CAT BUCYRUS 45 47-R Blast Hole Drill ELECTRICAL Maintenance Manual - PDF DOWNLOAD

Technical Manual

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ELECTRICAL MAINTENANCE

FOR MACHINES WITH HYDRAULIC HOIST/PROPEL

Hole Drill

BUCYRUS-ERIE

Blast

This purpose ofthis manual is to provide information concerning the electrical maintenance of the BucyrusErie® 45/47 -R Rotary Blasthole Drill.

The 45/47-R drill consists ofthree major units; the lower works, the mainframe, and the mast.

The lower works provides a foundation for the main frame and contains most of the equipment necessary to propel the drill.

The main frame includes the hydraulic, main air and auxiliary air systems, the hoist-propel transmission and the machinery house. The machinery house encloses the majority ofthe mechanical equipment necessary for the main and auxiliary air system, the hydraulic systems and electrical control systems. The machinery house is pressurized with fIltered air to minimize dirt and heat buildup. The operator's cab is located at the rear of the main frame and contains the operator's station.

The mast is mounted to the rear of the main frame and contains the machinery required for rotation and handling of the tool string.

This manual is consists oftwo chapters, each divided into sections. A table of contents is located in the front of this manual.

Familiarize yourself with the contents of this manual so that you can easily locate particular information when you need it.

Throughout this manual the words CAUTION, WARNING and NOTE appear in bold face type. CAUTION is preceded by the safety alert symbol A and indicates that injury to personnel could occur if the proper procedures are notfollowe d during opera tion or maintenance. Always read the CAUTION note carefully and use extreme care while performing that particular function.

WARNING indicates a possible hazard to the machine or its components if the proper procedures are not followed. Whenever the word WARNING appears, special attention should be given to prevent possible equipment damage.

NOTE is used to stress a point or to give additional information concerning the procedure being discussed.

These CAUTION's and WARNING's are not all-inclusive. It is impossible for Bucyrus-Erie Company to know, evaluate, and advise maintenance and service personnel in every conceivable way a service operation might be performed and of the resulting possible hazardous consequences of each method. It is therefore extremely important that anyone who uses a service procedure or tool which is not recommended by Bucyrus-Erie Company to first satisfy himself that the service procedure or tool he chooses will not jeopardize his own safety, the safety of others, or cause machine or component damage.

Every effort has been made to make this manual as complete and accurate as possible at the time of publication. Bucyrus-Erie Company reserves the right, however, to continually improve its products. Therefore changes to the equipment herein may have been made that are not reflected in this manual.

MACHINE SERIAL NUMBER

BUCYRUS-ERIE COMPANY

General Offices: South MilwaUkee, Wisconsin, U.S.A.

LIT S365 BECOM 591

CHAPTERl MAINTENANCE

SECTION 1• GENERAL MAINTENANCE

INTRODUCTION

Periodic inspection and maintenance of the electrical systems are important to assure continuous drill operation at peak performance. Because static and dynamic control operations occur frequently, it is requisite that regular inspections by performed so that replacement or repairs can be made before machine failure. Costly downtime can be reduced by following these rules:

1. Keep on hand renewal or repair parts.

2. Maintain an inventory of tools and equipment for effective electrical maintenance. A list of suggested tools and their application is provided in the appendix.

3. Maintain careful records for all electrical service. Use the electrical checklist in appendix as both a service record and as a reference to further electrical adjustments.

A CAUTION: All schematics or portions a of schematics shown in this manual are for general reference only. When performing any inspection or maintenance on the machine use ONLY the schematics supplied specifically for the machine.

SAFETY GENERAL

Safe electrical maintenance practices minimize the chance of personal injury or costly damage to equipment. Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to prevent accidents from occurring and are provided in the interest of all personnel. Overall safety depends upon a good sense of judgment and alertness on the part of the entire crew.

