200 Farmpacker

IMPORTANT – PLEASE READ!

The information provided in this manual has been carefully checked and is
believed to be accurate. However, changes are made periodically, THESE
CHANGES ARE INCORPORATED IN NEWER PUBLICATIONS.

Diamond Systems may improve and/or change products described in this

publication at any time. Due to continuing system improvements, Diamond
Systems is NOT RESPONSIBLE for inaccurate information, which may appear in
the manual.

In no event will Diamond Systems be liable for direct, indirect, special, exemplary,
incidental, or consequential damages resulting from any defect or omission in this
manual. Even if advised of the possibility of such damages.

In the interest of continued product development Diamond Systems reserves the

right to make improvements in this manual and the products it describes at
anytime, without notice or obligation.

For the latest product updates please call Diamond Systems Sales or Service.

MAY, 2001

23400 Haggerty Road, Farmington Hills, Michigan 48335-2635 USA

Office: 248-476-7100 FAX: 248-476-0849
Email: info@diamondsystem.com
 WARNING!
SAFETY AND SERVICING
CLEANING, REPAIRING AND/OR ADJUSTING

DO NOT OPERATE ANY PART OF THE

MACHINE UNLESS ALL GUARDS ARE IN
PLACE.
NEVER service, clean, repair and/or adjust any part of the machine
while the machine is still on and/or in operation.

STOP the machine and lock it out before servicing, cleaning,

repairing, and/or adjusting. If the machine cannot be stopped or
turned off, wait until production for the day is completed. If any
guards are removed for service, cleaning, repairing, and/or adjusting
the machine, replace all guards and secure them before restarting
the machine.

Keep all floors dry and free of broken egg, water, oil, and debris in
traffic area of the processing operation. IF the floor becomes wet it
take whatever steps are necessary to keep the floor dry.

Employees should not operate or service the equipment with loose

clothing or long hair.

Make sure all supervisors and employees

understand the importance of keeping all
guards in place and keeping the floor clean
and dry.

January, 2001
 2OOCPH
FARMPACKER
ForParts & Service:

UnitedStates:
Tel: 248-476-7274
Fax: 248-476-3617

Spain:
Tel: 34-94-432-9252
Fax: 34-94-433-6734

Malaysia:
Tel:60-3-5631-4991
Fax:60-3-5631-5991

Oftice 248'476-7100
DiamondAutomation 248-476'7106
DirectDial
23400 Haggerty Road + Ext. -
FarmingtonHills, Fax 248'476-0849
Michigan48335-2635 Service 248-476-7274
USA www.diamondsystem.com
E Mail - Info@diamondsystem.com
 CONTENTS

PageI of3

INTRODUCTION I

N{ACHINE SPECIFICATIONS AC Power 3

I/IAINTENAIICE LubricationandCleaning 516

INSTALLATION AC Hoolary 7
HouseBelt Hookup 8
SettingHouseBelt Delay 9
SettingEgg Courter Units l0

OPERATION Initial StartUp 1t

RI,'N MODE MESSAGES

ClamshellsNot Home t2
EmpB
Denester t2
Den€sterFlat Jam t2
DenesterNotHome t2
DenestingTbrough 13
EggsOut of PositionRemoveEggs t3
EggsOut of PositionSensorBlocked 13
EmergencyStop 13
Me,morySeH-TestError l4
MissineBothFlats l4
MissingFirst Flat i t4
Missing kft Flat t4
MissingRight Flat l5
Missing SecondFlat l5
Pie Se,osorTimeod t5
PtsherChainNot Home 15
Running l6
SafetyGuardOut of Place 16
24V Power t6
Waiting for Cycle Stop 16
Waitingfor Eggs 16
Waitine for StartBufron l6
WarningNo StartSensor t7

TIMING AhIDADruSTMENTS HeadTiming 19

Timing
Clamshell 20
Clcle StopBlock Timing 2l
DenesterAdiushents 22-24,18
Divider Arrangeme,nts 25
Long& ShortAdvanceAd 26,27
 Paee2 of3

MECHAMCALDRIVES SprocketsandChainDrives 28-31

TROI.]BLESHOOTING PackerMalfunctions 33,34

FarmpackerServiceRoutines 35
FarmpackerMaintenanceMode 35
Electical Timing 36
ElecnicalTiming Diagrams 37,38

ELECTRICAL DEVICE LOCATION 39

ELECTRICALDRAWINGS VO BoardLight Definitions 4l

Contol Box Schematic 4244
SystemSchematic 45-51
SubplateAssemblyDrawing 52
SubplatePartNumbers 53,54
Electical Box AssemblyDrawing 55
ElectricalBox AssemblyPartNurnbers 56

MECHAMCAL DRAWINGS SI.JBASSEMBLIES

Pin Bar Assembly 57
Divider Assembly- Thick 58
Divider Assembly- Standard 59
VPaddle ShaftAssembly 60
New V PaddleShaftAssembly 6l
Denester- Lift PlateAssemblYr 62
DenesterSidePlate 63
UpperClamshellAssembly &
Lower ClamshellAssembly 65
EndAlignment ShaftAssembly 66
PaddleWheelAssembly 67
SliderBar Assembly 68
White GuideBlock Assembly 69
StainlessSteelEgg GuideAssembly 70

MECTIAMCAL DRAWINGS M^AIORASSEMBLIES

PKSAssembly 7l
StackerInfeedPKS 72
Pre-ReservoirAssembly 73
OverheadShuttleAssembly 73
OverheadShuttleAssembly 74
ReservoirAssembly 75
Reservoir- Top 76
ReservoirTransfer 77
Head- FrontView 79-80
Head- Inside 81
 Page3 of3

MECHANICAL DRAWINGS MAJORASSEMBLIES

Head- L.H. Side 82-83
Head- R.H. Side 84
Head- PartNumbers 85-86
BaseDrawings 87-89
CrossShuttle 90-92
CrossShuttle- BottomView Den.End 93
CrossShuttle- BottomView 94-96
CrossShuttle- BottomView Drive End 97
Cross Shuttle - Back Side 98
All Guards 99

GLOSSARY 101-102
 INTRODUCTION

Our family here at DiamondAutomationis very pleasedthat after much researchand

considerationyou have confidentlychosenthis superiorbuilt, Americanmade,72,000
eggsper hour Farmpacker.

This efficient packer is the first successfulhigh capacrtyfarmpackeravailablein the

world. Its compactdesign,singledenester,easymaintenance and maximumthroughput
arequalitiesthat makethis packeran intelligentdecision.

Diamond'sexcellentcustomerserviceandsupportincludesa worldwidenetworkof sales

andserviceofficesthatwelcomeyour inquiriesandquestions.

We are confidentyou will be satisfiedand will enjoy your high quality Farmpacker.
Thankyou for the trust you haveplacedin us.

DiamondAutomation
 MACHINE SPECIFICATIONS

AC POWERINPUT: VAC,60rfz,1 PHASE

230-240
220-230VAC, 50 TfZ, 1 PHASE

POWERCONSIIMED: .746KW. I HP

CASESPERHOUR: VARI,ABLE SPEEDWITH 2OOCPH MAXIMUM

NOTE: Attemptingto run this Farmapckerabovethe Diamondrecommended

specificationmayvoid all waranties.

J . v
 MAINTENAI\CE

Thereare two key ingredientsthat go into operatinga long term, trouble free farmpacker.
They arepropermaintenanceandkeepingthe packerclean.

