AGI HI ROLLER User manual

Part Number: P115506 R3
Revised: 12/10/16
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.
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: [phone] / Fax: [phone]
www.hiroller.com / e-mail: [e-mail]

This product has been designed and constructed according to general engineering
standardsa. 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. For your
convenience, we include this sign-off sheet so you can record your periodic reviews.
a. Standards include organizations such as the American Society of Agricultural and Biological Engineers,
American National Standards Institute, Canadian Standards Association, International Organization for
Standardization, EN Standards, and/or others.
Date Employee Signature Employer Signature

TABLE OF CONTENTS
HIROLLER - BELT CONVEYORS
HIROLLER, MINI ROLLER, LOROLLER & HILIFE
P115506 R3 3
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. Lockout and Tagout Procedures .............................................................. 12
2.5. Electric Motor Safety.............................................................................................. 12
2.6. Safety Decals......................................................................................................... 12
2.6.1. Decal Installation/Replacement................................................................ 12
2.6.2. Safety Decal Locations and Details.......................................................... 13
3. Conveyor Components...................................................................................................... 17
3.1. Operator Orientation............................................................................................... 17
3.2. Component List...................................................................................................... 17
3.2.1. Head Sections & Discharges.................................................................... 18
3.2.2. Motor & Drive Mountings.......................................................................... 18
3.2.3. Trunking Sections..................................................................................... 19
3.2.4. Covers...................................................................................................... 20
3.2.5. Inlets/Loader............................................................................................. 22
3.2.6. V-Plow...................................................................................................... 23
3.2.7. Tail Sections............................................................................................. 24
3.2.8. Take-Up Sections..................................................................................... 24
4. Application Design Considerations ................................................................................. 27
4.1. Product/Capacity Considerations........................................................................... 27
4.1.1. Aspiration.................................................................................................. 27
4.2. Clearances............................................................................................................. 28
4.3. Discharge Considerations...................................................................................... 29
4.4. Inclines................................................................................................................... 29
4.5. Trunking Installation............................................................................................... 29
4.6. Loading Considerations.......................................................................................... 30
4.6.1. Special Loading Applications.................................................................... 31
4.6.2. Loading Goals .......................................................................................... 31
4.7. Splices.................................................................................................................... 33
4.8. Supports................................................................................................................. 33
4.9. Grounding............................................................................................................... 33

TABLE OF CONTENTS
HIROLLER - BELT CONVEYORS
HIROLLER, MINI ROLLER, LOROLLER & HILIFE
4P115506 R3
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. Tail Section Back Cover Removal & Installation....................................... 39
5.3. Inlet/Loader Installation .......................................................................................... 40
5.3.1. Skirt Installation ........................................................................................ 41
5.3.2. Discharge Considerations......................................................................... 42
5.4. Belt Installation....................................................................................................... 42
5.4.1. Pre-Installation.......................................................................................... 42
5.4.2. Belt Squaring & Cutting ............................................................................ 42
5.4.3. Splice Protector / Wiper Cleats................................................................. 46
5.4.4. Lubrication................................................................................................ 48
5.4.5. Belt Tension Procedure............................................................................ 48
5.4.6. Normal Idler Wear..................................................................................... 51
5.5. Leveling Tail Take-Up Section................................................................................ 52
5.6. V-Plow Adjustment................................................................................................. 52
5.7. Cover Installation.................................................................................................... 53
5.7.1. Made-To-Length Covers........................................................................... 53
5.7.2. Cut-To-Length Covers.............................................................................. 54
5.7.3. Cover Hardware........................................................................................ 55
5.8. Drive & Motor Final Check Before Start-Up............................................................ 56
5.9. Hazard Monitoring Devices .................................................................................... 56
5.9.1. Motion Sensor........................................................................................... 56
5.9.2. Plug Switch............................................................................................... 58
5.9.3. Belt Alignment Monitors............................................................................ 59
5.9.4. Belt & Pulley Alignment Monitors.............................................................. 68
5.10. Final Checklist...................................................................................................... 74
5.11. Test Start-Up........................................................................................................ 76
5.12. Final Inspection During Operation........................................................................ 76
6. Operation ............................................................................................................................ 79
6.1. Pre-Operational Checklist....................................................................................... 79
6.2. Conveyor Drive & Lockout Procedure.................................................................... 79
6.3. Operating Procedure.............................................................................................. 79
6.3.1. Start-Up and Break-In............................................................................... 79
6.3.2. Operating with a Full Load........................................................................ 80
6.3.3. Shutdown.................................................................................................. 80
6.3.4. Operating Tips.......................................................................................... 81
6.3.5. Plugging.................................................................................................... 81

