Full Automatic Gantry

Stacker

YCMD40
Operation Manual
(Mechanical Fascicule)
 Table of Contents
Introduction ...................................................................................... 1

Safety precautions .............................................................................. 1

Precautions ......................................................................................... 2

Chapter 1 General Regulations ...................................................... 3

1.1 Functions of this manual and correct methods of use ................. 3

1.2 Commissioning and maintenance ................................................4

1.3 Preparations by the customer .......................................................4

1.4 After-sales service ........................................................................ 5

1.5 Relevant regulations .....................................................................6

1.6 Safety overview ............................................................................6

1.7 Safety signs ................................................................................ 11

1.8 Signs for regular maintenance ................................................... 12

Chapter 2 Equipment Introduction ............................................. 13

2.1 Basic information .......................................................................13

2.2 Main composition ...................................................................... 15

2.3 Workflow ....................................................................................20

2.4 Scope of application ...................................................................22

Chapter 3 Transportation, Handling and Storage ..................... 23

3.1 Basic precautions ....................................................................... 23

3.2 Packing .......................................................................................23

3.3 Transportation, Handling and Storage .......................................23

Chapter 4 Equipment Installation ............................................... 25

4.1 Basic precautions ....................................................................... 25

4.2 Installation condition ................................................................. 25

4.3 Installation positioning .............................................................. 25

4.4 Power connection and inspection .............................................. 26

4.5 Waste removal ............................................................................ 27

4.6 Damage and treatment ............................................................... 27

Chapter 5 Preparations before Use of the Equipment ...............29

5.1 Basic precautions ....................................................................... 29

5.2 Overview of equipment safety system ...................................... 29

5.3 Operator precautions ..................................................................29

5.4 Overview of operation panel and switches ................................30

5.5 Preliminary system test ..............................................................31

5.6 Warning light ..............................................................................31

5.7 Emergency stop and restart ........................................................31

Chapter 6 Equipment Adjustment ............................................... 32

6.1 Basic precautions ....................................................................... 32

6.2 Product switching and adjustment .............................................32

Chapter 7 Maintenance and Repair .............................................36

7.1 Maintenance inspection and operation instructions .................. 36

7.2 Maintenance items and frequency ............................................. 38

104-317
7.3 Lubrication maintenance period ................................................ 40

Chapter 8 Atlas of Stacker Accessories ........................................41

104-317
 Introduction
Welcome to use this full automatic gantry stacker manufactured by our

company, and we will provide you with the best stacking solutions and

product services. To ensure normal installation and use of this machine, this

manual specifies methods of use and precautions in detail. Please read this

manual completely before installing and starting this machine.

Safety precautions

1. Please notice all safety warning signs on this machine and the safety

warnings in this manual to avoid any wrong operation. Please read them

carefully even if you have been very familiar with the operation of this

machine.

2. Any use of this machine for purposes or applications other than those

specified in the design will be deemed as improper use, and the consequences

caused by improper use shall be borne by the user.

3. When the stacking size, stacking form, and stacking quantity of the

stacks are changed, please consult our company technically, as a result of

which we will inform you of and record the parts that need to be changed.

4. This machine can only be used in accordance with this manual and be

inspected and maintained within the specified time under proper technical

design conditions.

5. The user must be familiar with all the movements of this machine and

strictly abide by the operation specifications.

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 6. In case of any abnormal function, you must rectify it immediately.

7. The operator must stay away from the power supply to avoid electric

shock.

8. This machine must be grounded for protection.

Precautions

1. This manual is prepared to facilitate the operator's reading. Please

properly keep this manual, and provide it to the operator and maintenance

personnel when needed.

2. As there is a certain association between the operation status and

installation layout of this machine, please follow the solutions provided by

sales engineers and set this machine in accordance with the solutions.

3. Without the permission of our company, the materials and attachments

provided in this manual cannot be copied or transferred to any third party.

4. Our company is committed to innovation and development of this

machine, so we reserve the right to improve relevant technologies and this

machine.

November, 2021

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 Chapter 1 General Regulations
1.1 Functions of this manual and correct methods of use

The contents of this manual are the necessary data for the safe operation

and running of this machine. The operator must understand and be able to

refer to this manual at any time.

This manual is a complete manual of this machine. In order to ensure its

integrity, please do not delete or modify any content of this manual during

use.

The operator shall be responsible for well keeping this manual and

handing it to the next operator timely. If this machine is transferred, please

transfer this manual to the new user together, and send the name and contact

information of the new user to our company in time.

This manual covers the detailed description of most components. The

specification and model of this machine are subject to change which may

make it not consistent with the diagrams in this manual without prior notice.

This manual is very easy to refer to, and the user can find the

corresponding contents according to the table of contents. All chapters are

arranged in turn to facilitate the user to obtain detailed data.

This manual can be basically divided into table of contents, abstract,

operating instructions of products, notes, and additional pages.

The notes are divided into: safety notes and general notes;
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 Safety notes: clarify the possible hazards to the operator or
the equipment during the normal operation of the equipment;

General notes: remind the reader of properties of a particular

device or of particular processes of a certain mechanism.

The warranty conditions shall be met in accordance with the terms and

conditions of the contract signed by both parties.

1.2 Commissioning and maintenance

According to the current regulations, all the equipment delivered to

customers has passed the commissioning and trial operation before leaving

the factory, and are qualified products.

Our company promises to replace all the spare parts of the ex-factory

equipment damaged under normal operation (operated according to the

requirements of this manual) during the warranty period.

1.3 Preparations by the customer

1. The customer shall take the preparatory measures: There shall be

connection points of power, compressed air and other public energies within 1

meter from the equipment installation position, and the equipment installation

space shall meet the requirements. Especially, the height is greater than 4 m.

