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Breaker assembly....................................................5
Fig. 81: Conveyor drive motor removal and installation
Connecting link Pin and cotter key (2 places)
Torque arm Head shaft
cover bolts (torque to 59 ft-lb)
Mounting bolt (torque to 280 ft-lb) Coupling
Mounting bolts (torque to 400 ft-lb) © DBT AMERICA 2007
Breaker assembly
The breaker assembly (Fig. 82) is assembled as a complete unit and should be removed as a unit for repairs except for the replacement of the shear hub assembly, bits and magnetic cutoff assembly. As soon as any component of the breaker assembly is worn or damaged, the component or complete assembly must be replaced.
The breaker assembly consists of the following main components:
■ breaker shaft ■ shear hub assembly ■ bearing housing (2) ■ bearing (2) ■ bits (20) ■ bearing retainer (2) ■ magnetic cutoff assembly ■ lockwasher (3) ■ breaker side plate (2) ■ retaining cap ■ dust cover ■ shims
Fig. 82: Breaker assembly main components
Shear hub Bearing (2) Pick (20) Not shown Breaker
Bearing retainer (2)
Magnetic cut-off assembly
Breaker side plate (2) Bearing housing (2)
How to remove the breaker assembly
To remove the breaker assembly from the machine proceed as follows (Fig. 83):
Remove covers and guards as required to gain access to the breaker assembly.
Release tension on the breaker drive chain and remove chain. (See Breaker drive chain removal in this chapter).
Disconnect, tag and cap the bearing central lubrication hoses.
Attach an appropriate lifting device around the breaker shaft assembly and apply just enough lift to remove the tweenty four (24) bolts, nuts, and lock washers (12 per side) that secure the breaker assembly to the frame.
NOTE: During disassembly, note the location of shim locations and thicknesses for installation purposes.
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.
With the aid of the lifting device, slowly lift the complete assembly out of the frame.
How to install the breaker assembly
To install the breaker assembly into the machine proceed as follows (Fig. 83):
With the aid of the lifting device, slowly lift the breaker assembly into the frame and align mounting holes.
Install shims between breaker side plates and feeder:
Measure outside to outside width of feeder frame at the four locations indicated in side view (Fig. 83).
Look at the two brass tags on the side plates of the breaker shaft. This is the amount of shims required fot that side if the frame measures exactly 50 inches (1270 mm).
Compare the measured distance to the nominal distance of 50 inches (1270 mm). If the actual frame differs from 50 inches (1270 mm) then shims must either be added or subtracted from what is called for on the brass tags.
© DBT AMERICA 2007
Example if actual frame width is wider than 50 inches (1270 mm):
Actual frame width = 50.25 inches (1276.4 mm)
Nominal frame width = 50 inches (1270 mm)
Actual frame width—nominal frame width = Shim thickness subtracted from what is called for on brass tags
50.25 inches (1270 mm) - 50 inches (1270 mm) = .25 inch (6.4 mm)
Remove 1/8 inch (6.4mm) shim from the shims called out on brass tags. (One on each side)
Example if actual frame width is narrower than 50 inches (1270 mm):
Actual frame width = 49.75 inches (1263.7 mm)
Nominal frame width = 50 inches (1270 mm)
Nominal frame width—actual frame width = Shim thickness added to what is called for on brass tags
50 inches (1276.4 mm) - 49.25 inches (1251 mm) = .25 inch (6.4 mm)
Add 1/8 inch (6.4mm) shim to the shims called out on brass tags. (One on each side)
It is important to remember to check the frame width at all four locations shown in the side view. If the frame width varies and the shaft is shimmed to just one measurement, the bearings could be put into a bind and burn up when the machine is operated. It may be required to put different shim amounts in at the four locations to keep the sides of the shaft assembly square in the feeder frame.
Check the gap between the bearing backing ring and the bearing housing on each side. It must measure between.050 - .110 inch (1.27 mm - 2.8 mm) to properly preload the caterpillar seals. The gaps do not have to measure the same as long as they are within the given range.
Secure the breaker with the tweenty four (24) bolts, nuts, and lock washers (8 per side) and securely tighten.
Install breaker drive chain and adjust tension. (See Breaker drive chain adjustment in this chapter).
Connect the bearing central lubrication hoses.
PlaceInstall covers and guards.
