Drive Over- Pit. Belt Accelerator & Multi-Purpose Belt Loader OWNER'S MANUAL (08/08)
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1 Drive Over- Pit Belt Accelerator & Multi-Purpose Belt Loader OWNER'S MANUAL (08/08)
2 Belt Accelerator & Multi-Purpose Belt Loader Table of Contents Warranty Information Inside Front Cover Safety Lubrication and Maintenance Hydraulic and Electric Requirements Dimensional Drawings Belt Wrap Diagram & Replacement Belts Cable Wrap Diagram Guard Bracket Locations Repair Parts Assembly Instructions Warranty CrustBuster/Speed King, Inc. of Dodge City, Kansas, warrants consumer products, so far as the same is of our own manufacture, against defects in material and workmanship under normal and reasonable use for a period of one (1) year after date of delivery to the original purchaser. Our obligation under this warranty is limited, however, to furnishing a replacement part for a defective part, or at our option to repair the defective parts without charge, either method F.O.B. our works, provided the consumer gives CrustBuster/Speed King,Inc. written notice within ten (10) days after said part appears to be defective and affords CrustBuster/Speed King,Inc. an opportunity to inspect. Unless otherwise expressly agreed to by CrustBuster/Speed King,Inc., the consumer shall bear the expense of installation. CrustBuster/Speed King, Inc. will not be liable for consequential damages where the loss is commercial, including but not limited to loss of profit, delays or expenses. This warranty sets forth the extent of our liability. The foregoing is in lieu of all other warranties, expressed or implied, including any warranties that extend beyond the description of the product.
3 Introduction Read this manual carefully. It will instruct you on how to operate and service your machine safely and correctly. Failure to do so could result in personal injury and/or equipment damage. Warnings 1. DO NOT service Drive Over-Pit before stopping all motors and locking out power source. 2. DO NOT operate Drive Over-Pit before checking for proper clearance for operation and clearing the area of people. 3. DO NOT operate the Drive Over-Pit without familiarizing yourself with the operator's manual. 4. DO NOT operate the Drive Over-Pit if guards or shields have been removed. 5. DO NOT drive over ramp with spring loaded skirtboards in "UP" position. 6. DO NOT stand or walk on conveyor belt before stopping all motors and locking out power source. Safety Precautions 1. Operator should read and understand operator's manual before operating Drive Over-Pit conveyor. 2. Never stand or climb on the Drive Over-Pit conveyor before disconnecting and locking out power source. 3. Disconnect and lock out power source before adjusting and servicing Drive Over-Pit conveyor. 4. Do not operate without guards and shields in place. 5. Stay away from hopper inlet when operating. 6. Stay away from moving belt when operating. 7. Keep area clean. 8. Operator should be familiar with controls and operation sequence prior to start up. 9. Read and understand all material safety data sheets (MSDS) for any chemical or material you are handling. 10. All electrical components should be wired by a qualified electrician. All federal, state, and local codes should be followed. 1
