Bulletin: SVB-100

Date Issued: February, 1, 2005

Category: Procedural

Subject: Machine Adjustments to Restore Factory Settings

Machine Models: FEEDMASTER¨ Block Push Bottom Feeder, Top Feeder, Jumbo Bottom Feeder, and Jumbo Top Feeder

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Problem:

Correct machine operation depends on the proper adjustment of the lift assembly, block pusher, shingle gate and Top Feeder inverter. Over time, normal wear and tear of machine parts can cause these components to go out of adjustment, causing incorrect stack division, excessive amounts of waste sheets or skewing of material. Periodic adjustment to restore factory settings can prevent these problems, keep the machine operating properly and reduce operator intervention with the machine.

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Recommended Action:

Alliance Machine Systems International, LLC recommends checking the following items and making any necessary adjustments as part of your preventative maintenance program. Items 1-6 should be done monthly and item 7 should be done weekly.

1. Check that the shingle gate is leveled and û” above the Extendo conveyor belts. E-flute machines can be set as low as Å”.

2. Check that the lift assembly stops when it just contacts the red zero crush rollers on the block pusher.

3. Check that the lift conveyor is leveled side to side and front to back, and is even with the infeed or separation conveyor.

4. Check that the block pusher plate is leveled and at the correct height above the lift conveyor.

5. On Top Feeders, check that the inverter is leveled.

6. On Top Feeders, check the timing of the inverter squaring shoes.

7. Remove dust buildup from the hydraulic power unit cooling fan.

This service bulletin contains procedures for checking and adjusting the machine components listed above. These procedures will be included in FEEDMASTER¨ maintenance manuals for new machines. Always follow proper safety procedures when working on a machine.  If you are unsure about anything in the procedures, contact your supervisor or Alliance Customer Service at 888-768-2200, option 2 for assistance.

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Procedures:

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Check and adjust shingle gate height

The bottom of the shingle gate should be level and û” from the top of the Extendo belts when in its lowest position. E-flute machines can be set as low as Å”.  If it is too high or too low, the operator adjusted rich feed settings for shingling will be incorrect. If it is not level, board skews as it passes under the gate and can jam in the finishing machine hopper.

Use the following procedure to check and adjust the shingle gate height.

1. Run all material off the Extendo conveyor so that there is nothing to block the photo eyes and keep the shingle gate from lowering.
2. At the main operator station, manually lower the shingle gate to its lowest position.
3. Lock out the machine according to instructions in your operator manual.
4. Measure the distance from the bottom of the shingle gate to the top of the Extendo belts at both ends of the shingle gate. It should be û” at both ends (Å” for E-flute).  If the shingle gate is properly adjusted, remove the lockout and resume operation.



5. The shingle gate has mounting bolts and an adjustment jack bolt on both sides. If the shingle gate needs to be adjusted, loosen the mounting bolts, then adjust the jack bolt until the bottom of the plate is the proper distance from the Extendo belt. Spacers can be placed under the shingle gate plate to aid in adjustment.
6. Tighten all mounting bolts and make sure the Extendo conveyor is clear.
7. Remove the lockout and resume operation.

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Check and adjust lift assembly top of travel

The top limit of the lift assembly is set to a fixed position that determines how much material is left on the lift after the last block is pushed. Over time, the lift chains can stretch so that the lift stops short of its top limit. The lower lift level causes extra waste sheets to be left on the conveyor. Excessive chain stretch can also cause the lift to hit the floor, which should be corrected immediately.

Check and adjust as follows:

Manually raise the lift until it stops.  Visually check how close the lift is to the block pusher. For most applications, the lift assembly should stop just as it touches the red zero crush rollers on the block pusher. If the machine consistently runs thicker material such as double wall, or warped material, the lift assembly can be adjusted slightly lower to compensate. If the lift assembly falls short of the block pusher, lower it and adjust the lift chain adjustment bolts at the top front corners of the main frame on both sides. Adjustments must be made equally on both sides so that the lift assembly remains leveled. Repeat the previous two steps until the lift stops at the proper height.

If the chains cannot be adjusted enough to correct the problem, they must be replaced. All the lift chains should be replaced at the same time to prevent uneven wear from occurring and causing the lift assembly to go out of adjustment.

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Check and adjust lift assembly leveling

 The lift assembly needs to be leveled both side to side and front to back for proper operation. Uneven stretching of the chains can cause it to go out of level. If the lift is not level side to side, blocks skew when they are pushed onto the Extendo or into the inverter on top feeders. If it is not level front to back, trailing sheets are left, which places a bigger load on the shingle gate and causes increases wear of the Extendo belts. In extreme cases, narrow loads are more likely to tip if the lift is not level.