LIIBRICATION:

1. Lubricate all chainswith a 30 weight motor oil once a week. Also check chain
tensions. Cleanbefore oiling if necessary.Don't forget the #25 chain on the end
alignmentrollers.

2. Greaseall bearingsand greasablerod endswith a multi-purposegreasebi-monthly,

makingsuregreaseis gettinginsidebearing.

3. Oil all of the oil lite bearingswith a #10 or #20 weightmotoroil.

4. Checkthe oil levelsin the reducersevery6 monthsor soonerif you noticethe seals
leaking. Theyusesynthetic90 weightoil.

5. Oil the lower clamsheltsand all internalmoving partswith a USDA approved,food

gradelubricant.

CLEAI\ING:

It is very important to keep specific areas of this farmpacker clean for ma><imum
"ease
productivity. For this re{Non,the farmpackerhasbeendesignedfor our customers
of removal"of certainitems. Theyarelistedbelow:

l. Removabledividersthat pivot up. Simplyremoverod endassemblyfor motion from

the divider angleand dividerspivot up so reservoirbed can be cleanedhasslefree.
Dividers were designedto be removedfor cleaningor exchangedwith thicker type
with the Easeof springloadedfingerlatches.

2. White divider blocks: A quick drop in/pull out bar assemblyfor easy accessto
paddlewheelcleaning.

3. Pin bar assembly: A quick drop in/pull out angleassemblyfor easyaccessto end
alignmentroller cleaning.

4. Stainlesssteel divider assembly: A quick drop in/pull out bar assemblyfor easy
accessto endalignmentrollersandpaddlewheelcleaning.
 "v" paddle wheel assembly: Simply pull shaff/paddleassembly
5. Spring loaded
towardsspringandremovefor cleaningof paddlesor accessto upperclamshells.

6. Stainlesssteelchuteassembly:A quick drop in/pull out bar assemblypulls out for

easycleaningor accessto upperclamshells.

BASIC CLEANING:

l. Removeand emptyall drip traysandpansand rinseout or wipe down with a damp

cloth.

air
2. Use a darnpcloth to wipe downthe farmpackerfor generalcleaning.Compressed
_to cleanpackeris approvedby DiamondAutomation. Never use directwater spray
(high pressureor not) to cleananypart of this packer.

3. End alignmentrollers should be cleaneddaily for optimum points down of egg

performance.Cleanwith dampclothor very soft brush.

4. Paddlewheel assemblyat (12) eggspresentsensorsshouldbe cleaneddaily. If not,

feed dust or debrismay give falseindicationsto sensorand a missingegg problem
may occur.

5. Stainlesssteelchuteassemblyshouldbe cleaneddaily for assuringclearpassage

"egg
of
eggsinto clamshellswithouthesitationor deflectionwhich may causeout an out
of position"messageor mayresultin eggbreakage'

6. All sensors,reflectorsandopticaldevicesshouldbe wipedwith a dry cloth bi-weekly

to assureno falseindicationsfrom feeddust,oil or otherforeignmaterials.

6
 AC HOOKTJP

Usingthe following chart,connectthe inputlinesto TB-1. TB-l is locatedin the

electricalconfrolbox nearthebottom.

voLTS (AC) FREQW) PHASE # OF WIRES

208 60 I a
J

230 60 I 3
240 60 I 3

TB-1

voLTS (AC) FREQW) PHASE # OFWIRES

200 60 3 4
200 50 a
J 4
208 60 J 4
230 60 3 4

TB.I

I 2 3 4 5 6 7 8 9 10 11 12

LI L2 L3 GND

voLTS (AC) FREQW) PHASE # OF WIRES

220/380 50 J 5
230/400 50 3 )
240/4t5 50 3 5

TB.I

L1 L2 L3 NEU GRD
 HOUSE BELT HOOK I,JP

The farmpackercontols the housebeltsthroughrelaysCR-l andCR-2. Useoneof the

following diagramsfor your application.

FOR MOTORSUNDER'/I H.P. CONNECTACCORDINGLY

TB.I
CR-I CR.2

I 2 3 14 s 16 7 8 9 t0 ll ltz

AC
Motor

FOR MOTORSOVER %H.P. CONNECTACCORDINGLY

TB-1

cR-1 CR-2

h
AC

8
 SETTING HOUSE BELT DELAY

1 . RemoveI/O-1 PCB from the cardgate.

2. Setswitchesaccordingly.

Off On

sw-1
sw-2
sw-3
sw-4

SECONDS SWITCHES
I 2 3 4

0.5 OFF OFF OFF OFF

1.0 ON OFF OFF OFF
1.5 OFF ON OFF OFF
2.0 ON ON OFF OFF
2.5 OFF OFF ON OFF
3.0 ON OFF ON OFF
3.5 OFF ON ON OFF
4.0 ON ON ON OFF
4.5 OFF OFF OFF ON
5.0 ON OFF OFF ON
5.5 OFF ON OFF ON
6.0 ON ON OFF ON
6.5 OFF OFF ON ON
7.0 ON OFF ON ON
7.5 OFF ON ON ON
8.0 ON ON ON ON
 SETTING EGG COITNTERT]NITS

RemoveVO-z PCB from the cardgate. Seeelectronicdevicechartfor its location.

Setswitchesaccordingly.

OPTION SWITCHES
I 2 3 4

NO COUNTER x OFF OFF X

COUNT IS DISPLAY€D IN EGGS X OFF ON X
COUNT IS DISPLAYED IN DOZENS x ON OFF x
COI.INTIS DISPLAYED IN WHOLE CASES X ON ON x

NOTE 1. The message centerwill displaythe countof eggspacked.It countseggsby

countingthe baseindexes.

NOTE 2. Inaddition,the counterwill not counthandcrankedcycles. It checksto seeif

the motoris on beforeincrementingthe count. If the motoris not on the counterignores
counting.

NOTE 3. You can clearthe currentcountby stoppingthe farmpackerandholding down

both the STOPandOVERRIDEbuttonssimultaneously.

NOTE 4. The counterwill not displayif the farmpackeris in an error condition. This
way the counterdisplaywill not interferewith any of the farmpackersafetymessages
which mighthavestoppedthe machine.The countwill not displayif the motoris off. If
you want to seethe countwhile the farmpackeris stopped,pressthe overridebutton.

l0
 INITIAL START UP

ACTION: Turn on the mainpowerswitch.

NOTE: This main power switchis not to be usedasa meansof turning

the packeron and offthroughout the day. Main powershouldbe
turned on beforeoperatingand at the end of the day's operating.
Also furn main power offto service,clean,repair and/or adjust
any part ofthe packer.

RESULT: The MessageCenterdisplays:

Diamond)OLX
Hi SpeedFarmpacker

ACTION: Loadthe denesterwith flats.

ACTION: Put (2) traysunderclamshells,and(2) traysbehindclamshelldrop.

ACTION: Pressthe green"Start" buttonswitch.

RESULT: Thepackermotorturnson and3 flats aredenested andadvancedon

the crossshuttlebeforethe headandreservoirmove.

\-. RESULT: Thenthe headstartsto cyclecontinuouslyandthe basepusher

advancesfor (6) cyclesonly. To clearthe headof any eggsleft in it.

ACTION: Placethe "HouseBelts" buttonswitchin the downposition.

RESULT: The housebeltsturn on.

RESULT: When(12) eggsarepresentat the (12) eggspresentsensors,the

paddlewheelclutchwill index(1) row of eggsinto the endalignment
rollerswhenthe leadingedgeof the pie sensoris seen.
If the packerstopspackingeggsit will stopandthen displaya
message acrossthe "MessageCenter". Referto the nextsectionfor
whatthesemessages mean.

