4060 Feeder Manual PDF

Issue 01 – Oct 1999 Title Page
4060
FEEDER
Operators and
Engineers Manual
Crabtree of Gateshead
Kingsway
Team Valley Trading Estate
Gateshead
Tyne & Wear
NE11 0SU
England
Telephone (0) 191 487 5071
Telefax (0) 191 487 3997
E-mail sales@crabpress.co.uk
Title Page Issue 01 - Oct 1999
This manual has been produced in order to provide operators and engineers with
recommended procedures and instructions for the installation, operation, maintaining and
servicing on the 4060 FEEDER.
Information contained within this manual is sufficient for normal operation, maintenance
and servicing and is correct at the date of publication. It must be appreciated, however,
that it has not been possible to include every setting and adjustment necessary for the
varied classes of stock used within the printing trade. Assistance and advice on any
problem arising from the operation of the Feeder can always be obtained from Crabtree
of Gateshead Service Department.
The policy of Crabtree of Gateshead is one of continued improvement to their products.
Instructions in this manual as well as machine design and construction may be subject to
changes in keeping with this policy. Crabtree of Gateshead therefore reserve the right to
make any changes without prior notice.
Amendments issued since last publication
Amendment No. Date Text affected
1 4-11-99 Section 2-2 Text updated.
2 29-11-99 Section 9-8 Added.
3 8-5-2000 Section 9-9 Added.
4 12-03-2001 Section 5-3 Main pushbutton station legend plate

updated.
 Crabtree of Gateshead 1999
NO COPYING IN ANY FORM WITHOUT WRITTEN PERMISSION FROM CRABTREE OF GATESHEAD

Issue 02 – Jan 1999 Contents
1 Purpose and Planning

Warranty
Health and Safety
Scope of use
Capabilities and performance data
Physical dimensions and weight
Required utilities
Power consumption
2 Handling, Installation, Storage and Transit

Responsibilities
Preparation of site and services
Reception and handling
Installation
Removal of preservative coating
Storage of equipment not to be used immediately
Connecting services
3 Technical Description
Introduction
Feeder Operation
4 Setting & Adjustment

Vacuum Valve
5 Operating Information
Feeder Controls
Loading the feeder
Operating the feeder
Emergency procedures
Shut-down procedures
Alarms
Fault diagnosis and correction
Page 0-1
Contents Issue 02 - Jan 1999
6 Maintenance
Maintenance schedule
Servicing schedule
Recommended lubricants
7 Disposal
Hazardous waste
8 Parts lists
Introduction
How to order parts
9 Options
Auxiliary Hoist
Motorised Conveyors
Scroll Sideguides
100mm Pile Offset Option
Operating Instructions for Intermediate Conveyor
Page 0-2
Issue 01 – Oct 1999 Purpose and Planning
Purpose and planning

Warranty 1-2
Health and safety 1-3
GENERAL 1-4
MOVING PARTS 1-4
HAZARDOUS SUBSTANCES 1-4
SHARP EDGES 1-4
HIGH PRESSURE FLUIDS 1-5
ELECTRICAL SHOCK 1-5
LIFTING EQUIPMENT 1-5
Scope of use 1-6
ELECTROMAGNETIC COMPATIBILITY 1-6
ELECTRICAL SUPPLY 1-6
AMBIENT AIR TEMPERATURE 1-7
HUMIDITY 1-7
ALTITUDE 1-7
Capabilities and performance data 1-8
Standard Production Speeds 1-8
Physical dimensions and weight 1-9
Required utilities 1-9
Power consumption 1-9
Page 1-1
Purpose and Planning Issue 01 - Oct 1999
Warranty
We undertake to repair or replace at our option, parts of our manufacture which, during
the period hereinafter defined, shall be found to be defective due either to faulty
workmanship or use of defective materials. This warranty shall be valid for a period of
12 calendar months from date of arrival of the goods at the Purchaser's premises or 14
calendar months from the date of notified availability for despatch, whichever of these
periods shall be the shorter.
This warranty is strictly subject to the following conditions:
(a) Unless otherwise agreed, installation and demonstration of the goods must have
been carried out by us, or under our supervision.
(b) The goods must have been correctly operated and adequately maintained.
(c) If we consider necessary, we may supply at our labour cost but excluding travel and
living expenses the services of one skilled engineer to assist in or supervise the
alleged defective part or parts but the Purchaser shall provide at his cost all the
necessary equipment and assistance including, but not limited to, labour for
dismantling and re-erection.
(d) Purchaser's materials provided for test purposes are at Purchaser's risk and expense.
(e) We shall accept no liability for damage from corrosive materials, incorrect solvents,
fluids or lubricants, incorrect or faulty power supply, or arising from the ingress of
foreign bodies or materials.
(f) Warranty claims must be made to us in writing within 14 days of the alleged defect
becoming apparent to the Purchaser. A full report on the defect shall be made and,
if required by us, the alleged defective part or parts shall be returned to our works at
the Purchaser's expense.
(g) In the case of goods not of our manufacture we shall pass on the manufacturer's
warranty, and any other indemnities given and shall not be liable for any greater
sum than we can recover under same.
(h) In the event of faulty workmanship on items or materials of Purchaser's supply
(other than for test purposes) our sole liability shall be to rectify same.
(i) Our warranty does not extend to either second hand goods or unless otherwise
agreed, goods manufactured to the purchaser's own drawings or specifications, or to
any equipment provided and fitted by the purchaser.
(j) Our warranty shall not be valid where repairs, modifications or alterations have been
carried out without our written agreement.
Save as mentioned in this clause all warranties conditions and representations where
express or implied by statute trade customer or otherwise and relating to the quality or
nature of the goods their condition or their life or wear or suitability for any particular
purpose of use under any specific conditions are hereby excluded notwithstanding that
the purchaser may have indicated that the goods are being bought for a particular
purpose.
We shall in no circumstances be liable to the Purchaser in contract tort or otherwise for
any direct or consequential damages loss or expense howsoever caused whether to the
Purchaser or to any other person or thing and whether arising directly or indirectly from
the defect and for the avoidance of doubt we shall not be liable for loss of profit, wastage
of goods, loss of press time or production, wastage of labour or any other loss or damage
whether or not of similar nature to the foregoing.
Page 1-2
Health and Safety

Before operating this equipment, read the Operators and Engineers Manual and become
familiar with it and the machine. Safe and efficient operation can only be achieved if the
machine is properly operated and maintained. Many accidents are caused by failure to
follow fundamental rules and precautions.
Common causes of accidents include:
Ÿ running the machine without the guards in place
Ÿ making adjustments while the machine is running
Ÿ reaching into the machine to clean, lubricate or adjust without first shutting off
power
Ÿ wearing clothes that can become entangled in the moving parts of the machine
Ÿ not concentrating when operating the machine
Ÿ allowing people to crowd around the machine when operating or maintaining
Ÿ poor communication between operators during make-ready
Ÿ cleaning moving parts while the machine is running
Ÿ wearing rings or watches when operating the machine
Ÿ allowing grease and oil to remain on platforms or on the floor around the machine
Ÿ failing to read and follow warnings and labels
Ÿ failing to maintain worm pins as highlighted in Section 6 Maintenance, Maintenance
Schedule.
The following words, found throughout this manual, alert you to potential dangerous
conditions to the operator, service personnel, or the equipment.
DANGER
This word warns of immediate hazards that will
result in severe personal injury or death.
WARNING
This word refers to a hazard or unsafe practice
that could result in severe personal injury or
death.
CAUTION
This word refers to a hazard or unsafe practice
that could result in minor personal injury or
product or property damage.
Page 1-3
GENERAL
All operations, including transport, installation, commissioning and periodic maintenance
must be carried out by skilled responsible technical personnel. Improper handling can
cause serious personal injury and damage to property.
The specific national, local and installation-specific regulations and requirements shall be
taken into account.
Warning signs affixed to the machine must, on all accounts, be observed and must never
be defaced or removed. Replacements can be obtained by contacting the Service
Department at Crabtree of Gateshead.
MOVING PARTS CAN CAUSE SEVERING, CRUSHING AND ENTANGLEMENT

Do not allow unauthorised or untrained personnel access to the machine.
Do not defeat or circumvent guards and protection devices.
When operating machinery do not wear jewellery, ties, belts or loose clothing. Long hair
must be kept under a hat or hair net.
Regularly check that safety devices and guards are in place and are working correctly.
Check that guards are replaced and secured if they have to be removed for maintenance.
When carrying out make-ready or maintenance ensure that a barrier is provided to
prevent access to exposed hazardous parts of the machine by unauthorised persons. Do
not allow people to ‘
crowd’around the machine and watch.
Communication is vital during make-ready. Ensure that operators can communicate
clearly and effectively when working together.
Test the functional operation of the emergency stop pushbuttons at the start of every
shift.
HAZARDOUS SUBSTANCES CAN CAUSE SKIN AND RESPIRATORY

IRRITATION
Ensure ventilation equipment is working correctly. Periodically check performance
against the design specification.
Containers for inks, varnishes and lacquers should be kept closed when not in use.
Store cleaning solvents in suitable closed containers. The containers should be labelled to
indicate that skin contact should be avoided.
Provide suitable lidded containers for the disposal of contaminated cleaning rags. The
containers should be labelled to indicate that skin contact should be avoided.
Wear impervious gloves and eye protection during operations where there is a risk of
contact with inks and solvents. Contaminated personal protective equipment should be
discarded and disposed after use.
Keep the machine clean and deal with spillages immediately.
Do not wash hands using abrasives or solvents.
SHARP EDGES CAN CAUSE SEVERING AND CUTTING

Wear cut-resistant gloves when handling metal stock.
Do not manually remove sheets moving on the conveyor sections of the machine.
Page 1-4
HIGH PRESSURE FLUIDS CAN CAUSE DAMAGE SEVERE PERSONAL

INJURY
Do not tamper with pressure or flow control devices.
Isolate and dissipate pneumatic energy before carrying out servicing or maintenance.
Test the functional operation of the emergency stop dump valve.
Wear impervious gloves and eye protection during operations where there is a risk of
contact with lubricating oils. Contaminated personal protective equipment should be
discarded and disposed after use.
ELECTRICAL SHOCK CAN CAUSE BURNS OR DEATH

Work on electrical equipment must only be carried out by qualified electricians.
Isolate and dissipate electrical energy before carrying out servicing or maintenance. Lock
the isolator to prevent re-energising.
After servicing or maintenance ensure that all connections are permanent and safe and
remove all dirt and moisture from terminal boxes.
LIFTING EQUIPMENT CAN TRAP AND CRUSH

