Roach Conveyors 138LRC, 196LRC, 138LRCS, 196LRCS Owner's Manual

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Page 1

Page 2

TECH HANDBOOK FOR LIVE ROLLER CURVES/SPURS

TABLE OF CONTENTS

TECH HANDBOOK FOR BELT DRIVEN LIVE ROLLERS ................................................ 2

-Caution Labels ................................................................................................. 2

CAUTIONS, WARNINGS AND HAZARDS .............................................................. 3

-Introduction ..................................................................................................... 3

-Cautions, Warnings and Hazards....................................................................... 3

SAFETY INFORMATION / RECEIVING & INSPECTION.............................................. 4

-Important Safety Guidelines................................................................................ 4

-Shortages, Damages and Return Authorizations ..................................................... 4

GENERAL INSTALLATION INFORMATION .............................................................. 5

-Slave Drive / Mating to Other Conveyors ............................................................ 5

-Identifying / Installing Permanent Floor Supports .................................................... 5

CEILING HANGERS AND POLYTIER SUPPORTS........................................................ 6

-Installation of Ceiling Hangers ............................................................................ 6

-Installation of Polytier Supports ............................................................................ 6

INSTALLATION OF BELTING ................................................................................. 7

-V-Belt Connections............................................................................................ 7

-Adjusting V-Belt Tension ..................................................................................... 7

-V-Belt Drive Pressure Adjustment .......................................................................... 8

-Replacing V-Belt And Sheaves ............................................................................ 8

V-BELT PATH ....................................................................................................... 9

-V-Belt Path for Spurs And Curves ......................................................................... 9

START-UP PROCEDURES ..................................................................................... 10

-Drive Chain and Sprocket Alignment ................................................................. 10

-Drive Chain and Sprocket Tension .................................................................... 10

-Gear Reducer Vent Plug .................................................................................. 11

-Preparing for Initial Start-Up .............................................................................. 11

MAINTENANCE SAFETY PRECAUTIONS ............................................................... 12

-Before Performing Maintenance ........................................................................ 12

-Maintenance and Follow-Up Details .................................................................. 12

MAINTENANCE AND LUBRICATION.................................................................... 13

-Periodic Maintenance Schedules ....................................................................... 13

-Recommended Lubricants ................................................................................. 14

-Report on Miscellaneous Maintenance Performed, Chart 1 .................................... 14

TROUBLE SHOOTING AND REPLACEMENT PARTS ................................................. 15

-Trouble Shooting / Serial Plate ......................................................................... 15

MODEL 138LRC ................................................................................................ 16

-Parts List for Unit With End Drive / Side Mount End Drive ..................................... 16

-Illustrations for Unit With End Drive / Side Mount End Drive .................................. 17

MODEL 196LRC ................................................................................................ 18

-Parts List for Unit With End Drive / Side Mount End Drive ..................................... 18

-Illustrations for Unit With End Drive / Side Mount End Drive .................................. 19

MODEL 138LRCS ............................................................................................... 20

-Parts List for Unit With End Drive / Side Mount End Drive ..................................... 20

-Illustrations for Unit With End Drive / Side Mount End Drive .................................. 21

MODEL 196LRCS ............................................................................................... 22

-Parts List for Unit With End Drive / Side Mount End Drive ..................................... 22

-Illustrations for Unit With End Drive / Side Mount End Drive .................................. 23

WARRANTY ..................................................................................................... 24

WARNING LABELS

ABOVE: Label attached to all protective guards (drives, roller guards, etc.) ABOVE: Label placed near all pulleys (center drives, end drives, tail pulleys)

ABOVE: Label placed near all drive assemblies and at 30’ intervals

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CAUTIONS, WARNINGS AND HAZARDS

INTRODUCTION

This manual was prepared as a “how-toguide” for installers, end-users and maintenance personnel. It is also intended to educate both owner (purchaser) and all individuals working around the unit, of potential hazards.

With proper installation and maintenance, conveyors are essential for achieving a variety of functions essential in today’s industrial marketplace. By following a simple, periodic maintenance schedule, the life of a typical conveyor (or, most any type of machinery--including our automobiles!) will increase when compared to a similar

unit in an application receiving little or no maintenance. You may find that a conveyor can become your best workplace friend by following simple safety guidelines.

Failure to follow even the most basic safety suggestions can result in serious personal injury.

Conveyors contain many moving parts-

-pulleys, belting, chains, sprockets, shafts, rollers, etc. Therefore, it is imperative to become familiar with basic unit operation and know all points of potential hazards.

Remember, when working around or near conveyors (and any industrial machinery)

DO NOT OPERATE BEFORE READING THIS MANUAL!

KEEP IN SAFE PLACE--DO NOT DISCARD!

it is your responsibility to become familiar with the unit, to know potential hazards (many are noted with caution labels) and to operate unit in strict accordance with the safety guidelines in this manual.

Keep this manual in a safe place for future reference. It should be placed where appropriate personnel may maintain proper maintenance and records.

This manual must be read by all new users before operating or working near this unit.

CAUTIONS, WARNINGS AND HAZARDS

ALWAYS anchor permanent supports to floor (or mounting surface). Use 3/8” x 2-1/2” (or longer) wedge anchors for

permanent installation in concrete flooring.

It is the responsibility of the customer and installation personnel

to supply and install net or mesh guarding on overhead mounted conveyors to prevent product and/or debris from falling to floor in areas where required.

Safety finger guards must NOT be removed form V-belt driven live

roller curves or spurs. If guard is removed for maintenance or other purposes, conveyor must NOT be placed into operation until All finger guards have been replaced.

Belt must be kept in good condition for safe work environment.

