MC3 ChipMaster Manual

ChipMaster
Operation & Maintenance
Manual

ChipMaster Conveyor
Operation & Maintenance Manual
2
Rev. 05-2021
MC3 Manufacturing Inc.
1979 Setterington Drive, RR2
Kingsville, Ontario N9Y 2E5, Canada
Phone: [phone]
Fax: [phone]
Email: [email protected]
Web: www.mc3mfg.com
The content of this manual is owned
and copyrighted by MC3 Manufacturing Inc.

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Operation & Maintenance Manual
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Rev. 05-2021
Table of Contents
Introduction
4
Delivery Inspection 5
Warranty 6
Safety 7
Safety Sign Off Form 10
Installation Instructions 11
Operating Safety 20
Operating Instructions 21
Maintenance 22
Troubleshooting 29
Replacement Parts 32
Recommended Spare Parts 34
Notes 36

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Introduction
Congratulations! You have made a wise choice of Hinge Belt
Conveyors. The MC3 ChipMaster Conveyor has been designed to
provide you with the highest standards of quality, reliability, and
durability. This manual has been prepared to familiarize you with
the operation and maintenance of your ChipMaster Conveyor. We
urge you to read this publication carefully and refer to it extensively
for correct operating procedures.
This manual is supplemented by a Safety Section, Lubrication, and
Maintenance Schedule. We urge you to read through this
information carefully. This will help to ensure safe and trouble-free
operation of your conveyor. All information, illustrations and
specifications in this manual are based on the latest product
information available. We, the manufacturer, reserve the right to
make any changes at any time.
For more great material handling solutions please visit
www.mc3mfg.com

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Operation & Maintenance Manual
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Delivery Inspection
Upon delivery of your ChipMaster Conveyor, check your packing slip or bill of landing accompanying
the unit. Should you find any components missing, contact MC3 Manufacturing Inc. immediately
with a description of the missing components and the serial number of the machine. See Fig. 1 for
serial tag location.
If any components have been damaged in transit, note it on the bill of lading and contact the Carrier
immediately.
The serial number is located near the gear drive unit.
Note:
For fast, correct service, please have the serial number when ordering parts for your conveyor.
Fig. 1

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Warranty and Limitations of Liability
 Seller warrants that the material and workmanship on the equipment manufactured by
MC3 Manufacturing will be free from defects at the time of shipment. If during the first 12
months (or 2000 hours, whichever comes first) of operation after final shipment, the Buyer
establishes to the Seller’s satisfaction that any part or parts manufactured by MC3
Manufacturing was defective at the time of shipment, MC3 Manufacturing, at its own
expense, will repair or replace (but not install) replacement parts. Buyer must contact MC3
Manufacturing within 12 months after delivery to user to allow any warranty coverage to
be applied. Seller’s liability under this warranty is limited to replacement parts only, and the
Seller will make no allowance for corrective work done unless agreed to in writing by MC3
Manufacturing. Charges for correction of defects by others will not be accepted unless
agreed to in writing, prior to work being performed, by an officer of the company. Damage
or deterioration due to extraordinary or ordinary wear and tear (including, but not limited
to, use of equipment to handle product of sizes, or weights and shapes, or at speeds or
methods which differ from information originally provided to Seller), chemical action, wear
caused by abrasive materials, or by improper maintenance and lubrication, or by improper
storage and handling shall not constitute defects. Failure to install or assemble equipment
properly shall not constitute defects. Warranty does not cover consumable items.
 Seller has made no representation, warranties, or guarantees, expressed or implied, not
expressly set forth on above paragraph. Seller shall not be liable hereunder for any
consequential damages included but not in limitation, damages which may arise from loss
or anticipated profits or production from increased cost or operation of spoilage material.
 The components used in manufacture of said equipment, which were manufactured by
others, will carry such manufacturer’s customary warranty, which Seller will obtain for
Buyer upon request.
 No representative of MC3 Manufacturing has been conferred with any authority to waive,
alter, vary, or add to the terms of warranty stated herein, without prior authorization in
writing executed by an officer of the company.
Note: To protect warranties on any conveyor components (i.e., gearbox, motor, bearings, belt, etc.)
call the Seller’s home office for authorization before disassembling or replacing. Failure to do so will
immediately void all warranties.

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Safety
Warning!
 Read and understand the operator’s manual and all other safety instructions before using
this equipment.
 Failure to follow operating instructions could result in serious injury or death.
This Safety Alert symbol means:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
DANGER - Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury. This signal word is limited to the most extreme cases.
WARNING - Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION - Indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury and/or property damage. It may also be used to alert
against unsafe practice.
For any questions not answered in this manual, please contact your dealer or:
MC3 Manufacturing Inc.
1979 Setterington Drive, RR2
Kingsville, Ontario N9Y 2E5, Canada
Phone: [phone]
Fax: [phone]
Email: in[email protected]
Web: www.mc3mfg.com
ATTENTION:
This symbol
identifies potential health
and safety hazards. It
marks safety precautions.
ATTENTION:
Your safety
and the safety of others
is involved.

