( B A L E OR GRAIN) OWNER S MANUAL AND SERVICE PARTS 13C /05

Transcription

1 C ONVERTIBLE CONVEYOR ( B A L E OR GRAIN) OWNER S MANUAL AND SERVICE PARTS 13C /05

2 CONTENTS FOREWARD. 3 IDENTIFICATION.. 3 WARRANTY.. 4 SAFETY PRECAUTIONS 5 UNDER CARRIAGE... 6 ASSEMBLY INSTRUCTIONS. 7 INSTALLATION OF ALLIGATOR STAPLE BELT FASTNER. 8 CONVEYOR BELT. 9 TRACKING BELT.. 10 BASIC RULES FOR TIGHTENING A CONVEYOR BELT 10 STARTING UP MAINTENANCE 11 MONTHLY LUBRICATION.. 11 CHANGING LUBRICANT. 11 SELECTION OF LUBRICANT.. 12 TROUBLE SHOOTING 12 SERVICE PART 13 2

3 FOREWORD This manual describes the installation, operation and maintenance of the MB Series belt conveyor from VALMETAL. Be sure to read it carefully before operating the machine or providing maintenance for it in order to obtain a thorough knowledge of efficient and safe procedures. IDENTIFICATION A name plate riveted to the side of the drive unit bears specification and serial numbers of the unit. Refer to these numbers when ordering parts. Serial number Model number : : WARRANTY This piece of equipment is covered by warranty. Your dealer will explain the warranty agreement and will complete the delivery and warranty registration form. NOTE: The warranty is valid only if both dealer and customer or their representatives have completed and signed the warranty registration form, and that the completed form is received by VALMETAL within 15 days from the date of installation. SAFETY ALERT SYMBOL Pay special attention to this safety alert symbol, it indicates an important safety message. For your protection, we urge you to read all safety messages found in the manual and on safety signs adhered to the machine. 3

4 LIMITED WARRANTY BASIC WARRANTY AND REMEDIES All VALMETAL products are warranted against defects in workmanship and materials for one year from date of delivery to the first purchaser. The warranty repair period for equipment used for commercial or rental purposes is limited to 90 days from date of delivery to the first retail purchaser. VALMETAL will repair or replace, free of charge, at its option, F.O.B. factory, freight prepaid, any parts proved defective in workmanship or materials. It is agreed that such replacement or repair is the exclusive remedy available from Valmetal, should any of Valmetal s products or parts prove defective. Valmetal will not be responsible for freight and labor charges involved for removing and replacing defective parts. EXCEPTIONS FROM THIS WARRANTY This warranty covers equipments under normal use and service, does not cover conditions resulting from misuse, negligence, alteration, accident or lack of performance of required maintenance. Replacement of maintenance items such as belts, spout liners, digger knives, blades, etc... are not covered. EXCEPTIONS FROM THE WARRANTY Motors are warranted directly by the motor manufacturer only and not by Valmetal. LIMITATION OF LIABILITY This warranty is in lieu of all other warranties, express or implied, written or oral. No employee, agent, dealer or any other person is authorized to give any warranties on behalf of Valmetal, nor to assume for Valmetal any other liability in connection with any its products. IN NO EVENT SHALL THE OWNER BE ENTITLED TO RECOVER FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SUCH AS, BUT NOT LIMITED TO, LOSS OF CROPS, LOSS OF PROFITS OR REVENUE, OTHER COMMERCIAL LOSSES, INCONVENIENCE OR COST OF RENTAL OR REPLACEMENT EQUIPMEN 4

