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AGI HI ROLLER Original Instructions Manual

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BELT CONVEYORS
HI ROLLER, MINI ROLLER, LO ROLLER & HI LIFE
ASSEMBLY, OPERATION, & MAINTENANCE
NORTH AMERICAN VERSION
ORIGINAL INSTRUCTIONS
A division of AgGrowth Industries: 4511 N Northview Ave, Sioux Falls, SD 57107
Toll free (US & Canada): 800-328-1785 / Phone: 605-332-3200 / Fax: 605-332-1107
www.hiroller.com / e-mail: sales@hiroller.com
Read this manual before using product. Failure
to follow instructions and safety precautions can
result in serious injury, death, or property
damage. Keep manual for future reference.
Part Number: P115506 R3
Revised: 12/10/16

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  • Page 1 BELT CONVEYORS HI ROLLER, MINI ROLLER, LO ROLLER & HI LIFE ASSEMBLY, OPERATION, & MAINTENANCE NORTH AMERICAN VERSION ORIGINAL INSTRUCTIONS A division of AgGrowth Industries: 4511 N Northview Ave, Sioux Falls, SD 57107 Toll free (US & Canada): 800-328-1785 / Phone: 605-332-3200 / Fax: 605-332-1107 www.hiroller.com / e-mail: sales@hiroller.com...
  • Page 2 This product has been designed and constructed according to general engineering standards . Other local regulations may apply and must be followed by the operator. We strongly recommend that all personnel associated with this equipment be trained in the correct operational and safety procedures required for this product. Periodic reviews of this manual with all employees should be standard practice.

  • Page 3: Table Of Contents

    OLLER ONVEYORS & H OLLER OLLER OLLER TABLE OF CONTENTS 1. Introduction .......................... 7 1.1. General Description....................8 2. Safety ............................ 9 2.1. General Safety Information ..................9 2.2. Installation Safety ....................10 2.3. Operational Safety....................11 2.4. Maintenance Safety....................11 2.4.1.
  • Page 4 OLLER ONVEYORS & H OLLER OLLER OLLER TABLE OF CONTENTS 5. Installation .......................... 35 5.1. Pre-Installation......................35 5.2. Head End & Tail End Trunking Installation............. 35 5.2.1. Head Section Mounting ................35 5.2.2. Tail Section Mounting ................37 5.2.3. Trunking Installation.................. 37 5.2.4.
  • Page 5 7.1.2. Lubrication Schedule ................83 7.2. Belt Tracking Guide....................84 7.2.1. Belt Tracking - Hi Roller & Mini Roller Models.......... 85 7.2.2. Belt Tracking - Hi Life Models..............89 7.2.3. Belt Tracking - Lo Roller & Hi Bulk Models..........91 7.2.4.
  • Page 6 OLLER ONVEYORS & H OLLER OLLER OLLER P115506 R3...

  • Page 7: Introduction

    Always give your dealer the serial number of your Hi Roller EBC when ordering parts or requesting service or other information.

  • Page 8: General Description

    OLLER OLLER 1.1. GENERAL DESCRIPTION Hi Roller® Conveyors are totally enclosed and self-cleaning belt conveyors. The conveyors are designed to convey granular, dry (non-sticking) bulk materials which are not excessively abrasive or corrosive; i.e. grains, oilseeds, absorbent clays, borax, fertilizers, etc.; while containing any fugitive dust and spillage from the conveyor.

  • Page 9: Safety

    2. S OLLER ONVEYORS AFETY & H 2.1. G OLLER OLLER OLLER ENERAL AFETY NFORMATION 2. Safety 2.1. GENERAL SAFETY INFORMATION The Safety Alert symbol identifies important safety messages on the product and in the manual. When you see this symbol, be alert to the possibility of personal injury or death.

  • Page 10: Installation Safety

    2. S AFETY OLLER ONVEYORS 2.2. I & H NSTALLATION AFETY OLLER OLLER OLLER YOU are responsible for the SAFE use and maintenance of your equipment. YOU must ensure that you and anyone else who is going to work around the equipment understands all procedures and related SAFETY information contained in this manual.

  • Page 11: Operational Safety

    9. The v-plow must be adjusted after the conveyor belt has been installed and properly tensioned. 2.3. OPERATIONAL SAFETY 1. Aspiration is very important to the proper operation of a Hi Roller Conveyor. Each conveyor should have adequate aspiration to maintain a slight negative pressure inside the enclosure.

  • Page 12: Lockout And Tagout Procedures

    AFETY OLLER OLLER OLLER 8. Preventative maintenance on a regular basis is very important to the proper operation of a Hi Roller Conveyor. 9. Maintenance should only be performed under normal ambient lighting or daylight. 2.4.1. L OCKOUT AND AGOUT...

  • Page 13: Safety Decal Locations And Details

    2. S OLLER ONVEYORS AFETY & H 2.6. S OLLER OLLER OLLER AFETY ECALS 2. Decide on the exact position before you remove the backing paper. 3. Align the decal over the specified area and carefully press the small portion with the exposed sticky backing in place.
  • Page 14 2. S AFETY OLLER ONVEYORS 2.6. S & H AFETY ECALS OLLER OLLER OLLER INSTALL ON OR BESIDE GUARD, DEPENDING ON AVAILABLE SPACE P115512 INSTALL NEAR EMERGENCY HANDLE P115522 P115506 R3...
  • Page 15 2. S OLLER ONVEYORS AFETY & H 2.6. S OLLER OLLER OLLER AFETY ECALS GENERAL EQUIPMENT LABEL - INSTALL ON CONVEYOR SPOUT P115513 INSTALL NEAR CONVEYOR DISCHARGE P115514 INSTALL NEAR CONVEYOR ELECTRIC MOTOR P115515 P115506 R3...
  • Page 16 2. S AFETY OLLER ONVEYORS 2.6. S & H AFETY ECALS OLLER OLLER OLLER P115528 INSTALL NEAR INLET(S) P115524 P115516 P115506 R3...

