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SERVICE BULLETIN

Bulletin: SVB 104A

Date Issued: May 6, 2004

Category: Design Improvement

Subject: Active-Trak pivot bolt replacement

Machine Models: All TEI 66" wide Bundle Breakers with serial numbers from P10126 to P10899

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Problem Recommended Action Procedure

Problem:

A Bundle Breaker operator recently reported finding a broken pivot bolt that rendered the Active-Trak mechanism inoperative. This machine had been in service for less than 2 years. To gain access and replace this part, maintenance personnel working underneath the machine unknowingly encountered an unsafe condition from heavy unstable structural parts when performing the repair.

The internal design of the Bundle Breaker feed table prevents easy access to inspect or replace this pivot bolt. Alliance is not aware of other similar reports of pivot bolt breakage, but we have incorporated the design change described below for all Bundle Breakers delivered in March 2004 and on. This change permits better access for improved maintenance.

The initial release of this service bulletin (dated Mar 26 2004) recommended an inspection and, if necessary, replacement of a broken pivot bolt with another pivot bolt of the same size.  This Revision A release recommends installation of larger-diameter shoulder bolts in place of the original shoulder bolts for improved reliability and operation.

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Recommended Action:

Alliance recommends that you replace the originally installed pivot bolts (2 locations) with larger replacement pivot bolts within 90 days after receipt of this service bulletin.

Alliance recommends that this modification be performed prior to performing any work that requires maintenance personnel to go underneath the Bundle Breaker

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Procedure:

  1. Raise and lockout platen assembly.

  1. De-energize and lock out the machine as described in the Operators Manual.

  1. Unlace the infeed table belt and outfeed table belt. To make replacing the conveyor belts easier, Alliance recommends attaching four narrow belts to one end of the unlaced belt.  These belts should remain threaded through the rollers on the underside of the conveyor.  Slide the belts far enough to expose the top flat surface of the frame assembly.  After the inspection or repair of the pivot bolt is finished, the four belts will make it much easier to reinstall the conveyor belt.

  1. Using the dimensions provided in Alliance drawing 1016690 Rev B (attached) locate and drill a 3” access hole in the top of the upstream and downstream frame assembly.

  1. While viewing through the access hole, slide the belt far enough so the belt does not cover the installed pivot bolt. This area typically fills full of corrugated dust.  The dust will need to be removed to see the bolt. See Fig 1 for details.

    2. WARNING – Do not crawl underneath the Bundle Breaker to inspect or repair potentially unstable parts without first installing workstands underneath the Bundle Breaker.   These parts may cause injury to personnel lying on the floor if workstands are not first installed.

  2. Removal and Replacement Procedure (Downstream).

    1. Be sure that pivot assembly is secure using either jack stands or straps.

    2. Remove the ¯3/8 jam nut from the underside of conveyor.

    3. Remove the shoulder bolt from active track pivot.  The bolt is accessed through new access hole in top of the conveyor frame.

    4. Using a ¯5/8 drill, drill out the ¯1/2 hole in the pivot frame to ¯5/8. 

    5. Using a ¯5/8 drill, drill out the 3/8-16 tapped hole in the support frame to ¯5/8.  This can be accomplished from above or below.

    6. Using a ¯5/8 x 1” long shoulder bolt (Alliance # 00X1670), add two ¯5/8 SAE washers (Alliance # 00X0105) and insert into the pivot frame and support frame.

    7. Add a 1/2” Washer (Alliance 00X0054) and a 1/2-13 Nylock Nut (Alliance # 00X0254) to bottom side of the pivot bolt and torque. (These parts may be obtained from the Alliance Spare Parts desk by calling 509-535-0356)

    8. Remove supports and re-install the belt, making sure the Active-Trak paddle is correctly installed in relation to the belt.

  3. Removal and Replacement Procedure (Upstream)

  1. Secure pivot assembly using straps secured around the pivot assembly and the support assembly.

  2. Remove photo eye cord (if equipped) and encoder cord from side of conveyor frame.

  3. Mark location, and remove four air lines from the air valve on the side of the main frame.

  4. Insert lifting eyes into four 3/8-16 holes in top of conveyor frame.  These lifting eyes can be made with two large washers welded to the top of a bolt.  Use straps and a boom truck or other suitable lifting device to apply tension to the conveyor frame.

  5. Remove six bolts on either side of conveyor frame.  Frame should be free to be lifted up. Lift frame 4-6 inches.  Insert stands or other devices to prevent frame from falling and provide a safe way to get under conveyor.

    • Follow the downstream removal and replacement procedure steps 6A-6G.
    • Remove safety stands.

  6. Lower frame back down to mainframe and reinstall six bolts.

  7. Reconnect parts per steps B & C above.

  8. Remove supports and re-install the belt, making sure the Active-Trak paddle is correctly installed in relation to the belt.

  1. Check for proper belt tension and machine operation per the Operator’s Manual prior to resuming production.

Please advise Alliance of any significant findings resulting from your inspection of the machine. Comments may be forwarded to Mr. Mike Thayer, Customer Service Manager, at mthayer@alliancellc.net.

Figure 1. Cross-section view of Bundle Breaker¨ feed table assembly
 
Figure 2. Cross-section view of shoulder bolt assembly

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