assembly workmanship standards en

Assembly Workmanship Standards

Nuts, Bolts, Torquing, Tightening, and General Assembly Information

Torquing and Match Marking

Torqueing Rules for Alliance Assembly Section

Match marking will be done with a Yellow Match Mark Pen. (Black for Hydraulic Fittings) The Match mark will extend from the Bolt, Nut, or Hyd Fitting to the Machine, Part, The Bearing Housing, ETC.

Marking Socket Head Cap Screws, Set Screws, Button Head Screws, Flat Heads, ETC.

These will be marked with yellow Marking Pen on the Head of the Bolt or Screw with another mark in

alignment with it on the frame or part showing it has been Torqued or Tightened to its Specification.

2


Blue LOCTITE #243 will be used in all applications, except where otherwise specified.

Screws, Set Screws, and Bolts in sizes /6mm and larger will be installed with LOCTITE applied, and Torqued.

The amount of LOCTITE applied to a bolt or screw will be a line sufficient to cross over two or three threads on the Screw or Bolt.

Not the circumference of the screw or bolt.

No LOCTITE on Nylock Nuts

3


Bearing Set Screws, smaller than /6mm will have Purple LOCTITE applied and be torqued.

You dont have to differentiate between Dimpled and Non Dimpled set screws.

Screws in Electrical Panels do not need to be torqued, have LOCTITE or Match Mark.

4


Jack Bolts Larger than 1/4/6mm, will have Blue LOCTITE applied to the bolt to secure the Jam Nuts, after final adjustment.They will be match marked across both nuts and to the Frame or Mount.

Button Head Screws, Hex Bolts, Socket Head Cap Screws, or Flat Head Screws used to hold Plastic Clamps,

UHMW Wear Strips, Etc. to a steel frame or part, will have Blue LOCTITE applied and tightened with sufficient force to tighten the bolt and not collapse the clamp or distort the UHMW or Plastic Part. A flat washer may be used on a plastic part with no countersink.

5


Steel Bolts that screw into Aluminum to fasten something, such as mounts to Aluminum Air Cylinders, Air Manifolds,

INA Rails, ETC. These will Not have LOCTITE, they will be tightened with sufficient force to make them snug without stripping out the parts.

They will be Match Marked to show they were tightened.

Aluminum parts that are installed on Steel Hydraulic Cylinders, such as Pilot Check Valves, Counter Balance Valves, ETC.

will not have LOCTITE applied, but they will be Torqued and Match Marked with a High Collar lock washer where needed.

6


Button Head Screws, Hex Bolts, Socket Head Cap Screws, Flat Head Screws, Cylinder Rods, ETC. that screw into UHMW,will be tightened without LOCTITE and with sufficient force to make it snug, without distorting the part or stripping out the threads.

Plexiglas Guards/Windows, Plastic Photo Eye Reflectors, these parts will not have LOCTITE installed;the LOCTITE reacts with the Plexiglas and cracks it. These will be fastened with bolts or screws and no LOCTITE and tightened with sufficient force

to faster them without cracking the Plexiglas or Plastic.

7


Take-up/Adjustment bolts will have a light coating of Anti-Seize installed, these are meant to be adjusted, No LOCTITE here.

Limit Switch Adjustment Mount Plates, Take up Pulleys, Inductive Sensor Mounts, Adjustable Idler Pulleys, ETC. Will be marked with a

single Dot showing they are tight.

Hydraulic Motor Torque Arm, Rubber Shock Bolt, the standard procedure will apply. No LOCTITE will be applied to Nylock Nuts,

they will be tightened with sufficient force to ensure a correct compression of the Rubber Shock.

8


All taper Locks on Main Shafts, Stub Shafts, Timing Shafts, Motor Couplers, Taper Lock Sprockets, Taper Lock Pulleys ETC, will have LOCTITE installed

and tightened or Torqued to Specification. They will be re-checked after the machine has ran in test and then Match Marked.

9


Red LOCTITE #263; the following Items will have Red LOCTITE applied, Torqued or Tightened and Match Marked; Hydraulic and Air Cylinder Rod End Cleviss

1 Bolts for LM, and Top Feeders, (Tightened, very Tight)

5/8 Flat Head Bolts for the UHMW, Lift Guide Blocks

10


Bolts that are to be removed for Shipping will be installed and tightened but no LOCTITE applied.

These will be identified with a black or yellow dot on the bolt head, where applicable. Black dots dont show up on black bolts

11


12


13


14


The Set Screw Dimpling Standard is as Follows;

All Bearings, Sprockets, Pulleys, Motors with Set Screws, Etc. will have at least one Set Screw hole dimpled.

All Set Screws will be LOCTITE and Torqued, unless specified in this standard.

Exceptions to this Standard;

Hardened Shafts will not be dimpled, (Hydraulic Motors, Electric Motors, Encoder Shafts, Etc.

15

Bolts and Bolt Length

Bolt Standard

Bolts are to protrude one or two threads thru material when applicable. Do Not cut off bolts the make the Length correct

In a blind hole application the bolt should engage into material at least 1.5x the diameter of the bolt.

Example for bolt: x 1.5 = engagement into threaded material.

16


In threaded plastics use longest bolt possible with out bottoming and distorting the Plastic.

Through Bolts need to be of sufficient length to hold the material and still have two to three threads sticking out from

the nut or fastener.

17


Shoulder Bolts need to be of sufficient length to hold the Material and Bottom out against the Shoulder and not have

any gap to cause looseness. Flathead bolts have to be of the correct length to pass through the material to be bolted

and fully engage threads in the material, steel, ETC. Button Head Bolts must be of sufficient length to pass through the

material and fully engage the threads in the material, steel, ETC.

18


Bolt Types and where to use them.

Flat Head Bolts will be used where a mount has a Counter Sink hole for them.

