New 4 Bearing Screenbox Assembly's

Screenbox Shaft Assembly
Covers Screenboxes
8x4, & 11x5
Issue 02EG
17/09/99
Screenbox shaft assembly
Page 1
FIG. 01
1. Clean the bearing housing surface on the screenbox, Lh/Rh, of any paint, rust or weld
splatter, (FIG.01.)
FIG. 02 FIG. 03
2. Clean the bearing housings, bottom (FIG.02) and the bearing housing caps (FIG.03) of
any paint, rust or weld splatter.
Face up Face down FIG. 04
3. Put four Lip seals, (2 per housing,) on a clean surface, noting to place two face up and two
face down (FIG.04.) For all Lip seal sizes of the various screenboxes refer to page 29.
Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Issue 02EG
17/09/99
Page 2
FIG. 05 FIG. 06
4. Fit the two lip seals, (FIG.05,) to the bottom of the bearing housings, Note: seals are face
up. Using a steel hammer tap the seals evenly into place, (FIG.06.)
FIG. 07
5. Fit the two lip seals, to the top of the bearing housing caps, and tap the seals evenly into
place, (FIG.07) using a steel hammer.
Note: seals are face down and Felt seals, should be soaked in oil before fitting.
FIG. 08
6. Fit grease nipples, (FIG.08) one per housing, to the bearing housings and tighten.

Issue 02EG
17/09/99
Page 3
FIG. 09
7. Place a piece of paper over the housing and tap out 1/4 of the outline of the housing,
(FIG.09.) Also mark the holes and make two or three pieces. These pieces of paper will
only be used as a shim should the housing fail to tolerance correctly, once fitted.
FIG. 10
8. Smear the two lip seals, of the bearing housings, (FIG.10) with grease, to allow for ease
of shaft fitting.
FIG. 11 FIG. 12
9. Fit all the bolts (B,) (hardness 10.9) into the screenbox, drive side only, (FIG.11.)
Note: hardened washers (W,) are fitted to the back of the bolts before they are pushed
through. Ensure washers correct way round, rough edge to the screenbox, (FIG.12.)

Issue 02EG
17/09/99
Page 4
FIG. 13
10. Fit gasket, (FIG.13,) over the bolts.
FIG. 14
11. Fit the bearing housing, (FIG.14) over the bolts, drive side only.
Note: Ensure grease nipple (G,) is at 7 o’clock.
B FIG. 15
12. Fit new spring washers and locknuts. Tighten all bolts evenly and always opposite to each
other, ie. 12-6, 3-9 etc. Torque all bolts evenly and always opposite to each other, ie. 12-6,
3-9 etc.to the correct value. Also torque the pipeunit bolts (B,) to the same value.
Note: For correct torque values, for the various screenboxes refer to page 28.

Issue 02EG
17/09/99
Page 5
FIG. 16
13. Using thinners and a clean cloth, wipe the inside of the bearing housing, (FIG.16.)
FIG. 17
RSR
14. Place an internal bore guage, inside the reference setting ring (RSR,) and set to zero,
(FIG.17.)
This reference setting ring is not used in the screenbox set-up and is a guide used
to set the internal bore gauge.

Issue 02EG
17/09/99
Page 6
FIG. 18
FIG. 19
15. Place the internal guage inside the bearing housing and check the tolerance, at 12-6,
(FIG.18) and 3-9, (FIG.19.) If the tolerances are off, the shim(s) you made earlier, can be
used. Remove the housing and place the shim in the correct position, depending on which
side of the housing is off.
Note: For correct tolerance values, for the various screenboxes refer to page 27.
FIG. 20
16. Retrieve the screenbox shaft and thoroughly wipe down with thinners and a clean cloth,
(FIG.20.) A light emery cloth can be used to remove any burrs or hardened dirt.

Issue 02EG
17/09/99
Page 7
FIG. 21
17. Check the tolerances on the shaft, (FIG.21.)

Note: For correct screen shaft tolerance values, for the various shafts refer to page 27.
FIG. 22
18. Fit the shaft slowly, from the idle side of the screenbox, (FIG.22.) Take care not to
damage the seal at the opposite side and ensure correct end is fitted.
Keyway end of shaft should be at the drive side.
B
FIG. 23
19. Fit all the bolts (B,) (hardness 10.9) into the screenbox idle side, (FIG.23.)
Note: hardened washers are fitted to the back of the bolts before they are pushed
through. Ensure washers correct way round, rough edge to the screenbox.
20. Fit the gasket and retrieve the remaining bearing housing. Fit housing over the bolts.
Refer to (FIG.13 and FIG.14.)