TABLE OF CONTENTS
HIROLLER - BELT CONVEYORS
HIROLLER, MINI ROLLER, LOROLLER & HILIFE
P115506 R3 5
7. Maintenance ....................................................................................................................... 83
7.1. Maintenance Schedules......................................................................................... 83
7.1.1. Basic Preventative Maintenance Schedule.............................................. 83
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. Belt Tracking Misalignments..................................................................... 93
7.2.5. Belt Camber.............................................................................................. 93
7.2.6. Skew (Bow) .............................................................................................. 94
7.3. Idler Replacement - Hi Roller Models..................................................................... 94
7.4. Idler Replacement - Hi Life Models........................................................................ 99
7.4.1. Bottom Flat Idler....................................................................................... 99
7.4.2. Side Troughing Idlers ............................................................................. 101
7.5. Liner - Bottom Return Pan.................................................................................... 103
7.5.1. Fasteners................................................................................................ 103
7.5.2. Replacement .......................................................................................... 104
7.6. Fixed Tripper - All Models .................................................................................... 106
7.7. Head & Drive Pulley Lagging ............................................................................... 112
7.7.1. Removing Lagging:................................................................................. 112
7.7.2. Installation of New Lagging Plates ......................................................... 114
8. Troubleshooting............................................................................................................... 117
9. Appendix........................................................................................................................... 125
9.1. Skirt Installation Drawings.................................................................................... 125
Limited Warranty and Terms Of Sale.................................................................................... 129

HIROLLER - BELT CONVEYORS
HIROLLER, MINI ROLLER, LOROLLER & HILIFE
6P115506 R3

HIROLLER - BELT CONVEYORS 1. INTRODUCTION
HIROLLER, MINI ROLLER, LOROLLER & HILIFE
P115506 R3 7
1. Introduction
Hi Roller® Conveyors has worked very hard to ensure this new conveyor incor-
porates the best available designs. We hope that the conveyor meets your
expectations.
Because we have been involved with thousands of very similar installations, we
can help make your installation and start-up as smooth as possible. A well-
planned and accurate installation will greatly improve the longevity and perfor-
mance of this equipment.
Please review this manual and the specifications for the conveyor before instal-
lation begins so that you understand the proper installation procedure. We look
forward to many years of working with you and encourage anyone who has
questions to call us.
This operator’s manual should be regarded as part of the equipment. Suppliers
of both new and second-hand equipment are advised to retain documentary
evidence that this manual was provided with the machine.
Always give your dealer the serial number of your Hi Roller EBC when ordering
parts or requesting service or other information.
• The serial number plate is located at the discharge end of the conveyor, on
the motor mount or near the discharge. Please mark the number in the space
provided for easy reference.
Model#
Serial #
Production Year
Note: The first and second numbers of the
serial number represent the year and
the third and forth numbers represent
the month of manufacture.

1. INTRODUCTION HIROLLER - BELT CONVEYORS
1.1. GENERAL DESCRIPTION HIROLLER, MINI ROLLER, LOROLLER & HILIFE
8P115506 R3
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. The conveyor is designed to be totally enclosed during normal
operations with all covers, guards, inspection doors, etc. installed at all times of
normal operations. Operating conditions are many above ground, storage
reclaim tunnels, receiving pits, and above water levels; inside and outside of
buildings, open & enclosed structures, and outdoors in most climates. There will
a limited number of exposed people and operators as the conveyors will be
typically installed in an industrial facility.
Conveyors are designed and manufactured to be a complete conveyor when
properly installed by the customer or his representative. Complete Approval
Drawings, Installation Drawings and Manuals are provided with each conveyor.
The customer and his representatives must follow these documents to properly
install each conveyor. The specifications provided with each conveyor must be
followed.
When operating or maintaining the conveyor, never:
• change the size of the electric motor or pulleys to change the belt speed with-
out written authorization from Hi-Roller.
• overfeed or overload the conveyor.
• operate the conveyor empty for extended periods of time.
• stand or walk on top of conveyor.
• load off-center on the belt, idlers, and shafting.
• use the conveyor to support other equipment.
• weld anything to the equipment.
• convey material other than dry granular material.