NOTE: The emergencystop is not to be usedto casuallystopthe packer.

lt is only to be usedin an emergency.

l1
 RUN MODE MESSAGES

CLAMSHELLS NOT HOME

camsensoris not on whenthe

Definition: This messagecomesup if the pie-shaped
greenstartbutton is Pushed.

Cause: Use of emergencystopbuttonor clamshellcoastproblem,or headhandwheel

was turnedwhenPackerwasstoPPed.

To restart: Bring the clamshellshome,turn theheadhandwheeluntil the pie-shaped

cam sensorturnson.

DENESTER EMPTY

missingflats.
Definition: Occursif therearesix consecutive

jam.
Cause: Empty denester,denester

To restart: Refilt denesterandpressstartbuffon.

DENESTER FLAT JAM

Definition: Occurswhenthe DenesterJamSensordetectsan object'

Cause: A flat out of Position.

To restart: Repositionthe cartonandpressthe startbuffon. NOTE: A flat doesnot

haveto be presentto proceed;simplypressthe startbutton.

DENESTERNOT HOME
is
Definition: Occursif an affemptis madeat startingthe packerwhenthe crossshuttle
not in its homePosition.

Cause: Crossshuttle'shandwheelhasbeenturnedwhenthe packerwas stopped.

sensor
To restart: Turn crossshuttle'shandwheeluntil red light on the crossshuttlestop
tuns on. Pressstartbutton.

t2
DENESTING THROUGH

Definition: Occurswhen eitherthe first or secondflat out of the denesteris missingon

the crossshuttle.

Cause: Empty denesteror flatsh,rngup in denester.

To restart: Packerdoesnot stop.

EGGS OUT OF POSITION REMOVE EGGSFROM CARTON

Definition: This messagecomesup whena strayegghasfoundits way into the headand

hasbeendepositedinto the carton. The machinestopsandwaits for the operatorto
removethe sfiay egg from the cartonto avoideggbreakage.

Cause: Strayegg.

To restart: Removeegg andpressthe greenstartbutton.

EGG OUT OF POSITION SENSORBLOCKED

Definition: This messageappearsif the eggin clamshellsensorbecomespermanently

blocked.

Cause: Feeddust,oil mist or foreignmaterialblockingsensorfaceor becausesensoris

bad.

To restart: Cleansensorandreflectoror changesensor,thenpressgreenstartbutton.

EMERGENCY STOP

Definition: Occurswhenthe emergencystopbottomis pressed.

Cause: Pressingof the emergencystopbutton.

To restart: Pull up on emergencystopbutton. Pressstartbutton.

NOTE: When restarting after an emergencystop,you might geta 6'clamshellsnot

home", "denesternot home" or both. Followthe restart procedurefor eachstop
condition.

13
MEMORY SELF''TEST ERROR

Definition: Whenpackeris initially poweredup it doesa selftest of its program. If

thereis a problemit will displaythis message.

Cause: Elecffonichardwaremalfunction.

To restart: ContactDiamondfor assistance.

MISSING BOTH FLATS

Definition: Occurswhenboth left andright flatsaremissingor out of position.

Cause: l. Both flats couldbe out of position.

2. This situationwill occurfirst thing in the morning'

To restart: l. If both flatsareout of position,repositionthemandpressstartbutton.

2. Inthe morningif thereareno eggsat the paddlewheel, pressthe override
buttonuntil thereare flats underthe clamshells.If thereare eggsat the
paddlewheel manuallyplaceflatsunderclamshells'

MISSING FIRST FLAT

Definition: Occurswhendenestermissesa flat.

Cause: Denestermissesa flat.

To restart: Packerdoesnot stoP.

MISSING LEFT FLAT

Definition: Occurswhena flat is out of positionor missingon the left packerbase

shuttle.

Cause: A flat is out of positionor missing.

Cause: A flat is out of positionor missing.

To restart: Repositionflat or manuallyplaceonein front of the sensorandpressthe

startbutton.

T4
 MISSING RIGHT FLAT

Definition: Occurswhen aflat is out of positionor missingon the right packerbase

\--, shuttle.

Cause: A flat is out of positionor missing.

To restart: Repositionflat or manuallyplaceoneat the sensorandpressthe startbutton.

MISSING SECONDFLAT

Definition: Occurswhen denestermissesaflat.

Cause: Denestermissesa flat.

To restart: Packerdoesnot stop

PIF' SENSORTIMEOUT

Definition: Messagecomesup whenthe softrvarethinksthe headclutchis on andthere

havebeenno leadingor trailing edgetransitionsof the pie-shapedcamsensor.

Cause: Maybethe headclutchVO is bad,the clutchis bad,the headclutchwire is

\- broken,setscrewsor pinch collarsareloose,pie-shapedcamsensoris bad.

To restart: Pressstartbutton.

PUSHER CHAIN NOT HOME

Definition: Occursif an attemptis madeat startingthe packerandthe basecyclestop

handcrankthe baseuntil the cyclestopsensor
sensoris not on. To get pastthis message,
comeson andtry startingagain.

Cause: Pushershavebeenmanuallymovedwith the handwheelwhenthe packerpushers

werestopped.

Cause: Basebrakeis not functioningproperly.

Cause: Cyclestopsensorblock not setproperly.

To restart: Turn the basehandwheeluntil the red light on the cyclestopsensorturnson.

Pressstartbutton. Seethe DeviceLocationChartfor the sensorslocation.

l5
RUI\NING

Definition: Occurswhenpackeris packingeggs.

To restart: Packerdoesnot stoP.

SAFETY GUARD OUT OF PLACE

Definition: Occurswhenoneof the six coversafetyswitchesis open.

Cause: A coveris open. Seedevicelocationchart.

To restart: Closeopencoverandthenpressstartbutton.

24V POWER

Definition: Occurswhen24 volts is not present.

Cause: Blown Fl or F2 fuse.

To restart: Turn offpacker, replacefuseandthencyclepackeron.

WAITING FOR CYCLE STOP

Definition: Occursif thereis a packermalfunction.

Cause: Mechanicalor electricalmalfunction.

To restart: Turn offpacker, correctmalfunctionandthencyclepackeron.

WAITING FOR EGGS

Definition: Occurswhenpackeris readyto packeggsbut theyarenot presentin the

paddlewheelat the (12) eggspresentsensors.

Cause: No eggs.

T6
WAITING FOR START BUTTON

Definition: Occurswhenpackeris packingeggsandthe stopbuttonis pressed.

Cause: Depressionof stopbutton.

To restart: Pressstartbutton.

WARNING NO START SENSOR(USEDTO BE MASTERTOOTIT)

Definition: Occursif thereis a packermalfunction.

Cause: Mechanicalor electricalmalfunction.