Issue 02EG
17/09/99
Page 8
FIG. 24 FIG. 25
21. Fit new spring washers and locknuts. Tighten all bolts evenly and always opposite to each
other, ie. 12-6, 3-9 etc. Torque all bolts evenly and always opposite to each other, ie. 12-6,
3-9 etc.to the correct value, (FIG.24.) Also torque the pipeunit bolts to the same value,
(FIG.25.)
Note: For correct torque values, for the various screenboxes refer to page 28.
22. Using thinners and a clean cloth, wipe the inside of the bearing housing, thoroughly.
23. Place the internal bore guage inside the reference setting ring and set to zero, (FIG.17.)
24. Place the internal bore guage inside the bearing housing and check the tolerance, at 12-6,
(FIG.18) and 3-9, (FIG.19.) If the tolerances are off, the shim(s) you made earlier, can be
used. Remove the housing and place the shim in the correct position, depending on which
side of the housing is off.
Note: For correct tolerance values, for the various screenboxes refer to page 27.

Issue 02EG
17/09/99
Page 9
Retrieve all the bearings required for the screenunit assembly, refer to page 30, for
correct bearing assembly type.
Bearings must be kept clean at all times. It is always easier to prevent bearings from becoming dirty
or rusty in the first place, than to clean them effectively afterwards
FIG. 27 FIG. 28
25. Degrease the bearing sleeve and nut, (FIG.27) and the bearing, (FIG.28) with a clean
cloth and thinners.
FIG. 29 FIG. 30
26. Using a clean surface, build the bearing. Place the sleeve first, then the bearing, (FIG.29.)
27. Place the locking ring over the sleeve, (FIG.30.)

Issue 02EG
17/09/99
Page 10
FIG. 31 FIG. 32
28. Smear grease on the bevelled side of the locking nut, (FIG.31) and screw it onto the
sleeve and against the locking ring (FIG.32.). Ensure that the lock nut and locking ring are both
orientated the correct way with the bevilled side beside the locking ring.
FIG. 33
29. Build the remaining three bearings, (FIG.33.)

Note: For correct bearing sizes, for the various screenboxes refer to page 30.

Issue 02EG
17/09/99
Page 11
Fitting bearing on drive side
FIG. 34
30. Place the inner bearing assembly over the shaft, on the drive side of the screenbox,
(FIG.34.). Using a steel hammer tap the bearing into position, inside the housing.
Hammer in the sequence of 12-6, 3-9 etc., so that the bearing goes on squarely.
FIG. 35 FIG. 36
31. Using a very blunt or square edged steel chisel and a steel hammer, tap the bearing fully
into place at the back of the bearing housing, (FIG.35 & 36.) Keep tapping the sleeve and
nut back into the housing, to prevent the bearing from tightening. Again hammer in the
sequence of 12-6, 3-9 etc., so that the bearing goes on squarely

Issue 02EG
17/09/99
Page 12
FIG. 37
32. Fit the bearing housing cap to the drive side. Using a measuring tape, measure from the
edge of the housing cap to the shoulder of the shaft, (FIG.37.)
33. Fit the bearing housing cap to the idle side. Using a measuring tape measure from the
edge of the housing cap to the shoulder of the shaft. With the two bearing housing caps in
position, centralise the screen shaft, so that there is equal projection of the shoulder.
34. At the drive side, tap the screen shaft back 3mm. This will compensate for when the
bearing, on the drive side, is tightened.
FIG. 38
35. Remove the bearing housing cap, on the drive side. Using a very blunt or square edged
steel chisel and a steel hammer, tighten the bearing until locking nut is flush with the
sleeve, (FIG.38.)

