AFC SmartPac Manual-MGZ

502-SP-002-04
SERVICE MANUAL
AND
REPAIR PARTS
FOR
AFC SmartPac ®
Series II (Model PV2-98)

VIBRATOR SHAFT
MANUFACTURED FOR:
BESSER COMPANY
MANUFACTURED BY:
WARNING - Read this manual before any
installation, maintenance and operation.
M A N U FA C T U R E R S O F M E C H A N I C A L A N D
FORCE CONTROL INDUSTRIES, INC. ELECTRICAL POWER TRANSMISSION EQUIPMENT
®
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
DIST. AUTORIZADO QRO (442) 1 95 72 60 ventas@industrialmagza.com
Limited Warranty
Force Control Industries, Inc. ("Force Control") warrants its products to be free from defects in mate-
rial and workmanship under normal and proper use for a period of one year from the date of ship-
ment. Any products purchased from Force Control that upon inspection at Force Control’s factory
prove to be defective as a result of normal use during the one year period will be repaired or
replaced (at Force Controls’ option) without any charge for parts or labor. This limited warranty shall
be void in regard to (1) any product or part thereof which has been altered or repaired by a buyer
without Force Control’s previous written consent or (2) any product or part thereof that has been
subjected to unusual electrical, physical or mechanical stress, or upon which the original identifica-
tion marks have been removed or altered. Transportation charges for shipping any product or part
thereof that the buyer claims is covered by this limited warranty shall be paid by the buyer. If Force
Control determines that any product or part thereof should be repaired or replaced under the terms
of this limited warranty it will pay for shipping the repaired or replaced product or part thereof back
to the buyer. EXCEPT FOR THE EXPRESS WARRANTY SET OUT ABOVE, FORCE CONTROL
DOES NOT GRANT ANY WARRANTIES EITHER EXPRESSED OR IMPLIED, INCLUDING
IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR USE. The warranty obliga-
tion set forth above is in lieu of all obligations or liabilities of Force Control for any damages. Force
Control specifically shall not be liable for any costs incurred by the buyer in disconnecting or re-
installing any product or part thereof repaired or replace under the limited warranty set out above.
FORCE CONTROL EXPRESSLY EXCLUDES ALL LIABILITY FOR ANY INDIRECT OR CONSE-
QUENTIAL DAMAGES THE BUYER MAY SUSTAIN IN CONNECTION WITH THE DELIVERY, USE,
OR PERFORMANCE OF FORCE CONTROL PRODUCTS. Under no circumstances shall any lia-
bility for which Force Control is held responsible exceed the selling price to the buyer of the Force
Control products that are proven to be defective. This limited warranty may be modified only in writ-
ing signed by a duly authorized officer of the company. This limited warranty applies exclusively to
Force Control products; warranties for motors and gear reducers and other component parts may
be provided by their respective manufactures. Any legal action for breach of any Force Control war-
ranty must be commenced within one year of the date on which the breach is or should have been
discovered.
A Return Goods Authorization (RGA) number must be obtained from the factory and clearly marked
on the outside of the package before any equipment will be accepted for warranty work. Force
Control will pay the shipping costs of returning the owner parts that are covered by warranty.
Force Control believes that the information in this document is accurate. The document has been
carefully reviewed for technical accuracy. In the event that technical or typographical errors exist,
Force Control reserves the right to make changes to subsequent editions of this document without
prior notice to holders of this edition. The reader should consult Force Control if errors are sus-
pected. In no event shall Force Control be liable for any damages arising out of or related to this
document or the information contained in it.
BESSER COMPANY
®
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
TABLE OF CONTENTS
Section 1 - DESCRIPTION AND OPERATION 7-4 Rear Hub Reassembly . . . . . . . . . . . . . . . . . . . . . . . . .23
1-1 AFC SmartPac Vibration System . . . . . . . . . . . . . . . . .1 7-5 Installing Rotary Union (#41) . . . . . . . . . . . . . . . . . . . .23
1-2 Benefits to the SmartPac Vibration System . . . . . . . . .1 7-6 Installing Piston Bearing Sub-Assembly
1-3 SmartPac Vibrator Shaft Operation . . . . . . . . . . . . . . .2 Into The Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
7-7 Installing Piston Assembly on Vibrator Shaft . . . . . . . .24
Section 2 - SPECIFICATIONS 7-8 Further Assembly Build-Up . . . . . . . . . . . . . . . . . . . . . .25
2-1 SmartPac Shaft Dimensional Specifications . . . . . . . .3 7-9 SmartPac Alignment and Balancing . . . . . . . . . . . . . . .26
2-2 Machine Technical Specifications . . . . . . . . . . . . . . . . .3 7-10 Main Shaft Bearing Reassembly . . . . . . . . . . . . . . . . .27
2-3 Control Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .3 A. Front Main Shaft Bearing . . . . . . . . . . . . . . . . . . . . .27
2-4 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . .3 B. Rear Main Shaft Bearing . . . . . . . . . . . . . . . . . . . . .28
2-5 Vibrator Shaft Orientation . . . . . . . . . . . . . . . . . . . . . . .4 7-11 Main Shaft Bearing Installation . . . . . . . . . . . . . . . . . . .28
2-6 Part Identification in Procedure Steps . . . . . . . . . . . . .4 A. Front Main Shaft Bearing . . . . . . . . . . . . . . . . . . . . .28
Besser Shaft Assembly Part Numbers . . . . . . . . . . . . . . . . .5 B. Rear Main Shaft Bearing . . . . . . . . . . . . . . . . . . . . .28
7-12 Lubricate Bearings to Prevent Rust . . . . . . . . . . . . . . .29
Section 3 - MACHINE SAFETY BULLETIN
7-13 Installing V-Belt Pulley and Locking Assembly . . . . . .29
3-1 Machine Safety Precautions . . . . . . . . . . . . . . . . . . . . .6
3-2 Machine Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . .7 Section 8 - REPAIR PARTS
8-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Section 4 - INSTALLATION
8-2 Ordering Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . .30
4-1 Removing SmartPac Vibrator Shafts . . . . . . . . . . . . . .11
8-3 Name Plate Information . . . . . . . . . . . . . . . . . . . . . . . . .30
4-2 Installing SmartPac Vibrator Shafts . . . . . . . . . . . . . . .11
4-3 Vibrator Shaft Mounting Bolt Usage . . . . . . . . . . . . . . .12 Figure 8.1 - Piston Bearing Replacement Kit . . . . . . . . . . . .31
4-4 Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . .13 Figure 8.2 - Complete Piston Replacement Kit . . . . . . . . . .31
AFC SmartPac Model Variations . . . . . . . . . . . . . . . . . . . . .14
Figure 8.3 - V-Belt Pulley, Locking Assembly &
Section 5 - MAINTENANCE, ADJUSTMENTS Hose Assembly Kit . . . . . . . . . . . . . . . . . . . . . .32
& TROUBLESHOOTING Parts List - Figure 8.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
5-1 General Maintenance and Care . . . . . . . . . . . . . . . . . .15 Figure 8.4 - SmartPac Series II Vibrator Shaft . . . . . . . . . . .33
5-2 Vibrator Selection Tips . . . . . . . . . . . . . . . . . . . . . . . . .15
5-3 Operational Guidelines . . . . . . . . . . . . . . . . . . . . . . . . .15 Figure 8.5 - Spacers and Thrust Washers Usage . . . . . . . .34
5-4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Parts List - Figure 8.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5-5 Frequency Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .16 Figure 8.6 - SmartPac Control Unit . . . . . . . . . . . . . . . . . . .35
5-6 Amplitude Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .16
8-4 Assembly Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5-7 Transducer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .16
Assembly Tool Kit (Continued) . . . . . . . . . . . . . . . . . . . .37
5-8 Verify Dump Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5-9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Section 9 - FACTORY REBUILD & RAPID
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . .17
EXCHANGE SERVICE
Section 6 - DISASSEMBLY 9-1 Factory Rebuild & Rapid Exchange Service . . . . . . . . .38
6-1 Removing SmartPac Assembly . . . . . . . . . . . . . . . . . .18
Section 10 - SYSTEM DIAGRAMS
6-2 Removing Main Shaft Bearings . . . . . . . . . . . . . . . . . .18
Figure 10.1 - Air/Hydraulic System Diagram
A. Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Vibration On/Full Stroke (Amplitude) . . . . . . . .39
B. Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6-3 Access to the Piston Assembly . . . . . . . . . . . . . . . . . .19
Vibration On/Half Stroke (Amplitude) . . . . . . . .39
6-4 Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6-5 Removing Front Hub Assembly . . . . . . . . . . . . . . . . . .20
Vibration Off . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6-6 Removing Ball Bearing (#19) . . . . . . . . . . . . . . . . . . . .21
Installation and Removal Instructions for
Section 7 - REASSEMBLY
Locking Ring (#12) . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
7-1 General Reassembly Information . . . . . . . . . . . . . . . . .22
Installation and Removal Instructions for
7-2 Front Hub Reassembly . . . . . . . . . . . . . . . . . . . . . . . . .22
Locking Assembly (#200) . . . . . . . . . . . . . . . . . . . . . . .42
A. Installing Ball Brg. (#19) & Brg. Retainer (#13) . . . .22
B. Installing Dowel Pins (#101) . . . . . . . . . . . . . . . . . . .22
Manual Revision and Printing History . . . . . . . . . . . . . . . . . .43
7-3 Installing Front Hub to Vibrator Shaft . . . . . . . . . . . . . .23
BESSER COMPANY
®
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
®
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Section 1 - DESCRIPTION AND OPERATION
1-1 AFC SmartPac VIBRATION SYSTEM The production versatility of the concrete products
machine is further enhanced because an operator can
The versatility of your Besser concrete products tune in (induce) or tune out horizontal vibration using the
machine is enhanced with the addition of AFC frequency controls on each 10 HP motor. Small compo-
SmartPac Vibration. By employing truly independent nents of horizontal vibration have proven beneficial
amplitude and frequency control, vibration is tuneable to when producing hard to fill unit shapes.
specific molds and requirements.The ability to control
both amplitude and frequency results in more com- Figure 1.1 shows the AFC SmartPac Series II (Model
paction and quicker finish times than can be obtained PV2-98) Vibrator Shafts on a typical Universal Half
with conventional vibration systems. For example, when High Mold set-up to produce (3) 7-5/8” wide x 3-5/8”
producing paving stone, low amplitude is used during high x 15-5/8” long units.
feed time and high amplitude is utilized during finish 1-2 BENEFITS TO THE AFC SmartPac VIBRATION SYS-
time.
TEM
AFC SmartPac’s Vibration results in variable mold dis-
placement allowing the operator to obtain optimum feed Longer mold life than with conventional vibration.
and finish times for a given mold which contributes to Independent feed and finish vibration settings.
the high production rates achieved by Besser concrete
Amplitude and frequency can be adjusted from the
product systems. Variable displacement is proven to control panel during the machine cycle.
be advantageous over fixed displacement types of
vibration in terms of production rate, versatility and most Settings can be stored for instant recall on future
importantly producing high quality concrete masonry production runs.
units. Reduces vibrator motor maintenance.
Vibration is adjustable and can be engaged or disen-
gaged multiple times within the machine cycle. “On the
Fly” adjustment is possible because the motors are run-
ning continuously.
Figure 1.1 - Typical AFC SmartPac Application
BESSER COMPANY
®
1
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
True Production Versatility featuring Independent volume of fluid delivered to each shaft determines the
amount of internal counterweight rotation, which con-
Amplitude and Frequency Control trols the shaft imbalance. The shaft is returned to a bal-
1-3 SmartPac VIBRATOR SHAFT OPERATION anced state by an internal Spring (#32) when fluid pres-
(See Figure 1.2) sure is relieved.
The AFC SmartPac Vibration System provides vibra- When fluid pressure is applied and a volume of fluid
tion to masonry product machines. enters the shaft, the Piston (#34) moves in an axial
Control of the AFC SmartPac Vibration System maybe direction. The spring force is overcome. The Bearing Pin
adjusted in two ways: (#18) and (3) Cam Follower Bearings (#14), attached to
the Piston (#34) rotates in the Cam Slot in the
(1) The Frequency of Vibration is adjusted by two AC Counterweight (#16). The greater the piston stroke, the
Variable Frequency Controllers through a range of 2500 greater the rotation of the Counterweight (#16) is.
to 2900 RPM shaft speed. Shaft speeds in excess of Resulting in a greater imbalance and Vibration Force.
2900 RPM may result in premature vibrator shaft bear- As a result, controlling the volume of fluid entering the
ing failure. shaft controls the Vibration Force (Amplitude).
(2) The Vibration Force (Amplitude) is determined by
the volume of fluid that is metered into each shaft. The
Figure 1.2 - Cross Section thru SmartPac Vibrator Shaft
2 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Section 2 - SPECIFICATIONS
2-1 SmartPac SHAFT DIMENSIONAL SPECIFICATIONS
Available MSB Lengths

