24 minute read
Breaker shaft and breaker power unit ......................... 5
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Breaker shaft and breaker power unit
The breaker power unit (Fig. 89) and the breaker shaft assembly (Fig. 90) can be removed or installed as a single assembly (Fig. 91) or as two separate assemblies.
The power unit (Fig. 89) consists of the following main components:
■ motor (200 hp)
■ connecting tube
■ magnetic coupling
■ gear reducer
WARNING! Magnets can cause pacemakers defibrillators, or other electronic medical devices to malfunction or reset to factory settings. People with any of these medical devices must maintain a safe distance (10 ft) when coupling is disassembled.
WARNING! Ferrous metals are powerfully drawn to the magnets in the magnet rotor and are very difficult to separate. Keep conductor components, tools, fasteners, and metal work surfaces such as steel benches away from the magnets. In the event of accidental magnetic attachment, use plastic wedges to separate parts from the magnets.
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Fig. 89: Breaker power unit main components
Gear reducer
Connecting tube
Motor (200 HP)
Fig. 90: Breaker shaft assembly
Magnetic coupling
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Fig. 91: Breaker shaft and power unit assembly
Power unit assembly
Breaker shaft assembly
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How to remove the breaker shaft and breaker power unit
To remove the breaker shaft and breaker power unit as a single 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 power unit and breaker shaft 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 breaker shaft, gear reducer, and electric motor.
6. Remove the power unit support structure.
7. Remove the under speed sensor and tachometer by loosening the nuts on the u-bolt and sliding the sensor out.
8. Attach an appropriate lifting device to the breaker shaft and power unit assembly in such a manner to keep breaker shaft and power unit level during the lift. Take all slack out of the lifting device in order to support the assembly when mounting hardward is removed.
9. Remove the hardware from the breaker side plates and the power unit reaction pin.
10. Lift the breaker shaft and power unit out of the machine as an assembly.
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Fig. 92: Breaker shaft and power unit removal and installation
1 5
6 8
3 19
4
3
6 2 7
9
10
12
11 31
25
27 20 21 26
14
30
18
15 13
17 16 22, 23, 24
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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
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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.
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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.
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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.
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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.
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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.
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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.
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How to install the breaker power unit
To install the breaker power unit (Fig. 92).
1. Ensure that the machine is locked and tagged out at 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.
2. Attach an appropriate lifting device to the power unit and position the power unit in 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.
3. Install the pivot pin.
4. Install the hardware that secures the bolt flange of the breaker shaft to the stub shaft.
5. Connect grease lines to the gear reducer and electric motor.
6. Remove motor junction box cover and tag and disconnect power leads.
7. Remove the breaker power unit covers.
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How to disassemble the breaker power unit
To disassemble the breaker power unit (Fig. 93):
WARNING! Magnets can cause pacemakers defibrillators, or other electronic medical devices to malfunction or reset to factory settings. People with any of these medical devices must maintain a safe distance (10 ft) when coupling is disassembled.
WARNING! Ferrous metals are powerfully drawn to the magnets in the magnet rotor and are very difficult to separate. Keep conductor components, tools, fasteners, and metal work surfaces such as steel benches away from the magnets. In the event of accidental magnetic attachment, use plastic wedges to separate parts from the magnets.
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.
IMPORTANT! Field disassembly or repair of the breaker shaft is not recommended. If the breaker shaft requires repair, please consult your service representative.
1. Remove the power unit from the machine (see power unit removal procedure in this section). While it is not required to remove the breaker shaft with the power unit, this procedure details the procedure for removing both.
2. Attach an appropriate lifting device to the breaker shaft (if attached) and remove the bolts, lock washers, and nuts from the coupling flange and stub shaft.
3. Remove the low speed output shaft cover bolts and the cover.
4. Remove the M30 hex head cap screw from the stub shaft.
5. Insert a hex head cap screw into the threaded hole in the gear reducer retainer plate. As the bolt is threaded into the hole, it will push the stub shaft out of the hollow bore of the reducer.
6. Install a lifting eye into the top of the electric motor.
7. Attach an appropriate lifting device to the electric motor.
8. Remove the connecting tube access cover.
9. Remove the bolts that attach the magnetic coupling to the shrink disc on the motor shaft.
10. Loosen the bolts that secure the shrink disc to the electric motor shaft. ________________________________________________________________ 5.136 FB110 Feeder Breaker
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11. Using a gear puller, a brass hammer, or a hammer and wooden block, carefully remove the shrink disc from the electric motor shaft.
12. Securely block the magnetic coupling so that it will not move when it is disconnected from the gear reducer shaft.
13. Remove the bolts that secure the shrink disc to the gear reducer shaft.
14. Attach a lifting device to the magentic coupling assembly and remove from the connecting tube. Note: Hubs must be removed from the magnetic coupling assembly before the power unit is reassembled.