Use appropriate length Flat Head Bolts with Nylon Locking Inserts, Locktite and 4 Internal Star Lock Washers for all Counter Sunk Torque arms and Mounts for Hydraulic Motors. Follow the standard in this Tab for correct bolt length.

The standard Torqueing procedures will apply.

19


Hex Head Bolts are the most commonly used bolts for our machinery. These will be used in all cases where specific

bolts are not called out. They can be Metric or American Standard, depending on the Machine.

Button Head Bolts are commonly used in a place where a machine operator will come in contact with them. This will

reduce the possibility of anyone getting caught on the bolt head. The standard Torqueing procedures

apply in all case.

Shoulder Bolts are used where specified by Engineering.

Socket Head Cap Screws are used where specified by Engineering or where a bolt head is recessed in a housing such

as Hydraulic Valve mounted to a Manifold or Air Valve mounted to a manifold. They are also commonly used

in places where it's difficult to get a wrench. The standard bolt lengths and Torqueing procedures will apply. Socket Head Cap Screws get installed with High Collar Lock Washers, unless there's a clearance issue making the

bolt too tall to clear something.

Pan Head Screws are commonly used to mount small components in Electrical Panels and in Junction Boxes. They

are also used to mount all small items such as Plastic Reflectors, Photo Eyes to the Mounts, Etc. The standard bolt

length and Torqueing procedures will apply.

20

Washers, Nuts, and Fasteners

Washers, Nuts, Nut-plates and Cotter Pins

All fasteners will have a locking devise or Lock Washer on the them. It can be a Nylock Nut, Jam Nut,

a Split Lock Washer, High Collar Lock Washer, or Internal Ring type Lock Washer. These will always be used in conjunction with LOCTITE unless specified in our Torqueing Standards.

Always torque all fasteners to Specification, it doesn't matter what type of Bolt, it has a Torque Specification.

Here is an example of a through bolt that has a Split Lock

Washer under the Nut. There is no washer under the Bolt

Head. This must have LOCTITE applied the the Bolt.

Below is an example of a through bolt with a Flat Washer

under the Bolt Head and a Fender Washer under the Nylock Nut.

There is no LOCTITE applied to a Bolt with a Nylock Nut.

21


Flat Thick Washers will be used in conjunction with a Split Lock Washer when the Bolt is going through a

Slotted Mount or Component with Slotted Mounts of some type or on a Bearing with a Square Mount Hole.

Use a Flat Washer when bolting a piece of UHMW (Plastic) to a mount. Use a thick Flat Washer when the Torqueing of the Bolt will bend the washer. It will work its way loose if you don't.

Here's an example of a Flat Washer

covering a Slot Mount, it's a through

Bolt. The Nut has a Split Lock Washer

under it, this requires LOCTITETorqueing.

Here's another example of a

Flat Washer over a Slot with a

though bolt. The nut on the

opposite side has a Split Lock

Washer under the Nut and

LOCTITE applied.

Here is a through bolt with no

washer under the Bolt head but

it has a Flat Washer, Split Lock

Washer under the Nut with

LOCTITE.

22


Bolts that mount through slots must have a Locking Washer on one end or the other. It will be under the Bolt Head if its not

a through bolt. Here's several examples of bolts with Flat and Lock Washers on slotted mounts. These are not

through bolts, they mount into something, in this case they bolt to the frame.


Here's a few more examples of

Bolts with Flat and Lock Washers

Mounted through Slots

23


Jam Nuts are used in conjunction with Lock Washer in many places, its determined by the thickness of the material

and the length of the bolt or stud it goes on. Always use a Large Nut when possible. Flat Washers go under the

Bolt Head of Take-up and Adjustment Bolts. No washers under the Jam Nuts.


Here's a Jam Nut with a Lock Washer

We install Cam Followers with Flat Washers

Split Lock Washers, LOCTITE, and Nuts.

Torque to Specification. Use Full Nuts when possible.

Here's an example of a Belt Tracking Bolt

with a nut as a Jam Nut, no Lock

Washer is required, because the

Shaft the bolt goes through is

threaded. No LOCTITE is used, this

is made to be adjusted.A Flat washer is required under all

adjustment bolt heads.

This requires a Flat Washer and Lock

Washer, this is adjustable. It has a Jam All take-up bolts will have a light coating

Nut, there isn't room on the Stud for a of Anti-seize applied, not belt tracking

full nut. bolts.

24


High Collar Lock Washers are used under a Socket Head Cap Screws (SHCS) Bolts,and they are usually in a

Recessed mount on a component. Here are a few examples of SHCS Bolts with High Collar Lock Washers.


We also use Internal Lock Washers on most

small screws and on Hydraulic Bulkhead Fittings.

The Lock Washers on the Hydraulic Fittings go

under the Fitting.

25


Nut Plates are used in place of Nuts in certain places on the machines. Most Main Shaft Bearings have Nut Plates

on the back side to bolt to. They require nothing special as far as installation.


Nut Plates on the Main Shaft

Bearing installation and on the

Idler Shaft Bearing Installation

Notice the bolt length, its

1-3 threads past the nut plate.

The Lock Washers are under the head of

bolt, they are locktited, torqued and

Match Marked,4 places.

26


Cotter Pins fall under fasteners, they fasten the chain together. Here are examples of cotter pins and chain installation.

Cotter Pins will be installed with the long leg of the cotter pin folded over. The direction that the Cotter Pin legs face is not

a factor. Orient the Master Link so the cotter pin is accessible for the Maintenance Mechanics.

Position the Master Link so you or any maintenance

mechanic can get to the link.

27


Exceptions to this Standard

Feedmax Extendo Side Tampers.

Engineering requested we use Flat Washers along with the

Split Lock Washers on the Extendo Tamper Arm Mount. The

Problem is the Split Lock Washers dig into the Powder Coat

Paint and it flakes off.

