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Breaker shaft and breaker power unit .........................5
■ Step 1: 25 ft-lb ■ Step 2: 50 ft-lb ■ Step 3: 70 ft-lb
If using a motor adapter plate that does not have the keepers already installed, weld four (4) keepers against the motor flanges to prevent motor movement.
Clean all dirt and debris from mounting area of crawler frame.
Attach an appropriate lifting device to the torque hub and slide complete assembly into crawler frame.
Secure torque hub assembly to frame with the twelve (12) bolts and lock washers. Apply Loctite 242 (blue) to bolts and torque incrementally and evenly in a crossing pattern as follows.
■ Step 1: 50 ft-lb ■ Step 2: 140 ft-lb ■ Step 3: 280 ft-lb ■ Step 4: 420 ft-lb
Connect hydraulic hoses to drive motor.
Install and connect crawler and track pad assembly (see How to install the crawler track pad assembly in this chapter).
Install the removable side plate and secure with the six (6) bolts and lock washers. Torque incrementally as follows.
■ Step 1: 300 ft-lb ■ Step 2: 600 ft-lb ■ Step 3: 905 ft-lb
Apply grease to anchor pin and slide anchor pin through crawler frame and tilt cylinder. Secure pin with slotted nut, washer and roll pin.
Purge hydraulic system of air.
Adjust crawler track pad tension (see How to adjust crawler track pad tension in this chapter).
Fig. 90: Crawler drive disassembly and assembly
1. crawler frame 2. torque hub 3. Washer (allen lock) 4. bolt 5. sprocket 6. washer (lock) 7. bolt 8. gasket (adaptor plate) 9. plate (adaptor) 10. washer (lock) 11. bolt 12. gasket 13. washer (flat) 14. nut 15. keeper 16. washer (lock) 17. bolt 18. crawler pad 19. bushing 20. bushing 21. pin (crawler anchor) 22. washer (flat) 23. nut (castle) 24. pin (cotter) 25. removable sideplate
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Breaker shaft and breaker power unit
The breaker power unit and the breaker shaft assembly can be removed and installed as a single assembly or as two separate assemblies.
Fig. 91 and 92 show the breaker power unit and breaker shaft installed in the machine.
Fig. 91: Breaker power unit and breaker shaft removal/installation
Breaker power unit Breaker shaft
Fig. 92: Breaker shaft and breaker power unit assembly removal/installation
1. Breaker assembly 2. Hex head bolt, 1-1/4X4-1/2 (24) 3. Lock washer, 1-1/4 (24) 4. Hex nut, 1-1/4 (24) 5. Stub shaft 6. Socket head shoulder screw, 1X3 (12) 7. Lock washer, 3/4 (12) 8. Hex nut, 3/4 (12) 9. Key 10. Power unit assembly 11. Pivot lug weldment 12. Pivot lug mount plate 13. Power unit reaction pin 14. Lock washer, 1”(4) 15. Hex head bolt, 1X2-1/4 (4) 16. Cotter pin, 3/8X4 (2) 17. Breaker shaft guard weldment 18. U-bolt, 2X3-3/4X3/8-16 19. Lock washer, 7/8 (7) 20. Flat washer, 7/8 (4) 21. Hex nut, 7/8 (4) 22. Hex head bolt, 4/8X2-3/4 (4) 23. End cap 24. Hex head bolt, 7/8X2-1/2 (3)
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How to remove the breaker shaft and breaker power unit assembly
To remove the breaker shaft and power unit as a single assembly proceed as follows (Fig. 92).
Turn the machine main circuit breaker (CB1) to the “OFF”position.
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.
Remove the roof anchor cylinder and roof cylinder mount weldment as an assembly (see roof anchor cylinder removal/installation procedure in this section).
Remove the central grease manifold from the cover support weldment. It is not necessary to remove the grease hoses from the manifold.
Remove the area light from the cover support weldment. It is not necesssary to remove the area light electrical cable.
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.
Remove the primay operator’s station mounting hardware from the cover support structure and remove the junction box access panel of the electric motr. Disconnect the cable leads from the motor leads. Tag for assembly purposes.
Remove and cap all grease lines from the breaker shaft, gear reducer, and electric motor.
Remove the under speed sensor and shaft guard.
Attach an appropriate lifting device to the breaker shaft and power unit assembly. Take all slack out of the lifting device in order to support the assembly when mounting hardward is removed.
Remove the hardware from the breaker side plates and the power unit reaction pin.
Lift the breaker shaft and power unit out of the machine as an assembly.
How to install the breaker shaft and power unit assembly
To install the breaker shaft and breaker power unit as a single assembly proceed as follows (Fig. 93).
Attach an appropriate lifting device to the complete unit 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.
Install the power unit reaction pin and the hardware into the breaker side plates.
Remove the lifting device.
Install the shaft guard and under speed sensor on the gear box.
Note: distance from the sensor end to end cap target is approximately 1/8”to 1/4”.
Remove caps and install all grease lines to the breaker shaft, gear box, and electric motor.
Install the primary operator’s station.
Install all power unit and breaker covers.
Install the area light on to the cover support weldment.
Install the central grease manifold.
Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.
Install the roof anchor cylinder and roof cylinder mount weldment (see roof anchor cylinder removal/installation procedure in this section).
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.
Unlock and remove tags from electric power at the power center.
Turn the machine circuit breaker on.
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. 93).
Turn the machine main circuit breaker (CB1) to the “OFF”position.
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.
Remove the roof anchor cylinder and roof cylinder mount weldment as an assembly (see Roof anchor cylinder removal/installation procedure in this section).
Remove the central grease manifold from the cover support weldment. Grease hoses do not need to be removed from the manifold.
Remove the area light from the cover support weldment. It is not necesssary to remove the area light electrical cable.
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.
Remove the primay operator’s station mounting hardware from the cover support structure and remove the junction box access panel of the electric motr. Disconnect the cable leads from the motor leads. Tag for assembly purposes.
Remove and cap all grease lines from the gear reducer and electric motor.
Remove the under speed sensor and shaft guard.
Attach an appropriate lifting device to the power unit assembly.
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.
Remove the bolts that connect the breaker shaft bolt flange to the stub shaft.
Remove the power unit reaction pin.
Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.
How to install the breaker power unit assembly
To install the breaker power unit proceed as follows (Fig. 93).
Attach an appropriate lifting device to the power unit 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.
Install the power unit reaction pin.
Bolt the breaker shaft bolt flange to the stub shaft.
Remove the lifting device.
Install the shaft guard and under speed sensor on the gear box.
Distance from sensor end to end cap target is approximately 1/8”to 1/4”.
Remove caps and install all grease lines to the gear box and electric motor.
Install the primary operator’s station.
Install all power unit covers.
Install the area light on to the cover support weldment.
Install the central grease manifold.
Reconnect the cable leads to motor leads and install junction box cover. Follow all MSHA, State, and Federal laws.
Install the roof anchor cylinder and roof cylinder mount weldment (see roof anchor cylinder removal/installation procedure in this section).
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.
Unlock and remove tags from electric power at the power center.
Turn the machine circuit breaker on.
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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