SPECIFIC SAFETY RULES

The following is a list of some important safety rules relating to electrical maintenance. The safety instructions given in this manual cover those problems encountered during normal maintenance. Additional precautions may be necessary to cover unusual circumstances. Be con-

stantly alert for any potentially dangerous conditions and correct them before proceeding with the normal work.

Only a qualified electrician should perform electrical maintenance.

Disconnect power before touching any part. Voltage may be present even when the machinery is not rotating.

Use safety glasses and/or other protective equipment to prevent possible eye injury.

Avoid contact with moving or electrically hot parts.

Avoid wearing clothing or jewelry which could catch in rotating machinery.

Follow safety practices for lifting and handling equipment. Hoist and slings should be of adequate capacity and in a safe condition.

INSPECTION

TRAIL CABLE

Inspect the trail cable regularly for cuts, cracks or other signs of damage. If there are any signs of damage, disconnect the power from the cable and repair, using acceptable electrical procedures and following local and national codes.

NOTE: Make certain that the ground connection is kept continuous. If the cable is spliced, a carefully soldered connection in the ground connection must also be made.

Check the ground rods regularly to see that resistance of the ground does not greatly exceed 25 ohms. Check the ground conne.ction at the machine end of the cable to see that it is carefully bonded to the machine base. Scrape away any dirt, rust or paint to ensure good contact. Always engage the machine through a resistance ground substation. Always use an approved ground check system.

Regularly check the cable grip which attaches the cable to the machine. If it becomes damaged or worn to such an extent that it will not hold the cable securely, replace it with a new one.

OPERATION CONTROLS, GAUGES AND INSTRUMENTS

Examine all pushbutton and rotary switches on the operator's instrument console (Figures 1 through 4) for sticking or binding contact between components. Check the breakers at the load center. See that the hourmeter, air gage and indicator lights are all operative as originally installed. Observe any problems connected with audible warningwarning devices such as buzzers, bells and horns within the cab. Inspect miscellaneous units such as the air conditioning controls and the cab thermostat. Any operating control or monitoring device which impairs the effectiveness of the drill operation should be replaced with a new unit.

CONTROL PANELS

With equipment de-energized, inspect weekly the static control and DC control cabinets of the machinery house (Figures 5 and 6). Also check carefully the components of the high voltage, AC and ground detection cabinets. These cabinets are identified in Figures 7 through 17. Refer to electric inspection guide in appendix.

CONTACTORS

Examine the contactors or magnetic switches and renew any silver tips on the contacts if they are badly worn. It is usually easier to try to dress tips than to change them out. Use a fine grained sandpaper. Should the tips be pitted, replace them. If prominent copper beads form on the surface of the tips, or if the tips turn a dark color from overheating, smooth up the contact faces with a fine grained sandpaper.

If is a good practice to keep one spare coil of each type contactor on hand, so immediate replacement can be made if a coil burns out. Keep all arc shields in place over the contact tips. Install new arc shields if the molded material is burned away enough to expose the metal supports.

OVERLOAD DEVICES

Check the overload relays in the cabinet. Thermal overload relays are installed on machines to protect each motor. Never arbitrarily increase the size of any thermal overload relay heater element, fuse size or use jumpers to remove a protective device from any circuit. These elements enable the overload relay to stop the motor should there be an excess of current. Correct the stoppage rather than patching it to avoid continuous

electrical problems. Inspect the overload relays for loose wires and mechanical interference during maintenance shifts.

TRANSFORMERS

Auto transformers and other dry type transformers, such as those supplying power to the electric light circuits, need no attention other than to insure that they do not come in contact with moisture.

Perform insulation power factor and resistance test for transformers. Use megger tests for measuring the DC resistance of insulation. A turns ratio and continuity check on secondary windings also are commonly employed testing procedures.

ELECTRICAL LIGHT PLANT

Inspect all high intensity lamps on the drill which are used to floodlight the mining area during periods of darkness and poor visibility. Check the floodlight lamp lenses and the floodlight mountings to be sure they are not cracked or broken. Proper maintenance includes upkeep of the incandescent and portable lights as well as the electrical wiring on the house. Repair all defective sockets and electrical lines with properly rated replacement elements to maintain well illuminated working areas aboard the machine.