Do not exceed the safe working load.
Do not use stock outside the specified parameters.
Periodically examine all load-bearing parts for signs of wear and fracture.
NOTE
Lifting chains may be subject to differing national legislation regarding periodic
examination.
Page 1-5
Scope of use
ELECTROMAGNETIC COMPATIBILITY
This machine is intended for use inside a factory in a heavy industrial environment. The
machine, when installed, is not connected to the public mains network but is connected
to an industrial distribution network with a dedicated distribution transformer. Typical
examples of heavy industrial environments where this machine is installed are industrial
printing factories, industrial manufacturing factories and industrial canning and packaging
factories.
The electromagnetic disturbances generated by this machine do not exceed a level that
could prevent other machinery from operating as intended. This machine shall continue
to operate as intended when exposed to electromagnetic disturbances at levels expected
at industrial locations. There may be a temporary loss of function to certain digital
readouts when they are exposed to an electrostatic air discharge of ± 8kV e.g. Sheet
Counter, Sheets Per Hour Indicator. These components will not be damaged and will
return to normal operation by removing and re-applying the machine power via the main
control panel isolator.
ELECTRICAL SUPPLY
The electrical equipment of the machine complies with EN 60204 Safety of machinery –
Electrical equipment of machines. It is designed to operate correctly under full load as
well as no load under the conditions of nominal supply specified below:
Voltage 90 … 110% nominal steady state voltage

Frequency 99 … 101% of nominal frequency continuously
98% … 102% short-time
Harmonics Harmonic distortion not to exceed 10% of the total r.m.s.
voltage between the live conductors for the sum of the 2nd
through 5th harmonic. An additional 2% max of the total
r.m.s. voltage between the live conductors for the sum of the
6th through 30th harmonic is permissible.
Voltage unbalance Neither the voltage of the negative sequence component nor
the voltage of the zero sequence component shall exceed
2% of the positive sequence component.
Voltage impulses Not to exceed 1.5ms in duration with a rise/fall time between
500ns and 500µs and a peak value not more than 200% of
the rated r.m.s. supply voltage.
Voltage interruption Supply interrupted or at zero voltage for not more than 3ms
at any random time in the supply cycle. There shall be more
than 1s between successive interruptions.
Voltage dips Voltage dips shall not exceed 20% of the peak voltage of the
supply for more than one cycle. There shall be more than 1s
between successive dips.
NOTE
Any doubts concerning the specification of the electrical supply should be relayed to the
Service Department at Crabtree of Gateshead.
Page 1-6
AMBIENT AIR TEMPERATURE

The machine is capable of operating correctly in an ambient air temperature between
+5°C and +35°C.
HUMIDITY
The machine is capable of operating correctly within a relative humidity range of 30% to
85% (non-condensing).
ALTITUDE
The machine is capable of operating correctly at altitudes up to 1000m above mean sea
level.
Page 1-7
Capabilities and performance data
Sheet size Max 1250× 1000 mm

normal range *1 Min 600 × 400 mm
Sheet thickness Max 1.00 mm
Steel *2 Min 0.13 mm
Sheet thickness Max 1.00 mm
Aluminium *2 Min 0.20mm
Sheet weight Max 5.0 Kg

Lateral sheet offset Max +/- 50 mm
from centreline *3
Scroll pitch Max 300 mm
Mechanical speed See *4 below
Weight on auxiliary Max 350Kg
Hoist bars (optional)
Weight of stock Max 5000 Kg
*1 The sheet length range of the Feeder can be changed to 500mm to 1100mm.
*2 Sheets heavier than 3Kg may have to be run at reduced speeds.
*3 Reduced at maximum sheet size.
*4 Production speeds
The 4060 Feeder is capable of high performance on a wide range of materials, including
tin-free steel, aluminium and heavy carton. It is designed to operate at a maximum
mechanical speed of 8000 sheets per hour, but production speeds are dependant on the
material to be fed, and also the design of the input stage of the downstream machine.
The following speeds are considered to be realistic when feeding into the Fastready
Coater, for example, in a normal production situation where sheet separation is not a
known problem.
Standard Production Speeds

For steel based materials, scroll sheet and rectangular plate:
For sheet weights up to 2.0 Kg, maximum speed 8000 sheets per hour.
For sheet weights between 2.0 and 3.5 Kg, maximum speed 7200 sheets per hour.
For sheet weights between 3.5 and 5.0 Kg, maximum speed 6500 sheets per hour.
For rectangular aluminium sheets, pre-sized or coated:
For sheets up to1000 mm wide, maximum speed 7200 sheets per hour.
For sheets over1000 mm wide, maximum speed 6000 sheets per hour.
For scroll aluminium sheet, the maximum speed is highly dependent on the scroll pattern
and sheet thickness, and in some cases the optimum production speed can be reduced.
Also, the sheet separation of virgin aluminium is particularly problematic. Please consult
Crabtree of Gateshead on these specific issues.
Page 1-8
Physical dimensions and weight

Approximate Net weight 1625 Kg
Approximate Gross weight (packed) 2420 Kg
Overall length) 2000 mm
Overall width 2100 mm
Overall height including air pumps 2200 mm
Pile height with pallet
(without conveyor rolls fitted to pile platform)
Fastready Coater application 715mm
Fastready Press application 650mm
Marquess Press application 780mm
F Coater application 715mm
Mailander 466 Coater application 715mm
LTG 4040 Coater application 715mm
LTG 122 Press application 715mm
Required utilities
Compressed air 6 bar
Three phase earth 400 V +/-10%
50Hz +/-0.1%
For other voltages consult Crabtree of Gateshead.
Power consumption
Compressed air 20 l/min
Pile hoist motor 4.1 KW
Creep motor 0.375 KW
Vacuum/Compressor pump 7.5 KW
Compressor pump 4.0 KW
kW power details are given for guidance only, and will vary with different voltages. In
specific cases consult Crabtree of Gateshead.
Page 1-9
THIS PAGE LEFT BLANK
Page 1-10
Issue 01 – Oct 1999 Handling, Installation, Storage and Transit
Handling, installation, storage and

transit
Responsibilities 2-2
CUSTOMER 2-2
CRABTREE OF GATESHEAD 2-2
Preparation of site and services 2-3
FOUNDATION 2-3
BUILDING ALTERATIONS 2-3
SERVICES 2-3
Reception and handling 2-4
Installation 2-5
UNPACKING 2-5
LIFTING & POSITIONING 2-6
Removal of preservative coating 2-7
Storage of equipment not to be used immediately 2-8
Connecting Services 2-8
ELECTRICAL 2-8
VACUUM/COMPRESSOR PUMP UNITS 2-9
Vacuum/Compressor Pump 2-9
Compressor Pump 2-9
INITIAL LUBRICATION 2-9
COMMISIONING CHECKS 2-9
Page 2-1
Handling, Installation, Storage and Transit Issue 01 - Oct 1999
Responsibilities
CUSTOMER
The customer is responsible for the following:
1 Providing details of their health and safety rules and regulations one calendar month
before the start of the installation
2 Local authority/state approval for the installation.
3 Environmental permits and testing.
4 Insurance for Crabtree of Gateshead Service Engineers during installation and
commissioning.
5 Office facilities for Crabtree of Gateshead Service Engineers, including a telephone
and fax.
6 Access to first aid facilities or medical assistance.
7 Lifting equipment with qualified operators.
8 The collection and disposal of installation rubbish and debris.
9 A dry storage area for the packing cases.
10 Materials required for testing and commissioning.
Crabtree of Gateshead are not responsible for any delays connected with the failure of
the customer to provide the above.
CRABTREE OF GATESHEAD
Crabtree of Gateshead are responsible for:
1 Supplying after sales service and spare parts for the installed equipment for a
minimum period of 10 years. This is from the date of purchase and at the prices
ruling at the time the service or parts are ordered.
2 Providing a detailed list of equipment that is required for the installation.
3 Carrying out the installation in accordance with the customer’
s health and safety
rules and regulations, if included in the contract price.
4 Keeping the installation area clean and tidy.
Page 2-2
Preparation of site and services
FOUNDATION
The customer is responsible for the design and design calculations of the foundation.
Necessary information with regard to stresses, forces etc. can be obtained from the
machine installation floor plan or from Crabtree of Gateshead Service Department. The
following considerations should be evaluated in the design stage:
1 There is sufficient stability to withstand possible shock forces due to machine
malfunctions.
2 The foundation should be designed so that vibrations are isolated and prevented
from reaching other parts of the building.
3 Adequate space is provided for inspection, maintenance, pipework, electrical cables
and trunking.
Foundations should be designed to meet the relevant standard.
The mounting area of the machine must be level and free from vibrations. For these
reasons a concrete foundation is recommended.
Before the installation can commence the site must be clear, all services must be
available and there must be adequate heating, lighting and ventilation.
BUILDING ALTERATIONS
The customer is responsible for all stackwork and ductwork and any associated
alterations and penetrations to the roof.
SERVICES
The customer is responsible for providing the services at the locations indicated on the
machine installation floor plan.
Page 2-3
Reception and handling

At despatch all machines are protected against corrosion and wrapped with a layer of
polythene. A layer of wax paper is placed over the machine to prevent the bubble and
barrier foil from sticking to the metal and painted surfaces. A layer of bubble wrap is
placed over the machine to prevent the foil barrier from busting during transit due to
contact with the sharp edges of the machine.
The machine is placed on a barrier foil groundsheet and bolted to the base of the packing
case. A barrier foil bag is placed over the machine and sealed and evacuated. The sides
of the case are built up around the machine, fastened with nails. Internal packing is
placed inside the case to provide additional stability and to prevent movement during
transit.
The packing cases are marked with the following information:
1 case number
2 net weight
3 gross weight
4 case dimensions
5 international handling symbols
‘
keep dry’ ‘
fragile’ ‘
centre of gravity’ ‘
slinging’
On receipt carefully move the packing cases into the storage area. Use the slinging and
fork truck markings to prevent damage to the packing cases. Cases can be overstored
with care.
CAUTION
Do not store packing cases more than two high.
Always store heavy cases at the bottom.
Page 2-4
Installation
The following checks are recommended before installation:
1 The foundation corresponds to the certified foundation drawing.
2 The erection site is clean.
3 The erection site is prepared for installation, e.g. channels have been provided for
services where necessary.
4 Access has been provided for inspection and maintenance.
Mark the centre line and any datum lines. Working from the packing case identification
list, position the packing cases close to the location where they will be erected.
UNPACKING
Before unpacking, check all numbered packing cases against the consignment list. If
packing cases show signs of external damage open immediately and check the contents.
Report damage immediately to Crabtree of Gateshead Service Department.
The packing cases are nailed together and can be unpacking using a ‘
jemmy’or a nail
remover.
Packing case side Internal packing
Nail remover Foil bag
Prise open the lid with the ‘

jemmy’
. Remove the lid with care and avoid contact with the
exposed nails. Remove all internal packing. Remove the packing case sides and ends.
Remove or make-safe protruding nails and store the packing cases in a suitable location.
Cut and remove the foil bag. At this stage do not remove the bubble wrap and wax
paper as these provide protection against dust. Unbolt the unit from the packing case
base.
Page 2-5
LIFTING & POSITIONING

