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Installation Guide Model 9405-9410 BOS and BOR Conveyor

2011-September-20 1

sda

Installation Guide

Model 9405 and 9410 BOS and BOR Conveyor

Model 9405-9410 BOS and BOR Conveyor Installation Guide

2011-September-20

Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Dematic Corp.

2011 Dematic Corp. All rights reserved Confidential sensitive. Not for further distribution.

This document contains confidential information, trade secrets and/or know-how which is the property of Dematic Corp., and may not be disclosed to any third party without the written permission of Dematic Corp.

Product and company names herein may be the trademarks of their respective owners.

Hereinafter Dematic Corp. shall be written as Dematic.

Dematic Corp. 507 Plymouth Avenue Grand Rapids, MI 49505 616-913-6200 800-530-9153 www.dematic.us

http://www.dematic.us/


2011-September-20 i

Contents

1 Product Safety ............................................................................... 1 1.1 Danger/Warning/Caution Convention .............................................. 1 1.2 General Safety ................................................................................ 1 1.2.1 Personnel ........................................................................................ 2 1.2.2 Equipment ....................................................................................... 3 1.2.3 Operation ........................................................................................ 3 1.2.4 Maintenance ................................................................................... 3

2 Equipment Summary .................................................................... 5 2.1 Model 9405 Slider Bed .................................................................... 5 2.2 Model 9405 Roller Box Bed ............................................................. 6 2.3 Model 9410 Belt-on-Roller ............................................................... 7

3 General Frame or Bed Assembly Installation ............................. 9 3.1 Unit Position and General Alignment ............................................... 9 3.2 Floor Supported Equipment .......................................................... 10 3.2.1 Floor Support Height Adjustment .................................................. 10 3.2.2 Attaching Floor Supports to Conveyor Bed ................................... 11 3.2.3 Installing Floor Supported Conveyor Sections ............................... 12 3.2.4 Securing Floor Supports ............................................................... 12 3.2.5 Ceiling Supported Equipment ........................................................ 13

4 9405/9410 Kit Installation ............................................................ 15 4.1 Installing a Model 9405 BOS Kit .................................................... 15 4.2 Installing a Model 9410 BOR Kit .................................................... 17 4.3 Installing a Model 9405/9410 Belt Unit Kit ..................................... 18 4.3.1 Installing End Pulley Assemblies ................................................... 19 4.3.2 Installing Snubber Rollers ............................................................. 20 4.4 Installing a Model 9405/9410 Power Tail Assembly ....................... 22 4.5 Installing a Model 9405/9410 Power Feeder Assembly ................. 27 4.6 Installing Power Feeder/Tail with Side Channels ........................... 30 4.7 Installing a Heavy Duty Power Feeder/Tail .................................... 30 4.8 Installing a Model 9405/9410 Noseover Assembly ........................ 32 4.9 Installing a 522# and 1000# Center Drive Assembly ..................... 33 4.10 Installing a Drum Motor Center Drive Assembly ............................ 34 4.10.1 Center Drive Position .................................................................... 36

5 Flat Belt Installation .................................................................... 39 5.1 Flat Belt Tensioning ...................................................................... 42 5.2 Flat Belt Tracking .......................................................................... 44 5.2.1 Squaring Beds .............................................................................. 45

6 Field Cutting Conveyor Beds ..................................................... 47


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6.1 Important Notes ............................................................................. 47 6.2 9405 Belt on Slider ........................................................................ 47

7 Supplemental Information .......................................................... 49 7.1 Taper Lock Bushings ..................................................................... 49 7.1.1 Removal ........................................................................................ 49 7.1.2 Replacement / Installation ............................................................. 49 7.2 Bearing Setscrews and Cap Screws Torque Specs ....................... 52


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Figures

Figure 1 Model 9405 Slider Bed ..................................................................... 5 Figure 2 Roller Box Bed .................................................................................. 6 Figure 3 Model 9410 Belt on Roller Bed ......................................................... 7 Figure 4 Locating the Center of the Unit ......................................................... 9 Figure 5 Adjusting Support Stand Height ...................................................... 10 Figure 6 Installing Floor Supports Bolts ........................................................ 11 Figure 7 Ceiling Hanger Height Adjustment .................................................. 14 Figure 8 Determining Return Roller Locations .............................................. 15 Figure 9 Installing a Model 9405 BOS Kit ..................................................... 16 Figure 10 Installing a Model 9410 BOR Kit ..................................................... 17 Figure 11 Model 9410 Carrier Roller Placement ............................................. 18 Figure 12 Installing a Model 9405/9410 End Pulley Assembly in BOS Beds ... 19 Figure 13 9410 End of Unit Roller Spacing ..................................................... 20 Figure 14 Installing a Model 9405/9410 Belt Unit Kit ....................................... 21 Figure 15 Snubber Roller Locations and Belt Path ......................................... 22 Figure 16 Loosening 3-inch Pulley Flange Bearing Bolts ................................ 23 Figure 17 Lifting the Power Tail Assembly into Place ..................................... 23 Figure 18 Installation of the 9405/9410 Power Tail Assembly ......................... 24 Figure 19 Adjusting the Power Tail Assembly Incline Angle ............................ 25 Figure 20 Installing the Incline Guards ............................................................ 26 Figure 21 Installation of the 9405/9410 Power Feeder Assembly ................... 28 Figure 22 Adjusting the Power Feeder Assembly Incline Angle ...................... 29 Figure 23 Heavy Duty Power Feeder Assembly ............................................. 31 Figure 24 Installing a 9405/9410 Noseover Assembly .................................... 32 Figure 25 Routing the Flat Belt through the Noseover Assembly .................... 33 Figure 26 Installing a 522# and 1000# Center Drive Assembly ....................... 34 Figure 27 Installing a Drum Motor Center Drive Assembly .............................. 35 Figure 28 Center Drive Locations ................................................................... 37 Figure 29 Model 9405/9410 Flat Belt Installation ............................................ 40 Figure 30 Belt Lacing Installation .................................................................... 41 Figure 31 Belt Clamping on Belt-on-Roller Conveyor ...................................... 43 Figure 32 Belt Tracking Roller Adjustment ...................................................... 44 Figure 33 Tie Rod Adjustments ...................................................................... 46 Figure 34 Squaring the Conveyor Beds .......................................................... 46 Figure 35 Cutting a 9405 Slider Pan ............................................................... 48 Figure 36 Taper Lock Bushings ...................................................................... 49 Figure 37 Dimple the Bushing ........................................................................ 50