  • Page 17: Conveyor Components

    3. C OLLER ONVEYORS ONVEYOR OMPONENTS & H 3.1. O OLLER OLLER OLLER PERATOR RIENTATION 3. Conveyor Components FITTED WITH CLAMPS FOR A NORTH AMERICAN MARKET FITTED WITH CLAMPS FOR AN INTERNATIONAL MARKET 3.1. OPERATOR ORIENTATION STANDARD ORIENTATION: TO DETERMINE REVERSIBLE CONVEYOR ORIENTATION: TO DETERMINE RIGHT AND LEFT, STAND BY TAIL SECTION RIGHT AND LEFT, STAND AT NON-DRIVE SECTION, AND...

  • Page 18: Head Sections & Discharges

    Figure 3.1 Standard Discharge Figure 3.2 Snubber Head Section Discharge 3.2.2. M & D OTOR RIVE OUNTINGS Hi Roller mounts most factory supplied motors and reducers according to manufacturers specifications. Figure 3.3 shows a right-hand mounted drive. P115506 R3...

  • Page 19: Trunking Sections

    3. C OLLER ONVEYORS ONVEYOR OMPONENTS & H 3.2. C OLLER OLLER OLLER OMPONENT Figure 3.3 Note: The shaft mount drive with synchronous cog-belt (Figure 3.3) is the most common type of drive. The in-line drive with synchronous cog-belt final drive belt and in-line drive with direct coupled drive (not shown) are not as common.

  • Page 20: Covers

    3. C ONVEYOR OMPONENTS OLLER ONVEYORS 3.2. C & H OMPONENT OLLER OLLER OLLER Figure 3.5 Note: For ease of assembly, sections are labeled and numbered starting with 1 on the tail section. 3.2.4. C OVERS Covers are made to fit over the width of the conveyor and 5’ of a section. 5’...
  • Page 21 3. C OLLER ONVEYORS ONVEYOR OMPONENTS & H 3.2. C OLLER OLLER OLLER OMPONENT Figure 3.7 NSPECTION OORS • For trunking, head, tail, and inlet/loader Figure 3.8 P115506 R3...

  • Page 22: Inlets/Loader

    Off-center loading is harmful to the belt, idlers, and shafting, and will cause belt- alignment problems. Custom loaders can be designed for specific overhead clearance considerations. Contact Hi Roller’s engineering department. ATES Gates control the flow of material down the back slope of the inlet when the gate opens (Figure 3.10).

  • Page 23: V-Plow

    3. C OLLER ONVEYORS ONVEYOR OMPONENTS & H 3.2. C OLLER OLLER OLLER OMPONENT Figure 3.11 3.2.6. V-P The v-plow is located just in front of the tail pulley. The v-plow: • acts as a dam to hold back large amounts of spilled material that would plug the conveyor, and •...

  • Page 24: Tail Sections

    3. C ONVEYOR OMPONENTS OLLER ONVEYORS 3.2. C & H OMPONENT OLLER OLLER OLLER 3.2.7. T ECTIONS Figure 3.13 Standard Tail Section w/ Inner & Outer Box Take-Up 3.2.8. T ECTIONS There is one take-up rod on each side of the take-up section on the centerline of the tail shaft bearings and they are used to tighten the belt (Figure 3.14).
  • Page 25 3. C OLLER ONVEYORS ONVEYOR OMPONENTS & H 3.2. C OLLER OLLER OLLER OMPONENT Figure 3.16 Head Take-Up Sections w/ Sliding Bearing Mounts & Rods P115506 R3...
  • Page 26 3. C ONVEYOR OMPONENTS OLLER ONVEYORS 3.2. C & H OMPONENT OLLER OLLER OLLER P115506 R3...

  • Page 27: Application Design Considerations

    Hi Roller's engineering department. • Capacity: Inclined conveyors of any type will not convey the same amount of material as a flat horizontal conveyor. Hi Roller's engineering department will calculate the capacity of a specific application.

  • Page 28: Clearances

    4. A PPLICATION ESIGN ONSIDERATIONS OLLER ONVEYORS 4.2. C & H LEARANCES OLLER OLLER OLLER OIST ATERIAL • A 2356 cfm system based on two 6” lines at approximately 6000 fpm is required to keep the lines clean. The aspiration lines will have to be insulated to eliminate condensation on the inside of the lines.

  • Page 29: Discharge Considerations

    4.4. INCLINES • Gradual: Hi Roller Conveyors can be installed with a gradual up-bend. This is the lowest cost, horsepower, and maintenance option. Hi Roller's engineering department must complete design calculations to determine the amount of gradual up-bend that can be installed on a specific application.

  • Page 30: Loading Considerations

    4. A PPLICATION ESIGN ONSIDERATIONS OLLER ONVEYORS 4.6. L & H OADING ONSIDERATIONS OLLER OLLER OLLER Figure 4.3 4.6. LOADING CONSIDERATIONS The loader must be placed on the conveyor trunking so it will load in the same direction of belt travel. It is at the loading point that the conveyor belt receives major abrasion and almost all of its impact.