4 Owner's and User's Statement of Responsibility Drive Over-Pit Belt Accelerator & Multi-Purpose Belt Loader I have had explained to me and accept responsibility for the following: I understand this Drive Over-Pit conveyor is a heavy, powerful, and bulky unit of equipment capable of causing injury or death when used improperly. I accept the responsibility associated therewith. I understand the danger of high voltage power lines in relation to high profile equipment and accept responsibility for its safe use in dangerous surroundings. I understand that neither I, any of my workers, nor anyone else should be allowed to work around the Drive Over-Pit conveyor area while it is in operation, or unstabilized for any reason. I understand the Drive Over-Pit can cause serious injury or death instantly. Therefore, I accept responsibility to avoid, and to cause my workers to avoid, working in an area or manner that would cause unnecessary risk of injury or death. I hereby acknowledge that I have been adequately instructed in the safe operation of this Drive Over-Pit conveyor and accept responsibility for same. I recognize that this list of potential risk and dangers is not necessarily complete and agree to exercise good common sense and judgement in the use of this Drive Over-Pit conveyor. Owner Date 2
5 Lubrication and Maintenance CAUTION: STOP ALL MOTORS AND LOCK OUT POWER SOURCE BEFORE SERVICING CONVEYOR. CAUTION: IF GUARDS OR SHIELDS ARE REMOVED TO SERVICE UNIT, REPLACE IMMEDIATELY AFTER COMPLETION OF WORK. IMPORTANT: THE LUBRICATION PERIODS RECOMMENDED ARE BASED ON NORMAL USAGE. SEVERE OR UNUSUAL CONDITIONS MAY REQUIRE MORE FREQUENT LUBRICATION. IMPORTANT: CLEAN FITTINGS THOROUGHLY BEFORE LUBRICATING. REPLACE MISSING OR DAMAGED GREASE FITTINGS IMMEDIATELY. SERVICE/YEARLY (PRIOR TO START UP) Electric Motor 1 to 2 Full Strokes SERVICE/WEEKLY ( 20 HOURS ) Flange Bearings LUBRICANT: Shell Oil Co. "Dolium R" Chevron Oils "SRI No. 2" Texaco Inc. "Premium RB" LUBRICANT: SAE Multi-Purpose Grease Drive Over-Pit Conveyor Maintenance Due to the characteristics of certain materials, a residue may build up. If this is a problem or gets excessive, wash out the conveyor. Allow to dry before using. Hydraulic Requirements: 15 gallons per minute at 1800 psi. In order to operate a hydraulic drive BeltVeyor and a hydraulic Drive Over-Pit Conveyor off of the same tractor, the tractor will need to have a Closed Center Hydraulic System with Individual Flow Control for each valve and a flow rate of 32 gallons per minute at 2000 psi. Electric Requirements: 5 hp 1800 RPM 3
6 Belt Accelerator -16" Dimensional Drawing 4
7 Multi-Purpose Belt Loader - 16" Dimensional Drawing 5
8 Multi-Purpose Belt Loader - 24" Dimensional Drawing 6
9 Belt Wrap Diagram 7
10 Drive Over-Pit Cable Wrap Diagram Drive Over-Pit Guard Bracket Locations Electric Drive 8
11 9
12 Ramp Repair Parts - 16" 10
13 Ramp Repair Parts - 16" Item Qty Part No. Description Jack 2000# Side Crank Hitch Weldment Take-up Bolt Square Nut 3/8" Bearing Slide Bearing 1" 2B Flange Lagged Roller 3 ½" w/ 1" x 19.75" shaft Ramp Weldment Shaft 1/2" x 119 7/8" Skirtboard Weldment Skirtboard Skirtboard Spring Tab Skirtboard Handle Lifting Bridge Wheel Arm Weldment Wheel Arm Bracket Item Qty Part No. Description Tire & Wheel Assembly Includes: Tire 9.5L x 15-6 Ply Wheel 5-Bolt 15" x 6" Tire Valve Stem Decal Check Wheel Lugs Hub 5 Bolt Complete (Includes Items #19 thru #27) Hub Seal Hub Bearing Inner Hub 5 Bolt w/cups only Hub Bearing Outer Spindle Washer Cotter Pin Spindle Nut Hub Cap Lug Nut Skirtboard Spring Assy Cotter Pin 1/8" x 1" Cable Pulley 3" Belt Cover 11