5 SAFETY PRECAUTIONS - Keep ALL guards in place. - DO NOT attempt to clean oil or adjust machine while in operation. - Keep hands, feet and clothing AWAY from power driven parts. - BE SURE main switch is off before resetting motor thermals. OPERATE EQUIPMENT SAFELY Do not allow anyone to operate, make adjustment or lubricate before reading and understanding this manual. Controls should be located so the complete machine can be observed during operation. Do not allow children or unauthorized personnel to operate the conveyor. Leave all guards, shields and safety devices in place. Never allow anyone near conveyor while operating. Be sure area is clear before operating conveyor. Never walk or stand underneath a conveyor. Keep alert when operating equipment. Should any damage to equipment occur, shut off and lock out power immediately, make necessary inspection and repairs before restarting and operating. After using equipment, shut off and lock out power. Never leave a machine running unattended. Failure to heed warnings may result in personal injury or death. Never climb on or use a conveyor as a ladder or as a manlift. PRACTICE SAFE MAINTENANCE Disconnect and lock out power before adjusting or servicing. Make certain the motor and all other moving parts have stopped before making adjustments or leaving equipment. Keep all hardware tight and properly adjusted. Do not allow anyone to make adjustment or lubricate before reading and understanding this manual. Keep all safety sings clean and readable. Failure to heed warnings may result in personal injury or death. WARNING : ELECTRICALPOWER CONNECTION All electrical work should be carried out by a qualified electrician in order to prevent accidents or damage, and in accordance with all local regulations. 5

6 UNDER CARRIAGE SAFETY PRECAUTIONS WARNING PLEASE DO NOT INSTALL UNDERCARRIAGE BEFORE READING THIS MANUAL. FAILURE TO READ AND APPLY INSTRUCTIONS CONTAINED HEREIN CAN RESULT IN SUDDEN FAILURE OF EQUIPMENT. Install the recommended undercarriage model. Never raise a conveyor on an uneven ground. Maintain MINNMUM of three wraps of cable on drum. Never exceed MAXIMUM rated line pull, (see side of winch) Make sure nobody is close to the equipment when raising or lowering conveyor. Never let a child or an inexperienced person operate the equipment. Never walk or stand underneath an elevator. Never climb on or use your conveyor as a ladder or as a manlift. Always move undercarriage slowly with the conveyor being at the lowest position in order to avoid the conveyor from falling sideways. Installing the security cable could save you from a serious accident if the rising system ever failed. DON T TAKE A RISK, INSTALL IT. Avoid violent motion and shock loads. Always move your conveyor slowly. FAILURE TO READ AND APPLY INSTRUCTIONS CONTAINED HEREIN CAN RESULT IN SUDDEN FAILURE OF EQUIPMENT, PROPERTY DAMAGE AND SERIOUS INJURY. 6

7 ASSEMBLY INSTRUCTIONS 1- Install drive end assembly to the end of a conveyor frame, bolt together with 1/2 x 1 1/4 hex. bolt, lock washers and nuts. 2- Install pan section sides on the conveyor frame slide the hinge pin through the slotted cross members at the ends of the frame section, as shown, fix the hinge to the pan section with 3/8 x 3/4 carriage bolts, lock washers and nuts. 3- Bolt together conveyor frames with 1/2 x 1 x 1/4 hex bolts, lock washers and nuts. 4- Fix a return roller support with a round hole on one side and one with a D hole on the other side to the tabs on the bottom tubes of the frame with 3/8 x 3/4 car. bolt, lock washers and nuts 6- Secure return roller assembly between the supports with a cutter pin. 7- Bolt idler end assembly to the end of the conveyor sections, use 1/2 x 1 1/4 hex. bolts, lock washers and nuts. 8- Put some never seez or grease on motor shaft to make it easier to remove for later maintenance, install the key and fix it to the gear box with bolts. 9- Assemble hopper supports to idler end frame but don t tight the bolts before installing conveyor belt. 10- Assemble hopper sides to hopper end and the assembly to the hopper supports. 5- Bolt together conveyor frame weldments, use 1/2 x 1 1/4 hex. bolt, flat washers, locks washers and nuts. 7