When installing the Tamper Arm Mounts and Pulley Guards,

use 1/4" Hex Head Bolts, Split Lock Washer, Flat Washer, and

Blue Locktite. Torque to Specification.

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Clamping and Fastening

Clamping of Conduit, Hoses, and Air Lines

Conduit clamps are of several different types, some are for Seal Tite Flex Conduit, some are for Plastic Conduit,

and some just clamp Cables to the frame. Here are several examples of the clamping process and how to do it.

All Electrical Cables and wiring will be supported approximately

every 18 inches by clamps. The clamps are mounted

with a 1/4" Hex Bolt and a Flat washer only and will be tightened

with LOCTITE applied. Do not over-tighten the bolts, it will

distort the clamp and damage the cable.

Rubber Grommets will be used where unwrapped (No Conduit)

Wiring, Hose, or Air Lines enter the Frame.

The plastic clamps can be stacked on top of each

other as needed. This example shows a single clamp

going to a double stacked clamp. This will be the case

in many places where there are numerous single wires

going to a cross tube or into Plastic Track. These are

still mounted with a 1/4" Hex Bolt with Flat Washer.

29


Seal Tite flex conduit is the most common type of flex conduit and is used on all the machines we manufacture. Here are

Several examples of how the conduit is mounted. We use Rigid Conduit Clamps to clamp the Seal Tite conduit

The clamps on the Seal-Tite conduit are all mounted with 1/4" or 6MM Hex Bolts and a Split Lock washer. You can add

a Flat washer if you need to for clearance on something. This bolt will be LOCTITED and Torqued the Specification.

Make sure the clamp is the correct size for the conduit, if its too loose the conduit will slip in the clamp and not stay in

the position you need.

30


Black Plastic Conduit is being used as well as Seal Tite, the Black Plastic has the same crush rating, but, its mounted to

the machines differently. The clamps we use are made for the conduit, and are mounted with a single 1/4" X 1 SHCS

or a 6MM X 16 SHCS. Do not use washers with these, but they will have Locktite applied and tightened.

6MM X 16 SHCS

Conduit installed in clamp

31


Hydraulic Tubing is fastened to the machine using a Black Plastic Tubing Clamp and a 1/4" Hex Head Bolt with a single

flat washer. It will have LOCTITE applied, but will not be torqued. It will be tightened sufficiently to not move but not so tight

that it will distort the clamp or damage the tubing.

32

Fittings and Pipe Dope

Thread Sealant, Pipe Dope and Teflon Tape, are all acceptable ways to seal Tapered Pipe Fittings, (Air and Hydraulic)

Many air fittings come from the Vender with sealant already applied, don't remove it the replace it with something else.

When applying Pipe Dope, keep it at least one thread from the end of the fitting to prevent contaminating the system

you are installing the fitting in. One band of sealant (Pipe Dope) around the fitting is sufficient.

Here are several examples of Fittings installed with Sealant.

The Black Colored Fittings come with sealant already applied.

The Brass and Steel Fittings need to have Sealant applied.

Always put sealant on Pipe Fittings you are installing in Aluminum

Manifolds, even if its a Vent or Muffler; you will not be able to

remove the fitting if you don't put sealant on it. It will prevent the Fitting from seizing in the manifold.

33

Fittings and Pipe Dope

Here is an example of Thread Sealer applied to Tapered Pipe Fittings we use in everyday applications. Notice the Sealant

is not at the end of the Fitting. It doesn't matter if the Fitting is Steel, Brass or Aluminum, it gets sealant if it doesn't have it.

These are not Tapered Pipe Fitting, do not put

Sealant on these.

These are "O" Ring Hydraulic

and Air Fittings, they require

lubrication, Air Oil or Lite Grease

is best. It will prevent the seal

from being damaged during

installation.

Apply a lite coating of Grease or Oil to the "O" ring before installing in any valve or manifold.

Air Fittings

34

Jam Nuts and Jack Bolts

Jam Nuts are used everywhere and there are different ways to Jam a Bolt. This standard will detail how to place them.

The Jam Nut is installed on the inside of the Threaded

Roller Shaft between the Shaft and the Tab

A flat washer needs to be under the Head of the Bolt as shown.

The Jack Bolt and The Tie Bolt are correct examples of

the way to Jam these. Flat Washers under the nuts,and in limited spaces, thinner Jam Nuts are used on the

Jack Bolts. This allows for greater adjustment length.

Always use Full Nuts when there is room for them.

35


Threaded Shaft, Adjustment Jam Nuts. Chain Adjuster Bolt Full Nuts

Flat Washers

Locktite Bolt 2 Full Nuts and a Jam Nut Mount Bolts 4 Ea.

Install LOCTITE on the Bolt and install it in the Shaft, Use Full Nuts to Jam the Adjustment Bolt in

Use 2 Full Nuts and 2 Flat Washers on the Bolt. After tracking this application. The Bolt is used for Adjustment,

the belt, install a thin Jam Nut on the end and Jam it tight, the 4 Slide Mount bolts are locking the chain

tension.

36


Threaded Tie Bolt, this is on the Ultra Stacker

Full sized nuts and Flat Washers

This is the correct way to Lock the Full Threaded Tie Bolt in place, it has

full nuts locking it in place and flat washers under the nuts.

37


Flat Head Adjustment Bolt, for belt tracking. Belt Tracking Bolt, Flat Washer, Mount, and Jam Nut

This is the correct way to position the Jam Nut, This Bolt is short for a reason, there isn't clearance

There isn't enough room to put a full sized nut for the Threaded Roller Shaft for farther adjustment.

on the adjustment bolt and still be able to adjust it. It has the Jam Nut on the Back Side. This has not been

adjusted as of yet, there is no tension on it.