Drive chain guards MUST be replaced after installation or mainte-

nance before unit start-up. Also, guards used to cover slave drive connections for slave driven curves or spurs must be replaced prior to startup after installation or maintenance.

To check drive sprocket alignment, shut “OFF” and lock out power source before attempting ANY adjustments.

To check drive sprocket tension, shut “OFF” and lock out power source before ANY adjustments are attempted.

To check drive sprocket tension, shut “OFF” and lock out power

source before ANY adjustments are attempted.

Electrical controls must be designed by a qualified electrical engi-

neer to ensure that appropriate safety features (emergency stops, pull cords, switches, etc.) are installed on unit for safe operation. Before conveyor start-up, all operators and other personnel coming in contact with unit must be properly trained and must have read accompanying Tech Handbook.

Only trained personnel shall perform maintenance functions. Before

maintenance operations are performed, shut conveyor “OFF” and lock out power source to prevent unauthorized start-up. When maintenance is completed, only authorized personnel shall be permitted to start conveyor following maintenance or other emergency shut-off.

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SAFETY INFORMATION / RECEIVING & INSPECTION

IMPORTANT SAFETY GUIDELINES

WARNING: All personnel coming in contact with this conveyor should be aware of the following safety guidelines BEFORE USING OR WORKING AROUND CONVEYOR. NOTE: ALWAYS notify Roach Manufacturing® whenever any conveyor is used in an application or condition other than was originally intended. Failure to notify Roach condition. Injuries resulting from negligence or violation of safety instructions hereby removes responsibility of product liability claims from Roach®. Any violation of above safety instructions hereby removes all product liability claims from Roach.

may allow conveyor to be operated in a hazardous operating

Do not operate conveyor with

protective guards removed. This includes chain guards, belt guards, snub roller guards, center drive guards and any other safety guard.

Do not walk, ride, climb, or touch

moving parts on a conveyor in operation.

Do not wear loose clothing or

uncovered hair around conveyor.

Do not work near conveyor without

knowing how & where to shut power “OFF” and lock out power source.

Do not remove jammed product with

conveyor running.

Do not replace parts or perform

maintenance on conveyor, or moving conveyor parts, without first shutting “OFF” power to conveyor and locking out power source.

Do not connect gravity to powered conveyor without safety gravity

connector brackets.

To prevent electrical shock, conveyor

must be grounded, and have proper electrical connections in accordance with federal, state, and local codes.

Safety pop out rollers in conveyors

installed above 7’-0” elevation must be retained by guard rail, clips, etc. Safety pop out rollers must be allowed to pop out when

conveyors are installed at or below 7’-0” elevation.

standards including OSHA and other federal, state, and local codes or regulations. Install protective guarding and other related safety precautionary equipment to eliminate hazardous operating conditions which may exist when two or more vendors supply machinery for related use.

product liability claims from Roach Manufacturing Corporation

It is the responsibility of conveyor end-user to comply with all safety

Any violation of above safety instructions hereby removes all

SHORTAGES, DAMAGES AND RETURN AUTHORIZATIONS

NOTE: Do not return goods to factory

without prior, written return authorization. Unauthorized returns are subject to refusal at factory. Also, some items (electric motors, gearbox, etc.) may be shipped direct from their manufacturer. Thus, two or more separate shipments may be required to receive all equipment.

Before uncrating, check quantity of items received against bill of lading to confirm that all equipment has been received. Next, determine if any damage has occurred. Damage and/or shortage in shipment should be reported immediately to both Roach and carrier. Obtain signed damage report from carrier agent and send copy to Roach. Do not repair any damage

before obtaining this report. Finally, consult factory to determine if entire shipment must be returned to factory for repair or if a replacement order should be entered for replacement equipment.

Therefore, it is imperative that the bill of lading (or, accompanying freight documentation) be checked to ensure receipt of ALL units ordered including ALL accessories.

After receipt and initial inspection, carefully remove crating and look for essential components and specific accessories that may have been boxed and attached (or ‘banded’) to crating material such as guard rails and hardware which may be packaged and shipped in this manner. Save all hardware for subsequent use by installation personnel.

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GENERAL INSTALLATION INFORMATION

SLAVE DRIVE / MATING TO OTHER CONVEYORS

NOTE: There are two primary methods of

installation for a curve--driven by its own gear motor or SLAVE driven from another conveyor.

Once conveyor is uncrated, installation of curve or spur may begin (note that in following text we will use “curve” for reference to both curves and curve spurs). Locate unit in the actual installation area.

There are two primary methods of installation for a curve--driven by its own gear motor or SLAVE driven from another conveyor. Most often, curves are SLAVE driven

by belt driven live rollers or slider bed belt conveyors, which eliminates gear motor drive assembly for curve.

Locate actual bed section of conveyor which is to slave drive curve to begin installation. Note that this conveyor is usually set up before curve is installed. Bed section labels are located on bed of driving conveyor showing where slave driven curve

will be installed (see illustration above). For curves not slave driven, location of installation in most usually noted by conveyor “mark numbers”.

Use mechanical hoist (fork truck or other available means) to raise bed sections to approximate installed elevation. Locate supports, attach to curve and mate curve with butt couplings.

IDENTIFYING/INSTALLING PERMANENT FLOOR SUPPORTS

CAUTION: Always anchor permanent sup-

ports to floor (or mounting surface). Use 3/8” x 2-1/2” (or longer) wedge anchors for permanent installation in concrete flooring.

