Outload Trough Roller Conveyor

Transcription

1 Outload Trough Roller Conveyor OWNER'S MANUAL (8/99)

2 Table of Contents Warranty Information Inside Front Cover Operator Qualifications / Sign Off Sheet Safety Instructions Specifications General Maintenance & Operation Stand Support Locations Dimensional Drawing Repair Parts: Head Tail Pans Support Stands Telescoping Spout 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 Operator Qualifications Operation of this conveyor shall be limited to competent and experienced persons. In addition, anyone who will operate or work around a conveyor must use good common sense. In order to be qualified, he or she must also know and meet all other requirements, such as: 1. Some regulations specify that no one under the age of 16 may operate power machinery. It is your responsibility to know what these regulations are in your 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 of servicing of all equipment with which the employer is, or will be involved." 3. Unqualified 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 qualified to operate the machinery. FAILURE TO READ THIS CONVEYOR MANUAL AND ITS SAFETY INSTRUCTIONS IS A MISUSE OF THE EQUIPMENT. Sign Off Sheet As a requirement of OSHA, it is necessary for the employer to train the employee in the safe operation and safety procedures with this Trough Roller. We include this sign off sheet for your convenience and personal record keeping. DATE EMPLOYER EMPLOYER'S SIGNATURE 1

4 BE ALERT! Your Safety is involved. General Safety Statement WATCH FOR THIS SYMBOL. IT POINTS OUT IMPORTANT SAFETY PRECAUTIONS. IT MEANS "ATTENTION BECOME ALERT!" YOUR SAFETY IS INVOLVED. It is your responsibility as an owner, operator, or supervisor to know and instruct everyone using this conveyor at the time of initial assignment and at least annually thereafter, of the proper operation, precautions, and work hazards which exist in the operation of this conveyor in accordance with OSHA Regulations. Safety Is No Accident The following safety instructions, combined with common sense, will save your equipment from needless damage and the operator from unnecessary exposure to personal hazard. Pay special attention to the caution notes in the text. Review this manual at least once each year with new and/or experienced operators. 1. Read and understand the operator's manual before operating this conveyor. Failure to do so is considered a misuse of the equipment. 2. Make sure conveyor is secure before operating. 3. Always keep children away from conveyor when operating. 4. The motor controls and reset button must be located so that the operator has a full view of the entire operation. 5. During regular operation of the conveyor, one person should be in a position to monitor the operation. A second person should always be nearby to shutdown the conveyor in case of an emergency. 6. Make sure everyone that is not directly involved with the operation is out of the work area before beginning the operation. 7. Keep the work area clear of grease, oil, water, and other objects that could cause a slip or a fall. 8. Make sure all safety devices, shields, and guards are in place and are functional before beginning the operation. 2

5 9. Shut off and lock out power to adjust, service, or clean the conveyor. 10. Keep hands, feet, and clothing away from moving parts. It is a good idea to remove all jewelry before starting the operation. 11. Visually inspect the conveyor periodically during operation for signs of excessive vibration, loose fasteners, and unusual noises. Electric Safety 1. Electric motors and controls should be wired by a qualified electrician and meet all standards set by Federal, State, and Local Electrical Codes. 2. Make certain electric motors are grounded. 3. A magnetic starter should be used to protect your motor. 4. Your motor must have a manual reset button. 5. Electrical power must be disconnected before resetting your motor. 6. A main power disconnect switch, with the ability to be locked in the off position, should be provided. The switch should be locked in the off position whenever work is to be done on the conveyor or the conveyor is going to be left unattended. 7. Disconnect power before resetting motor overload. CAUTION 1. Read and understand instruction manual before operating. 2. Keep all safety shields and devices in place. 3. Make certain everyone is clear before operating machine. 4. Keep hands, feet, and clothing away from moving parts. 5. Shut off power to adjust, service, or clean. 6. Make sure machine is secured before operating. 7. Disconnect power before resetting motor overload. 8. Make certain electric motors are grounded. 3