38


Belt Tracking, Threaded Roller Shaft and Adjustment Bolt. Take-up Belt Drive Adjustment

This is the most common Roller Adjustment Make sure the Take-up Bolt is long enough

Bolt and Jam Nut configuration, a flat washer to adjust for the Belt. Install the Jam Nut on

under the bolt head and a Jam Nut on the back bolt head side and a flat washer under the

side of the roller shaft. If you put the Jam Nut bolt head. Once the Belt is adjusted, lock

on the other side of the roller shaft, you the Jam Nut.

cant adjust the Roller.

39


Exceptions to this Standard;

There are no Exceptions at this time.

40

Conduit and Hose Bend Radius

Flex Conduit Bend Radius (Seal Tite), the Bend Radius will change with the diameter size of the Conduit. We use this

on most of our machines, here are several examples of bends on the machines and the Minimum Radius we can go.

The Minimum Bend Radius is also effected by the Size of the Wire Running through it. To the best of our knowledge

the Minimum Bend Radius is listed in the chart for the size wire and conduit we use.

The Charts below shows the Industry Standard Minimum Bend Radius of Seal Tite Conduit, Olflex Cables, and Aeros Conduit. These are matched together, to the sizes that will fit through the Conduit.

The limiting factors for the matched sizes are Highlighted. These are Minimum Radius Bends that we can do.

Static Radius; thats a Radius that does not move, it's clamped in position and can't move.

Dynamic Radius; is one that can move around with the machine parts that move.

Note; All Radius are measured off the Inside Bend of the Conduit.

Seal Tite Olflex Cable Aeros (Black Plastic) Olflex Cable

Conduit Static Dynamic Cable Static Dynamic Conduit Static Dynamic Cable Static Dynamic

Size Radius Radius Size Radius Radius Size Radius Radius Size Radius Radius

1 1/4 150 MM 240 MM 4/4 120 MM 180 MM 36 MM 80 MM 150 MM 4/4 120 MM 180 MM



1 120 MM 200 MM 10/4 60 MM 90 MM 23 MM 45 MM 100 MM 10/4 60 MM 90 MM

3/4 90 MM 160 MM 12/4 48 MM 72 MM 16.5 MM 35 MM 75 MM 12/4 48 MM 72 MM



3/8 60 MM 100 MM

41


Hydraulic Hose Bend Radius, we use Parker 451TC Hose in all applications on our machines.

The Bend Radius of the hose will change with the Diameter size of the Hose. Here are several examples of Hose Routing and the Bend Radius chart from the Parker Catalog, Dated Oct. 2011. This Chart will be our Bend Radius Standard.

Part # Minimum Bend Radius Note; The Radius is measured off the Inside of the bend.

Inches MM

451TC /ST -4 2" 50 MM

451TC /ST -6 2.5" 65 MM

451TC /ST -8 3.5" 90 MM

451TC /ST -10 4" 100 MM

451TC /ST -12 4.75" 120 MM

451TC /ST -16 6" 150 MM

-8 Hydraulic Hose Bend Radius 3.5"

-6 Hydraulic Hose Bend Radius 2.5"

42


Plastic Air Line Bend Radius; the Plastic Air Lines we use have a Minimum Bend Radius,

Its dependent on the size of the Air Line. The chart below lists the Air Lines by Part #, Diameter, and Radius.

It's safe to say if you keep the bend radius to 1 1/4" or Larger you will be well within the Manufacturers Radius.The smallest radius listed is 1/2" and the Largest is 1 1/4". Note; the Radius is measured off the inside of the bend.

Color Part # Hose Size Radius " Radius MMBlack 1A-157-01 1/8 1/4

Black 1A-151-01 1/4 1/2 10 MM

Black 1A-152-01 3/8 7/8

Black 1A-166-01 1/2 12.7M 1 1/8

Black 1A-159-01 8MM 3/4 19 MM

Blue 1B-158-07 6MM 1/2 12.7MM

Blue 1A-159-07 8MM 3/4 19 MM

Blue 1A-160-07 10MM 7/8 22MM

Blue 1A-161-07 15/32 12 MM 1/2 28.6 MM

Yellow 1A-152-08 3/8 9.5MM 7/8

43

Set Screw Dimpling

Dimpling of one Set Screw on each Bearing, Motor Collar, Pulley, Sprocket, Etc. is mandatory.

Any exceptions to this standard are listed in the Torquing and Match Marking section of this document.

The procedures for proper dimpling of shafts, to accept a set screw, are as follows;

The drill bit used for the dimple must be the same size as the Set Screw, it must fill the set screw hole. If you use too small a Transfer Punch or Drill Bit, you may not have the dimple centered in the hole.

This will cause incorrect setting of the Set Screw.

44

Anti-Seize

Anti Seize application; Anti-Seize will be applied to all take-up bolts that are used for Belt Tensioning on Conveyors and

applied to Hollow Shaft Motors. Hollow Shaft Motors are the Motors that slides on a shaft.

Apply a thin coat of Anti-Seize to the Threads of a Take-up Bolt, cover about a 2-3" section of the Threads close to

the end of the bolt and screw the bolt on. It will cover the Threads as it goes through the threaded shaft. A little goes

a long way.

Coat the Shaft before installing a Hollow Shaft Motor on the Shaft. You do not have to coat the inside of the Motor.

Exception; Do not put Anti-Seize on the Inverter Shaft of a High Speed Top Feeder.

Hollow Shaft Motor

Take-up Bolt

Belt Tensioning

45

Taper-Lock Bushings

Taper-Lock Bushings we use are of two types, one uses Set Screws to Lock it in place and the second uses Hex

Head or Socket Head Bolts to pull it together. There uses are similar, they are made to Lock several rotating partstogether. On all, the following installations, make sure the shafts are free of Oil, Paint, or Grease.

