Incline Drag Conveyor

Transcription

1 Incline Drag Conveyor ID ID2731 CONSTRUCTION AND OWNER S MANUAL P/N rev 4-10 [1]

2 The Symbol shown below is used to call your attention to instructions concerning your personal safety. Watch this symbol - it points out important safety precautions. It means ATTENTION - Become Alert! Your Personal Safety Is Involved! Read the message that follows and be alert to the possibility of personal injury or death. Be Alert! Your Personal Safety Is Involved The safety and performance of this incline drag conveyor, constructed and readied for operation will be affected by the installation and construction personnel. Careful consideration must be given to the structural requirements. We therefore highly recommend the use of a skilled construction company with a qualifi ed structural engineer. MFS/YORK/STORMOR cannot be responsible for the construction of the incline drag conveyor. The information contained in this manual is offered only as a convenience to the installer. No liability is expressed or implied toward the installation. A copy of this manual should be available at all times to the owner/operator. Additional copies may be requested from the company at the address shown on the back cover. Please reference part number # when requesting additional copies. Please Contact MFS/YORK/STORMOR or Your Dealer If You Have Any Questions Concerning This Manual Keep This Manual In A Safe Place Available For Future Reference 2

3 A GENUINE GLOBAL INDUSTRIES, INC. PRODUCT PREFACE You have purchased the finest Incline Drag Conveyor manufactured today. The following information is intended as a guide for: Incline Drag Conveyor pre-assembly, proper construction, and safe and proper use once constructed. General Safety Statement Your safety and the safety of others associated with grain system equipment is of prime concern to us at MFS/YORK/STORMOR. We wrote this manual to help you to better understand how to safely build and use this YORK Incline Drag Conveyor. It is your responsibility as the owner, builder, operator, or supervisor, to know what specific requirements, precautions, and hazards exist and to make these known to all personnel working with the equipment or in the area, so that they too may take any necessary safety precautions that may be required! Failure to read this Manual and its Safety Instructions by all personnel is a misuse of the equipment. We want you as our partner in safety! All personnel, including construction personnel, must read and understand all equipment Operator s Manuals before starting Incline Drag Conveyor construction! 3

4 Contents Be Alert...2 General Safety Statement Maintenance Safety...8 Grain Dust Explosions Operating Safety Lock-Out Warning Decals Specifications...15 Dimensions Parts Identifi cation Pre-Assembly

5 5 Assembly...21 Start Assembly Basic Components and Pit Head and Return Paddle Defl ector Intermediate Sections Tail, Pit, and Optional Components Chain and Paddles Pintle Chain Steel Bushed Roller Chain D Thread the Chain Covers TAII Reducer TM and Motor Mount Reducer Installation Pivot Mount / Bracket Torque Arm Rod Installation Motor Mount, Belt Centers, and Belt Guard..34 Belt Centers in Inches...36 Belt Centers in Centimeters...37 Motor Mount Assembly...38 Belt Guard Start-Up and Operation...41 Trouble Shooting...43 Index

6 Warranty MFS/YORK/STORMOR DIVISION (the Company) makes the following warranty to the initial retail purchaser of its products (the Customer). MATERIALS and WORKMANSHIP: The Company warrants products manufactured by it to be free from defects in materials and workmanship in normal use and service for a period of one (1) year after date of delivery to the Customer. COMPANY S OBLIGATION and CUSTOMER S EXCLUSIVE REMEDY: The Company s sole obligation and the Customer s exclusive remedy under this warranty is as follows: If within one (1) year after delivery to the customer the product fails to function properly due to a defect in either materials or workmanship, the Company will at its option, either repair the defective part or replace the defective part with a new or reconditioned part. Labor charges for removing defective parts and installing replacement parts, shipping charges with respect to such parts, and applicable sales and other taxes, if any, shall not be covered by this warranty. CONDITIONS, LIMITATIONS, AND EXCLUSIONS: There are no warranties or merchantability or fitness for a particular purpose with respect to any product manufactured or sold by the Company. Motors provided by the Company are in most instances warranted by the manufacturer thereof and are not warranted by the Company. The Company shall not be responsible under this warranty or otherwise for personal injury or for Incidental or Consequential Damages, including, without limitation, loss of use and lost profits. This warranty does not apply to defects or damages caused by misuse, improper maintenance, or improper installation of the Company s product or any equipment attached to or used in connection with the Company s product. The Company reserves the right to make changes or improvements to its products without incurring any obligation with respect to previously manufactured products. Field modification of this product without the expressed written permission of the Company constitutes a misuse of the product. The Company shall have no liability under this warranty until payment in full for the product in question has been made by the customer. The foregoing is the sole warranty made by the Company. No one is authorized to make other warranties on behalf of the Company. 6

7 11 Maintenance WARNING! DISCONNECT AND LOCK OUT ALL ELECTRICAL POWER BEFORE DOING ANY MAINTENANCE! Regularly scheduled maintenance can greatly increase the life of your equipment and reduce downtime. A good maintenance program includes general housekeeping, adequate periodic lubrication, chain tension adjustment, and periodic inspection. Remember to check the conveyor immediately if any unusual noise or vibration is detected. 1 Bearings are greased at the factory and do not need to be greased before start-up. Grease all bearings every hours after start-up. While the unit is running use only enough grease until you see the fresh grease at the seals. If you cannot lubricate bearings while unit is running, do it immediately upon shut down while bearing is still warm. Do not grease a cold bearing. 2 Be certain to maintain the reducer as specifi ed by the manufacturer. Follow the manufacturer s recommendations for periodic oil level inspection and changes. 3 Check the conveyor chain frequently for buckling or kinking while under load. Adjust the chain tension as required. Once the maximum take-up position is reached it will be necessary to remove some chain links. Establish a schedule for checking the chain tension. MFS/YORK/STORMOR recommends checking the tension at least once a quarter following the initial break-in period. 4 Oil motor every 1000 hours or once yearly if equipped with oil holes or a grease unit if zerks are available. 5 Check the V-belt drive after 10, 30, 100 and every 300 hours, or twice yearly thereafter. Refer to example a for correct belt tension. The best belt tension for a V-belt drive is the lowest tension at which the belt will not slip under the highest load. 6 Check for deterioration or looseness of any bolts or fasteners. 7 Check for worn, damaged or missing UHMW paddles. 8 Check the sprocket hub bolts and set screws after 8-10 hours of operation and on a regular interval thereafter. 9 Check that all guards and covers are properly located and installed. span belt deflection section AA Drive Belt Deflection Force Cross Section Smallest Sheave Diameter Range Motor RPM Belt Deflection Force Normal New AA force belt defl ection 1/64 per inch of span 3VX VX VX belt is 3/8 x 5/16, 5VX belt is 5/8 x 17/32 a BELT DEFLECTION 7