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Tables

Table 1 Return Roller Locations ................................................................... 15 Table 2 Determining Crown Roller Locations in the Downstream Conveyor .25 Table 3 Determining Crown Roller Locations in the Upstream Conveyor ..... 29 Table 4 Center Drive Bed Location .............................................................. 36 Table 5 Taper Lock Bushing Torques .......................................................... 51 Table 6 Bearing Setscrew Torques .............................................................. 52 Table 7 Bearing Cap Screw Torques ........................................................... 52

Installation Guide Model 9405-9410 BOS and BOR Conveyor Product Safety

2011-September-20 1

1 Product Safety

1.1 Danger/Warning/Caution Convention This product is furnished with safety guards and warning labels. When this equipment is applied at your facility, additional guards and warnings may be required because specific applications might create residual hazards that could not be anticipated or eliminated when the equipment was designed. Therefore, examine your installation and provide any additional required safety measures. Danger, warning, and caution conventions are explained in the following table:

Symbol Description

Danger statements indicate an imminently hazardous situation that if not avoided, WILL result in death or serious injury. Warning statements indicate a potentially hazardous situation that if not avoided, COULD result in death or serious injury. Caution statements indicate a potentially hazardous situation that if not avoided, will result in minor or moderate injury. It may also be used to alert against unsafe practices.

1.2 General Safety Never operate this equipment with missing, disabled, or inoperative safety devices. Operating equipment in this condition will result in serious injury or death. Immediately remove equipment in this condition from service.

Severe personal injury or damage to property may occur in the event of: ● Incorrect use or operation of the equipment, including allowing

untrained personnel to interface with or come into contact with the equipment. Only properly trained and authorized personnel are to operate this equipment.

● Incorrect or insufficient maintenance of the equipment. Only properly trained and authorized personnel are to service and maintain this equipment.

Model 9405-9410 BOS and BOR Conveyor Installation Guide Product Safety

2 2011-September-20

Do not perform adjustments, maintenance or other work on this equipment without following OSHA Lock-Out/Tag-Out requirements and state and local requirements. The purpose of this procedure is to protect all persons involved against unexpected restart. Personnel should be alerted to the hazard of stored energy which may exist after the power source is locked out. Refer to ANSI Z244.1 and OSHA 29 CFR 1910.147 for minimum requirements. Failure to follow these requirements may result in equipment damage, serious injury, or death.

If any defects relating to operating safety and reliability are detected or if any damage occurs, affected parts of the system must be taken out of operation immediately. Failure to do so may result in serious injury or death

Climbing, sitting, walking, or riding on equipment at any time may result in serious injury or death.

Under continuous operation, the external surface of various powered components might reach temperatures significantly above ambient temperature. Contact with unprotected skin may cause burns.

1.2.1 Personnel ● Personnel must be informed about the location and operation of emergency

stops and power disconnect points.

● Personnel must be alerted to potential hazards of entanglement in conveyors caused by such items as long hair, loose clothing, and jewelry. These hazards, if not avoided, could result in serious injury or death.

● Personnel must report to a supervisor all unsafe conditions or anything out of the ordinary that is observed prior to operating the system. Remove equipment in unsafe conditions from service immediately.

Installation Guide Model 9405-9410 BOS and BOR Conveyor Product Safety

2011-September-20 3

1.2.2 Equipment ● Use the equipment exclusively for appropriate conveyor loads that it is

designed to handle safely.

● Do not perform any unauthorized conversion or modification of the system, equipment, or safety devices. Such modifications could degrade safety and expose personnel to risk of serious injury or death.

● Never connect or disconnect any electrical cables while power is applied to the equipment as this can result in damage to the equipment or serious injury or death resulting from electric shock. Lock-out/tag-out equipment prior to service.

1.2.3 Operation ● Prior to start up, operators are to visually confirm that all personnel are clear

of the conveyor.

● During initial equipment startup, personnel must be notified prior to startup by the operator or via audible and/or visual indications followed by a delay.

● If safety devices are defective or if they do not function reliably, the equipment must not be put into operation. Notify your supervisor that equipment is not safe to operate and remove equipment from service.

1.2.4 Maintenance ● A routine safety inspection plan must be implemented before each shift

change and startup of the equipment.

● Maintenance (other than observation) must not be performed while a conveyor is in operation or motion unless proper maintenance or service requires the conveyor to be in motion. In which case, personnel shall be made aware of all hazards and how the task may be safely accomplished.

Model 9405-9410 BOS and BOR Conveyor Installation Guide Product Safety

4 2011-September-20

Installation Guide Model 9405-9410 BOS and BOR Conveyor Equipment Summary

2011-September-20 5

2 Equipment Summary

2.1 Model 9405 Slider Bed This belt conveyor is capable of horizontal and incline or decline transportation up to 25-degrees with most applications. The PVC flat belt moves along galvanized steel pans that span the common side channels. The solid base under the belt provides excellent impact resistance and stability (see Figure 1).