2. Power supply: three-phase five-wire system, 380 V, 50 Hz, and

capacity greater than 15 kw.

3. Air source: 0.6 Mpa~0.8 Mpa, 300 NL/min (free of oil and water).
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 4. The customer shall be responsible for: unloading tools and equipment,

installing and positioning tools and equipment, and commissioning

consumables, trial products, empty trays, etc.

5. The space required for installation of the main machine of the

equipment shall have a concrete floor with the flatness of less than 5 mm in

accordance with GB50209-2010.

1.4 After-sales service

1. If the customer needs any consultation and assistance, he shall just

send the relevant information to the specific maintenance department of our

company.

2. When the customer needs to replace or order parts, please provide the

following information:

1) The detailed receiving address of the goods to be sent;

2) The detailed receiving address of the invoice to be sent;

3) The number and relevant information of the required parts or

equipment;

4) The quantity of the required parts;

5) The order date;

6) The expected delivery date;

7) The signature and company seal of the orderer.

Note: In order to easily identify the required equipment and avoid any

mistake in the process of ordering parts, the above contents shall also include
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equipment model, equipment registration number, manufacturing time and

company name of the equipment.

Attention: Once you receive the parts that need for replacement during

the warranty period, please send the damaged parts back to our company

within 60 days.

1.5 Relevant regulations

1. The customer must comply with relevant international safety

regulations.

2. The customer must comply with relevant safety regulations of the

country where the equipment operates.

1.6 Safety overview

1. User responsibility

The basic safety proposed in this manual can be used as the safety

criteria of the equipment of our company. The general safety information and

the repair, maintenance and operation data of each specific equipment

constitute a complete operation manual.

The operator must be fully familiar with the contents of this manual

before starting the equipment.

The customer has the responsibility to abide by the requirements of this

manual. Any deviation or change in use must be allowed by this manual. We

will formulate a new operation manual according to the design change as the

safe operation regulations and rules of the subsequent equipment.

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 2. Safety first

The equipment of our company is designed and manufactured based on

recognized safety standards. However, whether the equipment can work

normally and safely completely depends on whether it can be operated,

repaired and maintained correctly under the management of specially

designated personnel.

In order to protect the safety of the operator and others, it is

necessary to strictly abide by the rules of the safety department as

described in this manual, pay attention to and abide by the warning signs

on the equipment, and build the habit of adhering to the safe operation

procedures by reading this manual. Please take this manual with you and

read it frequently to make better understanding of this manual. Do not

take chances.

3. Operating area

The operating area around the equipment shall be clearly

specified by the painted protective fences or zebra crossings. Only the

operator or approved specific personnel can enter the operating area

when the equipment control circuit is connected or disconnected or when

the equipment is running. Any tools or other equipment must be kept

outside the operating area.

4. Environment requirements for equipment operation

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 1) The equipment operation space must be planned with railings or

warning signs, and the marks shall be clear;

2) Only the operator is allowed to approach the operation space when the

equipment is running;

5. Safety instructions for equipment installation

1) Do not start this machine before the parts of the equipment are

connected or the safety devices are installed;

2) Do not install this machine in explosive or fire prone areas;

3) Do not modify this machine or install other parts without the

permission of our technicians; otherwise, our company will not be responsible

for any such consequences;

4) Please make sure that the power supply has been cut off before

starting the electrical installation work;

5) Please ensure a certain operation and maintenance space during

installation to facilitate the operator and disassembly during maintenance;

6) The power source device must be managed by a specially assigned

person to prevent accidental power on or improper switch action during

equipment maintenance;

7) Please install doors or covers for the power control source to avoid

any danger.

6. Safety system inspection

Before starting the equipment:

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 1) Check all safety devices and action devices;

2) Check all indicators, alarms, pressure gauges and their installation

devices or safety indicators to avoid any failure during operation;

3) Do turn off the air and other sources after equipment shutdown.

7. General safety rules

1) Before operating the equipment, the operator shall have a sufficient

understanding of the layout control function of the equipment and this manual

to avoid accidental injury and wear caused by improper operation of the

equipment;

2) On-site personnel shall wear necessary labor protection appliances

such as work clothes and safety helmets;

3) Be sure to clean the tools and sundries out of the operation space

before startup;

4) It is strictly forbidden to wear loose clothes, ties or long hair to

approach the equipment in operation;

5) It is strictly forbidden to play noisily and chase or engage in any

dangerous action in the operation space of the equipment;

6) Public energies, such as air and electricity, shall be closed when this

machine is shut down or not in use;

7) There must be the operator monitoring in real time during the

operation of the equipment;

8) Avoid putting your fingers or any part of your body into this machine
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or close to the running equipment;

9) Do not operate, move or change the safety devices in a rough manner;

otherwise, our company will not be responsible for the safety of the

equipment;

10) Do not operate this machine in the automatic mode after the safety

protection devices are removed. Do not open the fuse box when the power is

on;

11) Do not touch the switch, valve, and sensor without permission;

12) Do not oil moving parts manually;

13) After adjusting the operation, the equipment can be resumed only

when the safety devices are started.

8. Safety rules for equipment maintenance

1) The maintenance must be carried out by the personnel who is very

familiar with the equipment;

2) Make sure the equipment and power are switched off before

maintenance;

3) Ensure that the maintenance tools and the body are insulated;

4) The power must be turned off when replacing the fuse.