8 22 Safety GENERAL SAFETY REQUIREMENTS This MFS/YORK/STORMOR Construction/Safety Manual is written to assist and instruct those who are responsible for the complete incline drag conveyor assembly and for those who operate it once assembled. MFS/YORK/STORMOR assumes no liability with respect to proper constructed and inspection, assembly, or use of its products established under applicable laws, all of which is the sole responsibility of the purchaser and those doing the assembly work. Appurtenances and the accessories manufactured by us for use with our products conform only to applicable Federal and Safety Standards in effect at such time. SAFETY COMPLIANCE Occupational safety is of prime concern to us at MFS/YORK/STORMOR. This manual was written with the safety of the operator or others who come into contact with the equipment as our prime concern. The manual presents day to day work problems encountered by the operator and other personnel. We wrote this manual to help you understand safe operating procedures for incline drag conveyors with accessory equipment. It is your responsibility as the owner, builder, operator, or supervisor, to know what specifi c requirements, precautions, and hazards exist and to make these known to all personnel working with the equipment or in the area, so that they too may take any necessary safety precautions that may be required! Failure to read this Manual and its Safety Instructions by all personnel is a misuse of the equipment. We want you as our partner in safety. WARNING! Watch For This Symbol:! It Points Out Important Safety Precautions. It Means ATTENTION - Become Alert! Your Safety Is Involved. WORK AREA SAFETY STATEMENT Under no circumstances should persons not involved in the operation be allowed to trespass into or be present in the work area. It shall be the duty of all operators to see that children and/or other persons stay out of the work area! Trespass into the work area by anyone not involved in the actual operations, or trespass into a hazard area by anyone, shall result in immediate shut down by the operator. It shall be the duty of all operators to see that the work area has secure footing and is clean and free of all debris and tools which might cause accidental tripping and/or falling. It shall also be their responsibility to keep the work area clean and orderly during the operation. 8

9 2 Safety OPERATOR QUALIFICATIONS Operation of this unit shall be limited to competent and experienced persons. In order to be qualifi ed, they must know and meet all other requirements, such as, but not limited to, the following: 1 Some laws and regulations specify that no one under the age of 16 years may operate power machinery. It is your responsibility to know what these requirements are in your own area or situation. 2 Current OSHA regulations state in part: At the time of initial assignment and at least annually thereafter, the employer shall instruct every employee in the safe operation and servicing of all equipment with which the employee is, or will be involved * 3 Unqualifi ed persons are to stay out of the work area. 4 A person who has not read and understood all operating and safety instructions is not qualifi ed to operate the machine. * Federal Occupational Safety and Health Standards for Agriculture Subpart D. Section (a) (6). OSHA OCCUPATIONAL SAFETY AND HEALTH ACT OF 1970 Certain purchasers of our products may be subject to the requirements and standards of the William-Steiger Occupational Safety and Health Act of 1970, which prescribes standards for use of appurtenances of our manufacture, such as handrails, platforms, stairways, fi xed ladders, ladder cages, and guard rails. (Occupational Safety and Health Standards Section through ). Before installing these devices, familiarize yourself with the above Federal Standards. At the time of manufacture, these optional items conform to applicable standards MFS/YORK/STORMOR assumes no liability with respect to proper construction, assembly, inspection, or use of its products under applicable laws, all of which is the sole responsibility of the purchaser and those doing the assembly work. PROPER PERSONNEL To insure the safe use of all your material handling equipment be certain that only trained personnel install, maintain, and operate your incline drag conveyor! 9

10 2 Safety Grain Dust Explosions Any facility that stores and handles any type of grain is susceptible to a grain dust explosion. Grain dust is not dirt. It is not inert, but highly fl ammable and can be very explosive in a confi ned area. Seven elements must work together to produce a potentially deadly explosion. 1 Air - Air must be present to provide the oxygen necessary for combustion. 2 Fuel - In this case the fuel is the grain dust. The fi ner the dust, the easier it is to ignite. ALL INFORMATION ON THIS PAGE IS WARNING INFORMATION! 3 Suspension - A pile of grain dust will not explode, it must be suspended in air. 4 Minimum Concentration - There must be a minimum concentration of grain dust in suspension in the air. Current tests seem to indicate that minimum concentration is about 0.4 oz/ft 2. 5 Low Moisture - The grain dust must be of a relatively low moisture content. Ambient air moisture or relative humidity, has no bearing on the potentiality of an explosion. 6 Ignition Source - The ignition source could come from a fi re, an overheated bearing, a spark, welding or cutting sparks or debris, hot metal electric failure or other similar sources. 7 Confined Area - An explosive action must take place within a confi ned area. Recognizing this hazard, MFS/YORK/STORMOR believes that we all need to work together to prevent grain dust explosions in order to protect lives, jobs, property, and profi ts. A number of preventive measures can be taken to lesson the likelihood of an explosion. Following are some suggested measures. CONTROL THE DUST a Employ methods to clean the grain to reduce the fi nes b Use equipment to minimize the breakage, such as decelerators. Corn that is broken exposes the starch, the most explosive element of the grain. c Use an outside bag fi lter to capture the dust. d Use an air system on the bucket elevator to reduce the dust inside grain elevators and conveyors. e Spraying edible mineral oil on the grain signifi cantly reduces the air-born dust when handling grain. 10