Fig. 83: Breaker assembly removal and installation
© DBT AMERICA 2007
1. breaker shaft assembly 2. lock washer 3. flat washer 4. Bolt 5. bolt 6. nut 7. shroud
How to disassemble the breaker assembly (drive side)
To disassemble the breaker assembly (drive side) proceed as follows (Fig. 84 and 85):
Remove the breaker assembly from the machine. (See How to remove the breaker assembly in this chapter).
Remove the three (3) bolts and lockwashers (items 23 and 24) from shaft and remove end cap (item 22).
Remove the shear hub assembly (item 20) from shaft.
Remove the three (3) bolts and lockwashers (items 18 and 19) from shaft and remove side plate (item 17).
Remove the eight (8) bolts and lockwashers (items 15 and 16) from seal housing (item 9) and grease fitting guard (item 14).
Remove grease fitting guard (item 14) seal housing (item 9), seal (item 10), snap ring (item (11), back-up ring (Item 12) and o-ring (item 13) as an assembly from shaft.
Remove back-up ring (item 12) and o-ring (item 13) from seal housing (item 9).
Remove snap ring (item 11) and seal (item 9) from seal housing (item 8).
Remove sealing ring (item 4) from shaft.
Remove bearing housing (item 6) from shaft.
Remove bearing (item 3) and seal half (item 5) from shaft.
Remove remaining seal half (item 5) and bearing backing ring (item 2) from shaft.
Visually inspect all components for wear or damage and replace as necessary.
How to disassemble the breaker assembly (magnetic pulse cutoff side)
To disassemble the breaker assembly (magnetic pulse cutoff side) proceed as follows (Fig. 84 and 85):
Remove the breaker assembly from the machine. (See How to remove the breaker assembly in this chapter).
Remove the magnetic pulse cutoff assembly (item 26).
Remove the three (3) bolts and lockwashers (items 23 and 24) from shaft and remove end cap (item 21).
Remove the three (3) bolts and lockwashers (items 18 and 19) from shaft and remove side plate (item 17).
Remove the eight (8) bolts and lockwashers (items 15 and 16) from seal housing (item 9) and grease fitting guard (item 14).
Remove grease fitting guard (item 14) seal housing (item 9), seal (item 10), snap ring (item (11), back-up ring (Item 12) and o-ring (item 13) as an assembly from shaft.
Remove back-up ring (item 12) and o-ring (item 13) from seal housing (item 9).
Remove snap ring (item 11) and seal (item 9) from seal housing (item 8).
Remove sealing ring (item 4) from shaft.
Remove bearing housing (item 6) from shaft.
Remove bearing (item 3) and seal half (item 5) from shaft.
Remove remaining seal half (item 5) and bearing backing ring (item 2) from shaft.
Visually inspect all components for wear or damage and replace as necessary.
© DBT AMERICA 2007
How to assemble the breaker assembly (drive side)
To assemble the breaker assembly proceed as follows (Fig. 84 and 85):
Thoroughly clean all components with dry and lint free cloth prior to assembly.
Apply Loctite gasket eleminator 518 to the 1 1/2” radius of the shaft before installing bearing backing ring (item 2).
Install bearing backing ring (item 2).
Install bearing (item 3) and sealing ring (item 4) with bearing tool (P/
N 323334). Seat bearing with 60 tons of force. Do not heat bearing to install.
IMPORTANT! Apply a light coat grease to bearing housing bore to aid in installation.
After installing bearing, apply Isopropyl 12: alcohol to each housing bore.
Wipe each metallic face of seal (item 5) with lint free cloth. Do not use grease or oil on rubber. Apply SAE 30 oil to metallic faces only and install metallic face seal (item 5).
IMPORTANT! Bores of bearing backing ring (item 2 and bearing housing (item 6) must be oil and grease free. Seal (item 5) must be installed before bearing (item 3)
Slide bearing housing (item 6) over bearing (item 3).
IMPORTANT! Apply a light coat of grease to seal (item 10), back-up ring (item 12), o-ring (item 13) and shear hub (item 20) to aid installation.
Intalll seal (Item 10) into seal housing (item 9) as shown (Fig. 85,
Detail “B”) with the single lip toward the bearing and dual lips toward atmosphere. Use forming tool (P/N 333685) to aid installation.
Install snap ring (item 11) into seal housing (item 9).
Install back-up ring (item 12) and o-ring (item 13) into seal housing (item 9).
IMPORTANT! Ensure that 1/4” pipe plug (item 8) installed in face of bearing housing (item 6) is flush or below face of housing.