  • Page 31: Special Loading Applications

    A deflecting baffle or backplate should be placed in the loader to keep the material from rolling backward and spilling on the belt. Hi Roller's engineering department must be consulted for a properly designed and installed special loader.
  • Page 32 4. A PPLICATION ESIGN ONSIDERATIONS OLLER ONVEYORS 4.6. L & H OADING ONSIDERATIONS OLLER OLLER OLLER 8. For a 45° inlet, material must flow down the back slope of the inlet when the gate opens to ensure an even flow that properly acceleration with the speed of the belt (Figure 4.5).

  • Page 33: Splices

    • Mechanical: Flexco splices are standard on Hi Roller Conveyors. Different types of Flexco splices are recommended for each application. • Vulcanized: Hi Roller recommends that a mechanical splice is used during the first year of operation. The belt should be stretched and stabilized before a permanent vulcanized splice is installed because of the limited length of the take-up section of the conveyor.
  • Page 34 4. A PPLICATION ESIGN ONSIDERATIONS OLLER ONVEYORS 4.9. G & H ROUNDING OLLER OLLER OLLER P115506 R3...

  • Page 35: Installation

    Safety information is provided to help prevent serious injury, death, or property damage. Proper installation of the Hi Roller Conveyor is very important. By following the basic rules and planning for installation, start-up problems will be reduced dramatically.
  • Page 36 5. I NSTALLATION OLLER ONVEYORS 5.2. H & T & H RUNKING NSTALLATION OLLER OLLER OLLER TANDARD ECTION Mounting supports can be attached to the bearing mounting vertical plate or the bottom head section bolted connections of the standard head section as shown in Figure 5.1.

  • Page 37: Tail Section Mounting

    5. I OLLER ONVEYORS NSTALLATION & H 5.2. H & T OLLER OLLER OLLER RUNKING NSTALLATION 5.2.2. T ECTION OUNTING The tail section must be properly supported so there is no vertical or horizontal movement of the inner box of the take-up section. The support structure should be attached to the angle vertical flange of the inner box (left, top picture), or the angle bottom...
  • Page 38 5. I NSTALLATION OLLER ONVEYORS 5.2. H & T & H RUNKING NSTALLATION OLLER OLLER OLLER NOTICE Trunking must be installed straight and level with a tolerance less than +/- 1/8” over the entire length of the conveyor. Figure 5.4 2.

  • Page 39: Tail Section Back Cover Removal & Installation

    5. I OLLER ONVEYORS NSTALLATION & H 5.2. H & T OLLER OLLER OLLER RUNKING NSTALLATION 6. Support legs, feet, and support hangers. Trunking sections must be well supported every 20’ of the length of the conveyor. Important: Support structures and legs must never be welded to the trunking sidewalls or flanges.

  • Page 40: Inlet/Loader Installation

    5. I NSTALLATION OLLER ONVEYORS 5.3. I & H NLET OADER NSTALLATION OLLER OLLER OLLER Figure 5.9 4. The installation is the reverse of the removal. The security bolt must be removed by a mechanical technician. 5.3. INLET/LOADER INSTALLATION NOTICE Loaders/inlets must be installed properly to achieve proper loading of the belt.

  • Page 41: Skirt Installation

    5. I OLLER ONVEYORS NSTALLATION & H 5.3. I OLLER OLLER OLLER NLET OADER NSTALLATION 5.3.1. S KIRT NSTALLATION The skirts prevent side spillage of material and keep the load centered on the belt. Generally, the maximum distance between skirt boards is two-thirds the width of a troughed belt.

  • Page 42: Discharge Considerations

    5. I NSTALLATION OLLER ONVEYORS 5.4. B & H NSTALLATION OLLER OLLER OLLER The swing-down skirts are shown folded up, as viewed from the conveyor top (also see Figure 3.11 on page 23). 5.3.2. D ISCHARGE ONSIDERATIONS • Spouting angles: Materials flow differently in spouting. The proper angle must be maintained so that the material will flow freely in the spout.
  • Page 43 5. I OLLER ONVEYORS NSTALLATION & H 5.4. B OLLER OLLER OLLER NSTALLATION Note: If the conveyor is equipped with an intermediate discharge tripper, string belt according to Figure 5.12. Figure 5.12 2. Place a 2" x 12" wood plank or equivalent width on the trunking section (see Figure 5.13).
  • Page 44 5. I NSTALLATION OLLER ONVEYORS 5.4. B & H NSTALLATION OLLER OLLER OLLER Figure 5.14 4. Square the belt ends. (See Figure 5.15.) a. Use a double arc to establish a cut line on the belt. Using the centerline drawn on the belt, pick a point on the line at least two times the belt width. b.
  • Page 45 5. I OLLER ONVEYORS NSTALLATION & H 5.4. B OLLER OLLER OLLER NSTALLATION Figure 5.15 5. Check that the belt cut is square. (See Figure 5.16.) a. Measure lengthwise 50” or more from each edge of the belt using exactly the same measurement on either side.

