DEWATERING CONVEYOR - Employees · The drive chain needs to be routinely lubricated and chain tension checked. 1. See decals on conveyor and reference Lubrication Manual. 2. Lubricate

Revision Date 9/6/2019

DEWATERING CONVEYOR INSTRUCTION

MANUAL

www.usfarmsystems.com

2955 S. K Street Tulare, CA. 93274

(559)685-0340 (800)811-9462

Fax (559)685-9160

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TABLE OF CONTENTS How to Use this Manual ........................................................................................................................................................................ 1

Safety Instructions .................................................................................................................................................................................. 1

Qualifications ........................................................................................................................................................................................ 1

Warnings and Symbols ..................................................................................................................................................................... 1

Description ................................................................................................................................................................................................. 2

Installation ................................................................................................................................................................................................. 3

Tools/Equipment Needed ............................................................................................................................................................... 3

Conveyor on Cement Pad Installation ........................................................................................................................................ 3

Installing Conveyor Chain Limit Switch .................................................................................................................................... 4

Checking Rotation .............................................................................................................................................................................. 4

Checking Amp Draw .......................................................................................................................................................................... 4

Maintenance .............................................................................................................................................................................................. 4

Tools Needed ........................................................................................................................................................................................ 4

Scheduled Maintenance ................................................................................................................................................................... 5

Conveyor Bearings ........................................................................................................................................................................ 5

Drive Chain ....................................................................................................................................................................................... 5

Gearmotor ......................................................................................................................................................................................... 6

Cleaning Conveyor ......................................................................................................................................................................... 6

General Maintenance ........................................................................................................................................................................ 6

Preparation of Conveyor for Maintenance .......................................................................................................................... 6

Inspection ......................................................................................................................................................................................... 7

Disassembly of Conveyor ......................................................................................................................................................... 11

Replacement and Reinstallation ............................................................................................................................................ 15

Reassembly of Conveyor ........................................................................................................................................................... 17

Spare Parts ...................................................................................................................................................................................... 17

Troubleshooting Guide........................................................................................................................................................................ 18

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TABLE OF FIGURES Figure 1, Dewatering conveyor product features ...................................................................................................................... 2

Figure 2, Bearings grease location ................................................................................................................................................... 5

Figure 3, Drive chain & sprockets ..................................................................................................................................................... 7

Figure 4, Quick link point ..................................................................................................................................................................... 8

Figure 5, Worn sprocket that needs replacement (left) and new sprocket (right) ...................................................... 8

Figure 6, Top shaft and bearings ..................................................................................................................................................... 10

Figure 7, UHMW bearing with shaft .............................................................................................................................................. 10

Figure 8, Grooved UHMW bearing ................................................................................................................................................. 11

Figure 9, Loosening Chain .................................................................................................................................................................. 12

Figure 10, Cut Chain Location .......................................................................................................................................................... 12

Figure 11, Master link .......................................................................................................................................................................... 12

Figure 12, Removable cover ............................................................................................................................................................. 13

Figure 13, UHMW Bearing Housing ............................................................................................................................................... 13

Figure 14, Shaft alignment ................................................................................................................................................................. 14

Figure 15, Chain adjustment ............................................................................................................................................................. 14

Figure 16, BSH mounting bolts ........................................................................................................................................................ 14

Figure 17, Eccentric locking collar ................................................................................................................................................. 15

Figure 18, Weld locations ................................................................................................................................................................... 16

Figure 19, Looking down bottom of conveyor from top end .............................................................................................. 17

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HOW TO USE THIS MANUAL The following instruction manual is to be used for the purposes of inspecting, installing and performing

maintenance on US Farm System products. Each manual is specific to its product. Throughout this manual,

pay attention to safety warnings and notes that will assist you in performing various maintenance tasks.

Related documents and manuals are cross-referenced in this manual to provide additional relevant

information. If you are reading an electronic copy of this manual, there are links embedded in the manual

that you can use to navigate quickly between sections and other related documents.

Read instructions carefully and follow the order of procedures mentioned in each section. Before

performing any task in each section, review the required tooling list. The Scheduled Maintenance section

explains the routines to follow to keep your product running well. The General Maintenance section

explains more irregular maintenance and provides detailed instructions for disassembly and rebuild of

product. At the end of the manual there is a Spare Parts section with recommended spare parts to keep on-

hand to maintain day-to-day operation of product. A Troubleshooting Guide is also provided for finding the

cause of, and solutions to, common operational issues encountered with the product.