Figure 1 Model 9405 Slider Bed

Model 9405-9410 BOS and BOR Conveyor Installation Guide Equipment Summary

6 2011-September-20

2.2 Model 9405 Roller Box Bed This variation has rollers spaced along the slider bed under the belt. Though more expensive than standard slider bed, roller beds more effectively break the suction between the belt and bed in damp applications. Also, roller beds have less friction than slider beds. Roller beds use the same drives as standard beds (see Figure 2).

Figure 2 Roller Box Bed

Installation Guide Model 9405-9410 BOS and BOR Conveyor Equipment Summary

2011-September-20 7

2.3 Model 9410 Belt-on-Roller This conveyor is capable of horizontal or decline/incline transportation up to 25-degrees with most applications. The belt travels on rollers spaced every 4, 6, or 8 inches.

It has less belt friction than Model 9405, allowing longer runs without increasing the drive size. Because of its rollers with bearings, Model 9410 is more prone to impact damage than is 9405.

Figure 3 Model 9410 Belt on Roller Bed

Model 9405-9410 BOS and BOR Conveyor Installation Guide Equipment Summary

8 2011-September-20

Installation Guide Model 9405-9410 BOS and BOR Conveyor General Frame or Bed Assembly Installation

2011-September-20 9

3 General Frame or Bed Assembly Installation

3.1 Unit Position and General Alignment Any measurements locating the unit from the building structure must be taken at each end of the unit. Do not use intermediate measurements as these will make the unit follow the building line which may not be straight. See the project systems drawings for specific installation information.

Do not perform adjustments, maintenance, or other work on this equipment without following OSHA Lock-Out/Tag-Out requirements and state and local requirements. Failure to follow these requirements may result in serious injury and/or equipment damage.

Position and align components as follows per the systems drawings:

● Elevate

● Cross level

● Locate to the centerline.

See Figure 4 for a reference guideline.

Figure 4 Locating the Center of the Unit

Model 9405-9410 BOS and BOR Conveyor Installation Guide General Frame or Bed Assembly Installation

10 2011-September-20

3.2 Floor Supported Equipment 3.2.1 Floor Support Height Adjustment

To adjust the height of the floor supports:

1. Loosen the two bolts, Figure 5 - (1), located on the floor support leg (2).

2. Adjust the leg up or down to ascertain the desired height required for the floor supports.

3. Once the desired height has been set, tighten the two bolts. Figure 5 Adjusting Support Stand Height


2011-September-20 11

3.2.2 Attaching Floor Supports to Conveyor Bed Once you have determined floor support positioning based on the system layout drawing, use the following procedure to connect the floor supports to the conveyor sections.

1. Position the floor support assembly, Figure 6 - (3), underneath the conveyor section.

2. Use two bolts (2) on each side to secure the floor support to the conveyor side channel (1) (torque: 37 ft/lb). Install supports at bed joints except where interference occurs.

Figure 6 Installing Floor Supports Bolts



3.2.3 Installing Floor Supported Conveyor Sections 1. Position and align the conveyor bed at the desired location (see section

3.1). See the system layout drawings for specific location.

2. Secure the floor supports to the floor (see section 3.2.4).

3.2.4 Securing Floor Supports

3.2.4.1 Lagging to Concrete or Masonry :INFO: Explosive type anchors are not to be used.

1. Intermediate floor supports are anchored with a minimum of 3/8” diameter bolts. Stands over 5” high will be anchored with a minimum of 1/2” diameter bolts.

2. The end floor supports for each conveyor and floor supports for drives will be anchored with a minimum of 1/2” diameter bolts.

3. Anchoring is accomplished by drilling into the floor and inserting a suitable bolt anchor.

4. Anchor bolts for equipment that is subject to unusual vibration will be a minimum of 1/2” diameter.

3.2.4.2 Lagging to Plywood 1. Intermediate floor supports will be anchored with a minimum of 3/8”

diameter through bolts. Stands over 5” high will be anchored with 1/2” diameter minimum through bolts.

2. The end supports for each conveyor and support stands for drives will be anchored with 1/2” diameter through bolts.

3. Length of bolts will vary with the thickness of the plywood.



3.2.5 Ceiling Supported Equipment

3.2.5.1 Attaching Ceiling Hangers to Conveyor Sections Once you have determined ceiling hanger positioning based on the system layout drawing, use the following procedure to connect the ceiling hangers to the conveyor sections.

1. Position the ceiling hanger assembly underneath the conveyor section.

2. Secure the ceiling hanger to the side channel (from underneath).

:INFO: Header steel and ceiling attachment designs and configurations may vary considerably between applications and international markets due to local steel and or concrete construction standards. As such, consideration must be put into the interface between the conveyor attachment points and the respective ceiling support configuration. (See Model 3500.03 Service Manual for more information.)

3.2.5.2 Ceiling Hanger Height Adjustment To adjust the height of the ceiling hangers:

1. Loosen the jam nut located on each ceiling hanger take-up screw. (See Figure 7.)

2. Adjust the hanger up or down to ascertain the desired height required for the ceiling hanger.

3. Once the desired height has been set, tighten the jam nuts.



Figure 7 Ceiling Hanger Height Adjustment

3.2.5.3 Installing Ceiling Supported Conveyor Sections Position and align the conveyor bed at the desired location (see section 3.1). See the system layout drawings for specific location.

Installation Guide Model 9405-9410 BOS and BOR Conveyor 9405/9410 Kit Installation


4 9405/9410 Kit Installation

4.1 Installing a Model 9405 BOS Kit A model 9405 kit includes all the parts and pieces to create a complete BOS unit within an existing conveyor frame.

The following procedure describes the installation of one BOS unit.

1. Use the layout drawing to determine the location of the drop-in BOS kit.

2. If necessary, remove existing conveyor surface components that are currently in the location of the drop-in kit.

3. Install return roller brackets Figure 9 – (9), and return rollers (8), in the conveyor frame. See Figure 8 and Table 1 for return roller locations.