  • Page 46: Splice Protector / Wiper Cleats

    / bottom of trunking. The splice protectors / wiper cleats are extremely important to the proper operation of the Hi Roller Conveyor. These cleats protect the splice from prema- turely wearing out from sliding on the bottom return liner. The cleats also clean the bottom liner as the belt slides back to the tail section.
  • Page 47 5. I OLLER ONVEYORS NSTALLATION & H 5.4. B OLLER OLLER OLLER NSTALLATION Figure 5.17 Specifications Table 5.1 Belt Splice Protector / Wiper Cleat Spacing Belt No. Pads ECFT Bolts Dim. A Dim. B Width 12” 3/16” 3/16” 16” 1/4” 3/16”...

  • Page 48: Lubrication

    • The belt is tightened with the take-up rods that are located on the centerline of the tail pulley. Adjust these rods evenly to prevent misalignment of the tail pulley. Belt tension is very important for the proper operation of a Hi Roller Conveyor. P115506 R3...
  • Page 49 5. I OLLER ONVEYORS NSTALLATION & H 5.4. B OLLER OLLER OLLER NSTALLATION • The belt must be tightened to the proper specifications. Belt tension must be checked daily for the first several days, and then weekly until the belt has sta- bilized and adjustments are not required.
  • Page 50 5. I NSTALLATION OLLER ONVEYORS 5.4. B & H NSTALLATION OLLER OLLER OLLER Figure 5.19 P115506 R3...

  • Page 51: Normal Idler Wear

    ORMAL DLER • Normal Idler Wear - Hi Roller idler wear should not be evident in the weld area; a good rule of thumb is that the paint should not be worn off within 1” of the weld area (Figure 5.20).

  • Page 52: Leveling Tail Take-Up Section

    5. I NSTALLATION OLLER ONVEYORS 5.5. L & H EVELING ECTION OLLER OLLER OLLER 5.5. LEVELING TAIL TAKE-UP SECTION Important: Take-up rods, nuts, and washer areas must be properly lubricated. Level tail with leveling rod. Figure 5.21 5.6. V-PLOW ADJUSTMENT Important: The v-plow must be adjusted after the conveyor belt has been installed and properly tensioned.

  • Page 53: Cover Installation

    All of the covers that are going to be made-to-length must be measured using the same procedure; the location of each of these covers should be noted. These measurements need to be called in or sent to the Hi Roller engineering department.

  • Page 54: Cut-To-Length Covers

    5. I NSTALLATION OLLER ONVEYORS 5.7. C & H OVER NSTALLATION OLLER OLLER OLLER Figure 5.25 Figure 5.26 5.7.2. C ENGTH OVERS 1. To measure, determine the length from the cover channel flange that the cover will fit over as shown Figure 5.24. In the figure, the measurement below this length is 24".

  • Page 55: Cover Hardware

    5. I OLLER ONVEYORS NSTALLATION & H 5.7. C OLLER OLLER OLLER OVER NSTALLATION 2. Cut the cover 1" shorter than the required finished cover and grind edges smooth. With a 24” measurement, the cover will be cut to 23", which is 1" shorter than required for the finished cover.

  • Page 56: Drive & Motor Final Check Before Start-Up

    Hazard monitors must be installed and tested to ensure proper operation. Hazard monitors must be installed correctly to ensure proper operation. Hi Roller Conveyors recommends the properly located and installed use of these monitoring devices when specified by the application: Monitors must be wired properly into the control circuits so that the conveyor shuts down when a misalignment, bearing failure, etc.
  • Page 57 5. I OLLER ONVEYORS NSTALLATION & H 5.9. H OLLER OLLER OLLER AZARD ONITORING EVICES Figure 5.30 Figure 5.31 P115506 R3...

  • Page 58: Plug Switch

    5. I NSTALLATION OLLER ONVEYORS 5.9. H & H AZARD ONITORING EVICES OLLER OLLER OLLER 5.9.2. P WITCH Properly installed and tested plug switches must be included in the design. Figure 5.32 Figure 5.33 P115506 R3...

  • Page 59: Belt Alignment Monitors

    5. I OLLER ONVEYORS NSTALLATION & H 5.9. H OLLER OLLER OLLER AZARD ONITORING EVICES 5.9.3. B LIGNMENT ONITORS Note: The belt must be properly installed and tracked before belt alignment monitors can be installed. Refer to Section 5.4. Note: Model number equals the width of the belt.
  • Page 60 5. I NSTALLATION OLLER ONVEYORS 5.9. H & H AZARD ONITORING EVICES OLLER OLLER OLLER (Figure 5.35) NUBBER ECTION • The head pulley and belt alignment can be monitored with one rub block installed near the top centerline of the head pulley to detect a belt and head pulley misalignment.
  • Page 61 5. I OLLER ONVEYORS NSTALLATION & H 5.9. H OLLER OLLER OLLER AZARD ONITORING EVICES Figure 5.36) ECTION • The head pulley and belt alignment can be monitored with one rub block installed near the front centerline of the head pulley on the take-up slide plate to detect a belt and head pulley misalignment.
  • Page 62 5. I NSTALLATION OLLER ONVEYORS 5.9. H & H AZARD ONITORING EVICES OLLER OLLER OLLER Figure 5.37) EVERSIBLE RIVE ECTION • The drive pulley alignment can be monitored with one surface mounted sen- sor block installed near the front centerline of the drive pulley to detect a drive pulley misalignment.
  • Page 63 5. I OLLER ONVEYORS NSTALLATION & H 5.9. H OLLER OLLER OLLER AZARD ONITORING EVICES —N Figure 5.38) EVERSIBLE RIVE ECTION • The non-drive pulley alignment can be monitored with one surface mounted sensor block installed near the front centerline of the non-drive pulley to detect a non-drive pulley misalignment.
  • Page 64 5. I NSTALLATION OLLER ONVEYORS 5.9. H & H AZARD ONITORING EVICES OLLER OLLER OLLER —E (Figure 5.39) EVERSIBLE RIVE ECTION XISTING • The non-drive pulley alignment can be monitored with one surface mounted sensor block installed near the front centerline of the non-drive pulley to detect a non-drive pulley misalignment.
  • Page 65 5. I OLLER ONVEYORS NSTALLATION & H 5.9. H OLLER OLLER OLLER AZARD ONITORING EVICES & T —N Figure 5.40) TANDARD ECTION • The tail pulley alignment can be monitored with one surface mounted sensor block installed near the top centerline of the tail pulley to detect a tail pulley misalignment.
  • Page 66 5. I NSTALLATION OLLER ONVEYORS 5.9. H & H AZARD ONITORING EVICES OLLER OLLER OLLER & T —E Figure 5.41) TANDARD ECTION XISTING • The tail pulley alignment can be monitored with one surface mounted sensor block installed near the top centerline of the tail pulley to detect a tail pulley misalignment.
  • Page 67 5. I OLLER ONVEYORS NSTALLATION & H 5.9. H OLLER OLLER OLLER AZARD ONITORING EVICES —N & E Figure 5.42) ECTION XISTING • The tail pulley alignment can be monitored with one surface mounted sensor block installed near the top centerline of the tail pulley to detect a tail pulley misalignment.