SAFETY INSTRUCTIONS

QUALIFICATIONS Persons installing or maintaining US Farm Systems equipment must be familiar with instructions listed in

this document as well as have the skills required to perform such tasks. Make sure to reference the tools

needed section within this manual to ensure that you can safely install or perform maintenance on

equipment.

Avoid potential hazards. Always abide by warnings and labels placed on products. If decals are worn or

missing contact US Farm Systems for more information or replacements.

WARNINGS AND SYMBOLS The following notes and warnings are used throughout this instruction manual to draw attention to

important instructions:

WARNING⚠ Special information on preventing injuries or requirements and prohibitions to prevent damage to the product.

NOTE☝ Special instructions to simplify working with the machine or to aid in efficient use of the product.

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DESCRIPTION

Figure 1, Dewatering conveyor product features

The US Farm Systems Dewatering Conveyor is the last component of equipment in the mechanical

separation process. The function of the equipment is to stack manure after processing by an auger and (or)

sloped screen. The secondary function of the conveyor is to provide additional dewatering using a two-

piece tub design, which incorporates a perforated inner screen. The solids are conveyed by the chain

assembly to the top of the conveyor and off the end where it piles.

Various lengths and widths are available as well as stationary or swing styles. Swing conveyors can extend

the amount of time between stack removal by providing the functionality to rotate the conveyor up to 45

degrees from center in either direction (producing multiple stacks).

Chain Guard

Gearmotor

Motor Sprocket Top Shaft

Assembly

Top Bearing

Motor Sprocket

Bushing Idler Sprocket

Assembly

Bushing

Chain Assembly

UHMW

Bearing

Chain Tensioner

Bottom Shaft

Assembly

Limit Switch

Drain Hopper Sprocket

Dewatering Screens

Lifting Eyes

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INSTALLATION If the dewatering conveyor is being installed as part of a complete separator system, then it is best to refer

to the applicable installation manual and site plan provided with the separator system. The system

installation manual will provide more detailed instructions and dimensions. However, the qualitative

instructions below provide a quick reference for the processes of installation of a dewatering conveyor.

You may also contact your dealer or US Farm Systems for more information.

TOOLS/EQUIPMENT NEEDED • 15/16” socket and wrench

• Hammer

• Amp tester

• Grinder

• 3/4" socket and wrench

• 7/16” socket and wrench

• Crow bar

• Chain breaker

• Crane truck or other lift with chain hoist • Flathead screwdriver • Phillips screwdriver • Allen Wrenches

CONVEYOR ON CEMENT PAD INSTALLATION Before performing installation of conveyor, verify that the concrete anchor plates for the conveyor a-frame

kit have been properly installed into concrete pad and that the concrete pad has sufficiently set to prevent

cracking or collapse. Make sure to use an electrician or other qualified individual to wire the conveyor and

other controls to the electrical control panel(s).

WARNING⚠ Ensure power to electrical control panels is turned off prior to performing installation of screw press.

1. Weld and bolt, A-frame assembly in place on mounting plates provided in concrete pad.

a. Reference installation manual or site plan for a-frame mounting location.

2. Tie 1/2” rope to half links on sides of conveyor.

3. Install roller press or screw press on end of conveyor, if applicable.

4. With a crane, or other similar lifting mechanism, lift conveyor onto concrete pad into position and

bolt fixed base mount, or slide swing base with drain, in place.

5. Lift front of conveyor to desired installation angle, usually 30 degrees.

6. Using a bucket truck, connect pulley side of a-frame cable kit onto chain hanger kit. Then slowly

disconnect conveyor from crane hoist.

WARNING⚠ Do not walk on conveyor while it is suspended in the air. Injury or death from fall may occur.

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INSTALLING CONVEYOR CHAIN LIMIT SWITCH When installing the Conveyor Chain Limit Switch, it is important to set the wand in the ‘Up’ position to

prevent confusion when starting the conveyor.

1. Locate the mounting plate for the conveyor on the side of the Drain Box.

2. Set the Limit switch under the mounting plate completely flush.

3. Align the Limit switch using the bolt holes, along with the threaded end of the switch facing towards

the base of the conveyor.

