8 minute read
Conveyor power unit.....................................................5
Fig. 92, continued: Breaker shaft and power unit removal and
8, 7, 9, 10
31
1. Breaker shaft assembly 2. Filler plate (2) 3. Washer, lock 1-1/4 (24) 4. Bolt, hex head 1-144X4 (20) 5. Bolt, hex head 1-1/4X5 (4) 6. Nut, hex 1-1/4 (24) 7. Stub shaft 8. Screw, socket head shoulder 1X3 (12) 9. Washer, lock 3/4 (12) 10. Nut, hex 3/4 (12) 11. Power unit assembly 12. Bolt, hex head M30X80 13. Pivot lug weldment 14. Mounting plate, pivot lug 15. Reaction pin 16. Washer, lock 1” (4) 17. Bolt, hex head 1X2 (4) 18. Pin, cotter 3/8X4 (2) 19. Key 20. Cylinder mount weldment 21. Grease cylinder (3) 22. Washer, flat 3/8 (6) 23. Washer, lock 3/8 (6) 24. Bolt, hex head 3/8X1-1/4 (6) 25. Breaker retainer (2) 26. Breaker retainer (2) 27. Grease fitting (5) 28. Underspeed sensor mount 29. U-bolt 30. Power unit guide assembly 31. Low speed output shaft cover plate
How to install the breaker shaft and breaker power unit
To install the breaker shaft and breaker power unit as a single assembly (Fig. 92).
1. Attach an appropriate lifting device in such a manner as to keep the breaker shaft and power unit level during the lift and slowly lift the unit onto the machine.
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.
2. Install the power unit reaction pin and the hardware into the breaker side plates.
3. Install the tachometer and under speed sensor on the left hand side of the breaker shaft. The distance from the sensor end to end cap target is approximately 1/8 to 1/4 inch. Note: Ensure that a 1/213X1/2 hex head cap screw is installed in the breaker end cap or the tachometer will not read correctly.
4. Remove caps and install all grease lines to the breaker shaft, gear box, and electric motor.
5. Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.
6. If necessary, adjust the height of the breaker shaft using the grease cylinders. There is one grease cylinder mounted under each breaker side plate and one mounted under the reaction pin (see
Breaker shaft height adjustment procedure in this chapter).
7. Install the power unit cover support structure.
8. Install all power unit covers.
9. Turn the machine circuit breaker on.
10. Unlock and remove tags from electric power at the power center.
11. Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.
How to remove the breaker power unit assembly
To remove the breaker power unit proceed as follows (Fig. 92).
1. Turn the machine main circuit breaker (CB1) to the “OFF” position.
2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.
WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.
3. Remove all power unit covers.
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.
4. Remove the junction box access panel of the electric motor. Tag and disconnect the cable leads from the motor leads.
5. Remove and cap all grease lines from the gear reducer and electric motor.
6. Remove the under speed sensor and tachometer.
7. Attach an appropriate lifting device to the power unit assembly in such a manner as to keep the power unit level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting power unit reaction pin and bolts from breakershaft bolt fland and stub shaft are removed.
8. Remove the bolts that connect the breaker shaft bolt flange to the stub shaft.
9. Remove cotter pins from the power unit reaction pin.
10. Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.
11. Lift the power unit out of the machine.
How to install the breaker power unit assembly
To install the breaker power unit proceed as follows (Fig. 92).
1. Attach an appropriate lifting device to the power unit in such a manner that the power unit is level during the lift and slowly lift the unit onto the machine.
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.
2. Install the power unit reaction pin and secure with cotter pins.
3. Bolt the breaker shaft bolt flange to the stub shaft.
4. Remove the lifting device.
5. Install the tachometer and under speed sensor on the breaker shaft. Distance from sensor end to end cap target is
approximately 1/8” to 1/4”. Note: Ensure that a 1/2-13X1/2 hex head cap screw is installed in the breaker end cap or the tachometer will not read correctly.
6. Remove caps and install all grease lines to the gear box and electric motor.
7. Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.
8. Install all power unit covers.
9. Unlock and remove tags from electric power at the power center.
10. Turn the machine circuit breaker on.
11. Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.
How to remove the breaker shaft assembly only
To remove the breaker shaft assembly (Fig. 92).
1. Turn the machine main circuit breaker (CB1) to the “OFF” position.
2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.
WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.
3. Remove all breaker shaft and gear reducer covers.
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.
4. Remove and cap all grease lines from the breaker shaft.
5. Remove the underspeed sensor and tachometer from the breaker shaft by loosening the nuts on the u-bolt just enough to allow the senosr to slide out.
6. Properly support the breaker shaft gear reducer so that it does not fall during breaker shaft removal. Ensure that the power unit reaction pin is in place and not removed during this procedured.
7. Attach an appropriate lifting device to the breaker shaft. in such a manner that the breaker shaft is level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting hardware is removed.
8. Remove the hardware from the breaker side plates and from between the two halves of the bolt flange and the stub shaft flange.
9. Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.
10. Lift the breaker shaft out of the machine.
How to install the breaker shaft assembly
To install the breaker shaft assembly (Fig. 92).
1. Attach an appropriate lifting device to the breaker shaft in such a manner that the breaker shaft is level during the lift and slowly lift the unit onto the machine.
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.
2. Install the hardware into the breaker side plates.
3. Install hardware to attach breaker shaft bolt flange to stub shaft in gear reducer.
4. Remove support from under gear reducer.
5. Remove lifting device from breaker shaft.
6. Remove caps and install all grease lines to the breaker shaft.
7. Install all breaker covers.
8. If necessary, adjust the height of the breaker shaft using the grease cylinders. There is one grease cylinder mounted under each breaker side plate and one mounted under the reaction pin (see
Breaker shaft height adjustment procedure in this chapter).
9. Turn the machine circuit breaker on.
10. Unlock and remove tags from electric power at the power center.
11. Check for proper breaker shaft rotation direction. It may be necessary to switch the breaker motor leads if the shaft is turning in the wrong direction.
How to remove the breaker power unit only
To remove the breaker power unit (Fig. 92).
1. Turn the machine main circuit breaker (CB1) to the “OFF” position.
2. Lock out and tag the power center. Follow standard Federal and mine lockout/tagout procedures.
WARNING! Before performing maintenance on the machine, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.
3. Remove the breaker power unit covers.
4. Block underneath the gear reducer and the electric motor to prevent units from falling during removal.
5. Remove motor junction box cover and tag and disconnect power leads.
6. Remove grease lines from gear reducer and electric motor.
7. Attach an appropriate lifting device to the power unit. Take up slack in lifting device so weigth of power unit is supported by the lfiting device.
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.
8. Remove pivot pin and hardware connecting the bolt flange of the breaker shaft to the stub shaft.
9. Lift the breaker breaker power unit out of the machine.
