be made. The g;-ound connection at the machine end of the cabie should be carefully bonded to the r:-.achine base, making sure that all paint. rust or dirt has been scraped off the metal to ensure bood The ground connecdon at the pole end of the caole should be to some low-:-esista::ce ground such as an ae:-ial ground line (grounded at inte:-,-als along the line) and ca:-:-iec to :ht su?ply """here to tnt trans! o:-:ner grounc. :i;:-o:..!gr: ,d cUI""ie:lt-iir;;.i res!s-rance. Be gro:.:nc rods are c.riven ::1:0 the earth to a depth :0 per;::;anent moisture. Contact reS!St2:1Ce of the ground provided shouid not g;-eatly exceed 25 ohms and each ground shouid be tested reguiarly to determine if there 1S anv tendencv for the resistance to increase.
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• CARE, OPERATION AND MAINTENANCE BUCY£US-EiUE CO., SOUTR MILWAUltEE,"WlS • •••• -. BI115523
Even with best precautions there is the possibility of a short circuit occuring if the trail cable is severely cut or there is failure of insulation, et.c. on the machine. Therefore, short circuit protection should be installed where the trail cable connects to the supply line. An oil-circuit-breaker having high current-interrupting capacity, arid provided with an overload trip, is the best protection. A trip arrangement for opening the breaker if there is a ground fault may be incorporated. Disconnecting switches should also be provided so that the oil-cirCUit-breaker can be disconnected from the power line for inspection or repair. Fuses in the supply line are dangerous because of. the possibility of only. one or two fuses blowing. leaving the third line. connected. If the cable is connected to an aerial line, an approved type of lightning arrestor should be located on the terminal pole and adequately grounded to an independent ground rod.
A cable grip macle of woven mesh wire is provided for attachment of the cable to the machine (exon stripping machines which poweroperated cable reels) thus relieving the electrica-I conductors of any strain. If the cable grip becomes damaged or worn to such an extent that it will not hold the cable securely, replace it with a new one.
Simple Col1ector Ring Arrangement
Power is transmitted from the base to the revolving frame through a' simple collector ring. arrangement. Except for: some special instaIlations the large diameter collector rings on Bucyrus-Erie machines are of open construction, readily accessible for inspection or cleaning. Three rings, of different diameters. are' mounted at the center of rotation between the revolving frame and the base. being suspended from the revolving frame by porcelain insulators. The hrushes, or shoes, which bear on the collector rings, are mounted on porcelain insulators secured to the base. (On some machines the collector rings are mounted on the base and the shoes on the revolving frame.) The shoes have a slight vertical motion to allow for any variations in the rings or uneveness of the roller track. When first installed, each shoe should bear funy on its collector ring at all positions of the revolving frame. Make sure that the cap screws securing the. rings to the supporting insulators do not project beyond the countersunk or counterbored holes in the rings, The collector rings and brushes must be free of paint or rough spots. A thin coating of vaseline on the bearing surfaces will prolong the life of the shoes and prevent rusting of iron and steel parts. Keep the insulators cleaned of any
accumulation of dirt and make sure there is no coItection of dirt on the top of the base. Inspect the insulators frequently and if any are chipped or cracked, replace promptly with new ones. Do not try to inspect the collector rings unless you are positive the machine is disconnected from the power line.
Permanent wiring is installed from the collector rings to the motor starting device (or the power transformer, if required).
Induction Motor Starting Switches
On the smaller machines. powered with a single ind:1ction motor. the starting device consists of a three-pole magnetic switch opened and closed by push buttons at the operator's position. A motor starter of this type is provided with thermal overload relays for protection of the moto!" against overloads of more than momentary duration. As several types of magnetic switches and overload relays are used, full instructions cannot be given in this section. Refer to the manufacturer's bulletins for complete adjusting and maintenance instructions.
Typical magnetic starting switch for induction motors
-Allen Bradley Co.
This same general type of magnetic switch is used for starting the auxiliary induction motors (blowers. dipper-trip, oil pump etc.) on the WardLeonard electric machines.
Inspect the contact tips at regular intervals and re new if badly worn, following the instructions in the manufacturers' bulletins.
Do not tamper with the setting of the thermal overload relays. These are correctly set at the factory and should require no further adjustment. If a heater element bums out or otherwise becomes damaged, replace with a new element of exactly the same rating, following the procedure described in the manufacturers' bulletin.
Rev. 5-65 ( BI115523
On the larger machines the starting device for the motor of the motor generator set consists of an oil-circuit-breaker, usually manually operated, although push button operation can be furnished on special power line conditions require it, two-step starting (using a double throw oil-circuit-breaker and an auto-transformer) may be furnished, and is regularly furnished on the larger stripping shovels.
push button in the undervoltage coil circuit is provided to open the breaker from the operator's position. Be sure the undervoltage device operates properly because serious damage might result if the power should go off and breaker remain closed until power came on again. Keep the circuit-breaker-operating-lever linkage clean and free of dirt, and lubricate bearing surfaces occasionally with a few drops of high grade oil.
Alternating Current Motors
single driving motor of friction machines and the motor driving the motor generator set on Ward-Leonard machines are usually induction motors of the squirrel cage type. On the larger stripping machines the motor driving the motor generator set is usually a synchronous motor.
The auxiliary motors on the Ward-Leonard controlled machines; used' ;for the blowers, dipper trip, oil pump, etc; are usually squirrel cage induction motors. The propelling motors on the large stripping machines, having four independent caterpillar units, are usually wound-rotor induetion motors having a fixed resistance in the rotor circuit.
OiI-circuit-breakers are properly mounted and adjusted at the factory and little, if any, adjustment will be required. Before attempting to make any adjustments read the manufacturers' bulletin carefully.