4. Use the existing or issued mounting hardware to bolt the Limit Switch into place.

5. Lastly thread the cable to the threaded connection of the switch.

CHECKING ROTATION Always check rotation of the motor when installing a new conveyor for the first time or reinstalling a

conveyor after maintenance. Attach electrical wires to motor and panel per wiring diagrams inside the

motor junction box and electrical panel. Check the rotation of the chain before installation. The conveyor

chain will move forward, toward the end of the conveyor. If the conveyor is installed and the wires are

connected so the chain runs backwards, it may cause damage to the conveyor. Conveyor rotation is also

indicated on the motor with a decal for reference.

CHECKING AMP DRAW After installing the conveyor with the separator system and connecting associated components, you will

want to check that the conveyor is running without pulling excess amps (running above motor

specifications). Check the conveyor motor amp draw as follows:

6. Make sure there is no blockage in the conveyor trough.

7. Make sure conveyor chain is properly tensioned.

8. Check Allowable amps on the placard of motor.

9. Set-up amp meter and start the conveyor. Initial reading may be high until the piping is full.

10. If the amp readings are within the range specified, a qualified electrician should set the overload in

the separator panel to 10% above usage to protect the motor.

WARNING⚠ DO NOT run the motor if the amp readings are too high. The motor will be damaged and not covered under warranty. It is recommended that you call US Farm Systems at 1-800-811-9462.

MAINTENANCE The maintenance section is broken down into Scheduled Maintenance and General Maintenance sub-

sections. Representing routine and infrequent maintenance items respectively. Always make sure the

power is turned off, and proper lockout tagout procedures are followed, prior to performing any

maintenance on the unit.

NOTE☝ Order all parts needed prior to starting maintenance. Reference Spare Parts section in this document.

TOOLS NEEDED • 15/16” socket and wrench

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• Crane truck or other lift with chain hoist • Hammer

• Amp tester

• Grinder

• 3/4" socket and wrench

• 7/16” socket and wrench

• Crow bar

• Cutting torch

• Plasma Cutter (For Stainless)

• Phillips Screwdriver

• Flathead Screwdriver

• Allen Wrenches

• Saw horses or stands or blocking to place conveyor on, two or more needed

• Pipe or rod length of the conveyor

SCHEDULED MAINTENANCE The conveyor requires routine lubrication, cleaning and inspection to maintain operation and prevent

damage. Keeping up with maintenance will ensure equipment lasts longer and runs to specifications. Most

scheduled maintenance requires a bucket truck to service the conveyor in place or a crane truck to lower

the conveyor nearer to the ground.

WARNING⚠ Always turn off the power to the conveyor before performing any maintenance.

CONVEYOR BEARINGS The top shaft bearings need to be routinely greased to keep shaft freely rotating. See greasing instructions

below:

1. See decals on conveyor and reference Lubrication Manual.

2. Grease the remote zerks connected to top shaft bearings (Figure 2).

Figure 2, Bearings grease location

DRIVE CHAIN

Drive chain tensioner

Grease Zerks

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The drive chain needs to be routinely lubricated and chain tension checked.

1. See decals on conveyor and reference Lubrication Manual.

2. Lubricate the entire drive chain per instructions provided in the lubrication manual.

GEARMOTOR The motor and gearbox for conveyors are integrated together into a ‘gearmotor’. Conveyor gearmotors are

grease packed and require routine lubrication to flush out contaminants. Reference decals on conveyor and

Lubrication Manual.

CLEANING CONVEYOR The conveyor should be cleaned monthly, or as needed based on operating conditions. Cleaning the

conveyor helps to detect problems via inspection and keeps the conveyor performing and draining

optimally.

1. Prior to cleaning, if the conveyor still has solids present, you may temporarily run the conveyor

manually (on ‘hand’) to clean excess solids out.

2. Using a pressure washer with turbo nozzle, clean dewatering screens of conveyor.

a. Keep a distance of at least 1’ from end of pressure washer wand to screen while cleaning.

This will prevent damage to the screens.

WARNING⚠ Make sure to use proper eye or face protection when cleaning conveyor. Abrasive or hazardous materials may blow back into eyes or mouth.

3. After cleaning, inspect screens for build-up of calcium deposits.

a. If excessive calcium build-up occurs, this will need to be removed with muriatic acid for

screens to drain properly.

