Cumberland PowerTrak Load Block/Drive Screw Replacement Owner's manual

Date: 12-29-22 V3.0 4802-5093

Instructions

1004 East Illinois Street • Assumption, IL 62510 • 1-217-226-4421

4802-5093

Page 1 of 10

Printed in the USA

www.cumberlandpoultry.com CN-409077

PowerTrak™ Load

Block/Drive Screw Replacement

Tools Required

• 3/8" Ratchet and Extensions

• Small Screwdriver

• 7/16" Socket

• 9/16" Socket

• Grease Gun

• 7/16" Wrench

• SAE Allen Wrenches

• Metric Allen Wrenches

Optional Kits

Old Load Block Removal

Follow the below instructions on Page 2 to disassemble the PowerTrak™ unit, replace a worn load block

and/or drive screw assembly and then re-assemble the PowerTrak™. The 6450-5049 and 6450-5119 kits

include a new load block assembly and four cotter pins. The 6450-5120 includes a new load block

assembly, four cotter pins and a new drive screw. It is very important to replace the complete load block

assembly and not only the portions of the assembly.

When the shipment is received, check for shipping damage or missing parts. If any, call your Cumberland

distributor immediately.

Part # Description Note

6450-5049-HH Kit, PT Load Block Replacement Load block replacement for 60 RPM models ONLY.

6450-5120 Kit, PT Load Block/Drive Screw

Replacement For load block and drive screw replacement.

6450-5039-HH Kit, PT Load Nut (Brass) Replacement Load block replacement for 60 RPM models ONLY.

6450-5038-HH Kit, PT Load Nut (Nylon) Replacement Load block replacement for 15 RPM and 30 RPM models ONLY.

6450-5119 Kit, PT Load Block Replacement with

Nylon Nut Load block replacement for 15 RPM and 30 RPM models ONLY.

WARNING

These procedures require the usage of electrical power during part of the

installation. Use caution when working inside unit with the power ON.

Page 2 of 10 4802-5093

PowerTrak™ Load Block/Drive Screw Replacement

Installation

1. Disconnect all the electrical power from the PowerTrak™.

2. Open and remove the front access door.

Figure 1 PowerTrak™ Assembly

WARNING

Do not loosen the curtain cables from the load block while tension remains on

the cables. The sudden release of the cables under tension could cause personal

injury and/or property damage.

NOTE: Specific models will not include all parts shown.

1

2

3

4

5

6

7

8

9

10

2

11

12

13

14

15

16

17

12

4

21

22

23

25

24

20

18

19

Ref # Description

1Pulley Assembly

2Cable

3Upper Radial Bearing (2 Set Screws)

4 Grease Fittings

5Load Block

6 Hall Effect Device

7Thrust Bearing

8 Spider Coupling

9Lovejoy Motor Coupling

10 Motor Quick Disconnect

11 Auxiliary Connection for Pulleys or Cable

12 Cotter Pin (or) Roll Pin

13 High-Limit Adjustment Collar

14 Load Nut

15 Cable Locking Screw

16 Drive Screw

17 Low-Limit Adjustment Collar

18 Delrin Bushing

19 Set Screw

20 Motor Screws

21 Tensioning Springs

22 Guide Rod

23 Spring Cam Limit Switch Actuator

24 Terminal Block

25 Bottom Plate

4802-5093 Page 3 of 10

PowerTrak™ Load Block/Drive Screw Replacement

3. Release the tension from the PowerTrak™ load block cables. Remove the cable locking screws (15)

and disconnect the cables (2) from the load block (5). Refer to Figure 1 on Page 2.

4. Remove the cables (2) completely from the PowerTrak™ unit.

5. To aid in re-alignment of the limit switches, use a permanent marker to mark the position of the

following items.

a. High-limit adjustment collars (13) and low-limit adjustment collars (17) on the guide rod (22).

Refer to Figure 1 on Page 2.

b. The guide rod (22) entering the cam block (26) in the limit switch housing. Refer to Figure 2.

c. The position of the limit switch set screw (19) and cam block (26) relative to the limit switch

housing. Refer to Figure 2.

Figure 2 Limit Switch Assembly

6. Loosen the high-limit adjustment collars (13) and lower-limit adjustment collars (17) using an allen

wrench. Refer to Figure 1 on Page 2.

7. Remove the three cotter pins or roll pins (12) in the guide rod (22) above the tensioning springs (21).

Refer to Figure 1 on Page 2.

8. Loosen the set screw (19) on the limit switch assembly with an allen wrench. Refer to Figure 2.

9. Drop the guide rod (22) to the bottom of the enclosure.

NOTE:

If the load block (5) is already within 4" from the top of the drive screw (16), skip

Steps 10-12

and continue to

Step 13 on Page 4.