8 INSTALLATION OF "ALLIGATOR" STAPLE BELT FASTENER Length of belt required: Twice the length of conveyor sections plus 9 feet 6 inches. 1- Lay out belt on a solid work surface, (a piece of plywood laid on section makes a handy work bench), set a framing square along belt and cut at 90 degree angle with utility knife. IMPORTANT: A square cut is necessary for the belt to run straight on the rollers. 2- Center fastener strip on belt. Figure no.1 7- Repeat the procedure at each end of the belt to secure the fastener strip. Follow the sequence as shown in figure no.2. IMPORTANT: The word "ALLIGATOR" on fasteners should face up 3- Place the applicator tool in the center of the fastener strip. Push applicator and fastener strip tight against the belt end. Set cam levers firmly in place away from belt. See figure no.1 4- Insert staples. Use a staple dispenser or place individual staples in slot by hand. 5- VERY IMPORTANT: Position staple driver in applicator and push staples down by hand until staples contact belt. Otherwise staples can wander when driven by hammer. 6- Using lightweight hammer, strike staple driver until staple clinches on the anvil. Do not overdrive staples as fastener can be distorted. Figure no.2 8- After all staples are driven, turn the belt over and with a flat steel plate under the fastener strip, peen the staples ends flush with the surface of fastener strip. IMPORTANT: Be careful not to crush fastener loops. 8

9 9- Notch belt as needed in order to keep the belt from catching conveyor frame work, see figure no After applying fasteners to both ends of belt, mesh loops together and insert hinge pin. Use pliers to crimp hinge pin retaining washers on to pin ends. Figure no.3 CONVEYOR BELT Run belt on top of the conveyor sections, around idler end, over the return wheels assemblies and over tension rollers and around the drive roller and back on top of the sections, see figure no.4. NOTE : Make certain idler roller is all the way in. DRIVE IDLER END Figure no.4 9

10 TRACKING BELT Start by making sure that the adjuster bolts at the idler are tightened equally. The primary rule of tracking a conveying belt is : the belt moves towards that end of the pulley where it contacts first. If the belt moves to one side, move that end of the pulley out or the other end of the pulley in. CAUTION : Don t take chances, make sure everyone is clear of machine before operating. 1. Turn on motor and check to see if belt runs centered on drive roller. 2. If adjustment is necessary, TURN OFF MOTOR, loosen bearing bolts on adjusting screw side, loosen also gear box brackets bolts and also the gear box bolts in order to allow the gear box to move and stay in line as the drive roller is moved outward or inward. If the belt moves to the gear box side, move the end of the roller out, if the belt moves to the opposite side, move the end of the roller in. 3. Tighten all the bolts. 4. Run conveyor and check belt alignment, if further adjustments are necessary, repeat steps 1, 2, Check to see if belt runs centered on the idler roller. 6. If adjustment is necessary TURN OFF MOTOR and, with adjusting nut, move right end of the idler roller out if belt runs off the right or move left end of the idler roller out if the belt runs off the left. 7. Run conveyor and check belt alignment, if further adjustments are necessary, repeat step. BASIC RULES FOR TIGHTENING A CONVEYING BELT There is no formula for setting the proper tension of a carrying belt. Belt tension must be tight enough to: A) Prevent slippage between the drive pulley and the belt. B) Force the belt to conform to the crown on the crowned pulleys Belt tightening is done by means of the adjusting rods at the idler end. NOTE: When tracking the belt, allow the belt to run several minutes and at least three full belt revolutions to determine if additional adjustement si required. Check tracking while machine is loaded. Check tracking during the first 2-10 hours after start up. Check tracking periodically afterwards. 10

11 STARTING UP CAUTION : Don t take chances, make sure everyone is clear of machine before running. It may take many hours of running, under full load, for the gears their to reach highest efficiency. The gearbox may, if necessary, be put to work under full load immediately. However, it is better for the ultimate life of the gear to be run under gradually increasing loads (reaching the full load after about 20 to 40 hours) Temperature rise on the initial run will be higher than the temperature eventually reached after the gearbox is fully run-in. IMPORTANT: Reasonable precautions should be taken to avoid overloads in the early stage of running. MAINTENANCE CAUTION: Make sure the power is off before inspection. To maintain free ventilation of the gear box, the breather hole in the filler plug (air-vent) should be kept clear at all times. Regularly inspect set screw and reducer mounting bolts for tightness because loose fasteners can cause misalignment and excessive wear. - Check oil in gear box. - Grease flange bearings at drive and idler ends. - Oil chain on power brush. Use light weight oil. MONTHLY LUBRICATION CHANGING LUBRICANT - After 100 hours of running, a new worm gear unit should be drained, flushed and refilled with proper oil. - Oil should be changed at least every 2500 operating hours or every 6 months, whichever occurs first. - Never mix 2 different types of oil. Be sure to drain and wash before using another type of oil. 11