WARNING⚠ Muriatic acid is a poison, follow all precautions as stated on Muriatic acid container.

4. Using a hose, clean solids from the length of the conveyor trough, drain hopper, and hopper flapper.

Also flush out conveyor drain.

a. Flush the vacuum hose lines coming from the sloped screen drain tubs that are connected to

the nipples located on the back of the conveyor drain hopper.

b. Inspect the hopper for any blockage and the flappers for any twine or build up and clear out

as necessary.

GENERAL MAINTENANCE You should routinely inspect the entire unit at 1000 operating hours. Depending on operating conditions,

and the amount of abrasives present in the solids, a more frequent inspection may be recommended. The

following sections will explain how to inspect, disassemble, and reassemble conveyor components.

WARNING⚠ Prior to performing any maintenance on the unit, make sure the power is turned off, and proper lockout tagout procedures are followed.

PREPARATION OF CONVEYOR FOR MAINTENANCE

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The conveyor will need to be lowered prior to performing inspection or maintenance:

1. With a crane or similar lifting mechanism, connect a chain hoist to the four lifting eyes on the

conveyor trough.

2. Put tension on the chain hoist to support the conveyor with the crane and using a bucket truck,

disconnect the pulley side end of the cable kit from conveyor chain hanger kit.

3. Slowly lower the conveyor away from a-frame and place on support blocks on ground.

INSPECTION General maintenance should not be performed until after the conveyor has been thoroughly inspected. This

helps to ensure that any parts that require replacement are ordered from your dealer or US Farm Systems

prior to performing major maintenance. Refer to the following sections on how to inspect, perform

installation, and maintenance different conveyor components. Also, refer to the Troubleshooting Guide at

the end of this document for detailed instructions on causes of various malfunctions and their resolutions.

NOTE☝ The conveyor support cable and hardware must be inspected for rust or broken strands on cable at least once a year.

Drive Chain & Sprocket Assembly The drive chain connects the motor sprocket to the sprocket that turns the top shaft of the conveyor

(Figure 3). The drive chain can become loose from the constant tension caused during operation. The

sprockets also wear over time and the chain links stretch. This can cause the chain to start skipping.

Figure 3, Drive chain & sprockets

1. If not already done, turn off the power to the conveyor.

2. Remove the chain guard.

3. Disconnect the chain at the quick link (shown in Figure 4).

a. Generally, this is only necessary if there are any obvious signs of sprocket wear that require

further inspection.

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Figure 4, Quick link point

4. Inspect the three sprockets by checking their teeth to make sure none are broken or becoming

sharp. If there are broken teeth or signs of sharpening teeth from chain wear (Figure 5), reference

the Drive Chain & Sprocket Assembly Removal section to replace sprockets and chain.

NOTE☝ When worn sprockets are replaced, it is also recommended to replace the drive chain. When a chain is stretched it will cause premature wear to new sprockets.

5. If sprockets are acceptable, inspect chain for play. If loose, you may remove links in the drive chain

so optimal tension can be applied. When enough of these links are removed and drive chain can no

longer be shortened, replace it.

Figure 5, Worn sprocket that needs replacement (left) and new sprocket (right)

Inspection of Conveyor Chain & Sprockets The conveyor chain moves solids along the conveyor and is a common wear item. Therefore, it is important

to properly inspect the conveyor chain to prevent the chain from breaking and causing damage to the body

or screens of the conveyor. The drive and idle sprockets, at the top and bottom of the conveyor, drive and

tension the chain. The sprockets also wear over time and need to be replaced.

1. If not done previously, turn off the power to the conveyor.

2. Wash down the conveyor and check the chain for any broken links. Run the conveyor to inspect the

entire chain.

Quick link

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3. Also inspect the chain for bent or damaged chain flights. Damaged chain flights can be removed and

repaired in sections, or the entire chain may require replacement.

4. If there are broken chain links or damaged chain flights, reference Conveyor Chain Removal section.

5. Remove the cover on the top of the drain hopper and measure chain distance to back of conveyor.

a. If chain is within 2” of the back of the conveyor, it needs to be adjusted or shortened.

b. If chain is not too long but has too much play, then the chain needs to be tensioned.

c. Reference the Adjusting Conveyor Chain section to shorten or tension chain.

