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.

Torquing and Match Marking

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

Torquing and Match Marking

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.

Torquing and Match Marking

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.

Torquing and Match Marking

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.

Torquing and Match Marking

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.

Torquing and Match Marking

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.

Torquing and Match Marking

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.

Torquing and Match Marking

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

Torquing and Match Marking

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

Torquing and Match Marking

12

Torquing and Match Marking

13

Torquing and Match Marking

14

Torquing and Match Marking

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

Bolts and Bolt Length

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

Bolts and Bolt Length

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

Bolts and Bolt Length

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

Bolts and Bolt Length

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

Washers, Nuts, and Fasteners

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 LOCTITE

Torqueing.

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

Washers, Nuts, and Fasteners

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

Here's a few more examples of

Bolts with Flat and Lock Washers
Mounted through Slots

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Washers, Nuts, and Fasteners

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

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
Nut, there isn't room on the Stud for a
full nut.

24

All take-up bolts will have a light coating

of Anti-seize applied, not belt tracking
bolts.

Washers, Nuts, and Fasteners

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

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

Washers, Nuts, and Fasteners

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

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

Washers, Nuts, and Fasteners

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.

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Washers, Nuts, and Fasteners

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.

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Clamping and Fastening

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.

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Clamping and Fastening

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

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Clamping and Fastening

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.

Air Fittings

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

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.

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Jam Nuts and Jack Bolts

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 2 Full Nuts and 2 Flat Washers on the Bolt. After tracking
the belt, install a thin Jam Nut on the end and Jam it tight,

Use Full Nuts to Jam the Adjustment Bolt in

this application. The Bolt is used for Adjustment,
the 4 Slide Mount bolts are locking the chain
tension.

36

Jam Nuts and Jack Bolts

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

Jam Nuts and Jack Bolts

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,

There isn't enough room to put a full sized nut
on the adjustment bolt and still be able to adjust it.

This Bolt is short for a reason, there isn't clearance

for the Threaded Roller Shaft for farther adjustment.
It has the Jam Nut on the Back Side. This has not been
adjusted as of yet, there is no tension on it.

38

Jam Nuts and Jack Bolts

Belt Tracking, Threaded Roller Shaft and Adjustment Bolt.

Take-up Belt Drive Adjustment

This is the most common Roller Adjustment

Bolt and Jam Nut configuration, a flat washer
under the bolt head and a Jam Nut on the back
side of the roller shaft. If you put the Jam Nut
on the other side of the roller shaft, you
cant adjust the Roller.

Make sure the Take-up Bolt is long enough

to adjust for the Belt. Install the Jam Nut on
bolt head side and a flat washer under the
bolt head. Once the Belt is adjusted, lock
the Jam Nut.

39

Jam Nuts and Jack Bolts

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
Conduit
Size
1 1/4
1 1/4
1 1/4
1
3/4

Static
Radius
150 MM
150 MM
150 MM
120 MM
90 MM

Dynamic
Radius
240 MM
240 MM
240 MM
200 MM
160 MM

3/4
1/2
3/8

90 MM
75 MM
60 MM

160 MM
125 MM
100 MM

Olflex Cable
Cable
Static Dynamic
Size
Radius
Radius
120 MM 180 MM
4/4
6/4
88 MM 132 MM
8/4
72 MM 108 MM
10/4
60 MM
90 MM
12/4
48 MM
72 MM
14/4
10 MM
60 MM
16/4
8 MM
48 MM

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Aeros (Black Plastic)

Olflex Cable
Conduit Static Dynamic Cable Static
Size
Radius Radius
Size
Radius
36 MM 80 MM 150 MM 4/4 120 MM
29 MM 50 MM 120 MM 6/4
88 MM
23 MM 45 MM 100 MM 8/4
72 MM
23 MM 45 MM 100 MM 10/4 60 MM
16.5 MM 35 MM 75 MM 12/4 48 MM
16.5 MM 35 MM 75 MM 14/4 10 MM
16.5 MM 35 MM 75 MM 16/4
8 MM

Dynamic
Radius
180 MM
132 MM
108 MM
90 MM
72 MM
60 MM
48 MM

Conduit and Hose Bend Radius

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

Inches

Note; The Radius is measured off the Inside of the bend.