*MINIMUM SUPPORT HEIGHT

MEDIUM DUTY HEAVY DUTY

SM-1 7-1/4” SM-7 34-1/4” SH-1 6-1/4” SH-7 25-3/4”

SM-2 10-1/4” SM-8 46-1/4” SH-2 7-3/4” SH-8 31-3/4”

SM-3 13-1/4” SM-9 58-1/4” SH-3 10-3/4” SH-9 43-3/4”

SM-4 16-1/4” SM-10 70-1/4” SH-4 13-3/4” SH-10 55-3/4”

SM-5 20-1/4” SM-11 80-1/4” SH-5 16-3/4” SH-11 67-3/4”

SM-6 24-1/4” SM-12 92-1/4” SH-6 19-3/4” SH-12 29-3/4”

It is most common to use single tier permanent floor supports at each end of a curve, for models 138LRC and 196LRC. In the center of the curve, a single leg support is required underneath the outside frame rail. If the frame rail consists of two or more frame rails and is joined together in the center of the curve, a full support is required.

For model 138LRCS and 196LRCS curve

spurs, two supports are generally required, one support at the junction between the spur and the curve and one support at the tangent end of the curve.

Adjust elevation to top of conveyor by loosening bolts in support uprights, raising or lowering conveyor and fully tightening bolts at desired elevation. Tighten all bolts

Complete support installation by lagging support attachment plates to floor with two lag bolts in a diagonal pattern in support foot plate mounting holes. Conveyor must be level across width of unit before completing final support height adj.

*Supports are normally shipped at minimum support height. See chart above.

in supports before unit operation.

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CEILING HANGERS AND POLYTIER SUPPORTS

INSTALLATION OF CEILING HANGERS

WARNING: It is the responsibility of the

customer and installation personnel to supply and install net or mesh guarding on conveyors mounted overhead to prevent product and/or debris from falling to floor in areas where required.

Ceiling hangers are frequently used in highelevation applications for suspension from ceiling. The 5/8” diameter (#11 UNC) all threaded rod is supplied to allow infinite vertical adjustment along the length of the suspension rod (see illustration above).

Attach and firmly tighten U-shaped retainer (“hat”) bracket to underneath side of lower conveyor flange with hardware provided

to hold cross pipe (1” inside diameter) against underneath side of conveyor.

Do not tighten cross pipe locking bolts (these attach in the bottom of the U-shaped retainer bracket) until threaded suspension rods have been firmly secured to ceiling structure.

To adjust conveyor elevation, tighten or loosen lower nut and jam nut on threaded

INSTALLATION OF POLYTIER SUPPORTS

suspension rods to desired elevation. A lock washer must be used on suspension rods to maintain unit at desired elevation.

When unit is at operating elevation and unit has been levelled across bed width, tighten locking bolts in U-shaped bracket to secure position of cross pipe.

NOTE: To install, raise conveyor to desired elevation, place cross pipe underneath lower conveyor flange, attach cross pipe to upright legs and use U-shaped retainer (“hat”) bracket to connect cross pipe to lower conveyor flange.

POLYTIER SUPPORT CHANNEL HEIGHT

PSM-1 23” PSM-6 53” PSM-11 83”

PSM-2 29” PSM-7 59” PSM-12 89”

PSM-3 35” PSM-8 65” PSM-13 95”

PSM-4 41” PSM-9 71” PSM-14 101”

PSM-5 47” PSM-10 77” PSM-15 107”

Polytier supports provide convenient installation method for two or more tiers of conveyor. To install, raise conveyor to desired elevation (approximate). Place 1” inside diameter cross pipe underneath lower conveyor flange. Attach cross pipe to upright legs. Use U-shaped retainer (“hat”) bracket to connect cross pipe to lower conveyor flange. Do not tighten fully at this time.

There are two styles of attachment brackets available for use with polytier supports. Minimum elevation style (see illustration above) offers lowest unit elevation, 0” + depth of frame utilizing L-shaped mounting bracket. Standard elevation style offers unit elevation of 3-1/2” + depth of frame

When unit is at operating elevation and unit has been checked across width for level, tighten locking bolts in U-shaped bracket. Add knee braces for unit rigidity.

*NOTE: Overall conveyor height is dictated by type of drive assembly used--i.e. underneath, center drive, side mount, etc.

and includes bracket welded to cross pipe which is bolted to upright legs during installation.

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INSTALLATION OF BELTING

V-BELT CONNECTIONS

WARNING: Safety finger guards are located above V-belt on all live roller curves and spurs. Removal of finger guard assemblies may result in serious injury to personnel stationed near or coming in contact with conveyor. V-belt must be kept in good condition and belt tension must be properly adjusted for safe work environment. BEFORE ANY ADJUSTMENTS ARE ATTEMPTED, SHUT “OFF” AND LOCK OUT POWER SOURCE.

In some applications (180 degree, long straight tangents, etc.), curves are manufactured in two or more sections requiring the use of more than a single drive belt. Although set up and test run (and, subjected to quality control inspection) at the factory, unit may require disassembly for shipping. In such cases, V-belt must be re-connected before operation.

To reconnect belts, determine curve section containing double sheave drive assembly, or “drive section” in illustration above. This drive section features drive V-belt shipped mounted as required. The V-belt on the adjoining curve section, or “driven section”, must be attached to double sheave drive assembly. To install, loosen V-belt take-up sheave on driven section to allow adequate

ADJUSTING V-BELT TENSION

slack in V-belt for attachment to double sheave. Then, complete V-belt assembly by properly adjusting take-up sheave in center of driven section as outlined in following section.

NOTE: Depending on the model or BF of curve or spur, there are several take-up configurations available. See page 9 of manual for more information.

Maintaining proper belt tension is vital to proper unit operation and long V-belt life. Over-tensioning drive belt requires more horsepower, decreases belt life and may harm unit drive and take-up sheaves.

