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Head shaft sprockets .................................................... 5
11. Remove the four (4) 1” bolts, flat washers, lock washers, and nuts from each of the headshaft bearings. Note that there may be bearing shims under the bearing. If shims are present, make note of their thickness, quantity and location.
12. Attach an appropriate lifting device to the headshaft and slide out towards the rear of the frame.
WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.
How to install the headshaft
To install the headshaft assembly proceed as follows (Fig. 78):
1. Attach an appropriate lifting device to the head shaft and slide in the slots located at the end of the feeder breaker. The gear reducer may be installed on shaft if desired.
2. Reinstall bearing shims, if applicable, back into the same location as they were removed from. Make sure to install the shims of the same thickness and quantity.
3. Align the head shaft bearings with the mounting holes in frame and secure each with the four (4) 1” bolts, nuts, and lock washers.
Torque bolts to 645 ft-lbs.
NOTICE! After tightening the four (4) 1” bolts and nuts and before installing the gear reducer, ensure that the headshaft can turn freeely by hand. If it cannot, loosen the nuts and bolts and add or remove shims between the frame and the piloow block base as required.
WARNING! The headshaft must turn freely by hand or the bearings will fail prematurely.
4. Install the left and right sprocket guards, head shaft filler plates, tailpiece hoppers, amd tailpiece tilt cylinders (see Tailpiece installation procedure).
5. Connect the central lubrication hoses on both head shaft bearings.
6. Install the hydraulic motor onto the input shaft of the gear reducer.
a. Install the five (5) 1/2” mouting bolts, lock washers, and flat washers and torque to 100 ft-lbs.
b. Reconnect hydraulic hoses.
7. Install the conveyor gear reducer (see Conveyor gear reducer removal/installation procedure in this chapter). The gear reducer may have been installed.
8. Clean and lubricate splined end of headshaft and splined adapater with ISO 68 hydraulic fluid or coat with Never Seez.
9. Install cover support post.
10. Connect conveyor chain. (See Conveyor chain replacement in this chapter).
11. Adjust tension on the conveyor chain. (See Conveyor chain adjustment in this chapter).
Fig. 78: Headshaft removal and installation
Nut (8)
Lock washer (8)
Hex bolt (4) (5/8”X1-3/4”)
Pin
Swivel bearing
Male clevis
Hex bolt (5) (1/2” X 2 1/4”) Female clevis
Hydraulic motor Retaining bolt Shaft retainer Reducer end cover Headshaft bearing
Splined adapter Headshaft assembly Flat washer (8)
Hex bolt (8) (1” X 5”)
Headshaft sprockets
The headshaft sprockets transmit the torque of the hydraulic motor to the conveyor chain assembly and are part of the headshaft assembly. As soon as the sprockets are worn, they must be replaced. Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.
How to remove the headshaft sprockets
To remove the sprockets from the headshaft assembly (Fig. 79):
1. Remove the headshaft assembly from the feeder (see Headshaft removal in this chapter).
2. Remove the two (2) bearings from the headshaft.
3. Remove the two (2) set screws from each sprocket. It may be necessary to apply heat because the screw are retained with
Loctite.
4. Slide both sprockets from the drive shaft.
5. Remove old keys.
6. Inspect all components of the drive shaft for wear and damage.
See the Bucyrus parts manual for your machine for a replacement parts list.
How to install the headshaft sprockets
To install the sprockets on the headshaft (Fig. 79):
1. Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.
2. Insert one of the keys into the shaft keyway and slide first sprocket onto shaft (see Fig. 80 for location). It is customer preference on whether to weld the sprocket in place or not. See Fig. 79 for weld specifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.
3. Insert the other key into the shaft keyway and slide second sprocket onto shaft (see Fig. 79 for location). It is customer preference on whether to weld the sprocket in place or not. See
Fig. 80 for weld spcifications. Apply Loctite 242 (blue) to screws and torque to 100 ft-lbs.
4. Install bearings on shaft (ss Bearing installation procedure in this chapter). Note that the bearing housing must be installed on shaft so that the Taconite seal is facing the middle of the shaft. Only one of the bearings must have the internal spacer remvoed to allow the shaft to float and not be in a bind.
5. Install the drive shaft assembly in the feeder breaker. (See Drive shaft installation in this chapter.)______________________________________________________________