6 Outload Conveyor Specifications 16" - 24" Length: Belting: Belt Speed: Conveyor Sections: Head Drive Terminal: Tail Take-up Terminal: Weather Covers Power Requirements 25' through 43'; 45' available in 24" 16" or 24" wide PVC Chevron cover design 600 FPM 304 stainless steel construction 2 3/8" dia. PVC return rollers 2" dia PVC carrier rollers 10 ga. 304 stainless steel construction 6" lagged drive roller 1 5/16" drive shaft Regreasable flange mount ball bearings 18.4" drive sheave 4.2" motor sheave 304 stainless steel construction 3 1/2" tail roller 1 5/16" tail shaft Regreasable pillow block ball bearing Stainless steel hopper Grease packed take-up slides 304 stainless steel construction 1800 RPM, 3-phase, 60 Hz, TEFC electric motor 16" 25' to 26' 5 Hp 27' to 42' 7½ Hp 24" 25' to 36' 7½ Hp 36' to 45' 10 Hp Electric Motor Specifications 1. All electric motors to be 1800 RPM TEFC unless otherwise specified by the manufacturer. General Maintenance Preventive maintenance is the key to the long life of any mechanical device. Careful and systematic inspection of all trough roller conveyor equipment will assure maximum trouble free service. Correct belt tension and alignment are extremely important. Maintaining proper adjustments can add many hours of extra belt life. 4

7 Lubrication 1. All bearings which are fitted with grease zerks should be lubricated daily during heavy use. Before greasing the bearings, make certain the zerks are free of dirt. Otherwise, this will be passed into the bearing race. If the unit will be out of service for a period of time, purge the bearings. 2. Electric motors should be oiled in accordance with the manufacturer's recommendations. Pre-Operation Check List 1. Check all bearings for proper lubrication. 2. Check conveyor for foreign material or obstruction. 3. Check all V-belts for proper tension. 4. Start conveyor and check belt alignment while unit is empty. Operation Sequence 1. For each installation, placement of each conveyor will dictate the operation sequence. Normally, the last conveyor the material is transfered to, should be started first. Conveyor Belt Length Formula 1st Double the total length of trough sections. ' - " Belt 2nd For 1' Take-up and 2' Head Drive add 4' - 4" Belt Conveyor Belt Take-up After extended use, the conveyor belt may stretch to the extent that there is not sufficient take-up for tensioning. Addditional take-up may be obtained by cutting an 8" section from the belt and re-splicing. Splice kits may be obtained locally or ordered from the factory using the part numbers below. # " Belt Splice Kit # " Belt Splice Kit Conveyor Belt Replacement To replace the conveyor belt, pull out the splice pin and splice one end of the new belt to one end of the old belt. Pull the new belt in as you pull the old belt out. After you have run this unit and aligned the new belt, seal the splice with the belt splice rubber compound and let cure in accordance with instructions on container. Conveyor Belt Storage If unit is to be out of service for a month or longer, relieve tension from belt and clean off all material build-up. 1. Before attempting to train the belt, check all pulley and idler bearings. They should be located in the center of their slots, level, and at a 90 angle to the direction of the belt travel. 2. Slight adjustment of pulleys may be required to keep belt centered on them. i.e.-if the conveyor belt runs to one side of the pulley, apply more tension to the opposite side or release a little tension on the side of the pulley the belt is running to. 5