To increase drive belt tension (or, to take up slack in V-belt), move take-up sheave toward outside of curve (or spur) by adjusting take-up rod on take-up sheave (see illus-

tration above). Be careful not to over-tension belt.

To “decrease” belt tension, move take-up sheave toward inside of curve (or spur) by adjusting take-up rod on take-up sheave. When adjustment is complete, tighten jam nut to complete tensioning procedure. Make adjustments to drive belt in small increments.

For adjusting drive pressure applied to V-belt from drive sheaves, see next section.

NOTE: When adjusting V-belt tension, V-belt must remain parallel with end sheave until reaching first alignment sheave (sheave may be flat idler or V-grooved).

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INSTALLATION OF BELTING

V-BELT DRIVE PRESSURE ADJUSTMENT

Maintaining proper drive belt pressure is vital to proper unit operation and long V-belt life. Over-applying drive belt pressure requires more horsepower and may harm unit drive and take-up components. Belt life is drastically reduced when unit is operated with incorrect drive belt pressure.

Belt driven live roller curves and spurs require adequate drive pressure on the

drive belt to convey the heaviest unit load. Therefore, if curve or spur does not properly convey the heaviest unit load, adjust the drive belt pressure as outlined below.

To increase drive belt pressure, move sheave “up” (see above illustration) toward roller. To decrease drive belt pressure, lower sheave away from roller. Make

REPLACING V-BELT AND SHEAVES

adjustments in small increments. DO NOT place too much drive pressure on sheaves.

In worst conditions, conveyor may stall, thus causing motor to overheat and untimely unit shut down, when drive sheaves have been raised too high.

As outlined in previous sections, the importance of properly setting drive tension and drive pressure on V-belts simply cannot be overstated. When V-belt or drive sheaves are out of adjustment, life of sheaves and V-belting may be drastically reduced, thus requiring untimely replacement(s).

Before ANY maintenance operations are performed on belt driven live roller curves

or spurs, it is VITAL that ALL conveyors are shut “OFF” and power source is locked out. Confirm that power source has been locked out before beginning maintenance.

For replacing V-belt, remove conveyor tread rollers, loosen take-up assembly as previously noted and remove belt. Use old belt to identify replacement, which is readily available from Roach or may be

purchased locally to expedite replacement procedure. Install new belt, tread rollers and re-set belt tension.

Should any drive sheaves require replacement, consult Roach distributor for new sheaves. Remove nut from drive sheave axle, remove worn sheave and replace with new unit. Replace nut and set drive sheave pressure as previously outlined.

Page 9

V-BELT PATHS

V-BELT PATH FOR SPURS AND CURVES

Page 10

START-UP PROCEDURES

DRIVE CHAIN AND SPROCKET ALIGNMENT

CHAIN GUARD REMOVED FOR CLARITY

WARNING: DO NOT OPERATE CONVEYOR WITH CHAIN GUARD REMOVED

Set up and maintenance of drive sprocket and drive chain alignment is critical (on curves or spurs with drive assembly). A periodic visual inspection is recommended to confirm alignment of drive components (which includes both drive sprockets and drive chain). Should set screws become loose, drive sprockets are subject to excessive wear and ultimately, to untimely

replacement.

To check drive sprocket alignment, it is imperative that conveyor is shut “OFF” and power source is locked out before any adjustments are attempted. Remove chain guard cover and place straight-edge (see illustration above) across face of both drive sprockets. If re-alignment is

WARNING: To check drive sprocket alignment, it is imperative that conveyor is shut “OFF” and power source is locked out before any adjustments are attempted.

necessary, loosen set screws and adjust drive sprockets as required. Remember

to securely tighten set screws when alignment is complete.

Before replacing chain guard cover, check drive chain tension as described in following section, “Drive Chain and Sprocket Tension.”

DRIVE CHAIN AND SPROCKET TENSION

CHAIN GUARD REMOVED FOR CLARITY

WARNING: DO NOT OPERATE CONVEYOR WITH CHAIN GUARD REMOVED

Maintaining proper chain tension is especially important. Again, a periodic visual inspection is recommended to ensure chain tension within a pre-determined operating range.

Remember, before any adjustments are attempted, conveyor must be shut “OFF” and power source locked out.

to see if drive chain is operating within 1/2” range (see above illustration). If unit is out of tolerance, adjustment is necessary.

To adjust drive chain tension, tensioner bolt located on reducer push plate should be tightened (rotate clockwise) if chain tension is loose. Tighten until proper operating range is achieved. If chain tension is too

WARNING: To check drive sprocket tension, shut “OFF” and lock out power source before any adjustments are attempted.

tight, loosen tensioner bolt (rotate counterclockwise) as required. When adjustment is complete replace chain guard cover.

WARNING: Do not operate unit until chain guard cover is replaced. Serious operator or other personal injury could result if protective guarding is not replaced.

Before replacing chain guard cover, check

Page 11

START-UP PROCEDURES

GEAR REDUCER VENT PLUG

PosiVent Unique design incorporates a single seam

construction. Factory filled with synthetic lubrication for universal mounting. Lubed for life, no oil changes are required.

To expedite the installation and start-up process, all gear red ucers are shipped filled with oil. The reducers are sealed and lubed for life and require no oil changes.

PREPARING FOR INITIAL START-UP

Before conveyor start-up, all operators and other personnel coming in contact with unit must be properly trained and must have read accompanying Tech Handbook.

Provisions must be in order to instruct all personnel coming in contact with conveyor on the location of emergency stops, pull cords, etc.

A routine maintenance program should be implemented before unit is placed into

operation so that fundamental unit components are attended to. This maintenance program should include an inspection to ensure that any dangerous or hazardous operating conditions are noted and IMMEDIATELY corrected, as well as including electrical and mechanical unit inspections and corrections.

