QC Conveyors Automation Series Installation and operating instructions

AS40 Conveyors
Installation & Maintenance Instructions
QC Conveyors
4057 Clough Woods Dr.
Batavia, OH 45103 USA
[phone]
qcconveyors.com
Contents
Warnings 2
Tools 3
Installation 4
Drive Packages 11
Maintenance 16
Recommended Spare Parts 22
Troubleshooting 23
Exploded Views 24
Warranty Information 32
Service Record 35

2AS40 Conveyors | Installation & Maintenance Instructions
Warnings
When used improperly, conveyor
rollers can pinch or maim
Lock out power before servicing
conveyor
Do not use with guards removed Read this manual before operat-
ing
DANGER WARNING WARNING WARNING
Climbing, sitting, walking or riding
on conveyor at any time will cause
severe injury or death
Exposed moving parts can cause
severe injury; DISCONNECT
POWER before removing guard
Equipment may start without
warning - can cause severe injury.
KEEP AWAY
Servicing moving or energized
equipment can cause severe
injury LOCK OUT POWER

AS40 Conveyors | Installation & Maintenance Instructions 3
Tools
uRequired Tools
Set of Metric Wrenches (3mm-
13mm)
Tape Measure 10" Adjustable Wrench Screw Gun and T-30 Torx Bit
Aluminum cutting hack saw or
equivalent
Wide Flat Head Screwdriver Set of Metric allen wrenches
(3mm, 4mm & ball head 5mm)
Bubble level
uOptional Tools
3/8" Torque wrench QC Conveyors bearing removal
tool (part# 1A0077A)
Electric Chop Saw

4AS40 Conveyors | Installation & Maintenance Instructions
Installation
uCheck Your Shipment
Before opening the shipment, visually inspect the outside of the crate/box for shipping damage. Carefully unpack the crate/box, inspecting for component damage which
may have occurred inside the packing materials. Contact the carrier and QC Conveyors regarding any damage that may have occurred during shipment. Check the contents
of your shipment against the supplied packing slip and inform QC Conveyors of any discrepancies.
uGeneral Sequence of Installation
1Mount conveyor to stands or mounting brackets; install
angle brackets if appropriate. In
applications with three stands, install
angle braces only on outermost
stands.
2Attach sides, guides or un- derside idlers to conveyor and
adjust as needed.
3Install drive motor and mount- ing package. 4Lag conveyor to floor/ Engage caster locks and inspect
conveyor before use.
uAssistance
If you need assistance, please contact QC Conveyors customer service department Monday through Friday, 8am-5pm EST at [phone]. In addition, your local dis-
tributor has been trained at the factory and can provide support in many ways. You can also visit our website - qcconveyors.com - for additional information and technical
documents.

AS40 Conveyors | Installation & Maintenance Instructions 5
Stand Installation
Mounting Aluminum Stands to Conveyor
uMounting Aluminum Exact Width Stands
Stands should be placed as close to ends of conveyor as possible. Stands may be placed a maximum of 10’ apart for conveyors 6” wide or less with a load less than 20
lbs,; conveyors 8”-12” wide with a load less than 25 lbs.; conveyors 18”-24” wide. For all other conveyors, stands should be placed a maximum of 6’ apart.
1Remove the nuts holding the stand attachment brackets to
the top of the stand and remove the
brackets.
2Insert drop in nuts into t-slot on conveyor frame. 3Attach stand attachment brackets to conveyor using a
5mm allen wrench.
For Conveyors 6” wide or less:
flange should point outboard;
spacer must be installed between
stand attachment bracket and
conveyor frame.
For conveyors more than 6” wide:
flange should point inboard; no
spacer is necessary
4Place stand attachment brackets atop stands.
5Replace nuts and tighten.