English Metric
(Inches) (mm)
18.047 454
20.047 504
MSB = Mold Side Bar Spacing. 22.047 530
27.480 554
Figure 2.1 - SmartPac Dimensions
2-2 MACHINE TECHNICAL SPECIFICATIONS Air Control: 5 cfm (.14M3/minute) at 80 PSI for 10
Voltage: All available, including industrial voltages. cycles/minute.
Frequency: 50/60 Hz. Speed Control: Analog controlled frequency drives.
Horsepower: Two 10 HP motors (7.5 kW) Method of Weight Shift: Internally activated air over
hydraulic.
Shaft Amplitude: Programmable and variable
Fixed at 11,000 lbs. (49 kN), 13,000 lbs. (58 kN) and 2-4 MECHANICAL SPECIFICATIONS
15,000 lbs. (67 kN) for each shaft @ 2900 RPM. Straight bore bearings, synthetic lubrication same as
Shaft Speed (Frequency): Programmable and variable standard bearings.
2500 to 2900 rpm. Shaft speed in excess of 2900 RPM A Besser set of parts is available with all parts required
may result in premature vibrator shaft bearing failure. to change V3-12 Vibrapac through V6-12 Superpac
concrete products machines, from standard or
2-3 CONTROL SPECIFICATIONS Bescodyne vibration to the AFC SmartPac System.
Electrical Control: 110 VAC 50/60 Hz.
Fluid Pressure: 300-600 PSI (20-40 Bar)
BESSER COMPANY
®
3
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
2-5 VIBRATOR SHAFT ORIENTATION 2-6 PART IDENTIFICATION IN PROCEDURE STEPS
The front of the shaft is the hollow end where the rotary Refer to the figure illustration given in a procedure step
union is located. The rear of the shaft is the solid end. and to the master exploded view illustrations in Section
These terms are used in the procedure steps. (See 8 to help identify a part. Within a procedure step, the
Figure 2.2) item number of the part within parentheses references a
The SmartPac units are color coded as follows: part. For example, if you see “(#37)” in a procedure step,
look for call out number 37 in the Parts List for part iden-
• 11,000 lb units – Yellow tification.
• 13,000 lb units – Green
• 15,000 lb units – Red
Figure 2.2 - SmartPac Vibrator Assembly Orientation
4 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
AFC Smart Pac Series II
Besser Shaft Assembly Part Numbers
LEFT HAND SHAFT RIGHT HAND SHAFT
MSB
CENTER FORCE NEW SHAFT NEW SHAFT RAPID EXCH. FORCE NEW SHAFT NEW SHAFT RAPID EXCH.
DISTANCE CONTROL WITH MSB WITH MSB WITH MSB CONTROL WITH MSB WITH MSB WITH MSB
PART No. WITH S.O.P. W/O S.O.P. W/O S.O.P PART No. WITH S.O.P. W/O S.O.P. W/O S.O.P.
BESSER COMPANY
11,000 lb. ASSEMBLIES
18.047” SP11L18 477685 F1800 477685 F18EX SP11R18 477686 F1800 477686 F18EX
20.047” SP11L20 477685 F2000 477685 F20EX SP11R20 477686 F2000 477686 F20EX
22.047” SP11L22 477685 F2200 477685 F22EX SP11R22 477686 F2200 477686 F22EX
27.480” SP11L27 477685 F2700 477685 F27EX SP11R27 477686 F2700 477686 F27EX
454 mm SP11L45 477685 F4500 477685 F45EX SP11R45 477686 F4500 477686 F45EX
®
18.047” SP13L18 480503 F1800 480503 F18EX SP13R18 480504 F1800 480504 F18EX
20.047” SP13L20 480503 F2000 480503 F20EX SP13R20 480504 F2000 480504 F20EX
22.047” SP13L22 480503 F2200 480503 F22EX SP13R22 480504 F2200 480504 F22EX
27.480” SP13L27 480503 F2700 480503 F27EX SP13R27 480504 F2700 480504 F27EX
MEX (55) 53 63 23 31
DIST. AUTORIZADO QRO (442) 1 95 72 60
18.047” SP15L18 480501 F1800 480501 F18EX SP15R18 480502 F1800 480502 F18EX
MTY (81) 83 54 10 18
20.047” SP15L20 480501 F2000 480501 F20EX SP15R20 480502 F2000 480502 F20EX
22.047” SP15L22 480501 F2200 480501 F22EX SP15R22 480502 F2200 480502 F22EX
ventas@industrialmagza.com
27.480” SP15L27 480501 F2700 480501 F27EX SP15R27 480502 F2700 480502 F27EX
NOTES: S.O.P. refers to Besser Hardware Kit #646749 which includes Locking Assembly (#200), V-Belt Pulley (#201) and Hose Assembly (#202).
MSB refers to Main Shaft Bearings.
5
Section 3 - MACHINE SAFETY BULLETIN
This notice is issued to advise you that some previously accepted shop practices may not be keeping up
with changing Federal and State Safety and Health Standards. Your current shop practices may not
emphasize the need for proper precautions to insure safe operation and use of machines, tools, automatic
loaders and allied equipment and/or warn against the use of certain solvents or other cleaning substances
that are now considered unsafe or prohibited by law. Since many of your shop practices may not reflect
current safety practices and procedures, particularly with regard to the safe operation of equipment, it is
important that you review your practices to ensure compliance with Federal and State Safety and Health
Standards.
3-1 MACHINE SAFETY PRECAUTIONS
IMPORTANT
The operation of any machine or power-operated device can be extremely hazardous unless
proper safety precautions are strictly observed. Observe the following safety precautions:
• Always be sure proper guarding is in place for all pinch, catch, shear, crush and nip points.
• Always make sure that all personnel are clear of the equipment before starting it.
• Always be sure the equipment is properly grounded.
• Always turn the main electrical panel off and lock it out in accordance with published lock-out/tag-out
procedures prior to making adjustments, repairs, and maintenance.
• Always wear appropriate protective equipment like safety glasses, safety shoes, hearing
protection and hard hats.
• Always keep chemical and flammable material away from electrical or operating equipment.
• Always maintain a safe work area that is free from slipping and tripping hazards.
• Always be sure appropriate safety devices are used when providing maintenance and repairs to all
equipment.
• Never exceed the rated capacity of a machine or tool.
• Never modify machinery in any way without prior written approval of the Besser Engineering
Department.
• Never operate equipment unless proper maintenance has been regularly performed.
• Never operate any equipment if unusual or excessive noise or vibration occurs.
• Never operate any equipment while any part of the body is in the proximity of potentially hazardous
areas.
• Never use any toxic flammable substance as a solvent cleaner.
• Never allow the operation or repair of equipment by untrained personnel.
• Never climb or stand on equipment when it is operational.
It is important that you review Federal and State Safety and Health Standards on a continual basis. All
shop supervisors, maintenance personnel, machine operators, tool operators, and any other person
involved in the setup, operation, maintenance, repair or adjustment of Besser-built equipment should read
and understand this bulletin and Federal and State Safety and Health Standards on which this bulletin is
based.
6 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
3-2 MACHINE SAFETY SIGNS
Sign Machine Description Required
1 All Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Concrete Products Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Depalleter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 Skiploader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6 Skiploader/Mixer Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Skiploader/Mixer Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 Vertical: Pallet Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Horizontal: LSC-40A/LSC-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pallet Transport System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
9 Besser-Matic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 Besser-Matic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
11 Skiploader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
12 All Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 Overhead Block Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
14 Block Pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pallet Transfer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
15 Concrete Products Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
16 Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
17 Cuber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
18 Cuber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Block Turnovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Slat Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
To order safety decals, contact your local Besser representative

or the Besser Central Order Department.
Thank you!
WARNING:
The operation of any machine
or power-operated device can
be extremely hazardous unless
you strictly observe the correct
safety precautions. Make sure
you observe the following
safety precautions.
BESSER COMPANY
®
7
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
1 2 3
Large: 113236F0409 113237F0410 Vertical: 113240F0307
High Voltage Mixer Blade Hazard Crush Hazard
Width 4 1/2 inch Width 4 1/2 inch Width 3 1/2 inch
Height 9 5/8 inch Height 10 1/4 inch Height 7 1/2 inch
Small: 113236F0204 Horizontal: 113239F0604
High Voltage Crush Hazard
Width 2 inch Width 6 5/8 inch
Height 4 1/8 inch Height 4 inch
4 5 6
114692F1006 114688F0906 114689F0804
Nip Points Crush Hazard Fall Hazard
Height 9 1/2 inch Height 9 1/2 inch Height 7 3/4 inch
8 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
7 8 9
114690F0805 Vertical: 113244F0410 113242F0409
Falling Objects Crush Hazard Crush Hazard
Height 8 inch Height 10 inch Height 9 5/8 inch
Horizontal: 113245F1005
Crush Hazard
Width 10 inch
Height 5 3/4 inch
10 11 12
113243F0410 114691F1006 113249F0410
Falling Objects Shear and Fall Hazards Safety Instructions Decal –
Width 4 1/2 inch Width 5 3/4 inch Suggested Lockout
Height 10 inch Height 9 3/4 inch Procedure
Width 4 inch
Height 10 inch
BESSER COMPANY
®
9
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
13 14
113238F1005 113248F1006
Crush Hazard Crush Hazard
Width 10 inch Width 10 inch
Height 5 3/4 inch Height 6 inch
15 16
113241F0605 113246F0704
Crush and Pinch Points Nip Hazard
Width 6 5/8 inch Width 7 inch
Height 4 inch Height 4 1/2 inch
17 18
113247F1006 113250F1006
Crush Hazard Crush and Pinch Hazard
Width 10 inch Width 10 inch
Height 6 inch Height 6 inch
10 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Section 4 - INSTALLATION
4-1 REMOVING SmartPac VIBRATOR SHAFTS
1. Place the Mold Box with the SmartPac Vibrator Shaft
sets attached into the Roll-Over Fixture.
2. Roll the whole Fixture and Mold Box over to the
inverted Installation Position.
3. Break loose and remove the (2) Vibrator Mounting
Bolts and Hex Nuts from each Bearing Housing.
4. Insert a pry bar into each gap and pry the Front Main
Bearing Housing and the Rear Main Bearing
Housing loose from the Mold Bar notches as shown
in Figure 4.1. Figure 4.2 - Inverted Mold Box
3. After placing the vibrator housings in the mold side
bars make sure the top of the housing does not
come in contact with the mold side bar. This is criti-
cal to achieve the proper bolt torque.
4. Attach the bearing housings with the vibrator mount-
ing bolts, washers and hex nuts to the mold side
bars. Use a Hex Hd. Bolt/Flat Hd. Screw, Lock
Washer and Hex Nut for Standard Mounting.
Replace bolts with thread damage or thinning (neck-
ing). Do not apply lubrication to the threads of the
fastener or nut. See Section 4-3 for correct parts,
Besser Part Numbers and required torque for
Vibrator Mounting Bolts.
CAUTION - As shown on page 14, NEVER