12 SELECTION OF LUBRIFICANT Lubricating oil must have a viscosity sufficient to reduce friction and allow the speed reducer to operate smoothly under high load and impact. Consult table below for the choice of lubricant. Where the temperature range is expected, the synthetic oil EXXON SHC 629 is recommended. Please keep in touch with our engineering department, especially when operating reducers under special conditions such as high or low speed, high temperature or heavy loads. LUBRICANT Room temperature (C) Operating temperature (C) OIL GRADE TEXACO SHELL EXXON -30 to 0 Under 70 80W90 Mepora 150 Omala 150 Spartan EP 150 SHC to W110 Mepora 320 Omala 320 Spartan 320 SHC to 25 Under 70 80W110 Mepora 320 Omala 320 Spartan 320 SHC to W110 Mepora 320 Omala 320 Spartan 320 SHC 629 Over 25 Under 70 80W110 Mepora 460 Omala 460 Spartan 460 SHC to W110 Mepora 460 Omala 460 Spartan 460 SHC 629 TROUBLE SHOOTING PROBLEM POSSIBLE CAUSES CORRECTIONS Mistracking of conveying belt. Splice not square. Verify and resplice if necessary. Belt not properly tracked. See tracking belt section. Conveying belt too loose. Tighten so belt conforms to crowned pulleys. Material build-up on pulleys. Remove build-up on pulleys and eliminate point where material enter under belt. Use hopper to direct feed on center of belt. 12

13 CONVERTIBLE CONVEYOR (BALE OR GRAIN) SERVICE PARTS 13

14 DRIVE UNIT ITEM PART DESCRIPTION ITEM PART DESCRIPTION 1 MB-720 Drive roller (MB-7018) 11 Motor key MB-721 Drive roller (MB-8018) 12 Motor /4 "x 3" Key (MB-7018) 13 02C /8" Flat washer /16" x 4" Key (MB-8018) M-10 x 20 Hex. bolt 3 40-UCFL Flange bearing 1-1/4" (MB-7018) 15 MB-723 Roller 40-UCFL Flange bearing 1-3/8" (MB-8018) 16 MB-724 Cross member 4 02C /2" Lock washer 17 MB-725 Right roller bracket 5 02C /2" Hex. nut 18 MB-726 Left roller bracket 6 02C /8" Lock washer 19 MB-727 Support plate 7 02C /8" Hex. nut Adjusting bolt Reducer bracket (MB-7018) 21 01C /2" x 1-1/2" Carriage bolt Reducer bracket (MB-8018) 22 01C /8" x 1" Carriage bolt Gear reducer (MB-7018) 23 MB-729 Frame Gear reducer (MB-8018) Reducer bracket (MB-7018) 01C /8" x 1" Hex. bolt MB-776 Reducer bracket (MB-8018) 14

15 SECTION ITEM PART DESCRIPTION ITEM PART DESCRIPTION 1 MB ' Section frame 9 02C /8" Hex. nut MB-739 5' Section frame 10 01C /2" x 1-1/4" Hex. bolt 2 MB ' Pan 11 02C /2" Lock washer MB-742 5' Pan 12 02C /2" Hex. nut 3 MB-744 Pivot Roller 4 MB " Return roller support 14 02C /16" washer Axle 15 01C /8" x 1" Zinc cotter pin 6 MB " Return roller support 16 01C /8" x 3/4" Carriage bolt /8" Washer 17 MB-766 Axle w/ 3 rollers ass y 8 02C /8" Lock washer 18 MB-747 Return roller assembly w/ supports 15