To restart: Turn offpacker, correctrnalfunctionandthencyclepackeron. -

NOTE: Handcrankingpackerbasehandwheelmore than one cyclewill alsocause

to be displayed.To restart,pressthe start button.
this message

t7
D I A M O N D E E PPOC K E T R A Y 12/1o/sa
orNisTERsET uP.
AT DIAMOND
MAT'IUFACTURED
TNNTUPACKERS
ALL tr TNE OINUOTIO nqNn'rEotnuoNDDEEPPocKET
AuroMATroNs ARi'bEiJi-Nt _iEiTib-ici
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'ii[o-nelr-qqBG str. Vt nno resrEoFoRTHEsE
TRA\€.THERE nnb DRoP-Ut BARS THArAREPoslTloNED
THEDENESTER lN
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ANDSEETHEFARMNCiiN-IJIT'Ti.JN-
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DENESTER
DIAMONDIRAY
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JAWS
DENESTER
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BOTTOMTRAY

DENESTERJA\flS
NOTE
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REMO\ED

DENESTERJAW
ASSEMBLY
oNE SIDESFloYt/t'|.
t8
LOWERCLAMSHELL 2 O OF A R M P A C K E R 5/3 /s8
CRANKARM AT
B.D.C. H E A DT IM I N G
P U S H E RI N D E X
TRAILINGEDGE WITHLOWERCLAMSHTLL CRANK
(T.D.C.).
A R M A T T O P D E A DC E N T E R

L I N EU P HOLEST H R U
PADDLEWHEEL ( 2 ) s t D EP L A T E S& G A G E .
EDGE
LEADING

84000700
H E A DG A G E

PUSHER]NDEX-
EDGE
CLUTCH_TRAILING

qqw,,
\r
PADDLEWHEEL
CLUTCH
LEADINGEDGE
NOTE: GAP BETWEEN
FACE OF SENSOR&
CLUTCHCAM:.015".

NOTE:WHENPADDLEWHEELC A M I S J U S TI N F R O N TO F
SENSOR( L . E . D J. U S TG O E SO N ) E N D A L I G N M E N T
ROLLERSSHOULDBE AT 24".
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21
 D E N E S T TA
RD J U S T M I N T S
FIGURE JAWCTNTERS

DENESlER DENESTER
SIDE SIDE
PLATE PLATE

JAW LOOSEN JAW

ASSEMBLY NUT ASSEMBLY

ADJUSTTHE JAW CENTERSTO FLAT.

GUARDFROMDENESTER.
THEREARDENESTER
1 . REMOVE
2. TAKETHE FLATTHATWILLBE USEDON THISPACKERAND MEASURT
THAT
rHi brSrnNCE BETWEEN THE OUTERTWOCELLSoF THE FLAT.
DISTANCE IS WHATTHE TWOJAW ASSEMBLY CENTERSSHOULDBE.
3. BRINGTHE JAW ASSEMLIES TO TOP DEADCENTER.TURNTHE HAND
WHTTION THE CROSSSHUTTLE TO BRINGTHE JAW ASSEMBLIES TO
THE HIGHEST POINTPOSSIBLE.
+. ADJUSTBOTHOF THE JAW ASSEMBLIES IN OR OUT WTH A SCREW_
onrGn, iHnoucu THEHoLE lN THESIDEPLATE.
"JAW loqsE\ NUToN
SIUO flnSf. SEE FTGURE CENTERS".BE SURETHAT
EnCH JAW ASSEMBLY MO\ES THE SAMEAMOUNT.DO THISBY
COUNTINC THE ruRNS OF THE SCREWDRIVER.ADJUSTUNTILTHE
CTT TENS OF THE JAW ASSEMBLIESMATCH UP WTH THE DIMENSION OF
iHE CrNTERSOF THE OUTERTwo CELLS oF THE FLAT.
5 . BRINGTHE JAW ASSEMBLIES TO BOTTOM DEADCENTER. MAKESURE
iHi. .Inw ASSEMBLiESARE CENTERED IN THE DENESTER. THE DISTANCE
rnOru THE CENTinbr JAw ASSEMBLY To THE INSIDEoF SIDEPLATE
Musi BE THE sAuE oN BoTH SIDES.TAKEMEASUREMENT FRoM
CErlrEnoF JAwS, wHERETHE THREADED RoD GoES THRoUGH JAW
ASSEMBLIES.
6. FOR A FINAL CHECK,PLACE A FLAT IN THE DENESTERJAWS AND
CHECKTHE FIT.
7. IF EITHERJAW ASSEMBLYHAS BEEN ADJUSTED,CHECK-B-OTHOF THE
,,ADJUST
JAWS FOR CORRECTOPENING.SEE THE JAW OPENING".

22
 D E N I S T E RA D J U S T M T N T S
F I G U R E J A W O P E N IG
N 13/8
(35 mm)
TO
1 1/2 |
(samm)l--
NO FLATSIN DENESTER

HARWOOD
FLATS

A D J U S TT H E J A W O P E N I N G .
TO TOP DEADCENTERBY TURNINGTHE
1 . BRINGTHE JAW ASSEMBLIES
CROSSSHUTTLEHANDWHEEL. TURN SLOWLYAS APPROACHING THE
TOP UNTIL JAWS ARE CLOSEDAS FAR AS THEY WLL GO.
2 . WITHTHE JAW ASSEMBLIES AT THIS POSITION, TAKE A''JAW MEASUREMENT
ACROSSTHE TOP OF BOTH SETS OF JAWS.SEE FIG. OPENING,'.
IF JAWS ARE ADJUSTEDFOR HARDWOOD FLATS, THE TENSION ON THE
SMALLSPRINGS#9076077 AT THE END AND UNDERTHE JAW SHAFT
MUSTBE RELEIVED SLIGHTLY. WHENTHE JAWSARE IN THE OPEN
POS|TIONTHE SPRING#9076077 SHOULDHAVE ALMOSTNO TENSION.
3 . TO ACHIEVETHE DESIREDPOSITION, LOOSENTHE CAM ROLLERBOLT
FROMTHE ARM AND SLIDEIT IN THE SLOTTO GET THE CORRECT
JAW OPENING ASSEMBLY''.
I N B O T HA S S E M B L I E S .E E F I G U R E , , A R M
+. I F B O T HJ A W O P E N I N G AS R E N O T T H E S A M E ,T H E NL O O S E NT H E A R M
TO MATCH
WITHOUTTHf SLOTFROMTHE ROD AND ADJUST ''ARM THE JAWS
THE OTHERJAW ASSEM BLY. SEE FIGURE ASSEMBLY''.

FIGURE ARM ASSEMBLY

CAM ROLLER
ARM
WTHOUT
SLOT

PLATE CAM
3642700

AT TOP DEADCENTER.
WITHJAW ASSEMBLIES

23
 _'

D E N E S T EA
RD J U S T M E N T S
F I G U R E C L A M PP L A T E

A P P R O X T M A T E3L/Y1 6 "
( + . 2m m )
CLAMPPLATE

BLACK
KNOB

L . o 3 o ( . 8 m m )T o
060 (1.5 mm) GAP
WHENCLAMP PLATE
IS LIFTED.

ADJUSTTHE CLAMPPLATESTO THE STACK OF FLATS.

1. BRINGTHEJAW ASSEMBLIES TO TOPDEADCENTER WTH THE
DENESIERFULLOF FLATS BY TURNING THE CROSS SHUTTLE
HANDWHEEL.
2. TURNTHE BLACKKNOBSON THE OUTSIDE OF THE DENESTER SIDE
PLATEUNTILTHERElS APPROXIMATELY 3/16" (J.2 mm) CLEARANCE
BETWEEN THE CLAMP PLATE AND THE STACK OF FLATS ON BOTH
''CLAMPPLATE".
SIDES.SEEFIGURE
3. WITHTHE JAW ASSEMBLIES AT TOP DEADCENTER. LIFT THE CLAMP
PLATEUPWARD BY HAND.THEREMUSTBE A .030,, TO .060''
PLATE AND BLOCKON
''CLAMP CLAMP
(.a mm TO 1.5 mm) GAP..BETWEEN
AOTHSIDES.SEE FIGURE PLATE'"
4. TO ACHIEVE THE GAP DESIRED, LOOSEN THE RODEND ASSEMBLY
(rHE oNE THAr LIFrS rHE JAW lSSq1{B_!I).FRoM rHE LlFr ARM,
iruO ADJUSTTHE RODTO LENGTHNECESSARY. DO THE SAME
ADJUSTMENT TO THE OTHERSIDE.