Finally, when conveyor is initially started,

WARN ALL PERSONNEL TO KEEP CLEAR OF CONVEYOR DURING UNIT START-UP

Electrical controls must be designed by a qualified electrical engineer to ensure that appropriate safety features (emergency stops, pull cords, switches, etc.) are installed on unit for safe operation. Before conveyor start-up, all operators and other personnel coming in contact with unit must be properly trained and must have read accompanying Tech Handbook.

an immediate visual inspection should include motor, gear reducer, belt tracking (discussed in following section under “Belt Tracking”) and related adjustments noted in handbook for unit/component corrections.

Page 12

MAINTENANCE SAFETY PRECAUTIONS

BEFORE PERFORMING MAINTENANCE

CAUTION: Only trained personnel shall perform maintenance functions. Before maintenance operations are performed, conveyor must be

shut “OFF” and disconnects locked in the “OFF” position to prevent unit from unauthorized start-up.

One of the most important guidelines for maximizing conveyor operation and personnel safety is to implement a regular maintenance schedule and train personnel on the appropriate needs of the specific unit.

Only trained personnel shall perform maintenance functions. Before maintenance operations are performed, conveyor must be shut “OFF” and disconnects locked in the “OFF” position to prevent unit from unauthorized start-up during maintenance. All personnel should be informed of the safety procedures associated with unit maintenance and performance.

Do not perform any work on conveyors or conveyor system while in operation unless it is impossible to otherwise conduct adjustment, lubrication or other maintenance function. Only experienced, trained personnel possessing advanced hazards-training should attempt such critical operations.

MAINTENANCE AND FOLLOW-UP DETAILS

CAUTION: Only trained personnel shall perform maintenance functions. When maintenance is completed, only authorized personnel

shall be permitted to start conveyor following maintenance or other emergency shut-off.

While performing maintenance do not wear loose clothing. Immediately report any hazardous conditions--sharp edges, pinch (or nip) points or other conditions that may result when several manufacturers supply machinery which may create operating hazards.

When using mechanical aids such as hoists, cables, or cranes exercise extreme caution to prevent damage to conveyors or other integrated machinery which may create a working hazard when maintenance is completed and units are in operation.

Clean up any spilled lubricants or other materials used in the maintenance process or those which may be deposited during unit operation. Eliminating poor housekeeping practices increases unit efficiency while creating safer personnel working conditions.

After maintenance, conduct visual inspection to ensure that all safety devices and guards have been replaced. Confirm that all units are clear of tools, debris or other items. Before starting

conveyor, check condition of unit caution labels (see “CAUTION LABELS” at front of handbook). If labels have been destroyed or are not clearly legible, call 870.483.7631 to receive replacement labels. Placement of caution labels is critical to avoid unauthorized unit operation which may result in hazardous working conditions for all related personnel coming in contact with conveyor.

Warn personnel that conveyor is being prepared for start-up and to stay clear of unit. Do not start conveyor until all personnel are clear. When maintenance is completed, only authorized personnel shall be permitted to start conveyor following maintenance or other emergency shut-off.

Page 13

MAINTENANCE AND LUBRICATION

PERIODIC MAINTENANCE SCHEDULE

MODEL NO.__________

WEEKLY RECOMMENDED MAINTENANCE SCHEDULE*

COMPONENT DETAIL OF MAINTENANCE

V-Belt Inspect belt tension and sheave drive pressure applied to V-Belt.

V-Belt Pressure Sheaves Check & re-tighten axles. Check for overall wear.

Pillow Block/Flange Bear-

ings

Unit Safety Check

Conﬁrm placement of all guards including safety ﬁnger guards, pop-out rollers,

warning labels. Check for loose bolts, nip points & other hazards.

Lubricate in dirty, dusty or moist/wet conditions.

MONTHLY RECOMMENDED MAINTENANCE SCHEDULE*

COMPONENT DETAIL OF MAINTENANCE

Gear Reducer Check for leaks.

Drive Chain Check for proper operating tension & for overall wear & lubricate.

Drive Sprockets Check for overall wear & re-tighten set screws.

V-Belt Drive Belt Check for proper operating tension & overall wear.

Drive Sheaves Check & re-tighten set screws & check for overall wear.

Pillow Block/Flange Bear-

ings

Lubricate (normal conditions)

PERIODIC RECOMMENDED MAINTENANCE SCHEDULE*

COMPONENT DETAIL OF MAINTENANCE

Gear Reducer Check for leaks.

Drive Chain

Motor

*All charts are for guidelines in normal operating or ‘as noted’ conditions. Severe applications may warrant additional maintenance.

Clean (brush in solvent) & re-lubricate by applying lubricant to inside of chain with

brush or spout can at 2000 hour intervals.

Check & clear motor ventilation openings at 500 hour intervals

Check miscellaneous operating conditions (normal heat & noise).

Page 14

MAINTENANCE AND LUBRICATION

RECOMMENDED LUBRICANTS

MISC. LUBRICANTS

LUBRICANT BRAND/DESCRIPTION

General Purpose Grease

(For -30¯F to 300¯ operation)*

For extreme Temperature Operation

(-90¯F to 350¯F operation)*

Washdown Application*

(-30¯F to 225¯F operation)

(May require special consideration -- consult fac-

tory)

General Purpose Oil SAE 10; SAE 20 or SAE 30

*NOTE: Temperatures listed indicate the nominal operational temperature for the specific lubricant listed. This does not imply that the bearing housing, seals or any other conveyor unit component is rated to operate in this specific temperature range or environment. 250°F is the maximum operating temperature for standard bearing lubricants and bearing components. Although various lubricants may enhance bearing operation, special-order bearings may be required to achieve optimal bearing performance. For additional information, consult factory.