Figure 8 Determining Return Roller Locations

Table 1 Return Roller Locations

Conveyor Bed Length Roller Location “A” Roller Location “B”

23-7/8” None None 35-7/8” 18” None 47-7/8” 18” None 71-7/8” 30” None 95-7/8” 30” 66” 143-7/8” 30” 114”

4. Starting at the charge end of the conveyor frame, insert the non-spring loaded end of the idler roller (7) (if applicable), into the frame and slide the other end of the axle into the bed frame hole.

5. Install the downstream slider plate (6).

Model 9405-9410 BOS and BOR Conveyor Installation Guide 9405/9410 Kit Installation


6. Install the next idler roller (if applicable) at the end of the previously installed slider plate.

7. Repeat steps 5 and 6 for the length of the conveyor bed frame, completing the installation of one BOS kit.

8. Install safety labels as applicable. Figure 9 Installing a Model 9405 BOS Kit



4.2 Installing a Model 9410 BOR Kit A model 9410 kit includes all the parts and pieces to create a complete BOR unit within an existing conveyor frame.

The following procedure describes the installation of one BOR unit.

1. Use the layout drawing to determine the location of the drop-in BOR kit.


3. Install return roller brackets Figure 10 – (9), and return rollers (8), in the conveyor frame. See Figure 8 and Table 1 for return roller locations.

4. Starting at the charge end of the conveyor frame, insert the non-spring loaded end of carrier roller (7), into the frame and slide the other end of the axle into the bed frame hole. See Figure 11 for carrier roller placement.

Figure 10 Installing a Model 9410 BOR Kit



Figure 11 Model 9410 Carrier Roller Placement

5. Install remaining carrier rollers for the length of the conveyor bed frame, completing the installation of one BOR kit.

6. Install safety labels as applicable.

4.3 Installing a Model 9405/9410 Belt Unit Kit A model 9405/9410 kit includes all the parts and pieces to add Belt Unit Kit within an existing conveyor frame.

The following procedures describe the installation of one Belt Unit Kit.

1. Use the layout drawing to determine the location of the drop-in Belt Unit Kit.


3. Install safety labels as applicable.



4.3.1 Installing End Pulley Assemblies

4.3.1.1 Belt-on-Slider 1. Remove the end slider plate from the end of the conveyor. (See Figure 12.)

2. Replace with the shorter slider plate Figure 14 – (9), provided with the Belt Unit Kit Assembly.

3. Align the mounting slots in the end pulley assembly with the holes in the side channel and install hardware.

4. Align pulley mounting blocks with rectangular holes in the side channel and bolt into place. Torque bolts to 100 ft lb, or snug bolts and tighten 1/4-inch turn.

Figure 12 Installing a Model 9405/9410 End Pulley Assembly in BOS Beds



4.3.1.2 Belt-on-Roller 1. Align the mounting slots in the end pulley assembly with the holes in the

side channel and install hardware.

2. Align pulley mounting blocks with rectangular holes in the side channel and bolt into place. Torque bolts to 100 ft lb, or snug bolts and tighten 1/4-inch turn.

3. At the end of the unit, regardless of roller center spacing, there must be two carrier rollers spaced 6” apart above the first snubber roller as shown in Figure 13.

Figure 13 9410 End of Unit Roller Spacing

4.3.2 Installing Snubber Rollers 1. Determine the location of the snubber roller assemblies Figure 14 – (2), in

the conveyor frame. See Figure 15 for snubber roller locations.

2. Fasten the snubber roller mounting brackets to the side channels with the hardware provided.

3. Determine the location of the steering snubber roller assembly (3), in the conveyor frame. See Figure 15 for steering snubber roller locations.

4. Assemble the steering snubber roller assembly components.

a. Insert the threaded axle (5), into the hollow hex spacer (7), and insert them together into the steering snubber roller (3).

b. Slide spacers (11) over each end of the hollow hex axle.

c. Insert the steering snubber roller assembly into the rectangular holes in the conveyor frame located 16-inches from center of the end pulley.

d. Align steering snubber mounting blocks (10), with rectangular holes in the side channel and the ends of the threaded axle.



e. Attach the 1/2-inch acorn nuts and flat washers to each end of the threaded axle, securing the assembly to the steering snubber mounting block. Torque to 100 ft lb, or snug bolts and tighten 1/4-inch turn.

5. Attach snubber bottom guards (12), to the bottom of the conveyor frame. Figure 14 Installing a Model 9405/9410 Belt Unit Kit



Figure 15 Snubber Roller Locations and Belt Path

4.4 Installing a Model 9405/9410 Power Tail Assembly A model 9405/9410 Power Tail Assembly (G0057) includes all the parts and pieces to add a power tail unit within an existing conveyor frame.

The following procedure describes the installation of one power tail assembly kit.

1. Use the layout drawing to determine the location of the power tail assembly.

2. Remove carrier rollers from the section of downstream conveyor where the elastic belt will be assembled and set them aside.

3. Remove the drive belt guard on the power tail assembly by removing the single bolt located underneath the guard.

4. Loosen the bolts on the 3-inch pulley flange bearings on both sides of the power tail assembly.



Figure 16 Loosening 3-inch Pulley Flange Bearing Bolts

5. Using a pallet jack or similar lifting device, lift the power tail assembly into place at the end of the conveyor frame. Orient the assembly so the 3-inch pulley and elastic belt are downstream. (See Figure 17.)

Figure 17 Lifting the Power Tail Assembly into Place

6. Attach power tail assembly using splice plate assemblies (p/n K0079-36CAA) at bed joints. (See Figure 18.)



Figure 18 Installation of the 9405/9410 Power Tail Assembly

7. Bolt the bottom flange of power tail assembly to the support top bracket.

8. Adjust the incline angle on the power tail assembly:

a. Rotate the side frames on the upstream end of the assembly around the 3-inch pulley until the side frames align with splice plates on upstream conveyor. (See Figure 19.)

b. Bolt the inclined side frames to the splice plates.

c. Tighten the 3-inch pulley flange bearing bolts when the proper incline angle is achieved.