24
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25
 LONG AND SHORT ADVANCE ADJUSTMENTS

If it becomesnecessaryto disassemblethe long and short advanceassemblies,turn the

poweroff and follow the stepsbelow:

I. TUrNthE hANdWhECI UNtilthc PUSHER CHAIN COMES TO THE BEGINNING

OF TIIE FIRST STROKE. The clamshellframe assemblyshouldbe halfivay up
and the clamshellcrank arms shouldbe horizontal. SeeFIGIIRE - RATCHET
ASSEMBLIES. NOTE: Positionof ratchetandpawl.

Z. Make an alignmentmark on the chain and sprocketon both sidesso they can be
returnedto their originalpositionswhenbeingreassembled.Also conntthe number
of pitcheson the chainfrom rod endto first engagedsprockettooth. Follow the same
procedureon boththe L.H. andthe R.H. sides.

3. Disassemble the 5/16-18x 1'Abolt andfiber nut that anchorsthe rod end(with chain)
to arm. Slip the chainoverthe sprocketto remove.Both sidesif necessary.

4. Do the requiredrepairs. If the ratchetcamsmust be removedthen note the timing

holesare opposite.

with pusherchainat the FIRST STROKE. Make surethe pusherchain

5. Reassemble
DOES NOT movewhendoingthe nextstep.

6. L.H. and R.H. SIDE - Stip the chainover sprocketteethand sfretchspringuntil rod
end reacheslong and/orshortadvancearm with ratchetandpawl in original position.
Attachwith 5/16nut andbott. SeeFIGIJRE - RATHCET ASSEMBLIES.

7. Make sure that the over travel (gap:approx. .060") on the ratchet and pawl
assembliesare the sameon both sidesbetweenthe lst and 2nd strokeonly. If not,
then disassemble5/16-18nut and bolt that holdsthe rod end. Then loosenthe jam
nut on rod end and adjusta % turn at a time until gap is equal on both sides. Turn
handwheelto cycle packerand check gap eachtime an adjustmentis made. If gap
getsworse,turn rod end in oppositedirection. Adjustmentscan be madeon either or
both sides.

26
FIGURE R A T C H E TA S S E M B L I E S
O F R A T C H E TA S S E M B L I EAST
POSITION
B T G I N N I NOGF 1S T S T R O K I
DoG(enwr-)

RATCHET
APPROX.
.060"
GAP

L .H . S I D EO F P A C K E RB A S E
L O N GA D V A N C ER A T C H E TASSEMBLY

* EGGTRAYFLOW*

Doc (PAWL)

RATCHET

@@@o@o@@

R . H . S I D EO F P A C K E RB A S I
SHORTADVANCER A T C H EATS S I M B L Y
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31
JL
 PACKER MALFUNCTIONS

1. SYMPTOM: Pusherindex moving too soon or too late, or coasting past

causingmissingindex.
FIX: Checkheadtiming; seepusherindexclutch- trailing edge.
FIX: Checkcyclestoptiming.
FIX: Checkto makesurepusherindex brake is engaging. Send(1)
row of eggsthroughpaddle wheel at a time and check index
brake. Checkgap betweenclutch and clutch pate. Should be
.030".
FIX: Checkto makesurepusherindex clutch is engagingto advance
pusheron time.

2. SYMPTOM: Indexpushersnot moving.

FD(: Checkto makesureindex clutchis gettinga signal. Then check
to makesureclutchis engaging.
FD(: Checkcyclestoptiming.
FIX: Checklong and short advanceratchetassembliesto make sure
they are engagingproperly. Also check spring holding cam
roller againstcamis not brokenor malfunctioning.

3. SYMPTOM: MissingEggsin fay.

FD(: Checkto makesureall (12) sensorsareworking. Checkto make
sure sensoradjustmenthas not moved. Sensorshould not see
egguntil eggis all theway in the paddlewheel.
FIX: Checkheadtiming with gageto makesuretransferfrom paddle
wheel to end alignmentrollers is correct. Checkto see if any
eggshavefalleninto drip panbelowroller assembly.

4. SYMPTOM: Overheadshuttlefiring too soonor too late.

FD(: Seeelectricaltiming of overheadshuttlestartsensor.

5. SYMPTOM: Too many "eggs out of position - remove eggs from carton"
messages.
FIX: Check head timing to make sure eggs are transfening when
they'resupposed to.
FD(: Check pressure or drive of eggs going into dividers. Are the
extra eggsbeing forced over other eggsin paddlewheel? Are
there too many eggs on the reservoir? The ideal egg amount
should be eggs full to approximately2' past the center dead
plate. Checkegg hold down slats. They shouldbe positioned
just overthe biggesteggwithouttouchingit.
33
6. SYMPTOM: Paddledoesnot fire.
FD(: Checkpaddlewheel proximity sensorL.E.D. Does it comeon
when it is supposedto. Check gap betweensensorand disc -
Check(12) eggspresentsensors.CheckIIO - 3 board. Is signal
telling clutchto fire? Is powersignalreachingcoil in clutch?
"eggs out of position removeeggs
7. SYMPTOM: Extra row of eggs causing
from carton"message.
FD(: Checkheadtiming.
FIX: Checkto makesurepaddlewheel clutch is not doubleindexing.
Dog stuck in solenoidwhile (2) ratchetsgo by. CheckIlO - 3
board.

8. SYMPTOM: Overheadshuttledoublefires or coastspaststop.

FIX: Checkoverheadshuttlestopsensorandbrake'

g. SYMPTOM: Eggsfalling throughclamshells,

FD(: Arm for clamshellopenhas slippedand gap when closedis too
big. Gapshouldbe .69 from tip to tip whenclosed.
FD(: Eggs may be droppingat the wrong time. Check headtiming
with gauge.

34
 FARMPACKER SERVICE ROUTINES

You may enterthe servicemodeby depressingand holding either the Stopbutton or the
Startbuttonwhile turningpoweron. The servicemodepromptmessage on the displayis:

FARMPACKER SERVICEOTROUTINES

At this point, any changeof stateof any input device on the machinewill display a
messageon the messagedisplay. For example,whenyou releasethe Startor Stopbutton
after turning power on, you will see the messageSTART BUTTON UP or STOP
BUTTON UP on the display.

The servicemodecanbe usedat anytime to testthe pushbuttonsandsensordevices.

You will get a different messagefor eachchangeof stateof any push button by simply
pressingthe buttonandreleasingit.

You wilt get a messagefor the 5 metalproximity sensorsby putting a screwdriverin front
of themandthenremovingit. The 5 proximity sensorsarethe cyclestop,cross-overhead
shuttlestart,crossshuttlestop,andoverheadshuttlestopsensors, pie sensor.

You will get a messagefor the 7 optical sensorsby simply breakingthe beamwith your
hand. l"Ite 7 optical sensorsare the piggyback,flow control (housebelts),denesterjam,
denestermissingflat, eggin clamshells,andthe right andleft missingflat sensors.