Ref # Description

19 Set Screw

26 Cam Block

Make sure that extra care is taken to prevent bending the guide rod during this

process. If the guide rod is bent, excessive rod wear and/or functional problems

may occur.

Page 4 of 10 4802-5093

PowerTrak™ Load Block/Drive Screw Replacement

10. Connect the electrical power to the PowerTrak™.

11. Turn the motor ON and run the load block (5) to within 4" from the top of the drive screw (16). If the

load block (5) is completely stripped, disconnect all the electrical power and run the load block (5)

upward by hand.

12. Disconnect all the electrical power from the PowerTrak™.

13. Unplug the motor quick disconnect (10).

14. While supporting the motor (28), remove the three/four motor screws/nuts (27) and set the motor

(28) aside. Refer to Figure 3.

Figure 3 Motor Screws

15. Loosen the delrin bushing set screw (19) using an allen wrench. Rotate the delrin bushing (18)

(if equipped) upward approximately 12". Refer to Figure 4.

Figure 4 Delrin Bushing

WARNING

Only a qualified electrician should perform the necessary electrical connections.

Keep hands and clothing away from the rotating and moving parts.

Failure to follow these instructions may result in property damage, serious injury

or death.

27

28

Ref # Description

27 Remove 3-4 Motor Screws/Nuts

28 Motor

19

18

Ref # Description

18 Delrin Bushing

19 Set Screw

4802-5093 Page 5 of 10

PowerTrak™ Load Block/Drive Screw Replacement

16. While supporting the load block (5) and drive screw (16), loosen the two set screws (19) from the

upper radial bearing (3) and carefully lower the drive screw (16) to rest on the delrin bushing (18).

Refer to Figure 5 and Figure 6.

Figure 5 Upper Radial Bearing Set Screws

17. Turn the drive screw (16) by hand and run the load block (5) off the top of the drive screw (16).

Refer to Figure 6.

Figure 6 Separate the Drive Screw from Load Block

18. Remove the four screws and nuts from the bottom plate (25) and lay bottom plate (25) to the side.

Refer to Figure 7.

NOTE: While the bottom plate (25) is loose, make sure that extra care is taken to prevent

disconnecting the wires from the limit switch assembly to the terminal block (24).

Figure 7 Removing the Bottom Plate

19

Ref # Description

19 Set Screws

18

29

16

Ref # Description

16 Drive Screw

18 Delrin Bushing

29 Load Block Assembly

25

Ref # Description

25 Bottom Plate

Page 6 of 10 4802-5093

PowerTrak™ Load Block/Drive Screw Replacement

NOTE: If the drive screw (16) is not being replaced, skip Steps 19-20 and continue to Step 21.

19. Remove the delrin bushing (18) (if equipped) from the drive screw (16).

20. Remove the drive screw (16) from the PowerTrak™. Refer to Figure 8.

Figure 8 Separate the Drive Screw from Load Block

21. Slide the load block (5) over the top of the drive screw (16) and the guide rod (22).

22. Twist the load block (30) counter-clockwise out of the side tracks. Refer to Figure 9.

NOTE: Do not pry or use tools to remove the load block assembly (29) from the side tracks. The

side tracks can be damaged if tools are used.

23. Inspect the side tracks for denting or burrs which may interfere with smooth load block operation.

Figure 9 Removing the Old Load Block

IMPORTANT: Do not reuse the old aluminium load block. Replacement of the complete load block

assembly is required.

16

Ref # Description

16 Drive Screw

Make sure extra care is taken to prevent bending the guide rod during this

process. If the guide rod is bent, excessive rod wear and/or functional problems

may occur.

WARNING

The PowerTrak™ enclosure contains sharp metal edges. Wear gloves during

this next step and make sure extra care is taken to prevent personnel injury or

equipment damage.

30

Ref # Description

30 Twist Load Block

4802-5093 Page 7 of 10

PowerTrak™ Load Block/Drive Screw Replacement

New Load Block and/or Drive Screw Installation

NOTE: If the drive screw (16) was not replaced, skip Steps 1-2 and continue to Step 3.

1. Insert the drive screw (16) through the PowerTrak™ thrust bearing (7). Refer to Figure 1 on Page 2

and Figure 10.

2. Attach the delrin bushing (18) (if equipped) to the drive screw (16). Turn the drive screw (16) by hand

and run the delrin bushing (18) down the drive screw (16) approximately 8".

Figure 10 Installing the Drive Screw to New Load Block

NOTE: Make sure that the new load block assembly (29) is placed in the correct orientation. The

grease fitting (4) and cable locking set screws (19) must point outward. The nut with the

grease fitting (4) should be on the top side facing the pulley assembly (1). For models with a

nylon load nut, the snap ring (31) should face downward as shown in Figure 12.