9. Safety rules for electrical equipment

1) When moving the equipment, the power switch must be turned off and

all relevant connectors shall be removed;

2) When testing the equipment, please check whether the circuit and the
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required current exceed the supply current;

3) Enough time must be allowed for the capacitor to discharge. If manual

discharge is required, please take care;

4) The doors of the electrical control cabinet can only be opened to

check the circuit and wiring, and it is forbidden to open the doors at any other

time. When the doors are closed, please give the keys to a specially

designated person for management;

5) All electrical equipment must be fixed and overload devices must be

designed;

6) All sealed trunking must be covered;

7) All electrical parts must be placed at a specific position, not beyond

the sealed space of the electrical control cabinet or trunking, etc.

10. Safety specification of air compressor

1) It is forbidden to use the air compressor system before the container is

not covered or the safety devices and indicators are not installed;

2) Please turn off the power after the operation;

3) Check the air compressor system frequently and do a good job for

maintenance.

1.7 Safety signs

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 Watch your hand No entry during
Watch out equipment Danger electric shock
operation

1.8 Signs for regular maintenance

Attention: During the maintenance and repair of this

machine, the power switch and air source switch must be turned off

and marked with special signs (such as "do not turn it on during the

shutdown and maintenance of this machine") to ensure that the

switches cannot be reopened by any personnel.

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 Chapter 2 Equipment Introduction
2.1 Basic information

1. Layout

The general standard configuration layout of this YCMD40 stacker is

shown in Figure 2.1.

2.1 Equipment layout

2. Main technical parameters

1) Operating voltage: three-phase five-wire system, 380 V, 50 Hz

2) Air source: 0.6 Mpa~0.8 Mpa, 300 NL/min (free of oil and water);

3) Equipment dimension: L×W×H=9,120×6,150×3,545 (mm);

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 4) Maximum pallet size: L×W×H=1,300×1,200×150 (mm);

5) Minimum pallet size: L×W×H=1,000×900×150 (mm);

6) Stacking height (including pallet height): 1,750 mm;

7) Maximum weight of each layer of stacking: 260 kg.

8) Minimum height of the production line at the inlet: 1,050 mm or 750

mm;

9) Height of full stack conveyor: 550 mm.

3. Environmental conditions

1) Altitude: 3 m~2,000 m above sea level;

2) Ambient temperature: -5°C~40°C;

3) Humidity: 30%～80%.

4. Working noise

Working noise: ≤65 dB; affected by the containers being packed,

machine power, building acoustic characteristics, the actual noise (DB) will

be reduced or increased.

5. Requirements on pallet

The pallet, also known as the tray, etc., is a base for stacking scattered

articles. It can make full use of the space for articles and is convenient for

storage and conveying. Its materials are generally plastic cement, plastics,

wood, iron and so on, with the shape of rectangular or square, either one-sided

or two-sided.
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 1) Precautions: The load capacity of each pallet shall be less than or

equal to 2 tons. In order to ensure the safety in transportation, the height of

the center of gravity of the cargo shall not exceed 2/3 of the pallet width.

2) Appearance requirements:

a. The pallet shall be square and flat at the top and bottom to ensure

smooth conveying on the roller.

b. During stacking and placing, it shall be aligned up and down, and the

left and right dislocations shall not be more than 30 mm.

c. The pallet shall be free of any damage and shall slide relatively

without being stuck.

d. The maximum width shall be no more than 1,200 mm, and the

minimum width shall be no less than 900 mm.

e. There shall be holes for forklifts on all sides.

2.2 Main composition

The main composition of this YCMD40 stacker is shown in Figure 2.2.

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 1. Stacker 2. Electrical control cabinet 3. Protection net 4. Pallet conveyor
5. Stack divider 6. Operation screen 7. Separator 8. Aligner

Figure 2.2 Main composition of YCMD40 stacker

1. Separator

The two-section whole belt is adopted for conveying, and it will be

accelerated in the second section, so that objects are separated in the

conveying process and box blocking can be avoided. The left and right baffles

at the inlet can adjust the inlet width according to the boxes. There is an

optical sensor at the inlet to control the incoming boxes, as shown in Figure

2.3.

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 Figure 2.3 Separator

2. Aligner

The aligner adopts the flat top fine-pitch mesh belt chain plate driven by

a servo motor for aligning conveying with accurate positioning and rapid

action. The operator only needs to adjust the parameters on the HMI for

corresponding stacking method to separate the packs according to the preset

stacking method without manual and mechanical adjustment, so the operation

is simple, as shown in Figure 2.4.

Figure 2.4 Aligner

The steering mechanism adopts an air cylinder push type. One corner of

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the box on the move is blocked by the baffle to rotate, which is convenient for

staggered stacking. When blocked, under the action of the buffer air cylinder,

the box has a small impact force with stable and proper steering;

The pushing and aligning area is equipped with an optical counting

sensor, which controls the column and row counting according to the optical

signals;

The aligning and pushing can be done automatically according to the

preset box arrangement sequence;

Both the aligned column pushing and the whole layer pushing are driven

by the chain. Two push rods push the boxes circularly, saving time and

improving efficiency. The action is jointly controlled by the chain

photoelectric switch and encoder.

3. Stacker

The stacker adopts a rectangular tube gantry pillar structure, as shown in

Figure 2.5.

The stacks on trays are conveyed by roller-type transmission, lifted by

chain-type transmission, with the stacking shape arranged by clamping boxes

around, and controlled by the air cylinder;

When a layer of boxes is stacked on the stacking platform, a tray will

automatically move to the position above the stacking plate, and the box

clamping air cylinder will be pushed out to clamp the boxes, and then the tray

will exit with the boxes unloaded onto the pallet. The stacking operation of
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one layer is completed.

Figure 2.5 Gantry stacker

4. Pallet distributor

The rectangular-tube frame structure is adopted, the stacking width can

be adjusted according to the pallet specifications, and 10 layers of pallets can

be preset, as shown in Figure 2.6.