HIROLLER - BELT CONVEYORS 2. SAFETY
HIROLLER, MINI ROLLER, LOROLLER & HILIFE 2.1. GENERAL SAFETY INFORMATION
P115506 R3 9
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. Follow the instructions in the safety messages.
Why is SAFETY important?
• Accidents disable and kill.
• Accidents cost.
• Accidents can be avoided.
SIGNAL WORDS: Note the use of the signal words DANGER, WARNING,
CAUTION, and NOTICE with the safety messages. The appropriate signal word
for each message has been selected using the definitions below as a guideline.
DANGER
Indicates an imminently hazardous situation
that, if not avoided, will result in serious injury
or death.
WARNING
Indicates a hazardous situation that, if not
avoided, could result in serious injury or
death.
CAUTION
Indicates a hazardous situation that, if not
avoided, may result in minor or moderate
injury.
NOTICE
Indicates a potentially hazardous situation that, if not
avoided, may result in property damage.

2. SAFETY HIROLLER - BELT CONVEYORS
2.2. INSTALLATION SAFETY HIROLLER, MINI ROLLER, LOROLLER & HILIFE
10 P115506 R3
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.
Remember, YOU are the key to safety. Good safety practices not only protect
you, but also the people around you. Make these practices a working part of your
safety program.
Important: Below are general instructions that apply to all safety practices. Any instructions
specific to a certain safety practice (e.g., Operational Safety), can be found in the
appropriate section. Always read the complete instructional sections and not just
these safety summaries before doing anything with the equipment.
• It is the equipment owner, operator, and maintenance personnel's responsi-
bility to read and understand ALL safety instructions, safety decals, and man-
uals and follow them when assembling, operating, or maintaining the
equipment. All accidents can be avoided.
• Equipment owners must give instructions and review the information initially
and annually with all personnel before allowing them to operate this product.
Untrained users/operators expose themselves and bystanders to possible
serious injury or death.
• Use this equipment for its intended purposes only.
• Do not modify the equipment in any way without written permission from the
manufacturer. Unauthorized modification may impair the function and/or
safety, and could affect the life of the equipment. Any unauthorized modifica-
tion of the equipment voids the warranty.
• Do not allow any unauthorized person in the work area.
2.2. INSTALLATION SAFETY
1. Splice protections / wiper cleats must be properly installed to obtain proper
reloading, to prevent product build-up on the return pan / bottom of the
trunking, and to prevent wear on the belt splice.
2. Splice protectors / wiper cleats must be properly installed on both mechanical
and vulcanized splices.
3. Never weld any item to any part of the covers, trunking, head section, or tail
section.
4. Ensure that there is proper support for the head section, tail section, and
trunking sections.
5. Clearances around the head section, tail section, and trunking are very
important for proper operation and maintenance.
6. Trunking must be installed straight and level.
CAUTION
Loaders/inlets must be installed properly to
achieve proper loading of the belt. Improper
loading can cause damage to the conveyor
components.