Figure 19 Adjusting the Power Tail Assembly Incline Angle

9. Install the crown roller into the downstream conveyor frame.

a. Determine the location of the crown roller in the downstream conveyor frame. See Figure 18 and Table 2 for location.

b. Slide the crown roller inside the elastic belt.

c. Insert the non-spring loaded end of carrier roller into the conveyor frame.

d. Slide the other end of the axle into the conveyor frame hole on the opposite side.

Table 2 Determining Crown Roller Locations in the Downstream Conveyor

Zone Length Distance from End of Side Channel

24” 10.9” 36” 22.9” 48” 34.9” 72” 58.9”



10. Install the previously removed carrier rollers, less one.

a. Slide the carrier rollers inside the elastic belt.

b. Insert the non-spring loaded end of carrier rollers into the frame.

c. Slide the other end of the axles into the bed frame holes on the opposite side.

:INFO: Elastic belt is self-tracking on the crown roller.

11. Install and track flat belts as applicable. (See section 5.)

12. Replace the drive belt guard.

13. Install the incline guards as shown in Figure 20. Figure 20 Installing the Incline Guards



4.5 Installing a Model 9405/9410 Power Feeder Assembly

A model 9405/9410 Power Feeder Assembly (G0058) includes all the parts and pieces to add a power feeder unit within an existing conveyor frame.

The following procedure describes the installation of one power feeder assembly kit.

1. Use the layout drawing to determine the location of the power feeder assembly.

2. Remove carrier rollers from the section of upstream conveyor where the elastic belt will be assembled and set them aside.

3. Remove the drive belt guard on the power feeder assembly by removing the single bolt located underneath the guard.

4. Loosen the bolts on the 4-inch pulley flange bearings on both sides of the power feeder assembly.

5. Using a pallet jack or similar lifting device, lift the power feeder assembly into place at the end of the conveyor frame. Orient the assembly so the 3-inch pulley and elastic belt are upstream. (See Figure 17.)

6. Attach power feeder assembly using splice plate assemblies (p/n K0079-36CAA) at bed joints. (See Figure 21.)



Figure 21 Installation of the 9405/9410 Power Feeder Assembly

7. Bolt the bottom flange of power feeder assembly to the support top bracket.

8. Adjust the incline angle on the power feeder assembly:

a. Rotate the side frames on the downstream end of the assembly around the 4-inch pulley flange bearing until the side frames align parallel with side frames and splice plates on the downstream conveyor. (See Figure 22.)

b. Bolt the inclined side frames to the splice plates.

c. Tighten the 4-inch pulley flange bearing bolts when the proper incline angle is achieved.



Figure 22 Adjusting the Power Feeder Assembly Incline Angle

9. Install the crown roller into the upstream conveyor frame. Determine the location of the crown roller in the upstream conveyor frame. See Figure 21 and Table 3 for locations.

a. Slide the crown roller inside the elastic belt.

b. Insert the non-spring loaded end of carrier roller into the conveyor frame.

c. Slide the other end of the axle into the conveyor frame hole on the opposite side.

Table 3 Determining Crown Roller Locations in the Upstream Conveyor

Zone Length Distance from End of Side Channel

24” 10.9” 36” 22.9” 48” 34.9” 72” 58.9”



10. Install the previously removed carrier rollers, less one.

a. Slide the carrier rollers inside elastic belt.

b. Insert the non-spring loaded end of carrier rollers into the frame.

c. Slide the other end of the axles into the bed frame holes on the opposite side.

:INFO: Elastic belt is self-tracking on the crown roller.

11. Install and track flat belts as applicable. (See section 5.)

12. Replace the drive belt guard.

13. Install the incline guards as shown in Figure 20.

4.6 Installing Power Feeder/Tail with Side Channels Power feeder/tail assemblies with side channels (G0116 or G0117) come completely assembled and only require installation to the upstream and downstream conveyor using splice plates. Reference sections 4.4 and 4.5 as necessary.

4.7 Installing a Heavy Duty Power Feeder/Tail Heavy duty power feeder/tail assemblies (G0118 or G0119) come completely assembled and only require installation to the upstream and downstream conveyor using splice plates. Reference sections 4.4 and 4.5 as necessary.

Once installed, the power feeder/tail laced belt will require tensioning and tracking.

To tension the belt lower the take-up brackets Figure 23 – (52) and tension the belt. See section 5.1 as necessary.

To track the belt, see section 5.2.



Figure 23 Heavy Duty Power Feeder Assembly



4.8 Installing a Model 9405/9410 Noseover Assembly A model 9405/9410 Noseover Assembly includes all the parts and pieces to add a noseover unit onto an existing conveyor frame.

The following procedure describes the installation of one noseover assembly kit.

1. Use the layout drawing to determine the location of the noseover assembly.

2. Install the noseover splice assemblies (p/n K0407-22) onto the ends of the existing conveyor frames.

a. Align the holes in the noseover splice assembly end plates with the holes at the end of the upstream conveyor side channels.

b. Insert bolts through the end plates and side channels and finger-tighten.

c. Repeat this procedure for the noseover splice assembly located on the downstream conveyor frame.

3. Lift the noseover assembly onto the end of the downstream conveyor frame and align holes in the noseover frame with the noseover splice assembly. (See Figure 24.) Insert hardware and finger-tighten.

4. Align the noseover assembly with the noseover splice assembly end brackets on the upstream conveyor frame. Insert hardware and tighten into place.