Figure 2.6 Stack divider

The lifting structure adopts chain transmission and PLC. The pallet is

placed by use of the air cylinder with the PLC.

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 Working principle: The PLC controls the motor to ascend or descend

according to the stacking completion signal of the stacker, transfers and

places the pallets through the optical signal, with the cylinder acting to clamp

for ascending or descending, while notifying the pallet conveying motor to

work for start or stop.

5. Pallet conveyor

The pallet conveyor adopts a sheet metal structure and roller conveying.

The width at both sides can be adjusted according to the pallet specifications.

The motor rotation is controlled by the stacking signals and PLC; according

to the requirements of the procedure, the pallets are sent to the pallet locating

position, and when the hook plate is blocked, the stacker starts to work; the

hook plate falls down after the stack is full, the motor starts to send the full

stack to the packing place, and then the packed full stack will be sent to the

warehouse, as shown in Figure 2.7.

Figure 2.7 Pallet conveyor

2.3 Workflow

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 Product combination Separator Aligner Stacker

Empty stack Stack divider Stacking

position

Stack-out Full stack

Logistics warehouse position position

Figure 2.8 Workflow

The products are sent to the entrance of the conveyor by the conveyor,

and enter the conveyor after photoelectric detection. The control action is set

according to the stacking requirements and procedures. The boxes are

conveyed to the transverse pushing area by the roller, and then sent to the

aligning area by the PLC with photoelectric control to push the boxes

transversely. A row of boxes is formed by roller conveying. After shaping, the

aligning and box pushing mechanism acts to push the row of boxes to the

second row of the aligning area. After a layer is formed, the turning plate is

opened, and the aligning and box pushing mechanism acts to push a layer of

boxes into the pallet of the stacker. The stacker rises or falls according to the

number of layers. At the same time, the tray moves to above the pallet, and

the boxes are clamped for aligning until the air cylinder acts to make the

products arranged neatly. The tray retreats to the waiting area, while the

clamping cylinder is released to make the products neatly stacked on the

pallet to the number of stacks. The stacker rises to the set height, and the

finished stack is conveyed and pushed out by forklifts or pallets manually, as

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shown in Figure 2.8.

2.4 Scope of application

As supporting equipment of packing machinery, this YCMD40 pillar

stacker is suitable for stacking cartons, iron drums, shrink films, plastic packs,

etc.

Operations not allowed by the equipment:

1. Change other products not approved by our company or increase the

speed of products;

2. Use parts which are not original;

3. Change the connection line;

4. Move the protection facilities provided for this machine.

Attention: Before making any final changes, please be sure to get

in touch with our company!

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 Chapter 3 Transportation, Handling and
Storage
3.1 Basic precautions

For the safe operation of the equipment, please refer to "Safety

overview" in Chapter 1.

3.2 Packing

According to the different modes of transportation and product types, our

company will adopt the corresponding packing methods to ensure the safety

and integrity of the equipment in the process of transportation. According to

customer requirements, the equipment is usually packed with wooden frame

or paperboard and wrapping film.

The operator who is in charge of transportation, loading and unloading

shall pack the equipment according to the size, transportation mode and

destination of the equipment after on-site assembly and testing.

Our company will attach the relevant information onto the wooden box,

i.e. the number, gross weight, net weight, and size of the wooden box, side

lines at the top and bottom, lifting and handling methods and packing list.

3.3 Transportation, Handling and Storage

Generally, the equipment is transported by road, and loaded and

unloaded by a forklift. Before loading and unloading, the weight, center of

gravity, lifting or forklift position, overall size and other information of the
23
equipment shall be confirmed. After loading, the equipment shall be fixed,

avoiding shaking and bumping of sub-equipment during the transportation.

The equipment shall be stored in a dry and ventilated environment, and

cannot be exposed to rain, stacked, overturned, or tilted.

Attention: Please ensure that there is no problem with the lifting

hook of this machine and related components before lifting. Please handle

with care when lifting all objects to prevent damage to the equipment caused

by lifting parts of the crane.

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 Chapter 4 Equipment Installation
4.1 Basic precautions

This machine will be correctly installed by our technicians on site. For

the safe operation of this machine, please refer to "Safety precautions" in

Chapter 1.

4.2 Installation condition

1. Please make sure that there is enough space for easy installation and

maintenance under the conditions free of moisture, flammable materials and

explosive gas.

2. Before the equipment enters the site, get familiar with the equipment

installation site and ascertain both the air source and the power supply. Ensure

that the installation site is level and can bear the weight of this machine, and

the height of the workshop can meet the equipment requirements.

4.3 Installation positioning

1. According to the designed equipment layout, determine the reference

point, and first place each sub-equipment in the approximate position

according to the layout and sequence. Check the position of the incoming

inlet relative to the reference point, and draw a line to make a positioning

mark.

2. The equipment can be positioned according to the conveying sequence

of stacked products:
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 1) Place the front steering separator according to the positioning mark at

the inlet, and then position each sub-equipment according to the layout until

the aligner is positioned.

2) Position the gantry stacker to make the longitudinal center line of the

gantry stacker aligned with that of the aligner, with the distance between the

base end of the gantry stacker and the leg of the aligner of about 320 mm.

Adjust the anchor of the stacker to make the stacker level. Thus, the

positioning of the stacker is completed.