Bushing No. Lb.-In Nm

1210, 1108 55 6,2

1210, 1215, 1310 175 19,9

1610, 1615 175 19,9

2012 280 31,8

2517, 2525 430 48,8

3020, 3030 800 90,8

3535 1000 114

4040 1700 193

4545 2450 278

5050 3100 352

6050, 7060, 8065 7820 888

1085, 12010 13700 1556

Mfg. Torque Specifications by Part #

Taper-Lock Face

This is an example of a Bushing Taper Lock with Set Screws, for assembly, clean the shaft of all Grease, Oil, and Paint.

Lightly oil the Set Screws, make sure the Sprocket is where you need it. Tighten according to manufactures specification.

The Manufacturer recommends when you reach the Torque Setting, shock the Taper by hitting the face

of the Taper with a Brass Hammer or a Brass Drift and Hammer. This will assist in setting the Taper. Torque all

the Set Screws and repeat the process two or three times.

On All Taper Locks, always tighten/torque in a rotation pattern, making at least 3 tightening/torqueing rotations

on the parts. Each successive rotation will yield less and less movement/torqueing of the bolts.

46

Taper-Lock Bushings

Taper-Lock with Bolts; this is normally used to mount a Motor to a Shaft or Roller. It consists of several pieces,

Tapers and the Center. We use several different styles, some are Belt Pulleys and some are Sprockets.

INSTALLATION INFORMATIONInstallation Screws

Bush B.C. Qty. Size Screw

Sym. Dia. Torque

QT 2,00 2 1/4/-20 x 7/8 90

JA 1,65 3 10-24 x 1 54

SH 2,25 3 1/4 x 1-3/8 108

SDS 2,69 3 1/4 x 1-3/8 108

SD 2,69 3 1/4 x 1-7/8 108

SK 3,31 3 5/16 x 2 180

SF 3,88 3 3/8 x 2 360

E 5,00 3 1/2 x 2-3/4 720

F 5,63 3 9/16 x 3-5/8 900

This is a two piece held together with SHCS.

Replace the bolts provided, with SHCS

10/24 X 1" and Split Lock Washers.

Clean the Shaft free from Oil, Grease, or Paint. Apply Purple LOCTITE and Torque

This is a three piece held together with Hex Head Bolts. To Mfg. Specs provided with Taper Lock The above chart is for this Taper Lock. Clean the Shaft free of

Oil, Grease, or Paint. Do not oil the Bolts, apply Blue LOCTITE and Split

Lock Washers to the Bolts and Torque to the Manufacturers Specification.

We use several different sizes, consult the Installation Chart

thats provided with the Taper Lock for proper Torque.

47

Taper-Lock Bushings

Pulley Taper Lock on the Block Pusher Block Pusher Spur Gear Taper Lock

Belt Adjuster.

Use SHCS 10/24 X 3/4" with Split Lock

Washers. Apply Purple LOCTITE and After positioning on the Rack Gear, make sure the

Torque to Manufacturers Specification Bolts have High Collar Split Lock Washers, apply

provided with the Taper Lock. Blue LOCTITE and Torque to Manufacturers Spec

It Should be about 36 In Lbs. provided with the Taper Lock. It should be about

10 Ft Lbs.

48

Taper-Lock Bushings

Sprocket Taper Lock with 2 Set Screws Sprocket Taper Lock with 2 Set Screws

on the Block Pusher Motor. on the Block Pusher Timing Shaft.

Install the Taper Lock using Blue LOCTITE on the Set Screws. Torque to the Manufacturers Specification provided with the

Taper Lock. After initial torqueing, shock the Taper Insert with a Brass Hammer or a Brass Drift and Hammer and

re-torque the Set Screws. Repeat this procedure 2 or 3 times. This will insure it's torqued correctly.

Remember to Match Mark the Set Screws.

49

Taper-Lock Bushings

Belt Drive Taper Lock Pulleys

Apply Blue LOCTITE to the Bolts or Set Screws, Torque to the Manufacturers Specification provided with the Taper Lock.

After initial torqueing, shock the Taper Insert with a Brass Hammer or Brass Drift and Hammer. Re-torque bolts or Set

Screws. Repeat this process 2 or 3 times to insure it's torqued correctly. Always torque in a rotation pattern to insure

the Taper Lock is evenly seated. Remember to Match Mark the Bolts and Set Screws.

50

Bearings, Camfollowers & Grease

Main Frame Bearing Mounting; in all cases the bearing grease Zerks will face Down Stream, toward the end of the

Extendo. There are exceptions to this for clearance issues, Engineering design and Field Service customer feedback.

The Mount Bolts were are outlined in the Washers, Nuts, and Fasteners section. There are bearings that have no

Grease Zerks. Specific Bearing mounting is listed here, in this section.

Exceptions to this Standard; there are exceptions and they will be listed on the last pages of this section.

Main Shaft Bearing Installation (Feedmax) Main Shaft Bearing Installation (HSTF)

Down Stream

Notice the Hex Bolts have a single Split Ring Lock washer under each bolt head and they are Match Marked.

51


Idler Stub Shaft Bearing (HSTF/P) End of Extendo Timing Shaft Bearings (Feedmax)

Downstream Drive Side Bearing

This is a view from inside the Main Frame.

The Grease Zerk is facing Downstream.

Ops Side Bearing

Downstream

52


Extendo Pivot Mount Bearings, (HSTF/P) Block Pusher Tilt Frame Bearing (Feedmax)

Both of these examples are showing the Grease Zerks facing down stream and they are mounted with Hex Head

Bolts with a single split ring lock washer.