15. Attach a lifting device to the connecting tube and take up the slack so that the weight of the connecting tube is resting on the lifting device.
16. Remove the bolts that secure the connecting tube to the gear reducer and lift the connecting tube out of the frame.
17. Using a gear puller, a brass hammer, or a hammer and wooden block, carefully remove the shrink disc from the gear reducer.
18. Remove fan from gear reducer by loosening the set screw and removing the key.
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Fig. 93: Breaker power unit assembly and disassembly
1 5 6 7
4
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9 8 3 2 10
1. Gear reducer 2. Magnetic coupling assembly 3. Electric motor 4. Connecting Tube 5. Flat washer, 1-1/4”(4) 6. Lock washer, 1-1/4”(4) 7. Bolt, hex head, 1-1/4X5-1/2 (4) 8. Lock washer, 3/4”(8) 9. Bolt, hex head, 3/4X2-1/4 (8) 10. Connecting tube cover 11. Flat washer, 1/2”(2) 12. Lock washer, 1/2”) (2) 13. Bolt, hex head, 1/2X1 (2)
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Fig. 93, continued: Breaker power unit assembly and disassembly
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Fig. 94: Magnetic coupling assembly
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How to assemble the breaker power unit
To assemble the breaker power unit (Fig. 93 and Fig. 94):
WARNING! Magnets can cause pacemakers defibrillators, or other electronic medical devices to malfunction or reset to factory settings. People with any of these medical devices must maintain a safe distance (10 ft) when coupling is disassembled.
WARNING! Ferrous metals are powerfully drawn to the magnets in the magnet rotor and are very difficult to separate. Keep conductor components, tools, fasteners, and metal work surfaces such as steel benches away from the magnets. In the event of accidental magnetic attachment, use plastic wedges to separate parts from the magnets.
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.
1. Remove the key from the gearbox input shaft and modify it by cutting it to the length of the fan hub. Note the location of the fan to aid in reinstallation and remove the fan.
2. Attach a lifting device to the connecting tube and secure the connecting tube to the gear reducer with four 1-1/4X5-1/2 hex head bolts, lock washers, and flat washers. Torque to 1,900 ft-lb.
3. Ensure that the coupling hubs and the mounting shafts are deburred, degreased, clean, and dry.
4. Mark engagement lengths on the motor and gearbox shafts:
Motor shaft engagement length: 3.33 inches Gearbox shaft engagement length: 1.74 inches
5. Install the fan on the gearbox and insert the modified key from Step 1. Secure the fan by tightening the set screw.
6. Remove the gearbox hub from the magnetic coupling by inserting jacking screws (save for later installation) to jack hub from conductor plate.
7. Loosely install hub connections bolts into the gearbox side hub.
8. Place gearbox side shrink disc on gearbox side hub. NOTE: Do
not tighten shrink disc cap screws at this time.
9. Install the gearbox side hub and shrink disc onto the gearbox shaft until it aligns with the engagement mark made on the shaft in Step 5.
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10. Tighten the gearbox shrink disc clamp bolts as follows until the hub cannot be hand rotated independent of the shaft.
a. After confirming correct position of the hub and shrink disc, hand tighten three equally spaced locking screws, making sure that the outer collars of the shrink disc are parallel. Hand tighten the remaining locking screws.
11. Place a dial indicator on the hub and measure for radial and face runout. Total Indicated Runout (TIR) must be less than 0.003 inch (0.08 mm). (Fig. 95)
Fig. 95: Run out measurement
Hub connection bolt
Shrink disc
Face runout
Pilot diameter (radial) runout
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12. If runout is greater than 0.003 inch, locate the high point of TIR at 12:00 and apply a blow with a soft face mallet on the edge of the hub to correct runout. Once TIR is less than 0.003 inch, proceed to
Step 12. If TIR cannot be achieved, installation cannot continue.
13. When correct TIR is achieved, final torque (22 ft-lb) the shrink disc bolts as follows:
a. Using a torque wrench set to 23 ft-lb, tighten locking screws in a clockwise sequence using 1/4 turns for several passes until 1/4 turns can no longer be achieved.
b. Continue to apply overtorque for 1 to 2 more passes. Note:
Overtorque is required to compensate for system related relaxation of locking screws since tightening a given screw will always relax adjacent screws.
c. Reset the torque wrench to 22 ft-lb and check all locking crews.
No screws should turn at this point. If screws turn, repeat Step b for 1 to 2 more passes.
14. Remove the electric motor shaft key from the electric motor shaft (it is not used in this application).
15. Clean, degrease, and dry the electric motor shaft.
16. Remove the electric motor shaft drive hub from the magnetic coupling by removing the connecting cap screws (save for later installation) and inserting hub jacking screws to jack hub from conductor plate of the magnetic coupling.