install an older SmartPac Vibrator Shaft (Model
PV1-91) with a newer SmartPac Series II (Model
Figure 4.1 - Removing & Installing Vibrator Shafts PV-2-98) Vibrator Shaft. Always install the same
models of Vibrator Shafts together.
5. Lift and remove the SmartPac Vibrator Shaft
Assembly with a soft sling and overhead hoist. 5. Make sure the shafts will rotate freely by hand prior
to installation of the mold into the machine. Shafts
CAUTION - Never lift the SmartPac Vibrator not rotating freely may indicate a preload on the
Shafts by the Bearing Housings. This could outer bearing race. Tap the housing with a brass
damage the Oil Seals in the Bearing Housings. hammer to relieve the preload on the bearings.
6. Clean paint off bearing housing before inserting into
4-2 INSTALL SmartPac VIBRATOR SHAFTS mold side bar.
1. Make sure the mold side bar pockets are clean and IMPORTANT - See Section 4-4 for an installa-
free from all concrete. tion checklist. Failure to follow these installa-
tion instructions may cause the following:
2. Set the new SmartPac vibrator shafts into position
on the mold bars. You may have to use the pry bar in • Broken bearing housings
each gap to nudge the bearing housings down until • Broken mold side bars.
they seat themselves completely into the mold bar • Egg shaped bolt holes in bearing housing
notches. See Figure 4.2. • Premature bearing wear
• Iratic vibration
NOTE - Don’t forget that when the Mold Box is
• Major damage to bearings and housings
inverted the L.H. Shaft is on the right side and the
• Broken components inside the SmartPac
R.H. Shaft is on the left side as shown in Figure 4.2.
BESSER COMPANY
®
11
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
4-3 VIBRATOR SHAFT MOUNTING BOLT USAGE Special Bolts, Washers and Nuts have been developed
for the Ultrapac Mold that can be used up to 10 times.
Standard vibrator mounting bolts can only be used one (See Figure 4.3)
time, then they must be replaced. If the bolts are not
replaced when vibrators are changed they will fail and A Complete SOP Fastening System can be ordered with
may cause damage to the vibrator assembly and the Part No. AL-648371. It includes the following parts:
mold side bars. (4) AL-488059 Hex Hd. Bolt, 3/4” x 13” Lg.
After the bolts are torqued to yield the first time, the (4) AL-488060 Flat Socket Hd. Bolt, 3/4” x 13-1/4” Lg.
(8) AL- 087871 3/4”-10 Full Height Flexloc Nut
threads will stretch to a point where further reuse of the
(12) AL- 115333 Hardened Washer
bolts will result in fatigue and cause it to break. (1) Instruction Drawing
The following is a list of Standard Vibrator Shaft Bolts
with Besser Part Numbers:
A. Standard Vibrator Mounting Bolts
National Course Thread
Besser
Part No. Part Description
AL-215652 Hex Hd. Bolt, 3/4” x 12” Lg.
AL-215653 Hex Hd. Bolt, 3/4” x 12-1/2” Lg.
AL-215654 Hex Hd. Bolt, 3/4” x 13” Lg.
AL-215655 Hex Hd. Bolt, 3/4” x 13-1/2” Lg
AL-215656 Hex Hd. Bolt, 3/4” x 14” Lg.
AL-227374 Hex Hd. Bolt, 3/4” x 14-1/2” Lg.
AL-244561 Hex Hd. Bolt, 3/4” x 15” Lg.
AL-397037 Hex Hd. Bolt, 3/4” x 15-1/2” Lg.
AL-109157 Hex Hd. Bolt, 3/4” x 16” Lg.
AL-087883 Lock Washer, Medium, 3/4”
AL-087808 Hex Nut, Heavy, 3/4” (Grade B)
AL-069368 Flat Hd. Slotted Bolt, 3/4” x 13” Lg.
AL-397343 Flat Hd. Slotted Bolt, 3/4” x 13-1/2” Lg.
AL-422738 Flat Hd. Slotted Bolt, 3/4” x 15” Lg.
AL-445610 Flat Hd. Slotted Bolt, 3/4” x 15-1/2” Lg.
National Fine Thread
AL-221934 Hex Hd. Bolt, 3/4” x 12” Lg.
AL-221935 Hex Hd. Bolt, 3/4” x 13” Lg.
AL-221936 Hex Hd. Bolt, 3/4” x 14” Lg.
AL-407944 Hex Hd. Bolt, 3/4” x 15” Lg. Figure 4.3 - Ultrapac Fastening System
AL-087700 Special N. F. Locking Nut
Torque Hex Nuts to -
Torque Hex Nuts to - 250 Ft. Lbs. (339 Nm) With Hex Hd. Bolts - 340 Ft. Lbs. (461 Nm)
B. Vibrator Fastening System For Ultrapac Mold With Flat Hd. Bolts - 190 Ft. Lbs. (257 Nm)
WARNING:
SERIOUS DAMAGE CAN OCCUR TO THE
SMARTPAC VIBRATING SHAFT ASSEM-
BLY OR THE MOLD SIDE BARS IF THE
VIBRATOR MOUNTING BOLTS ARE NOT
TORQUED PROPERLY.
12 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
4-4 INSTALLATION CHECK LIST
Table 2.1 summarizes operational checks and adjust- WARNING - Do not operate the system if the
ments for the SmartPac System. For complete informa- vibrators or control unit is not functioning
tion, refer to your machine’s operation and maintenance correctly.
manual.
SMARTPAC INSTALLATION CHECKLIST