53


Shingle Gate Linear Bearings Block Pusher Linear Bearings

These Bearing need to be installed with the Grease Zerks facing to the outside, you can't get to them to

service them if they are on the inside. These are mounted with a SHCS and Split Ring Lock Washer

with Locktite applied.

SHCS and Split Ring Lock

Washer Mount Bolt

54


Shingle Gate Hold Down Bearing (Square Mount Holes)

Square Hole Bearing Mount

this requires a Flat Washer and

a Lock Washer to mount it

This Bearing has an Eccentric

Locking Collar to lock it in place

on a shaft.

Place the collar on the bearing

and on the shaft, rotate the

collar clockwise as you are looking

at it from the front.

When the collar gets tight, insert a punch into the hole on the Locking

Collar and strike it with a Hammer, locking it in place. Apply Locktite to the

Set Screw and Torque it to specification.

55


Pillow Block Bearings (HSTF/P) Pillow Block Bearing (Ultra Breaker)

These Pillow Mounts have

Slotted Mount Bolt Holes and

require thick or hardened

Flat Washers as well as

Split Lock Washers to mount

them.

This Bearing has an Eccentric Locking Collar.

Place the collar on the bearing and on the shaft

rotate the collar clockwise as you are looking

at it from the front.

The Pillow Block Bearings are When the collar gets tight, insert a punch into the hole on the Locking

typically mounted with the Set Collar and strike it with a Hammer, locking it in place. Apply Locktite to the

Screws to the outside of the Shaft. Set Screw and Torque it to specification. It doesn't get dimpled.

On all of these installations make sure the Grease Zerk is easily accessible. See Exceptions Section, last page.

56


Two Bolt Flange Roller Bearing Two Bolt Bearing with Remote Grease Fitting

The 2 Bolt Flange Roller

Bearing on the Ultra Breaker

is installed with Carriage Bolts,

a Split Lock Washer, and

a Nut.

The Ultra Breaker also has Remote Grease Fittings and Manifold, remove the

grease Zerk and replace it with an adapter fitting and plastic tube fitting. This

a design standard on the Ultra Breaker.

57


Ultra Breaker Pop-up Roller Bearing

Shown in the Up, (Power On) Position Shown in the Down, (Power off) Position

This bearing is mounted with three Hex Head Bolts with a single Split Ring Lock Washer under each bolt. Notice the Grease Zerk, it's accessible when power is off. Make sure the Grease Zerk does not come in

contact with anything. It will damage the grease Zerk.

Make sure there is no

58


Non-Eccentric Cam Followers

Non-Eccentric Cam Followers will be installed with

a Flat Washer, Split Lock Washer, LOCTITE, and

a Jam Nut. Use a Full Nut whenever possible.

Torque to Specification.

No room for a full nut here.

Eccentric Cam Followers

PRIOR TO ASSEMBLY, IT IS NECESSARY TO MARK THE TALL LOBE OF THE CAM ON THE CAM

FOLLOWER. THE MARK SHOULD BE APPLIED TO WHICHEVER SIDE IS READILY VISIBLE. THIS

MARK CAN BE APPLIED WITH A PAINT PEN OR GREASE PENCIL. BE SURE TO HOLD CAM

FOLLOWER STATIONARY WITH AN ALLEN WRENCH WHILE TORQUING TO MAINTAIN ADJUSTMENT.

A FLAT WASHER, LOCK WASHER AND LOCKTITE ARE APPLIED THEN TORQUE TO

59



The High Speed Top Feeder and Standard Top Feeder Main Frame Bearing Grease Fittings on the outside of

the Main Frame are positioned to face each other. This is for the Maintenance Mechanic, they can reach both

bearings with one placement of their ladder.

60



There are many bearings on our machines that can't be rotated to have the Zerks facing Downstream. Place

the bearing to make it accessible as possible for the Maintenance Crews. Here are several examples of Grease

Zerks and Bearing placement. This is not meant to be all inclusive, and many of these you cant readily see.

Plastic Belt Conveyor Drive INA Rail Sliding Bearing Waste Kick Roller Bearing

Belt and Encoder Bearing, HSTF Mod LM Conveyor Drive Pulley

61



Ultra Breaker Platen Camfollowers

The Ultra Breaker Platen Up/Down Non-Eccentric Cam-

Followers do not have Flat Washers installed.

The Platen Assembly Metal is much thicker than other

Installations, a Flat Washer will cause the Nut to be held on

with minimal thread engagement. Only use a Split Lock Washer

in this Installation.

62

Painting Parts and Protection

Painting of Motors

We do not paint Motors. Leave them the color they come from the vender. The only time we paint a motor if the

Customer Corporate Spec calls for a specific color or it the motor requires touch-up paint.

HPU Motors and Tank assemblies

These get painted machine color. The HYDAC Coolers are supposed to be painted Black from the vender, if you

receive one not painted, contact the paint department. AO-10 Style Coolers are Painted Machine Color.

HSTFP Hyd. Power Unit. HYDAC Oil Coolers A0-10 Style Oil Cooler

63


Walk on Paper

Walk on Paper will be placed on any surface that will get damaged during the build process, primarily from foot traffic.

This is normally the Lift Conveyor, Separation Conveyor, Lift Frame, Extendo outside frames, and Main Frame Cross

Tubes. Do Not Put Walk on Paper on paint that is not completely dry. It will leave blemishes in the paint

and we will have to re-paint the parts.

Walk-On PaperWalk-On Paper

64


Air Transfer Table Blowers

All Blowers and Motors get painted machine color.

Loadmaster Air Transfer Table Blower Ultra Stacker Air Knife Blower

Hydraulic Motors

All Hydraulic Motors from our venders should be painted Black, if they are not, get them painted.

65


Safety Barriers will be installed around all machines with Power on.

66


Shaft Painting Black; when and what to paint and what color; 1st they must be clean of Oil, Grease, or Dirt.

