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Conveyor power unit.................................................... 5
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Fig. 94: Conveyor power unit Conveyor power unit
The conveyor power unit (Fig. 94) has been assembled as a unit and can be removed and installed as a unit.
The power unit consists of the following main components:
■ electric motor (125 hp)
■ coupling
■ connecting tube
■ Open loop load sense pump
Electric motor
Connecting tube
Lock washer
Flat washer
Hex head bolt Lock washer Hex head bolt
Open loop load sense pump Flat washer Coupling Motor mount (Bolt, washer, and lock nut)
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How to remove the conveyor power unit (Fig. 94)
1. Turn the main circuit breaker on the feeder breaker to the “OFF” position.
2. Lock and tag out the power to the feeder breaker at the main power center. Follow all Federal, State, and mine rules.
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 covers.
4. Attach an appropriate lifting device to the power unit. Take up the slack in the lifting device so that the power unit is supported and wont’tilt and fall when unbolted from the frame.
WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or devices and keep a safe distance from suspended loads.
5. Disconnect, tag, and cap all hydraulic hoses.
6. Disconnect grease lines to conveyor electric motor.
7. Remove access cover on junction box of conveyor and motor and remove the cable leads from the motor leads.
8. Reinstall junction box cover.
9. Remove the four bolts that secure the motor to the frame.
10. Lift power unit assembly from machine.
WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or devices and keep a safe distance from suspended loads.
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How to install the conveyor power unit (Fig. 94)
1. Attach an appropriate lifting device to the power unit and lift the power unit into the machine.
WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or devices and keep a safe distance from suspended loads.
2. Align the electric motor foot bolt holes with the mounting plate bolt hoes.
3. Install the four 3/4”diameter hex bolts, washers, and nuts. Torque to 380 ft-lbs.
4. Connect hydraulic hoses.
5. Ensure that the hydrostatic pump is primed. To prime the hydrostatic pump, remove the case drain fitting (see Fig. 92) and pour hydraulic fluid (Spec. 100-1) until the pump housing is full.
6. Connect grease lines to the electric motor.
7. Remove junction box cover.
8. Attach motor leads to cable leads and seal junction box cover. Follow all Federal, State, and mine regulations.
9. Install machine covers.
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How to disassemble the conveyor power unit (Fig. 94)
WARNING! Before removing each pump and the connecting tube be sure to properly support the component. Failure to properly support the component may result in damage to the component or injury to personnel.
WARNING! Remove all fittings from the pumps and plug the ports before removal. Failure to remove fittings and plug ports could result in damage to the pumps.
1. Remove two M10 bolts and spring washers and remove priority gear pump. Save the o-ring and splined pump insert from the rear of the open loop pump (Fig. 95).
IMPORTANT! Remove and save the o-ring and splined pump insert from the rear of the open loop pump.
Fig. 95: Open loop pump assembly
O-ring
Bolt (2) Spring washer (2) Splined insert
Priority gear pump Open loop pump
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2. Remove the bolt and lock washer from hinged access cover on the connecting cover and open the access cover.
3. Loosen the two socket head cap screw bolts that retain the Rotex coupling half to the open loop pump splined shaft.
4. Remove the four bolts, lock washers, and flat washers on the open loop pump.
CAUTION! The pump is heavy. To avoid injury, use proper lifting techniques.
5. Slide the open loop pump shaft, coupling hub, and element clear of the connecting tube.
6. Remove the eight bolts, lock washers, and flat washers and then remove the connecting tube.
7. Loosen the set screw from the coupling hub on the electric motor shaft and slide the hub off of the shaft.
8. Remove the key from the electric motor shaft.
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How to assemble the conveyor power unit (Fig. 94)
1. Install the key in the electric motor shaft.
2. Apply Never Seez to the electric motor shaft and install the coupling hub onto the electric motor shaft. Roughly position the hub even with the end of the shaft. Do not tighten the set screw as final positioning of the hub will be determined at the end of assembly.
3. Install the element onto the coupling hub on the electric motor.
4. Apply Never Seez onto the open loop pump splined shaft. Install the remaining coupling hub onto the hydrostatic pump splined shaft (refer to Fig. 96 for dimensions).
5. Clean all mating surfaces on the connecting tube and the electric motor.
6. Apply Loctite 242 (blue) to the eight bolts and install bolts, flat washers, and lock washers into the connecting tube. Torque incrementally and evenly to 170 ft-lbs as follows:
■ Step 1: 50 ft-lbs ■ Step 2: 100 ft-lbs ■ Step 3: 170 ft-lbs
IMPORTANT! It is extremely important that the connecting tube pulls up evenly on the electric motor. If the connecting tube is cocked, misalignment between the pump and the electric motor will occur and the coupling will fail.
7. Install the open loop pump. Align the pilot hub on the pump with the pilot bore of the connecting tube while simultaneously engaging the jaws of the Rotex coupling halves.
8. Install four bolts, flat washers, and lock washers and torque incrementally and evenly to 280 ft-lbs as follows:
■ Step 1: 90 ft-lbs ■ Step 2: 200 ft-lbs ■ Step 3: 280 ft-lbs
Refer to Figure 96 to verify distance between the coupling jaws and the coupling element of 0.18”. This distance must be maintained to avoid element failure. Adjust the gap as required by repositioning the hub on the electric motor shaft as required.
9. Check coupling half alignment by using a straight edge across the two coupling halves (see Fig. 96). Rotate the electric motor and measure the spacing in at least two places to ensure the electric motor and pump shafts are aligned. If there is misalignment, the connecting tube may be cocked or the mating surfaces may not be clean. This misalignment must be corrected before proceeding with assembly. ______________________________________________________________
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IMPORTANT! The coupling halves must be aligned before proceeding with assembly. If the coupling haves are not aligned, component failure may occur.
10. Apply Loctite 242 (blue) to the set screw on the coupling hub of the electric motor shaft and torque to 275 in-lbs.
11. Remove the end plate from the open loop pump in order to install the back gear pump by removing the four bolts.
12. Verify that the o-ring and splined pump insert are pre-installed by the pump manufacturer. If not, the o-ring and splined pump insert that were removed during disassembly can be reused or replaced with a new o-ring and splined insert (see the parts manual that shipped with your machine).
13. Apply clean hydraulic fluid to the shaft of the piggy back gear pump and to the o-ring of the hydrostatic pump.
14. Install the gear pump being careful to properly align the splines and not cut the o-ring.
15. Install the four bolts, lock washers, and flat washers in the gear pump. Torque incrementally and evenly to 80 ft-lbs as follows:
■ Step 1: 20 ft-lbs ■ Step 2: 50 ft-lbs ■ Step 3: 80 ft-lbs
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Fig. 96: Conveyor power unit disassembly/assembly
Electric motor to coupling mating surface
Place straight edge along this edge to determine alignment