17. Loosely install hub connection bolts into the electric motor hub and place electric motor side shrink disc on hub.
18. Install motor side hub and shrink disc on to the electric motor shaft until it aligns with the engagement mark made on the shaft in
Step 5. Note: Do not tighten shrink disc cap screws at this
time.
19. Tighten the electric motor shrink disc clamp bolts as follows until the hub cannot be hand rotated independent of the shaft:
a. After confirming correct position of the hub and shrink disc, hand tighten three equally spaced locking screws, making sure that the outer collars of the shrink disc are parallel. Hand tighten the remaining locking screws.
20. Place a dial indicator on the hub and measure for radial and face runout. Total Indicated Runout (TIR) must be less than 0.003 inch (0.08 mm). (Fig. 95)
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21. If runout is greater than 0.003 inch, locate the high point of TIR at 12:00 and apply a blow with a soft face mallet on the edge of the hub to correct runout. Once TIR is less than 0.003 inch, proceed to Step 12. If TIR cannot be achieved, installation cannot continue.
22. Attach a lifting device to the electric motor and align motor with connecting tube. Install eight mounting bolts and hand tighten only. NOTE: Do not remove lifting device; let the weight of the
motor rest on the lifting device, not the hand tight connecting bolts.
23. Install the center assembly of the magnetic coupling by attaching a lifting device to the assembly and aligning the match marks on the magnet rotor and gearbox hub. Torque hub/rotor cap screws (gearbox side only) to 85 ft-lb.
24. Align match marks on the conductor housing of the magnetic coupling and the electric motor hub. Attach the conductor housing to the motor hub with cap screws and torque to 60 ft-lb.
25. If housing lines up with motor hub, go to Step 26. If it does not, rotate the coupling until it is lined up.
26. Insert jacking screws into jacking holes in conductor housing. Adjust jacking screws until air gap is near equal on both sides of the magnet rotor.
27. After the electric motor hub is tightened to magnetic coupling and BEFORE the electric motor shrink disc is tightened to the electric motor side hub, the eight (8) bolts installed in Step 22 must be incrementally and evenly torqued to 400 ft-lb in a crossing pattern.
28. Final torque (44 ft-lb) the electric motor side shrink disc bolts as follows:
a. Using a torque wrench set to 46 ft-lb, tighten locking screws in a clockwise sequence using 1/4 turns for several passes until 1/4 turns can no longer be achieved.
b. Continue to apply over-torque for 1 to 2 more passes. Note:
Over-torque is required to compensate for system related relaxation of locking screws since tightening a given screw will always relax adjacent screws.
c. Reset the torque wrench to 44 ft-lb and check all locking crews. No screws should turn at this point. If screws turn, repeat Step b for 1 to 2 more passes.
29. Remove all jacking screws from the conductor housing assembly.
30. Inspect hubs for proper engagement with shaft.
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31. Inspect coupling assembly to ensure air gap is spaced equally on both sides of the magnet rotor.
a. If the magnet rotor is touching the copper conductor housing, reinsert the jacking screws into the jacking holes in the conductor housing.
b. Loosen the shrink disc cap screws on the motor side, and
c. Repeat Steps 24 through 26.
32. Replace the connecting tube access cover.
33. Apply never Seeze to the key and stub shaft and install the sub assembly into the hollow bore of the gear reducer.
34. Install an M30 hex head cap screw into the end of the stub shaft and torque to 900 ft-lb.
35. Install the low speed output shaft cover and bolts. Torque to 15 ftlb incrementally and evenly in a crossing pattern.
36. Attach an appropriate lifting device to the breaker shaft (if removed with the power unit) and secure the coupling flange to the stub shaft with twelve (12) 1X3 shoulder bolts, and twelve (12) 3/4 lock washers and nuts. Torque to 376 ft-lb.
37. Install the assembled power unit into the machine (see Power unit installation procedure in this chapter).
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Fig. 93: Breaker shaft and power unit installation
Breaker shaft
Breaker power unit
To adjust the height of the breaker shaft and power unit:
1. Remove covers to gain access to both ends of the breaker shaft and power unit.
2. Remove all breaker shaft side plate and reaction pivot mount hardware.
3. Loosen only, do not remove, the retainers located on the reaction pivot mount.
4. Locate the grease cylinder manifold on the feeder frame rear pivot mount.
To lower:
5. To lower the breaker shaft and power unit, make sure grease needle valve openings are pointed away from people and slowly crack open one at a time.
6. Incrementally and evenly lower the breaker shaft and power unit to the desired height and close the needle valves.
7. Install all hardware, tighten the retainer hardware on the reaction pivot mount, and install all covers.
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To raise:
5. To raise the breaker shaft and power unit make sure grease needle valves are closed and pointed away from people and slowly pump grease into grease cylinder.
6. Incrementally and evenly raise the breaker shaft and power unit to the desired height.
7. Install all hardware, crack each needle valve to remove store pressure from grease cylinders, tighten the retainer reaction pivot mount bolts, and install all covers.