  • Page 68: Belt & Pulley Alignment Monitors

    • EXISTING—The tripper top and bottom pulleys can be monitored similar to the mounting in Figure 5.43. However, the mounting locations must be reviewed by Hi Roller Conveyors. Each existing tripper section will have to be reviewed and specifications will be required for each type. Please contact Hi Roller Conveyors.
  • Page 69 All applications require different shim arrangements to properly locate the rub blocks. The number of shims will vary depending on the mounting and appli- cation. Please contact Hi Roller Conveyors to confirm the proper location and mounting of these devices.
  • Page 70 5. I NSTALLATION OLLER ONVEYORS 5.9. H & H AZARD ONITORING EVICES OLLER OLLER OLLER Figure 5.46 Brass Rub Block Mounting w/ Outer Shims & S TANDARD ECTIONS NUBBER ECTIONS Figure 5.47 P115506 R3...
  • Page 71 5. I OLLER ONVEYORS NSTALLATION & H 5.9. H OLLER OLLER OLLER AZARD ONITORING EVICES TANDARD RUNKING ECTIONS Figure 5.48 TANDARD ECTIONS Figure 5.49 YPICAL URFACE OUNT ENSORS Figure 5.50 shows a typical wiring harness with a temperature sensor molded in the end of the washer type end.
  • Page 72 Figure 5.51 and 5.52 show the mounting of a surface mounted sensor on the side of a tail and head section of a Hi Roller Conveyor. Please note that the proper location is very important. All applications require different arrangements to properly monitor the pulley.
  • Page 73 5. I OLLER ONVEYORS NSTALLATION & H 5.9. H OLLER OLLER OLLER AZARD ONITORING EVICES Figure 5.53 EARING ONITORS There are many different types of bearing monitors that can be used to monitor the head, snubber, tripper, and tail bearings. The customer must specify the supplier of these devices.

  • Page 74: Final Checklist

    5. I NSTALLATION OLLER ONVEYORS 5.10. F & H INAL HECKLIST OLLER OLLER OLLER 5.10. FINAL CHECKLIST Complete final checklist and file with management. CAUTION Complete the final inspection checklist before start-up to ensure proper and safe operation of the conveyor. Head Section Properly installed w/ clearances around head section, bearings, motor, drive, etc.
  • Page 75 5. I OLLER ONVEYORS NSTALLATION & H 5.10. F OLLER OLLER OLLER INAL HECKLIST Control gates installed properly so material flow directed down backplate of loader. Control gates open from the back toward the front of the loader. Side loading controlled by a control gate. High velocity flow slowed and controlled.

  • Page 76: Test Start-Up

    5. Visually check tail section and v-plow. 6. Visually check intermediate trunking sections. 7. Operate while personnel visually check all sections. Important: Regular inspections and preventative maintenance are very important to the proper operation of a Hi Roller Conveyor. P115506 R3...
  • Page 77 OLLER OLLER INAL NSPECTION URING PERATION Please fill out the information below and send a copy  by mail or fax to Hi Roller Conveyors. Conveyor Owner/Company ___________________________________ Contact __________________________________________________ Address __________________________________________________ City _____________________________________________________ Zip/Postal Code ____________________________________________ PHONE: _________________________FAX: ___________________...
  • Page 78 5. I NSTALLATION OLLER ONVEYORS 5.12. F & H INAL NSPECTION URING PERATION OLLER OLLER OLLER P115506 R3...

  • Page 79: Operation

    6. O OLLER ONVEYORS PERATION & H 6.1. P OLLER OLLER OLLER PERATIONAL HECKLIST 6. Operation WARNING Before continuing, ensure you have read and understand the relevant information in the safety section. Safety information is provided to help prevent serious injury, death, or property damage.

  • Page 80: Operating With A Full Load

    6. O PERATION OLLER ONVEYORS 6.3. O & H PERATING ROCEDURE OLLER OLLER OLLER 5. The conveyor should be inspected from the head section to the tail section to be sure everything is operating properly. 6. Make sure to inspect belt tracking, loading, discharging, clearances, self- cleaning, reloading, etc.