Shell Dolium R (Shell Oil Co.)

(or Suitable equivalent)

Mobiltemp SHC-32 (Mobil Oil Corp.)

(or suitable equivalent)

Shell Alvania No. 3 (Shell Oil Co.)

(or suitable equivalent)

MAINTENANCE AND LUBRICATION

REPORT ON MISCELLANEOUS MAINTENANCE PERFORMED

REPORT ON MAINTENANCE

CONVEYOR

MARK NO.

REPAIREDBYINSPECTION

DATE

DETAIL OF MAINTENANCE COMPLETED OR INSPECTED

LIST PARTS REPLACED OR REPAIRS

Page 15

TROUBLE SHOOTING AND REPLACEMENT PARTS

TROUBLE SHOOTING / SERIAL PLATE

TROUBLE SHOOTING

TROUBLE PROBABLE CAUSE REMEDY

Motor & gear reduc-

er running excessively

hot, or hard to start

Motor & gear re-

ducer makes exces-

sive noise

A. Drag on conveyor

B. Lack of lubricant C. Frozen sprocket

D. Frozen roller E. Overload F. Electrical

A. Lack of lubrication B. Damaged Gears C. Faulty Bearing

A. Inspect entire conveyor for obstruction causing drag on chain. B. Check for leaks. C. Check and inspect all sprockets and bearings. Replace sprockets failing to rotate or that are difﬁcult to rotate. D. Check all rollers for rotation. E. Reduce cause and/or increase motor horsepower. F. Check wiring and circuits, take ampere reading, replace motor if necessary.

A. Check for leaks. B. Replace unit. C. Replace bearing.

Drive chain, con-

veying chain or

sprockets experience

excessive wear

Drive chain,

conveying chain

or sprockets make

excessive noise

Pulsating chain

Broken chain

Sprocket loose on

shaft

Excessive slack in

chain

A. Excessive chain tension B. Sprockets misaligned C. Chain not lubricated

D. Damaged sprocket or chain E. Misalignment of chain guard F. Dirty chain

A. Insufﬁcient chain tension B. Chain not adequately lubricated C. Sprockets misaligned

A. Insufﬁcient chain tension B. Misalignment of chain guard C. Overload

A. Frozen bearing or sprocket shaft B. Worn or damaged chain C. Obstructed or jam

A. Loose set screws B. Worn or damaged key

A. Normal wear A. Expect rapid chain growth in ﬁrst two weeks of operation.

A. Reduce chain tension. B. Realign with straight edge across sprocket faces. C. Lubricated chain with approved lubricant, wipe away excess lubricant. D. Replace Damaged Component. E. Adjust chain guard assembly as necessary. F. Clean thoroughly and lubricate with approved lubricant.

A. Adjust chain tension. B. Lubricate chain with approved lubricant, wipe away excess lubricant. C. Realign sprockets with straight edge across sprocket faces.

A. Adjust chain tension. B. Adjust chain guard assembly as necessary. C. Inspect for obstruction to or drag on conveyor.

A. Inspect for damaged bearings, replace if necessary. Re place links as required. B. Replace chain as required. C. Remove obstruction to clear jam.

A. Realign sprockets with straight edge and tighten set screws. B. Replace with new key.

B. Adjust chain tension as speciﬁed in the manual.

ORDERING REPLACEMENT PARTS

To order any replacement parts or when calling for assistance with any powered conveyor, ALWAYS provide unit serial number.

Shown at actual size, this aluminum plate is placed on the conveyor frame near the location of the drive assembly.

To order replacement parts or add-on components, contact the Roach distributor who originally furnished the unit if possible. If this is not possible, contact the National

Sales Office at 870-483-7631 for the name of the authorized Roach distributor in your area. Have unit model number and serial number BEFORE calling. Refer

to unit drawings (in rear section of handbook) for part numbers if ordering replacement parts.

Page 16

MODEL 138LRC

PARTS LIST FOR UNIT WITH END DRIVE / SIDE MOUNT END DRIVE

ITEM

1 138G roller w/5/16” shaft 35 5/16” ﬂat washer 2 138T tapered roller 36 3/8” ﬂange nut 3 138G grooved roller w/5/16” hex shaft 37 3/8” ﬂat washer

4 Take-up sheave mounting channel 38 7/16” lock washer 5 45°/90° inside curve channel 39 1/2” hex nut 6 Splice plate 40 1/2” lock washer 7 Bolt-in butt coupling, left hand 41 1/2” ﬂange nut 8 Bolt-in butt coupling, right hand 42 1/2” ﬂat washer

9 Pillow block mounting bracket 43 Orange nylon ﬁnger guard 10 Take-up rod support angle 44 Black nylon sheave spacer/adapter 11 Sheave mounting channel 45 V-belt sheave w/1-3/16” bore 12 Idler sheave angle 46 Nylon 3” O.D. V-groove sheave 13 Left hand outside tangent drive channel 47 Steel 4” O.D. V-groove take-up sheave 14 Right hand outside tangent drive channel 48 V-belt 15 Left hand inside tangent side channel 49 Drive band 16 Right hand inside tangent side channel 50 Motor 17 Take-up mounting angle 51 Gear reducer 18 45°/90° outside curve channel 52 Drive sprocket 19 Tail sheave shaft 53 Gear reducer drive sprocket 20 Drive sheave shaft 54 #50 (thru 1-1/2 HP) ir #60 roller chain 21 Bed spacer rod 55 Chain guard angle mount (Not shown)

22 3 hole ﬂange bearing w/1-3/16” bore 56 Reducer push plate assembly 23 Pillow block bearing w/1-3/16” bore 57 Underneath motor base plate