Issue 02EG
17/09/99
Page 13
FIG. 39
36. Using a copper hammer, shock the screen shaft by, firmly tapping the end of the shaft,
two or three times, (FIG.39.) Turn the shaft as you hit it. This will ensure that the rollers
are free in the bearing. Be careful not to damage the end of the shaft.
Feeler Guage
FIG. 40
37. Using a feeler guage, (for correct tolerance values refer to page 27,) push it in between
the roller and outer ring on the drive side. Ensure both rows of roller bearings are caught,
(FIG.40.) Rotate the shaft with your free hand to check the clearance.
NOTE: Check clearance of the top five rollers.
When checking the using the feeler guages, the tolerances quoted on page 27 will show two
settings, e.g 2-3 (0.001 inch). This means that when the 3 thousandth feeler guage is used there
should be no movement when trying to remove it from the bearing rings. When using the 2
thousandth feeler guage there should be some movement when trying to remove the feeler guage
38. At this stage the bearing should not require any adjustment if steps 14 and 15 have been
correctly completed

Issue 02EG
17/09/99
Page 14
FIG. 41 FIG. 42
39. Check the measurement (FIG.41.) Lock the bearing, by tapping the locking tab down into
the space on the locking nut (FIG.42.)
Note: It maybe necessary to slightly tighten the locking nut to align the tab. Never loosen
the locking nut to align the tab.
Fitting bearing on idle side
40. Remove the bearing housing cap and place the correct bearing assembly over the shaft, on
the floating side of the screenbox, (FIG.34.) Using a steel hammer tap the bearing into
position, inside the housing. Hammer in the sequence of 12-6, 3-9 etc., so that the bearing
goes on squarely.
Grease
hole
Bearing
FIG. 26
Groove
41. Using a very blunt or square edged steel chisel and a steel hammer, tap the bearing further
into place, (FIG.35.)
Note: Bearings need to be positioned with the groove aligned with the grease hole,
(FIG.26.)
Keep tapping the sleeve and nut back into the housing, to prevent the bearing from
tightening. Again hammer in the sequence of 12-6, 3-9 etc., so that the bearing goes on
squarely.

Issue 02EG
17/09/99
Page 15
42. Using a copper hammer, shock the screen shaft by firmly tapping the end of the shaft,
two or three times, (FIG.39.) Turn the shaft as you hit it. This will ensure that the rollers
are free in the bearing. Be careful not to damage the end of the shaft.
43. Using a feeler guage, (for correct tolerance values refer to page 27,) push it in between the
roller and outer ring. Ensure both rows of roller bearings are caught, (FIG.40.) Rotate the
shaft with your free hand to check the clearance.
NOTE: Check clearance of the top four rollers.
When checking the using the feeler guages, the tolerances quoted on page 27 will show two
settings, e.g 2-3 (0.001 inch). This means that when the 3 thousandth feeler guage is used there
should be no movement when trying to remove it from the bearing rings. When using the 2
thousandth feeler guage there should be some movement when trying to remove the feeler guage
45. At this stage the bearing should not require any adjustment if steps 14 and 15 have been
correctly completed
46. Lock the bearing, by tapping the locking tab down into the space on the locking nut
(FIG.42.)

Issue 02EG
17/09/99
Page 16
FIG. 43
47. Fit the bearing locating rings, (FIG.43,) (for correct number/size of locating rings for each
screenbox, refer to page 30.)
Note: locating rings are only fitted to the drive side housing.
48. Fit the bearing housing cap to the bearing housing, to ensure it fits correctly.
49. Remove the bearing housing cap from the bearing housing.
FIG. 44 FIG. 45
50. Using a grease gun, fill the bearing with grease until grease shows from the bearing.
FIG.44. Rotate the shaft as grease is inserted. Also pump a small quantity of grease along
the face of the bearing, FIG.45.
(N.B. Do not overfill the bearings with grease.)

Issue 02EG
17/09/99
Page 17
51. As in step 50, fill the floating bearing with grease until grease shows from the
bearing. FIG.44. Rotate the shaft as grease is inserted. Also pump a small quantity of
grease along the face of the bearing, FIG.45.
FIG. 46
52. Using a peice of emery cloth, clean both bearing housing caps inside and wipe down with
thinners and a clean cloth, FIG.46.
FIG. 47 FIG. 48
53. Smear both bearing housing caps with grease, FIG.47. Place a gasket sealer (Wurth -
Silicon RTV - red,) around both bearing housing caps, FIG.48. Apply some grease around
lipseal
Note: A gasket sealer, ie. Hermetite green, must be used as a sealer for all rinser boxes.
Hermite ‘Green’ heavy duty is a hard setting gasket compound.