3. Rotate the new load block (5) into the side tracks above the drive screw (16) and the guide rod (22)

with the correct orientation as mentioned in previous step.

4. Slide the load block (5) over the top of the drive screw (16) and the guide rod (22). Turn the drive

screw (16) by hand and run the load block (5) down the drive screw (16) approximately 4". Refer

to Figure 11 or Figure 12. Figure 11 shows the load block assembly (29) for the 60 RPM models.

Figure 12 shows the load block assembly (29) for the 15 RPM and 30 RPM models.

Figure 11 Installing the New Load Block

(60 RPM Models ONLY) Figure 12 Installing the New Load Block

(15 RPM and 30 RPM Models ONLY)

16

Ref # Description

16 Drive Screw

29

31

29

Ref # Description Ref # Description

29 Load Block Assembly 31 Snap Ring

Page 8 of 10 4802-5093

PowerTrak™ Load Block/Drive Screw Replacement

5. Push the drive screw (16) upward into the upper radial bearing (3) while making sure the bottom of

the drive screw (16) is flush against the thrust bearing (7). Tighten the two set screws (19).

Refer to Figure 13 and Figure 14.

Figure 13 Upper Radial Bearing

6. Rotate the delrin bushing (18) (if equipped) downward by hand until the drive screw (16) is flush

against the thrust bearing (33) on the bottom side and the delrin bushing (18) is flush against the

bearing plate (32) on the top side. Do not overtighten the delrin bushing (18). The delrin bushing

(18) must be able to freely turn with the drive screw (16). Hand-tighten the set screw (19). Refer

to Figure 14.

NOTE: DO NOT OVERTIGHTEN THE SET SCREW.

Figure 14 Delrin Bushing

7. Re-attach the bottom plate (25) with four screws and nuts that are removed previously. Refer to

Figure 15.

Figure 15 Attaching the Bottom Plate

19

Ref # Description

19 Set Screw

33

32

19

Ref # Description

19 Set Screw

32 Delrin Bushing Flush Against

Bearing Plate

33 Drive Screw Flush Against

Thrust Bearing

25

Ref # Description

25 Bottom Plate

4802-5093 Page 9 of 10

PowerTrak™ Load Block/Drive Screw Replacement

8. Install the motor (28) with the three/four motor screws/nuts (27). Make sure the drive screw (16),

spider coupling (8) and lovejoy motor coupling (9) are correctly installed as shown. Refer to

Figure 1 on Page 2 and Figure 16.

Figure 16 Motor Screws

9. Connect the motor quick disconnect (10) connector.

10. Make sure the limit adjustment collars (13 and 17) are near the marked positions, verify the

placement of the tensioning springs (21) and install the three cotter pins (12) in the guide rod (22).

Refer to Figure 1 on Page 2.

11. Align the cam block (26) and guide rod (22) based upon the markings from Step 5 and Figure 2 on

Page 3. Tighten the set screw (19) on the limit switch assembly with an allen wrench.

12. Set the high and lower limit adjustment collar (13 and 17) positions based upon the markings from

Step 5

and

Figure 2 on Page 3

. Tighten the limit adjustment collars (13 and 17) using an allen wrench.

13. Run the ends of cables (2) through the pulley assembly (1) to the load block (5). On the load

block (5), there will be four small holes on the top surface. Run the cables (2) down the small holes

toward the center of the block (5), loop around and come up through the small holes toward the

outside of the block (5). Refer to Figure 17 on Page 10. Tighten the set screws (19) on the face of

the load block (5) with an allen wrench.

14. Reconnect the power to the PowerTrak™.

Ref # Description Ref # Description

8Spider Coupling 27 Remove 3-4 Motor Screws/Nuts

9Lovejoy Motor Coupling 28 Motor

16 Drive Screw

16

27

8

9

28

27

WARNING

Only a qualified electrician should perform the necessary electrical connections.

Keep hands and clothing away from the rotating and moving parts.

Failure to follow these instructions may result in property damage, serious injury

or death.

Page 10 of 10 4802-5093

PowerTrak™ Load Block/Drive Screw Replacement

15. Connect a grease gun to the grease fitting (4) on the load block nut. Use the manual setting on

the controller to move the load nut (14) from one end of the screw to the other while applying the

grease. This ensures that the full range of the load nut (14) is well lubricated.

16. Refer to the PowerTrak™ manual (4801-0154) for additional information on setting the upper and

lower limits.

17. Verify the proper PowerTrak™ operation at the open and closed positions.

18. Install the door to protect the machine from the elements.

Figure 17 Installing the Cables

Ref # Description

1Pulley Assembly

2Cable

5Load Block

2

1

5

2

Cumberland PowerTrak Load Block/Drive Screw Replacement Owner's manual

Cumberland PowerTrak Load Block/Drive Screw Replacement Owner's manual

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