8 Conveyor Belt Tension / Alignment PRIOR TO START-UP, CHECK TO SEE THAT THE BELT IS FREE FROM ANY OBJECTS THAT WOULD BIND OR TEAR THIS BELT. 1. When starting for the first time with no load on the belt, apply power for a few seconds only to see that the conveyor belt travels in the proper direction and is well centered in the trough. 2. The belt is tensioned by adjusting the take-up bolts located at the "TAIL". The belt should be tensioned tight enough so the drive pulley does not slip when the conveyor is running "under load", or when the conveyor is started "under load". 3. It should be noted that too much tension on the conveyor belt will make alignment / training more difficult, shorten the life of the belt, and waste power. Re-adjust the tension after the conveyor is running "under load". Conveyor Belt Alignment / Training 1. Before attempting to train the belt, check all pulley and idler bearings. They should be located in the center of their slots, level, and at a 90 angle to the direction of the belt travel. 2. Slight adjustment of pulleys may be required to keep belt centered on them. i.e.- If the conveyor belt runs to one side of the pulley, apply more t e n s i o n t o t h e opposite side or release a little tension on the side of the pulley the belt is running to. 6

9 Outload Conveyor Stand Support Locations 25' - 42' 45' Only 7

10 Outload Conveyor Dimensional Drawing (25 Incline) 8

11 Outload Conveyor Dimensional Drawing (25 Incline) Conveyor Mid Section Lengths Lengths A B 25' (2)- 10' (1)- 3' 9'- 11" 22'- 6½" 26' (2)- 10' (1)- 4' 10'- 4" 23'- 5¼" 27' (2)- 10' (1)- 5' 10'- 9" 24'- 4" 28' (2)- 10' (1)- 6' 11'- 2" 25'- 3" 29' (2)- 10' (1)- 7' 11'- 7¼" 26'- 2" 30' (2)- 10' (2)- 4' 12'- ¼" 27'- ½" 31' (2)- 10' (1)- 5' (1)- 4' 12'- 5¼" 27'- 11" 32' (3)- 10' 12'-11½" 28'-10½" 33' (2)- 10' (1)- 6' (1)- 5' 13'- 3½" 29'- 9¼" 34' (2)- 10' (1)- 7' (1)- 5' 13'- 8½" 30'- 8" 35' (3)- 10' (1)- 3' 14'- 1½" 31'- 7" 36' (3)- 10' (1)- 4' 14'- 6½" 32'- 6" 37' (3)- 10' (1)- 5' 14'-11¾" 33'- 4¼" 38' (3)- 10' (1)- 6' 15'- 4¾" 34'- 3½" 39' (3)- 10' (1)- 7' 15'- 9¾" 35'- 2½" 40' (3)- 10' (2)- 4' 16'- 6" 36'- 1¼" 41' (3)- 10' (1)- 5' (1)- 4' 16'- 8" 37'- 0" 42' (4)- 10' 17'- 1" 37'- 11" 43' (3)- 10' (1)- 6' (1)- 5' 17'- 6" 38'- 10" 45' (4)- 10' (1)- 3' 18' 4" 40'- 7½" 9

12 Outload Conveyor Head Repair Parts 16" Outload Conveyor Spout Weldment Lagged Roller 6" 2 A Shaft 1 5/16" x 27 1/2" Bearing 1 5/16" 2B Fl Head Frame Motor Mount V-Belt B Sheave 2B 18.4 SK Guard End Cover Guard Bracket Guard 24" Outload Conveyor Spout Weldment Lagged Roller 6" w/shaft Bearing 1 5/16" 2B Fl Head Frame Motor Mount V-Belt B Sheave 2B 18.4 SK Guard End Cover Guard Bracket Guard 10

13 Outload Conveyor Tail Repair Parts 16" Outload Conveyor Lagged Roller 3 1/2" w/shaft Bearing 1 5/16" PB Zerk 1/4"-28 x 17/32" Take-up Tube Take-up Base Take-up Bracket LH Take-up Bracket RH Square Nut 3/4" Guide Strap Guide Skirtboard Back-up Strap Hopper Weldment Hopper Wiper Hopper Wiper Strap Wear Plate Screw #10-24 x ½" Slotted Flat Machine SS Hex Nut #10-24 SS 24" Outload Conveyor Lagged Roller 3 1/2" Bearing 1 5/16" PB Zerk 1/4"-28 x 17/32" Take-up Tube Take-up Base Take-up Bracket LH Take-up Bracket RH Square Nut 3/4" Guide Strap Guide Skirtboard Back-up Strap Hopper Weldment Hopper Wiper Hopper Wiper Strap Wear Plate Screw #10-24 x ½" Slotted Flat Machine SS Hex Nut #10-24 SS 11