SmartPac to Mold
Assure the left and right hand units are the same model.
Verify that the left and right sides of the bearing housings are snug up to the mold side bar.
Damage to the mold side bar or bearing housings may prevent this from occurring. If this is the case,
replace the worn components.
Check for a gap of 1/16 inch between the top of the bearing housing and the mold side bar.
If the top of the housing is in contact with the mold side bar severe damage can occur to the
transmission of vibration into the mold side bar.
SmartPac brg. housing nuts and bolts are torqued to: Hex Hd. Bolts-340 Ft.Lbs.;Flat Hd. Bolts-190 Ft.Lbs
Assure that the shafts can be turned freely by hand when the SmartPac units are bolted to the mold.
If the shafts are not turning freely, it is an indication of preloading the bearing. This situation
does not allow the bearing to rotate properly and can result in the overheating and failure of
the bearings.
Assure SmartPac units are on the proper side of the mold.
Mold Assembly with SmartPacs in the Machine
Verify that lower hoses at the “V” fitting on the dump valve assemblies are filled with ATF fluid.
This prevents air from entering your lines and possibly causing erratic shifting of the unit.
Verify that control unit tank is 3/4 filled with ATF fluid.
Verify that air pressure for the cylinder rod end is set to 60 psi (413.7 kPa).
Verify that air pressure for cylinder cap end is set to 30 psi (206.9 kPa).
Thoroughly clean both ends of the quick disconnects and attach hoses to dump valve assemblies.
Operate air valve to extend air cylinder rod.
Retract air cylinder. Wait two seconds and then extend air cylinder rod again while watching both vibrators
shift 90 degrees. If vibrators do not shift fully when rod is retracted, stop operation and refill reservoir tank.
Assure that when air cylinder rod is extended, both vibrators return to balanced position.
Assure the shafts are rotating inward.
Adjust one motor to match the RPM of the other motor (+/- 2 RPM)
Table 2.1 - Installation Checklist
BESSER COMPANY
®
13
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
14
AFC SmartPac ® Model Variations
CAUTION - AFC SmartPac® and AFC SmartPac® Series II
Shafts must NEVER be installed together.
AFC SmartPac YES AFC SmartPac AFC SmartPac YES AFC SmartPac
L.H. Shaft R.H. Shaft Series II Series II
(Model PV1-91) THIS IS OK. (Model PV1-91) THIS IS OK.
L.H. Shaft R.H. Shaft
(Model PV2-98) (Model PV2-98)
®
MEX (55) 53 63 23 31
DIST. AUTORIZADO QRO (442) 1 95 72 60
AFC SmartPac NO AFC SmartPac AFC SmartPac NO AFC SmartPac
L.H. Shaft Series II Series II R.H. Shaft
(Model PV1-91) THIS IS NOT OK. R.H. Shaft L.H. Shaft THIS IS NOT OK. (Model PV1-91)
(Model PV2-98) (Model PV2-98)
MTY (81) 83 54 10 18
ventas@industrialmagza.com
L.H. = Left Hand R.H. = Right Hand
BESSER COMPANY
Section 5 - MAINTENANCE, ADJUSTMENTS & TROUBLESHOOTING
5-1 GENERAL MAINTENANCE AND CARE 5-2 VIBRATOR SELECTION TIPS
1. Store in clean dry area. Select a vibrator according to your plant’s equipment
2. Lubricate Main Shaft Bearings before storing. and production. See the Table below for some general
3. Keep Quick Disconnects clean and capped. rules for standard products. For larger concrete units
you may want a larger SmartPac unit and for lower
4. For extended storage, spray rust preventative in tube height product smaller SmartPac units.
holes and seals.
5. Handle SmartPac Vibrator Shaft Assemblies with YOUR USE THIS TYPE OF VIBRATOR
care. Don’t hit or pry on counter weights. MACHINE 11,000 Lbs. 13,000 Lbs. 15,000 Lbs.
6. Mount to good Mold Side Bars and make sure that 3-At -A-Time X
the Main Shaft Bearing Housings are seated direct- 4-At -A-Time X X
ly to the bar and the Vibrator Mounting Bolts are
properly torqued.
5-At -A-Time X
7. Always lift the SmartPac Vibrator Shaft by the shaft
6-At -A-Time X X
using a soft sling and overhead hoist. A 3/8” eye bolt
can also be installed in the rear end of the Vibrator
Shaft (#1).
5-3 OPERATIONAL GUIDELINES
Never lift the SmartPac Vibrator Shaft by the Follow these operational guidelines to optimize your
bearing housings. This could damage the Oil SmartPac vibrator’s performance.
Seals. 1. If the weights are too heavy, you may see the follow-
8. Thoroughly clean both ends of the Quick ing:
Disconnects before engaging. a. The material will have the appearance of “boiling”
9. Replace the O-Ring in each Quick Disconnect each or “bubbling” during feed time.
month or when they become worn or damaged. b. Segregation of material within each cavity.
10. Never operate the system pressure above 80 PSI. If you notice these conditions, lower the amplitude.
11. Always use new clean fluid when filling the system. 2. Use only the rotary unions supplied by Besser. The
Contaminants will cause erratic operation. rotary union is a special design and cannot be
12. Do not disassemble the SmartPac Vibrator Shaft replaced by standard stock rotary unions.
Assembly unless it is necessary to replace worn or 3. There may be front to back movement
damaged parts. of the vibrator shafts while mounted in the mold side
13. Tighten the V-Belt Pulley to recommended torque of bars. This movement may be as much as 1/16 inch
18 Ft. Lbs. Over tightening will cause the rotary [2 mm]. Do not be alarmed as this will not effect
union to bind and reduce its life. vibrator performance.
14. Never put undue pressure on the rotary union. fit- A. Control Unit
tings or connection hose. 1. The hydraulic supply tank should be maintained at
15. Lubricate each Main Shaft Bearing Housing every 8 no less then 3/4 full.
hours with 1 fluid ounce of NLGI Rated Synthetic, 2. The hydraulic lines from the pump to the vibrator
Grade 2 Extreme Pressure Grease. See Figure 5.1 shaft must be of equal length and size to assure
for location of grease fittings. smooth and equal shifting of the right and left hand
16. When installing Locking Collars (#12) torque screws vibration units.
to 23 Ft. Lbs. on a new one and 22 Ft. Lbs. for one 3. The air silencer will require periodic cleaning
that has been previously used. depending upon plant environment conditions.
17. Always have guards in place when operating vibra- 4. The air filter on the supply tank needs periodic
tor drive motors. cleaning depending upon plant environment condi-
18. Keep system in top condition by replacing worn tions.
belts, pulleys and/or hoses.
BESSER COMPANY
®
15
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
5-4 LUBRICATION
(See Figure 5.1)
Vibrator bearing housings should be lubricated every
eight hours with one fluid ounce of NLGI Rated
Synthetic, Grade 2 Extreme Pressure Grease. (Besser
part number 114135).
5-5 FREQUENCY ADJUSTMENT
Do the following to check or set the vibrator frequency of
AFC SmartPac systems.
1. Stop the machine when feed drawer is over the mold.
2. Start vibrator motors with vibration off.
Top of vibrator belts must be moving towards center
of machine. Figure 5.2 - Transducer Adjustment
3. Bring up SmartPac screen on monitor.
4. Retract air cylinder rod by manually activating valve.
• Set shaft speed to desired rpm. • Register reading should go to 900 – 1000.
• Check shaft speed with strobe light (Besser Part # • Both vibrator weights should shift 90°.
115212) or photo tachometer(Besser Part # 5. Extend air cylinder rod and recheck zero.
112910).
6. Enter zero into register N10:26.
4. Adjust one motor to match the rpm of the other
7. Set amplitude on SmartPac screen to 500.
motor (+/- 2 RPM).
8. With vibrator motors off, set vibrator switch to hand.
Use registers #N10:30 and #N10:31 to adjust motor
speeds. (#N10:40 and #N10:41 for Ultrapac II) 9. Check register reading. Subtract 500 from this read-
ing and enter result into register #N10:26 (SLC500),
5-6 AMPLITUDE ADJUSTMENT or #543 (PLC2).
Make amplitude adjustments with the vibrator motors • This value is the “offset” that compensates for
stopped and the large cylinder rod in the control panel delays in the system. The offset should be updated
fully extended. With this condition set up, adjust the periodically.
transducer to read zero while monitoring register 10. Operate vibration “hand” and check reading on reg-
#N10:21 (SLC500), or #467 (PLC2). ister #N10:21 (SLC500), or #467 (PLC2).
5-7 TRANSDUCER ADJUSTMENT • Reading should be close to 500.
(See Figure 5.2) • Vibrator weights should be shifting about halfway.
Adjust the transducer by doing the following. 5-8 VERIFY DUMP VALVES
1. Loosen transducer mounting screws. Use the following procedure to check the dump valves
2. While watching register, #N10:21 (SLC500), or #462 for leaks.
(PLC2) move transducer to get zero on the register. 1. Turn the vibrator motors off.
3. Tighten transducer mounting screws. 2. Put the vibrators in manual.
3. Manually shift the weights and watch for
the weights to roll back. If they roll back,
you may have a leaky valve.
5-9 TROUBLESHOOTING
Read the entire maintenance section to
assure the vibration system is set up cor-
rectly and recommended actions are being
taken. If troubles with the vibration system
are still present the following are guidelines
which may help solve the problem.
Figure 5.1 - Main Shaft Bearing Lubrication
16 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
TROUBLESHOOTING CHART
Concern Possible Problem Actions
Not vibrating at start-up. Leaky dump valves. Check dump valves. See Section 5-8.
Slow shifting or jerky Restricted air silencer. Check air silencer for restrictions.
shifting of weights. Clean or Replace, if needed.
Piston chamber has air pocket. Cycle unit while not rotating drive motors
for approximately 20 mi.
Concrete dust & Debris between Clean between moving parts.

moving parts. (See Figure 5.3)
Broken ball bearing Roll SmartPac unit in quiet area and

listen for loose ball bearings.
Vibration not shutting off. Broken spring. Replace spring.
Left and right hand vibration Verify units are installed properly.
units switched. (See Figure 4.2.)
Concrete dust & Debris between Clean between moving parts.

moving parts. (See Figure 5.3)
Unequal shifting of vibrator Restricted oil filter. Check filter.

weights.
Leaky dump valves. Check dump valves. See Section 5-8.
Main bearings overheating. Bearings preloaded. Rotate shafts by hand prior to

starting.
Too much grease. Remove excess grease and follow

procedure in Section 5-4.
Not enough grease. Add grease per procedure in

Section 5-4
CLEAN BOTH ENDS OF UNIT.

IMPORTANT
When storing SmartPac
units always cover with a
cloth or plastic tarp to
keep concrete dust and
other contaminants out of
the unit.
SmartPac Vibrator Shaft
Units should be cleaned
after removal and before
every installation on the
machine.
Figure 5.3 - Cleaning SmartPac Unit of Concrete Dust & Debris
BESSER COMPANY
®
17
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Section 6 - DISASSEMBLY
CAUTION - Do not damage the Oil Seal (#39)
WARNING when removing this Bearing Closure (#38).
Before attempting any disassembly proce- 4. Inspect the Oil Seal (#39) and press it out with an
dure, open the drive motor disconnect, shut- Arbor Press if it needs replaced.
off the control electrical supply and the
hydraulic supply. Lock them out to avoid any 5. Attach the Front Bearing Puller #601-SP-020 and
possibility of personal injury. pull the whole front bearing loose from the Vibrator
Shaft (#1) as shown in Figure 6.1.
Unless the SmartPac Vibrator Shaft is to be complete-
ly overhauled, it should be disassembled only to the
extent necessary to gain access to any worn or dam-
aged parts.
See Section 8 for a visual reference to all parts being
disassembled.
See Pages 36 and 37 for Disassembly Tools
6-1 REMOVING SmartPac ASSEMBLY

(See Figures 8. 1 to 8.5)
1. Disconnect the Hydraulic Hose (#202) and drain the
fluid out of the Vibrator Shaft (#1).
2. Remove any Belt Guards. Release the Drive Belt
Tension and remove the Drive Belts from the V-Belt
Pulley (#201). Figure 6.1 - Front Bearing Puller
3. Remove the whole Mold Box with the SmartPac It may be necessary to moderately heat up the
Vibrator Shafts attached out of the machine and Bearing to approx. 250° F. to remove it from the
place it in the Roll-Over Fixture. shaft. CAUTION-Use protective gloves.
4. Take the SmartPac Vibrator Shafts off the Mold After it is loosened up, it can then be removed from
Box as per instructions given in Section 4 - the Vibrator Shaft (#1) by hand.
Installation, 4-1 Removing SmartPac Vibrator
Shafts. Place on a suitable work bench. CAUTION - Be careful not to damage the Oil
Seal (#31) when removing this Front Bearing.
5. Remove the V-Belt Pulley (#201) and Locking
Assembly (#200) as per manufacturers instructions 6. Inspect the Oil Seal (#31) and remove it with an
given at the back of this manual on Pages 40 & 41. Arbor Press if it is damaged and needs replaced.
6-2 REMOVING MAIN SHAFT BEARINGS 7. Be careful not to lose the Spacer (#46). Set it aside.
(See Figure 8.4) NOTE: This spacer in not on shafts with 27.48" MSB
length or any metric shaft lengths.
A. Front Bearing
NOTE: If the Front Bearing is not damaged it
does not have to be removed to gain access to
the Piston Assembly.
1. Take the Retaining Ring (#40) out of the Vibrator
Shaft (#1) and pull the Swivel Union (#41) out.
2. Take the (4) Screws (#3) and (4) Lockwashers (#4)
out of the Front Bearing Closure (#38).
3. Carefully pull the Front Bearing Closure (#38) off the
Vibrator Shaft (#1).
Figure 6.2 - Removing Roller Bearing (#7)