1. Lower the lift to the bottom limit.
2. Lock out the machine according to your operator manual.
3. Use a level to check that the lift is level from side to side, and level from front to back. Also place a 6’-8’ straight edge across the lift conveyor and infeed conveyor to make sure that they are level with each other.
4. Adjustment bolts are located at all four corners of the lift, at the bottom of each chain. Adjust one or more as required to level the lift. Maintain the 12” TOR height of the lift.



5. Repeat the previous two steps until the lift is level in all directions.
6. Remove the lockout and resume operation.

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Check and adjust block pusher plate position

The block pusher plate is set at a fixed position above the lift conveyor at its bottom limit. This position is used to calculate stack division for block pushing. If it is out of position, stacks are not divided properly into blocks and the waste sheet system does not operate correctly. The top of stack photo eye is also used to calculate stack division by sensing the top of the stack as it is lifted.

If the plate is not vertical and leveled, trailing sheets can be left on the lift or material is skewed. The plate does not usually require adjustment unless cam followers have been replaced or adjusted or the plate has been moved from its original factory setting.

Before measuring the block pusher height or making any adjustments, make sure that the lift assembly is properly adjusted. Then proceed as follows:

Make sure that the pusher plate cylinders are retracted except for the 2” cylinder, which is extended for normal operation. If the machine has raiseable block pusher for tall stacks, it should be lowered to the full down position. Lower the lift assembly to the full down position. Lock out the machine according the instructions in your operator manual. Place a level on the front face of the block pusher plate to make sure that it is leveled vertically. If the block pusher plate is not vertical, it is usually because the cam followers at the ends of the block pusher cross bar are worn. There are four cam followers on each side of the cross bar. Replace them as needed to level the plate.

6. Repeat the previous two steps until the front face of the block pusher plate is vertical.

7. Measure the distance from the top of the lift conveyor to the bottom edge of the pusher plate at both ends of the plate. The correct block pusher height is listed on the table below, along with the correct height of the top of stack photo eye. Note: For correct measurement, make sure that the block pusher plate cylinders are retracted, except for the 2” cylinder.

 

If the plate is not at the correct height above the lift, loosen the four mounting bolts, which can be accessed through a hole in the front of the plate. Move the plate up or down as required and retighten the mounting bolts. Repeat the previous two steps until the block pusher is at the correct height above the lift assembly. Remove the lockout and resume operation.

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Check and adjust top feeder inverter adjustments

Top feeders and jumbo top feeders have an inverter that accepts blocks from the block pusher, turns them over and places them on the Extendo conveyor. The inverter is supported by a crossover chain that can stretch over time and cause the inverter to be out of level. This can cause blocks to jam when they are pushed into the inverter.

1. Lower the inverter to the full down position.
2. Lock out the machine according the instructions in your operator manual.
3. Place a level across the inverter to make sure it is leveled from side to side.
4. If the inverter is not level, tighten the crossover chain on either side.
5. Repeat the previous two steps until the inverter is leveled.

6. Remove the lockout and resume operation.

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Check top feeder inverter squaring shoe timing

The squaring shoes in the top feeder inverter tamp the material square as the inverter rotates. In order to work effectively, they must be timed properly with the inverter rotation. If the squaring shoes tamp too soon, the bottom sheet in the block drags on the infeed belt and is crushed. If they tamp too late, the motion of the inverter skews the material in the direction of flow.

Incorrect timing indicates that there is a mechanical problem that needs to be resolved. Observe the squaring shoes as the inverter rotates. When they are timed correctly, the squaring shoes are against the material when it reaches the midpoint of its rotation. If they tamp at the wrong time, it could be due to the following:

• Binding of the inverter rotation motor or the squaring shoes
• Incorrect motor speed
• Incorrect position of the home sensor for rotation. It should be set so that the inverter is 1¡ or 2¡ above level when it is in the upper position.
• Inverter rotation is too fast or too slow.

The 180¡ rotation of the inverter should take approximately 3 seconds. Rotation speed can be adjusted using the flow control for the inverter rotation valve on the two-station hydraulic manifold. The flow control on one side adjusts the forward rotation, and the flow control on the other side adjusts reverse rotation. To adjust either one, loosen the set screw and turn the flow control. Retighten the set screw when adjustment is complete.

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Clean dust from hydraulic power unit cooling fan

Dust buildup reduces the effectiveness of the cooling fan on the hydraulic power unit, increasing the likelihood of overheating. Once a week, turn off the hydraulic power unit and blow compressed air through the cooling fins to remove dust. Wear safety glasses and use an air gun regulated at 30 psi.

If there is already an accumulation of dust, remove the fan assembly and clean out as follows:

1. Lock out the machine according the instructions in your operator manual.
2. Remove the bolts to the fan cover.
3. Remove the motor mount bolts and remove the fan assembly from the hydraulic power unit.
4. Vacuum the dust from the inside of the cooling unit.
5. Replace the fan assembly and fan cover.
6. Remove the lockout and resume operation.

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