14 16'' Pan Repair Parts 3' Pan '-16" Covered Pan Bundle '-16" Pan Assembly '-16" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 16" ' Weather Cover " Cover Strap 4' Pan '-16" Covered Pan Bundle '-16" Pan Assembly '-16" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 16" ' Weather Cover " Cover Strap 5' Pan '-16" Covered Pan Bundle '-16" Pan Assembly '-16" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 16" ' Weather Cover " Cover Strap 7' Pan '-16" Covered Pan Bundle '-16" Pan Assembly '-16" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 16" ' Cover " Cover Strap 6' Pan '-16" Covered Pan Bundle '-16" Pan Assembly '-16" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 16" ' Weather Cover " Cover Strap 10' Pan '-16" Covered Pan Bundle '-16" Pan Assembly '-16" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 16" ' Weather Cover " Cover Strap " Cover Strap 12

15 24'' Pan Repair Parts 3' Pan '-24" Covered Pan Bundle '-24" Pan Assembly '-24" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 24" ' Weather Cover " Cover Strap 4' Pan '-24" Covered Pan Bundle '-24" Pan Assembly '-24" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 24" ' Weather Cover " Cover Strap 5' Pan '-24" Covered Pan Bundle '-24" Pan Assembly '-24" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 24" ' Weather Cover " Cover Strap 7' Pan '-24" Covered Pan Bundle '-24" Pan Assembly '-24" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 24" ' Cover " Cover Strap 6' Pan '-24" Covered Pan Bundle '-24" Pan Assembly '-24" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 24" ' Weather Cover " Cover Strap 10' Pan '-24" Covered Pan Bundle '-24" Pan Assembly '-24" Pan Weldment Roller 2 x Roller Clip Spreader Roller Bracket Roller 2 3/8" x 24" ' Weather Cover " Cover Strap " Cover Strap 13

16 Support Stand Repair Parts 25' thru 33' Stand Support Angle Truss Rod 10' Lower Truss Arm 60½" Leg 10' Upper Truss Arm 64" Stand Angle Short Cross Brace 82" Cross Brace Angle Leg Extension 60" HOLE ALIGN- MENT CONVEYOR LENGTH 25' 26' 27' 28' 29' 30' 31' 32' 33' A C D E F G H I J K M (16") B C D E F G H I J M (24") C D E F G H I J K 14

17 Support Stand Repair Parts 34' thru 38' Stand Support Angle Truss Rod 10' Lower Truss Arm 84½" Leg 14' Upper Truss Arm 167¼" Stand Angle Long Cross Brace 135" Cross Brace Angle Leg Extension 60" HOLE ALIGN- MENT CONVEYOR LENGTH 34' 35' 36' 37' 38' A C D E F G N (16") O O O O O N (24") P P P P P M B C D E F 15

18 Support Stand Repair Parts 39' thru 42' Stand Support Angle Truss Rod 10' Lower Truss Arm 84½" Leg 14' Upper Truss Arm 64" Stand Angle Long Cross Brace 135" Cross Brace Angle Leg Extension 60" HOLE ALIGN- MENT CONVEYOR LENGTH 39' 40' 41' 42' A H I J K N (16") O O O O N (24") P P P P M G H I J R (16") S S S S R (24") T T T T Q B C D E 16

19 Support Stand Repair Parts 45' x 24" Stand Support Angle Truss Rod 10' Lower Truss Arm 88½" Leg 14' Upper Truss Arm 95" Stand Angle Long Cross Brace 135" Cross Brace Angle Leg Extension 60" HOLE ALIGN- MENT A N M R Q CONVEYOR LENGTH 45' K P G T E 17