11 2 Safety f Paint equipment that is in the interior of a facility with a coating that is slick, not allowing the dust to accumulate. g Enclose all conveyors to keep the dust from escaping. CONTROL THE IGNITION SOURCE a Apply a no smoking policy in all potentially hazardous areas. b Use only explosion proof lights. c All welding and cutting is to take place on the outside of the facility d Properly lubricate bearings on all equipment at the required intervals. e Use magnets to trap metal that might be mixed in with the grain. f Check the lagging on the bucket elevator head pulley and replace it if it is worn or smooth. g Use recommended safety devices such as heat detectors on bearings, motion sensors on the boot shaft, belt alignment sensors, or limit switches to shut down the system if the leg is choked. Make certain all electrical wiring, lights and outlets meet local codes (Danger, do not jog a choked leg) GRAIN DUST EXPLOSION MYTHS Throughout the years several myths have surrounded grain dust explosions. These are some of the most common: a Grain dust explosions do not occur in times of high humidity False: Dust explosions have occurred during rain storms. b Grain dust explosions do not occur in wooden elevators. False c Grain dust explosions do not occur in small country elevators. False: 70% - 80% of grain elevator explosions occur in small country terminals. d There are only 2 explosions that occur, a primary and a secondary False: Up to 13 explosions have been documented during one incident. ALL INFORMATION ON THIS PAGE IS WARNING INFORMATION! EXPLOSION VENTING Explosion vents for the trunking can be supplied as optional equipment for all models of bucket elevators. Explosion vents for heads are standard on all York SC bucket elevator models and optional on smaller units. These vents, should an explosion occur within a leg, may possibly minimize damage to the leg and prevent a secondary explosion. Note: Remember: Good housekeeping and safety procedures will help protect lives, jobs, property and profits. 11

12 2 Safety Operating Safety ALL INFORMATION ON THIS PAGE IS WARNING INFORMATION! Follow these 4 BASIC SAFETY RULES for your incline drag conveyor to make certain that accidents do not occur! Make certain that everyone working with or around your incline drag conveyor follows these rules! 1 Be certain that all covers, grates, and guards are in place and securely fastened before operating! 2 Never step or walk on conveyor covers, grates or guards! 3 Lock out all power before removing covers, grates or guards! Secure all chains and belts so that they can t move before working on any part of your bucket elevator or conveyor. 4 Don t modify or redesign your incline drag conveyor without first obtaining written approval from MFS/YORK/STORMOR. Following these 4 basic safety rules is a proven way to reduce accidents! Be certain to provide all employees working on or near your incline drag conveyor with effective safety training, including management. It is ok to add extra safety rules for your job site but DO NOT SUBSTITUTE other safety procedures for the 4 safety rules! Following the safety rules given for the safe use of your incline drag conveyor requires a commitment at all levels within your company. SECONDARY SAFETY DEVICES Devices such as interlock switches, may be helpful but are not fail safe and should not be substituted for a proper lock out procedure. Do not rely on a switch that can fail, can lose adjustment or can be bypassed. A proper lock-out procedure will prevent accidents. REMEMBER! There is no substitute for a commitment to safety! 12

13 2 Safety Lock-Out FOLLOW A PROPER LOCKOUT PROCEDURE This suggested procedure must be performed EVERY TIME your incline drag conveyor is to be worked on. Stick with these steps and they will assist in preventing accidents. 1 Shut down the incline drag conveyor in a normal manner. 2 Shut off energy to the incline drag conveyor at the main power source. 3 Turn the power switch back on to confirm that power has been deactivated. 4 Attempt to restart the conveyor to guarantee that the power is shut off and then return the switch to the off position. 5 Using your own lock, lockout all (other) energy sources which could provide any power to the incline drag conveyor. 6 With your lock in place test the disconnect to make certain the power cannot be restored. 7 Make absolutely certain that the power can t be supplied by any way to the incline drag conveyor. 8 All authorized personnel must put his/her own personal lock on the switch to lock it in the off position. Everyone must use only his or her own personal key. 9 Nobody is to return power to the incline drag conveyor until all work on the conveyor has been completed and, all locks have been removed. Company management needs to look for maintenance or other employees working on the equipment without following the proper lock out procedure. Management also needs to look for any cover or guard not in its proper place. It is the responsibility of everyone to report any missing grates, guards, equipment failures, or failures to lock out. Make certain that no cover is removed unless power is locked out. ALL INFORMATION ON THIS PAGE IS WARNING INFORMATION! SAFETY QUESTIONS OR CONCERNS Please be free to contact MFS/YORK/STORMOR with any specifi c safety needs surrounding your incline drag conveyor or its use! 13

14 2 Safety Warning Decals WARNING P/N Exposed conveyors and moving parts can cause severe injury BEARING INSPECTION SCHEDULE SAFE OPERATION OF THIS EQUIPMENT REQUIRES PROPER MAINTENANCE BEARING LOCATION: DATE GREASE NAME DATE GREASE NAME MFS/YORK/STORMOR, GRAND ISLAND, NE 1 on each side of the head, and 1 on each side of the tail MARK WITH BALL POINT PEN P/N LOCK OUT POWER before removing cover or servicing 1 on each intermediate section cover, 1 on each head cover, and 1 on each tail cover. 1 on each guard cover SAFETY SIGNS 1 per each inspection cover Safety and operational decals as shown here are installed on your incline drag conveyor in the locations indicated. Be certain all of these decals are in their correct locations on the incline drag conveyor and are in good condition. Check all safety decals and replace any that are worn, missing, or illegible. They may be ordered as any other part is ordered. See your dealer for additional information or contact the factory direct at the address listed on the back cover of this manual. 14