18 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
8. Press the Roller Bearing (#7) out of the Bearing Housing 1. Set the SmartPac Assembly on the Support Fixture
(#8) with an Arbor Press as shown in Figure 6.2. #601-SP-019. (See Figure 6.4)
B. Rear Bearing 2. Use the (2) L-Clamps, which are furnished in the
Assembly Tool Kit, to clamp the SmartPac
1. Take the (4) Screws (#3) and (4) Lockwashers (#4) Assembly together as shown in Figure 6.4.
out and remove the End Bearing Closure (#6) from
the Bearing Housing (#8). 3. Remove the Rear Locking Ring (#12) as per manu-
facturers instructions in the back of this manual on
2. Take the Retaining Ring (#29) off the end of the Page 40.
Vibrator Shaft (#1) .Also remove Spacer (#30a) for
metric length shafts only. 4. Take the (2) L-Clamps off. The internal spring will
force the Rear Hub Assembly back some. Continue
3. Attach a standard Bearing Puller and pull the whole pulling the Rear Hub Assembly off the rear of the
Rear Bearing off the Vibrator Shaft (#1) as shown in Vibrator Shaft (#1).
Figure 6.3.
5. Take the Thrust Washers (#42a) and the Spring
(#32) off the Vibrator Shaft (#1). NOTE - There are
(2) Thrust Washers (#42a) for the 27.48" long shaft.
6. Remove the (6) Flat Hd. Screws (#15) and slide the
Sleeve (#17) off.
NOTE - These (6) Screws have Blue Loctite #242
on the threads. Use an impact wrench to break
them loose. If they get damaged in removal, there
are (6) new ones in the Minor Overhaul Kit.
7. Take the Counterweight (#16) off.
8. Put the Tapered Sleeve #601-SP- 014 on the rear end
of the Vibrator Shaft (#1) as shown in Figure 6.5.
Figure 6.3 - Removing Rear Main Bearing 9. Pull the Thrust Washer (#42b) and Piston Assembly
4. On English length shafts, except for the 27.48"
length, the Spacer is (#30b) and is on the inside of
the Bearing (#7). Remove it and set it aside.
5. Inspect the Oil Seal (#31) and remove it with an
Arbor Press from the Bearing Closure (#9) if it needs
replaced.
6. Press the Roller Bearing out of the Rear Bearing
Housing (#8) with the same procedure as shown in
Figure 6.2.
Figure 6.5 - Tapered Sleeve #601-SP-014
6-3 ACCESS TO THE PISTON ASSEMBLY
(See Figure 8.4) off the Vibrator Shaft (#1).
10. Pull the Piston Cartridge (#107) off the Vibrator
Shaft (#1).
NOTE: This may require light air pressure
applied to the rotary union to get it out of the pis-
ton bore.
CAUTION - Be careful not to damage the
internal O-Ring (#36) when removing the
Piston Cartridge (#107).
11. Remove both O-Rings (#35) and (#36) from the
Piston Cartridge (#107).
Figure 6.4 - L-Clamps and Support Fixture #601-SP-019 6-4 PISTON DISASSEMBLY
BESSER COMPANY
®
19
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
(See Figure 8.1, 8.2 & 8.4)
The SmartPac Vibrator Piston can only be repaired
one of two ways.
(A) As a Complete Assembly. (See Figure 8.2 for
Complete Piston Replacement Kit.)
(B) The Piston Bearing Sub-Assembly can be

replaced. (See Figure 8.1 for the Piston Bearing
Replacement Kit.)
1. Using the Dowel Pin Remover #601-SP-018 press
the (2) Roll Pins (#106) down in the Piston (#34) as
shown in Figure 6.6.
NOTE: These (2) Roll Pins (#106) do not have to
be completely removed. They just have to be
pushed down far enough to clear the Counter
Balance Pin (#100) and the Bearing Pin (#18).
Figure 6.7 - Removing Piston Bearing Assembly
2 Place the Piston (#34) into the Cradle Assembly Tool
#601-SP-027 with the Bearings (#14) pointed down
1. Remove the Shims (#130 to #135) from the Bearing
Retainer (#13).
2. Remove the Locking Ring (#12) as per manufacturers
Instructions in the back of this manual on Page 40.
3. Pull the Front Hub Assembly off the Vibrator Shaft
(#1).
4. If any of the (4) Pins (#101), located in the Front Hub
(#21), needs replaced, then press them out with an
arbor press and the Dowel Pin Remover #601-5P-
018, which is sup¬plied in the Assembly Tool Kit #02-
5P-002-03. (See Figure 6.8)
6-6 REMOVING BALL BEARING (#19)
(See Figure 8.4)
Figure 6.6 - Removing Dowel Pins (#106)
as shown in Figure 6.7. Use the 3/8" x 6-1/2" Lg.

Soc. Hd. Cap Screw to press the Piston Bearing
Sub-Assembly out of the Piston (#34). This 3/8" Cap
Screw is furnished with the Assembly Tool Kit
#02¬SP-002-03.
6-5 REMOVING FRONT HUB ASSEMBLY

(See Figure 8.2)
Figure 6.8 - Removing Dowel Pins (#101)
20 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
This procedure is the same for either the Front Hub 4. Use Tool #601-SP-025 to press the Ball Bearing
(#21) or the Rear Hub (#11). (#19) out of the Bearing Retainer (#13). (See Figure
You may also have to heat the hub and bearing up with 6.10)
a blow torch to loosen up the Loctite adhesive. The Disassembly Procedure is now
1. Place the Hub into an arbor press.
2. Use the Bearing Removal Tool #601-SP-023 as
shown in Figure 6.9 to take the Ball Bearing (#19)
and the Bearing Retainer (#13) off the Hub. Insert
the (3) protruding pins on the tool into the (3) holes
in each hub.
3. Press until the Ball Bearing (#19) and the Bearing
Retainer is removed from the Hub.
Figure 6.10 - Removing Ball Bearing (#19) from

Bearing Retainer (#13)
Complete for your SmartPac Vibrator Shaft

Assembly.
Figure 6.9 - Removing Ball Bearings (#19) and Bearing

Retainer (#13) from Hub
BESSER COMPANY
®
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MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Section 7 - REASSEMBLY
7-1 GENERAL REASSEMBLY INFORMATION 1. Apply a light coat of Green Loctite #609 to the O.D.
of the Ball Bearing (#19) and the I.D. of the Bearing
1. Make sure that all mating surfaces of the Vibrator Retainer (#13).
Shaft (#1), Bearings and the Piston are free of all
scratches, nicks or any other surface damage that 2. Press the Ball Bearing (#19) into the Bearing
would affect the operation of the SmartPac Vibrator Retainer (#13) with an arbor press as shown in
Assembly. Figure 7.1. Use the small end of Tool #601-SP-024
and press until the bearing is seated in the retainer.
2. Use CRC Brakleen (or equivalent) to clean all parts
before reassembly. IMPORTANT - Wipe off any excess Loctite.
3. Use Loctite Primer T to clean and prime any sur- 3. Apply a light coat of Green Loctite #609 to the I.D. of
faces that are to be Loctited at Reassembly. the Ball Bearing(#19) and the O.D. of the Front Hub
(#21).
4. Use Blue Loctite #242 for the installation of the (6)
Flat Head Screws (#15) and on the areas of the 4. Place the Front Hub (#21) into an arbor press and
Shaft (#1) where the Main Roller Shaft Bearings (#7) install the Bearing and Retainer onto the Hub. Use the
contact the shaft. large end of Tool #601-SP-024 as shown in Figure 7.2.
5. Use Green Loctite #609 to reassemble the Piston
and Sleeve Bearing components.
6. NLGI Rated Synthetic Grade 2 Extreme Pressure
Grease is recommended for all surfaces that require
lubrication at reassembly. This will just be called
Grease after this.
7. Make sure that the internal bore in the Vibrator Shaft
(#1) is thoroughly cleaned and free of any foreign
material before installing the Rotary Union (#41) into
the shaft.
When you are replacing the Complete Piston Assembly,
make sure that you have the correct part for a R.H. or
L.H. Assembly. Both parts are stamped “LH” or “RH” on
the rear face.
7-2 FRONT HUB REASSEMBLY
(See Figure 8.4) Figure 7.2 - Installing Bearing & Retainer onto Hub
A. Installing Ball Bearing (#19) and Bearing Retainer IMPORTANT - Wipe off any excess Loctite.
(#13) on to Front Hub (#21) B. Installing Dowel Pins (#101) into Front Hub
Figure 7.1 - Installing Bearing (#19) into Bearing

Retainer (#13)
Figure 7.3 - Installing Dowel Pins (#101)
22 BESSER COMPANY
®
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
1. Clean the (4) Dowel Pins (#101) and the (4) holes in Make sure the bore in the Vibrator Shaft (#1) is com-
the Front Hub (#21) with Loctite Primer T. pletely clean and smooth.
2. Apply a film of Green Loctite #609 to one end of If you are installing a new Rotary Union (#41), then it
each dowel Pin (#101) and press them into the Front may be required to lightly file the stamped part number
Hub (#21) with an Arbor Press until they are firmly area to obtain the correct slip fit in the bore.
seated as shown in Figure 7.3. 1. Apply Grease to the O-Ring on the Rotary Union
IMPORTANT - Wipe off any excess Loctite. (#41) and slip it into the bore.
7-3 INSTALLING FRONT HUB TO VIBRATOR SHAFT 2. Install the Retaining Ring (#40) into the Vibrator
Shaft (#1).
NOTE - Be sure to locate the sharp edge of the
Retaining Ring (#41) away from the Rotary Union
(#40) as shown in Figure 7.5.
Figure 7.4 - Installing Front Hub to Vibrator Shaft

1. Thoroughly clean the shaft, hub I.D. and the hub O.D. Figure 7.5 - Installing Rotary Union (#41)
where the Locking Ring (#12) rides with CLC
Brakleen (or equivalent). 7-6 INSTALLING PISTON BEARING SUB-ASSEMBLY
2. Place the Vibrator Shaft (#1) in a vertical position INTO THE PISTON (See Figures 7.6, 7.7 and 7.8)
with the rotary union end pointed up. Make sure 1. Lightly coat the OD of the Bearing Pin (#18) and the
there are (4) clearance holes in the bench top for the ID of the hole in the Piston (#34) with Green Loctite
(4) Dowel Pins (#101) which are pointing downward. #609.
(See Figure 7.4)
2. Place the Piston (#34) into the Cradle Assembly Tool
3. Slide the Front Hub (#21) down and over the Vibrator #601-SP-027 and press the Bearing Pin (#18) into
Shaft (#1) with the locking ring end up until it firmly the Piston (#34) as shown in Figure 7.6.
seats on the proper shaft shoulder. Lightly tap it with
a soft hammer to ensure that the Front Hub (#21) is
seated properly.
4. Prepare the Locking Ring (#12) for installation by
setting a common gap between the inner and outer
rings and applying a light film of oil to the I.D.
5. Install the Locking Ring (#12) onto the Front Hub
(#21) as per manufacturer’s instructions given in the
back of this manual on page 38. Torque Screws to
23 Ft. Lbs for a new ring and 22 Ft. Lbs. for a ring
previously used.
7-4 REAR HUB REASSEMBLY
The procedure for the Rear Hub Reassembly is the
same as the Front Hub Reassembly except for one
thing. There are no Dowel Pins in the Rear Hub.
7-5 INSTALLING ROTARY UNION (#41)
(See Figure 8.3) Figure 7.6 - Installing Bearing Pin (#18)
BESSER COMPANY
®
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MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
3. Cross-drill a 3/16” hole through the Bearing Pin
(#18) and install a Roll Pin (#101) into the Piston
(#34) as shown in Figure 7.7.
Figure 7.7 - Cross Drilling Piston Bearing Pin (#18)