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

Conduit and Hose Bend Radius

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
Black
Black
Black
Black
Black
Blue
Blue
Blue
Blue
Yellow

Part #
1A-157-01
1A-151-01
1A-152-01
1A-166-01
1A-159-01
1B-158-07
1A-159-07
1A-160-07
1A-161-07
1A-152-08

Hose Size

Radius "
1/8
1/4
1/4
1/2
3/8
7/8
1/2
12.7M 1 1/8
8MM
3/4
6MM
1/2
8MM
3/4
10MM
7/8
15/32 12 MM
1/2
3/8
9.5MM
7/8

Radius MM
10 MM

19 MM
12.7MM
19 MM
22MM
28.6 MM

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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.

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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.
Take-up Bolt
Hollow Shaft Motor

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 parts
together. On all, the following installations, make sure the shafts are free of Oil, Paint, or Grease.
Bushing No.
1210, 1108
1210, 1215, 1310
1610, 1615
2012
2517, 2525
3020, 3030
3535
4040
4545
5050
6050, 7060, 8065
1085, 12010

Lb.-In
55
175
175
280
430
800
1000
1700
2450
3100
7820
13700

Nm
6,2
19,9
19,9
31,8
48,8
90,8
114
193
278
352
888
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 INFORMATION
Bush
Sym.

B.C.
Dia.

QT
JA
SH
SDS
SD
SK
SF
E
F

2,00
1,65
2,25
2,69
2,69
3,31
3,88
5,00
5,63

Installation Screws
Qty.
Size

2
3
3
3
3
3
3
3
3

1/4/-20
10-24
1/4
1/4
1/4
5/16
3/8
1/2
9/16

Screw
Torque
x 7/8
x1
x 1-3/8
x 1-3/8
x 1-7/8
x2
x2
x 2-3/4
x 3-5/8

90
54
108
108
108
180
360
720
900

This is a three piece held together with Hex Head Bolts.

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

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
To Mfg. Specs provided with Taper Lock

Taper-Lock Bushings

Pulley Taper Lock on the Block Pusher

Belt Adjuster.

Block Pusher Spur Gear Taper Lock

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

Washers. Apply Purple LOCTITE and
Torque to Manufacturers Specification
provided with the Taper Lock.
It Should be about 36 In Lbs.

After positioning on the Rack Gear, make sure the

Bolts have High Collar Split Lock Washers, apply
Blue LOCTITE and Torque to Manufacturers Spec
provided with the Taper Lock. It should be about
10 Ft Lbs.

48

Taper-Lock Bushings

Sprocket Taper Lock with 2 Set Screws

on the Block Pusher Motor.

Sprocket Taper Lock with 2 Set Screws

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

Bearings, Camfollowers & Grease

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

Bearings, Camfollowers & Grease

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

Bearings, Camfollowers & Grease

Shingle Gate Linear Bearings

Block Pusher Linear Bearings

SHCS and Split Ring Lock

Washer Mount Bolt

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.

54

Bearings, Camfollowers & Grease

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

Bearings, Camfollowers & Grease

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.

The Pillow Block Bearings are

typically mounted with the Set
Screws to the outside of the Shaft.

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.
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. It doesn't get dimpled.

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

56

Bearings, Camfollowers & Grease

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

Bearings, Camfollowers & Grease

Ultra Breaker Pop-up Roller Bearing

Shown in the Up, (Power On) Position

Shown in the Down, (Power off) Position

Make sure there is no

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.

