CAT BUCYRUS-ERIE 47-R ELECTRICAL MAINTENANCE MANUAL BI005452

Technical Manual

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MAINTENANCE

The purpose of this manual is to provide information concerning the electrical maintenance of the 45-R and 47-R rotary blast hole drills.

The drill consists of three major units; the lower works, the mainframe and the mast. The lower works provides a foundation for the mainframe and contains a portion of the equipment necessary to propel the drill. The mainframe includes the hydraulic, main air and auxiliary air systems, the hoist-propel transmission and the machinery house. The machinery house encloses the majority of the mechanical equipment necessary for the main and auxiliary air systems, the hydraulic systems and electrical control systems. The machinery house is pressurized with filtered air to minimize dirt and heat build-up. The operator's cab, mounted to the mainframe, provides the operator's station, and encloses the majority of the controls necessary to operate the drill.

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

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 not followed during operation 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. !tis 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, however, reserves the right to continually improve its products. For this reason changes may have been made to the machine or its equipment that are not detailed in this manual.

MACHINE SERIAL NUMBER

BUCYRUS-ERIE COMPANY

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

15M SPS 885

CHAPTER 1 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 be 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 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 occuring 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 constantly 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. Hoists and slings should be of adequate capacity and in a safe condition.

INSPECTION

TRAIL CABLE

Inspect the trail cable regularly for cuts, cracks, or any 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 connection 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.

OPERATING 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 gauge, and indicator lights are all operative as originally installed. Observe any problems connected with audible warning 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 ofthe 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 ofthe tips, or if the tips turn a dark color from overheating, smooth up the contact faces with a fine grained sandpaper.

It 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 pro-

tect each motor. Never arbitarily 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 transfomers. 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 a failure or blackout in the system of the light plant, first check, and ifnecessary, 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 45R OPERATOR'S CONSOLE ELECTRIC MACHINE

CONSOLE

TYPICAL 47R OPERATOR'S CONSOLE ELECTRIC MACHINE

46. OIL PUMP START PUSHBUTTON

47. OIL PUMP STOP PUSHBUTTON

48. HYD. OIL TEMP. INDICATOR

49. HIGH AIR TEMP. INDICATOR

50. GROUND FAULT INDICATOR

51. AUX. AIR COMPRESSOR CONTROL

52. FILTER FAN CONTROL

53. AIR CONDo AND/OR CAB HEATER CONTROL

54. FILTER CLOGGED INDICATOR

55. WATER PUMP CONTROL

5b. RAD. FAN/WATER PUMP CONTROL

57. BAG-TYPE DUST CONTROL UNIT

58. WATER TEMP. INDICATOR

59. LUBE LEVEL INDICATOR

60. FUSE FAILURE MONITOR

61. DEPTH INDICATOR

63. AUTO LUBE SYSTEM REMOTE PANEL

64. DIESEL ENG. EMERG. STOP CONTROL

65. ENGINE AMMETER

66. ENGINE COOLANT TEMP. GAUGE

67. ENGINE OIL PRESSURE GAUGE

68. ENGINE FUEL GAUGE

TYPICAL

FIGURE 4

31-+--+--"",-"'"

47R OPERATOR'S CONSOLE DIESEL MACHINE

1.

2. GROUND FAULT CABINET

3. HOIST/PROPEL CONTROL CABINET

10.

11.

12.

13. BAG-TYPE DUST CONTROL MOTOR

14. WATER INJECTION MOTOR

15. ROTARY MOTOR

16. CHAIN EQUALIZER MOTOR

17. FAN/PUMP MOTOR

18. HOIST/PROPEL MOTOR

19. COMPRESSOR LUBE MOTOR

20. BIT LUBE MOTOR

21. OIL COOLER MOTOR

22. OIL PUMP MOTOR

23.

TYPICAL 47R ELECTRICAL EQUIPMENT LOCATION

FIGURE

TYPICAL ELECTRIC MACHINE WITH SCREW COMPRESSOR

TYPICAL DIESEL MACHINE WITH VANE COMPRESSOR

1. OPERATOR'S CONTROL PANEL

2. GROUND FAULT CABINET

3. HOIST/PROPEL CONTROL CABINET

4. HIGH VOLTAGE CABINET

5. LOW VOLTAGE START CABINET

6. RESISTOR & DC CONTROL CABINET

7. REACTOR CABINET

8. LOW VOLTAGE CABINET

9. LIGHTING LOAD CENTER

MAIN AIR COMPRESSOR MOTOR

ALTERNATOR

AUX. AIR COMPRESSOR MOTOR

MAIN TRANSFORMERS

TYPICAL LIGHTING LOAD CENTER

FIGURE 7

1. SIGNAL HORN

2. ON/OFF SWITCH

3. START PUSHBUTTON

4. INDICATOR (GREEN)

5. INDICATOR (GREEN)

6. INDICATOR (RED)

TYPICAL LUBRICATION SYSTEM CONTROLS

FIGURE 8

1. AUXILIARY POWER BREAKER

2. RADIATOR FAN BREAKER

3. HOIST BLOWER BREAKER

4. MAIN CONTROL BREAKER

5. LUBE SYSTEM BREAKER

6. OIL PUMP RESET BUTTON

7. FILTER FAN RESET BUTTON

12 8. AUXILIARY COMPRESSOR RESET BUTTON

9. RADIATOR FAN RESET BUTTON (VANE COMPRESSOR)

10. WATER PUMP RESET BUTTON (VANE COMPRESSOR)

11. COMPRESSOR LUBE RESET BUTTON (VANE COMPRESSOR)

12. HOIST BLOWER RESET BUTTON

TYPICAL LOW VOLTAGE CABINET CONTROLS

FIGURE 9

1. ROTARY BREAKER

2. HOIST BREAKER

3. AIR CONDITIONER OR CAB HEATER BREAKER

4. LIGHTING BREAKER

5. CHAIN EQUALIZER RESET BUTTON

6. ROTARY RESET BUTTON

7. HOIST RESET BUTTON

TYPICAL RESISTOR AND DC CABINET CONTROLS

FIGURE 10

1. INTAKE FILTER INDICATOR

2. COMPRESSOR AIR DISCHARGETHERMOMETER

3. COMPRESSOR DRIP TYPE LUBRICATOR

4. COMPRESSOR COOLANT THERMOMETER

5. COMPRESSOR COOLANT FLOW METER

TYPICAL VANE COMPRESSOR CONTROLS

FIGURE 11

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. MAIN AIR COMPRESSOR START PUSHBUTTON

2. MAIN AIR COMPRESSOR STOP PUSHBUTTON

2. PHASE SEQUENCE INDICATOR

TYPICAL HIGH VOLTAGE CABINET CONTROLS

FIGURE 13

TYPICAL SCREW COMPRESSOR CONTROLS

TYPICAL DIESEL

CONTROLS

7. HOURMETER

FIGURE 14

1. OIL PRESSURE GAUGE

2. WATER TEMPERATURE GAUGE

3. AMMETER

4. TACHOMETER

5. STARTING SWITCH

6. FUEL GAUGE

ENGINE

FIGURE 15

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