- Temperature range -20oC to +300oC
- Resistant to petrol, oil, steam, water, fuel, acid and anti-freeze
- Quick drying

Issue 02EG
17/09/99
Page 18
FIG. 49
54. Fit the bearing housing cap to the bearing housing and tighten up evenly, (FIG.49.)
FIG. 50 FIG. 51
55. Using thinners and a clean cloth, wipe down the shaft and inside of the flywheel,
(FIG.50.) and (FIG.51.)
FIG. 52
56. Ensure the correct taperlock is fitted inside the flywheel and place the flywheel over the
screen shaft (FIG.52.)
Note: For correct taperlock sizes, for the various screenboxes refer to page 31.

Issue 02EG
17/09/99
Page 19
Taperlock Split
Line FIG. 53
57. Ensure the split in the taperlock is aligned to the line on the shaft, (FIG.53.)
Tighten the taperlock to the correct torque value, (FIG.53.)
Note: (For correct taperlock torque values, for the various flywheels refer to page 31.)
FIG. 54
58. Place the correct outer bearing assembly over the shaft, both sides of the screenbox,
(FIG.54.) Note: Ensure assembly is correct way round, sleeve and nut first

Issue 02EG
17/09/99
Page 20
FIG. 57 FIG. 58
59. Retrieve the two bases, of the plumber block bearing housings, (Fig.57) and place them
on a clean work surface. Open the housings and remove the seals, 8 off in total.
Using thinners and a clean cloth, throughly clean the insides of the housings.
60. Place two off the seals, into each base, (Fig.58.)
Smear each seal in turn with a small quantity of grease, (Fig.59.)
FIG. 59

Issue 02EG
17/09/99
Page 21
FIG. 60 FIG. 61
61. Retrieve the two plumber block bearing housing caps, (Fig.60) and place them on a clean
work surface.
Using thinners and a clean cloth, throughly clean the insides of each cap.
62. Place the remaining seals, into each cap, (Fig.60.)

Smear each seal in turn with a small quantity of grease, (Fig.61.)
FIG. 62
63. Fit the bases of both plumber blocks to the subframe and loosely secure with bolts,
M16 x 140 (Fig.62.)
Note: Place two washers (W,) on the top sides of the bearing bases. There is no washer
put on the under side.

Issue 02EG
17/09/99
Page 22
FIG. 64
68. Fig.64 shows a typical finished frame.
FIG. 65
69. Secure, 4 off, lifting chains to the screenunit, (FIG.65.)

Note: Shorten 2 off, the chains at one end of the screenunit, so it can be lifted with a
slant. This allows for easy fitting.
FIG. 66
70. Carefully lower the screenunit into the frame, (FIG.66.)

Issue 02EG
17/09/99
Page 23
FIG. 67
71. Take care to align the bearings, on both sides, into their outer housing, (FIG.67.)
Ensure the adjusting bolts are properly seated into the top of the spring plates, (FIG.63.)
Lower the screenunit fully into it’s position and remove the chains.
FIG. 68 FIG. 69
72. Centralise the screenunit in the subframe, (FIG.68 & FIG.69.) Repeat for each corner.
Note: Off-set the screenunit 3mm more to the idle side. This will be compensated for
when you tighten the drive side

Issue 02EG
17/09/99
Page 24
Plummer
Block
Spacer
FIG. 69A
Rubber Block
72A. Before tightening the plummer block to the sub frame, rotate the flywheel until it is directly
above the bearing. Measure the distance between the bottom of the bearing and the top
of the rubber block. Insert shim 3mm less than this measurement between the bearing and the
rubber block than tighten the bolts securing the bearing to the sub frame, e.g if the measurement
is 11mm use a 8mm spacer
FIG. 70
73. Loosen the bearing on the drive side, by tapping back the bearing sleeve, (FIG.70.)

Issue 02EG
17/09/99
Page 25
FIG. 71 FIG. 72
74. Fit the locating ring to the drive side of the screenunit.
For correct number/size of locating rings for each screenbox, refer to page 30.)
FIG. 73 FIG. 74
75. Recheck the measurement, to ensure screenunit is aligned squarely, (FIG.73.)
76. Slightly tighten the bearing on the drive side, by tapping the bearing sleeve, (FIG.74.)

