Description

BUCYRUS MT4400AC Technical Manual

BUCYRUS MT4400AC Technical Manual PDF

Page
GENERAL INFORMATION
INTRODUCTION
RELATED PUBLICATIONS
SAFETY INFORMATION
CONTROLS AND INDICATORS
FUNCTIONAlDESCRIPTION
PLANNED MAINTENANCE SCHEDULES
MOTORIZED WHEEL PLANNED MAINTENANCE SCHEDULE
ALTERNATOR PLANNED MAINTENANCE SCHEDULE
DYNAMIC RETARDING ASSEMBLY PLANNED MAINTENANCE SCHEDULE
CONTROL PLANNED MAINTENANCE SCHEDULE
MOTORIZED WHEEL PLANNED MAINTENANCE PROCEDURES
CHECK AXLE BOX FOR OIL LEAKAGE
CHECK FOR EXTERNAL OIL/GREASE LEAKAGE
INSPECT HUBCAPS FOR DAMAGE
CHECK WET DISK BRAKES FOR LEAKS
CHECK GEARCASE OIL LEVEL
CLEAN/REPLACE GEARCASE BREATHER FILTERS
CHECK FILTER VENT TUBE FOR TRAPS/BLOCKS
CHECK AXLE BOX DOOR SEAL
CLEAN THE AXLE BOX
VISUALLY INSPECT FOR MUD/DEBRIS BUiLDUP
CHECK FOR TIGHT CABLE CONNECTIONS
CHECK WHEEL SPEED SENSOR PLUG AND CONNECTIONS
CHECK THERMAL SENSOR
CHECK HYDRAULIC LINES FOR LEAKAGE,
CHECK FOR LOOSE, BROKEN OR MISSING EXTERNAL BOLTS
CHECK BRUSH LENGTH, CONDITION AND MOVEMENT
CHECK THE BRUSHHOLDER
CLEAN THE TEFLON BAND
BLOW OUT THE ROTOR/COMMUTATOR AREA
CHECK ROTATING/STATIONARY COIL CONDITION
VISUALLY CHECK COMMUTATOR CONDITION
REMOVE AND CLEAN MAGNETIC PLUGS
TAKE GEARCASE OIL SAMPLE
ANALYZE GEARCASE OIL SAMPLE
CHANGE/FILTER THE GEARCASE OIL
FLUSHING THE GEARBOX

