This is a property of type Text.
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It is vital for correct function that all the shown components are thoroughly degreased before assembly .
To do this, wash all parts with FE10 solvent spray and dry with airline.
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<div class="icon-instructions-text">...Ensure your work area is very clean and free from Dust/swarf. Use a clean cloth or paper towel to lay on your bench to ensure parts remain clean once washed</div>
</div><br/> +, Once all fitted rotation of assembly in housing should be checked . Rotation should be smooth and consistent with no high spots or lumps +, 1 Spacer should be able to move in the directions shown, but it must have resistance, such as it wont fall under its own weight .
2 If the spacer is to tight, the drive dog spacer will need reducing in size slightly to correct the fit. To do this, disassemble the parts by removing the spiral pin, bevel gear and first bearing and releasing the drive dog spacer.
3 With a 240 grit sanding pad on a flat surface, use circular motions to lightly relief the face indicated by a minute amount. Repeat on both sides. Remember to only take a small amount of, generally 4 rotations will suffice for safe adjustment
4 Reassemble and check fit of spacer. If its still to tight, repeat above step
5 If the spacer is to loose, the spiral pin may have distorted on assembly. To adjust in this instance, the following is required. Use the press and place the assembly vertically , and using the press apply pressure in the direction shown to help centralise the roll pin
6 If the bearings do not require bearing fit, move to next step. If bearing fit was loose, disassemble components and reassemble with smears of bearing fit for bearings +, …
R0000728 and R0000729 are mirror images to each other
Please inspect pictures to clarify and confirm correct hand to be built
(Supplied unit to be refurbished will always be rebuilt as the same hand ) +, Always use Loctite 243 on all fasteners fitted unless stated different
All bearings should be an acceptable fit, with Loctite 641 and FE10 solvent used if required
All fasteners should be marked once finalised +, 1 Check fit of Motor drive gear D0007873 onto B0000335 motor. Ensure fit is smooth and pinion can be fitted by hand.
2 If gear does not fit onto spindle by hand, remove key from motor shaft and
* Check motor gear fits on shaft with no key present. If not rework bore of motor gear to ensure correct fitment
* Check key passes through motor gear keyway . If not rework keyway until key passes through by hand
* Re fit key and check motor gear now fits by hand onto motor shaft
3 Set motor pinion flush to top of shaft and secure with 2 off M6 x 10 KCP grubscrews and Loctite 243. Ensure these are fully tightened +, …
Always use Loctite 243 on all fasteners fitted unless stated different
All bearings should be an acceptable fit, with Loctite 641 and FE10 solvent used if required
All fasteners should be marked once finalised +, Ensure that keyway B0000041 passes through bevel gear D0007867.
Fit key to shaft
Fit Pinion gear to shaft
Secure with M5x16 socket cap and D0007721 washer. Do not use adhesive at this point . Do not fit shims at this point +, Check backlash present by the following steps
1 Insert 4mm key into fastener shown and use to stop rotation of vertical shaft
2 Rock spindle clockwise and anti clockwise to gauge backlash present
Ideal backlash is 1mm movement in rotation of spindle (2) +, …
1 Use FE10 solvent to wash parts shown to remove residual grease and contaminants
2 Thoroughly dry with compressed air line gun +, Fit 28mm internal circlips to pulley +, 1 Apply Match head size drops to outer face of one bearing, smear around outer surface with finger and press into bore using bearing press
2 Repeat for second bearing
3 Remove any excess bearing fit with a rag from front faces +, …
All bolts to have Loctite 243 adhesive applied unless otherwise stated
All Threaded Pneumatic connections to have Loctite 570 applied
All bolts to be pen marked once adhesive applied and correct tension added +, Fit D0004147E Turntable Shaft Mk5 to B0001087 Angular Contact Bearing 70 I/D 125 O/D 24 Long x 1 as shown
If fit is loose, use loctite 641, if fit is tight inspect parts to drawings +, '''<s>PICTURES REQUIRED</s>'''
Identify larger diameter outer cage of bearing assembly B0000028 Thrust Bearing 140 I/D 180 O/D 31 Long (FAG)
This can be done easily by using the D0004320E Thrust Bearing Housing Mk5 as a reference. One outer cage will easily fit into the housing, and 1 will not.