6. Inspect sprockets for broken or uneven teeth. Sprockets should be removed and replaced if these

features are seen so chain will not be damaged.

a. Inspect top and bottom shafts where the sprockets are attached. If the sprocket has come

loose, the shaft will likely be grooved or damaged.

NOTE☝ When worn sprockets are replaced, it is also recommended to replace the conveyor chain. When a chain is stretched it will cause premature wear to new sprockets.

Inspection of Conveyor Screens and Trough Wear Strips The dewatering screens and the wear strips inside the trough of the conveyor need to be inspected for

wear caused by the conveyor chain. It is also important to inspect the conveyor screens for excessive

calcium build up. Excessive mineral deposits on the dewatering screens of the conveyor prevent the

conveyor from draining efficiently which may affect the dryness of the solids.

1. If not done previously, turn off the power to the conveyor.

2. Clean the conveyor per the Cleaning Conveyor section in this document.

3. Inspect for screens for holes or cracks, and areas where the metal seems very thin. The screens

tend to wear where the chain contacts the screen. Reference Conveyor Chain Removal for

instructions on replacing worn out screen sections.

4. Inspect wear strips on the bottom of the conveyor trough. If the strips are nearly worn down it is

recommended to weld new wear strips onto the bottom of the conveyor trough.

5. Also inspect screens for build-up of calcium deposits.

a. If excessive calcium build-up occurs, this will need to be removed with muriatic acid for

screens to drain properly.

WARNING⚠ Muriatic acid is a poison, follow all precautions as stated on Muriatic acid container.

Inspection of Top Shaft Assembly & Bearings The top shaft is attached to a sprocket that drives the conveyor chain and the top bearings stabilize the top

shaft (Figure 6). The top bearings can wear out over time due to the thrust generated by the conveyor

chain. An improperly installed set collar on the bearing can also cause failure. If the bearings fail or the

chain sprocket comes loose from the top shaft, the shaft will likely be damaged and require replacement.

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Figure 6, Top shaft and bearings

1. To inspect the top bearings, remove the sprocket per the Drive Chain & Sprocket Assembly Removal

section and loosen or remove the conveyor chain per the Conveyor Chain Removal section.

a. There must be very little tension applied to the top shaft to properly inspect bearings.

2. Inspect the bearings and top shaft.

a. Pry on the top shaft, if there is any play with the shaft, bearings should be replaced.

b. If the top bearing set collar came loose on either bearing, the shaft will be grooved and

damaged and will require replacement.

Inspection of Bottom Bearings The bottom shaft is attached to a sprocket that drives the conveyor chain and the lower bearings stabilize

the lower shaft (Figure 7). The UHMW bottom bearings are different than the top bearings and do not

require greasing. These bearings wear over time due to constant pressure and contact with the rotating

bottom shaft. If the bearings fail, it is likely that further damage may be caused to the conveyor.

Figure 7, UHMW bearing with shaft

1. To inspect the lower bearings, remove the drain hopper cover.

2. Inspect the bearings and bottom shaft.

a. If there is any play with the shaft, bearings should be replaced.

b. If the lower bearings are grooved to one side too far, they may need to be replaced. Check if

the shaft is grooved or damaged. If shaft and bearings are grooved, replace both via the

Lower Shaft Assembly & Bearings Removal section. If shaft is ok, rotate the bearings 180

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degrees so that they don’t risk failing (reference Inspection of Lower UHMW Bearing

Adjustment section).

Inspection of Lower UHMW Bearing Adjustment If the lower conveyor shaft is not damaged enough to be replaced but the bearings are grooved too far to

one side, rotating the bearing will allow the shaft to contact the untouched side of the bearing. This is just

as good as replacing the bearing and will lower the chances of the bearing failing.

1. To rotate the bearing(s), detach the corresponding UHMW bearing housing from the conveyor

body.

2. Slide off the bearing(s) and rotate them so that the grooved side is on the opposite face of the shaft

than before (reference Figure 8).

Figure 8, Grooved UHMW bearing

3. Reattach bearing(s).

4. Reattach UHMW bearing housing onto conveyor.

DISASSEMBLY OF CONVEYOR If any issues are observed during inspection, further disassembly may be required to perform maintenance

or replacement. The following sections will give instructions of the disassembly of the different conveyor

components.