5. Tighten all hardware. Figure 24 Installing a 9405/9410 Noseover Assembly



6. Route the flat belt above the crossmembers and the snubber roller. (See Figure 25.)

Figure 25 Routing the Flat Belt through the Noseover Assembly

4.9 Installing a 522# and 1000# Center Drive Assembly A 522# and 1000# Center Drive Assembly includes all the parts and pieces to add a center drive unit onto an existing conveyor frame.

The following procedure describes the installation of one center drive assembly.

1. Use the layout drawing to determine the location of the center drive assembly.

2. Remove the drive belt cover mounting angle from the top of the center drive assembly. (See Figure 26.)

3. Attach the center drive to the conveyor frame and tighten hardware.

4. Bolt the drive belt cover mounting angle onto the lower conveyor side channel flange.

5. Fasten the drive cover to the drive belt cover mounting angle and center drive assembly.

6. Adjust snubber rollers as needed. (See Figure 15 for snubber roller locations.)



Figure 26 Installing a 522# and 1000# Center Drive Assembly

4.10 Installing a Drum Motor Center Drive Assembly A Drum Motor Center Drive Assembly includes all the parts and pieces to add a drum motor center drive unit onto an existing conveyor frame.

The following procedure describes the installation of one drum motor center drive assembly.

1. Use the layout drawing to determine the location of the drum motor center drive assembly.

2. Attach the drum motor center drive to the conveyor frame and tighten hardware. (See Figure 27.)

3. Adjust snubber rollers as needed. (See Figure 15 for snubber roller locations.)



Figure 27 Installing a Drum Motor Center Drive Assembly



4.10.1 Center Drive Position 1. Position the center drive assembly within the conveyor unit where a

minimum amount of return belt is under high tension (see Table 4).

Table 4 Center Drive Bed Location

Conveyor Position Operation Mode Recommended Bed Location

Horizontal (belt) 1-way Near discharge end

Horizontal (belt) 2-way Same product weight each direction

Middle

Horizontal (belt) 2-way Different product weight each direction

Near end discharging the heaviest load

Horizontal (live roller)

1-way Near charge end


2-way Same product weight each direction

Middle


2-way Different product weight each direction

Farther from end discharging heaviest load

Incline (belt) 1-way Near high end

Decline (belt) 1-way Near low end

Incline/Decline 2-way Middle

2. Install the center drive on the bed as follows:

a. Locate the required drive mounting position on the drive bed. (See Figure 28.)

b. Make sure a support is located as close as possible to the end drive.

:INFO: With inclined belt units, the drive will be near the conveyor discharge end, with the motor at the low end of the drive. This is acceptable at 0 to 14 degree inclines. At inclines 15 degrees or greater, an "S" series reducer is required to prevent potential oil leakage at the seal between the motor and gearbox. The "S" series reducer has two bearings on the input shaft between the reducer and motor to reduce the risk of leakage.

c. Make sure the drive and all pulleys are square. Measure diagonally across center drive mounting holes: From side channel outer corner mounting hole at one end, to side channel outer corner mounting at opposite end. Then measure the other two corners. The two measurements must be equal within plus or minus 1/16-inch.



d. Position center drive on underside of drive bed so mounting holes on center drive side channels align with holes in drive bed.

3. If the center drive is 8 feet or less above the working surface or is over a walk-way, be sure to install a Bottom Belt Guard (p/n K0062-77AAA through ABH) below and alongside the belt where the belt protrudes under the bed.

Figure 28 Center Drive Locations

Installation Guide Model 9405-9410 BOS and BOR Conveyor Flat Belt Installation


5 Flat Belt Installation

1. Wipe all surfaces clean that belt will touch, removing oil and any other foreign materials.

2. Check to ensure that return belt path along bottom of bed is clear and clean. Include idler and return rollers in this check.

:INFO: Ensure that adjustable pulleys in end pulley assembly (if used) are at minimum position to allow the most slack belt possible for belt installation.

3. Place the roll of belt to be installed on the conveyor at the discharge (unloading) end.

4. Ensure that the load-carrying surface of the belt faces up as the end of the belt is pulled off the roll, over the carrier rollers or slider plates, and to the end pulley.

5. Pull the belt down and around the end pulley. Thread the end of the belt back along the return path over idler rollers as applicable. (See Figure 15 for belt path.)

6. Route belt around remaining end pulley and bring ends of belt together on top bed surface.

:INFO: Use of a belt puller to bring ends of belt together may be necessary.

7. If necessary, clamp one end of belt and press other end against and rotate end pulley to bring belt ends together (see Figure 29).

8. With the belt ends pulled together and the lacing meshed, install the lacing pin. (See Figure 30.)

Model 9405-9410 BOS and BOR Conveyor Installation Guide Flat Belt Installation


Figure 29 Model 9405/9410 Flat Belt Installation



Figure 30 Belt Lacing Installation



5.1 Flat Belt Tensioning After a few weeks of operation, a new belt will have worn in and stretched. The belt must be tensioned at that time and periodically thereafter.

1. Check the take-up pulley in the drive unit to see if it can be used to adjust the belt tension. If the take-up is already in the extreme (maximum) position, you will have to remove a take-out section of the belt; go to step 2. Otherwise tension the belt by adjusting the take-up pulley as follows:

a. Loosen the jam nuts on the take-up pulley adjustment screws.

b. Turn the adjustment screws alternately and evenly to move the take-up pulley away from the drive pulley.

:INFO: The belt must be tightened no more than is necessary to prevent slipping on the drive pulley when operating under load.

c. Tighten the jam nuts on the adjustment screws.

d. Go to step 4.