6AS40 Conveyors | Installation & Maintenance Instructions
uStand Height Adjustment
1Loosen two lower screws in each stand bracket using a
5mm allen wrench.
2Adjust stand height by turning bolt using a 3/4”
wrench. Turn clockwise to lower or
counter-clockwise to raise. Ensure
conveyor is level.
3Tighten jam nut against top plate of stand. 4Tighten two lower screws in each stand bracket using a 5mm
allen wrench.
uInstalling Cross Ties
For applications using a single cross tie, the cross tie should be installed between the cross bars of the stands. For applications using two cross ties, the cross ties should
be installed between the uprights of the stands.The installation process is the same for each.
4
x2
x
1Using a 5mm allen wrench, loosen two socket head cap
screws in each cross tie adjustment
plate.
2Slide adjustable cross tie pieces to fit between stands. 3Loosen triangular Quick Clamp on each end of cross tie. 4Ensuring the socket head cap screw is facing you, slide Quick
Clamp into tee slot at desired mount-
ing position.
4
x
5Using a 5mm allen wrench, tighten Quick Clamp. 6Using a 5mm allen wrench, tighten two socket head cap
screws in each cross tie adjustment
plate.

AS40 Conveyors | Installation & Maintenance Instructions 7
uMounting Angle Braces
1Insert drop in nut into inner stand leg t-slot. 2Insert drop in nut into con- veyor frame’s t-slot. 3Align angle brace over drop in nut in stand. 4Insert socket head cap screw through angle brace and into
drop in nut on stand (do not fully
tighten).
5Slide up and align angle brace with drop in nut in
frame.
6Insert socket head cap screw- sthrough angle brace and into
nut in conveyor frame.
7Tighten socket head cap screw on frame. 8Tighten socket head cap screw on stand.
9Check with bubble level to ensure conveyor is level.
>Repeat for opposite side.
Injury is possible if the stands are not lagged to the oor, cross ties are not used, or angle braces are not present. Never place a conveyor in operation until all proper
mounts are installed and secured.
Warning: Moving conveyors with casters can create dynamic forces that could tip the conveyor. Use caution when moving a conveyor with casters.

8AS40 Conveyors | Installation & Maintenance Instructions
Mount Installation
2
x
1Insert drop in nuts into t-slot in desired mount location.
>Proceed to correct mount type.
uFlush Mount
2
x2
x2
x
1Align mount to drop in nuts. 2Insert socket head cap screws through mount and
into drop in nut.
3Tighten screws to secure mount to frame. 4Insert screws (not provided) into desired mounting surface
and tighten.
uRaised Mount
Mount‘s foot can be placed facing inward or outward depending on application.
1Align mount to drop in nuts. 2Insert socket head cap screws through mount and
into drop in nut.
3Tighten screws to secure mount to frame. 4Insert screws (not provided) into desired mounting surface
and tighten.

AS40 Conveyors | Installation & Maintenance Instructions 9
Side /Guide Installation
uInstalling Fixed Side Rails
2
x
1Insert drop in nuts into t-slot on frame. 2Align guide brackets with drop in nuts. 3Insert socket head cap screw through guide clamp and into
drop in nuts.
4Insert two drop in nuts into t-slot at tail end of frame.
2
x2
x
5Align clamping block to drop in nuts. 6Insert screws through clamp- ing block and into drop in
nuts.
7Loosen tracking block screws. (Do not remove) 8Slide guide rail in between clamps and frame until in
place.
2
x2
x
9Tighten screws in clamping blocks. 10Tighten screws in guide clamps. 11Retighten screws in track- ing block.

10 AS40 Conveyors | Installation & Maintenance Instructions
uInstalling Adjustable Guide Brackets
1Insert economy nuts into t-slot of guiderail and slide
into position
2Loosely thread adjusting rod into nuts. 3Place a cross block onto each guiderail and set aside. 4Insert drop in nuts into t-slot on frame.
2
x
2
x
5Align guide bracket, keeping the larger hole up, with drop
in nuts and insert screws.
6Tighten socket head cap screws. 7Insert a rod vertically through the larger hole on top of
guide bracket.
8Secure rod from below with socket head cap screw.
9Tighten cap screw. 10Slide guiderail assembly over vertical rods on
frame.
11Adjust guides to desired width and tighten rods. 12Tighten screw on cross block to secure rod.
13Adjust guide to desired height and tighten screw
on crossblock to secure. (Guide
should NOT touch belt)