Clean then heat the bearing housing to expand, and then fit the larger outer bearing cage using loctite 641 . Ensure cage is sitting correctly on the bottom of the thrust housing +, …
All bolts to have Loctite 243 adhesive applied unless otherwise stated
All Threaded Pneumatic connections to have Loctite 570 applied
All bolts to be pen marked once adhesive applied and correct tension added +, 1 Use 8mm hand reamer to clean holes indicated in D0004033E Alignment Disc Mk5
2 Attach smaller bearing outer cage to disc using press
3 Use 8mm hand reamer to clean indicated holes on D0004019E Turntable Mk5 (5334E) +, 1 Fit bearing cage from B0000028 Thrust Bearing 140 I/D 180 O/D 31 Long (FAG), Apply more grease then position assembly shown on top and visually align 8mm reamed holes
2 Position D0004019E Turntable Mk5 as shown. Ensure hard stop is in centre position
All 8mm reamed holes should align through the 3 parts. Turntable shaft, alignment disc and turntable
3 Add 2 off m4 x 20 socket caps and tension lightly to indicated holes to fix together
4 Insert 4 off 8mm x 50mm hardened dowels to fix all three parts in correct alignment
5 Remove 2 off previously fitted M4 socket caps, apply adhesive and apply final tension
6 Add 4 off m14 x 60 socket caps and A form washers to finalise fixing of turntable plate
Check rotation once assembled . Movement should be smooooooth and consistent +, …
All bolts to have Loctite 243 adhesive applied unless otherwise stated
All Threaded Pneumatic connections to have Loctite 570 applied
All bolts to be pen marked once adhesive applied and correct tension added +, D0004015 Front Slider
D0004016 Rear Slider
1 Add M6 x 6 grubscrews to indicated holes, 4 off in total. Use Loctite 572 to seal grubscrews to blocks . Ensure grubscrews sit flush with face of block when fitted. Tap hole deeper with M6 tap to allow grubscrew to sit further in if not possible to achieve flush fitment .
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<div class="icon-instructions-text">...Always use an airline to remove internal swarf from blocks is tapping is required</div>
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2 Fit 4 off B0000033 Linear Bearing as shown. Ensure yellow face of bearing is fitted on the indicated faces.
Ensure when fitted that no ball chamber is visible on bearings
3 Fit 4 off M6 straight grease nipples to indicated points (2 per slider) Use loctite 572 to seal
<br/> +, Insert H0004630 Shaft 20mm: 345 Ejector Cross x 1 into D0004329 Rod End Plate (5304) as shown
Dimple in shaft is offset, when correctly fitted, shaft is equally protruding either end of block
Secure with M8 x 20 kcp grubscrew, ensuring dimple is entered by the grubscrew +, …
All bolts to have Loctite 243 adhesive applied unless otherwise stated
All Threaded Pneumatic connections to have Loctite 570 applied
All bolts to be pen marked once adhesive applied and correct tension added +, Fit 3 off saw cut sensors from electrical dept.
Ensure orientated as shown
Labelled as
X208
X209
X269
Use test box to set
X208 at home position. Cylinder contracted
X209 Saw cut out position. Cylinder extended, use air to lift head
X269 Saw mid switch . Set this in the middle of the 2 previous fitted sensors
<br/> +, Fit D0005628 Saw chute infill panel to H0004637 Offcut Chute
Use M6 x 10 pointed grubscrews in infill section to use as markers
Position as shown
Use M6 x 12 socket caps with M6 A form washers to fix +, …
Use Drill driver with pozi 2 attachment to fix D0000399 pusher flights to chain saddles H0007776. Use F0000249 fasteners to secure
No adhesive is required on these fixings
Attach 19 flights to each chain .
Do not fit chain connection link B0000056 +, Ensure B0000056 chain links and completed chains are stored together ready for installation. +
Rotary drive ring needs checking before fitment.
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#Check teeth for burrs, damage and debris. Use compressed air to clean all areas
#V edge should be checked for damage. Check entire circumference with fingers to identify any damage, lumps or high low spots
#Check drive ring has been countersunk in the shown area +, Check that D0007651faceplate holes indicated (1) are countersunk the same as holes indicated (2 ). If not , countersink to correct
3. Clean all holes with compressed air
Thoroughly clean faceplate with solvent +, Journal washers should be inspected to ensure all washers supplied are within tolerance .
Thickness of washer should not exceed 0.05mm difference between all washers supplied. Report any that are incorrect via NCR system +, …
All bolts must have Loctite 243 adhesive applied unless otherwise stated.
All bolts must be marked with pen once completed to indicate adhesive and correct tension has been applied +, D0003985 needs preparing before fitting
1 All back plates for the rotary trunking need to be checked for correct countersink depth. Any protrusion from main face will case energy chain failure
Check and if proud, use a countersink to increase depth +, Mounting bracket D0006240 needs fitting to D0003985
1 Measure position of bracket onto circular guard (291mm)
2 Use a pointed m5 grubscrew screwed into bracket hole indicated, hold in position on guard, and use hide hammer to transfer position mark
3 Drill to 6mm and fix bracket with m5x 16 cap head and large m5 washer
4 Drill 6mm through indicated hole
5 Fix with M5 x 16 countersink, large m5 washer and nyloc nut
6 This countersink bolt head must be flush to block. If proud, use a countersink bit to increase depth
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All bolts must have Loctite 243 adhesive applied unless otherwise stated.