16 IDLER END ITEM PART DESCRIPTION ITEM PART DESCRIPTION 1 MB-727 Support plate 12 02C /2" nut 2 MB-737 Roller bracket 13 02C " jam nut 3 MB-728 Frame 14 01C " nylon lock nut 4 40-UCFL /8" dia. flange bearing 15 02C /8" nut 5 MB-723 Roller with bearing 16 01C /8" x 3/4" hex. bolt T Bearing only 17 01C /8" nylon lock nut 6 MB-735 Idler roller 18 MB x 13 threaded rod 7 MB-724 Cross member 19 01C /2" x 1-1/2" carriage bolt 8 CB-913 Roller 20 01C /8 x 1 cotter pin 9 01C /8" x 3/4" carriage bolt Bearing bracket 10 02C /8" lock washer 22 MB-726 Left roller bracket 11 02C /2" lock washer 23 MB-725 Right roller bracket 16

17 GEAR BOX (HOLLOW) ITEM 70 SERIES (45-715) PART 80 SERIES (45-815) PART DESCRIPTION Gear housing Oil Plug Worm gear Output bearing Output cover TC TC Output oil seal C frame SC SC Input oil seal Input cover bearing Worm shaft M8 x 16 hex. bolt Input cover M6 x 20 hex. socket head cap screw Sight glass Air vent breather 17

18 BRUSH KIT ITEM PART DESCRIPTION ITEM PART DESCRIPTION Brush 13 01C /8" x 3" Hex. bolt 2 40-UCFL /4" Flange bearing 14 02C /8" Lock washer Tightener bracket 15 02C /16" Washer B B24 x 3/4" Sprocket /16" x 3/16" x 1" Key B B24 x 1-1/4" Sprocket (série 70) /4" x 1/4" x 1" Key (série 70) 60-40B B24 x 1-3/8" Sprocket (série 80) /16" x 5/16" x 1-1/4" Key (série 80) #40 Roller chain 18 01C /8" Lock nut 7 CM-1153 UHMW Tightener 19 02C /16" Washer 8 MB /2" Spacer 20 01C /8 x 1-1/4" Carriage bolt Front guard 21 01C /8 x 3/4" Carriage bolt Left guard 22 01C /8" x 1/2" Hex. bolt Right guard 23 01C /8" Flange lock nut 12 01C /8" x 2-1/4" Carriage bolt 18

19 HOPPER ITEM PART # DESCRIPTION 1 MB-748 Back 6" high MB-749 Back 13" high 2 MB-750 Left side 6" high MB-752 Left side 13" high 3 MB-753 Right side 6" high MB-754 Right side 13" high 4 01C /8" x 3/4" Carriage bolt 5 02C /8" Washer 6 02C /8" Lock washer 7 02C /8" Hex. nut 8 MB-757 Angle bracket 9 MB-758 Hopper bracket 19

20 HEAD SPOUT & FUNNEL ITEM PART # DESCRIPTION 1 MB-759 End plate 2 MB-760 Right side 3 MB-761 Left side 4 01C /8" x 3/4" Carriage bolt 5 02C /8" Hex. nut 6 02C /8" Lock washer 7 02C /8" Washer 8 MB-763 Front or rear plate 9 MB-765 Side plate 10 01C /8" x 1" Hex. bolt 20

21 BALE CHUTE ITEM PART # DESCRIPTION 1 CB-991 Gutter only 2 CB-992 Rear support 3 MB-736 Front angle support 4 01C /8" x 1" Hex. bolt 5 01C /8" Nylon lock nut 21

22 230 BOUL. INDUSTRIEL ST-GERMAIN, QUÉBEC CANADA, J0C 1K0 TEL.: (819) FAX : (819) info@valmetal.com PRINT IN CANADA MAY 2011 MANUEL NUMBER : 13C