Remove or make-safe protruding nails and store the packing case base in a suitable
location.
Lift the machine using suitable slings. For weight of the machine refer to Section 1
Purpose and Planning Physical dimensions and weight.
WARNING
Make sure that all slings and lifting equipment are
of adequate load carrying strength and have been
tested regularly.
Sling from the four eyebolts situated at the four corners of the feeder. Lift the machine
slowly and carefully, avoiding all violent movement and jerking.
Position the machine on a level, stable, floor foundation, aligning it with its associated
printing press or equipment and onto foundation bolts fixed into the floor. Level the
machine laterally and longitudinally with the aid of spirit levels and by placing suitable
packing supplied under the machine’ s feet. Tighten the foundation bolt nuts.
Page 2-6
Removal of preservative coating
WARNING
Marine pollutant. Disposal of used/contaminated
product must be in accordance with local and
national legislation. Do not empty into drains,
sewers or water courses.
All machines leave the factory of Crabtree of Gateshead with a preservative coating of
Rustilo DWX 33 applied to all exposed metal and ‘ blakodised’surfaces.
Rustillo DWX 33
Rustilo DWX 33 is a high quality soft film solvent deposited preservative that, on
evaporation of the solvent, leaves a powerful preservative film. This soft, greasy
preservative film prevents rust and provides good water displacement for a minimum of
12 months.
Rustilo DWX 33 should be removed using a petroleum solvent such as white spirit (CAS
No 64742-88-7). Metal surfaces coated with the preservative should be rubbed with a
cleaning rag impregnated with white spirit.
Page 2-7
Storage of equipment not to be used immediately
CAUTION
Exposed metal surfaces will rust. Check the
condition of the preservative coating. Wrap
polythene or wax paper around exposed metal
surfaces.
Special attention must be given to machines, assemblies and spare parts that are to be
stored for a long period of time before commissioning or use. In such cases the
machine, assembly or spare part should be stored indoors, in a dry room or building
where the temperature varies as little as possible.
Connecting Services
NOTE
The following refers to a standard Feeder.
ELECTRICAL
Connect the electrical supply to the machine’
s connection box. All wires can be identified
by numbered or international colour coded sleeves. A wiring diagram is supplied with
each machine.
Page 2-8
VACUUM/COMPRESSOR PUMP UNITS

Position of the pumps is on top of the feeder. The bolts for mounting the pump frame
should be fitted using a thread adhesive.
Connect the appropriate hose to the pumps as follows:
Vacuum/Compressor Pump
NOTE
Ensure that the connecting hose is perfectly clean and free from oil or foreign matter,
which could be drawn into the pump body.
1. Connect the 32mm bore pipe from the vacuum connection on the pump to the
vacuum inlet connection on the vacuum valve.
2. Connect the 19mm bore pipe from the pressure outlet on the pump manifold to the
vacuum valve pressure connection.
3. Connect the 25mm bore pipe from the pressure outlet on the pump to the pressure
connection on the pressure/vacuum distribution manifold attached to the mainframe tie
bar.
Compressor Pump
Connect the 32mm bore pipe from the pump pressure connection to the Male Tee
connector attached to the mainframe tie bar
NOTE
The pumps are uni-directional and must run in the direction of rotation shown by the
arrows on the top of the pump body.
WARNING
SERIOUS DAMAGE CAN BE CAUSED TO THE

ROTOR BLADES IF THE PUMPS RUN IN THE
WRONG DIRECTION FOR ANY LENGTH OF TIME.
INITIAL LUBRICATION
Check the oil level in the vari-drive gearbox if fitted through the oil sight window and
replenish as necessary. Ensure that each pile raise worm shaft bath is filled with grease.
For further details of lubrication and recommended lubricants refer Section 6
Maintenance, Servicing and Recommended lubricants.
COMMISSIONING CHECKS
The machine functions must be checked by operating the controls as listed in section 5
Operating Information, Feeder Controls. This will mean starting the machine, which is
linked with the feeder, and carrying out a trial run with sheets. During this trial run, the
sideguides must be adjusted for the size of sheet being handled, the feeder timed with
the machine being fed, dropwheels set and pile height control adjusted. For details of
these setting up procedures and adjustments refer to Section 4 Setting, Setting &
Adjustment.
The double sheet detector must also be set up during the trial run. Refer to the
Operating Instruction Handbook for details on setting the detector.
Page 2-9
Page 2-10
Issue 01 – Oct 1999 Technical Description
Technical description
Introduction 3-2
4060 FEEDER 3-2
Feeder Operation 3-4
PILE RAISING/ LOWERING EQUIPMENT 3-4
SEPARATING AND FORWARDING MECHANISM 3-6
SUCTION AND AIR SYSTEMS 3-7
DROPWHEELS AND FEED ROLLERS 3-7
SYNCHRONISED SIDEGUIDES 3-8
SHEET ADVANCE AND RETARD DEVICE 3-9
SHEET REJECT DEVICE 3-10
Page 3-1
Technical Description Issue 01 - Oct 1999
Introduction
4060 FEEDER
The Fastready Feeder is capable of a very high performance over a wide range of
materials including tinplate, tin-free steel, aluminium and heavy carton. The machine is
designed to operate up to a mechanical speed of 9,000 sheets per hour. This is far in
excess of normal requirements and will therefore easily feed a metal decorating press, for
example, at a mechanical speed of 6,000 sheets per hour, or coater at 8,000 sheets per
hour. Each feeder is tested in our works prior to despatch.
It has been specifically designed to progressively remove individual sheets from palletised
stock and feed them to a processing machine. Feeder control is such that the sheet feed
and depalletising cycle is fully automatic. Re-loading the feeder with full pallets is
normally from the rear, although frame design is such that side loading is as readily
effected.
Single sheet feeding is assured by means of a double sheet detector. In operation the
sheets are fed between a pair of sensing heads which are set to monitor the thickness of
sheet passing between them. When a thickness of sheet exceeds this setting, e.g. two
sheets are fed through, a signal from the detector unit initiates a sheet reject mechanism
and linkage which diverts the sheet/s onto a reject tray.
The mechanical drive for feeder operation is taken from the machine it is feeding through
a vari-drive gearbox incorporating an adjustable differential timing facility. This facility
enables the positioning of the tail of the sheet to be adjusted to suit the forwarding dogs
of the associated machine whilst the feeder is operating.
The machine frame comprises a four leg structure suitably braced by horizontal beams
along the sides and the front.
A platform, suspended on chains, supports each full pallet and raises the pile of sheets
automatically as the sheets are removed from the top of the stack. The separation and
forwarding of each sheet from the pile and into the feed mechanism is by means of air
blasts from front, rear and sides together with six suction separators for non-ferrous
materials with the addition of magnetic side, rear and overhead separators for tinplate.
The vacuum of the separators and air blast is supplied by oil free dry running pumps
Instruction leaflets for these pump units are supplied with the feeder.
Once separated from the pile each sheet is passed between feed rollers and dropwheels
which move the sheet onto feed belts for subsequent delivery to the infeed belts of the
associated processing machine.
A pushbutton station mounted on the feedside (F.S.) of the framework provides control
facilities for feeder operation.
For details of the controls and feeder operation refer to Section 5 Operating Information
Feeder Controls.
For the purposes of convenience the manual shall describe a typical 4060 Feeder.
The electrical system provides the power and control facilities necessary for the operation
of the Automatic Sheet Feeder. Full details of the complete electrical system are shown
schematically on the wiring diagram, supplied with each feeder.
Depending on operational requirements the feeder is provided with its own control
equipment cabinets, incorporating a mains isolator switch, with transformer, relays, PLC
etc. A connection box for supply connections with the electrical system of the machine it
is feeding is also provided.
Page 3-2
The pile hoist motor and pump receive a three phase supply through miniature circuit
breakers and motor contactors. Thermal overload units protect from overheating.
A transformer provides reduced voltage supply for the control circuit, which incorporates,
relays, solenoids, contacts and mechanically operated limit switches. This is necessary
for the correct sequential operation of the feeder. Control pushbuttons are mounted on a
station fitted to the feeder. These enable the operator to start and stop the feeder and
operate the pile hoist motor.
The terms feedside (FS) and driveside (DS) are used in the text and refer to the
respective sides of the feeder. The feedside is the side fitted with most of the operating
controls, and is the side from which the operator usually works the feeder. It is on the
left hand side looking in the direction of sheet travel. The driveside is on the right hand
side looking in the direction of sheet travel.
There are a number of options that may be fitted to the 4060 feeder as original
equipment. In all cases this is determined by the customer specification and can consist
of such items as an auxiliary hoist, motorised conveyor rolls etc.
In situations where non-Crabtree parts are fitted as original equipment, this manual
should be read in conjunction with the supplier manuals for those parts.
Page 3-3
Feeder Operation
PILE RAISING /LOWERING EQUIPMENT

The equipment consists of cross bars supported by beams, which are suspended on four
chains. Each pair of chains operates on sprockets keyed to two horizontal shafts fitted
with wormwheels inter-connected by a worm shaft fitted with worm gears. The worms
are partially immersed in a grease bath to maintain constant lubrication of the worm and
wormwheel during machine operation. The wormshaft is connected via sprockets and
chain to the main braked hoist motor and a complementary pile height creep motor.
Both motors have provision for chain tensioning.
Wormwheel
Worm gear
Page 3-4
The main braked hoist motor is activated to fast raise and lower the main stillage of
sheets as follows:
1. To RAISED POSITION
The pile height control mechanism automatically stops the stillage in the sheet
feed position.
Pile Height Control Mechanism
2. To LOWER POSITION
The rotary limit switch controls the pile plate or cross bars with infeed conveyor.
See Setting 4-12.
The pile height creep motor is only activated when the feeder is in the sheet feed mode.
It maintains via the pile height control mechanism an optimum level for accurate sheet
feeding with minimum sheet height deviation.
In the event of a stillage overrun in the raised position due to the pile height control
mechanism being out of position or faulted, the four microswitches mounted on the slide
carriage assembly will stop the main hoist motor when the electrical circuit is broken.
When the last sheet of the stack is fed, the last sheet detector is activated, an audible
warning device is activated and the main hoist motor automatically lowers the empty
pallet.
Control of the main hoist motor for raising or lowering the stillage is by pushbuttons on
the feeder control panel.
Page 3-5
SEPARATING AND FORWARDING MECHANISM