20 Telescoping Spout Repair Parts Spout Weldment Hex Nut 3/8" SS Eyebolt 3/8" x 2 ½" Cable Clamp 3/16" Swivel Pulley 1 ½" HHCS 1/4" x ½" SS Lock Washer 1/4" SS Hex Nut 1/4" SS Cable 3/16"x7"x19"xFt HHCS 3/8" x 1" SS Lock Washer 3/8" SS Winch Mount " Vinyl Cap Cable Pulley Plate Cable Winch Winch Handle Lock Pin HHCS 1/4" x 3/4" SS Flat Washer 1" Roll Pin 5/16" x 1 3/4" Hair Pin Flat Washer 3/8" SS 18

21 Outload Conveyor Head Assembly Guard Bracket Locations STEP #1 Assemble the head frame weldment "A" to the TR section "B" using hardware attached to the section. STEP #2 Attach the spout "C" to head frame "A" using five (5) 5/16" x 1" carriage bolts and hex nuts. (The hole and bolt shown in spout attaches to guard bracket in STEP #7. STEP #3 Assemble electric motor to motor mount "C" using four (4) 3/8" x 1 3/4" stainless steel bolts, flat washers, and hex nuts. LEAVE THESE FASTENERS LOOSE. STEP #4 Assemble sheave, bushing, and key "D" to the motor. Assemble sheave, bushing, and key "F" to the drive shaft. LEAVE THE SHEAVES AND BUSHINGS LOOSE. Using a straight edge, align the two (2) sheaves and secure the motor mount bolts and the bushings. STEP #5 Assemble the V-belts and tighten using the motor mount take-up bolt. STEP #6 Assemble the belt guard end cap "G" to the belt guard body "H" using four (4) 1/4" x 1/2" stainless steel bolts and four (4) 1/4" stainless steel hex nuts. STEP #7 Using the "Belt Guard Bracket Location" diagram as a guide, attach the guard assembly to head frame using three (3) belt guard biackets "I" and six (6) 5/16" x 1" stainless steel bolts, flat washers, and hex nuts. STEP #8 Check for clearance between guard, belts, and sheaves before operating. 19

22 Outload Conveyor Tail Assembly STEP #1 Using the hardware attached to the TR section, assemble the take-up assembly "A" to the TR section "B". Attach the hopper "C" to TR section "B" by inserting 5/16" x 1" HHCS into top corner of TR section and insert and tighten front bolts of hopper into each side of TR section. STEP #2 Secure the spout to section as shown using the 5/16" x 1" bolts attached to sides of spout. 20

23 Outload Conveyor Stand Assembly (Suggested Assembly) STEP #1 Refer to stand support locations on pages Assemble angle "A" to conveyor and angle "B" to conveyor with 3/8" x 1" HHCS and nylocks. STEP #2 Using 1/2" hardware, assemble channel iron legs "C" to angle "B" loosely allowing legs to rotate into place as TR is lifted. STEP #3 Attach leg "D" to leg "C" and remainder of trussing. Make sure all fasteners are tight and set. Anchor TR into place. 21

24 Outload Conveyor Weather Cover Assembly 22 STEP #1 Starting at the tail or take-up end, install the first weather cover 1" up from the edge of the pan section. (Make sure dimple is UP.) STEP #2 Where each pan section is bolted together, you will install a 4" weather cover strap. Simply slide the next weather cover up against the one previously installed (Make sure dimples are correct) and fit the cover strap into place. Secure using four (4) 1/4" x 3/4" stainless steel carriage bolts, flat washers, and hex nuts. STEP #3 Run a bead of silicone between the leading edge of the weather cover strap and the "up" dimple.

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26 P.O.Box 1438 Dodge City, Kansas (620)