3) Position the pallet conveyor. The distance between the side of the

pallet conveying positioning section and the gantry pillar shall be about 100

mm~150 mm, and the distance between the pallet feeding end and the outer

side of the gantry base shall be about mm. Adjust the anchor to make the

conveying height about 550 mm, and then position the stack divider to make

the longitudinal center line of the stack divider aligned with that of the pallet

conveyor. The outlet end shall be about mm away from the outer side of the

gantry base. Adjust the anchor to make the equipment level. Then, position

and connect other sections of the pallet conveyor according to the layout.

4.4 Power connection and inspection

Attention: All operations related to the electrical system must be

carried out with this machine disconnected from the main power supply.

After the positioning of each sub-equipment is completed, the electrical

26
connection can be carried out. Electrical connection shall be operated by

professional personnel, such as electrical maintenance personnel and

electrical engineers.

First, take out the unconnected wires in the electrical control cabinet due

to transportation, and reconnect the power wire and the signal wires according

to the attached circuit diagram and the digital codes on the wires to ensure

that the frequency and transmission voltage value of this machine (refer to the

data on the nameplate of electrical equipment) are consistent with the main

power supply.

Second, connect all grounding wires and cables of the equipment to

ensure reliable grounding of the equipment.

Third, connect each air pipe and air consumption unit, such as air valve,

air cylinder, etc. according to the air circuit diagram. The air pressure is 6

kg/cm2~7 kg/cm2, and the maximum air consumption of the interface is 300

NL/min.

4.5 Waste removal

If the customer requires special grease to protect this machine, please

clean it before installation.

4.6 Damage and treatment

Attention: This machine does not contain dangerous parts or

materials that need special treatment. The regulations on various materials,

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mainly including the following types, shall be implemented according to the

regulations of the country:

Aluminum, electroplating or baking paint. Stainless steel 300/400 series

and polyethylene plastic elastomer. Gear oil, electric motor, cable and related

sheath, electric eye or driving device.

If the equipment parts are damaged, please find out the corresponding

model according to the parts list and contact our company for ordering.

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 Chapter 5 Preparations before Use of the
Equipment

Attention: During any maintenance, be sure to cut off the power

supply and air supply, and relieve the pressure.

5.1 Basic precautions

For the safety of the equipment, please refer to "Safety overview" in

Chapter 1.

5.2 Overview of equipment safety system

The protection of this machine consists of the following two components:

1) Fixed component, which must be removed with special tools; 2)

Detachable component, connected by electronic buckles.

5.3 Operator precautions

1. The operator must be trained and qualified before taking the post. The

operator shall be equipped with and wear necessary protective workwear,

helmet, goggles, work shoes, etc.

2. The operator must be familiar with the functions of various

mechanisms of the equipment and the functions of various electrical operation

buttons, such as emergency stop. The operator shall also be familiar with the

areas that may cause personal injury to avoid such injury caused by

violations.

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 3. When dealing with the faults during equipment operation, the

equipment must be stopped, with a notice board (such as "Suspended", "Do

not turn on the switch", etc.) placed near the equipment to ensure that the

switch is not turned on by unauthorized personnel.

4. Do not remove the safety protection facilities on the equipment.

Non-operators are not allowed to enter the safety protection area.

5. During the operation of the equipment, the operator should stand by

the equipment. It is convenient to observe all links of production. In case of

abnormal conditions, such as packet jamming, packet switching, etc., it can be

handled in time.

6. If there is a sudden danger during operation, immediately stop the

operation of the equipment and cut off the power supply and air source.

5.4 Overview of operation panel and switches

The following figures show the composition of the operation screen and

panel. The operator shall clearly understand the function of each button before

operation. For specific operation instructions, please refer to the Electrical

Fascicule.

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 5.5 Preliminary system test

1. Check whether the power supply meets the requirements;

2. Check whether the air source supply meets the requirements;

3. Check whether the connection of the hardware pipeline is correct.

5.6 Warning light

This machine adopts red sound and light alarms. If there is any fault, the

alarm will automatically sound and flash in red.

5.7 Emergency stop and restart

There are red emergency stop buttons on the equipment for emergency stop

(Note: This button is only allowed to be pressed for emergency stop rather

than normal shutdown.). One of the buttons is on the operation panel and the

other is attached to the lifting table of the equipment to stop this machine in

case of emergency.

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 Chapter 6 Equipment Adjustment
6.1 Basic precautions

For machine safety tips, please refer to "Safety overview" in Chapter 1.

6.2 Product switching and adjustment

When the stacker changes the products to be stacked, in addition to the

recipe switching in the program, mechanical adjustments are also required:

1. Adjustment of the separator

1) Adjust the level and height of the lead screw (A) to make it fit the

aligning inlet, as shown in Figure 7.1;

2) Adjust the guiding position by adjusting the lead screw (B) according

to the box specifications, so that boxes can be conveyed smoothly;

3) Adjust the tightness of the conveyor via the lead screw (C) to

appropriate tension;

4) Adjust the transmission chain via the screw (D) to make the chain

transmission noiseless and not slippery.

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 Figure 7.1 Adjustment of the separator

2. Adjustment of the aligner

1) Horizontal adjustment: Adjust the anchor nut (A), adjust the

conveying surface of the mesh belt conveyor to be horizontal, and tighten the

nut (A), as shown in Figure 7.2.

Figure 7.2 Adjustment of the aligner

3. Adjustment of the lifting table

Unscrew the set screws of the guide rods at A and B to make that the

distance between the left and right guardrails at A is greater than the distance

between the left and right guardrails on the aligner, that is, the inlet is in a

trumpet shape, and the end distance narrows, which is less than the distance

between the left and right clamping push plates, so that the packs will not get

33
stuck and hang up during operation. Then, tighten each set screw.

The adjustment at B is to make each box clamping air cylinder in the

clamping state (first be sure to cut off the air source and relieve the pressure).