4. Lightly coat the remaining O.D. of the Bearing Pin
(#18) and the I.D. of the (3) Bearings (#14) with
Green Loctite #609. Figure 7.9 - Installing Piston
5. Press the (3) Bearings (#14), one at a time, onto the 1. Lubricate the Piston Cartridge (#107) with Grease and
Bearing Pin (#18) with an Arbor Press and Bearing install both O-Rings (#35) and (#36) on it.
Installation Tool #601-SP-013 as shown in Figure 7.8.
2. Apply a liberal amount of Grease to the piston bore
in the Front Hub (#21) and the 2.550” shaft diameter.
(See Figure 7.9)
3. Place the Tapered Assembly Tool #601-SP-014 on
the rear end of the Vibrator Shaft (#1).
4. Carefully slide the Piston Cartridge (#107) down and
over the shaft until it rests on the Front Hub (#21) as
shown in Figure 7.9.
CAUTION - Be very careful not to damage the
O-Rings on the Piston Cartridge.
5. Lubricate the (4) Dowel Pins (#101), piston dowel
holes and the rear face of the Piston Cartridge
(#107) with a liberal amount of Royal Purple
Grease. (See Figure 7.9)
6. Push the Piston Sub-Assembly down and over the
Vibrator Shaft (#1) and onto the (4) Dowel Pins (#106).
Tap with a soft hammer to make sure that the Piston
Figure 7.8 - Installing Cam Follower Bearings (#14) Cartridge (#107) and Piston (#34) is firmly seated
against each other in the Front Hub (#21) piston bore.
6. Install the Retaining Ring (#20) on the Bearing Pin
(#20). IMPORTANT: Make sure that you have a R.H.
piston for a R.H.Assembly or a L.H. piston for
7-7 INSTALLING PISTON ASSEMBLY ON TO THE
a L.H. Assembly. (See Figure 7.10 on the next
VIBRATOR SHAFT (See Figure 8.4) page.)
First set the Vibrator Shaft and Front Hub in a vertical 7. Seat the piston bushings by lightly tapping the
position with the rotary union end pointed down. Use Counter Weight Pin (#100) side to side with a soft
suitable bracing and support. hammer.
24 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
CAUTION: Make sure that the Trantorque and
L.H Assembly Ring Assembly is firmly locked on the shaft
before applying air pressure to the shaft.
9. Attach a Pneumatic Test Set-Up (or similar) as
shown in Figure 7.11 to the Rotary Union (#41) and
apply 60 to 80 PSI air pressure. The piston will move
up to the Trantorque and Ring Assembly #601-
SP-021. Maintain this air pressure for approx. 30 to
60 seconds. Watch the pressure gauge very closely
for any leaks.
R.H Assembly
When applying air pressure also check around the
Swivel Union (#41) for any air leakage. Use “Snoopy”
air leak detection fluid (or equivalent) to check for any
air leaks. Follow instructions on the bottle.
IMPORTANT - There must not be any pressure
drop at all for this test.
10. Remove the Trantorque and Ring Assembly #601-
SP-021 and the Pneumatic Test Set-Up from the shaft.
Figure 7.10 - Correct Piston Orientation CAUTION - Do not attempt to remove the
It is necessary at this time to check the piston for leaks. Trantorque and Ring Assembly #601-SP-021
with the air pressure connected. Disconnect
8. Slide the Trantorque and Ring Assembly #601-
the air pressure first.
SP-021 down over the shaft and lock it so it is
approx. 1/2” from the rear face of the Piston (#34) as 7-8 FURTHER ASSEMBLY BUILD-UP
shown in Figure 7.11. (See Figures 7.12 , 8.4 and 8.5)
Figure 7.11 - Testing Piston for Leaks Figure 7.12 - Further Build-Up
BESSER COMPANY
®
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MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
1. Grease the rear face of the Piston (#34). and Rear Hubs are resting on the (4) key stock
2. Place the Thrust Washer (#42b) over the shaft until upright members of the fixture. (See Figure 7.13)
it rests on the rear face of the Piston (#34). Apply This will automatically align the Rear Hub (#11) with
some Grease to the rear face of this Washer (#42b). the Front Hub (#21).
3. Drop the Spring (#32) over the shaft until if firmly 12. Compress the entire assembly with the (2) L-Clamps
rests on the Thrust Washer (#42b). so that both hubs are seated solidly into the Sleeve
4. Place a Thrust Washer (#42a) over the shaft and rest (#17) as shown in Figure 7.13.
it on the Spring (#32). NOTE - On a 27.48” long 7-9 SmartPac ALIGNMENT & BALANCING
shaft there will be (2) Thrust Washers (#42a). (See Figure 7.14)
5. Place the Counter Weight (#16) into place with the
Roller Cam (#14), which is on the Piston Assembly,
nestled in the counter weight cam slot.
IMPORTANT - Do not move or adjust the pis-
ton to accomplish this.
6. Replace the exact same number of Shims (#130) to
(#135), if possible, or place .040” thick Shims
(#130) to (#135) on the Front Hub Assembly.
NOTE - This is only a starting point for the
Alignment and Balancing Procedure described in
the next Section 7-9.
7. Place the Sleeve (#17) over the assembly and attach
with (2) Flat Hd. Screws (#15). Tighten, but do not
use Loctite or torque yet .
NOTE - This is only temporary until the Alignment
and Balancing Procedure is completed.
8. Make sure that the Rear Hub (#21) and the shaft
where the Rear Hub seats is thoroughly cleaned of
all grease and dirt.
9. Apply a film of Grease to the inner surface that con-
tacts the Thrust Washer (#42a).
10. Lower the Rear Hub (#11) down and over the shaft.
NOTE - This Rear Hub (#11) only has to be in an
approx. position at this time.
11. With soft slings and an overhead hoist lift the whole
assembly up and over to the Support Fixture #601-
SP-019. Set it down so the flat surfaces of the Front
Figure 7.14 - Counterweight Alignment & Balancing
The Offset Dimension, as shown in Figure 7.14 above,

has to be measured to determine the required Shims
Figure 7.13 - Support Fixture #601-SP-019 & L-Clamps
26 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
(#130) to (#135) to correctly balance the SmartPac
Counterweight mechanism.
There is a small amount of backlash movement
between the Piston Sleeve Bearings and the cam slot in
the Counterweight (#17) so there will be a Maximum
Offset Dimension and a Minimum Offset Dimension.
Manually turn the Sleeve (#17) for each position.
The Maximum Offset Dimension (X MAX) and the
Minimum Offset Dimension (X MIN ) must be measured to
determine the Average Offset Dimension (XAVG ). Use a
set of Calipers as shown in Figure 7.15.
Figure 7.15 Correct Alignment of Notches
Example: X MAX = .026” ; X MIN = .030”
7. Make sure that the Rear Hub (#21) and the shaft
X MAX + X MIN .026” + .030” = .028” where the Rear Hub seats is thoroughly cleaned of
= XAVG
2 2 all grease and dirt.
The formula to convert this XAVG to the required Shim 8. Apply a film of Grease to the inner surface that con-
Thickness is as follows: tacts the Thrust Washer (#42a).
XAVG 9. Lower the Rear Hub (#11) down and over the shaft.
= Required Shim Thickness
7 NOTE - This Rear Hub (#11) only has to be in an
.028” approx. position at this time.
= .004”
7 10. With soft slings and an overhead hoist lift the whole
SUMMARY: A .004” shim will create the average assembly up and over to the Support Fixture #601-
movement of .028” as calculated above. SP-019. Set it down so the flat surfaces of the Front
and Rear Hubs are resting on the (4) key stock
In each of the (4) Conditions - A - B - C and D shown upright members of the fixture. (See Figure 7.13)
in Figure 7.11, this means that you will add or remove
This will automatically align the Rear Hub (#11) with
.004” of shim thickness from the existing .040.
the Front Hub (#21).
• L.H. Vibrator Unit 11. Compress the entire assembly with the (2) L-Clamps
Condition A - Remove .004” (.040” - .004” = .036”) so that both hubs are seated solidly into the Sleeve
Condition B - Add .004” (.040” + .004” = .044”) (#17) as shown in Figure 7.13.
• R.H. Vibrator Unit 12. Prepare the Locking Ring (#12) for installation by
setting a common gap between the inner and outer
Condition C - Add .004” (.040” + .004” = .044”)
rings. Also apply a light film of oil on the I.D. of the
Condition D - Remove .004” (.040” - .004” = .036”) Locking Ring.
1. Measure and determine the Required Shim 13. Install the Locking Ring (#12) on the Rear Hub (#11)
Thickness as demonstrated above. as per manufacturer’s instructions given at the back
2. Take the (2) L-Clamps off and lift the SmartPac of this manual on page 38. Torque screws to 23 Ft.
Assembly off the Support Fixture. Set the assembly Lbs. for a new ring and 22 Ft. Lbs. for a ring pre-
back in the vertical position with the Front Hub point- viously used.
ing downward.
7-10 MAIN SHAFT BEARING REASSEMBLY
3. Remove the Rear Hub Assembly and the Sleeve (#17). (See Figure 8.4)
4. Add or remove Shims (#130) to (#135) as required. Clean all parts thoroughly before Reassembly.
5. Place the Sleeve (#17) over the assembly. Attach
A. Front Main Shaft Bearing
with a couple of Flat Hd. Screws (#15) to check
alignment. The notches should be aligned as shown 1. Place the Bearing Housing (#8) into an Arbor Press.
in Figure 7.15. Use the Bearing Closure (#9) to press the Roller
Bearing (#7) into the Housing (#8).
6. Clean the (6) Flat Head Screws (#15) with Loctite
Primer T. Apply a little Blue Loctite #242 to the 2. Press the Oil Seal (#31) into the Bearing Closure (#9).
screws and install them into the Sleeve (#17). 3. Press the Oil Seal (#39) into the Front Bearing
Torque to 14 Ft. Lbs. Closure (#38).
BESSER COMPANY
®
27
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
NOTE - Both Oil Seals (#31) and (#39) must be CAUTION - Wear suitable work gloves when
installed backwards so the grease pressure can handling heated parts.
be relieved during operating time. 9. Clean off any excess Loctite.
4. Install the (2) Grease Fittings (#10) into the Bearing 10. Apply Grease to the shaft where the Oil Seal (#39)
Housing (#8). rides.
B. Rear Main Shaft Bearing 11. Slide the Bearing Closure (#38) with the Oil Seal
(#39) in it over the shaft shoulder and insert the pilot
1. Place the Bearing Housing (#8) into an Arbor Press. into the Bearing Housing (#8).
Press the Roller Bearing (#7) into the Housing (#8)
until it is centered in the housing. CAUTION - Be very careful not to damage the
lip of the Oil Seal (#39).
2. Press the Oil Seal (#31) into the Bearing Closure
(#9). 12. Attach with (4) Hex Hd. Screws (#3) and (4)
Lockwashers (#4). Torque to 14 Ft. Lbs.
NOTE - The Oil Seal (#31) must be installed
backwards so the grease pressure can be B. Rear Main Shaft Bearing
relieved during operating time. Let the Front Bearing cool or clamp in place before
3. Install the (2) Grease Fittings (#10) into the Bearing turning in over.
Housing (#8). 1. Place the assembled SmartPac Vibrator Shaft into a
4. Install the Grease Fitting (#5) into the Bearing End work bench hole with the Rotary Union (#41) facing
Closure (#6). down.
7-11 MAIN SHAFT BEARING INSTALLATION Repeat Steps 2 thru 5 in previous section A. Front Main
(See Figure 8.4) Shaft Bearing.
A. Front Main Shaft Bearing 6. Slide the Spacer (#30b) over the shaft until it rests
on the shaft shoulder.
1. Place the assembled SmartPac Vibrator Shaft into a
work bench hole with the Rotary Union (#41) facing up. NOTE - This Spacer (#30b) is not used on
Vibrator Shafts with a MSB Length of 27.48” or
2. Apply Grease to the shaft area where the Oil Seal any metric length shafts.
(#31) rides.
7. Apply a generous amount of Blue Loctite #242 to
3. Slide the Bearing Closure (#9) with the Oil Seal the shaft bearing journal.
(#31) in it over the shaft shoulder.
CAUTION - Be very careful not to damage the
lip of the Oil Seal (#31).
4. Clean the inner race of the Roller Bearing (#7) and
the shaft bearing journal with Loctite Primer T.
5. Heat the Bearing Housing (#8) and Roller Bearing
(#7) to 200° F.
CAUTION - Wear suitable work gloves when
handling heated parts.
6. Slide the Spacer (#46) over the shaft until it rests on
the shaft shoulder. Make sure the inside bevel on
the Spacer goes towards the shoulder.
NOTE - This Spacer (#46) is not used on Vibrator
Shafts with a MSB Length of 27.48” or any met-
ric length shafts.
7. Apply a generous amount of Blue Loctite #242 to
the shaft bearing journal.
8. Slide the heated assembled Bearing Housing (#8)
and Roller Bearing (#7) over the shaft bearing jour-
nal until it seats against the Spacer (#46) or the shaft
shoulder. Be sure that the (2) Grease Fittings
Figure 7.16 - Installing Retaining Ring (#29)
(#10) are facing the rotary union end of the shaft.
28 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
8. Slide the heated assembled Bearing Housing (#8)
and Roller Bearing (#7) over the shaft bearing journal
until it seats against the Spacer (#30b) or the shaft
shoulder. Be sure that the (2) Grease Fittings (#10)
are facing the Rear Hub on the shaft.
CAUTION - Wear suitable work gloves when
handling heated parts.
9. Clean off any excess Loctite.
10. Install a Spacer (#30a) on the shaft for all metric
length shafts.
11. Install the Retaining Ring (#29) onto the shaft end
with the sharp edges away from the bearing as
shown in Figure 7.16. Be sure that this Retaining
Ring (#29) snaps into the groove.
12. Attach the End Bearing Closure (#6) with (4) Hex
Hd. Screws (#3) and (4) Lockwashers (#4). Torque
to 14 Ft. Lbs.
7-12 LUBRICATE BEARINGS TO PREVENT RUST
After the vibrator is fully assembled, do the following:
1. Fill both the front and back bearing housings with
NLGI Rated Synthetic Grade 2 Extreme Pressure
Grease. Fill each bearing housing with approximately
1 Fluid Oz. of Grease This step assumes new bear-
ings have no lubrication.
2. Spray multipurpose synthetic lubricant (Besser P/N
114044) into the 0.125 inch [3.17 mm] vent hole in
the Sleeve (#17) for 5 – 10 seconds to treat the
interior of the assembly.
7-13 INSTALLING V-BELT PULLEY (#201) AND
LOCKING ASSEMBLY (#200)
(See Figure 8.3)
1. Make sure that the shaft and bore areas are thor-
oughly cleaned and then lightly oiled.
2. Place the V-Belt Pulley (#201) and Locking
Assembly (#200) on the shaft and as close to the
Front Main Bearing as possible to reduce overhang
load. Do not torque the screws yet .Final position-
ing will be determined when attaching the drive belt.
3. Remount the SmartPac Vibrator Shaft Assembly
back on the Mold Bars as specified in Section 4 -
Installation; 4-2 Installing SmartPac Vibrator
Shafts.
4. Reposition the V-Belt Pulley (#201) and Locking
Assembly (#200) to align with the drive belt. Torque
as per manufacturer’s instructions shown on Page
41 in the back of this manual.
5. Reattach any belt guards that were removed at dis-
assembly.
BESSER COMPANY
®
29
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Section 8 - REPAIR PARTS
8-1 GENERAL INFORMATION 3. Part Reference Number (From Parts List and
Exploded View Drawing).
This section describes and illustrates all available repair
parts for the SmartPac Series II (Model PV2-98) 4. Part Name (From Parts List).
Vibrator Shafts. 5. Quantity (As Required).
Parts are identified on the exploded view drawings. The 6. Complete Shipping Information.
main assembly is shown on Figure 8.2. The SmartPac
Control Unit is shown on Figure 8.5. These Reference IMPORTANT - Failure to include all of the above
Numbers are the same as used in the parts listing. information will only delay your parts order. Unless
another method is specified for shipping information,
Several Kits are also available and they are: parts weighing less than 150 Lbs. will be shipped United
1. V-Belt Pulley and Hose Assembly Kit is shown on Parcel Service. Parts weighing more than 150 Lbs. will
Figure 8.1. be shipped Motor Freight. Air freight and other trans-
portation services are available but have to be specified
2. Complete Piston Assembly Kit is shown on Figure on your order.
8.3.
3. The Assembly Tool Kit is shown on page 30. 8-3 NAME PLATE INFORMATION
4. Overhaul Kits are also available. They are desig- (This Name Plate is located on the Front Hub.)
nated by * in the parts listing.
8-2 ORDERING REPAIR PARTS