Conveyor Chain Removal The dewatering conveyor screen is usually replaced in sections rather than one piece. Inspect the screen to

locate where it is damaged and how much of it will need to be replaced.

1. Remove conveyor chain by detaching a master link (Figure 11) then use a crane truck or other lift

with chain hoist to lift out of conveyor frame.

2. Locate damaged section of screen.

3. Cut the side welds of the damaged screen section(s).

4. Carefully lift and slide out panel(s).

5. Reference Conveyor Screens Reassembly once ready to reassemble.

If after inspecting the conveyor chain (reference Inspection of Conveyor Chain & Sprockets) you find that

the chain is too loose or has broken links, additional maintenance will be required. A loose chain can be

adjusted, but eventually you will run out of room in the bottom of the conveyor to adjust the chain tension

and should remove links from the chain. A chain that is stretched too much can also cause premature wear

Grooved face

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to the top and bottom conveyor sprockets or cause the chain to skip. Consider changing the entire conveyor

chain if the chain has stretched considerably or follow these steps to shorten and reconnect the conveyor

chain:

1. Clean out the UHMW bearing slide housing as shown in Figure 13 (so the bearing will slide freely).

2. Completely loosen the all thread adjusters until they are almost completely removed (Figure 9).

Figure 9, Loosening Chain

3. Grind off a chain link (Figure 10).

Figure 10, Cut Chain Location

4. Pull chain up to figure out where you will need to reconnect.

5. Cut out excess link(s).

6. Reconnect with master link & insert roll pins (Figure 11). Tighten adjustment nut on each side until

slack is removed. Then tap nut with hammer to make sure slack is fully removed.

Figure 11, Master link

Loosen here

Cut here

Master link

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7. Reference Adjusting Conveyor Chain section steps 5 and 6.

Adjusting Conveyor Chain If the chain is measured to be within 2” of the back of the conveyor during the inspection process (see

Inspection of Conveyor Chain & Sprockets), it will need to be adjusted to keep the suitable tension in the

chain. A sloppy chain can cause damage to the shafts, conveyor screen, and conveyor sprockets. Follow

these instructions:

1. Turn off power.

2. Remove cover shown in Figure 12.

Figure 12, Removable cover

3. Spray out inside of UHMW bearing housing to allow bearing to slide freely during adjustment

(Figure 13).

Figure 13, UHMW Bearing Housing

4. Tighten adjustment nut on each side until slack has been removed. Then tap nut with hammer to

make sure slack is fully removed.

5. Measure distance from each side of the bottom shaft to back of conveyor to make sure it is equal

(Figure 14). If not, repeat step 4.

NOTE☝ If chain is within 2” of the back of the conveyor, it is time to remove some links or replace the chain assembly. Reference Inspection of Conveyor Chain & Sprockets section.

Remove cover

Clean here

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Figure 14, Shaft alignment

6. Re-tension tensioning mechanism shown in Figure .

Figure 15, Chain adjustment

Top Shaft Assembly & Bearings Removal If the top shaft, top bearings, or conveyor sprocket need to be replaced, you will need to remove the drive

chain and sprocket and temporarily disconnect the conveyor chain at a master link (Figure 11). Reference

Drive Chain & Sprocket Assembly Removal section. When replacing the top shaft or conveyor sprocket, it is

recommended to replace the entire top shaft assembly.

1. Loosen bearing mounting bolts and unbolt bearing from end of conveyor (Figure 16).

Figure 16, BSH mounting bolts

Mounting Bolts

Tension adjustment Slack adjustment

Make sure distances here are equal

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2. Loosen the eccentric locking collar set screws (Figure 17).

Figure 17, Eccentric locking collar

3. Unlock the eccentric locking collar(s) using a spanner wrench or hammer and drift.

4. Slide eccentric locking collar(s) off bearing’s inner ring and off shaft.

5. Slide bearing(s) off shaft.

6. Replace top shaft assembly.

7. Reference Top Shaft Assembly & Bearings Reassembly when ready to reassemble.

Lower Shaft Assembly & Bearings Removal If the lower shaft, lower bearings, or conveyor sprocket need to be replaced, you will need to temporarily

disconnect the conveyor chain at a master link (Figure 11). When replacing the bottom shaft or conveyor

sprocket, it is recommended to replace the entire bottom shaft assembly.