Shafts and rollers that have obvious imperfections and blemishes are to be painted black, preferably prior to installation.

Never paint them machine color or Bearing Gray.

The outside stub shafts to be painted clear coat

Main shafts to be painted flat black on the inside

Examples of typical rollers and shafts that need to

be painted black are;

All stub shafts on non-lag rollers are painted flat black

Inside of leg roller & coupler to be painted flat black

Chantland pulleys will be painted flat black

Heavy duty hex shaft rollers and hex shafts

67


More Black Paint Items; Belt Drive Rollers on Lift Conveyor, Extendo, Separation Conveyor, Inclines, ETC will have the

the End Hubs Painted Black. The Shafts, any couplers and bearings have to be clear coated.

Here are several examples of the Drive Rollers;

Bearing and Shafts Clear Coat. End Hubs painted Black, Chantland Pulleys, and Flat

Surface Belt Drive Sprockets

68


Shaft Painting, Clear Coat; only shafts that are clear of Blemishes, Grease, Oil, or Dirt can be Clear Coated.

Some examples of shafts that can be Clear Coated are shaft protruding from the end of a frame or Bearing Ends. All writing, Lettering, and Numbers must be removed from the shaft before clear coating, and always, Clear Coat after the

Sub-Assembly is complete. You won't be able to assemble the parts with Clear Coat on them.

Clear Coated Shafts Clear Coated

69


Clear Coating or Painting of Bare Metal is a must. Here are a few more examples.

Clear Coat only

70

Air Bag Installation

Active Track Airbag Installation; most Air bags we used are installed one way. The Following is the Standard for

Installing Airbags.

Do Not Use Split Lock Washers

in the Assembly of the Airbags

on the Active Track. These are

made of rubber and plastic, the

tension applied by trying to

Torque the bolts and collapse

the Lock Washer will destroy the

Airbag.

The Stud/Air side of the Airbag will The Airbag side of the Assembly

be installed with a Flat Washer and will be installed with a Bolt and Flat

a Jam Nut with LOCTITE applied. Washer and no LOCTITE applied.

Do not Torque the Jam Nut, make This side of the Airbag has Plastic

it sufficiently tight so it will not move. Threads for Mounting.

71

Enclosure Wiring, Spares

Enclosure and J-Box Spare Wires and Service Loops.

All Electrical Enclosures and Junction Boxes have the potential to be very messy and unorganized if the wiring

pulled into the box is left too long and causes re-work, or lost time if it's too short. This Standard will outline how long

the Spare Wires can be with Service Loops.

This is the correct routing for a Feedmax Low Voltage Panel, Wrap premade long cables inside the Panduit,

where possible. This will make the panel less cluttered. Wiring will be secured to the Din Rail provided.

Pre-made

Ethernet Cables

72


Service Loops/Spare Wires in a Cable.

Spare wires will have Heat Shrink applied to the ends of the wires; we have has them short out in the past. Spare wires,

that are part of a multi-wire cable, will be no longer than 4" longer that the longest terminated wire in the cable. They will

be rolled up and Zip Tied.

Spare Wire with Heat Shrink and Zip Ties. Spare Wires with Heat Shrink applied, they are 4"

longer than the longest terminated wire in that bundle.

73


Service Loops/Spare Wires in Enclosures

Route the wiring up and around through the Panduit, The service loop in the Ultra Breaker Ops Station Lock-

where possible. Notice the Yellow wiring. This serves Out sensor wiring needs to be twice the distance from

as a service loop, it can be routed directly if need be. the Sensor to the terminal.

Enclosure on Ultra Breaker Ops Station on Ultra Breaker

74


Service Loops/Spare wires in Enclosures (HSTF)

Ultra Breaker Standing Enclosure.

These are the unused wires from several Photo Eyes. The Ultra Breaker Enclosure has a false bottom in it. The cables

They need to be as long as the Black Wire in the cable. in the bottom will have a service loop of 1-2 Ft, depending

This wire may be needed if we have to switch from Where the Cable is connected. They are Zip Tied to the Lower

Normally Open the Normally Closed. A Photo Eye Panel Cover.

cable will always have a wire not used, it will be either white or black. Don't cut it off.

The High Voltage Cables connect to the Left

Hand Side of the Enclosure, there are 6 of them

and they route to the front

75


Ultra Breaker Standing Enclosure.

Complete Cable installation, with Zip Ties to the Lower Cover. This is with the Lower Panel installed.

Each Cable has a service loop of 1-2 feet. It will fill the

Lower portion of the Enclosure, thats what it's for.

76


Encoder Wiring

External Encoder Wiring (2-Wire Shielded) will be ran inside Yellow Plastic Air Line. The reasoning for this is protection

for the wiring and ease of installation of the wire. The Wire used for the Encoder (2-Wire Shielded) has a tendency to

not want to lay straight in a wire bundle. We protect the wiring and make it easier to install by putting it in plastic air line.

It must be "Yellow Plastic Line", that makes it different from all other wiring. Here are several examples of this installation.

Rotating Inverter wiring installation HSTF. Edge of Stack Encoder

Loader Lift Encoder.

77

Holes in Frames

Holes in Frames and Grommets

All holes in frames that have wiring running through them will have protective liners in the holes. This can be Spiral

Wrap, Grommets, Flexible Hole Liners, Plastic Conduit or Seal Tite Conduit, or Split Rubber Hose.

Wiring will be protected in all holes. It is encouraged to line a hole if Air or Hydraulic Hose is running through it.

78

Holes in Frames

Holes in Frames

Conduit is for wiring, Abrasion Sock will not work for

Electrical wiring, its for Hydraulic Hose and Air Lines traversing

a hole in the frame. See the last page for ExceptionsWhen in doubt about whether to line a hole or not, Line it. The intent

of this part of the standard is to protect anything traversing a hole.