14 Ramp Repair Parts - 24" 12
15 Ramp Repair Parts - 24" Item Qty Part No. Description Jack 2000# Side Crank Hitch Weldment Take-up Bolt Square Nut ½" Take-up Bracket Bearing 1 5/16" 2B Flange Lagged Roller 3½" x 24" w/ 1 5/16" x 29" shaft Ramp Weldment Shaft 1/2" x 119 7/8" Skirtboard Weldment Skirtboard Skirtboard Spring Tab Skirtboard Handle Lifting Bridge Wheel Arm Weldment Wheel Arm Bracket Item Qty Part No. Description Tire & Wheel Assembly Includes: Tire 9.5L x 15-6 Ply Wheel 5-Bolt 15" x 6" Tire Valve Stem Decal Check Wheel Lugs Hub 5 Bolt Complete (Includes Items #19 thru #27) Hub Seal Hub Bearing Inner Hub 5 Bolt w/cups only Hub Bearing Outer Spindle Washer Cotter Pin Spindle Nut Hub Cap Lug Nut Skirtboard Spring Assy Cotter Pin 1/8" x 1" Cable Pulley 3" Belt Cover Motor Mount 13
16 Belt Accelerator Repair Parts -16" Hydraulic Drive 14
17 Belt Accelerator Repair Parts -16" Hydraulic Drive Item Qty Part No. Description Frame Weldment Skirtboard Brace RH Slide Pan Roller 3 1/2" x 16" Shaft 1" Bearing 1" 2B Flange Skirtboard Brace LH Top Cap Seal Cable Pulley 3" Winch 10' Cable 1/4" Galvanized Clamp Weldment Support Tube ' Pan Weldment Head Frame Pan Cover Lagged Roller 3 1/2" Shaft 1" Roller Weldment 2" Skirtboard Strap Skirtboard Chain #40 Coupler x 16 Item Qty Part No. Description Drive Guard (4 7/8") Drive Guard (6 ½") Drive Guard Side Plt (4 7/8") Drive Guard Side Plt (6 ½") Hyd Motor H Seal Kit Hose.500 x 240".750 MOR (2) Sprocket #40 16T Key 1/4" x 1 1/4" Seal Flow Control Valve Valve Mount Adapter Straight MOR x.750 MOR Adapter Tee.750 JICM (2) x.750 Male Pipe Adapter 90E.750 MOR x.750 JICM Hose.500 x 48".75 JICF Sw x.50 M Pipe Hose.500 x 240".750 MOR x.750 JICF Sw NOTE: When using a Belt Accelerator (Hydraulic or Electric Drive) to dump into a SpeedKing 14" BeltVeyor, attach hopper strap "A" (# ) to BeltVeyor. 15
18 Belt Accelerator Repair Parts -16" Electric Drive 16
19 Belt Accelerator Repair Parts -16" Electric Drive Item Qty Part No. Description Frame Weldment Skirtboard Brace RH Slide Pan Roller 3 1/2" x 16" Shaft 1" Bearing 1" 2B Flange Skirtboard Brace LH Top Cap Seal Cable Pulley 3" Winch 10' Cable 1/4" Galvanized Clamp Weldment Support Tube ' Pan Weldment Head Frame Pan Cover Lagged Roller 3 1/2" Shaft 1" Roller Weldment 2" Skirtboard Strap Skirtboard Jackshaft 1" Spacer Item Qty Part No. Description Chain Guard Back Plate Chain Guard Side Chain Guard Assembly Includes #23 & # Nylon Idler Sprocket #50 18T x 1" Chain Guard Front Plate Key 1/4" x 1 1/4" Chain #50 x 41 Pitches Chain #50 Connector Link Chain #50 Offset Link Belt Guard Bracket Belt Guard Back Plate Belt Guard Side Belt Guard Assembly Includes #34 & # V-Belt B Sheave 2B 4.0 SH Bushing 1 1/8" SH QD Belt Guard Front Plate Bushing 1" SDS QD Sheave 2B 6.8 SDS Seal NOTE: When using a Belt Accelerator (Hydraulic or Electric Drive) to dump into a SpeedKing 14" BeltVeyor, attach hopper strap "A" (# ) to BeltVeyor. 17