Arrange the packs according to the stacking way of the packs to be stacked,

make the arrangement compact and square, and then adjust the clamping

plates around to the appropriate position, and tighten the set screws at B, as

shown in Figure 7.3.

Figure 7.3 Adjustment of the lifting table

4. Adjustment of the stack divider

If the pallet size changes, adjust the stack divider. First put an empty

pallet, loosen the bolt fixing the air cylinder base at A (first be sure to cut off

the air source and relieve the pressure), make the air cylinder push rod

retracted, and then push the left and right clamping rods. Adjust the insert

block at B to make it inserted into the hole on the pallet, and make the left and

right clamping rods clamp the pallet. Then, fix the bolts at A and B, as shown

in Figure 7.4.

34
 After adjustment, the operator can manually test the clamping and stack

dividing conditions to ensure smooth operation.

Figure 7.4 Adjustment of the stack divider

35
 Chapter 7 Maintenance and Repair
7.1 Maintenance inspection and operation instructions

Note: In the process of maintenance, the equipment must shut

down, and the billboard (such as suspend to use, do not open the switch,

etc.) must be placed near the equipment to ensure that the switch will be

not opened by the personnel not authorized;

Maintenance and replacement: After this machine is used for a period,

the vulnerable parts such as transmission chain, belt, bearing, sliding sleeve,

etc. must be repaired and replaced.

Inspection period
(times)
Equipm
Times Times
ent Inspection items Inspection contents
per per Times
Name
day week

Whether the appearance is abraded or

√
broken
Separat Transmission belt Whether the movement is normal and
√
or and chain the pin is loose
Whether there is any wear and
√
whether the movement is smooth
Whether the appearance is abraded or
Transmission belt √
broken
Whether the appearance is abraded or
Pushing chain √
broken
Aligner
Whether the fastening screws are
Expansion sleeve √
loosened
Whether there is any wear and
Push rod √
whether the movement is smooth
Lifting chain and Whether the operation is normal,
Stacker √
pallet chain whether the pins are fastened and

36
 whether the bolts are loosened

Sprocket and Whether the fastening screws are

√
expansion sleeve loosened
Whether there is any noise and
Bearing √
whether the movement is smooth
Guide rod sliding Whether the operation is smooth and
√
film whether there is any abrasion

37
 7.2 Maintenance items and frequency
Inspection period
Ti Ti Ti
Ti
me me me
Inspection me
No. Inspection contents s s s
items s
per per per
per
we mo yea
day
ek nth r
There is no damage to the appearance √
Whether the movement, contact roller and
√
connecting rod are normal
1 Limit switch Whether the relevant signs are complete √
The component is firmly installed without
√
looseness
There is no falling off of the terminal √
There is no damage to the appearance √
Whether the movement is normal √
Whether the relevant signs are complete √
Photoelectric
2 There is no falling off of the reflector √
switch
The component is firmly installed without
√
looseness
There is no falling off of the terminal √
There is no damage to the appearance √
Whether the movement is normal √
Whether the relevant signs (line marks and
Proximity √
3 component marks) are complete
switch
The component is firmly installed without
√
looseness
There is no falling off of the terminal √
Measurement and inspection of motor operational
parameters (voltage, current, resistance and √
temperature)
4 Motor Whether the brake motor works normally √
Whether the relevant signs (line marks and
√
component marks) are complete
There is no falling off of the terminal √
The button switch works normally √
Operation
The operation switch is firmly installed without
5 switch and √
looseness
indicator
The indicator works normally √

38
 There is no falling off of the terminal √
The component signs of the operation switch and
√
indicator are complete
In action inspection, the manual mechanism works
√
normally and is free of noise
Pneumatic
There is no air leakage and sound in the connector
components √
6 and air pipe
like solenoid
The speed regulating device works normally √
valve, etc.
Whether the relevant signs are complete √
There is no falling off of the terminal √
Check the level of the oil ejector √
Whether the filter drainage is normal √
Air source Clean the oil cup and filter tank √
7
treatment unit Whether the air pressure regulating device is
normal and the corresponding air pressure contact √
works normally
Compare the displayed value with the actual
measured value. If there is any deviation, the √
instrument shall be calibrated
Electrical The appearance shall be clean and the outer cover
√
8 instrumentati shall be well sealed
on There is no falling off of the terminal √
The instrument is firmly installed without oil
√
leakage
The signs of electrical components are complete √
The external trunking is well sealed, waterproof
√
and dustproof
External Wire protection devices (corrugated tubes, cable
9 trunking and joints, etc.) are in good condition without falling √
cable off
The grade of wires and cables shall be intact
√
without falling off
Record and check the voltage and current
√
parameters of the main power supply
Check whether the electrical components inside
the electrical control cabinet are burnt and need to √
Electrical
be replaced
10 control
The sealing effect of the electrical control cabinet
cabinet
is good, and the waterproof and dustproof are √
normal
The lighting, ventilation and refrigeration
√
functions of the cabinet are normal
11 Overall Operation panel √

39
 cleanliness Inside of electrical control cabinet √
All external instruments √
All external sensors √
Note: "Times per day" in the table means inspect once every 24 hours; "Times per
week" means inspect once every 168 hours; "Times per month" means inspect once every
5,140 hours; "Time per year" means inspect once every 1,839,600 hours.