Install assembled seal housing (item 8) and secure with the eight bolts (item 14) and lockwashers (item 13).
Install side plate (item 17) and secure with three (3) bolts (ttem 19) and lockwashers (item 18).
Install shear hub (item 20).
Install retainer cap (item 22) and secure with three (3) bolts (item 24) and lockwashers (item 23). Torque bolts (item 24) to 360 –390 ft-lb and install retaining wire (item 25).
Fig. 84: Breaker shaft assembly and disassembly
1. breaker shaft 2. bearing backing ring 3. breaker bearing 4. sealing ring 5. breaker seal 6. bearing housing 7. adapter 8. pipe plug 9. seal housing 10. breaker seal 11. internal snap ring 12. back-up ring 13. breaker o-ring 14. grease fitting guard 15. lock washer 16. bolt 17. breaker side plate 18. lock washer 19. bolt 20. breaker shear hub 21. end cap 22. retainer cap 23. lock washer 24. bolt 25. tie wire 26. magnetic pulse cutoff assembly 27. breaker bit 28. retainer ring 29. pipe plug 30. shim .25” 31. shim .13” 32. shim .06” 33. shim .03 © DBT AMERICA 2007
How to assemble the breaker assembly (magnetic pulse cutoff side)
To assemble the breaker assembly proceed as follows (Fig. 84 and 85):
Thoroughly clean all components with dry and lint free cloth prior to assembly.
Apply Loctite gasket eleminator 518 to the 1 1/2” radius of the shaft before installing bearing backing ring (item 2).
Install bearing backing ring (item 2).
Install bearing (item 3) and sealing ring (item 4) with bearing tool (P/
N 323334). Seat bearing with 60 tons of force. Do not heat bearing to install.
IMPORTANT! Apply a light coat grease to bearing housing bore to aid in installation.
After installing bearing, apply Isopropyl 12: alcohol to each housing bore.
Wipe each metallic face of seal (item 5) with lint free cloth. Do not use grease or oil on rubber. Apply SAE 30 oil to metallic faces only and install metallic face seal (item 5).
IMPORTANT! Bores of bearing backing ring (item 2 and bearing housing (item 6) must be oil and grease free. Seal (item 5) must be installed before bearing (item 3)
Slide bearing housing (item 6) over bearing (item 3).
IMPORTANT! Apply a light coat of grease to seal (item 10), back-up ring (item 12), o-ring (item 13) and shear hub (item 20) to aid installation.
Intalll seal (Item 10) into seal housing (item 9) as shown (Fig. 85,
Detail “B”) with the single lip toward the bearing and dual lips toward atmosphere. Use forming tool (P/N 333685) to aid installation.
Install snap ring (item 11) into seal housing (item 9).
Install back-up ring (item 12) and o-ring (item 13) into seal housing (item 9).
IMPORTANT! Ensure that 1/4” pipe plug (item 8) installed in face of bearing housing (item 6) is flush or below face of housing.
Install assembled seal housing (item 8) and secure with the eight bolts (item 14) and lockwashers (item 13). ______________________________________________________________
Fig. 85: Breaker shaft assembly Install retainer cap (item 22) and secure with three (3) bolts (item 24) and lockwashers (item 23). Torque bolts (item 24) to 360 –390 ft-lb and install retaining wire (item 25).
Install side plate (item 17) and secure with three (3) bolts (ttem 19) and lockwashers (item 18).
Install magnetic pulse cutoff (item 26).
© DBT AMERICA 2007
How to remove the breaker bit
To remove the breaker bit from the breaker shaft bit holder proceed as follows (Fig. 86):
Remove the external retaining ring from the shank end of the bit with a pair of external retaining ring pliers.
Remove the bit from its holder. If the bit will not pull easily from its holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.
IMPORTANT! If the bit will not pull easily from its holder, it may be necessary to insert a bar behind the shank end of the bit and pry it out.
How to install the breaker bit
To install the breaker bit in the breaker shaft bit holder proceed as follows (Fig. 86):
Clean any dirt or debris from inside or around the holder and insert the shank end of the bit into the bit holder.
Install the external retaining ring on the shank end of the bit with a pair of external retaining ring pliers. Ensure that the retaining ring is completely seated inside grooved area of the bit.
Fig. 86: Breaker bit removal and installation
Retaining ring
Bit holder
Breaker bit