2. Long belts are shipped with one or more take-out sections. A take-out section is a length of belt (usually 12-inches long) laced into the main belt. Take-out sections can be removed after the main belt stretches. To remove a take-out section, follow the procedure below:

a. Jog the conveyor until the belt take-out section is located in an accessible area.

b. Loosen the jam nuts on the take-up pulley adjustment screws.

c. Turn the adjustment screws alternately and evenly to move the take-up pulley toward the drive pulley. Adjust the screws until one has moved to its home (minimum) position and the other has been moved an equal number of turns.

d. If applicable, remove enough carrier rollers to allow removal of the take-out section.

e. Twist the lacings 90 degrees and remove the lacing pin that secures the take-out section to the rest of the belt. Remove the take-out section.

f. Clamp one end of the belt (see Figure 29 for Belt-on-Slider Conveyor, or Figure 31 for Belt-on-Roller Conveyor).



Figure 31 Belt Clamping on Belt-on-Roller Conveyor

g. Bring the ends of the belt together and mesh the lacing. Use of a belt puller may be required.

h. Install the lacing pin to secure the lacing. (See Figure 30.)

i. If applicable, replace the carrier rollers removed from the conveyor.

3. Adjust the take-up pulley to tension the belt.

a. Turn the adjusting screws alternately and equally to move the take-up pulley away from the drive pulley.

:INFO: The belt must be tightened no more than is necessary to prevent slipping on the drive pulley when operating under load.

b. Turn the adjusting screws until the belt is just taut enough to conform to the crown of the pulley and snug enough to move the product load without slippage.

c. Tighten the jam nuts on the adjusting screws.

4. Operate the unit and watch the belt. The belt should not slip at the drive pulley and should droop slightly between the return belt idler rollers.

5. Verify that the belt is tracking correctly (see section 5.2). Adjust as required.



5.2 Flat Belt Tracking Belt tracking should be adjusted when the belt wanders off center and stays off center. If the belt wanders off center and then returns to center during a complete rotation, no tracking adjustment is necessary. This kind of mistracking is caused by a lengthwise camber in the belt and will correct itself with use.

If the belt is mistracking badly, it can run off center very quickly. Be prepared to shut the conveyor off if the belt wanders enough to run off the pulley or cause damage.

1. Verify that the belt is properly tensioned. Adjust as required (see section

5.1).

2. Turn the unit on and watch the belt as is travels over the bed surface and through all components.

:INFO: End pulleys must be kept as square as possible. Do not use an end pulley to track a belt unless other adjustments are not available.

3. If the belt mistracks on a return roller, adjust the roller immediately upstream as required to track the belt (see Figure 32).

Figure 32 Belt Tracking Roller Adjustment



4. If the belt mistracks on the take-up or drive pulley:

a. Verify that the take-up and drive pulleys are square to the bed. Adjust as required.

b. Adjust the roller or pulley immediately upstream of the drive as required to track the belt.

5. If the belt mistracks on an end pulley:

a. Verify that the end pulley is square to the bed. Adjust as required.

b. Adjust the upstream roller or pulley as required to track the belt.

6. If tracking is not accomplished using the steps outlined above:

a. Verify that the conveyor is at the correct height, is level, and is properly aligned. Adjust as required.

b. Verify that the take-up pulley, drive pulley, snubber, and end pulleys are square to the bed. Adjust as required.

c. Work back through steps 1 through 5 above.

7. If tracking is still not possible, verify that the conveyor beds are square. If the beds are square, the belt needs to be replaced. If the beds are out of square, they need to be disassembled, squared up, and reassembled. (See section 5.2.1.)

5.2.1 Squaring Beds Measure diagonally across the top of each bed section between points X-X and Y-Y. These points should be the corresponding roller holes nearest the bed ends, not the ends of the bed side channels. (See Figure 33.) Compare the two diagonal measurements. If the measurements differ by more than 1/8 inch, square the bed as follows (see Figure 34):

1. Loosen the support or splice plate mounting hardware on one side of the bed section.

2. If a bed has tie-rod diagonal braces (recommended every 2-10 beds on a unit), loosen them.



Figure 33 Tie Rod Adjustments

Figure 34 Squaring the Conveyor Beds

3. Use a pry bar or wedge to pry the bed side channels apart until the X-X and Y-Y dimensions are equal (bed is square). (See Figure 34.)

4. Tighten the support or splice plate mounting hardware.

5. Tighten the tie rods, being careful to avoid over-tightening them and bowing in the side channels.

:INFO: Use tie rods to square the carrier rollers to the flat belt for centering (tracking) the belt on flanged skate wheels.

Installation Guide Model 9405-9410 BOS and BOR Conveyor Field Cutting Conveyor Beds


6 Field Cutting Conveyor Beds

6.1 Important Notes ● Field cuts must be made in a professional manner. Burrs/sharp edges must

be removed and exposed surfaces painted. The field cut should resemble a professionally fabricated cut as closely as possible.

● It is very important to cut both side channels the same length and make sure the cuts are square.

● Determine the bed and location of the field cut from the layout drawing(s).

6.2 9405 Belt on Slider Us the following procedure to field cut a 9405 bed.

1. Remove the pan from the frame.

2. Cut the frame to the desired length.

3. Cut the slider pan as shown in Figure 35.

4. Reassemble the slider pan to the frame.

Model 9405-9410 BOS and BOR Conveyor Installation Guide Field Cutting Conveyor Beds


Figure 35 Cutting a 9405 Slider Pan

Installation Guide Model 9405-9410 BOS and BOR Conveyor Supplemental Information


7 Supplemental Information

7.1 Taper Lock Bushings This is a generic procedure that applies to all taper lock bushings with setscrews.

Make sure that a Taper Lock bushing is not under belt tension when the bushing is being removed. Otherwise, Taper Lock bushing threads will be damaged, making the bushing unusable, and other equipment damage could occur.

7.1.1 Removal 1. Remove all screws holding the bushing(s) in place.

2. Insert screws in the bushing holes as indicated by a blackened circle (see Figure 36). Loosen the bushing by alternately tightening the screws.