58

Bearings, Camfollowers & Grease

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

Bearings, Camfollowers & Grease

Exceptions to this Standard

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

Bearings, Camfollowers & Grease

Exceptions to this Standard

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

Belt and Encoder Bearing, HSTF

Waste Kick Roller Bearing

Mod LM Conveyor Drive Pulley

61

Bearings, Camfollowers & Grease

Exceptions to this Standard

Ultra Breaker Platen Camfollowers

The Ultra Breaker Platen Up/Down Non-Eccentric CamFollowers 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

63

A0-10 Style Oil Cooler

Painting Parts and Protection

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 Paper

Walk-On Paper

64

Painting Parts and Protection

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

Painting Parts and Protection

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

66

Painting Parts and Protection

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

Painting Parts and Protection

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

Painting Parts and Protection

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

Painting Parts and Protection

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

be installed with a Flat Washer and
a Jam Nut with LOCTITE applied.
Do not Torque the Jam Nut, make
it sufficiently tight so it will not move.

The Airbag side of the Assembly

will be installed with a Bolt and Flat
Washer and no LOCTITE applied.
This side of the Airbag has Plastic
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.

Pre-made
Ethernet Cables

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.

72

Enclosure Wiring, Spares

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

Enclosure Wiring, Spares

Service Loops/Spare Wires in Enclosures

Route the wiring up and around through the Panduit,
where possible. Notice the Yellow wiring. This serves
as a service loop, it can be routed directly if need be.

The service loop in the Ultra Breaker Ops Station LockOut sensor wiring needs to be twice the distance from
the Sensor to the terminal.

Enclosure on Ultra Breaker

Ops Station on Ultra Breaker

74

Enclosure Wiring, Spares

Service Loops/Spare wires in Enclosures (HSTF)

Ultra Breaker Standing Enclosure.

The High Voltage Cables connect to the Left

Hand Side of the Enclosure, there are 6 of them
and they route to the front

These are the unused wires from several Photo Eyes.

They need to be as long as the Black Wire in the cable.
This wire may be needed if we have to switch from
Normally Open the Normally Closed. A Photo Eye

The Ultra Breaker Enclosure has a false bottom in it. The cables
in the bottom will have a service loop of 1-2 Ft, depending
Where the Cable is connected. They are Zip Tied to the Lower
Panel Cover.

cable will always have a wire not used, it will be

either white or black. Don't cut it off.

75

Enclosure Wiring, Spares

Ultra Breaker Standing Enclosure.

Complete Cable installation, with Zip Ties to the Lower Cover.

Each Cable has a service loop of 1-2 feet. It will fill the
Lower portion of the Enclosure, thats what it's for.

This is with the Lower Panel installed.

76

Enclosure Wiring, Spares

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

All Large Holes will be

lined with split rubber
hose.
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 Exceptions
When 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.

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

Exceptions to this Standard

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.

The tape is just wrapped around the

padding, not on the machine surface.

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.

83

Shipping Standards

Securing of loose Items.

Shingle Gate Hold down roller, padded and secured.

Padded and Zip Tied to the Main Frame expanded

metal.

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.

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 pulled tight and Shrink Wrap is

tight on the corners
Zip Ties holding the Padding

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.

86

Shipping Standards

Conveyor Systems

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.

OSB Board on Conveyor

Belts and Scrap Belting
under Metal Banding.

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.

87

Shipping Standards

Leveling Jack Bolts,

Attaching Parts, Padded and

secured to the Main Frame.
Zip Ties and Bolts are used
here.

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.

88

Shipping Standards

Stacking Conveyor Systems

The upper conveyor is bolted to skids that are

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

The Lower conveyor will be bolted

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.

89

Shipping Standards

Shipping Frames
The Doors are supported and Secured to the Shipping
Frame. The Wiring is supported, off the Floor.

Tilt Frame securely bolted

to the Shipping Frame.

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.

90

Shipping Standards

Shrink Wrapping

Shrink Wrap, Corrugated Sheets and more Shrink Wrap.

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.

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.

Raise the Lift Transducer, don't
leave it sticking down.

On Pit Model Feedmax Machines

On all Feedmax Machines

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.

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