FARMPACKER MAINTENANCE MODE

This farmpackeris capableof running without eggs or ftays. The sensorinputs are
blocked internally which makesthe farmpackerthink it has eggsand trays, therefore,it
will run. Do not run eggsfor productionin this mode. The switch is on IlA 2 board
switch#4.

The farmpackercannotrun without eggsgoing through the clamshellswithout being in

the maintenancemode. In otherwords, you can't fake the farmpackerinto thinking it has
eggsby blocking all (12) eggspresentsensorandexpectingit to run. It will stopwith an
"egg in clamshellsensorblocked"message.

If there is a problemand you needto evaluateit, but don't want to run (12) eggswide
becauseof breakage,you can run one egg at a time by blocking (11) of the (12) eggs
presentsensors,leavingone on the end unblocked,but first turn the housebelts off, run
the packerand clearthe reservoirof eggs. This will stop eggsfrom going into the (11)
sensorblockedlanes. Thenyou cansend(1) eggat a time throughthe packerto evaluate
the problemarea.
35
 ELECTRICAL TIMING

NOTE: Refer to "Electrical Timing Diagrams" for item locations.

1. SENSORGAP ADJUSTMENT
a. At the Cycle Stop,CrossOverheadShuttlestart,OverheadStopandCross
ShuttleStopsensors,adjustthe gapbetweenthe sensorandmetalfor .050"
(1MM).

2. CYCLE STOP SENSORCOLLAR

(seecycle stoPtiming)

3. CROSSSHUTTLE STOP SENSORCOLLAR

a. While observingCrossShuttleHomeViewing Window,turn the CrossShuttle
Handwheeluntil the nut is centeredin the window.
b. Wittr a3/16" Allen wrench,loosenthe CrossShuttleStopSensorsetcollar.
Rotatecollar clockwiseuntit light on sensorjust turnson. Retightensetcollar-

4. CROSS/OVERIIEAD START SENSORCOLLAR

With the packerturnedon in the ServiceMode,turn the packerbase
handwheeluntil the clamshellsarebottomdeadcenterof the third row of eggs.
At this time take a straightedgeandplaceit acrossthe backof a pusherout to
the packerbasebed. Make a markon thebed. Measure%" (6MM) aheadof
this mark andmakeanothermark. Turn the handwheeluntil the pusherhas
advancedto the 7r" (6MM) mark. At this time,usinga %"wrench,loosenthe
sensorcollar,rotateit countercloclcwiseuntil the sensorlightjust comeson
andthenretightencollar.

5. OVERIIEAD SHUTTLE SENSORSLIDE BRACKET

a. Put packerin the run modewith housebeltsoff.
b. gtock l l of the L2 eggpresent sensors.The oneremainingsensorwill be used
to run packer.
c. Install flats into the denester.
d. Rgn the packeruntil the OverheadShuttlecycles. Measurethe gapbetween
the overheadShuttleBar Assy. andthe front of the shuttle. Referto the
ElectronicTiming Diagramsfor item locations.The gapshouldbe 2'88"
(72MM). If it is not, with a7116"wrench,adjustthe slidethatthe Overhead
ShuttteStopsensoris mountedto, recyclethe shuttleandmeasureagain.
Repeatuntil this gaPis reached.

36
 ELECTRICAL
TIMINGDIAGRAMS

1.) SENSORGAP ADJUSTilENT

3.) CROSSSHUTTLESTOP SENSORCOLI,AR

SET
COLLAR

cRossslruTTLE gtoss SF|UTTLE CROSSSHUTILE

.HANDIITIEEL STOPSENSOR
Ho}J|EVEWING
wtNDow

37
 -l

ELECTRICAL
TIMINGDIAGRAMS
4.) CRoSs-o\ERHEAD
STARTsENSoRcoLtAR

MEASUREAI'ID MARK
MARKAT BOTTOIIDEADCENTER
OF srd CEI.J-0F FLAT 1/4'(6 mm) AHEAD.

STRAIGHTEDGE

5.) O\ERHEAD
SF|UTTI-E
SENSOR
SUDEBRAKCET

ADJI.'ST FOR
LAE' (73 tYtM)

38
 DA
2OOL.H. FARMPACKER_ELECTRIC V I C EL O C A T I O N
EL
R I G H TS I D EV I E W 8046047
8046032 (12) EGGSPRESENT
PIGGYBACK
SENSOR SENSOR
\
8008117

8046032
FLOWCONTROL
(HouSEBELr)
SENSOR
"[n COVERSAFETY

4356000
OPERATOR
STATION
8031032
PRE_RESCLUTCH o

o o
8046032 8031032
MISSINGRIGHT BASE CLUTCH
FLAT SENSOR
8046035 8046052 8031032
ALL SENSORCABLES PADDLECLUTCH/ HEADCLUTCH
PUSHERSENSOR

LEFTSIDEVIEW 9195046 4356300

PADDLEWHEEL DISPLAY
CLUTCH ASSEMBLY
8046032 EGGStN
CLAMSHELLSENSOR

8046032
r PKS JAM

[-l[ ' 8046012

OVERHEAD
SHUTTLE
STOPSENS.
\r*'o* ,
9195022
OVERHD.
SHUTTLE
BRAKE
8008117
COVERSAFETY 3752900
MOTOR
8031027 CONTROL
BASE BRAKE ASSY.
8031032 8046032
8046012 O\ERHEAD MISSING 8046012
CYCLESTOP SHUTTLE LEFT TRAY cRoss/o\ERHEAD
SENSOR CLUTCH SENSOR SHUTTLESTARTSENSOR

B A C K S I D E V I E WO F C R O S SS H U T T L E
DENESTER o=.-_ 8046032 8031032
r DENESTERJAM SENSOR CROSSSHUTTLE
CLUTCH
TRAY FLOW o
+

4357500
ELECTRICAL
ASSEMBLY
BOX
8046032 v 8046012
1
TRAYSENSOR
MISSING CROSS
SHUTTLE
STOP SENSOR
8008117
COVFR SAFEry

39
40
 2OOF'ARMPACKER VO BOARD LIGHT DEFINITIONS

il et&
r0 r&
ur&
12@
rc@
11(&
ls (&
ro (&
rz t&
rs (D

LEDS YO.l BOARD IIO.2 BOARD VO.3 BOARI)

Red#9 M. Flat @enester) Stafi Switch Pre-OrientorSensor

Red#10 +24V Supply EmergencyStop Gurd Int
Red#11 Rieht SideM. Flat O. HeadShut.StartSen Left StackerInt.
Red#12 t2 EggsPresent CrossShuttleStopSen. Egg Out of Positioit
Red#.13 Anti Jam@enester) StopSwitch
Red#14 Flow Control Ove,rrideSwitch Anti-JamPKS
Red#15 Left SideM. Flat Cycle StopSensor RiehtStackerInt.
Red#16 Housebelt Sw. On/Off O. HeadShuttleStopSen. Pie Timing Sensor
Red#17
Red#18

Green#l O. Head ShuttleBreak Pre-OrientorClutch

Green#2 Sonalert Not Used
Green#3 Main Clutch CrossShuttleClutch PaddleEnableClutch
Green#4 Not Used NotUsed
Green#5 Not Used Not Used
Green#6 Main Break Housebelt Contactor BaseBrake
Green#7 Not Used Not Used
Green#8 O. Head Shut.Clutch Motor Contactor HeadClutch

Yellow Fl O. Head ShuttleBreak Pre-OrientorClutch

Yellow F2 Main Clutch CrossShuttleClutch PaddleEnableClutch
Yellow F3 Main Break Housebelt Contactor BaseBrake
Yellow F4 O. Head Shut Clutch Motor Contactor HeadClutch