15 33 Specifications CONSTRUCTION Galvanized G-90. AR Steel Available. Consult factory. All bolted construction. Pillow Block Bearings. Take-ups in head or tail section. Drive from discharge end. HEAD SECTION Heavy duty drive shaft and bearings. 11 gage sides. TAIL SECTION Cast sprocket, heavy duty drive shaft bearings. INTERMEDIATE SECTION Conveying trough Return trough Cover PADDLES 8 gage bottom 11 gage sides 11 gage bottom 14 gage sides 14 gage Model x 8 x 3/8 UHMW, Model x 9 x 3/8 UHMW, Model /4 x 12 1/2 x 1/2 UHMW INCLINE DRAG CONVEYOR HORSEPOWER Horizontal HP = ((BPH) x I.O. Length) (75,000) (For Corn, Wheat, Milo) Incline HP = ((BPH) x Height in Ft.) 30,000 Model ID Series: (Horizontal HP + Incline HP) = Total Horsepower Requirement Model IDC Series: (Horizontal HP + Incline HP + 5HP) = Total Horsepower Requirement CAPACITY FORMULA Model ID 1220: Capacity = 75 Bu/Hr/1 RPM = 3 Ft/Min of Chain Speed Model ID 1624: Capacity = 158 Bu/Hr/1 RPM = 3.92 Ft/Min of Chain Speed Model ID 2731: Capacity = 473 Bu/Hr/1 RPM = 4.69 Ft/Min of Chain Speed 15

16 BE SURE TO INSTALL DRIVE GUARD BEFORE STARTING WARNING BEARING INSPECTION SCHEDULE BEARING INSPECTION SCHEDULE 3 Specifications Dimensions SECTION A - A SECTION B - B OPTIONAL DISCHARGE (AT 45 DRAGS ONLY) A - H H (R) A B 2" [51 mm] on ID1220 and ID1624; 3" [76 mm] on ID2731 B E Q E D C A B A - T (P) (T) (S) 37 3/4" ID /4" ID16 16

17 3 Specifications * Model AH AT B E F G I* J K L M N P ID1220 ID1624 ID /8 [810 mm] 37 7/8 [962 mm] 50 [1,270 mm] 40 [1,016 mm] 36 [914 mm] 36 [914 mm] 24 [610 mm] 24 [610 mm] 24 [610 mm] Includes bottom splice plate 12 [305 mm] 16 [406 mm] 18 [457 mm] 12 1/2 [318 mm] 13 1/2 [343 mm] 18 1/2 [470 mm] 20 [508 mm] 24 [610 mm] 31 [787 mm] 30 [810 mm] 31 1/4 [794 mm] 42 [1,067 mm] 12 [305 mm] 16 [406 mm] 26 3/4 [679 mm] 24 [610 mm] 32 [813 mm] 52 [1,321 mm] 12 [305 mm] 16 [406 mm] 27 [686 mm] 15 1/4 [387 mm] 19 1/4 [489 mm] 30 [762 mm] 20 1/2 [521 mm] 28 1/4 [718 mm] 48 [1,219 mm] 8 1/2 [216 mm] 10 [254 mm] 13 1/4 [337 mm] Degree Model ID1220 Model ID1624 Model ID2731 C D H C D H C D H 6 [152 mm] 11 3/4 [298 mm] 17 1/2 [445 mm] 23 1/4 [591 mm] 28 3/4 [730 mm] 34 [864 mm] 39 [991 mm] 43 3/4 [1,111 mm] 48 [1,219 mm] 1/4 [6 mm] 1 [25 mm] 2 1/4 [57 mm] 4 [102 mm] 6 1/2 [165 mm] 9 [229 mm] 12 1/4 [311 mm] 16 [406 mm] 20 [508 mm] 23 [584 mm] 24 [610 mm] 23 [584 mm] 21 [533 mm] 19 [483 mm] 17 [432 mm] 15 [381 mm] 13 [330 mm] 10 [254 mm] 6 [152 mm] 11 3/4 [298 mm] 17 1/2 [445 mm] 23 1/4 [591mm] 28 3/4 [730 mm] 34 [864 mm] 39 [991 mm] 43 3/4 [1,111 mm] 48 [1,219 mm] 1/4 [6 mm] 1 [25 mm] 2 1/4 [57 mm] 4 [102 mm] 6 1/2 [165 mm] 9 [229 mm] 12 1/4 [311 mm] 16 [406 mm] 20 [508 mm] 28 [711 mm] 27 [686 mm] 25 [635 mm] 24 [610 mm] 21 [533 mm] 19 [483 mm] 17 [432 mm] 14 [356 mm] 12 [305 mm] 6 [152 mm] 11 3/4 [298 mm] 17 1/2 [445 mm] 23 1/4 [591 mm] 28 3/4 [730 mm] 34 [864 mm] 39 [991 mm] 43 1/4 [1,099 mm] 48 [1,219 mm] 1/4 [6 mm] 1 [25 mm] 2 1/4 [57 mm] 4 [102 mm] 6 1/2 [165 mm] 9 [229 mm] 12 1/4 [311 mm] 16 [406 mm] 20 [508 mm] 39 [991 mm] 37 [940 mm] 34 1/2 [876 mm] 32 [813 mm] 29 [737 mm] 26 [660 mm] 23 [584 mm] 19 1/2 [495 mm] 16 [406 mm] Note: See page 24 now for concrete pit dimensions! 17

18 3 Specifications Parts Identification ILLUSTRATION OF BASIC COMPONENTS NOTE: The incline drag conveyors illustrated on these (2) pages are all right hand drive conveyors. attachment UHMW paddle link head section cover splice cotter pin NOTE: The chain section is shown as though it was on the return side of the conveyor motor mount return paddle deflector Model IDC Series by-pass inlet tail section bottom splice plate intermediate section (5-10 standard lengths) intermediate section (5-10 standard lengths) return flow bottom splice plate curve section 18