Figure 36 Taper Lock Bushings

7.1.2 Replacement / Installation 1. Clean the shaft, bore of bushing, outside of bushing, and hub bore of all oil,

paint, and dirt, and file away any burrs.

2. Insert the bushing into the hub. Match the hole pattern, not the threaded holes (each completed hole will be threaded on one side only).

:INFO: If two bushings are used on the same component and shaft, fully tighten one bushing before working on the other.

Do not lubricate the bushing taper, bushing bore, hub taper, or the shaft. Doing so could result in breakage of the product.

Model 9405-9410 BOS and BOR Conveyor Installation Guide Supplemental Information


3. Lightly oil the setscrews, and thread them loosely into the half-threaded holes indicated by a clear circle within a circle (see Figure 36).

4. With the key on the shaft, position the assembly on the shaft, allowing for the small axial movement that occurs during the tightening procedure.

Stake the key behind the bushing by marking the key with a chisel. If the key goes through the bushing, repeat on the other side. Do not mar the shaft. Do not use worn hex key wrenches. Doing so might result in a loose assembly or might damage the screws.

5. Alternately and progressively torque the setscrews to the recommended

torque settings (see Table 5)

:INFO: When installing a bushing in sintered steel product (such as a sheave or coupling), follow the torque recommendations on the product hub if present.

Where bushings are used with lubricated products such as chains, gears, or grid couplings, be sure to seal all pathways (where lubrication could leak) with RTV or a similar material.

6. Without hitting the bushing directly with a hammer, dimple the face of the

bushing in four places using a drift punch or sleeve. Also dimple around the key as shown in Figure 37 to help lock the key in place.

Figure 37 Dimple the Bushing



Table 5 Taper Lock Bushing Torques

Bushing No. Torque (lb/in) Torque (lb/ft)

1008, 1108 1210, 1215, 1310 1610, 1615

55 175 175

4.6 14.6 14.6

2012 2517, 2525 3020, 3030

280 430 800

23.3 35.8 66.7

3535 4040 4545

1,000 1,700 2,450

83.3 141.7 204.2

5050 6050, 7060, 8065 10085, 120100

3,100 7,820 13,700

258.3 651.7 1,141.7

7. Repeat hammering and re-torque until the recommended torque no longer turns the setscrews.

The bushing must be square with the hub after installation is complete. Any deviation greatly weakens the bushing’s holding ability.

8. Re-inspect screw tightness with a torque wrench after initial run-in, and

periodically thereafter. Repeat steps 5, 6 and 7 if a bushing is loose.

9. Install all guards that were removed to gain access to the bushing.

Make sure all guards removed to gain access to the bushing have been re-installed before restarting the conveyor, or serious injury could result.



7.2 Bearing Setscrews and Cap Screws Torque Specs When replacing sprocket, sheave, and bearing collar setscrews, tighten to the setscrew torques listed in Table 6 using a torque wrench.

When replacing Dodge D-LOK mounted bearings and Sealmaster Skwezloc bearings, tighten the cap screws to the torque listed in Table 7 using a torque wrench:

Table 6 Bearing Setscrew Torques

Setscrews

Setscrew Thread Hex Wrench Size Torque Pound -Inches Pound - Feet

#10 3/32” 36 3.0 1/4” 1/8” 87 7.3 5/16” 5/32” 165 13.8 3/8” 3/16” 290 24.2 7/16” 7/32” 430 35.8 1/2” 1/4” 630 51.7 5/8” 5/16” 1270 105.8 Setscrew Thread (mm)

Hex Wrench Size (mm)

Torque (nm)

M6 3 7 M8 4 16 M10 5 28.5

Table 7 Bearing Cap Screw Torques

D-LOK and Skwezloc Cap Screws

Cap Screw Thread

Hex Wrench Size

Torx Wrench Size

Torque Pound - Inches Pound - Feet

#8 1/8” T-25 66 5.5 #10 5/32” T-27 86 7.2 1/4” 3/16” T-30 171 14.3 5/16” 1/4” T-45 380 31.2



:INFO: Skwezlock bearings use Torx cap screws.

When replacing such bearings, please also note the following:

● Clean the shaft and bearing bore thoroughly, as necessary.

● Be sure that the bearing is not on a worn section of the shaft.

● For tighter fits, tap the inner ring face only, but DO NOT hammer on the housing.

● The bearing outer ring OD is spherical and swivels in the housing to accommodate misalignment. Snug hold-down bolts, and use the shaft to swivel each bearing until the final position is in the center, with free movement top-to-bottom as well as side-to-side. Pass the shaft through both bearings without forcing. This prevents pre-loading of the bearings.

● If applicable, tighten hold-down bolts. Turn the shaft by hand.

:INFO: Resistance to turning should be the same as before full tightening of hold-down bolts.

● Replace any setscrews with knurled-cup screws with a locking patch.

● For setscrew-mounted bearings, tighten the setscrew alternately, using the appropriate hex wrench. Do not overtighten. Install the setscrew either by tightening the setscrew and backing it off 1/2 turn or by tightening until the setscrew meets the shaft or key, and complete the tightening with a torque wrench.

:INFO: Do not drill through the setscrew holes for spot drilling of the shaft.

● For eccentric collar-mounted bearings, slide the collar against the cam end of the inner race. Use a punch in the hole provided in the collar; tap the collar smartly in the direction of shaft rotation.

● For D-LOK and Skwezloc collar-mounted bearings, be sure the collar is square and tight against the shoulder on the inner ring. Tighten the cap screw using the appropriate hex wrench.

● For cap screw-mounted bearings, do not overtighten. Install the cap screw either by tightening and backing it off 1/2 turn or tighten until the cap screw is snug, and complete the tightening with a torque wrench.

● For expansion bearings (H-E Series), locate the inner unit in the housing to allow expansion in the desired direction before locking it to the shaft.

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