7.3 Lubrication maintenance period

No. Inspection items Inspection contents Lubrication maintenance period
Gear box Change the engine Once /3000 working hours or once/year
1
oil
Bearing Change the engine Once /3000 working hours or once/year
2
oil
Lubrication Twice/week
3 Chain Check the tightness Twice/month
Check the abrasion Twice/year
Chain guide plate and Check the abrasion Twice/month
4
adjusting gear
Belt and synchronous Check the tightness Once/month
5
belt Check the abrasion Twice/year
Belt pulley and Check Once/week
6
supporting pulley Oiling Once/week
7 Gear Lubrication Once/month
8 Roller Check the abrasion Twice/year
9 Grease fitting Oiling Once/week
10 Sliding film 3 Three times/week

40
 Chapter 8 Atlas of Stacker Accessories
1. Main machine of the stacker

No. Code Name Total quantity

1 MD40_1_4-XSD234 Lifting slider 1
2 YC-M-R-018 Lifting motor 1
3 YCMD40-HH354_01_6 Lifting component 1
4 YCMD40-HH354_01_9 Upper cover plate 1
5 YCMD40_01-1 Chain shield 2
6 YCMD40_01_1 Base component 1
7 YCMD40_01_2 Pillar 1 1
8 YCMD40_01_3 Pillar 2 1

41
2. Pillar of main machine of the stacker

No. Code Name Total quantity

1 GB_T7810_UCP210 Insert bearing with housing 2
2 YC-1004-2800 Stroke switch sliding groove 1
3 YCMD40_01_2-1 Guide rail bar 1 1
4 YCMD40_01_2-2 Guide rail bar 2 1
5 YCMD40_01_2-3 Stopper 2
6 YCMD40_01_2-4 Stopper 1
7 YCMD40_01_2-5 Cover plate 1
8 YCMD40_01_2-6 Buffer block 2
9 YCMD40_01_2_1 Pillar component 1

3. Slider components

42
 No. Code Name Total quantity
1 MD40-BG_1_4_12 Front push plate 1
2 MD40-BG_1_4_26 Flange part 1
3 MD40_1_4_23-XSD243 Front push plate component 1
4 MD40_1_4_24-XSD243 Rear push plate component II 1
5 MD40_1_4_25-XSD243 Left and right push plate components 2
6 MD40_1_4_6-XSD234 Sliding plate component 1
7 MD40_1_4_7-XSD234 Sliding plate component 1
8 YC-M-R-017 Motor reducer of stacker sliding plate 1
9 YCMD40-HH354_01_5 Sliding plate component 1
10 YCMD40_01_4-10 Connecting shaft 1
11 YCMD40_01_4-12 Guide shaft 4
12 YCMD40_01_4-14 Fixing base 2
13 YCMD40_01_4_1 Side plate weldment 1
14 YCMD40_01_4_10C Push arm welding 1
15 YCMD40_01_4_11 Rotating arm 2
16 YCMD40_01_4_13 Torque arm component 2
17 YCMD40_01_4_14 Driven pulley component 2
18 YCMD40_01_4_15 Flange 1
19 YCMD40_01_4_16 Flange 2 1
20 YCMD40_01_4_17C Air cylinder component 1
21 YCMD40_01_4_2 Side plate 2 component 1
22 YCMD40_01_4_3 Connecting rod 3
23 YCMD40_01_4_4 Flange part 2
24 YCMD40_01_4_5 Slider transmission shaft component 1
25 YCMD40_01_4_8 Connector 1
26 YCMD40_01_4_9C Fixing base 1

4. Sliding plate component

43
 No. Code Name Total quantity
1 CF16-B Needle roller cam guide device 4
2 CF20-B Needle roller cam guide device 4
3 GB_T7810_UCFU206 Insert bearing with housing 1
4 MD40_1_4_6-1-XSD234 Fixing plate 1
5 YCMD40-HH354_01_4_6-6 Boom 1
6 YCMD40-HH354_01_4_7_1 Hook component 2 1
7 YCMD40_01_4_6-2 Fixing angle iron 2
8 YCMD40_01_4_6-3 Connector 1
9 YCMD40_01_4_6-4 Deflection sleeve 4
10 YCMD40_01_4_6-5 Stopper 2

5. Slider transmission shaft component

No. Code Name Total quantity

1 GB_T7810_UCFC27 Insert bearing with housing 2
2 YCMD40_01_4_5-1 Driving shaft 1 1
3 YCMD40_01_4_5-2 Sprocket 2 2
4 YCMD40_01_4_5-3 Fixing plate 2
5 Z3_35X60 Z3 expansion sleeve 2

6. Rear box clamping push arm

44
 No. Code Name Total quantity
1 MD40-BG_1_4_12_1 Push plate holder 1
2 MD40-BG_1_4_26 Flange part 1
3 YCMD40_01_4_12-1 Guide shaft 2

7. Differential separator

No. Code Name Total quantity

1 08B-1-64_GB_T1243 Chain 1
2 YCMD40_03-06 Chain shield 1
3 YCMD40_03-07 Chain cover 1
4 YCMD40_03-08 Roller with compressed spring 1
5 YCMD40_03-09 Transition plate 2
6 YCMD40_03-10 Aluminium profile L=534 mm 2
7 YCMD40_03_01 Frame 1
8 YCMD40_03_02 Supporting mechanism 4
9 YCMD40_03_04 Bearing seat 4
10 YCMD40_03_07 Motor fixing bracket 1
11 YCMD40_03_08 Motor unit 1
12 YCMD40_03_09 Guardrail 2
13 YCMD40_03B-3 Conveyor 1 with bar 1
14 YCMD40_03B_3 Driven roller with V-groove 2
15 YCMD40_03B_5 Driving roller component I 1
16 YCMD40_03B_6 Driving roller component II 1
17 YCMD40_03B_11 Belt support plate welding I 1
18 YCMD40_03C-4 Conveyor 2 with bar 1
19 YCMD40_03C_12 Belt support plate welding II 1