19 3 Specifications cover splice head section motor mount return paddle deflector Model ID Series flow return intermediate section (5-10 standard lengths) intermediate section (5-10 standard lengths) by-pass inlet tail section head section bottom splice plate cover splice motor mount tail section return paddle deflector by-pass inlet hopper bottom splice plate Model IDC Series intermediate section (5-10 standard lengths) intermediate section (5-10 standard lengths) return flow bottom splice plate curve section 19

20 44 Pre-Assembly CONVEYOR SUPPORT This conveyor requires support. It is not self supporting. It isn t designed to be part of any truss system. PREPARING FOR CONSTRUCTION Before construction, study this entire manual. Also study any applicable documents (including but not limited to extra construction info provided with some units. OSHA Regulations and National Electric Code). SEE THE PACKING LIST Your incline drag conveyor has been carefully checked before shipment. However, you should check your shipment upon arrival to insure it is complete. Distribute the parts in an orderly fashion at the construction site to facilitate later assembly. Use the packing list that is provided with the shipment to verify that all parts have been received. GENERAL ASSEMBLY INSTRUCTIONS Actual incline drag conveyor construction will vary between contractors depending on available equipment, crew experience and personal preference. However, we suggest the following procedures: 1 Place and completely assemble supporting structures. 2 Connect the basic components using splices. 3 Check for alignment between sections. Then add the chain and fl ight. 4 Perform initial chain tightening, tension, and adjustment. 5 Install the reducer, and drive assembly. 6 Install inlet transitions. 7 Do fi eld wiring. 8 Check for loose fasteners and try the operation of the incline drag without material. 9 Conclude with any necessary fi nishing touches. 20

21 55 Assembly Start Assembly Note: It is strongly advised that a generous amount of caulking be applied to the mating flange surfaces of each basic component before assembly. Do this to make the incline drag conveyor water and dust tight. 1 assemble support structures Be certain that support structures are in place and completely assembled. 2 set the sections out in order Check that all the incline drag sections are set out next to the installation area according to the order of installation. Note: The incline drag conveyor body is normally shipped pre-assembled but can be shipped knocked down. It is made to self align during assembly. When assembling main components check for alignment. Use a string along side the conveyor and try to make joints flush (especially bottoms). Do this so paddles brush less against sides and vibration is lessoned. 3 bolt intermediate sides to the bottom If your incline drag conveyor wasn t assembled when it came, start intermediate sections assembly by bolting the intermediate sides to the intermediate bottom using 3/8 x 1 bolts, lock washers, and hex nuts. See that the bottom has the proper offset from the sides. This offset is made up at the head and tail ends of the conveyor. Before tightening the sides to the bottom, see that the sides are square and parallel to each other, leaving out the end bolts. Using drift pins will assure alignment of the bottom rows of holes. Torque the nuts at 240 in-lbs. Note: Check that the component sides are square and parallel to each other. 21

22 5 Assembly / Basic Components and Pit Note: Before assembling basic components, thread a rope through the components as they are assembled. This will aid with chain insertion. Basic Components and Pit Head and Return Paddle Deflector 4 install the return paddle defl ector Before bolting together any of the basic components install the return paddle defl ector <example a>. It is important to make certain this part is in place because it will prevent material in your conveyor from falling back down the incline. Wait to install the head until <step 6>. head 3/8 x 1 bin bolt 3/8 fl ange nut PADDLE DEFLECTOR CONNECTION intermediate section return paddle defl ector note the 2 [51mm] recess a INSTALL THE RETURN PADDLE DEFLECTOR 22

23 5 Assembly / Basic Components and Pit Intermediate Sections intermediate section 5/16 bin bolt with fl ange nut 3/8 bin bolts and fl ange nuts (typical) intermediate section tail head bottom splice 3/8 x 1 bin bolts and flange nuts (typical) b INTERMEDIATE SECTION TO INTERMEDIATE SECTION 5 join intermediate and mid sections Start assembling body components together by bolting the intermediate sections together fi rst using splices <example b>. See that the bolts in mating fl anges all face the same direction. NOTE: Remove bolts on the cover ends to connect intermediate sections and then return the bolts to their original positions. Next, bolt into place any bypass inlet sections, inlet hopper sections (see pit dimensions in <example a> on the next page). 23

24 5 Assembly / Basic Components and Pit Tail, Pit, and Optional Components WARNING! Brace the head well to allow for drive weight and torque transmission through the head! 6 install head and tail sections Bolt on the head and tail sections in the same manner used to join intermediate sections. standard inlet hopper pit 7 install any optional components If any optional equipment was ordered with your unit, see the instructions that came with your optional equipment and install this equipment. If you are installing an inlet hopper grate, see <example a> which shows suggested pit dimensions. ID1220 ID1624 ID2731 X 30 [762 mm] 32 [813 mm] 42 [1,067 mm] 54 1/2 [1,384 mm] 3 1/8 [79 mm] X 49 [1,245 mm] a SUGGESTED INLET HOPPER PIT DIMENSIONS Note: Chain installation can be done at various times during assembly. Usually the entire conveyor is bolted together before the chain is added. Typically the UHMW paddles are installed prior to the chain installation. 24

25 5 Assembly / Chain Chain Chain and Paddles 8 assemble the chain Find a large flat open area and connect the 10 [3,048mm] sections of chain using connecting links and cotter pins. Bolt together the UHMW paddles <examples b and c>. Use 5/16 x 1 1/4 bolts, nuts, and lock washers. Torque nuts to the correct specifications. Normally 2 [610 mm] of cotter chain is included with the conveyor. Any take-up adjustment should be done in this 2 [610 mm] section. (See the next page for D3983 roller chain assembly.) flow side connecting pin 5/16 x 1 1/4 bin bolts, nuts, and lock washers UHMW paddle toward head link 9 remove cover and adjust take-up Remove most of the conveyor cover to ease in threading the chain. Before placing the chain into the conveyor, be certain that the take-up is in its closest position toward the conveyor body. b connecting link return side UHMW paddle cotter pin FLOW CHAIN SECTION WITH UHMW PADDLES attachment NOTE: Examples on this page show pintle chain. Higher capacity or longer conveyors will use steel bushed roller chains. side bar barrel toward head pin c RETURN CHAIN SECTION TOP VIEW 25