20 Multi-Purpose Belt Loader Repair Parts-16" Hydraulic Drive 18
21 Multi-Purpose Belt Loader Repair Parts-16" Hydraulic Drive Item Qty Part No. Description S-Wrap Frame Back-up Strap Skirtboard S-wrap Seal RH S-wrap Skirtboard S-wrap Seal Strap RH S-wrap Seal Strap LH S-wrap Seal LH Lagged Roller 3 1/2" Shaft 1" x 21 3/4" Bearing 1" 2B Flange Shaft 1" x 21 3/4" Roller Weldment 2" Clamp Cable Pulley 3" Winch 10' Cable 1/4" Galvanized Top Cap Seal Top Cap ' Pan Weldment Truss Bar Weldment Pan Cover Roller Assembly 2 3/8" Roller Carrier Brackets Item Qty Part No. Description Lagged Roller 6" Head Frame Spout Weldment Drive Guard (4 7/8") Drive Guard (6 ½") Drive Guard Side Plt (4 7/8") Drive Guard Side Plt (6 ½") Hyd Motor H Seal Kit Hose.500" x 240".750 MOR (2) Sprocket #40 16T Chain #40 Coupler x Key 1/4" x 1 1/4" Flow Control Valve Valve Mount Adapter Straight MOR x.750 MOR Adapter Tee.750 JICM(2) x.750 Male Pipe Adapter 90E.750 MOR x.750 JICM Hose.500 x 48".75 JICF Sw x.50 M Pipe Hose.500 x 240".750 MOR x.750 JICF Sw 19
22 Multi-Purpose Belt Loader Repair Parts-24" Hydraulic Drive 20
23 Multi-Purpose Belt Loader Repair Parts-24" Hydraulic Drive Item Qty Part No. Description S-Wrap Frame Back Up Strap Skirtboard S-Wrap Seal RH S-Wrap Skirtboard S-Wrap Seal Strap RH S-Wrap Seal LH S-Wrap Seal Strap LH Lagged Roller 3½" x 24" 1 5/16" Bore x 31 1/4" Bearing 1 5/16" 2B Flange Shaft 1 5/16" x 31 1/4" Roller 2 3/8" x 26" Clamp Cable Pulley 3" Winch 10' Cable 1/4" Galvanized Top Cap Seal Top Cap ' Pan Truss Bar Pan Cover Roller Assembly 2 3/8" Roller Carrier Bracket Lagged Roller 6" Head Frame Shaft 1 5/16" x 33 1/4 Item Qty Part No. Description Spout Drive Guard Drive Guard Side Hydraulic Motor H Seal Kit Hose ½" x 240" 3/4" MOR (2) Sprocket #50 18T -1 5/16"B Chain #50-2 x 17 Pitch Chain Connector # Flow Control Valve Valve Mount Adapter Straight 1 1/16 MOR x 3/4 MOR Adapter Tee 3/4 JICM (2) x 3/4 MOR Adapter 90E 3/4 MOR x 3/4 JICM Hose ½" x 48" 3/4 JICF SW x ½ MP Hose ½" x 240" 3/4 MOR x 3/4 JICF Sw Sprocket #50 18T -1"B Key 5/16" x 1 1/4" Bearing Plate Motor Mount Assembly 21
24 Multi-Purpose Belt Loader Repair Parts-16" Electric Drive 22
25 Multi-Purpose Belt Loader Repair Parts-16" Electric Drive Item Qty Part No. Description S-Wrap Frame S-Wrap Fame -25E Incline Back-up Strap Skirtboard S-wrap Seal RH S-wrap Skirtboard S-wrap Seal Strap RH S-wrap Seal Strap LH S-wrap Seal LH Lagged Roller 3 1/2" Shaft 1" x 21 3/4" Bearing 1" 2B Flange Shaft 1" x 21 3/4" Roller Weldment 2" Clamp Cable Pulley 3" Winch 10' Cable 1/4" Galvanized Top Cap Seal Top Cap ' Pan Weldment ½' Pan -25E Incline Item Qty Part No. Description Truss Bar Weldment Pan Cover 8' Pan Cover 7½' -25E Incline Roller Assembly 2 3/8" Roller Carrier Brackets Lagged Roller 6" Head Frame Spout Weldment Belt Guard Bracket Belt Guard Bracket Belt Guard Back Plate Belt Guard Sides Belt Guard Assembly (Includes #30 & #31) Sheave 2B "Bore V-Belt B Belt Guard Front Plate Sheave 2B 3.6 SH Bushing 1 3/8" SH QD 23
26 Multi-Purpose Belt Loader Repair Parts-24" Electric Drive 24