The separation of individual sheets from the stillage is by means of an air blast to front
and rear blowers, with suction produced by a dual pump unit.
Front Sucker
Air blast to front of sheet through pile plate
Separating Magnets Rear Sucker
Rear Blower Sheets
A separate pump unit provides the air blast for the side blowers. In addition magnet
separators are situated at the side, rear and overhead positions of the stillage.
Suction cylinders mounted on the rear separator bar and forwarding slide carriage apply
suction to the individual sheets.
A simple piston valve controls suction to the suction cylinders. The valve is operated by a
cam driven from the main chain wheel drive, which is fixed to the camshaft. The valve is
timed to direct suction to the various cylinders at precise periods in the feed cycle, and is
easily adjusted by rotating the cam plate relative to the timing belt pulley. When suction
is applied to a cylinder the piston rod extends and the sucker contacts the sheet. At this
point full suction is directed to the sheet and through internal vacuum porting the sucker
lifts the sheet.
During feeder operation the rear suckers separate the sheet at the back before the
Page 3-6
forwarding suckers lift the front edge and carry the sheet forward between the feed
rollers and dropwheels. The dropwheels in conjunction with the tapewheels carry the
sheet down to the associated machine. As the sheet enters the dropwheels the
forwarding suckers release the sheet.
The horizontal motion of the front suction cylinders and slide carriage is controlled by the
action of the conjugate forwarding cams mounted on the cam shaft. Linkages connected
to each cam follower lever arm and to the ends of the slide carriage allow the pivot
shafts to oscillate.
As the cams rotate, the followers, through the lever arm and linkage system via the pivot
shaft, move the carriage forwards and backwards in a linear motion utilising a ball rail
guide system.
SUCTION AND AIR SYSTEMS

Two pump units are fitted to the feeder. The pump units are conveniently positioned on
top of the feeder. Their respective ports are connected via flexible hoses to the air valve
for suction, to an air blast valve and to the side blowers.
The first pump unit generates suction for the forwarding of the sheets and air pressure
for front and rear sheet separation. The second unit can be manually activated to
provide air blast for side blowers, which can be manually adjusted via valves fitted.
DROPWHEELS AND FEED ROLLERS

When the top sheet of the pile has been completely separated and is held at its front
edge by the forwarding suckers, the latter moves forward until the front edge of the
sheet enters the dropwheels.
At this point the suction holding the front edge of the sheet is released and the
dropwheels and feed rollers convey the sheet to the feed board.
The feed rollers are continuously driven via the camshaft through a chain drive and
sprocket arrangement.
Page 3-7
SYNCHRONISED SIDEGUIDES
The sideguides are adjusted by means of a handwheel, which operates a leadscrew
system. This enables the sideguides to be readily adjusted to accommodate the varying
widths of sheets. With the standard set-up the offset is limited to +/- 12mm.
The sideguides can also be readily offset from the feeder centreline, using the adjusting
handle for sideguide offset.
Locking
LockingHandle
Handle Handwheel
Adjusting Handle for Sideguide Offset
Page 3-8
SHEET ADVANCE AND RETARD DEVICE

The vari-drive unit is a differential gearbox fitted within the feeder input drive
configuration. Its function is to adjust the timing of the feeder in relation to the machine
being fed while on a production run. This adjustment is carried out by activating a small
reversible electric motor, which in turn drives the differential part of the vari-drive unit.
The vari-drive unit is particularly useful in applications where length of sheet governs
feeder timing.
Vari-drive Unit
Page 3-9
SHEET REJECT DEVICE

The device includes a double sheet detector, which uses two non-contacting sensing
heads to detect the thickness of sheet being fed through the feeder. Should sheets of
additional thickness pass between the detector head and its receiver a reject solenoid is
energised. This operates a set of reject fingers, which normally lie below the feed path
of the sheets. The fingers are pneumatically raised by the action of a linkage and the
rejected sheet/s is delivered into a reject tray. When the offending sheet is passed
through the detector unit the solenoid is de-energised and the reject fingers lower to
their normal position.
Full operating and setting instructions for the double sheet detector are provided in a
separate publication supplied with the machine.
Double Sheet Detector

Non Contacting Heads
Page 3-10
Issue 01 – Oct 1999 Setting & Adjustment
Setting & Adjustment
PILE HEIGHT ADJUSTMENT 4-2

SETTING THE DROPWHEELS 4-3
Nip adjustment 4-3
Lateral adjustment 4-3
Vacuum Valve 4-4
SETTING INSTRUCTIONS 4-4
Sequence Timing Switch (Proximity switch) 4-4
To set the Vacuum Valve ON Time 4-5
To set the Vacuum Valve Release point 4-6
System Pressure Settings 4-7
TIMING THE FEEDER 4-8
ROTARY LIMIT SWITCH ADJUSTMENT 4-9
CAM FOLLOWER SETTINGS AND/OR
ADJUSTMENT ON CONJUGATE CAM ASSEMBLY 4-11
Page 4-1
Setting & Adjustment Issue 01 - Oct 1999
PILE HEIGHT ADJUSTMENT

The exact height at which the pile is worked will vary somewhat according to the weight
and type of stock being handled and also its condition. For reasonably flat sheets, about
0.25mm (0.010”) thick, satisfactory results should be obtained if the working level of the
pile is approximately 3mm to 6mm (1/8” – 1/4”) below the top of the pile plates.
Pile Plate
3mm to 6mm
Sucker
When the feeder is in operation, the height of the pile is automatically maintained by the
pile hoist creep motor. The motor is energised when the level of the pile falls below a
certain limit. During sheet feeding the operation of the pile hoist creep motor is
controlled by the adjustable pile height control mechanism. The assembly is positioned
approximately mid-way along the bar and is adjustable to vary the working height
according to the stock being used.
To adjust the points of operation for starting and stopping the pile hoist creep motor turn
the knurled screw on the top of the assembly clockwise to increase the pile raise height
and counter clockwise to decrease it.
Knurled Adjustment screw
Page 4-2
SETTING THE DROPWHEELS

Nip adjustment
Care must be taken when adjusting the dropwheels to make sure that both dropwheels
apply the same pressure on the sheet. If not one corner of the sheet will start sooner
than the other and the sheet will be fed askew and therefore out of position when
reaching the lays. To adjust the nip between the dropwheel and feed roller proceed as
follows:
1 Hold Adjusting nut with 19mm spanner.
2 Loosen Locknut with another 19mm spanner.
3 The Adjusting nut can now be rotated to either raise or lower the Dropwheel.
4 Once the desired position has been attained, hold the Adjusting nut and tighten
the Locknut.
Locknut M10 Socket Cap Screw
Adjusting nut
Dropwheel
3mm Feeler Gauge
Rubber Tyre
Feed Roller
Lateral Adjustment
For average size sheets the dropwheels should not need adjusting laterally. If very large
or very small sheets are used, it may be desirable to move the dropwheel assemblies and
the feed rollers to suit the size of sheet.
To adjust the position of the dropwheel proceed as follows:
1 Loosen M10 Socket Cap Screw.
2 Slide dropwheel assembly to desired position
3 Tighten M10 Socket Cap Screw.
To adjust the position of the feed roller proceed as follows:
1 Displace the Rubber Tyre from the Feed Roller.
2 Locate the M8 Socket Set Screw and loosen.
3 Slide Feed Roller to desired position.
4 Tighten the M8 Socket Set Screw.
5 Replace the Rubber Tyre onto the Feed Roller.
The pulleys, which drive the feed belts, may also need adjusting to suit the size of sheet.
It should be noted that the drop wheels must always run on the feed rollers, never on
the belts or belt pulleys. The pulleys being smaller in diameter than the feed rollers, to
allow for the thickness of the belt.
Page 4-3
Vacuum Valve
The Vacuum Valve directs the suction to the Front and Rear Sucker cylinders at precise
periods in the feed cycle. Control of the suction to the cylinders is by means of a spool
valve operated by a connecting link driven by an eccentric on the camshaft.
Before leaving the Factory, the position of the valve spool is set to the optimum setting
for consistent sheet feeding. i.e. The suction to the forwarding suckers is replaced by
positive air pressure just as the leading edge of the sheet enters the nip between the
drop wheels and the feed rollers.
SETTING INSTRUCTIONS
Should the Timing require resetting on the machine the following procedure should be
followed.
Tools required: 0.8mm Feeler Gauge

6”Rule (straight edge)
6mm Socket head key
3mm Socket head key (Used as a toggle pin)
17mm Wrench
6mm Wrench
Sequence Timing Switch (Proximity Switch):

The Switch is fitted to the Vacuum Valve; its signal is used for the following operations
• Upon pressing the Start Feeder pushbutton the switch ensures that the vacuum is
applied, via the Vacuum pump solenoid valve, at the correct part of the feed cycle.
This prevents the Front Suckers from operating after the forwarding carriage has
begun its travel forward, thus preventing mis-feeding of the first sheet and also
possible damage to the Front sucker piston.
• Upon pressing the Start Feeder pushbutton the switch counts a pre set number of
cycles of the Vacuum valve spool before it opens the Vacuum pump solenoid valve.
This ensures that the vacuum is fully established before feeding commences.
• Upon pressing the manual Reject Sheet pushbutton the switch provides a timing
signal for the manual sheet reject operation
NOTE
It is therefore very important that the Proximity Switch is positioned as low as possible,
flush with the valve body.
Page 4-4
To set the Vacuum Valve ON time:

1 In manual jog control, jog the Press or Coater that drives the Feeder in either
direction until the Eccentric Drive to the valve is at Bottom Dead Centre (BDC).
Alternatively undo the 3 screws securing the Eccentric Drive plate and rotate the
plate manually until the BDC position is reached. Retighten the 3 screws.
2 At this position the spool is in the fully down position, and the top or free end of the
spool should be 0.8mm proud of the top of the valve body.
3 If the spool is not in the correct position, adjustment is made at the screw
connection of the drive link. Using a toggle inserted in the spool, undo the lock nut
and rotate the spool to achieve the 0.8mm setting.
4 Ensure that the lock nut is tight before moving to the next step.
Screw
Connection
Drive Link
Bottom
Dead Centre
Position
Proximity Switch
Top of Spool
0.8
mm
Page 4-5
To set the Vacuum Valve Release point:

1 Jog the Press or Coater to the position where the Feeder forwarding carriage is at
mid-position, as indicated by the pointer and symbol on the timing disc.
2 Undo the 3 screws securing the Eccentric Drive Plate, and rotate the plate manually
to the position shown below, where the step on the spool is level with the end of the
valve body and the eccentric pin is to the right of the centreline. (The timing disc
and Eccentric Drive Plate rotate Counter Clockwise. The valve therefore reaches the
release point after the Bottom Dead Centre position used in the “To set the Vacuum
Valve ON time”).
3 Replace / retighten the 3 clamping screws.
Pointer
Carriage
Mid-Position
indicator
Securing
Screw
Eccentric
Drive Plate
Top of Spool
Proximity Step of Spool

Switch level with top of
Valve
Page 4-6
System Pressure Settings:

1 The Vacuum pressure is set by adjusting the relief bypass valve on the Vacuum
pump indicated in the picture below. This is adjusted until 0.4 bar is indicated on the
vacuum gauge.
2 The Release pressure is set by fully closing the pump relief valve (maximum
pressure). Once that has been set adjust the throttle valve until an average pressure
of 0.35 bar (5 psi) is indicated on the pressure gauge. Once this has been set
remove the operating handle on the throttle. (No operator adjustment is then
possible).
Vacuum Relief Pressure

Bypass Valve Relief Valve
Throttle Valve
Note: Remove
handle once
pressure is set
Page 4-7
TIMING THE FEEDER

Feeder sheet delivery can be timed with the machine feeding, by adjusting the vari-drive
gearbox. This adjustment is carried out by activating a small electric motor, which drives
the differential part of the vari-drive unit. The adjustment is done via a Bi-directional
switch on the F.S. of the proceeding unit.
Page 4-8
ROTARY LIMIT SWITCH ADJUSTMENT

NOTE
Side bar safety limit switches automatically stop the hoist motor and the associated
processing machine should the moving pile contact and lift the sideguide assembly. The
dual pump suction solenoid is also de-activated thus stopping the suction.
The rotary limit switch, which determines the raise and lower travel limits of the pile
raise/lower system is chain driven via a sprocket fitted to the O.S. pile raise worm shaft.
The switch unit itself is base plate mounted to the horizontal channel of the machine
frame. A removable cover encloses the operating mechanism, which consists of
adjustable cams, reduction gear driven from the chain and wormshaft. Each cam
operates the contacts of one switch unit.
Figure 1 shows an arrangement of the internal components. The arrow on the insulating
shield covering each switch unit points to the corresponding adjusting pinion
Rotary Limit Switch, (enclosure cover removed), showing insulating shields covering each
switch.
Also each corresponding cam has a white marker on the gear teeth to help locate the
position of the cam.
Page 4-9
To adjust the trip point of each of the switch units proceed as follows:
1 Remove the enclosure cover.
2 Loosen the two cam clamping screws on top of the cam assembly one half turn.
3 Locate the adjusting pinion for each cam by referring to the indicating arrow on
insulation shield. See photograph below.
Clamping screw Switch 1
White Marker
Switch 2
Switch 3 Switch mounting screws Adjusting pinion
Switch 1 This limits the upper extent of travel of the pile platform
Switch 2 This limits the lower extent of travel of the pile platform
Switch 3 This stops the pallet 120mm from the floor, as a safety feature.
4 Depress pinion with a screwdriver until gears mesh.

5 Rotate cam in direction to operate switch.
6 The white marker on the gear teeth is directly over the cam lobe that trips the
switch. When the operating cam has been adjusted so that cam lobe has tripped
the switch, the adjustment is complete.
7 Re-tighten clamping screw and replace the cover of the switch.
Page 4-10
CAM FOLLOWER SETTINGS AND/OR ADJUSTMENT ON CONJUGATE CAM

ASSEMBLY
NOTE
There are two identical assemblies of the pivot shaft and pivot arms complete with cam
followers. (One on the F.S. and one on the O.S. of the feeder cam shaft).
The non adjustable cam follower runs on the Positive Return Cam ‘
B’and the adjustable
cam follower runs on the Positive Return Cam ‘
C’. See the photograph of the Camshaft
Assembly below.
The factory set clearances between the cam followers and the mating cams are 0.08mm
(0.003”) minimum to 0.20mm (0.007”) maximum.
To check this tolerance and reset if required follow the step guide as tabulated below:
1. Rotate the camshaft until the front sucker bar is in the Carriage Fully Back
position.
2. Using hand pressure press the upper cam follower via the lever arm forward onto
the Positive Return Cam ‘
B’. See photograph of the Camshaft Assembly below.
Upper Cam Follower Lever Arm
Positive Return Cam ‘

B’
Page 4-11
3. With the cam follower lever in this position, the clearance between the lower cam
follower and the mating item, Positive Return Cam ‘ C’, should be as stated in the
tolerances given above. See photograph of the Camshaft Assembly below.
M8 Socket Lower Cam Follower

Set Screw
M20 Locknut
0.08mm to 0.20mm
Eccentric Bush
Positive Return Cam ‘

C’
4. If the tolerance is greater or less adjust as follows:

5. Loosen the M20 locknut using a ring spanner.
6. Slightly loosen the M8 socket set screw. Do not remove.
7. Rotate the eccentric bush in the direction necessary to increase or decrease the
tolerance gap. See photograph of the Pivot Shaft Assembly below.
8. When the tolerance gap is achieved tighten the M8 set screw which holds the
eccentric bush in position to prevent further rotation.
9. Re-tighten the M20 locknut and recheck the tolerance setting.
10. Rotate camshaft and check for tolerance clearance at different positions before
commencing feeder production.
NOTE
If the tolerances stated cannot be achieved this could be due to excessive cam follower or
cam wear. To rectify, replacement of either/or both the cam follower and cam may be
necessary to stop erratic feeding, due to hesitant forward and rearward travel of the
carriage.
Page 4-12
Issue 01 – Oct 1999 Operating Information
Operating information
Feeder Controls 5-2

Raise Main Pile pushbutton 5-2
Lower Main Pile pushbutton 5-2
Stop Main Pile pushbutton 5-2
Start Feeder pushbutton 5-2
Stop Feeder pushbutton 5-2
Vari-drive Bi-Directional switch 5-2
Reject Sheet pushbutton 5-2
Sideblower OFF/ON Selection switch 5-2
Vacuum Gauge 5-2
Pressure Gauge 5-2
MAIN PUSH BUTTON LEGEND PLATE 5-3
Loading the feeder 5-4
Operating the feeder 5-5
Emergency procedures 5-6
Shut-down procedures 5-6
Alarms 5-6
Fault diagnosis and correction 5-7
Mechanical faults 5-7
Electrical faults 5-7
OPERATIONAL FAULTS 5-12
General faults 5-12
Page 5-1
Operating Information Issue 01 - Oct 1999
Feeder Controls
Brief details on the function/effect of each control used during feeder operation follow:
NOTE
Operators should familiarise themselves with all controls before attempting to operate the
machine.
Raise Main Pile pushbutton

Starts the pile hoist motor to run in required direction and so raise the feeder pile
platform.
Motor will run continuously until the pushbutton is released or the pile height control
mechanism is reached.
Lower Main Pile pushbutton

Starts the pile hoist motor to run in required direction and so lower the feeder pile
platform.
Motor will run continuously until the pushbutton is released or the mainpile lower limit in
the rotary limit switch is reached.
Stop Main Pile pushbutton

When operated inhibits any pile motion.
Start Feeder pushbutton

Starts dual pump unit to generate the required suction and airblast. After a delay to
allow for sufficient suction a solenoid is energised on the suction port of the dual pump
unit allowing suction to be applied to the air cylinders.
The feeder will then start to feed sheets.
Stop Feeder pushbutton

De-energises solenoid on suction port of dual pump unit, cutting off suction to air
cylinders. Stops operation of the dual pump unit motor.
Feeder stops feeding sheets.
Vari-Drive Bi-Directional switch

Enables operator to advance or retard the position of the sheet relative to the
appropriate processing machine.
Reject Sheet pushbutton

Rejects a sheet into the reject tray.
Sideblower OFF/ON Selection switch

Enables the sideblower pump.
Vacuum Gauge
Registers the vacuum applied by the dual pump unit to suction cylinders.
Pressure Gauge
Registers the air pressure supplied to the air blast positions, from the dual pump unit.
Page 5-2
MAIN PUSH BUTTON LEGEND PLATE
Page 5-3
Loading the feeder

To load the feeder initially with a stacked pallet of sheets proceed as follows:
1. Switch on the electrical supply to the feeder and power up the machine.
2. Press the Lower Main Pile pushbutton. The hoist will lower continuously until
the pile beams and platforms reach their lower limit (or the pushbutton is
released).
3. Load a full pallet of sheets onto the pile platform, ensuring that the sheet stack is
central and against the vertical front pile plate. Use pile centralising handle if
required, to adjust the position of the stack.
Sheets loaded onto Pile Platform
Sheet position
Sheet position can be moved as indicated, using the Pile Centralising Handle
Pile Centralising Pile Platform

Handle
Pile Centralising Handle fits here
4. Press the Raise Main Pile pushbutton. The motor will run continuously until
the pushbutton is released or the pile height control mechanism is reached.
Page 5-4
Operating the feeder

1. Load the feeder with a full pallet of sheets as detailed in previous Section 5-4,
Loading the feeder.
2. Ensure that the printing press or the machine the feeder is supplying is already
running.
3. Press the Start Feeder pushbutton. The air pressure gauge will show a
PSI/Bar reading and the vacuum gauge will show a Hg reading. These readings
can be varied according to the pump settings to obtain pressure/vacuum
requirements for customer’ s individual sheet feeding methods. The feeder will
now feed continuously and the pile will be raised automatically to its correct
feed-off level as the sheets are removed.
4. During feeder operation it is recommended that the operator should periodically
check:
4.1 That the sheets are being lifted, separated and fed onto the feed rollers
correctly and evenly.
4.2 The air pressure and vacuum gauges for correct operational readings.
4.3 That the sheets are entering the online equipment at the correct time.
If there is evidence of faulty feeding refer to Section 5-7 Fault diagnosis and
correction, for details of the possible cause and necessary remedial action.
5. To stop the feeding operation at any time, press the Stop Feeder pushbutton.
Page 5-5
Emergency procedures
1 Press the nearest emergency stop pushbutton.
2 Isolate the main power at the electrical panel.