26 5 Assembly / Chain Steel Bushed Roller Chain D Option 2 D3983 roller chain assembly Find a large flat open area and connect the 10 [3,048 mm] sections of chain using connecting links and cotter pins. See <examples a and b>. Bolt the UHMW paddles to the chain. Use 5/16 bin bolts, flat washers, lock washers, and nuts, on the steel bushed roller chain. Torque the nuts to the correct specifications. UHMW paddle ( ) 5/16 bin bolt, fl at washer, lock washer and nut toward head reinforcement ( ) a CHAIN SECTION WITH REINFORCEMENT AND PADDLES toward head sidebar pin attachment reinforcement UHMW paddle b CHAIN SECTION TOP VIEW 26

27 5 Assembly / Chain Thread the Chain 10 thread the chain Thread the chain through the conveyor. Position the chain over the sprockets in the head and tail sections. Make certain the chain and paddles are facing the correct way as shown in <example c>. Be certain that the paddles and chain are not facing the wrong way as shown in <example d>. CORRECT INSTALLATION c THREAD THE CHAIN INCORRECT! DAMAGE MAY OCCUR d INCORRECT CHAIN INSTALLATION 27

28 5 Assembly / Chain WARNING! Remove all debris inside the conveyor before installing the covers! 11 connect the chain Adjust the telescoping take-ups to shorten the center distance between the shafts of the chain conveyor <example b>. Eliminate the slack and pull the chain ends tight with a puller or come-along suited for the length of the conveyor and connect the chain <example a>. (1) or (2) chain paddles may need to be removed so that they will not be damaged by the come-along. To remove a link from the chain, grind the head of the pin so it is fl ush with the side-bar. Then use a small punch along with a hammer to drive the pin through the side-bar. When connecting the (2) ends of the chain, use either a shoulder or tear-drop pin. come-along connecting pin with cotter pin UHMW paddle removed 12 chain adjustment Make the fi nal chain adjustment as shown using the tail or head take-up (depending on where the take-up is) <example b>. a CHAIN TIGHTENING USING COME-ALONG tail section turn here loosen tighten b TAKE-UP ADJUSTMENT 28

29 5 Assembly / Chain 13 rotate the conveyor chain some Rotate the chain on the sprockets by hand at least one entire revolution and check to see that the chain isn t catching on the flanges or rubbing on the sides due to the sprocket not being centered. 29

30 5 Assembly / Covers Covers 14 install the covers Proper cover splices are shipped loosely. When bolting on the covers, be certain to include the cover splice at every seam and at every cover splice <example a>. Use the caulking provided. Use 5/16 x 1 bin bolts with seal washers and fl ange nuts. cover cover splice 5/16 X 1 bin bolt fl ange nut intermediate sections a BOLT COVERS ON CORRECTLY 30

31 5 Assembly / TAII Reducer and Motor Mount TAII Reducer TM and Motor Mount Reducer Installation 15 install the reducer Install your reducer according to the reducer manufacturer s instructions. See the manual(s) that came with your reducer and drive components. Select the correct rod mounting position. reducer conveyor head 1 maximum left position 2 left position 3 center position 4 right position 5 maximum right position 1 5 torque arm bracket Typical Drive Assemblies Rod Mounting Position 31

32 5 Assembly / TAII Reducer and Motor Mount Pivot Mount / Bracket 16 pivot mount or pivot mount bracket Install your pivot mount or pivot mount bracket as shown in the examples below. For assemblies with pivot mounts - The pivot mount can be installed so face A is closest to the conveyor head or the pivot mount can be installed so that face B is closest to the conveyor head. The torque arm rod foot must install to the correct pivot mount face for your installation. Select the correct position for your installation. TA1 - TA6 TA5 - TA9 A B intermediate section intermediate section pivot mount torque arm bracket torque arm bracket pivot mount bracket PIVOT MOUNT INSTALLATION PIVOT MOUNT BRACKET INSTALLATION 32

33 5 Assembly / TAII Reducer and Motor Mount Torque Arm Rod Installation 17 install the torque arm rod assembly Install your torque arm rod assembly as shown below and according to the manufacturer s instructions. DODGE TM torque arm rods TA1 - TA6 reducer pivot mount head intermediate section torque arm rod torque arm rod foot pivot mount reinforcement TORQUE ARM ROD AND PIVOT MOUNT INSTALLATION TA5 - TA9 reducer pivot mount bracket head intermediate section torque arm rod foot torque arm rod pivot mount reinforcement TORQUE ARM ROD AND PIVOT MOUNT BRACKET INSTALLATION 33

34 5 Assembly / TAII Reducer and Motor Mount Motor Mount, Belt Centers, and Belt Guard MOTOR MOUNT POSITION 18 install the motor mount There are (5) holes on your motor mount bracket and (3) holes on your motor mount. So, the motor mount can be installed in (3) different positions, M1, M2, and M3. M1 is the lowest position that the motor mount can be installed in and M3 is the highest position that the motor mount can be installed in. Use the motor mount height table on the next page and install your motor mount as shown in your motor mount manufacturer s instructions and as indicated on the following pages. reducer motor mount DODGE TM motor mounts motor mount bracket EXAMPLE - MOTOR MOUNT INSTALLATION 34