4l
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52
; DWG.NO. # 4356700

ITEM QTY PART NO. DESCRIPTION

1 1 3636100 PCBASSY I/O.1
2 1 3636200 PCBASSY I/O-2
3 1 3636300 PCBASSY t/O-3
4 1 4349600 TATCHBLOCK CARDCAGE
5 1 4349700 PI-ATE.POWERSUPPLY
6 1 4356800 SUBPI.ATE
7 1 4356900 CPU-gASSY
I 2 8003087 SNUBBER
9 58' 8004139 CABLE,2 CONDUCTOR SHIELDED
10 90" 8004140 WIRE,22 AWG, BLUE
11 43' 8004166 WIRE,22AWG, BI-ACK
12 426" 8004167 WRE,22 AWG, WHITE
13 846" 80u202 W|RE,14 AWG, BLACK
14 203' 80il203 WRE, 14 AWG, GREEN
15 28' 8004207 WIRE,16 AWG, BIACK
16 108" 8004218 WIRE, 16 AWG, BROWN
17 56' 8004219 WIRE,16AWG, BLUE
18 53" 800422;0 WRE, 16 AWG, GREEN
19 59' 84U221 WRE, 16 AWG, ORANGE
20 52' 80u22 WIRE,16 AWG, RED
21 109' 8004236 WIRE,22 AWG, BROWN
22 6 8005010 GROMMET, 3/8'OD x1l4'lD x 1/16"
23 1 8005310 LABEL,GROUNDSYIL,IBOL
24
25 1 8008184 MAINPOWERSWITCH
26 2 8013131 CONTACTOR24VDC4 POLE
27 2 8015054 TERMINAL,CRIMP,RING
28 11 8015109 TERMINAL,CRIMP,SPADE
29 1 8015117 TERMINAL,CRIMP,RING
30 43 8015132 TERMINAL,CRIMP, PIN
31 8 8015140 TERMIML, CRIMP,DUMMYPIN
32 2 8015146 WIRENUT
33 4 8015152 TERMIT.IAL,CRIMP,
u 5 8015174 TERMINAL,CRIMP,FEMALE PIN
35 I 8015191 TERMll.lAL,CRIMP,CONTACTPIN
36 2 8015257 END CIAMP
37 14 8015258 TERMIIIALBLOCK- GRAY
38 1 8015259 ENDPLATE. GRAY
39 1 801524[ MARKINGSTRIP# 1-10
40 1 8015265 MARKINGSTRIP# 11.20
41 1 8015266 i'ARKINGSTRIP#21.30
42 3 8015272 TERMINALBLOCK-GREEN
43 2 80'15274 TERMII{ALBLOCK. GRAY,MlO/10
4 21' 8015299 DIN RAIL,SLOTTED15X35MMDEEP
45 14' 8015299 DIN RAIL,SLOTTED15X35MMDEEP
46 1 8015305 MARKINGSTRIP# 1-50
47 1 8015307 itARKtNGSTRIP# 51-100

53
; DWG.NO. # /#156700

ITEM QTY PART NO. DESCRIPTION

48 2 8015308 JUMPER,4POLE
49 42 8015310 TERMINAL BLOCK.BRANCH- BEIGE
50 4 8015312 TERMINALBLOCK- BRANCH- BLUE
51 1 8015313 ENDPLATE-BLUE
52 4 8015314 TERMIML BLOCK.BRANCH.BRO\AN
53 3 8017236 EDGECONNECTOR 44POS
54 3 8017239 PLUG
KE\TING
55 1 8021184 FUSEGDGSA
56 1 8021191 FUSEBLOCKENDPI-ATE
57 3 8021192 FUSEBLOCK
58 2 8021205 FUSEHOLDER
59 1 8021230 FUSEGDG2A
60 1 8021273 CIRCUITBREAKER2 POLE8 A
61 1 8021274 CIRCUITBREAKER2 POLE16 A
62 1 8021275 FUSEGDG500MA
63 2 8021276 FUSEKTK.R€FASTBLOW
64 1 80?2019 CARDCAGE
65 40' 8023035 WIREDUCT1'X2'+ COVER
66
67 1 8026009 DIoDE- 1N4003
68 2 8026099 ARCSUPPRESSORDC
69 1 8026100 ARCSUPPRESSOR DC ENDPISTE
70 1 8037006 SOMLERT
71 1 8038041 LINEFILTER
72 1 8042038 POVVERSUPPLY24VDC
79 1 BO42O39POWERSUppLy 5V,+12,-12 VDC
74 2 8240210 FIAT WASHER1/4
7s 2 82s0168 1l+20 JAM NUT
76 2 8250355 1l+20 X 2.5"H.H.BOLT
77 23 8250623 1G32X 3/8' P.H.SCREW
78 2 8250639 1l+20 x 1'H.H. BOLT
79 2 9038003 1l+20 ESNANUT
80- 2 903S017 1l+20 THINESNANUT
81 2 9076151 SPRING
82 1 8017379 RECEPTACLE2XlTPOS
83 8 8015191 RECEPTACLE CONTACT2&'22AWG

54
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55
; DWG.NO. # 4357500

ITEM QTY PARTNO. DESCRIPTION

1 1 3634600 NAMEPI.ATE
2 1 3752900 MOTORCONTROLASSY
3 1 4291600 2OOFP COMPONENTLOCATIONDECAL
4 1 4356700 2OOFP SUBPTATEASSY
5 1 4357600 2OOFP ENCLOSURE DETAIL
6 3 8005175 HOLEPLUG 1I2"
7 1 8005299 DTSPLAY BASE
8 1 8005300 DISPIAYBASEGASKET
I 1 8005319 LABLE'LIGHTING BOLT'
10 1 8 0 1 8 1 1 3WIRE GRIP 3/4'
11 114' 8024161 LtoulD'TITEN.M.112"
12 1 8024162 UT FITTING1/2"STRAIGHT
13 2 802416/. HOLESEAL1'CONDUIT
14 1 8024166 t/T FITTING1/T 90 DEG.
15 20" 8024171 LtoulD-TITEN.M.3/4"
16 1 8024173 T/T FITTING3/4' STRAIGHT
17 1 8024191 UT FITTING3/4'45 DEG.
18 1 8024196 HOLESEAL2" CONDUIT
19 4 8250572 1O-31X1I2. PH X MS ST.SL.
20 4 8250666 #10 HEXNUT,ST.SL.
21 4 8250729 #10 SPLITLOCKWASHER

56
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 200 Farmpacker
CrossShuttle
BottomViewDenester End
p g . 1o f 5

37s6400
SHAFTASSY.
L.H.SHOWN 9005044
37s6403 3/4"BRG.
R.H.OPPOSITE (2) REQ'D.