All Large Holes will be

lined with split rubber

hose.

79

Holes in Frames

Holes in Frames

Control Wiring and Air Lines in Conduit. Air Line Protected by Grommet, It will rattle in

the hole if it doesn't have a Grommet.

80

Holes in Frames

Expanded Metal Holes

Always protect anything going through the

Expanded Metal on the sides of machine.

Wiring needs to have a Grommet to protect it

and the sharp edges of the Expanded Metal

must be covered with split rubber hose to prevent injury to the mechanics and damage to hoses, wiring, Etc.

81

Holes in Frames


In the case of the Block Pusher on Pre-Feeders, the Electrical Cable

for the Photo Eye runs in the Abrasion Sock that the Hoses are in.

82

Shipping Standards

Shipping Standards Read this entire section before starting the shipping process.

Machines will be; Padded, Shrink Wrapped, Padded, and Shrink Wrapped again and then wrapped in plastic; in this order.

This is the 1st step in shipping, Do not put tape on any painted

surface. It leaves a very sticky residue thats difficult to

remove. You can attach padding with, tape going to padding

or tape going to itself. See the above examples.

The tape is just wrapped around the

padding, not on the machine surface.

83

Shipping Standards

Securing of loose Items.

Never leave an object or part of the machine un-secured.

Every item must be padded and attached to the Main Frame, Extendo, Shipping Frame, Etc. Loose items will

come loose and cause damage to another part or it will get lost. All small parts that have to be removed for shipping

need to be padded and packed in boxes and secured in the Main Frame. They must be secured well or they will come loose.

Padded and Zip Tied to the Main Frame expanded

metal.

Shingle Gate Hold down roller, padded and secured.

84

Shipping Standards

Padding of Parts

Parts that can't be removed and protrude from the machine must be well padded and shrink wrapped. The Trucking Co.

tarps will get damaged and we will have to pay for their repair. Pad and wrap well. Do Not apply tape to the machine

surface.

85

Shipping Standards

Padding of Corners

Padding of all corners and securing the padding is an important part of the shipping. Padding must be secured so it

will not move or shift when the tarps are placed on the load, or while its in transit. It will come loose and the tarps will

damage the paint.

Zip Ties holding the Padding

Padding pulled tight and Shrink Wrap is

tight on the corners

86

Shipping Standards

Conveyor Systems

Conveyors must be banded or bolted to the Main Frame, Shipping Frame, or Major part of the Machine. They are heavy

and will move around as the truck bounces down the road. Use padding under the metal banding, the bands will cut through the white foam padding. The best method is to use pieces of old conveyor belting. Always place a sheet of

OSB Board between the Conveyor sections when stacking them. You will punch a hole in the conveyor belting if you

don't. These belts cost $350.00 and up, don't damage them.

OSB Board on Conveyor

Belts and Scrap Belting

under Metal Banding.

OSB Under Conveyor Frame

when stacking them.Parts stacked on top of conveyors

must have OSB on top of the

conveyor belt. You will damage

the belt if you don't.

87

Shipping Standards

Leveling Jack Bolts,

Make sure you retract and lock down all Leveling Jack Bolts

before you stack the conveyors. They will damage Rollers,

Belts, and anything else under them.

Attaching Parts, Padded and secured to the Main Frame. Zip Ties and Bolts are used here.

88

Shipping Standards

Stacking Conveyor Systems

Buy-out conveyors need to have wood or metal skids bolted to the bottom of the legs. These can be double stacked to

save room on the truck and that saves shipping costs. It you double stack them you must have skids on the upper conveyor

to prevent damage to the lower conveyor. Here's a perfect example of the correct way to stack conveyors.

The truck driver will use the skids to tie down the load. You must insure the conveyor is very secure to the skids.

The upper conveyor is bolted to skids that are

bolted to the lower conveyor. It can't move.

The Lower conveyor will be bolted

89

Shipping Standards

Shipping Frames

Engineering provides us with Shipping Frames when needed. Always check the Bill of Materials (BOM) to see if there's a

Shipping Frame for your machine. The Frame of the machine will be bolted to the shipping frame and all Doors,

Wiring, Etc. will be secured so it will not come loose or move around during shipping.

Tilt Frame securely bolted

to the Shipping Frame.

The Doors are supported and Secured to the Shipping

Frame. The Wiring is supported, off the Floor.

90

Shipping Standards

Shrink Wrapping

Completely wrap the machine in Shrink Wrap, from top to bottom. When you apply padding you can tape it to the

Shrink Wrap and keep it off the machine. You can apply Corrugated Sheets for extra protection if needed, see the

above example.

Shrink Wrap, Corrugated Sheets and more Shrink Wrap.

91

Shipping Standards

Wrapping in Plastic

The finished product should look like this, everything wrapped in plastic and shrink wrapped again. Be

sure to put the Project # on the side of the machine, "Thats all"

92

Shipping Standards

Securing Pit Model Lift Conveyor.

The Feedmax Lift Conveyor must be secured for shipping. Install Flat Bar Supports in the front corners of the

Main Frame and Angle Supports in the rear corners. This will support the Lift. This only needs to be

accomplished on the Pit Model Feedmax.

On all Feedmax Machines On Pit Model Feedmax Machines

Raise the Lift Transducer, don't

leave it sticking down.

93

Shipping Standards

Cleaning of Surfaces

All conveyor belts will be wiped clean with cleaner to remove all smudges, foot prints, marks, tapping fluid, Etc.

All parts that have damaged paint will be wiped clean and repainted.

Remove all Footprint, Smudges, ETC.

94

assembly workmanship standards en

Documents

loctite installedthe

flat head screws

match marking blue loctite

match markingsteel bolts

socket head cap screws

purple loctite

dimpled set screws

match markingjack bolts