NOTE
Ensure that all electrical supplies to the line are disconnected e.g. UV drying equipment,
automatic ink duct systems, anti-flecking devices, non-Crabtree coater, etc.
3 Shut off the compressed air supply at the shut off valve.
4 Inform site supervision.
Shut-down procedures
1 Press a STOP FEEDER pushbutton.
2 Stop the machine and press an EMERGENCY STOP pushbutton.
3 Isolate the main power at the electrical panel.
4 Shut off the compressed air supply at the shut off valve.
Alarms
An audible alarm bell is fitted to the Feeder. The bell rings for 5 seconds after the last
sheet has been fed by the feeder, into the reject tray. When the bell stops ringing the
pile platform automatically lowers to the lower position (approximately 120mm above the
operator platform). This is a safety feature to ensure the platform does not lower onto
the operators feet. The following actions should then be taken:
1 Lower the pile platform to the floor using the Lower Main Pile pushbutton.
2 Remove the empty pallet from the pile plate.
3 Load a full pallet onto the pile platform.
4 Raise the pile platform to the feed position using the Raise Main Pile pushbutton.
The feeder is now ready to feed sheets.
Page 5-6
Fault diagnosis and correction

Mechanical faults
Because of the open design of the machine, any mechanical faults will be easily
discernible. Their rectification will become obvious when reference is made to the
associated spare parts manual. Mechanical faults are usually the result of poor
maintenance. It is therefore essential that the attentions listed in Section 6 Maintenance,
Servicing schedule, be carried out at the periods recommended.
For details of possible faults and remedial action necessary on the pump units, refer to
the relevant instruction leaflets.
Electrical faults
Electrical system fault diagnosis is best accomplished by referring to the circuit diagram
supplied with the feeder and with the aid of a multi-test meter.
It is recommended that faulty components be replaced by new items. Consult separate
Parts Manual.
NOTE
All the safety microswitches on the feeder and reject tray are monitored by the mimic
display shown on the pushbutton station, which registers when a microswitch circuit is
broken. The feeder will only run when all the mimic lights are out.
DETAILS OF THE MIMICS ARE AS FOLLOWS:

Ref Circuit Diagram Possible Cause Action
Nomenclature
1 Feeder electrical If mimic light is ON: To clear the fault,
fault ensure the machine is
one of the main motor circuit
at standstill, press an
breakers (detailed below) has
emergency stop push-
tripped – this will stop the
button. Remove power
feeder:
from the feeder using
MAIN HOIST Q16/7; the local isolator. Open
the control panel
MAIN HOIST BRAKE Q18;
situated on the top of
SECONDARY HOIST Q19; the feeder, locate the
circuit breaker and
FEEDER PUMP Q20.
reset by setting the
switch to the UP
position.
If the fault persists,

check the setting of
the circuit breaker
matches the full load
current of the motor,
monitor the motor
current if necessary.
Page 5-7

Nomenclature
If mimic light is FLASHING: To clear the fault,
ensure the machine is
one of the auxiliary motor
circuit breakers (detailed
below) has tripped – this will
not stop the feeder:
from the feeder using
SIDEBLOWER PUMP Q23; the local isolator. Open
the control panel
FEEDER TIMING Q21/2;
OUTSIDE CONVEYOR Q24/5 the feeder, locate the
(if fitted); circuit breaker and
INSIDE CONVEYOR Q26/7
switch to the UP
(if fitted).
position. Please note
that circuit breakers for
the inside and outside
conveyors are fitted as
standard, these circuit
breakers should not be
reset if the conveyor
rolls are not fitted.

check the setting of
the circuit breaker
matches the full load
current of the motor,
monitor the motor
current if necessary.

and the above motor circuit
breakers are healthy, the cause
may be the following:
AIR CONDITIONER CIRCUIT from the feeder using
BREAKER TRIP MCB4 (if fitted). the local isolator. Open
the control panel
the feeder, locate the
circuit breaker and
switch to the UP
position.

check the air flow for
the air conditioner unit
is not blocked.
Page 5-8

Nomenclature
and the above circuit breakers
are healthy, the cause will be
the following:
PANEL THERMOSTAT THERM, from the feeder using
the local isolator. Open
the control panel and
leave the doors open
for some time to
dissipate the heat.
Ensure the panel fans

(if fitted) are
operational and the
filters are clean and
free from dust.
Ensure correct
operation of the air
conditioning unit (if
fitted).

monitor the
temperature inside the
panel during normal
operation. If this is
excessive i.e. greater
than 40°C consider
fitting air conditioning
to the panel.
2 Pile height rear Main pile or auxiliary pile has Lower hoist and check
support bar L/S disturbed the support bar for obstructions.
(O/S) indicator releasing the limit switch – this
will stop the feeder.
3 Pile height rear Main pile or auxiliary pile has Lower hoist and check
support bar L/S disturbed the support bar for obstructions.
(N/S) indicator releasing the limit switch – this
will stop the feeder.
4 Pile height Main pile or auxiliary pile has Lower hoist and check
overrun L/S disturbed the support bar for obstructions.
(offside) releasing the limit switch – this
indicator will stop the feeder.
Page 5-9

Nomenclature
5 Pile height Main pile or auxiliary pile has Lower hoist and check
overrun L/S disturbed the support bar for obstructions.
(nearside) releasing the limit switch – this
indicator will stop the feeder.
6 Pile raised Main pile has reached the limit No pallet on hoist.
indicator of upper travel.
Rear pile control

assembly set too far
back causing hoist to
travel past the pile
height control limit
switch.
Pile height control limit

switch/assembly faulty.
It is unlikely that this
mimic will be
illuminated in this case
as the support bar
limit switches would
operate first.
7 Pile lowered Main pile has reached the limit This is a normal
indicator of lower travel. condition when the
lower travel is stopped
by the lower limit
switch.
8 Drive door guard Nearside door open, offside Close relevant door
open indicator door open. ensuring the safety
switch tongue is
located correctly in the
safety switch body.
9 Vertical guard Front vertical feeder guard Close guard, securing

open indicator open. by catches at both
offside and nearside.
10 Horizontal guard Front horizontal feeder guard Close guard, securing

open indicator open. by catches at both
offside and nearside.
Page 5-10

Nomenclature
11 Reject tray guard Reject tray guard is raised. Close (lower) guard.
open indicator
Note that sheet

rejection is inhibited
with this guard raised.
Attempts to reject a
sheet will stop the
machine.
12 Reject tray Reject tray is raised. Lower tray.

raised indicator
Note that sheet

rejection is inhibited
with this guard raised.
Attempts to reject a
sheet will stop the
machine.
Page 5-11
OPERATIONAL FAULTS
Operational faults, i.e. feeding troubles, are generally due to incorrect adjustments or
settings.
The following table lists a number of conditions, which may possibly occur during feeding
operations and the necessary remedial action to clear them.
GENERAL FAULTS
FAULT POSSIBLE CAUSE REMEDY
Faulty separation Suction cylinders picking up two Increase and/or reposition air
& forwarding of sheets. blowers and/or reposition
sheet. suction cylinders as necessary.
Suction cylinders fail to raise Check vacuum system and
sheet due to insufficient suction, components and rectify as
blockage in air line, piston necessary.
sticking in cylinder, compression
spring broken, worn rubber
suckers.
Insufficient blast pressure. Check air intake filter and
replace with a new filter if
blocked or dirty.
Faulty sheet Pressure (nip) settings of drop Reset drop wheels.
feeding. wheels unequal.
Pile height incorrect. Reset to correct height, i.e. 6mm
below top of front blower
bracket.
Rubber suckers sticking to the Clean & fit new suckers.
sheet caused by ink/varnish
being picked up by the suckers.
Front edge of pile is not parallel Reposition pile.
to the plate.
Pile too far from pile plate should Reposition pile.
be in contact with pile plate but
a gap of 6mm can be
accommodated.
Sheet feed not Pile not raised to feed height Raise pile
enabled
(indicator not
flashing)
Pile height proximity not sensing Adjust sensitivity of serial via
sheets. potentiometer located beside the
sensor LED.
Machine sheet feed enable not Check machine sheet feed
present. enable conditions.
Page 5-12
Issue 01 – Oct 1999 Maintenance
Maintenance
Maintenance schedule 6-2

GENERAL 6-2
Servicing Schedule 6-3
FORWARDING SLIDE CARRIAGE 6-3
REMOTE LUBRICATION 6-5
GENERAL LUBRICATION 6-6
GENERAL MAINTENANCE 6-8
Dual Pump Unit or Individual Pump Units 6-9
Rotary Switch Maintenance 6-9
Recommended lubricants 6-10
Page 6-1
Maintenance Issue 01 - Oct 1999
Maintenance Schedule
GENERAL
The feeder is designed for minimum maintenance and most bearings are either dry
sliding bearings, self lubricating or sealed for life units requiring little or no attention.
Crabtree of Gateshead hereby provide notice, under Section 6 of the
Health and Safety at Work etc Act 1974 that inadequate maintenance
of worm pins on the 4060 Feeder has resulted in failure. Failure of
these pins causes the pile platform to suddenly lower on one side,
ejecting any load that is being carried.
All load-bearing parts of the 4060 Feeder require maintenance and
should be regularly inspected by a competent person.
We strongly recommend that you class the feeder as a lifting appliance
and subject it to thorough examination every 14 months, in accordance
with Section 26 of the Factories Act 1961.
The worm pins should be inspected and replaced as part of the 14
month examination.
The following servicing schedules detail the minimum attention considered necessary to
ensure reliability and trouble free operation of the machine. This information has a
tabular form summarising the servicing required and the service interval (indicated by
symbol *).
NOTE
DAILY activities should be carried out after 24 hours operation, WEEKLY activities should
be carried out after 168 hours and MONTHLY activities should be carried out at the start
of each calendar month.
WARNING
Before carrying out any servicing work on the
machine, always ensure that all electrical supplies
to the machine are switched “OFF”.
Page 6-2
Servicing Schedule
FORWARDING SLIDE CARRIAGE
Ball Rail Guide Lubrication Units
Ball Rail Runner Block
It is recommended that the lubrication units be re-filled after 5000 Km of travel. Under
high speed operating conditions, 7200 sheets per hour or greater, the units will travel at
least 19440km per year. Therefore refilling should take place every 3 months.
Page 6-3
Note
Remote lubrication points are provided for the hoist chains, forwarding cams and the
timing chain. These accessed through the inspection doors on each side of the feeder.
Lubrication manifold
Lubrication points viewed on Feedside of Feeder.
Lubrication manifold
Lubrication points viewed on Driveside of Feeder.
Page 6-4
REMOTE LUBRICATION
EQUIPMENT MAINTENANCE TASK FREQUENCY GENERAL
TO BE PERFORMED COMMENTS
(See Maintenance
12 MONTHLY
instructions for further
3 MONTHLY
6 MONTHLY
MONTHLY
details)
WEEKLY
DAILY
Pile raising Oil lubricate load chain *
sprockets
Forwarding Wipe clean conjugate *
mechanism forwarding cams &
lightly grease
Grease cam followers *
Wipe clean dropwheel
cam & lightly grease *
Timing chain Oil chain *
Page 6-5
GENERAL LUBRICATION
(See Maintenance
12 MONTHLY
3 MONTHLY
6 MONTHLY
MONTHLY
details)
WEEKLY
DAILY
Complete Clean down feed roller *
machine drop wheels &
feed belts
Air valve Remove piston, clean *
out valve
lightly smear with
grease before piston is
replacement
Pile raising Examine sprocket
teeth for wear &/or
damage *
Check grease in worm
shaft baths &
replenish if necessary *
Inspect drive chains
for wear. Lubricate
chains. If necessary
adjust chain tensions
by altering the position
of the pile hoist motor
&/or creep motor *
Creep motor The gearbox is a
helical gearbox sealed for life unit and
requires no
maintenance
Creep motor The clutch is a no slip,
electro- no wear type &
magnetic requires no further
toothed clutch maintenance
NOTE: The clutch air
gap is pre-set on
assembly & requires
no further adjustment
Page 6-6
GENERAL LUBRICATION (CONTINUED)