Contact the Besser Central Order Department when
ordering any Repair Parts or Kits. Please specify all
of the following information:
1. Complete Model Number (On Name Plate).
2. Serial Number (On Name Plate and stamped under
the name plate on the Front Hub).
30 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Piston Bearing Replacement Kit
BESSER Part Number:

(#490734)
FORCE CONTROL Part Number:

(#02-SP-903-03)
INCLUDES:
• (3) Bearings (#14)
• (1) Retaining Ring (#20)
• (1) Bearing Pin (#18)
Figure 8.1 - Piston Bearing Replacement Kit
Complete Piston Replacement Kit
BESSER Part Numbers:

L.H. ASSEMBLY - (#490733)
R.H. ASSEMBLY - (#490735)
FORCE CONTROL Part Numbers:
L.H. ASSEMBLY - (#02-SP-901-03)
R.H. ASSEMBLY - (#02-SP-900-03)
INCLUDES:
• Piston Sub-Assembly (#34A)
- (1) Piston (#34)
- (2) Sleeve Bearings (#37)
- (1) Counter Balance Pin (#100)
- (4) Bushings (#102)
- (2) Roll Pins (#106)
• Piston Bearing Replacement Kit

- (1) Bearing Pin (#18)
- (3) Bearings (#14)
- (1) Retaining Ring (#20)
Figure 8.2 - Complete Piston Assembly
BESSER COMPANY
®
31
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
V-BELT PULLEY, LOCKING ASS’Y. & HOSE ASS’Y. KIT
2 Groove Pulley
(Besser Part No. 646749)
(Force Control Part No. 02-SP-904-03)
4 Groove Pulley
(Besser Part No. 646891)
(Force Control Part No. 02-SP-90X-03)
Figure 8.3 - V-Belt Pulley and Hose Assembly Kit
Repair Parts List (Figure 8.4)

AFC SmartPac Series II (Model PV2-98) Vibrator Shaft
®
REF. REF.
PART NAME QTY. No. PART NAME QTY.
No.
1 Vibrator Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ³*30a Spacer, .087” Thick . . . . . . . . . . . . . . . . . . . . . AR
3 Hex Hd. Screw, 3/8”-16 x 3-1/2” Lg. . . . . . . . . . 8 ³*30b Spacer, .087” Thick . . . . . . . . . . . . . . . . . . . . . AR
4 Shakeproof Lockwasher, 3/8” . . . . . . . . . . . . . . 8 *31 Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
*5 Grease Fitting, 1/4” Straight . . . . . . . . . . . . . . . 1 *32 Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*6 Bearing End Closure . . . . . . . . . . . . . . . . . . . . 1 *35 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 Spherical Roller Bearing . . . . . . . . . . . . . . . . . 2 *36 O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 Bearing Housing . . . . . . . . . . . . . . . . . . . . . . . . 2 38 Bearing Closure . . . . . . . . . . . . . . . . . . . . . . . . 1
9 Bearing Closure . . . . . . . . . . . . . . . . . . . . . . . . 2 *39 Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*10 Grease Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 4 *40 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 Rear Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 *41 Rotary Union . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*12 Locking Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ³*42a Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . AR
13 Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . 2 ³*42b Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . AR
*15 Flat Hd.Screw, 3/8”-16 x 1-1/2” Lg. . . . . . . . . . 6 ³*46 Spacer, .127” Thick . . . . . . . . . . . . . . . . . . . . . AR
16 Counter Weight 101 Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
L.H. Shaft Assembly . . . . . . . . . . . . . . . . . . . 1 107 Piston Cartridge . . . . . . . . . . . . . . . . . . . . . . . . 1
R.H. Shaft Assembly . . . . . . . . . . . . . . . . . . . 1 *130 Shim, .002” Thk. Red . . . . . . . . . . . . . . . . . . . . AR
17 Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 *131 Shim, .005” Thk. Blue . . . . . . . . . . . . . . . . . . . . AR
19 Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 *132 Shim, .010” Thk. Brown . . . . . . . . . . . . . . . . . . AR
21 Front Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 *133 Shim, .015” Thk. Pink . . . . . . . . . . . . . . . . . . . . AR
22 Serial & Patent Name Plate . . . . . . . . . . . . . . . 1 *134 Shim, .020” Thk. Yellow . . . . . . . . . . . . . . . . . . AR
23 Drive Screw, #10 x 3/8” Lg. . . . . . . . . . . . . . . . 3 *135 Shim, .025” Thk. White . . . . . . . . . . . . . . . . . . . AR
*29 Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . 1
* - Indicates parts in the Overhaul Kit. (Use Part

Number #7P-SP-Customer’ Model Number to
order an Overhaul Kit.)
³ - See Page 34 (Figure 8.5) for quantity used,

where used and on what shaft lengths used.
AR - As Required.
32 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
SmartPac® Series II (Model PV2-98) Vibrator Shaft
Figure 8.4 - SmartPac Vibrator Shaft Assembly
BESSER COMPANY 33
®
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Figure 8.5 - Spacers and Thrust Washer Usage
SPACERS (#30a), (#30b) and (#46)

SHAFT CENTER .087” THICK .087” THICK
DISTANCE LENGTH SPACER (#30a) SPACER (#30b) SPACER (#46)
454 mm (1) NONE NONE
18.047” NONE (1) (1).087” Thk.
20.047” NONE (1) (1).127” Thk.
530 mm (I) NONE NONE
21.047” NONE (1) (1).087” Thk.
22.047” NONE (1) (1).148” Thk.
27.480” NONE NONE NONE
THRUST WASHER (#42a) and (#42b)