35 5 Assembly / TAII Reducer and Motor Mount M1 M2 M3 DODGE TM motor mounts MOTOR MOUNT HEIGHT POSITIONS Motor Mount Height ID1220 ID1624 D12100, D16150, D21200 Reducer MM Height Reducer MM Height Reducer MM Height TA1 MM3 TA1 M3 TA1 M3 TA2 MM3 TA2 M3 TA2 M3 TA3 MM3 TA3 MM3 TA3 M3 TA4 MM2 TA4 MM3 TA4 MM3 TA5 M2 TA5 MM3 TA6 M2 TA6 MM3 TA7 MM2 TA7 MM3 TA8 MM2 TA8 MM3 35

36 5 Assembly / TAII Reducer and Motor Mount BELT CENTERS IN INCHES drive sheave motor DODGE TM motor mounts head ID1220 MIN. - MAX. Belt Centers driven sheave Motor Frame 182T and 184T 213T and 215T 254T and 256T 284T and 286T 324T and 326T Reducer MM height 3-5 hp hp hp hp hp TA1 MM TA2 MM TA3 MM TA4 MM TA5 MM TA6 MM TA7 TA8 TA9 BELT CENTERS ID1624 Motor Frame 182T and 184T 213T and 215T 254T and 256T 284T and 286T 324T and 326T Reducer MM height 3-5 hp hp hp hp hp TA1 MM3 TA2 MM TA3 MM TA4 MM TA5 MM TA6 MM TA7 MM TA8 MM TA9 Motor Frame 182T and 184T ID T and 215T 254T and 256T 284T and 286T 324T and 326T Reducer MM height 3-5 hp hp hp hp hp TA1 MM3 TA2 MM3 TA3 MM3 TA4 MM3 TA5 MM TA6 MM TA7 MM TA8 MM TA9 36

37 5 Assembly / TAII Reducer and Motor Mount BELT CENTERS IN CENTIMETERS drive sheave motor DODGE TM motor mounts head ID1220 MIN. - MAX. Belt Centers driven sheave Motor Frame 182T and 184T 213T and 215T 254T and 256T 284T and 286T 324T and 326T Reducer MM height 3-5 hp hp hp hp hp TA1 MM TA2 MM TA3 MM TA4 MM TA5 MM TA6 MM TA7 TA8 TA9 BELT CENTERS ID1624 Motor Frame 182T and 184T 213T and 215T 254T and 256T 284T and 286T 324T and 326T Reducer MM height 3-5 hp hp hp hp hp TA1 MM3 TA2 MM TA3 MM TA4 MM TA5 MM TA6 MM TA7 MM TA8 MM TA9 Motor Frame 182T and 184T ID T and 215T 254T and 256T 284T and 286T 324T and 326T Reducer MM height 3-5 hp hp hp hp hp TA1 MM3 TA2 MM3 TA3 MM3 TA4 MM3 TA5 MM TA6 MM TA7 MM TA8 MM TA9 37

38 5 Assembly / TAII Reducer and Motor Mount MOTOR MOUNT ASSEMBLY top plate adjusting studs The motor mount may be installed in any of the mounting levels (M1, M2, or M3 as shown previously in this manual section). Install the motor mount uprights to the input side of the reducer. Assembly bottom plate jam nuts uprights bottom plate bolts Remove (4) or (6) housing bolts from the reducer as needed. Place the motor mount in position and reinstall the bolts through the motor mount uprights and reducer housing. Tighten bolts to the torque specifi ed in the table on the next page. a MOTOR MOUNT COMPONENTS Components Refer to example a for locations of component parts. Using the hardware provided, assemble uprights (the angled parts to which the reducer is fastened) to the u-shaped, rectangular bottom plate. Notice that there are (8) slots cut into the plate. Assemble the uprights in the innermost slots. The bottom plate may be mounted with the vertical fl anges up or down (as shown in example a). Snug bolts only, do not torque bolts at this time. Fasten (4) long threaded studs to the (4) corners of the bottom plate using jam nuts, (1) stud on each side of the upright. Securely tighten these nuts, as they will not require any further adjustment. Add (1) additional jam nut to each stud and thread approximately to the middle of the stud. Assemble top motor plate (the fl at rectangular plate with many holes) on top of the jam nuts. Assemble the remaining jam nuts on studs to secure top motor plate. Do not fully tighten these nuts yet. Mount the motor onto the top plate and bolt securely. Install the motor sheave and reducer sheave as close to the motor and reducer housings as practical. Loosen the bottom plate bolts and slide the motor and mounting plate to accurately align the motor and reducer sheave. Securely tighten the bottom plate bolts. Install the required number of V-belts and tension belts by alternately adjusting the jam nuts on the (4) adjusting studs provided on the motor mount. Check all bolts to see that they are securely tightened. Verify that the V-belt drive is properly aligned before operating the reducer. DODGE TM motor mounts WARNING! To ensure that the drive is not unexpectedly started, turn off and lock-out or tag power source before proceeding. Remove all external loads from the drive before removing or servicing the drive or accessories. Failure to observe these precautions could result in bodily injury. 38

39 5 Assembly / TAII Reducer and Motor Mount BELT GUARD Recommended Bolt Torque Values Housing Bolt Recommended Torque Values Reducer Size Fastener Size Torque in Ft.-Lbs. TA0107L 5/ TA0107H 5/ TA2115H 3/ TA3203H 3/ TA4207H 1/ TA5215H 1/ TA6307H 1/ TA7315H 5/ TA8407H 5/ TA9415H 5/ TA10507H 3/ TA12608H 3/ BELT GUARD ILLUSTRATION belt guard EXAMPLE COMPLETED BELT GUARD ASSEMBLY 39