HIROLLER - BELT CONVEYORS 2. SAFETY
HIROLLER, MINI ROLLER, LOROLLER & HILIFE 2.3. OPERATIONAL SAFETY
P115506 R3 11
7. Inlet and discharge connections must be installed properly to maintain a free
flow of material to and from the conveyor.
8. Conveyor belt must be installed properly.
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.
2. Covers and guards must be bolted in place for safe operation.
3. Conveyor covers can never be used as walkways.
4. Untrained personnel must be kept outside of the work area.
5. Keep body parts and clothing away from all moving parts.
6. Lock out power before servicing any moving part.
7. Hazard monitors must be installed and tested correctly to ensure proper
operation.
8. A final inspection before start-up is extremely important! Complete the “Final
Checklist” on page 74 to ensure proper and safe operation of the conveyor.
2.4. MAINTENANCE SAFETY
1. Lock out power before performing any maintenance.
2. Covers must be clamped in place to keep dust and weather contamination
out of the enclosure.
3. Drive/reducers are shipped dry and must be filled with the proper oil/lubricant
(as specified by the manufacturer) before start-up.
4. Bearings must be checked weekly to ensure proper operation. They must be
lubricated every 6 months, or with heavy usage, every 3 months. For more
information, see the manufacturer’s schedule.
5. Conveying belt tension, tracking alignment, and drive belt tension must be
checked weekly, or more often during seasonal weather changes.
6. To prevent damage to the gear reducer, ensure oil is filled to the level
specified by the manufacturer.
7. Only qualified personnel should service electrical components.
WARNING
If conveyors are not installed properly, they
will not operate at specified capacity and belt
damage can occur.
Improperly installed belts can rub on sidewall
and cause heat, creating a fire hazard.

2. SAFETY HIROLLER - BELT CONVEYORS
2.5. ELECTRIC MOTOR SAFETY HIROLLER, MINI ROLLER, LOROLLER & HILIFE
12 P115506 R3
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. LOCKOUT AND TAGOUT PROCEDURES
To minimize possibility of serious injury or death to workers from hazardous
energy release (for example, when restarting the equipment) and prevent worker
deaths from all forms of hazardous energy release, follow all lockout and tagout
procedures when installing and servicing equipment. Ensure that lockout and
tagout procedures are adhered to. For example:
• De-energize, block, and dissipate all sources of hazardous energy.
• Lock out and/or tag out all forms of hazardous energy.
• Ensure that only 1 key exists for each assigned lock, and that you are the
only one that holds that key.
• After verifying all energy sources are de-energized, service or installation
may be performed.
• Ensure that all personnel are clear before turning on power to equipment.
For more information on occupational safety practices, contact your local health
and safety organization.
2.5. ELECTRIC MOTOR SAFETY
• To prevent serious injury or death, only qualified personnel should service
electrical components.
• Keep electrical components in good repair.
• Ground electric motor before using.
• Inspect drive belts before using. Replace if frayed or damaged.
2.6. SAFETY DECALS
• Keep safety decals clean and legible at all times.
• Replace safety decals that are missing or have become illegible. See decal
location figures that follow.
• Replaced parts must display the same decal(s) as the original part.
• Replacement safety decals are available free of charge from your distributor,
dealer, or factory.
2.6.1. DECAL INSTALLATION/REPLACEMENT
1. Decal area must be clean and dry, with a temperature above 50°F (10°C).

HIROLLER - BELT CONVEYORS 2. SAFETY
HIROLLER, MINI ROLLER, LOROLLER & HILIFE 2.6. SAFETY DECALS
P115506 R3 13
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.
4. Slowly peel back the remaining paper and carefully smooth the remaining
portion of the decal in place.
5. Small air pockets can be pierced with a pin and smoothed out using the sign
backing paper.
2.6.2. SAFETY DECAL LOCATIONS AND DETAILS
Replicas of the safety decals that are attached to the equipment and their
messages are shown in the figure(s) that follow. Safe operation of the equipment
requires that you familiarize yourself with the various safety decals and the areas
or particular functions that the decals apply to, as well as the safety precautions
that must be taken to avoid serious injury, death, or damage.
INSTALL NEAR CONVEYOR DISCHARGE
P115508
P115509
P115510
INSTALL
BEHIND
GUARDS ON
MACHINE
P115511

2. SAFETY HIROLLER - BELT CONVEYORS
2.6. SAFETY DECALS HIROLLER, MINI ROLLER, LOROLLER & HILIFE
14 P115506 R3
INSTALL ON OR
BESIDE GUARD,
DEPENDING ON
AVAILABLE
SPACE
P115512
P115522
INSTALL NEAR EMERGENCY HANDLE