24 3/8” x 3/4” HHCS 58 End drive chain guard assembly 25 3/8” x 1-1/4” HHCS 26 3/8” x 1-1/2” HHCS OPTIONAL SIDE MOUNT END DRIVE PARTS LIST 27 3/8” x 1-3/4” HHCS 50 Motor 28 3/8” x 2-1/4” HHCS 51 Gear reducer 29 7/16” x 1” HHCS 52 Drive sprocket 30 1/2” x 1-1/2” HHCS 53 Gear reducer drive sprocket 31 1/2” x 6” HHTB 54 #50 (thru 1-1/2 HP) ir #60 roller chain 32 5/16” x 3/4” carriage bolt 55 Reducer push plate assembly 33 3/8” x 3/4” carriage bolt 56 Side mount motor base plate 34 5/16” ﬂange nut 57 Side mount chain guard assembly

DESCRIPTION ITEM

DESCRIPTION

Specify Unit Serial Number when ordering replacement parts to ensure proper allocation of components (See Ordering Replacement Parts on page 15).

Recommended Spare Parts are shown in red. Charted are item numbers and part descriptions. When

ordering use example below.

Example: Need a replacement 138T tapered roller for 138LRC

Part No: SN 123456 - 2 - 138T tapered roller

Page 17

MODEL 138LRC

ILLUSTRATIONS FOR UNIT WITH END DRIVE / SIDE MOUNT END DRIVE

Page 18

MODEL 196LRC

PARTS LIST FOR UNIT WITH END DRIVE / SIDE MOUNT END DRIVE

ITEM

1 196S roller 35 5/16” ﬂat washer

2 254T tapered roller 36 3/8” ﬂange nut

3 196S grooved roller 37 3/8” ﬂat washer

4 Take-up sheave mounting channel 38 7/16” lock washer

5 45°/90° inside curve channel 39 1/2” hex nut

6 Splice plate 40 1/2” lock washer

7 Bolt-in butt coupling, left hand 41 1/2” ﬂange nut

8 Bolt-in butt coupling, right hand 42 1/2” ﬂat washer

9 Pillow block mounting bracket 43 Orange nylon ﬁnger guard 10 Take-up rod support angle 44 Black nylon sheave spacer/adapter 11 Sheave mounting channel 45 V-belt sheave w/1-3/16” bore 12 Idler sheave angle 46 Nylon 3” O.D. V-groove sheave 13 Left hand outside tangent drive channel 47 Steel 4” O.D. V-groove take-up sheave 14 Right hand outside tangent drive channel 48 V-belt 15 Left hand inside tangent side channel 49 1/8” Dia. x 9-1/2” lg.Drive band 16 Right hand inside tangent side channel 50 Motor 17 Take-up mounting angle 51 Gear reducer 18 45°/90° outside curve channel 52 Drive sprocket 19 Tail sheave shaft 53 Gear reducer drive sprocket 20 Drive sheave shaft 54 #50 (thru 1-1/2 HP) ir #60 roller chain 21 Bed spacer rod 55 Chain guard angle mount (Not shown)

22 3 hole ﬂange bearing w/1-3/16” bore 56 Reducer push plate assembly 23 Pillow block bearing w/1-3/16” bore 57 Underneath motor base plate

DESCRIPTION ITEM

DESCRIPTION

Specify Unit Serial Number when ordering replacement parts to ensure proper allocation of components (See Ordering Replacement Parts on page 15).

Recommended Spare Parts are shown in red. Charted are item numbers and part descriptions.

When ordering use example below.

Example: Need a replacement 254T tapered roller for 196LRC

Part No: SN 123456 - 2 - 254T tapered roller

Page 19

MODEL 196LRC

ILLUSTRATIONS FOR UNIT WITH END DRIVE / SIDE MOUNT END DRIVE

Page 20

MODEL 138LRCS

PARTS LIST FOR UNIT WITH END DRIVE / SIDE MOUNT END DRIVE

ITEM

1 138G roller w/5/16” hex (shortened for spur) 38 5/16” ﬂange nut

2 138G roller w/5/16” hex 39 5/16” ﬂat washer 3 138T tapered roller 40 3/8” ﬂange nut

4 Spur assembly (specify 30° or 40°) 41 3/8” ﬂat washer

5 138G grooved roller 42 7/16” lock washer

6 138G pinned roller w/5/16” hex (shortened for spur) 43 1/2” hex nut 7 Take-up sheave mounting channel 44 1/2” lock washer 8 Splice plate 45 1/2” ﬂange nut

9 Bolt-in butt coupling (left hand) 46 1/8” x 1” cotter pin 10 Bolt-in butt coupling (right hand) 47 1/2” ﬂat washer 11 Pillow block mounting bracket 48 Orange nylon ﬁnger guard 12 Take-up rod support angle 49 Black nylon sheave spacer/adaptor 13 Sheave mounting channel 50 V-belt sheave w/1-3/16” bore 14 Flange bearing mount 51 Flat idler sheave 15 Spur mounting bracket 52 Nylon 3” O.D. V-groove take-up sheave 16 32-1/2” IR inside curve channel 45°/60° 53 Steel 4” O.D, V-groove take-up sheave 17 Idler sheave angle 54 V-Belt 18 Outside tangent drive side channel 55 Drive band 19 Inside tangent side channel 56 Motor 20 Take-up mounting angle 57 Gear reducer 21 32-1/2” IR outside curve channel 45°/60° 58 Drive sprocket 22 Roller mounting clip 59 Gear reducer drive sprocket 23 Drive sheave shaft 60 #50 (thru 1-1/2 HP) or #60 roller chain 24 Tail sheave shaft 61 Chain guard angle mount (not shown) 25 Bed spacer rod 62 Reducer push plate assembly