(See Maintenance
12 MONTHLY
3 MONTHLY
6 MONTHLY
MONTHLY
details)
WEEKLY
DAILY
Universal joint Grease lubricate *
Drive shaft Sealed for life unit
bevel box
(if fitted)
Main chain
drive
(if fitted) *
Adjustable Lightly grease *
sideguides leadscrews
Page 6-7
GENERAL MAINTENANCE
LOCATION MAINTENANCE TASK FREQUENCY GENERAL
(See Maintenance
12 MONTHLY
3 MONTHLY
6 MONTHLY
MONTHLY
details)
WEEKLY
DAILY
Feeder Examine drop wheels *
mechanism for wear & replace if
necessary
Examine feed rollers
for wear & replace
*
tyres if necessary
Check timing belts for
wear & tension.
Replace as necessary *
Airblast/suction Clean & check pump * Refer to dual
dual pump pressure & suction pump unit
system filters instruction
(dry running oil leaflet for all
Clean pump body *
free pump) details of
Check all hosepipe servicing
runs & fittings for
security &
deterioration. *
Tighten as necessary
*
Replace as necessary
Vari-drive Check gearbox oil level * 1st oil change
gearbox after 500
Change gearbox oil
(if fitted) operating hours
or 1 month
Suction Check plastic suckers *
cylinder for wear & replace as
necessary
Suction Clean cylinder bore *
cylinder I) Remove rubber
(3 piece body) sucker
See Plate 15A ii) Remove four M5 top
& bottom end cap tie
bolts
iii) Clean piston, piston
ring & cylinder bore
iv) Reassemble
Panel fans Remove and clean
filters *
Replace filters *
Page 6-8
Dual Pump Unit or Individual Pump Units

No special attention is required for these pumps beyond an occasional inspection. If
performance falls off, this may well be due to excessive internal wear which is often
indicated by a rise in temperature, but it should be appreciated that it is a feature of
compressors to generate heat when working.
For complete servicing and maintenance information refer to the relevant instruction
leaflet.
Rotary Switch Maintenance

The unit has been lubricated at the factory. An increase in life may be obtained by
occasionally placing a small quantity of gear grease on the worm and worm gear.
If a switch should need replacement, follow the procedure below. See Section 4 Setting,
Setting & Adjustment, Rotary Limit Switch Adjustment, for reference and item
identification.
1. Remove the enclosure cover.
2. Remove old switch.
3. Turn cam so that cam lobe is away from cam follower on bracket.
4. Install new switch along with bracket and insulation pushing the bracket towards
the centre post as far as possible.
5. Tighten both mounting screws.
6. Loosen both mounting screws ½ turn.
7. Loosen the cam clamping screws ½ turn.
8. Using the adjusting pinion rotate the cam lobe past the cam follower. This will
push bracket into proper position.
9. Re-tighten both mounting screws.
10. Re-adjust cam as detailed in Section 4 . Setting, Setting & Adjustment, Rotary
Limit Switch Adjustment.
Page 6-9
Recommended lubricants
The following lubricants are approved by Crabtree of Gateshead for use on the 4060
Feeder.
LUBRICANT WORM BATHS UNIVERSAL VARI-DRIVE GENERAL OIL

CAM PROFILES JOINTS GEARBOX LUBRICAION
LEAD SCREWS (CHAINS ETC)
CASTROL * Castro Grease Alpha SP150 Magna 68
LM
ESSO Teresso 52 Multi-purpose H Spartan EP150 Nuray 100
MOBIL * Mobil grease MP Mobil gear 629 Mobil DTE 26
or
Mobil SHC 629
SHELL Alvania R2 Alvania R2 or R3 Omala 150 Vitrea 100
DUCKHAMS Admax LEP2 * Garnet 320 Garnet 68
REGENT Multifac EP2 * Meropa 150 Omnis 100
TEXACO
ROCOL * * * *
OVOLINE * * * Lithium EP 00
grease
LUBRICANT LUBRICATION CAMS & CAM

UNITS FOLLOWERS
CASTROL * *
ESSO * *
MOBIL * *
SHELL Tonna 2 X 220 *
DUCKHAMS * *
REGENT * *
TEXACO
ROCOL * *
OVOLINE * Lithium EP 00
grease
NOTE
* indicates that a suitable lubricant from the company has not been tested or approved by
Crabtree of Gateshead.
CAUTION
The use of oil or grease of differing composition
may result in premature damage to bearings and
lubricated surfaces. Consult your lubricant
supplier before using products bearing different
brand names.
Page 6-10
Issue 01 – Oct 1999 Disposal
Disposal
Hazardous waste 7-2
DEFINITION 7-2
DESCRIPTION AND STORAGE 7-2
DESCRIBING THE WASTE 7-2
KEEPING WASTE SAFELY 7-2
CONTAINERS 7-3
WASTE TO BE COLLECTED 7-3
USING A WASTE CARRIER 7-3
Page 7-1
Disposal Issue 01 - Oct 1999
Hazardous waste
DEFINITION
A waste is hazardous if it is classified as:
Highly flammable
Irritant
Harmful
Toxic
Carcinogenic
Corrosive
DESCRIPTION AND STORAGE

To ensure proper handling of waste it is important that it is properly and clearly described
and that this information is passed on to successive holders of the waste. The following
is a checklist of relevant questions:
can the waste be safely mixed with other waste?
does the waste need special containment?
can it be safely incinerated?
can it be safely buried in a landfill site?
can it be transferred from one vehicle to another?
DESCRIBING THE WASTE

Documentation must be completed signed and kept by all parties if the waste is
transferred. The documentation must state the quantity of waste transferred and how it
is packed - whether loose or in a container.
There must also be a description of the waste, either separately or combined as a single
document. The description of the waste should always mention any special problems,
requirements or knowledge.
It is essential to label drums and containers with a description of the waste.
The description should include the name of the substance or substances, the process that
produced the waste, and where appropriate chemical and physical analysis.
The description must provide enough information to enable subsequent holders to avoid
mismanaging the waste.
KEEPING WASTE SAFELY

Waste holders must safeguard against:
corrosion or wear of containers;
accidental spillage or leakage;
accident or weather allowing waste to escape;
waste blowing away or falling off during transport;
scavenging by vandals, thieves, children or animals.
Page 7-2
Issue 01 – Oct 1999 Disposal
CONTAINERS
Waste handed over to another person should be in an appropriate container and should
be clearly labelled.
WASTE TO BE COLLECTED
Waste left outside premises should be in containers that are strong enough to resist
wind, rain and animal disturbance - especially food waste.
All containers must therefore be secured or sealed e.g. drums with lids, bags tied up and
skips covered. Use of weather-proof labels is an important consideration where waste is
stored outside.
Waste should be stored in suitable containment areas until collection.
USING A WASTE CARRIER

In almost all circumstances anyone carrying waste in the course of their business or for
profit must be registered with the local Environment Agency.
Page 7-3
Disposal Issue 01 - Oct 1999
Page 7-4
Issue 01 – Oct 1999 Parts Lists
Introduction
The terms and abbreviations OFFSIDE (O.S.) and DRIVESIDE (D.S.) refer to the
respective sides of the machine; the feedside being the operator’
s side (the left side
when looking in the direction of sheet travel).
The various assemblies and parts, which make up the standard version of the Crabtree
4060 Feeder, can be identified from the following lists when used in conjunction with the
associated illustrations.
How to order parts

We rely on your co-operation to be able to deliver spare parts quickly and according to
your specification. When placing orders for spares:
1 Always quote the machine serial number and the year of construction.
2 Quote the part number and description together with the catalogue page
number e.g. Page 7-2, taken from the Separate Parts Manual
3 Please quote the exact address and forwarding instructions.
Orders may be placed by:

TELEPHONE: (0) 191 487 5071
TELEFAX: (0) 191 487 3997
E-MAIL: spares@crabpress.co.uk
POST: Spares Department
Crabtree of Gateshead
Kingsway
Team Valley Trading Estate
GATESHEAD
Tyne & Wear
NE11 0SU
Page 8-1
Parts Lists Issue 01 - Oct 1999
Page 8-2
Issue 01 – Oct 1999 Options
Options
Auxiliary Hoist 9-2

OPERATING INFORMATION 9-2
OPERATION 9-2
GENERAL FAULTS 9-3
Motorised Conveyor 9-4
INSTALLATION 9-4
Setting the friction torque limiter 9-4
OPERATING INFORMATION 9-5
OPERATION 9-5
GENERAL FAULTS 9-6
MAINTENANCE 9-6
Friction torque limiter 9-6
Chains 9-6
Scroll Sideguides 9-7
100mm Pile Offset Option 9-8
SPECIFICATION 9-8
OPERATION 9-8
METHOD OF ADJUSTMENT 9-8
MAINTENANCE 9-8
Operating Instructions for Intermediate Conveyor 9-9
FULL LINE MODE 9-9
COATER ONLY MODE 9-12
Page 9-1
Options Issue 01 - Oct 1999
Auxiliary Hoist
OPERATING INFORMATION
Auxiliary Hoist Lower selector switch
Lowers the auxiliary hoist.
Auxiliary Hoist Auto selector switch

Enables the auxiliary hoist function.
Auxiliary Hoist Raise selector switch

Raises the auxiliary hoist.
Run selector switch

Enables normal operation of the feeder via main hoist.
Reload selector switch

Allows main hoist to be lowered during sheet feed
(hoist control is transferred to the auxiliary hoist provided the beam limit switch is
actuated.)
OPERATION
The procedure for operating the auxiliary hoist is as follows:
1. Lower the auxiliary hoist using the appropriate selector switch.
2. Insert cross beams between pallet wooden slats in such a position to ensure the
beam limit will be made.
3. Raise the auxiliary hoist using the appropriate selector switch (to make beam
limit switch).
4. Operate selector switch to reload position.
5. Auxiliary hoist is now operational.
6. Lower main hoist via the appropriate push button.
7. Load new stillage.
8. Raise main hoist until the new pile breaks the beam limit switch.
9. Operate selector switch to run.
10. Sheet feed control is now via the main hoist.
11. Remove cross beams.
12. Lower the auxiliary hoist using the appropriate selector switch.
Page 9-2
GENERAL FAULTS
FAULT: Auxiliary hoist motion inhibited.
CAUSE: Linear actuator thermal cut-out operated.
REMEDY: Remove guard on 4060 feeder offside, check temperature of linear
actuator, check for mechanical restrictions, ensure brake is operational.
FAULT: Attempt to lower main hoist stops sheet feed.