AS40 Conveyors | Installation & Maintenance Instructions 11
Drive Packages
Conveyor may tip after motor is installed if feet are not properly lagged to oor if outriggers are not installed.
QC Conveyors recommends that all wiring be completed by a certied electrician to ensure correct installation. Refer to documentation contained in the motor’s box for
instructions on electrical connections.
uSide Drive Mounting Package
The Drive Package will ship separate from the conveyor with the speed reducer attached, and the speed reducer’s coupler already attached to its shaft. For Standard Duty Drives
the speed reducer and motor will ship installed on the drive mounting package.
1Remove and discard three cap head screws from drive side
bearing block. (Leave bearing block
in place)
2Install 4mm x 14mm key to shaft. (Shipped with mount-
ing package)
3Using a flathead screwdriver, stake key. This will stop it
from sliding
4Align pins to bearing plate and slide mounting package
over pulley’s shaft against bearing
plate.
5Insert three socket head cap screws. 6Tighten two socket head cap screws. 7The third socket head cap screw will need to be tight-
ened at an angle through access
points using a ball head allen
wrench.
8Ensure set screws on couplings are tight. (Belt may
need to be rotated to reveal set
screws in window)

12 AS40 Conveyors | Installation & Maintenance Instructions
uPivot Drive Mounting Package
The Drive Package will ship separate from the conveyor. For Standard Duty Drives the speed reducer and motor will ship installed on the drive mounting package.
3
x
1Loosen two set screws in drive mounting plate. 2Rotate drive mounting plate into workable position. 3Remove and discard three socket head cap screws from
drive side bearing plate. (Do not
remove bearing plate)
4Align pins on mounting plate to holes on bearing plate and
slide assembly over shaft.
3
x3
x4
x
5Install flat head screws into countersunk holes. 6Tighten screws in countersunk holes. 7Loosen four hex nuts holding gearbox in position. 8Tighten jacking screw to allow gearbox to move toward
conveyor.
2
x
9Remove tape holding key in place. (Do not remove Key) 10Slide top sprocket onto conveyor‘s output shaft
and key.
11Tighten set screws to secure top sprocket. 12Install timing belt over sprockets.

AS40 Conveyors | Installation & Maintenance Instructions 13
uPivot Drive Mounting Package (continued)
4
x3
x
13Run jacking screw out to create tension on belt.
(Approximately 6lbs of force to
deflect one span of belt .09")
14Retighten four hex nuts. 15Replace guard and secure in place with socket head
cap screws.
16Rotate pivot drive into desired position for
operation.
17Retighten set screws to secure pivot drive in
place.

14 AS40 Conveyors | Installation & Maintenance Instructions
uHeavy Duty Top/Bottom Drive Mounting Packages
The Drive Package will ship separate from the conveyor. For Heavy Duty Drives, the motor is always shipped in its own box; the right angle speed reducer will be attached to the
drive mounting package.
4
x3
x
1Remove and discard three socket head cap screws from
drive side bearing plate. (Do not
remove bearing plate)
2Remove four socket head cap screws from guard and
remove guard.
3Mount drive package over drive mounting plate. 4Align mounting holes and install three socket head
screws.
3
x
2
x
5Tighten three socket head screws. 6Remove nylon tape holding key in place (do not remove
key).
7Slide top sprocket onto con- veyor‘s output shaft and key. 8Tighten set screws to secure in place.
3
x
9Loosen three socket head cap screws holding speed
reducer in position.
10Tighten jacking screw so speed reducer can move
toward conveyor.
11Install timing belt over sprockets. 12Run square head screw out, moving speed
reducer away from conveyor and
creating tension on belt.