40 5 Assembly / TAII Reducer and Motor Mount TORQUE-ARM II BELT GUARD INSTALLATION WARNING! To ensure that the drive is not unexpectedly started, turn off and lock out or tag power source before proceeding. Remove all external loads from the drive before removing or servicing the drive or accessories. Failure to observe these precautions could result in bodily injury. WARNING! Make certain all guards are properly installed before proceeding. Exercise extreme care to avoid contact with rotating parts. Failure to observe these precautions could result in bodily injury. Components 1. Move the belt guard and hardware from the box and verify all parts are available. The belt guard assembly consists of one back cover, one front cover, (2) brackets, and necessary hardware. 7. Close the cover and secure with (2) cap screws and washers. 8. Check the machine for proper operation. 2. Using the hardware provided, assemble the (2) brackets to the back cover as shown in the example at right. 3. Position the back cover over the motor shaft and reducer input shaft. The long slot in the back cover fi ts over the motor shaft. 4. Align the back cover assembly to the Torque Arm II motor mount and attach using (4) cap screws, washers, and nuts. Securely tighten the brackets to the motor mount and back cover. 5. Install the motor and reducer sheaves. Install the belts and adjust accordingly. 6. Align hinges on the front cover to pins on the back cover and assemble. DODGE TM MOUNTING BRACKETS IN POSITION B 40

41 65 Start-Up and Operation PRE-START-UP INSPECTION Before operating the incline drag conveyor, check all areas for SAFETY and machine damage which could have happened during construction. Then follow this step by step procedure for initial start-up and operation exactly, paying close attention to the warning statements. A Disconnect and Lock Out all Electrical Power! B Check entire conveyor for loose bolts, construction tools, construction debris and any other material not related to the conveying or material handling process and remove before start-up. C Check for proper chain and paddle direction. Check the chain tension and adjust if needed. D Check to see that all appropriate warning decals are present on the conveyor. (See the Warning Decals section on page 14 of this manual.) E Check and be certain that the incline drag conveyor has been properly aligned. F Check all set screws in drive sheaves, head and tail sprockets, shaft bearings (see chart on the next page) and gear reducer. G Check lubrication of gear reducer. Reducer is shipped less oil. BEFORE LOADING THE CONVEYOR INSPECTION A Connect electrical power, run conveyor empty, check V-belt alignment, and check all set screws on sprockets, V-belts, drives, etc. Operate the conveyor empty under power for a period of time. Keep personnel away from moving parts. Disconnect and lock-out all electrical power. Make any needed adjustments. B Check and operate all discharge gates to see that they open and close properly. Also check all special accessories for fi t and operation. C Children and unauthorized persons should not have access to the electric controls! D Check and be certain that the pits are designed to prevent personal injury! E Check and be certain that the electrical equipment has been installed to meet safety codes! This includes explosion proof equipment where used! F After completing the start-up and all adjustments are set for operation, fi nish the assembly by installing the rest of the covers and any accessory components. G Reconnect electrical power. 41

42 6 Start-Up and Operation CHECK YOUR INCLINE DRAG CONVEYOR MOTOR A Check electrical current draw on the motor. INSPECTION OF THE CONVEYOR IS SUGGESTED AFTER THE FIRST 8-10 HOURS OF OPERATION A Check electrical current draw on the motor. B Inspect motor drive for looseness of pulleys, sprockets, belts, chains, or torque arm. C Check for oil leakage or gear reducer overheating. D Check the head and tail sprocket hub bolts and set screws. Torque Values for Set Screws SET SCREW BEARING SET SCREW DIAMETER SOCKET SIZE DODGE REX / LINK BELT 5/16 5/ ft-lbs 125 ft-lbs 3/8 3/ ft-lbs 225 ft-lbs 42

43 Trouble Shooting Trouble Problem Cause / Solution BELT: slipping or overheating CHAIN: premature wear on chain and sprockets MOTOR: can't start chain belt is a potential fire hazard and the conveyors optimum speed is reduced chain not installed correctly motor rotation reversed conveyor filled with material damaged reducer belt tension is incorrect / adjust it install new chain as required; see the chain section of this manual wired wrong / wire correctly material not shut off while conveyor was stopped broken gears or bearing / replace them paddle caught in conveyor loosen the paddle MOTOR: starter kicking out motor overloaded conveyor overloaded / adjust load line voltage low wrong drive sheaves motor too small current draw excessive starter not sized to motor heaters wrong size NOISE: and, or vibration excessive motor/starter device defective drive and take-up tail sprockets aren't centered on the shaft. (correct as soon as possible) conveyor chain tension is not correct check chain and paddles for damage from foreign object caught in conveyor check for loose or missing hardware or paddles motor, reducer, or bearing noise is excessive dents, punctures, bowed panels, or bowed lids are hindering conveyor flow fix or replace set screws may have been loose or it may have been improperly installed / adjust the sprocket to center and make sure set screws are tight the chain tension is either too loose or too tight / adjust it remove foreign object and replace parts as needed check for and replace any missing bolts or paddles faulty motor, reducer, or bearing / check oil levels, shaft seals, and drive components. Fix as needed repair or replace any damaged parts 43

44 Trouble Shooting Trouble Problem Cause / Solution NOISE: and, or vibration excessive (continued) the noise is originating from equipment interfacing with the conveyor noise at flanges wear in bearings excessive speed low oil level check auxiliary equipment and make any needed repairs trough out of alignment / adjust alignment abrasive in oil produce wear / replace worn bearing; flush drive and replace oil check specification and alter drive settings to proper speed reduced muffling effect of the oil / add oil CAPACITY: reduced capacity the bottom may be out of alignment obstructions at conveyor inlets, bins, hoppers, or chutes feeding the conveyor clumping of moist material on the paddles or along though sides which are effectively reducing conveyor capacity check and align properly conveyor overloaded / adjust load line voltage low check conveyor and replace any damaged or broken paddles, attachments, or chain / remove any foreign objects and replace any possible damage to chain or paddles due damaged apart (don't attempt to reweld to foreign object caught in the conveyor attachment on to the chain) heat treated chain attachments can become brittle and crack resulting in chain breakage chain too loose improper chain speed plugging material size and shape adjust take-up for proper chain tension check shaft rpm / adjust if needed discharges are clogged / check them and unplug as needed the material may be restrictive / alter flow accordingly 44