45
 8. Motor unit

No. Code Name Total quantity

1 R37DT80N4 Gear motor 1
2 YCMD40_03_08-01 Sprocket 1

9. Final assembly components of the aligning area

No. Code Name Total quantity

1 MD40_2VB_3 Aligning conveyor 1
2 MD40_2VB_10 Steering mechanism 1
3 SAF47DRN90S4 1
4 YC-M-R-001-DRN Gear motor 1
5 YCMD40_01_1_2 Anchor component 4
6 YCMD40_02-1A Box pushing rail 4
7 YCMD40_02-3 Buffer block 4
8 YCMD40_02-4 Synchronous belt XH200 2
9 YCMD40_02-5 Blind plate 7
10 YCMD40_02_1 Frame 1

46
11 YCMD40_02_12 Guardrail 2
12 YCMD40_02_14 Leg component 1
13 YCMD40_02_2 Temporary storage area 1
14 YCMD40_02_4 Driving shaft 1
15 YCMD40_02_5 Encoder unit 1
16 YCMD40_02_6-1 Motor fixing plate 1
17 YCMD40_02_7 Box pushing 1
18 YCMD40_02_8 Tensioner 2
19 YCMD40_02_9 Trunking 1

10. Conveyor

No. Code Name Total quantity

1 MD40_2V_3_22 Rear cover welding 1
2 MD40_2V_3_23 Aligning gravity conveyor roller 11
3 MD40_2VB_3-1 Side plate 1
4 MD40_2VB_3-2 Side plate 1
5 MD40_2VB_3-4 Connecting support plate 6
6 MD40_2VB_3-7 Blind plate 1
7 MD40_2VB_3_1 Support 2
8 MD40_2VB_3_19 Blind plate welding 1
9 MD40_2VB_3_24 Pressing drive wheel component 1
10 MD40_2VB_3_25 Support 1
11 MD40_2VB_3_27 Driving pulley component 1
12 MD40_2VB_3_28 Driven pulley component 1
13 MD40_2VB_3_5 V belt pressing component 5

47
 14 MD40_2VB_3_7 V belt pressing component 1
15 MD40AD_2_3_16 Partition component 2
16 MDL30_3_2_6-4 Fixing clamping plate 2
17 SJD-B208-L5283 Annular type triangle belt 2
18 YCMD40_02_3-5 Square tube 1
19 YCMD40_02_3_11 Flange support 3
20 YCMD40_02_3_12 Box blocking plate component 1
21 YCMD40_02_3_14 Aligning guardrail welding 1
22 YCMD40_02_3_17 Aligning conveyor roller 31
23 YCMD40_02_3_18 Aligning conveyor roller 8
24 YCMD40_02_3_3-2 Adjusting support rod 2
25 YCMD50_2_2_8 Driven pulley component 2

10. Pallet positioner

No. Code Name Total quantity

1 YCMD40_04_1-3 Power roller 19
2 YCMD40_04_1-4 10A-1 chain 17
3 YCMD40_04_1-5 10A-1 chain 1
4 YCMD40_04_1_1 Pillar 1 1
5 YCMD40_04_1_2 Pillar 2 1
6 YCMD40_04_1_3 Motor fixing bracket 1
7 YCMD40_04_1_4 Motor unit 1
8 YCMD40_04_1_7 Adjusting anchor 4
9 YCMD40_04_2-1 Side plate 1 1
10 YCMD40_04_2-2 Side plate 2 1
11 YCMD40_04_2-5 Guard plate 1
12 YCMD40_04_2_5 Pallet positioner 1 1

48
 13 YCMD40_04_2_8 Pallet positioner 2 1

11. Solid stack in place

No. Code Name Total quantity

1 YCMD40_04_1_1 Pillar 1 2
2 YCMD40_04_1_7 Adjusting anchor 4
3 YCMD40_04_4-1 Side plate 1 1
4 YCMD40_04_4-2 Powerless roller 10
5 YCMD40_04_4-3 Side plate 2 1
6 YCMD40_04_4_1 Stopper 1
7 YCMD40_04_4_2 Guardrail 4 1
8 YCMD40_04_4_3 Limit component 1
9 YCMD40_04_4_4 Protective block 1

12. Stack divider

49
No. Code Name Total quantity
1 SA67DT80N4 Gear motor 1
2 SA67NLB SA67 motor torque arm 1
3 YCMD40_05_01 Frame 1
4 YCMD40_05_02 Lifting clamp plate 1
5 YCMD40_05_03 Stack stopper component 2

13. Main transmission components

No. Code Name Total quantity

1 GB_T7810_UCP208 Insert bearing with housing 2
2 YCMD40_05_01_02-01 Transmission shaft 1 1
3 YCMD40_05_01_02-02 Sprocket 1 2

14. Driven pulley components

50
 No. Code Name Total quantity
1 GB_T276_6204 Deep groove ball bearing 2
2 YCMD40_05_01_03-01 Small driven shaft 1
3 YCMD40_05_01_03-02 Sprocket 1
4 YCMD40_05_01_03_01 Fixing base 1

15. Lifting clamp plate

No. Code Name Total quantity

1 CF_30-B Needle roller cam guide device 4
2 SE-63X160-S Air cylinder component 2
3 YCMD40_05_02-01 Sliding shaft 2
4 YCMD40_05_02-02 Fixing cushion plate 2
5 YCMD40_05_02-03 Connecting plate 2
6 YCMD40_05_02-05 Connector 4
7 YCMD40_05_02_01 Right clamping plate 1
8 YCMD40_05_02_02 Lifting frame 1
9 YCMD40_05_02_03 Left clamping plate 1

51
※ Note: After reading this manual, please keep it properly for
future reference.

52