Circuit breakers are centrally located at the load center. In the event of failure or blackout in the system of the light plant, first check and, if necessary, repair the electric wiring or reset the appropriate circuit breaker governing the problem area to restore proper lighting and electrical power. Should a total lighting blackout occur, trace the wiring back through the plant to the lighting circuit breaker transformer and disconnect switch. It may be necessary to simply reset the main lighting breaker to relight the machine or make the electrical receptacles operative again.

TYPICAL 45·R OPERATOR'S CONSOLE ELECTRIC MACHINE FIGURE

TYPICAL 45·R OPERATOR'S CONSOLE DIESEL MACHINE FIGURE 2

TYPICAL 47·R OPERATOR'S CONSOLE

MACHINE

TYPICAL 47·R OPERATOR'S CONSOLE

TYPICAL LIGHTING LOAD CENTER FIGURE 7

TYPICAL LUBRICATION SYSTEM CONTROLS FIGURE

TYPICAL LOW VOLTAGE CABINET CONTROLS FIGURE 9

5 CHAIN EQUALIZER RESET BUTTON 6 ROTARY RESET BUTTON 7 HOIST RESET BUTTON

TYPICAL RESISTOR AND DC CABINET CONTROLS

FIGURE 10

1 MAIN AIR COMPRESSOR BREAKER

2 MAIN AIR COMPRESSOR START PUSHBUTTON

3 MAIN AIR COMPRESSOR STOP PUSHBUTTON

4 PHASE SEQUENCE INDICATOR

5 MAIN AIR COMPRESSOR RESET BUTTON

TYPICAL LOW VOLTAGE START CABINET CONTROLS

FIGURE 12

1 INTAKE FILTER INDICATOR

2 COMPRESSOR AIR DISCHARGE THERMOMETER

3 COMPRESSOR DRIP TYPE LUBRICATOR

4 COMPRESSOR COOLANT THERMOMETER

5 COMPRESSOR COOLANT FLOW METER

TYPICAL VANE COMPRESSOR CONTROLS

FIGURE 11

1 MAIN AIR COMPRESSOR START PUSHBUTTON

2 MAIN AIR COMPRESSOR STOP PUSHBUTTON

3 PHASE SEQUENCE INDICATOR

TYPICAL HIGH VOLTAGE CABINET CONTROLS FIGURE 13

DC MOTORS (WESTINGHOUSE 600 SERIES)

PROCEDURE FOR SHAFT REMOVAL AND REPLACEMENT

1. Remove armature from frame and remove front and rear bearings (Figure 28) from shaft.

2. Remove both front and rear shaft collar (Figure 28). These collars were originally shrunk in place, but can sometimes be removed with a puller by quick heating the collar without allowing the shaft to heat up. Care should be taken not to damage the collars if it is to be reused. If this method fails, the collars can be cut off in a lathe and new ones made for replacement.

3. A pressure ring (Figure 29) (Le., a piece of pipe, preferably hardened steel) must be made to fit up against the rear end plate (Figure 28). The dimensions of this pressure ring will vary with the size of the motor, but a few simple rules will apply to all.

a. The ring should be as close a fit as possible to the shaft without impeding the movement of the shaft through it.

b. The wall thickness should be small enough so that the ring clears the coil support arms.

c. The ring must be slotted to slide over the key in the rotor core (Figure 28).

d. After the slot is lined up with the rotor key, notches must be cut in the end of the ring to clear the rivets in the rotor cone. Pressure should not be applied to these rivets.

e. The ends of the ring must be parallel so as to exert pressure evenly.

4. Place armature in the press and apply pressure (Figure 30) between the ring and the commutator end of the shaft. If the shaft is to be reused, pressure should not be ap-

FRONT BEARING ASSEMBLY

FRONT SHAFT COLLAR

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