All bolts must be marked with pen once completed to indicate adhesive and correct tension has been applied +, D0003985 needs preparing before fitting
1 All back plates for the rotary trunking need to be checked for correct countersink depth. Any protrusion from main face will case energy chain failure
Check and if proud, use a countersink to increase depth +, 1 Measure position of bracket onto circular guard (291mm)
2 Use a pointed m5 grubscrew screwed into bracket hole indicated, hold in position on guard, and use hide hammer to transfer position mark
3 Drill to 6mm and fix bracket with m5x 16 cap head and large m5 washer
4 Drill 6mm through indicated hole
5 Fix with M5 x 16 countersink, large m5 washer and nyloc nut
6 This countersink bolt head must be flush to block. If proud, use a countersink bit to increase depth +, …
The stroke assembly must be dismantled in the exact manner stated as many sections can only be removed once mating parts have been extracted
Please use the following steps accurately +, Remove M5 socket cap and washer and slide off blade guard
Blade guard to be reused +, use 24mm ring spanner and saw blade pin spanner to remove blade from assembly
Dispose of saw blade and M16 bolt
Keep M16 Washer and blade flange for rebuid +, …
All bolts to have Loctite 243 adhesive applied unless otherwise stated
All Threaded Pneumatic connections to have Loctite 570 applied
All bolts to be pen marked once adhesive applied and correct tension added +, Check the indicated area for correct fitment
There should be no gap present , check with feeler gauges
Tolerance 0.002"/0.05mm +, Pass to machine shop for alignment machining
Indicated faces required skimming to be true to each other +, …
All bolts to have Loctite 243 adhesive applied unless otherwise stated
All Threaded Pneumatic connections to have Loctite 570 applied
All bolts to be pen marked once adhesive applied and correct tension added +, Check fitment of D0004772 Outer Bearing Spacer into D0004026 Bearing Housing
Spacer should pass through bearing housing when aligned correctly .
Check for burrs on bearing if spacer doesn't pass through +, Check fitment of D0004030 Lock Ring onto D0004027 Saw Spindle
Lock ring should wind to base of thread by hand +, …
All bolts to have Loctite 243 adhesive applied unless otherwise stated
All Threaded Pneumatic connections to have Loctite 570 applied
All bolts to be pen marked once adhesive applied and correct tension added +, Use 16mm hand reamer to check sizing of bores in following parts
1 D0004545 Slide Support End x 2
2 D0004338 Slide Support Bar x 1
3 D0004337 Slide Bar Holder x 1 +, 1 Fit 2 off D0004545 Slide Support End and fix with M8 x 20 socket cap and M8 x 12 kcp grubscrew per side . Do not finalise fasteners
2 Align end plates as shown using straight edge , to set end plates flat to each other
3 Finalise fixings and recheck end plate position has been held with straight edge +, …
All bolts to have Loctite 243 adhesive applied unless otherwise stated
All Threaded Pneumatic connections to have Loctite 570 applied
All bolts to be pen marked once adhesive applied and correct tension added +, Check upstroke plate has helicoils fitted in indicated holes.
M8 thread will be present if they have, thread will be larger than M8 if they havent
Use workshop helicoil kit and add M8 x 1.5 od helicoils if not present +, 1 Mount cylinder bearing block and 2 off bearing block as indicated to D0004021 Upstroke Plate. Lightly secure with M6 x 25 socket caps and A form washers . Do not apply adhesive
2 Mount remaining bearing block as shown, incorporating D0004343 Lower Damper Bracket as shown . Use M6 x 25 socket caps, again do not apply adhesive or apply final tension +, …
Use Loctite 243 on all fasteners
Pen mark bolts when finalised +, 4 off
1 Lightly Fix D0007723 motor mount to bearings as shown . Use 8 off M6 x 12 socket caps to fix.
2 Use 0.05mm feeler gauge to check datum faces are in contact, if not remove and inspect parts
3 Finalise bolts
<br/> +, 4 off
1 Attach D0007600 cylinder mount using 2 off M5 x 20 socket caps
2 Attach lighty pre built cylinder assembly using 4 off M6 x 20 socket caps
3 Attach cylinder thread and adjust stroke of cylinder to achieve measurement of 28mm
4 Adhesive and lock off cylinder nut
5 Use clearance in indicated holes to achieve correct cylinder alignment . Stroke of cylinder should be free and consistent
6 Finalise all bolts
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M0000101 is not required for bench assembly , and will not be shown within the work instruction .
Ensure this part is issued with each assembled clacker +, D0008339 Gap Closer Arm x 1
D0008340 Gap Closer Base x 1
D0008496 Clacker Pins x 1
F0000185 M6 x 16 Hex set S/S x 1 +, Use ball pein hammer to locate D0008496 Clacker Pins into D0008340 Gap Closer Base as shown
Ensure pin does not go past indicated face +, …
M0000101 is not required for bench assembly , and will not be shown within the work instruction .
Ensure this part is issued with each assembled clacker +, D0003196 Dipper Arm ( Ecoline) x 1
D0003197 Dipper Base ( Ecoline) x 1
D0003894 Flapper pivot pin x 1
F0000185 M6 x 16 Hex set S/S x 1 +, Use ball pein hammer to locate D0003894 Flapper pivot pin into D0003197 Dipper Base as shown
Ensure pin does not go past indicated face +, …
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