HIROLLER - BELT CONVEYORS 2. SAFETY
HIROLLER, MINI ROLLER, LOROLLER & HILIFE 2.6. SAFETY DECALS
P115506 R3 15
GENERAL EQUIPMENT
LABEL - INSTALL ON
CONVEYOR SPOUT
P115513
INSTALL NEAR
CONVEYOR
DISCHARGE
P115514
INSTALL NEAR
CONVEYOR
ELECTRIC MOTOR
P115515

2. SAFETY HIROLLER - BELT CONVEYORS
2.6. SAFETY DECALS HIROLLER, MINI ROLLER, LOROLLER & HILIFE
16 P115506 R3
P115528
INSTALL NEAR INLET(S)
P115516 P115524

HIROLLER - BELT CONVEYORS 3. CONVEYOR COMPONENTS
HIROLLER, MINI ROLLER, LOROLLER & HILIFE 3.1. OPERATOR ORIENTATION
P115506 R3 17
3. Conveyor Components
3.1. OPERATOR ORIENTATION
3.2. COMPONENT LIST
• Head Sections and Discharges
• Motor and Drive Mountings
• Trunking Sections
• Covers
• Loaders/Inlets
•V-Plow
• Tail Sections
• Take-Up Sections
FITTED WITH CLAMPS
FOR A NORTH
AMERICAN MARKET
FITTED WITH CLAMPS FOR AN
INTERNATIONAL MARKET
STANDARD ORIENTATION: TO DETERMINE
RIGHT AND LEFT, STAND BY TAIL SECTION
AND LOOK TOWARD HEAD SECTION.
REVERSIBLE CONVEYOR ORIENTATION: TO DETERMINE
RIGHT AND LEFT, STAND AT NON-DRIVE SECTION, AND
LOOK TOWARD DRIVE END SECTION.

3. CONVEYOR COMPONENTS HIROLLER - BELT CONVEYORS
3.2. COMPONENT LIST HIROLLER, MINI ROLLER, LOROLLER & HILIFE
18 P115506 R3
3.2.1. HEAD SECTIONS & DISCHARGES
• Head sections usually come with either a standard discharge (Figure 3.1)
or snubber head discharge, which is bolted to the head section (Figure
3.2). Discharges usually have an inspection hatch at the top and a four-
sided frame for transitions.
Figure 3.1 Standard Discharge
Figure 3.2 Snubber Head Section Discharge
3.2.2. MOTOR & DRIVE MOUNTINGS
Hi Roller mounts most factory supplied motors and reducers according to
manufacturers specifications. Figure 3.3 shows a right-hand mounted drive.

HIROLLER - BELT CONVEYORS 3. CONVEYOR COMPONENTS
HIROLLER, MINI ROLLER, LOROLLER & HILIFE 3.2. COMPONENT LIST
P115506 R3 19
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.
3.2.3. TRUNKING SECTIONS
HEAD / DRIVE END TRUNKING SECTIONS
• High leg end channel, inspection door location, and special flanges (Fig-
ure 3.4).
Figure 3.4
TAIL / NON-DRIVE END TRUNKING SECTIONS
• High leg end channel, inspection door, and two equal middle flange chan-
nels and opposite end of the high leg end channel.
INTERMEDIATE TRUNKING SECTIONS
• Each intermediate section has two equal flange channels, an equal flange
channel on the end, and another in the middle of each section (Figure
3.5).

3. CONVEYOR COMPONENTS HIROLLER - BELT CONVEYORS
3.2. COMPONENT LIST HIROLLER, MINI ROLLER, LOROLLER & HILIFE
20 P115506 R3
Figure 3.5
Note: For ease of assembly, sections are labeled and numbered starting with 1 on the
tail section.
3.2.4. COVERS
Covers are made to fit over the width of the conveyor and 5’ of a section.
STANDARD 5’ COVERS
Figure 3.6
Note: Covers can be cut to length at the factory if ordered to specific lengths. (Contact
Hi-Roller’s engineering department.)
INLET/LOADER
• Figure 3.7 shows a hold-down clamp (with a bend) near the inlet.