BUCYRUS MT4400AC Technical Manual
PERFORM ARMATURE COMMUTATOR PROFILE
INSPECT SUN PINION GEAR
INSPECT THE OB AND IB THRUST WASHERS
INSPECT THE LOW SPEED PLANET BEARINGS AND GEARS
MEASURE GEAR ENDPLAY
CHECK GEAR BACKLASH
REMOVE DIRT/GREASE FROM SEAL AREA
CHECK WEAR ON TORQUE TUBE (TT) WEARBAND
LUBRICATE WHEEL HUB BEARINGS
ALTERNATOR PLANNED MAINTENANCE PROCEDURES
VISUALLY INSPECT FOR MUD OR DEBRIS BUiLDUP
INSPECT BRUSH ACCESS COVERS AND GASKETS
CHECK FOR LOOSE OR DAMAGED POWER CABLE CONNECTIONS
CHECK FOR LOOSE OR BROKEN EXTERNAL BOLTS
CHECK AIR INTAKE AND EXHAUST FOR RESTRICTIONS
CHECK TEMPERATURE SENSOR (IF EQUIPPED)
GE Proprietary and Confidential Information
iii
BI
GEKA, OHV Drive System, Planned Maintenance
CONTENTS (Cont’d)
Page
CHECK SLIP RING CONDITION
CHECK SLIP RINGS AND TIE RING ASSEMBLIES CONNECTIONS
CHECK BRUSH LENGTH, CONDITION AND MOVEMENT
CHECK BRUSHHOLDER CONDITION, SPACING AND TENSiON
BLOW OR VACUUM OUT SLIP RING AREA
CHECK ROTOR AND STATOR CONDITION
CHECK BUS RINGS AND FIELD LEADS FOR CRACKED, FRAYED OR DAMAGED INSULATION
CHECK ENGINE SPEED SENSOR CABLE FOR DAMAGE
CHECK ENGINE SPEED SENSOR FOR LOOSE SPEED SENSOR CABLE CONNECTION
RETARDER ASSEMBLY PLANNED MAINTENANCE PROCEDURE
VISUALLY INSPECT FOR MUD OR DEBRIS BUiLDUP
CHECK FOR TIGHT CABLE CONNECTIONS
VACUUM OR BLOW OUT COMMUTATOR AREA
CHECK BRUSH LENGTH, CONDITION AND MOVEMENT
CHECK BRUSHHOLDER CONDITION, SPACING AND TENSION
CHECK COMMUTATOR CONDITION
INSPECT THE GRID RESiSTORS
INSPECT THE BLOWER FAN BLADES FOR DAMAGE
CHECK COMMUTATOR AND EXCITING COIL CONDITION
CHECK FOR TIGHTNESS OF EXPOSED BOLTS
INSPECT GRID BOX STRUCTURE
CHECK GROUND BRUSH (IF APPLICABLE)
PROFILE GRID BLOWER COMMUTATOR(S)
CONTROL PLANNED MAINTENANCE PROCEDURES
CHECK SHUNTS
CHECK FOR TIGHT CABLE CONNECTIONS c
INSPECT COVERS, GASKETS AND DUCTWORK
VACUUM MAIN CONTROL CABINET
CHECK AIR INTAKE AND EXHAUST FOR RESTRICTIONS
CHECK WIRES AND CONNECTIONS FOR ARC OR FLASH DAMAGE
INSPECT CONTACTOR ARC CHUTES
INSPECT CONTACTOR TIPS
INSPECT MAGNET VALVES FOR LEAKS AND CONTAMINATION
INSPECT INTERLOCKS, POSITION SENSORS, AND RELAYS
INSPECT CABINET DOOR SEALS FOR DAMAGE
INSPECT CABINET COVERS FOR LOOSE OR MISSING HARDWARE
CHECK FILTER PANEL RESISTORS, CAPACITORS AND CONNECTIONS
CHECK GROUND FAULT RESISTORS AND CONNECTIONS
CHECK THE POWER CABLE CONNECTIONS TO THE RECTIFIER PANEL/MODULES
INSPECT TERMINAL INSULATORS AND CONNECTIONS
MEGGER MOTOR ARMATURE CiRCUiT
CHECK REVERSER OPERATION
VEHICLE OPERATION TESTS (VOT)
CHECK CPU CARD BATTERY (BRAM) VOLTAGE
iv
GE Proprietary and Confidential Information
BUCYRUS MT4400AC Technical Manual
OHV Drive System, Planned Maintenance, GEKA c LIST OF FIGURES
Figure Title Page
Inspection Points for DC (GE, GE and GE) and Small AC Wheels
(GEB and GEB)
Inspection Points for Large AC Wheels (GDY, GDY and GDY)
GearcaseVenf Connections
Typical DC Motorized Wheel
Brushholder Assembly (Without Brushes Installed)
Typical Small AC Motorized Wheel
Commutator Problems Chart
DC and Small AC Motorized Wheel Magnetic Plug
Magnetic Plug Examples
‘Baster’ Type Oil Sample Tool
Typical Oil Suction Tool for Oil Sampling
Motorized Wheel Oil Sample History Tracking Spreadsheet Example
Approved Synthetic Gear Oils, Viscosity/Temperature Ranges
Typical Commutator Profile Kit
Probe Installed in the Inboard Path Brush Holder
(Commutator marked by Felt Marker to Show Start/Stop Point
Typical Profile Display from a Recorded Profile Record
Example One of a Recorded Commutator Profile
Example Two of a Recorded Commutator Profile
Example Two of a Recorded Commutator Profile
Typical Sun Pinion Gear, Drive Ring and Armature/Rotor Shaft Assembly
for DC and Small AC Wheels
Sun Pinion
NOGO Drive Ring Pie Gauge A for GE, GE, GE and GEB
NOGO Drive Ring Pie Gauge A for GE, GE, GE and GEB
NOGO Drive Ring Pie Gauge A for GE, GE and GEB
Drive Ring (No Go) Pie Gauge Check Process
Sun Pinion Gear Installation
Sun Pinion Gear Removal Tool
Nonreusable Gear Tooth Conditions
Severe Crack from Tooth Root to Center
Repairable/Reusable Gear Tooth Conditions
Abnormal Thrust Washer Conditions
Dimensional Check of Inboard Thrust WasherLarge AC Wheels
Tool Retainer Holding Tube
Tool Retainer Disassembly
Tool , Outboard Support Plate
Retainer Assembly
GE Proprietary and Confidential Information
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GEKA, OHV Drive System, Planned Maintenance
LIST OF FIGURES (Cont’d)
BUCYRUS MT4400AC Technical Manual
Figure Title Page
ToolRetainer Holding Tube
Disassembly Tool (ToolPart )
Retainer Disassembly Tool (Parts, , )
Tool Retainer Disassembly
Removable Retainer Disassembly Procedure
Retainer Disassembly Tools Installed in Motorized Wheel
Low Speed Planet Bearings Visible
Low Speed Bearing Spall
Planet Gear EndPlay Check
Dirt Seal Area
Wear Groove Check Location on Torque Tube
Small DC Wheels Torque Tube Seal and Wear Band
Typical Wheel Bearing Lubricant Access
Alternator Inspection Points for the GTA
Alternator Inspection Points for the GTA
Alternator Inspection Points for the GTA
Alternator, Collector Ring End
GTA , GTA , or GTA Speed Sensor Location
C
Retarder Assemblies, Dual and Single Blower Motor
Layout of Dual and Single Blower Retarder Assemblies
Grid Blower Motor External Components
Grid Blower Motor Internal Components
Brushholder Dimensions
TypicalAmp andorAmp Shunts
Damaged Contactor Components
Typical Electric Contactor Representative of CM, CM, and CM
Major Components of Electric Contactor TypeA A AL
Typical Air Operated Reverser
Major Components of Electric Contactor Type AAAM
Typical ElectroPneumatic Contactor
Filter Panel FM
Battery Location on the FBCard
Typical CPU Card Layout with Bolted Battery Connections
Battery on CPU Card with Bolted Battery Mounting