STEP: 1

Locate the breaker to a suitable working location and remove the front cover.

STEP: 2

Remove the 1/2" bolt that attaches the main spring guide shaft to the top cover.

STEP: 3

Remove the top cover hardware.  Bolts are located on the inside and back of the breaker frame, as well as on top.

STEP: 4

Remove the top cover.  Remove the bushing through which the main spring guide was bolted.

STEP: 5

After removing the bushing, install the 1 1/2" X 1/2" bolt provided with the replacement kit.  Tighten the bolt which additionally compresses the main spring.  Compress until the connecting straps on each side of the yoke assembly can be removed.  As the spring is compressed, moving the assembly "side to side" will aid in removal of the connecting straps.

NOTE:   DO NOT REMOVE THE BOLT UNTIL THE SPRING ASSEMBLY IS REINSTALLED IN THE BREAKER WITH THE CONNECTING STRAPS ATTACHED.

STEP: 6

The main spring can then be safely removed from the mechanism.

STEP: 7

Viewing the exposed mechanism from the top, the trip prop assembly is clearly visible.  The original trip prop is gold plated while the replacement trip prop is plated red.  Stop disassembly if a red trip prop is already installed.

STEP: 8

Release the spring that holds the trip prop down against the mechanism.

STEP: 9

Remove the "C" clip on the left side of the trip prop shaft.

STEP: 10

Slide the shaft to the right approximatley1 1/2", while holding the bushing, washers, and trip prop in place.

Note: It is not necessary to completely remove the trip prop shaft from the mechanism.   The shaft and the right hand bushing can be left in place.  Do not allow the right hand bushings or washers to fall into the breaker.

STEP: 11

The trip prop, one bushing, and three washers can now be removed.  Keep the washers and bushing clean for reinstallation.

STEP: 12

The bearing of the new trip  prop is prelubricated.  Use care to keep it clean.  Install the new "red" trip prop, while carefully reinstalling the previously removed bushing and washers.

STEP: 13

Place the main spring assembly on top of the mechanism.  Verify that the base plate of the spring fits properly on the guide.  

Locate the connecting straps on each side of the main spring yoke.  They will fit loose until the spring compression is loosened.  Tape or cord can be used to hold them in place.

STEP: 14

While holding the connecting straps on the main spring yoke, slowly remove the 1/2" bolt used to compress the spring.
CAUTION:  REMOVAL OF THE COMPRESSION BOLT PRIOR TO ATTACHING THE CONNECTING STRAPS WILL RESULT IN THE DANGEROUS EXPANSION OF THE MAIN SPRING.

STEP: 15

The main spring is held by the connecting straps until the top plate is installed.

NOTE:  DO NOT ATTEMPT TO OPERATE THE BREAKER UNTIL THE TOP AND MAIN SPRING GUIDE BOLT IS INSTALLED.

STEP: 16

Place the main spring bushing on top of the yoke assembly prior to installing the top plate.

STEP: 17

Replace the plate using care to realign the interlock shaft through the hole in the plate.

STEP: 18

Attach the breaker top plate.  Use removable Locktite on all hardware during the reassembly.

STEP: 19

Install the original main spring guide bolt and torque to 50 ft. lbs.  Again use Locktite on the bolt threads.

STEP: 20

Place the front cover on the breaker, verifying that the interlock pin protrudes through the front.

STEP: 21

Complete the procedure by installing the front cover hardware.  No adjustment is necessary.  The breaker must be tested however to verify proper operation.  Close and trip the breaker electrically a minimum of 10 times.

The nameplate should be stamped with the provided "T" stamp to identify a modified breaker.  Record the date and serial number for maintenance records.