AS40 Conveyors | Installation & Maintenance Instructions 15
uHeavy Duty Top/Bottom Drive Mounting Packages (continued)
3
x4
x
13Retighten three socket head cap screws. 14Replace guard. 15Insert and tighten four socket head cap screws.
uInstall Heavy Duty Motor to Speed Reducer
1Remove ring holding key in place. 2Remove and discard key that is included with motor. 3Install Leeson speed reducer key to keyway on motor. 4Lightly strike just behind the key with a screwdriver and
hammer.
5Rotate keyway on motor to 12 o’clock position. 6Remove plug from speed reducer. 7Rotate quill pin on speed reducer so that keyway is in
12 o’clock position.
8Apply anti-seize compound to speed reducer input quill and
motor shaft.
4
x4
x
9Install motor onto speed reducer. 10Rotate motor so workbox is in desired position. 11Install 4 hex head screws. 12Tighten 4 hex head screws to secure.

16 AS40 Conveyors | Installation & Maintenance Instructions
Maintenance
Belt Tracking
>For best results, make adjustments to only one side.
uBelt Tracking at Drive End
3
x
3
x
1Loosen three driver assembly screws on each side of bear-
ing block.
2With conveyor running, rotate square head tracking screw
toward drive pulley on side where
belt is riding too close.
3Let conveyor make several rotations to ensure belt is
tracking properly.
4Retighten driver assembly screws. (Three on each side)
The Drive End is tracked when the belt can make a full revolution without contacting either bearing plate.
uBelt Tracking at Tail End
1Rotate adjustment screw to move tail on side where belt
is riding too close.
2Let belt make several rotations to ensure proper
tracking.
Tail End is tracked when belt can make a full revolution without contacting either side of frame.
To see a video of this process, scan this code on
your phone or tablet. You may also visit
http://bit.ly/as40tracking

AS40 Conveyors | Installation & Maintenance Instructions 17
Belt Change
uRemoval of Existing Belt
2
x
2
x
1Simultaneously push in both buttons to disengage locking
mechanism. (Frame end could have
sharp edges)
2Rotate tension release tail assembly up and towards the
drive end.
3Loosen screws on mounts/ brackets on opposite side
of drive.
4Remove screws from stand brackets or mounts. (if stand
brackets are not used, proceed to
step 7)
2
x
5Loosen screws on stand. (Do not remove) 6Slide stand bracket down for clearance. 7Slide belt sideways to clear drive pulley bearing plate. 8Pull belt off of tension release tail.
To see a video of this process, scan this code on
your phone or tablet. You may also visit
http://bit.ly/as40belt

18 AS40 Conveyors | Installation & Maintenance Instructions
uInstallation of New Belt
>If stand brackets are not being used, skip steps 3 & 6.
2
x
1Starting at tail end, loop belt over frame and tension
release tail assembly.
2Loop belt around conveyor frame towards drive end. 3Slide frame bracket up to engage conveyor frame. 4Insert screws through bracket or mount used and into
frame’s drop in nuts.
2
x
2
x
5Tighten screws. 6Tighten screws on stand. 7Rotate tension release tail assembly down and into the
locked position. (Frame end could
have sharp edges)
Conveyor is now ready to be tracked. See belt tracking section of manual.

AS40 Conveyors | Installation & Maintenance Instructions 19
Belt Tensioning
uBelt Tension at Tail End
1Adjust the set screws on the tail assembly so the tail pulley
assembly moves direction need. (In
to relieve tension, out to increase
tension) (Adjust both screws the
same amount).
uBelt Tension at Drive End
3
x3
x
1Loosen six driver assembly screws in bearing blocks
about half a turn.
2Extend the square head tracking screws on both sides
of the conveyor until desired ten-
sion is achieved (extend screws the
same amount).
3Retighten six driver assembly screws to lock assembly into
position.
If additional belt tension is needed after following these steps, it is recommended that a new belt be installed.

20 AS40 Conveyors | Installation & Maintenance Instructions
Care and Cleaning
uBelt Care / Cleaning
1Inspect Belt for any fraying or tears and replace if needed. 2Spray proper cleaning solu- tion on a clean rag. 3Wipe belt with rag. 4Cycle conveyor to reveal op- posite side of belt.
5Wipe belt with rag.