  • Page 81: Operating Tips

    6. O OLLER ONVEYORS PERATION & H 6.3. O OLLER OLLER OLLER PERATING ROCEDURE 6.3.4. O PERATING • Always listen for any unusual sounds or noises. If any are heard, stop the machine and determine the source. Correct the problem before resuming work.
  • Page 82 6. O PERATION OLLER ONVEYORS 6.3. O & H PERATING ROCEDURE OLLER OLLER OLLER P115506 R3...

  • Page 83: Maintenance

    Important: Bearings must be properly lubricated and checked weekly to ensure proper operation. Hi Roller Conveyors are installed in many different types of applications. A lubri- cation schedule must be developed for each application. P115506 R3...

  • Page 84: Belt Tracking Guide

    (included in the supplied with the con- veyor). • The idler bearing lubrication schedule will vary by model, size, and belt speed. See Table 7.2 for idler shaft speeds. Table 7.2 Idler Shaft Speeds - Hi Roller Conveyors - All Models rpm@350 rpm@700 Model Size Idler Dia.

  • Page 85: Belt Tracking - Hi Roller & Mini Roller Models

    7. M OLLER ONVEYORS AINTENANCE & H 7.2. B OLLER OLLER OLLER RACKING UIDE • The normal sequence of training is to start with the return run working toward the tail pulley, followed by a top run in the direction of belt travel. Start with the belt empty.
  • Page 86 7. M AINTENANCE OLLER ONVEYORS 7.2. B & H RACKING UIDE OLLER OLLER OLLER Figure 7.1 & T ULLEYS Belt tracking is adjusted at the head and tail pulley by changing the position of the pulleys. This can be done with two different adjustments: 1.
  • Page 87 All of these must check out before attempting to train the belt with the idlers. 1. Hi Roller and Mini Roller idler adjustments are completed by loosening the two bearing retainer bolts. This should be done on the bearing that is easiest to work on.
  • Page 88 7. M AINTENANCE OLLER ONVEYORS 7.2. B & H RACKING UIDE OLLER OLLER OLLER Figure 7.3 4. If the belt is tracking to the right in the conveyor, the end of the idler should be shifted in "A" position. If the belt is tracking to the left, shift the end of the idler in the "B"...

  • Page 89: Belt Tracking - Hi Life Models

    7. M OLLER ONVEYORS AINTENANCE & H 7.2. B OLLER OLLER OLLER RACKING UIDE 7.2.2. B RACKING ODELS Remember, squareness of the conveyor must be checked. Idlers must be checked to be sure that they have not become loose during shipping or installation.
  • Page 90 7. M AINTENANCE OLLER ONVEYORS 7.2. B & H RACKING UIDE OLLER OLLER OLLER 2. The nuts on the inside of the conveyor are welded to a nut clip so that these nuts will not have to be held in order to loosen the bearing bolts. After loosening these bolts, the end of the flat-horizontal idler can be shifted either forward or backward.

  • Page 91: Belt Tracking - Lo Roller & Hi Bulk Models

    7. M OLLER ONVEYORS AINTENANCE & H 7.2. B OLLER OLLER OLLER RACKING UIDE 7.2.3. B & H RACKING OLLER ODELS Remember, squareness of the conveyor must be checked. Idlers must be checked to be sure that they have not become loose during shipping or installation.
  • Page 92 7. M AINTENANCE OLLER ONVEYORS 7.2. B & H RACKING UIDE OLLER OLLER OLLER Figure 7.9 3. If the belt is tracking to the right in the conveyor, the end of the idler should be shifted in "A" position. If the belt is tracking to the left, the end of the idler should be shifted in "B"...

  • Page 93: Belt Tracking Misalignments

    1. The belt may not be contacting the center flat area of the idlers. This can be caused by a stiff belt. This must be corrected; review belt specifications with Hi Roller engineering department. 2. The above points 2 - 6 also apply to an empty belt.

  • Page 94: Skew (Bow)

    In a straight warp or solid woven carcass, skew is of little significance. It is usually a cosmetic defect and is not indicative of a cambered belt. 7.3. IDLER REPLACEMENT - HI ROLLER MODELS Figure 7.11 Hi Roller Idler and Typical Trunking P115506 R3...
  • Page 95 7.12. Note: Stand is shown for the larger Hi Roller idlers - Models 26 to 54. Models 18 and 22 require a stand with a 20” opening. 4. Remove idler up through the top of the trunking with belt raised up and held with stand as shown in Figure 7.12.
  • Page 96 OLLER OLLER 11. In some cases, the inlet/loader skirts, crossbraces, and other components may have to be removed for proper clearance to replace the Hi Roller idler. Figure 7.13 Note: The crossbrace and come-a-longs in Figure 7.13 are for Models 25-54 of the larger Hi Roller idlers.
  • Page 97 7. M OLLER ONVEYORS AINTENANCE & H 7.3. I OLLER OLLER OLLER DLER EPLACEMENT OLLER ODELS b. The nut retainers can be held in place by using a self-drilling and -tapping screw from the outside of the trunking sidewall just above the centerline of the bearing bolts.
  • Page 98 7. M AINTENANCE OLLER ONVEYORS 7.3. I & H DLER EPLACEMENT OLLER ODELS OLLER OLLER OLLER • The bearings and stub shafts should be replaced as an assembly when- ever replacing the idler. • If the existing bearings and stub shafts are to be reinstalled, make sure that the stub shafts have the burrs and cuts removed with emory cloth.