1. Remove UHMW bearing housings from the conveyor body.

2. Slide off lower bearings.

3. Replace bottom shaft assembly.

4. Reference Lower Shaft Assembly & Bearings Reassembly when ready to reassemble.

Drive Chain & Sprocket Assembly Removal If sprocket damage or wear is seen during inspection of conveyor drive chain or sprockets, then follow

these instructions to replace faulty parts:

1. Remove drive chain via quick link point (Figure 4).

2. Loosen and remove sprocket bushings where applicable. Remove and replace idler sprocket

assembly.

3. Slide off worn sprockets.

4. Reference Drive Chain & Sprocket Assembly Reassembly when ready to reassemble.

REPLACEMENT AND REINSTALLATION Refer to the sections below to reassemble your conveyor. Depending on the extent to which your conveyor

was disassembled, you will generally want to follow these sections in the order they are presented.

Conveyor Screens Reassembly

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1. Carefully lift and slide new screen section(s) into place.

2. Weld new sections on sides where they contact conveyor frame as well as where screen sections

meet (Figure 18).

NOTE☝ Use stainless-steel welding wire during welding

Figure 18, Weld locations

Top Shaft Assembly & Bearings Reassembly To reinstall the top shaft assembly and bearings, follow the steps in of this document in reverse order.

Apply a liberal coating of Never Seize to all sliding parts and use Locktite 271 on all bolts. Once re-installed

grease all top bearings per Lubrication Manual.

Lower Shaft Assembly & Bearings Reassembly To reinstall the lower shaft assembly and bearings, follow the steps in Lower Shaft Assembly & Bearings

Removal section of this document in reverse order. Apply a liberal coating of Never Seize to all sliding parts

and use Locktite 271 on all bolts.

Drive Chain & Sprocket Assembly Reassembly To reinstall the drive chain and sprockets, follow the steps in Drive Chain & Sprocket Assembly Removal

section of this document in reverse order. Apply a liberal coating of Never Seize to all sliding parts and use

Locktite 271 on all bolts.

Conveyor Chain Reassembly 1. Using pipe or rod the length of the conveyor, push rope to bottom of conveyor under screen (Figure

19).

Side welds

Section weld

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Figure 19, Looking down bottom of conveyor from top end

2. Tie rope to the chain and pull back, pulling chain as you feed it on top.

3. Connect chain at master link.

4. Adjust all-thread.

5. Make sure limit switch is up.

REASSEMBLY OF CONVEYOR 1. With a crane, or other similar lifting mechanism, lift conveyor onto concrete pad into position and

bolt base, or pivot base, in place.

2. Using a bucket truck, connect pulley side of cable kit onto chain hanger kit. Then slowly disconnect

conveyor from crane hoist.

SPARE PARTS To maintain operation and maximize uptime of your product, it is recommended that you stock some spare

parts for timely repair. The parts listed in the product parts book are recommended. Refer to the Conveyors

Parts Book supplied along with this manual. If applicable, always supply the product serial number, part

number, or original invoice number when ordering parts.

NOTE☝ These parts/sizes/lengths vary per unit. Serial Number required when ordering parts.

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TROUBLESHOOTING GUIDE

Fault Cause Solution

Chain is skipping Chain is not catching onto

sprocket teeth when being

pulled

Drive sprockets need to be

replaced; reference Drive Chain

& Sprocket Assembly Removal

• NOTE: Chain might need to

be replaced if damaged

Drain is plugged 1. Material is coming back through chain causing build up

2. Hoses between separator and conveyor tub are plugged

1. Chain wipers need to be replaced and drain needs to be cleaned out

2. Unplug hoses or readjust if slacking too much

Sprocket and motor is spinning but chain is not moving

1. Chain fell off sprocket 2. Keystock is sheared

1. Inspect chain and reinstall (replace if damaged)

2. Replace keystock • NOTE: shaft may be damaged

and require replacement

Chain flights are bent or damaged

1. Bottom shaft is misaligned

2. Trough has obstruction

1. Realign bottom shaft in correct orientation

2. Clear any obstructions that are in the trough

3. Replace chain flights or entire chain base on expert recommendation

Chain shutoff switch trips 1. Chain is stretched

2. Chain is broken

1. Inspect for source of wear or cause of stretched or broken chain

2. Replace chain