Issue 02EG
17/09/99
Page 26
FIG. 75 FIG. 76
77. Shock the shaft by tapping the end of the bearing it and turning the flywheel at the same time,
(FIG.76.)
roller and outer ring. Ensure both rows of roller bearings are caught, (FIG.76.) Rotate the
shaft with your free hand to check the clearance.
NOTE: Check clearence of the top four rollers.
Tug on the feeler guage, if it is loose and can be pulled out easily, the bearing needs
another tightening. Refer to (FIG.74.) Tighten only a small turn at a time.
roller and outer ring. Ensure both rows of roller bearings are caught. Rotate the shaft with
your free hand to check the clearance.
NOTE: Check clearence of the top four rollers.
Tug on the feeler guage. There should be a little play in the bearings. If bearing needs
another tightening, refer to (FIG.74.) Tighten only a small turn at a time.
FIG. 77
80. Lock the bearing, by tapping the locking tab down into the space on the locking nut
(FIG.77.)

Issue 02EG
17/09/99
Page 27
FIG. 78 FIG. 79
81. Fill out the bottom half of the bearing housing with grease, (FIG 78 and 79,) but again
do not overfill. Also pump a small quantity of grease along the face of the bearing.
D
FIG. 80
82. Fit and tighten down the top half of the bearing housing, (FIG.80.)
Note: Housing can only be fitted one way, dowel (D) must match hole (H,) (FIG. 80.)
Ensure the seals are properly seated and the grease nipples are fitted. At this stage also
check that the grease nipple has been fitted to the inside bearing housing. Rotate the
flywheel to ensure that the shaft is free.
83. Going to the opposite side, the floating side, ensure bearing is in the middle of the
housing and repeat steps 77 to 82.
FIG.81
84. Shaft assembly is now complete, (FIG.81.)

Issue 02EG
17/09/99
Page 28

Issue 02EG
17/09/99
Page 29
Inside Bearing Housing Bolts
Length of
Screenbox size Bolting torque No. off
bolt
8x4 80mm 245Nm (180 lbf.ft.) 12

10 x 5 80mm 245Nm (180 lbf.ft.) 12
11 x 5 80mm 245Nm (180 lbf.ft.) 12
All bolts are 5/8" UNF. fine thread, 10.9 grade with hardened
washer on the inside and spring washer on the outside.

Issue 02EG
17/09/99
Page 30

Issue 02EG
17/09/99
Page 31

Issue 02EG
17/09/99
Page 32
Flywheel taperlock sizes
Screenbox size Taperlock size Part number
8x4 3020 - 3" 02050446

11 x 5 3020 - 3" 02050446
Procedures for Fitting

& Torque settings of couplings
1 Degrease shaft-using thinners, clean taper-locks and inside of couplings

with cloth that has been lightly dipped in thinners.
2 Insert taper-lock inside coupling lining up holes and fitting grub screws
loosely opposite each other.
3 Place key in shaft keyway, and locate coupling on shaft.
4 Hammer against large-end of bush, using a block or sleeve to prevent damage.
(To ensure that the taper-lock is seated squarely in the bore.
5 Tighten screws alternately to the recommended torque settings.
6 Fully fill 3rd hole with grease to prevent dirt getting in from the working environment.
Torque Settings
1610 Bush = 20(Nm) - 130 Coupling
2012 " = 30(Nm) - 150 "
2517 " = 50(Nm) - 180 " 6x4
3020 " = 90(Nm) - 230 " 8x4 & 10x5
3525 " = xx(Nm) - xxx " 10x5 Rinser

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Screenbox Shaft Assembly

Face up Face down FIG. 04

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

10. Fit gasket, (FIG.13,) over the bolts.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

17. Check the tolerances on the shaft, (FIG.21.)

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

27. Place the locking ring over the sleeve, (FIG.30.)

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

29. Build the remaining three bearings, (FIG.33.)

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Fitting bearing on drive side

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Fitting bearing on idle side

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Hermite ‘Green’ heavy duty is a hard setting gasket compound.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

62. Place the remaining seals, into each cap, (Fig.60.)

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

68. Fig.64 shows a typical finished frame.

69. Secure, 4 off, lifting chains to the screenunit, (FIG.65.)

70. Carefully lower the screenunit into the frame, (FIG.66.)

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

75. Recheck the measurement, to ensure screenunit is aligned squarely, (FIG.73.)

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

84. Shaft assembly is now complete, (FIG.81.)

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Inside Bearing Housing Bolts

8x4 80mm 245Nm (180 lbf.ft.) 12

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

Flywheel taperlock sizes

Screenbox size Taperlock size Part number

8x4 3020 - 3" 02050446

Procedures for Fitting

1 Degrease shaft-using thinners, clean taper-locks and inside of couplings

Powerscreen International Distribution Ltd., Dungannon, N.Ireland.

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