  • Page 99: Idler Replacement - Hi Life Models

    7. M OLLER ONVEYORS AINTENANCE & H 7.4. I OLLER OLLER OLLER DLER EPLACEMENT ODELS 7.4. IDLER REPLACEMENT - HI LIFE MODELS Figure 7.17 Typical Hi Life Cross Section Idler replacement on all Hi Life Models can typically be done without splitting the belt.
  • Page 100 7. M AINTENANCE OLLER ONVEYORS 7.4. I & H DLER EPLACEMENT ODELS OLLER OLLER OLLER a. Nut retainers on the inside of the trunking hold the nuts and therefore a wrench is not required on the inside nut. See Figure 7.19. b.

  • Page 101: Side Troughing Idlers

    7. M OLLER ONVEYORS AINTENANCE & H 7.4. I OLLER OLLER OLLER DLER EPLACEMENT ODELS 9. Align the bearings with the marks previously made during disassembly. 10. Tighten the bearing bolts on both sides - this MUST be done first. 11.
  • Page 102 7. M AINTENANCE OLLER ONVEYORS 7.4. I & H DLER EPLACEMENT ODELS OLLER OLLER OLLER 5. Set bolts and idler stationary shaft must first be loosened. Loosen the locknuts and then turn out the set bolts until the idler stationary shaft is free. 6.

  • Page 103: Liner - Bottom Return Pan

    7. M OLLER ONVEYORS AINTENANCE & H 7.5. L OLLER OLLER OLLER INER OTTOM ETURN 7.5. LINER - BOTTOM RETURN PAN The bottom return pan liner is a special carbon impregnated UHMW (ultra-high molecular weight) plastic. This special plastic is not readily available from most suppliers.

  • Page 104: Replacement

    7. M AINTENANCE OLLER ONVEYORS 7.5. L & H INER OTTOM ETURN OLLER OLLER OLLER Figure 7.24 • Pop Rivets, Floating Liner - after 2002: The bottom return pan liner has been held in place since 2002 with special pop rivets. The pop rivets are spe- cially installed to allow the liner to float.
  • Page 105 7. M OLLER ONVEYORS AINTENANCE & H 7.5. L OLLER OLLER OLLER INER OTTOM ETURN • This liner is not tightly fastened to the bottom which allows the UHMW liner to expand and contract at a different rate than the steel bottom. The UHMW has a much greater expansion and contraction rate than steel.

  • Page 106: Fixed Tripper - All Models

    7. M AINTENANCE OLLER ONVEYORS 7.6. F & H IXED RIPPER ODELS OLLER OLLER OLLER Figure 7.27 LINER SHOWING SLOTTED HOLES PAN SHOWING SLOTTED HOLES Figure 7.28 Liner Showing Slotted Holes 7.6. FIXED TRIPPER - ALL MODELS Fixed trippers must be installed correctly to ensure proper operation. The following list indicates the critical areas: 1.
  • Page 107 7. M OLLER ONVEYORS AINTENANCE & H 7.6. F OLLER OLLER OLLER IXED RIPPER ODELS Figure 7.29 Typical Fixed Tripper Figure 7.30 2. The belt must be threaded through the pulleys correctly (see Figure 7.31). To form a continuous loop, the top carrying belt is a.
  • Page 108 7. M AINTENANCE OLLER ONVEYORS 7.6. F & H IXED RIPPER ODELS OLLER OLLER OLLER Figure 7.31 Figure 7.32 3. The tripper valve must be adjusted properly for proper operation in the pass- through and discharge positions. Clearances must be checked and adjusted to eliminate leakage in each position at the top pulley and side discharge spouts.
  • Page 109 7. M OLLER ONVEYORS AINTENANCE & H 7.6. F OLLER OLLER OLLER IXED RIPPER ODELS Figure 7.34 Tripper Valve Up Figure 7.35 Discharge Spout Note: Discharge spout has removable sides for ease of relining internal wear points and a top inspection door. P115506 R3...
  • Page 110 7. M AINTENANCE OLLER ONVEYORS 7.6. F & H IXED RIPPER ODELS OLLER OLLER OLLER Figure 7.36 4. Electric or manual actuators must be properly adjusted. See Figure 7.37. P115506 R3...
  • Page 111 7. M OLLER ONVEYORS AINTENANCE & H 7.6. F OLLER OLLER OLLER IXED RIPPER ODELS Figure 7.37 NOTICE In case of actuator malfunction, use emergency handle: • Bolt handle to pivot. • Disconnect actuator. • Rotate and lock out for pass through. 5.

  • Page 112: Head & Drive Pulley Lagging

    If nothing helps, contact Hi Roller Conveyors. 12. If the belt trains significantly different when loaded vs. empty, contact Hi Roller.
  • Page 113 7. M OLLER ONVEYORS AINTENANCE & H 7.7. H & D OLLER OLLER OLLER RIVE ULLEY AGGING 2. Remove retainer bolts and locknuts (see Figure 7.40): • Drive the lagging plate to the side of the conveyor that has adequate clearance to remove the entire lagging plate.