9007004 9186916
RODEND 1''PINCHCOLIAR
0561200 (2) REQ'D.
HOOKASSY.
0460400
LEATHERBRAKE
2949400
HUB

93
 200 Farmpacker
CrossShuttle
BottomView
pg,zof5
3591300
ARMASSY.
3756600 3591600 L.H.SHO\^/NI
3604500 SHAFT BRACKET 3s91303
CHAINTRACK R.H.OPPOSITE
3604600 9005048 9186916 9005048
RAIL 1" BRG. 1"PINCHCOLI.AR BEARING

3604100
ARMASSY. 9186912 3588200 9054018
L.H.SHOWN 3/4''PINCHCOLLAR CAMASSY. CAM FOLLOWER
3604103 I..H.SHO\AN
R.H.OPPOSITE 3756300 3588202 3756200
PIVOTARM R.H.OPPOSITE CAMASSY,
L.H.SHOV'IN L.H.SHOWN
3756303 3756203
R.H.OPPOSITE R.H.OPPOSITE
94
 200Farmpacker
CrossShuttle
BottomView
pg.3of5

9007007
ROD END 9076097
3607900 3586400 9005044 8031032 SPRING
ROD STRAP 3/4" BRG. CLUTCH (2)REQ'D.

3607000 9196003 9186912

ARM 4OAlTIDLERSPRKT. 3/4"PINCHCOLLAR
3606900
STUBSHAFT 9076070 3607800
9048062 SPRING SHAFT
5/8'' SETCOLI-AR

95
 200Farmpacker
CrossShuttle
BottomView
pg.4ofs

3641400
9186910 3589903 GEARBOX
COLISR
5/8"PTNCH IDLERBRKI RIGHTANGLE
1:'1MTIO

96
 200Farmpacker
CrossShuttle
BottomViewDriveEnd
pg.5of5

3451400
RACHETASSY.
2630900
RACHET
2681500
PAWL
0254500
SPRING

3591100 3607100
SHAFT SPACER
(4) REQ'D.

97
 200Farmpacker
CrossShuttte
BackSide

toouvuu
ANTI-BK"UP BRG
$4CI404 3604300 3604400 2779940
ROUGHTREAD GUIDE PLATE INNERACE
(2) REQ'D. L.H.SHOWN L.H.SHOWN 3607500
3605901 3604301 3604401 SPACER
SENSORBRKT. R.H.OPPOSITE R.H.OPPOSITE (2) EA. REQ'D.
L.H.SHOWN
3605902 4267104 3619200 3659200
R.H.OPPOSITE GUIDE SENSORBRKT. SENSORBLOCK

3609600 3619400 3604700 3621000 3591500

PUSHERCHAINASSY. BRACKET PLATE HAND\A/IIEEL LEG
3640700 (2) REQ'D"
3702400 OTHEREND 3606000
BRACKET 3605800 FRAMEASSY.
PLATE
REFLECTER L.H.SHOWN
3606001
R.H.OPPOSITE
98
2 O OF A R M P A C K E R G U A R D S
R I G H TS I D EV I E W 3620400
SHIELD_TOP

3620300
SHIELD_FRONT
3641800 9124122
GUARD_RES. LATCH
(4) REOD
4340201
GUARD-HEAD

3620700
GUARD_RHBASE
LH PACKER
3620802
GUARD_RHBASE
RH PACKER

LEFTSIDEVIEW

4340202
GUARD-HEAD
3926600
5641700 GUARD-OVI-ID
GUARD-PKS SHTTLBRAKE

3620800
GUARD-LHBASE
LH PACKER 5609500
3620702 GUARD-O\ERHEAD
GUARD-LHBASE SHUTTLEDRI\E
RH PACKER

4117900 BACK SIDE VIEW,OF CROSSSffi

5826800 GUARD-DEN.
3651600 3590400
BAR-GRD (2) REQD DOOR
BAR-GRD 902601E
HINGE
3641900 (2) REQD
GUARD

36s1000 3862500
GUARD-EXIT GUARD
 GLOSSARY

relay switchesthat
covER SAFETY SWITCII: They aremagneticallyactivatedreed
switches' See
areusedto insurethat all coversare installedandclosed. Thereare6
DeviceLocation Chart.
devicethat is
cRoss oVERIIEAD SHUTTLE START SENSOR: Metat sensing
overheadShuttles.
usedasa timing sensorto ten the computerto starttrrecross and
flatsto be
cRoss SI{UTTLE: The shuttleassemblythat denestsandpositions
transferredto the packerbaseshuttles(left andright).
whenactivated
cRoss SITUTTLE CLUTCH: An elecfiomechanicaldevicethat
engagesthe crossshuttle.
that is usedasa timing
cRoss SHUTTLE STOP SnNsoR: A metal sensingdevice
sensorto telt the computerto shutoffthe cross shuttle.
the pusherchainsbrakeon the
cycl,E STOP SENSOR: Metal sensingdevicethat tells
missingrow of eggs'
basewhento engage.Not everytime, only when thereis a

DENESTER: Separatesandplacesflats onto the cross shuttle'

checkswith the computerto
EGG IN CLAMSIIELL SENSOR: An optical devicethat
time
seeif an egg is supposedto be in the clamshellsat a specific
dwice that tells the
FLOW CONTROL SENSOR (HOUSEBELT): An optical
it shouldturn offthe house
computerthat there are too many eggsin the reservoirand
belts.

devicethat when activatedengagesthe headto

rrf,,AD CLUTCE: An electromechanical
nrn.
sensesif a flat is out of position'
JAIVI SENSOR,DEI\TESTER: An opticaldevicethat
that whenactivatedbecause
IVIAIN BRAKE @ASE): An elecfiomechanicaldevice
preventingcoast'
ttrereareno "ggr,'rtops the pusherchainson the base,therefore
that whenactivatedengages
MAIN CLIJTCH @ASE): An electomechanicatdevice
the pusherchainson the base'

MAIN MOTOR: A DC electric motor that drivesthe farmpacker'

101
MISSING FLAT SENSOR: Theyareopticaldevicesthattell the computerthat thereis
"Rightside","Leftsideoo
a flat presentor not. Therearethreemissingflat sensors, and
"Denestgr".

OVERIIEAD SIfUTTLE: Transfersflats from the CrossShuttleto the PackerBase

Shuttles(left andrigh|.

OVERIIEAD SI{UTTLE BRAKE: An electromechanical devicethat whenactivated

stopsthe OverheadShuttlethereforepreventingcoast.

devicethatwhenactivated
OVERIIEAD SHUTTLE CLUTCH: An elecfiomechanical
engagesthe OverheadShuttle.

OVERHEAD SHUTTLE STOP SENSOR: A metalsensingdevicethat is usedasa

timing sensorto tell the computerto turn off the OverheadShuttleclutch andengagethe
overheadshuttlebrake.

PACKER BASE SIIUTTLES: Main shuttlesthat carry the flats throughthe packing
station. There is a left anda right shuttle. Left andright is in relationto eggflow.

PADDLEWHEEL CLIITCH: A (a) stopwrap springclutchthat'smountedat the end

of the paddlewheelassemblyandis activatedby the pie sensorwhen(12) eggsare
present.

PIE SENSOR: A metalsensingdevicethat is usedasa timing sensorto tell the

paddlewheelclutchto fire at leadingedgeandthe main(base)clutchat trailing edge.

PIGGYBACK SENSOR: An opticaldevicethat tells the computerwhenblockedto

disengagethe pre-reservoirclutch until the sensoris unblocked.

PRE RESERVOIR CLUTCH: An electromechanical devicethat is controlledby the

Piggybacksensorbeforethe dividen on the reservoirthat controlsthe pressureof the
eggs. Whenthere aretoo many eggsin front of the dividen they startto climb slightly,
therefore,blocking the pigryback sensorcausingthe clutch to disengage,andstopping
the secondbelt until the sensoris unblocked,theninstantlycomingbackon.

TWELVE EGGS PRESENT SENSORS:An opticaldevicethat tells the computerto

fire the paddlewheelclutch at the time whenthe leadingedgeof the pie sensoris seen.

r02