6 minute read
Conveyor power unit ....................................................5
How to remove the breaker shaft assembly
To remove the breaker shaft assembly 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 all 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 and cap all grease lines from the breaker shaft.
Properly support the breaker shaft reducer so that it does not fall during breaker shaft removal. Ensure that he power unit reaction pin is in place and not removed during this procedured.
Attach an appropriate lifting device to the breaker shaft. 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.
Disengage the pilot fit (1/8 inch) between the stub shaft and bolt flange before attempting to lift the power unit from the machine.
Lift the breaker shaft out of the machine.
How to install the breaker shaft assembly
To install the breaker shaft assembly proceed as follows (Fig. 93).
Attach an appropriate lifting device to the breaker shaft 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 hardware into the breaker side plates.
Install hardware to attach breaker shaft bolt flange to stub shaft in gear reducer.
Remove support from under gear reducer.
Remove lifting device from breaker shaft.
Remove caps and install all grease lines to the breaker shaft.
Install all breaker covers.
Turn the machine circuit breaker on.
Unlock and remove tags from electric power at the power center.
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 disassemble the breaker power unit
To disassemble the breaker power unit proceed as follows (Fig. 93):
Remove complete unit from machine. (See breaker shaft and breaker power unit removal/installation procedure in this section.)
Cut the bolt safety wire from the end of the three cap retainer bolts.
Remove the end cap bolts, lockwashers, and end caps.
Attach an appropriate lifting device to the breaker shaft and remove from the hollow output shaft of the gear reducer.
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! Bucyrus America, Inc. does not recommend field disassembly or repair of the breaker shaft. If the breaker shaft requires repair, please consult your Bucyrus America, Inc. service representative.
Install a lifting eye into the top of the electric motor.
Attach an appropriate lifting device to the electric motor.
Remove the connecting tube access cover.
Remove the three socket head cap screws from the taperlock bushing on the electric motor shaft.
Install two bolts back into the taperlock bushing mounting/ unmounting screw holes and separate the taperlock bushing from the flex coupling.
Remove the electric motor from the connecting tube by removing eight bolts and lock washers.
Remove the gear reducer from the connecting tube by removing the twelve bolts and lock washers.
Remove the flex coupling from the torque limiter by removing eight
M12 bolts and lock washers.
Remove the torque limiter from the companion flange by removing the twelve 7/16”bolts and lock washers.
Remove the three bolts from the taperlock bushing on the gear reducer input shaft.
Install two bolt back into the mounting/unmounting holes and separate the taperlock bushing from the companion flange.
How to assemble the breaker power unit
To assemble the breaker power unit proceed as follows (Fig. 93):
Install 1/2”key in keyway of high speed shaft of the gear reducer.
Install 2 3/8”taper lock bushing and companion flange onto high speed shaft of the gear reducer. See Fig. 92 for correct orientation and location on shaft. Torque bolts to 104 ft-lbs.
Install torque limiter onto companion flange using twelve 7/16”UNF bolts and lockwashers. Torque to 67 ft-lbs.
Install 7/8”key into motor shaft.
Install flexible coupling and taperlock bushing onto motor shaft.
Install three taperlock bushing bolts (refer to Fig. 92 for proper location on electric motor shaft). Torque to 104 ft-lbs.
Install connecting tube onto gear reducer using twelve bolts and lockwashers. Torque to 379 ft-lbs.
Install electric motor, flexible coupling, and taperlock bushing subassembly onto connecting tube using eight bolts. Torque to 379 ftlbs.
Bolt the flexible coupling onto the torque liimiter using eight M12 bolts and lockwashers. Torque to 379 ft-lbs.
Refer to Fig. 93 for correct clearance between flex coupling jaws and coupling element.
If clearance is incorrect, loosen the taper lock bushing bolts and reposition the taperlock bushing accordingly. Retorque the bolts to 90 ft-lbs.
Install the connecting tube access cover.
Apply Never Seez to breaker shaft end and install key into keyway.
Install breaker shaft into hollow gear reducer low speed shaft.
Install end cap, lockwashers, bolts, and safety wire.
Install shaft guard onto gear reducer.
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Fig. 93: Breaker shaft and power unit disassembly and assembly
Breaker shaft
End cap retainer bolts and safety wire (located behind weldment)
End cap (located behind weldment)
Shaft guard weldment
Fig. 93: Breaker shaft and breaker power unit disassembly and assembly (continued)
Companion flange Taper lock busing Torque limiter Connecting tube access cover Flexible coupling Taper lock bushing
Gear reducer Electric motor
Socket head bolt (12) 7/16-20 X 1 1/4”NF Hex bolt (12) 3/4”X 2”
Socket head bolt (3) 1/2” -13 X 1 1/2” Socket head bolt (8) M12 X 1.75 X 35 Hex bolt (8) 3/4”X 2”
Socket head bolt (3) 1/2” -13 X 1 1/2”
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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)
■ connecting tube
■ coupling
■ hydrostatic pump
■ piggyback gear pump
Fig. 94: Conveyor power unit main components
Electric motor
Gear pump Connecting tube
Coupling
Case drain
Hydrostatic pump Hex bolt (8) 5/8 X 1 3/4 NC Motor mounts
Hex bolt (4) 1/2 X 1 1/2 Grade 2 Hex bolt (4) 3/4 X 2 NC