  • Page 114: Installation Of New Lagging Plates

    7. M AINTENANCE OLLER ONVEYORS 7.7. H & D & H RIVE ULLEY AGGING OLLER OLLER OLLER Figure 7.42 7.7.2. I NSTALLATION OF AGGING LATES 1. Install new lagging plates: •In some cases, the metal edge will have to be ground smooth so that the metal plate can be eas- ily installed in the retainers.
  • Page 115 7. M OLLER ONVEYORS AINTENANCE & H 7.7. H & D OLLER OLLER OLLER RIVE ULLEY AGGING 2. Retainers need to be flattened if loosened from removal of lagging plate. Use a hammer or punch. 3. Install new retainer bolts and locknuts: •Drill new 1/4"...
  • Page 116 7. M AINTENANCE OLLER ONVEYORS 7.7. H & D & H RIVE ULLEY AGGING OLLER OLLER OLLER •Lagging plate rubber needs to be clean for the bolt head. •Install 3/8" (9.5 mm) bolt from the outside of the lagging plate so that the locknut is installed on the inside of the pulley.

  • Page 117: Troubleshooting

    8. T OLLER ONVEYORS ROUBLESHOOTING & H OLLER OLLER OLLER 8. Troubleshooting Table 8.1 Belt Tracking Problem Cause/Solution 1. All portions of the conveyor belt running to • square idlers one side at a given point on the structure. • advance, in the direction of belt travel, Idlers immediately preceding trouble point the end of the idler that the belt has are not at right angles to the belt direction.
  • Page 118 - check for proper tensions • hot and oily materials will attack the belt covers - contact Hi Roller engineering • material is too abrasive for the belt specifications • material is too hot for the belt specifications 6.
  • Page 119 • check specifications - conveyor may be installed at too steep an angle - call Hi Roller engineering • Rated capacity cannot • belt speed must be verified to the be reached specification from Hi Roller •...
  • Page 120 8. T ROUBLESHOOTING OLLER ONVEYORS & H OLLER OLLER OLLER Problem Effect Solution 10. Cleaning system • material build up under • splice protectors / wiper cleats failure. the belt must be properly installed • material build up • moisture and water must be elim- inated from the inside of the con- veyor •...
  • Page 121 • check specifications - conveyor shuts down under small may be installed at too steep an full load. angle - call Hi Roller engineering • material build up under the return bottom belt - splice protector / wiper cleat must be installed properly •...
  • Page 122 24. Spillage. • excessive reloading at • loading problems, bi-directional the tail section loaders require a special design - contact Hi Roller engineering • loading problems, control gate not properly installed, see Sec- tion 4.6. • loading problems, flow of mate-...
  • Page 123 4.6. loaded • belt misalignment • loading problems - bi-directional loaders require a special design, contact Hi Roller engineering • loading problems - control gate not proper installed, see Section 4.6. • loading problems - flow of mate- rial is not directed down the back- plate of the loader, see Section 4.6.
  • Page 124 8. T ROUBLESHOOTING OLLER ONVEYORS & H OLLER OLLER OLLER P115506 R3...

  • Page 125: Appendix

    9. A OLLER ONVEYORS PPENDIX & H 9.1. S OLLER OLLER OLLER KIRT NSTALLATION RAWINGS 9. Appendix 9.1. SKIRT INSTALLATION DRAWINGS Figure 9.1 Fixed Skirt Installation Type IV Inlet Model 18-54 P115506 R3...
  • Page 126 9. A PPENDIX OLLER ONVEYORS 9.1. S & H KIRT NSTALLATION RAWINGS OLLER OLLER OLLER Figure 9.2 Swing Skirt Installation Type IV Inlet Model 18 P115506 R3...
  • Page 127 9. A OLLER ONVEYORS PPENDIX & H 9.1. S OLLER OLLER OLLER KIRT NSTALLATION RAWINGS Figure 9.3 Swing Skirt Installation Type IV Inlet Model 22 P115506 R3...
  • Page 128 9. A PPENDIX OLLER ONVEYORS 9.1. S & H KIRT NSTALLATION RAWINGS OLLER OLLER OLLER Figure 9.4 Swing Skirt Installation Type IV Inlet Model 26-54 P115506 R3...

  • Page 129: Limited Warranty And Terms Of Sale

    HI ROLLER product. HI ROLLER'S warranties hereunder extend only to the direct customer of HI ROLLER (or to the first user of the HI ROLLER product if the direct customer purchases solely for the purpose of resale). HI ROLLER makes...
  • Page 130 GENERAL PROVISION: The failure of HI ROLLER to enforce any right will not be construed as a waiver of HI ROLLER'S rights to performance in the future. The purchaser may not assign any rights or delegate any performance owed under this agreement without the express written consent of HI ROLLER management.
  • Page 131 For actual installation criteria and dimensions, do not use any published adver- tising information or catalog dimensions as some components may have been redesigned. HI ROLLER will furnish any information required to install and fit the product for each specific order.
  • Page 132 OLLER ONVEYORS & H OLLER OLLER OLLER P115506 R3...
  • Page 133 EC Declaration of Conformity MANUFACTURER: Hi Roller Conveyors (a division of Ag Growth International), 4511 N Northview Ave, Sioux Falls, SD, 57107-0833, Phone: 605.332.3200, FAX: 605.332.1107 AUTHORIZED REPRESENTATIVE: (Name and address of the person in the Community authorized to compile the technical file): Managing Director, AGI-PTM, Via Mario Tognato, ...
  • Page 134 Part of the Ag Growth International Inc. Group 4511 N Northview Ave Sioux Falls, SD 57107 Toll free (US & Canada): 800-328-1785 Phone: 605-332-3200 Fax: 605-332-1107 www.hiroller.com e-mail: sales@hiroller.com © Ag Growth International 2014...

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