26 3 hole ﬂange bearing w/1/3/16” bore 63 Underneath motor base plate 27 Pillow block bearing w/1-3/16” bore 64 End Drive Chain Guard Assembly

28 3/8” x 3/4” HHCS 29 3/8” X 1-1/4” HHCS OPTIONAL SIDE MOUNT END DRIVE PARTS LIST 30 3/8” X 1-1/2” HHCS 56 Motor 31 3/8” X 1-3/4” HHCS 57 Gear reducer 32 3/8” X 2-1/4’ HHCS 58 Drive sprocket 33 7/16” X 1” HHCS 59 Gear reducer drive sprocket 34 1/2” X 1-1/2” HHCS 60 #50 (thru 1-1/2 HP) or #60 roller chain 35 1/2” X 6” HHTB 61 Reducer push plate assembly 36 5/16” X 3/4” carriage bolt 62 Side mount motor base plate 37 3/8” X 3/4” carriage bolt 63 Side mount chain guard assembly

DESCRIPTION ITEM

DESCRIPTION

Specify Unit Serial Number when ordering replacement parts to ensure proper allocation of components (See Ordering Replacement Parts on page 15).

Recommended Spare Parts are shown in red. Charted are item numbers and part descriptions. When

ordering use example below.

Example: Need a replacement 138T tapered roller for 138LRCS

Part No: SN 123456 - 3 - 138T tapered roller

Page 21

MODEL 138LRCS

ILLUSTRATIONS FOR UNIT WITH END DRIVE / SIDE MOUNT END DRIVE

Page 22

MODEL 196LRCS

PARTS LIST FOR UNIT WITH END DRIVE / SIDE MOUNT END DRIVE

ITEM

1 196S roller (shortened for spur) 38 5/16” ﬂange nut

2 196S roller 39 5/16” ﬂat washer

3 254T tapered roller 40 3/8” ﬂange nut

4 Spur assembly (specify 30° or 40°) 41 3/8” ﬂat washer

5 196S grooved roller 42 7/16” lock washer

6 196S pinned roller (shortened for spur) 43 1/2” hex nut

7 Take-up sheave mounting channel 44 1/2” lock washer

8 Splice plate 45 1/2” ﬂange nut

9 Bolt-in butt coupling (left hand) 46 1/8” x 1” cotter pin 10 Bolt-in butt coupling (right hand) 47 1/2” ﬂat washer 11 Pillow block mounting bracket 48 Orange nylon ﬁnger guard 12 Take-up rod support angle 49 Black nylon sheave spacer/adaptor 13 Sheave mounting channel 50 V-belt sheave w/1-3/16” bore 14 Flange bearing mount 51 Flat idler sheave 15 Spur mounting bracket 52 Nylon 3” O.D. V-groove take-up sheave 16 32-1/2”/48” IR inside curve channel 45°/60° 53 Steel 4” O.D, V-groove take-up sheave 17 Idler sheave angle 54 V-Belt 18 Outside tangent drive side channel 55 1/8” Dia. x 9-1/2” lg. Drive band 19 Inside tangent side channel 56 Motor 20 Take-up mounting angle 57 Gear reducer 21 32-1/2”/48” IR outside curve channel 45°/60° 58 Drive sprocket 22 Roller mounting clip 59 Gear reducer drive sprocket 23 Drive sheave shaft 60 #50 (thru 1-1/2 HP) or #60 roller chain 24 Tail sheave shaft 61 Chain guard angle mount (not shown) 25 Bed spacer rod 62 Reducer push plate assembly

26 3 hole ﬂange bearing w/1/3/16” bore 63 Underneath motor base plate 27 Pillow block bearing w/1-3/16” bore 64 End Drive Chain Guard Assembly

DESCRIPTION ITEM

DESCRIPTION

Specify Unit Serial Number when ordering replacement parts to ensure proper allocation of components (See Ordering Replacement Parts on page 15).

Recommended Spare Parts are shown in red. Charted are item numbers and part descriptions. When

ordering use example below.

Example: Need a replacement 138T tapered roller for 196LRCS

Part No: SN 123456 - 3 - 254T tapered roller

Page 23

MODEL 196LRCS

ILLUSTRATIONS FOR UNIT WITH END DRIVE / SIDE MOUNT END DRIVE

Page 24

Roach conveyoRs

WaRRanty

• MaterialsusedbyRoachConveyorsareofgoodquality.

• AnypartprovingtobedefectiveinmaterialsorworkmanshipuponRoachinspec-

tion, will be replaced at NO cost, FOB, Trumann, Arkansas, for one year. Installation expense will be paid by others.

• Roachliabilityincludesfurnishingsaidpartorparts;Roachisnotliableforconsequential damages, such as loss of profit, delays or expenses incurred by failure of said part or parts.

• Failureduetoabuse,incorrectadjustments,exposuretocorrosiveorabrasiveenvironment or operation under damp conditions does not constitute failure due to defects in workmanship or materials.

• ComponentpartsnotmanufacturedbyRoach(motors,gearreducers,etc.)will

be repaired or replaced at the option of their manufacturer. Contact nearest authorized service center for all warranty claims.

NOTE: Motors or gear reducers tampered with before inspection shall be considered free of ALL Warranty Claims.

--All specifications are subject to change without notice--

--Drawings are intended for illustration ONLY and are not to scale--

Tel 870-483-7631 Fax 870-483-7049

ROACH CONVEYORS

808 HIGHWAY 463 NORTH

TRUMANN, ARKANSAS 72472-1310

[email protected]

www.roachconveyors.com

MCW06622-18

05-2007