27 Multi-Purpose Belt Loader Repair Parts-24" Electric Drive Item Qty Part No. Description S-Wrap Frame S-Wrap Frame -25E Incline Back Up Strap Skirtboard S-Wrap Seal RH S-Wrap Skirtboard S-Wrap Seal Strap RH S-Wrap Seal LH S-Wrap Seal Strap LH Lagged Roller 3½" x 24" 1 5/16" Bore x 31 1/4" Bearing 1 5/16" 2B Flange Shaft 1 5/16" x 31 1/4" Roller 2 3/8" x 26" Clamp Cable Pulley 3" Winch 10' Cable 1/4" Galvanized Top Cap Seal Top Cap ' Pan ' Pan -25E Incline Item Qty Part No. Description Truss Bar Pan Cover 8' Pan Cover 10' -25E Incline Roller Assembly 2 3/8" Roller Carrier Bracket Lagged Roller 6" Head Frame Shaft 1 5/16" x 33 1/ Spout Belt Guard Bracket Belt Guard Bracket Belt Guard Back Belt Guard Side Belt Guard Assembly Sheave 2B 11.0 SK V-belt B Belt Guard Front Sheave 2B 3.6 SH Bushing 1 3/8 SH QD Bushing 1 5/16 SK Key 5/16" x 1 1/4" Truss Bar Bracket Right Truss Bar Bracket Left 25
28 Assembly Instructions CAUTION: Most component parts of the Drive Over-Pit Belt Accelerator as well as the Multi-Purpose Belt Loader are heavy. Use a safe lifting device when unloading and during the assembly process. Pre-Assembly Notes: Fasteners may vibrate loose during shipping. It is recommended you check nuts, bolts, set screws, and sheave alignment on pre-assembled parts prior to start-up. Before starting assembly procedures, refer to the illustrated parts lists and familiarize yourself with these parts. Open the parts carton and lay out parts for easy identification. 26
29 Assembly Instructions Belt Accelerator - Electric Drive Refer to belt guard bracket locations on page 7. Using the two spacers D, 5/16" X 1½" carriage bolts, lock washers, and hex nuts, assemble chain guard C to head frame side A as shown. Attach nylon idler E to chain guard C on head frame A as shown using a ½" x 3 ½" carriage bolt, eight flat washers as spacers, and secure with a flat washer, lock washer, and hex nut. Refer to Figure #3 to assemble sprockets and chain. Attach front plate F to guard assembly C using 5/16" x 3/4" washer head self tapping screws. Figure #1 Figure #3 Refer to Figure #2 and attach belt guard brackets G to head frame side B using 5/16" x 1 1/2" carriage bolts, flat washers, lock washers, and hex nuts. Attach the belt guard assembly H on the other end of brackets G using 5/16" x 1 1/2" carriage bolts, flat washers, lock washers, and hex nuts. Bolt the motor to head frame using 3/8" x 1 1/2" HHCS, flat washers, hex nuts, and lock washers. Refer to Figure #3 to assemble and align sprockets and chains. Attach front plate I to belt guard assembly H using 5/16" x 3/4" washer head self tapping screws. Figure #2 27
30 Assembly Instructions Multi-Purpose Belt Loader - Electric Drive Figure #4 Refer to guard bracket locations on page 7. Attach belt guard bracket B to head frame A as shown using 3/8" x 1" carriage bolts, flat washers, lock washers, and hex nuts. Bolt brackets C to head frame using 5/16" carriage bolts, flat washers, lock washers, and hex nuts. Attach the top slots of all brackets to guard assembly D. Bolt the motor to head frame using 3/8" x 1 1/2" HHCS, flat washers, hex nuts, and lock washers. Refer to Figure #5 to assemble and align sheaves and belts. Attach front plate E to belt guard assembly D using 5/16" x 3/4" washer head self tapping screws. Figure #5 28
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32 P.O.Box 1438 Dodge City, Kansas (620)
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