SHAFT CENTER 11,000 Lbs. 13,000 Lbs. 15,000 Lbs.
DISTANCE LENGTH (#42a) (#42b) (#42a) (#42b) (#42a) (#42b)
454 mm NONE (1) NONE (1) NONE (1)
18.047” NONE (1) NONE (1) NONE (1)
20.047” NONE (1) NONE (1) NONE (1)
21.047” NONE (1) NONE (1) NONE (1)
22.047” NONE (1) NONE (1) NONE (1)
27.480” (1) (1) (1) (1) (1) (1)
34 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Repair Parts List (Figure 8.6)
SmartPac Series II (Model PV2-98) Control Unit
®
BESSER BESSER
KEY PART NAME QTY. KEY PART NAME QTY.
PART No. PART No.
1 111641 5-Way Air Valve . . . . . . . . . . . . . . . . . . 7 8 114292 Breather . . . . . . . . . . . . . . . . . . . . . . . . 1
2 114604 Valve Assembly . . . . . . . . . . . . . . . . . . 2 9 114844 BKS-S33M-00 Connector . . . . . . . . . . 1
3 114198 Filter Assembly . . . . . . . . . . . . . . . . . . 1 10 114909 Q5 N5 Tandem Cylinder Ass’y. . . . . . . 1
4 113931 Transducer . . . . . . . . . . . . . . . . . . . . . . 1 11 106152 LFG-2 - 030-P Gauge . . . . . . . . . . . . . 2
5 115211 BLT-5-Feet-Std. . . . . . . . . . . . . . . . . . . 2 12 115209 NAN-400-NO4 Silencer . . . . . . . . . . . . 1
6 115210 Magnet . . . . . . . . . . . . . . . . . . . . . . . . . 1 13 115257 VXX-5524-UG-120 5-Way Air Valve . . 1
7 114195 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 14 115258 R26-04-000 Regulator . . . . . . . . . . . . . 2
NOTE: Contact Besser Company to order any replacement

parts for this SmartPac Control Unit.
SmartPac® Series II (Model PV2-98) Control Unit
Figure 8.6 - SmartPac Control Unit
BESSER COMPANY
®
35
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
8-4 ASSEMBLY TOOL KIT for SmartPac VIBRATOR SHAFT
(Besser Part No. _______) (Force Control Part No. 02-SP-902-03)
1. (2) Heavy Duty L-Clamps (12” to 16” Opening)

Wilton #6316 (or equivalent) Can be purchased at any welding sup-
ply house.
Function - Used to compress SmartPac Assembly to remove and
install the Rear Hub (#11).
2. Bearing Press Tool #601-SP-013

Function - Used to install the (3) Bearings (#14) onto the Piston
Bearing Assembly.
3. Tapered Assembly Tool #601-SP-014

Function - Used to ease installation of parts onto the Vibrator Shaft.
4. Trantorque and Ring Assembly #601-SP-021

Function - Used as a positive stop when testing the newly installed
piston for leaks.
5. Dowel Pin Remover #601-SP-018

Function - Used to remove the (4) Dowel Pins (#101) from the Front
Hub (#21) and the (2) Dowel Pins (#106) from the Piston (#34).
6. SmartPac Support Fixture #601-SP-019

Function - Used to support the SmartPac Vibrator Shaft Assembly
to align the Rear Hub (#11) with the Front Hub (#21).
7. Front Bearing Puller #601-SP-020

Function - Used to remove the Front Main Shaft Bearing from the
Vibrator Shaft.
36 BESSER COMPANY
®
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
8. Bearing and Bearing Retainer Removal Tool #601-SP-023
Function - Used to remove the large Ball Bearing (#19)
and the Bearing Retainer (#13) from the Front Hub (#21) &
the Rear Hub (#11).
9. Arbor Press Tool #601-SP-024

Function - Used to install the large Ball Bearing (#19)
and the Bearing Retainer (#13) on to the Front Hub (#21) &
the Rear Hub (#11).
10. Bearing Removal Tool #601-SP-025

Function - Used to remove the large Ball Bearing (#19)
from the Bearing Retainer (#13).
11. Piston Cradle Assembly #601-SP-027

Function - Used to support and cradle the Piston Assembly
for Disassembly and Reassembly Procedure
12. Green Loctite #609 13. Blue Loctite #242
BESSER COMPANY 37
®
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Section 9 - FACTORY REBUILD & RAPID EXCHANGE SERVICE
9-1 FACTORY REBUILD AND RAPID EXCHANGE SER- These Re-conditioned Cores are shipped in a
VICE Returnable Shipping Container for you to ship your
old failed core directly to Force Control for a “Core
A Rapid Exchange Service is offered by Force Credit”.
Control exclusively through the Besser Company.
Neither Force Control or the Besser Company can be
responsible for any units returned without following the
Features and Advantages of the Rapid Exchange Service:
procedures outlined.
1. SmartPac Shafts are rebuilt with genuine O.E.M.
If you are not using one of the Returnable Shipping
parts to assure maximum life.
Containers extra care must be given to the packaging of
2. Emergency 24 hour or same day service available. returned units. Firmly attach the shaft assembly to a
3. Full factory warranty - Our commitment to quality. suitable skid. Shipment damaged units always delay
repairs. It is usually impossible to recover damage costs
4. Factory tested - For maximum performance. from the carrier. Whenever possible describe the prob-
5. Re-conditioned cores are factory rebuilt to latest revi- lems you are having with the failed unit on your shipping
sions. papers.
Before returning any units to Force Control, contact the
Contact: Besser Central Order Department for
Besser Company Central Order Department for ship-
complete return address.
ping instructions and order processing. The Besser
Company will arrange proper authorization with Force Return to: Force Control Industries, Inc.
Control for Same Day Shipment of a Re-conditioned
Core directly to you and the return of your old Core.
38 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Section 10 - SYSTEM DIAGRAMS
Figure 10.1 - Air-Hydraulic System Diagram - Vibration On/Full Stroke (Amplitude)
Figure 10.2 - Air-Hydraulic System Diagram - Vibration On/Half Stroke (Amplitude)
BESSER COMPANY
®
39
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Figure 10.3 - Air-Hydraulic System Diagram - Vibration Off
40 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
INSTALLATION AND REMOVAL INSTRUCTIONS FOR LOCKING RINGS (#12)
BESSER COMPANY
®
41
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
INSTALLATION AND REMOVAL INSTRUCTIONS FOR LOCKING ASSEMBLY (#200)
42 ®
BESSER COMPANY
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
Manual Revision & Printing History
SmartPac Vibrator Shaft (Model PV2-98)
REVISION
REVISION PRINTING REVISION
REVISION INITIATED
DATE DATE REVISION/ACTION DESCRIPTION MADE BY:
NUMBER BY:
(Mo./Yr.) (Mo./Yr.) (Name) (Name)
502-SP-002-00 -------- 12/02
4/03 -------- Added alignment and balancing section to Section 7 Mark House Brooks
Removed all information concerning any Piston Disassembly and Tim

Brooks
Reassembly. Piston can only be ordered as a complete assembly. Vonderhaar
2/04
502-SP-002-01
Added important Mounting Bolt information in Installation Section, Mike
-------- Brooks
also Besser Part Numbers for special mounting bolts. Sharratt
Added important information about cleaning concrete dust and debris

Ken
4/04 between moving surfaces before installing unit on machine in Section Brooks
Baker
5.
Ken
502-SP-002-02 8/04 -------- More Piston Bearing Changes. Brooks
Baker
Reverted back to Ball Bearing type Piston Bearings. Changed

Joe
502-SP-002-03 3/05 Disassembly, Reassembly and Repair Parts. Expanded Factory Brooks
VonDerHaar
Rebuild & Rapid Exchange Service to its own Section 9
Change max speed from 3100 RPM to 2900 RPM. Changed order
502-SP-002-04 9/06 of installation checklist (Attach Hoses first). Added Adjust motor Jerry Perkins Watkins
to checklist.
BESSER COMPANY
®
43
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18
AFC SmartPac ® VIBRATOR SHAFTS
FORCE CONTROL INDUSTRIES, INC.

Providing today’s industries
with Oil Shear Clutch and
Brake Drives that delivers:
Flexibility Efficiency
Endurance Performance
and Dependability
“BUILT TO LAST - GUARANTEED TO PERFORM”
MANUFACTURED FOR: MANUFACTURED BY:
BESSER COMPANY FORCE CONTROL INDUSTRIES, INC.

801 Johnson Street Fairfield, Ohio
P.O. Box 336
Alpena, Michigan 49707 U.S. A.
Phone - (517) 354-4111
Fax - (517) 354-3120
http://www.besser.com
®
MEX (55) 53 63 23 31 MTY (81) 83 54 10 18

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502-SP-002-04

Series II (Model PV2-98)

Figure 1.1 - Typical AFC SmartPac Application

Figure 1.2 - Cross Section thru SmartPac Vibrator Shaft

Available MSB Lengths

Figure 2.1 - SmartPac Dimensions

Figure 2.2 - SmartPac Vibrator Assembly Orientation

To order safety decals, contact your local Besser representative

CAUTION - As shown on page 14, NEVER

SMARTPAC INSTALLATION CHECKLIST

Table 2.1 - Installation Checklist

Figure 5.1 - Main Shaft Bearing Lubrication

Concrete dust & Debris between Clean between moving parts.

Broken ball bearing Roll SmartPac unit in quiet area and

Vibration not shutting off. Broken spring. Replace spring.

Concrete dust & Debris between Clean between moving parts.

Unequal shifting of vibrator Restricted oil filter. Check filter.

Main bearings overheating. Bearings preloaded. Rotate shafts by hand prior to

Too much grease. Remove excess grease and follow

Not enough grease. Add grease per procedure in

CLEAN BOTH ENDS OF UNIT.

Figure 5.3 - Cleaning SmartPac Unit of Concrete Dust & Debris

6-1 REMOVING SmartPac ASSEMBLY

Figure 6.2 - Removing Roller Bearing (#7)

(B) The Piston Bearing Sub-Assembly can be

Figure 6.6 - Removing Dowel Pins (#106)

as shown in Figure 6.7. Use the 3/8" x 6-1/2" Lg.

6-5 REMOVING FRONT HUB ASSEMBLY

Figure 6.10 - Removing Ball Bearing (#19) from

Complete for your SmartPac Vibrator Shaft

Figure 6.9 - Removing Ball Bearings (#19) and Bearing

Figure 7.1 - Installing Bearing (#19) into Bearing

Figure 7.4 - Installing Front Hub to Vibrator Shaft

Figure 7.7 - Cross Drilling Piston Bearing Pin (#18)

Figure 7.14 - Counterweight Alignment & Balancing

The Offset Dimension, as shown in Figure 7.14 above,

8-2 ORDERING REPAIR PARTS

BESSER Part Number:

FORCE CONTROL Part Number:

Figure 8.1 - Piston Bearing Replacement Kit

Complete Piston Replacement Kit

BESSER Part Numbers:

• Piston Bearing Replacement Kit

Figure 8.2 - Complete Piston Assembly

Figure 8.3 - V-Belt Pulley and Hose Assembly Kit

Repair Parts List (Figure 8.4)

* - Indicates parts in the Overhaul Kit. (Use Part

³ - See Page 34 (Figure 8.5) for quantity used,

Figure 8.4 - SmartPac Vibrator Shaft Assembly

SPACERS (#30a), (#30b) and (#46)

THRUST WASHER (#42a) and (#42b)

NOTE: Contact Besser Company to order any replacement

SmartPac® Series II (Model PV2-98) Control Unit

Figure 8.6 - SmartPac Control Unit

1. (2) Heavy Duty L-Clamps (12” to 16” Opening)

2. Bearing Press Tool #601-SP-013

3. Tapered Assembly Tool #601-SP-014

4. Trantorque and Ring Assembly #601-SP-021

5. Dowel Pin Remover #601-SP-018

6. SmartPac Support Fixture #601-SP-019