CAUSE: Auxiliary hoist sheet feed not enabled.
REMEDY: Ensure beam limit switch is actuated, ensure selector switch is in Reload
position.
Page 9-3
Motorised Conveyor
INSTALATION
The inside conveyor rolls are to be positioned within the feeder and set level using a
spirit level. The feeder pile platform is then to be lowered into the conveyor and the
conveyor finally positioned with the pile platform beams parallel to the conveyor rollers.
The rolls are to be fastened to the floor with the foundation bolts provided.
The outer conveyor rolls are set level and parallel to the internal rolls with a gap between
the two sufficient to tension the connecting chain. The chain tensioner set in the middle
of the adjusting slot. Finally fasten the roll to the floor.
Setting the friction torque limiter

The motor for the inside rolls has a friction torque limiter on the output shaft of the
gearbox, and is to be set at installation. (This is provided to prevent damage to the
conveyor when advancing the stillage into the feeder pile plate). The torque limiter is to
be assembled with two disc springs mounted in parallel (see picture). The lock nut is to
be tightened the minimum amount necessary to advance a stillage on the conveyor
without slipping then tighten the nut another half turn. Bend over a tab on the washer
into a slot in the nut.
Page 9-4
lock nut
washer
OPERATING INFORMATION
Conveyors Inside selector switch
Enables inside conveyor rolls (i.e. conveyor rolls inside feeder envelope).
Conveyors selector switch

Enables both inside and outside conveyor rolls.
Conveyors Outside selector switch

Enables outside conveyor rolls (i.e. conveyor rolls outside feeder envelope).
Conveyor Forward pushbutton

Operation will advance the conveyors (towards the 4060 Feeder). The actual conveyors
operated are selected by the Conveyors selector switch.
Conveyor Reverse pushbutton

Operation will reverse the conveyors (away from the 4060 Feeder). The actual
conveyors operated are selected by the Conveyors selector switch.
OPERATION
The inside conveyors can be operated at any time provided they are selected.
The outside conveyors can be operated at any time provided they are selected and the
main pile hoist is at the lower position.
If the main pile hoist is raised, the outside conveyor can be operated until the conveyor
roll switch is actuated. This switch is located at the interface between the outside and
inside conveyors and is used to prevent a new stillage from being driven into the main
hoist when raised.
Page 9-5
GENERAL FAULTS
FAULT: Outside conveyor will not advance but will reverse.
CAUSE: Conveyor roll limit switch is actuated or faulty.
REMEDY: Check limit switch actuation and electrical integrity.
FAULT: No conveyor motion, electrical fault mimic flashing

CAUSE: motor protection circuit breaker tripped.
REMEDY: As per Operating Information, Action section page 5-8.
MAINTENANCE
Friction torque limiter
The torque limiter will require adjustment periodically. This will become apparent when
the conveyor will no longer advance the stillage. To adjust the torque limiter bend back
the tab on the washer, tighten the nut the minimum amount to advance the stillage on
the conveyor without slipping then tighten the nut a further half turn. Finally bend over a
tab on the washer into a slot in the nut.
Chains
The chains should be checked for tension and lubricated monthly.
The tensioner must be adjusted so the slack side of the chain has between 4mm and
6mm of total movement.
Lubrication is to be carried out with a brush or oil can and should be sufficient to keep
the chain wet with oil and allow penetration of oil into the chain joints. (See
recommended lubricants).
Page 9-6
Scroll Sideguides
When feeding scroll sheets the complete set of standard sideguides are removed, (by
withdrawing the pivot pin), from the machine and replaced with the optional scroll
sideguides.
The scroll sideguides are fitted with magnets, which should be set in line with scroll
“ears” to give maximum sheet separation. Also provided are chrome plated “ramps”
which are fastened to the inside face of the sideguides. Two sets of “ramps” are
provided, narrow ones for small scrolls and wide ones for larger scrolls. Ramps should be
positioned as shown below:
Page 9-7
+/- 100mm Pile Offset Option
SPECIFICATION
Additional Offset of the pile is possible within the standard machine sheet size limits.
Normal operation of the machine is possible and the additional offset is performed in
addition to normal settings.
OPERATION
The additional offset is achieved by adjusting the feed side ‘ side guide’independent to
the drive side ‘
side guide’. With the offset distance set, the normal setting for sheet width
can then be made.
METHOD OF ADJUSTMENT
The following stages should be followed.
1 Slacken the locking screw on the central section of the lead-screw.
locking screw
2 While restricting the central section, rotate the feed side lead-screw to give the
desired offset.
3 Re-tighten the lock-screw in the central section of the lead-screw.
4 Set the side guide to the width of the sheet to be fed.
5 Check the offset to ensure correct feeding.
6 To reset to standard, repeat steps 1 to 5.
MAINTENANCE
As the standard feeder.
Page 9-8
Operating Instructions for Intermediate Conveyor
WARNING:
Prior to operation of the conveyor it must be
securely bolted to the floor.
FULL LINE MODE

In order to change from Coater Only Mode to Full Line Mode, the following steps
must be taken:
1. On the conveyor console, select Full Line Mode
Console is in
2. Lower the main hoist on the Feeder so that it is in the Fully Lowered Position.
Main hoist in Fully

Lowered Position
Page 9-9
3. Raise the hinged conveyor (it can only be raised when the rack is Fully Back).
Hinged conveyor raised

while rack is Fully Back
4. Using the handle on the side of the conveyor, wind the rack towards the Feeder until
the safety latch is engaged.
Handle for racking

forward and back
Safety catch when in

the latched position
Page 9-10
5. Check visually to ensure that the pins on the front and rear chain weights are clear of
the conveyor.
Check that both pins

are clear of
obstruction
Page 9-11
COATER ONLY MODE

In order to change from Full Line Mode to Coater Only Mode, the following steps
must be taken:
Note
The conveyor cannot be operated in Coater Only Mode unless the rack is in its fully back
position.
1. On the conveyor console, select Coater Only Mode
Console is now in
Coater Only Mode
2. Lift the safety latch at the side of the conveyor.
Latch lifted
up to
release the
catch
Page 9-12
3. While the safety latch is up, wind the rack Fully Back away from the Feeder.
Rack is now Fully Back
4. Lower the hinged conveyor.
Hinged conveyor in the

Lowered Position
Page 9-13

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Issue 01 – Oct 1999 Title Page

Amendments issued since last publication

Amendment No. Date Text affected

1 4-11-99 Section 2-2 Text updated.

2 29-11-99 Section 9-8 Added.

3 8-5-2000 Section 9-9 Added.

4 12-03-2001 Section 5-3 Main pushbutton station legend plate

 Crabtree of Gateshead 1999

NO COPYING IN ANY FORM WITHOUT WRITTEN PERMISSION FROM CRABTREE OF GATESHEAD

1 Purpose and Planning

2 Handling, Installation, Storage and Transit

4 Setting & Adjustment

Purpose and planning

Health and Safety

MOVING PARTS CAN CAUSE SEVERING, CRUSHING AND ENTANGLEMENT

HAZARDOUS SUBSTANCES CAN CAUSE SKIN AND RESPIRATORY

SHARP EDGES CAN CAUSE SEVERING AND CUTTING

HIGH PRESSURE FLUIDS CAN CAUSE DAMAGE SEVERE PERSONAL

ELECTRICAL SHOCK CAN CAUSE BURNS OR DEATH

LIFTING EQUIPMENT CAN TRAP AND CRUSH

Voltage 90 … 110% nominal steady state voltage

AMBIENT AIR TEMPERATURE

Capabilities and performance data

Sheet size Max 1250× 1000 mm

Sheet thickness Max 1.00 mm

Aluminium *2 Min 0.20mm

Sheet weight Max 5.0 Kg

*2 Sheets heavier than 3Kg may have to be run at reduced speeds.

*3 Reduced at maximum sheet size.

Standard Production Speeds

Physical dimensions and weight

THIS PAGE LEFT BLANK

Handling, installation, storage and

Preparation of site and services

Reception and handling

Packing case side Internal packing

Nail remover Foil bag

Prise open the lid with the ‘

LIFTING & POSITIONING

Removal of preservative coating

Storage of equipment not to be used immediately

VACUUM/COMPRESSOR PUMP UNITS

SERIOUS DAMAGE CAN BE CAUSED TO THE

THIS PAGE LEFT BLANK

PILE RAISING /LOWERING EQUIPMENT

Pile Height Control Mechanism

SEPARATING AND FORWARDING MECHANISM

Air blast to front of sheet through pile plate

Separating Magnets Rear Sucker

Rear Blower Sheets

SUCTION AND AIR SYSTEMS

DROPWHEELS AND FEED ROLLERS

Adjusting Handle for Sideguide Offset

SHEET ADVANCE AND RETARD DEVICE

SHEET REJECT DEVICE

Double Sheet Detector

Setting & Adjustment

PILE HEIGHT ADJUSTMENT 4-2

PILE HEIGHT ADJUSTMENT

Knurled Adjustment screw

SETTING THE DROPWHEELS

Locknut M10 Socket Cap Screw

3mm Feeler Gauge