THE MOST IMPORTANT MAINTENANCE POINT IS KEEPING THE OIL IN THE BREAKER UP TO THE CORRECT LEVEL AND OF NORMAL DIELECTRIC STRENGTH.
A very small amount of moisture in the oil will lower its insulation value to a dangerous point. , Therefore, if no method of testing the dielectric strength of the oil is available, oil should be changed at least once a year. At any time the oil is renewed, carefully examine the contacts to make sure they are properly aligned and in good condition. Replace any contacts which are burned or otherwise unsatisfactory.
No overload trip is supplied on the oil-circuitbreaker on the machine and short circuit protection, preferably an oil-circuit-breaker with overload trip, should be installed at the point where the trail cable connects to the supply line.
The oil-circuit-breakeron the machine is provided with an undervoltage device which will open the breaker when the supply voltage is cut off or drops below a certain minimum value. A
Whenever the three-phase supply line to an mdU'ction or synchronous, motor has been disconnected, a careful check should be made wne!'1 starting again to see that the direction of rotatio):! of the motor is correct. If the rotation is not correct, interchange any two of the three supply lines.
Alternating current motors are usually built for a maximum temperature of 90 degrees Centigrade (194 degrees Fahrenheit) taken by the thermometer. This temperature is too hot for the ,hand. In case of any doubt as to the temperature of tbe motor, thermometer readings should be taken.
Motors are built to operate on sup' ply line voltage 10 per cent above or below the nominal rating. Supply line voltage that is too low is usually evidenced by lack of power or excessive heating. A synchronous motor, operatl ng from a suppJy line below the nominal rated voltage, may require additional field excitation to hold the rotor "in step". Correct the voltage condition, if possible, so that normal excitation will be sufficient.
Alternating current motors require little attention other than to see that dirt or dust is not allowed to accumulate on the windings agd that the bearings are properly lubricated.
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Oil circuc brea:ker - Genf31 E! ec::i c Company
BI115523
Collector rings of wound-rotor and synchronous motors must be kept clean and polished. Ordinarily the rings will require only occasional wiping with a piece oi canvas or non-linting cloth. If the rings become worn or pitted so that excessive sparking occurs, grind· or turn them to restore a smooth and true surface. Be sure all dust and dirt is blown out of the spaces between the collector rings.
Collector ring brushes must move freely in the holders and make firm contact with the rings. Check the brushes frequently to see that they are not stuck in the holders. New brushes should be ground to perfect fit with fine sandpaper. Maintain the brush. spring tension at a pressure of from Z to 3 pounds per square inch for carbon or graphite brushes. When replacing worn brushes, use the corre'c.t grade as furnished by Bucyrus-Erie Company:
Induction motors of small and medium size are usually furnished with haIl or rolIer bearings. Induction or synchronous motors of the larger sizes may hav!; oil-lubricated sleeve bearings.
Actual lubrication requirements of any particular motor or generator vary to a great extent on the details of construction, therefore it is impossible to give detailed lubrication instructions which will apply to all motors and generators. Manufacturers bulletir:s covering the electrical equipment are included wi'th the instructions furnished for the machine.: Read the bulletin applying to the particular piece of equipment for detailed maintenance instructions.
Couplings
The couplings used for connecting separate units of the motor generator set may be either of'two general types, depending upon the construction of the motor generator set. Flexible couplings are usually used where both units to be connected have shafts supported at both ends. Solid (or ri[id) couplings are used where one or both shafts are supported at one end only.
couplings .are of the flanged type and consist of two steel members rigidly bolted together. One half has a projecting ring on the face of the flange and the other half has a corresponding recess in the face of the flange. The fitted bolts holding the coupling halves together pennit no flexibility. therefore the coupling halves must be very accurately aligned when assembling the coupling. The coupling was correctly installed at the factory but because of possible distortion in the supporting base, resulting from handling o. from settling of the machine framework, it is well
to check the alignment after the machine first goes into service and at increasingly greater intervals thereafter until it is definitely established that the alignment has not changed-
The first step in checking alignment of a motorgenerator set consisting of two or more units all coupled with solid, flanged couplings, is to loosen all bolts and remove all but two diametrically opposite bolts in each coupling. Next. use jacking bolts to force the coupling halves far enough apart to pennit inserting feelers between the coupling faces. Always open up the couplings next to the two-bearing unit (usually the driving motor) first, and do not open up the couplings too far, because the total end play must be divided between the couplings. After opening all couplings, remove the jacking bolts from all couplings and check alignment starting with one of the couplings next to the two-bearing unit.
Check the coupling haJves for parallel faces by measuring the' gap between halves with feeler gauges. Measure the gap at four points spaced 90 degrees apart around the coupling, then tum both shafts H revolution and again take the four gauge measurements. Repeat this procedure two mote times, turning the shafts revolution each time, taking care to turn both shafts the same amount, so that the relative position of the coupling halves is not disturbed.
The measurements on the sides of the coupling should check within O.OOZ in. for all positions but the top and bottom readings may show a constant difference due to the tendency for the shafts to drop slightly at the open coupling.
Correction of vertical misalignment is obtained by adding or removing shims under the frame feet. Correction sidewise, is obtained by removing the dowels, loosening the foot bolts and tapping the feet until the desired movement is obtained. Tighten the foot bolts before recheck: ing the alignment. After correct alignment is obtained drill new dowel holes and insert the dowels.
The flexible couplings used may be any of several different types depending upon the manufacturer of the motor generator set.
The "Fasts" flexible coupling, used on some sets, is not a universal joint and the same care must be taken in alignment of the coupling as for the solid coupling. In addition to checking the gap between coupling halves, check the hubs for concentricity by pfacing a straightedge on the rims of the hubs. Insert shims, if necessary, so that
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