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Safety - It’s in your interest
Safety Guidelines
 Safe operation is one of our main concerns. However, it is up to the operator to practice
caution and maintain safe operating procedures.
 To avoid personal injury, study the following precautions and insist that those working with
you follow them.
 DO NOT allow persons to operate this conveyor until they have read this manual and/or
been instructed by a qualified person.
 DO NOT use this conveyor while under the influence of drugs or alcohol.
 Replace any safety decals that may be missing or are unreadable. Location of decals are
indicated in this manual.
 Check that all guards are in place and securely fastened before starting the conveyor.
 NEVER operate the conveyor with guarding removed.
 Ensure all moving parts have completely stopped before opening shields or reaching into
conveyor.

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Installation Safety
 Wear safety glasses, safety shoes, and gloves.
 Ensure area around installation site is free of debris and obstructions.
 Be aware of any sharp edges while handling conveyor components.
 Be careful in and around the conveyor(s) during installation, and be aware of the location
of other personnel.
 When using the ‘come along’ winch to pull in the belt, ensure that the hooks are securely
attached before applying any pressure to ensure that they do not fly off and cause injury.
 Check that the frame is free of any protrusions (like welds) that could prevent the belt from
running smoothly in the frame.
 Ensure there are no foreign objects (nuts, bolts, tools etc.) on the frame or belt before
starting for the first time.
 Ensure that the conveyor belt and drive chain are correctly adjusted before starting for the
first time, and that all adjuster locknuts are tight to prevent slipping.
 Check the oil level in the gear reducer.
 Double check that all bearings, locking collars, and sprocket set screws are tight before
starting for the first time.
Safety Devices
This conveyor is fitted with a torque limiter as standard equipment to protect against excessive
torque loads.
When excessive torque is generated, the drive sprocket will slip against the linings and the conveyor
belt will stop moving. The gear motor will continue to run in this condition. See the General
Maintenance section on page 26 for further instruction on the torque limiter.

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Operation & Maintenance Manual
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Sign Off Form
MC3 Manufacturing Inc. follows the general Safety Standards specified by the Occupational Health
and Safety Administration (OSHA). Anyone who will be operating and/or maintaining this conveyor
must read and clearly understand ALL safety, operating, and maintenance instructions presented in
this manual.
Do not operate or allow anyone to operate this conveyor until such information has been reviewed.
Annually review this information.
Make these periodic reviews of SAFETY and OPERATION a standard practice for all your conveyors.
We feel that an untrained operator is unqualified to operate this conveyor.
A sign-off sheet is provided for your record keeping, showing that all personnel who will be working
with this conveyor have read and understood the information in this operator’s manual, and have
been instructed in the safe operation of this conveyor.
Date Employee Signature Employer Signature

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Operation & Maintenance Manual
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Rev. 05-2021
Installation
The key to a successful installation is careful and methodical working principles. Follow all
instructions fully and complete the installation in the order described. Some operations cannot be
completed until a later component has been installed.
Note: Before beginning the installation, ensure that you have fully read the following information,
and that you are comfortable in your abilities to complete the various tasks.
Ensure that you have read all the safety information in the preceding pages in order to protect
both yourself and co-workers from injury, and to protect the equipment from damage.
Only qualified personnel should assemble and install the equipment.
Only a qualified electrician should wire in the equipment according to your local electrical codes.
Depending upon the type and configuration, some conveyors are supplied fully assembled, and
only require installing, while others are supplied partially assembled, and need to be completed on
site.
Please follow the relevant instructions below for your specific conveyor.
Note: If special circumstances or questions arise, please contact MC3 Manufacturing Inc. at: (519)
325-1370 quoting the serial number of the machine.
Installation Tools
Following is a list of tools required to complete the installation
 Overhead crane or lift truck
 Welding equipment (required if your conveyor has an extended in-feed and has a welded
joint)
 Portable drills and carbide drill bits (required if your conveyor will be fastened to the
concrete floor).
 Portable grinder (required if your conveyor has an extended infeed and has a welded joint)
 Hand winch
 Assorted clamps and vice grips
 Measuring tape, square, and level
 Hand tools including wrenches, hammers, pliers, screwdrivers, etc.

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Operation & Maintenance Manual
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Fully Assembled Conveyors
 Unpack the conveyor and check for damage
 Ensure the installation area is flat and free of debris
 Position the horizontal in-feed section as desired and ensure that it is level in both directions
 Conveyors are supplied with one of three leg options:
o Fixed
o Adjustable
o Castors
 For fixed legs, drill through the holes in the feet and use suitable anchors to fasten the
conveyor to the floor
 For adjustable legs, slacken the clamping bolts on the legs and adjust the leg length. Re-
tighten the clamping bolts and check the in-feed for level. Drill through the holes in the feet
and use suitable anchors to fasten the conveyor to the floor
 For castors, lock the wheels with the wheel locks (if fitted)
 Ensure that the belt drive sprockets are correctly spaced on the drive shaft to align with the
belt rollers
 Ensure that the motor drive sprockets are axially aligned to prevent premature chain wear
and overloading of the drive motor
 Ensure all sprockets are securely fastened
 Check the oil level in the gear reducer
 If your conveyor is supplied with its own control box, this now needs to be wired into a
suitable electrical supply
 If your conveyor is supplied without a control box, then it will need to be wired into the
control system of your machine
Note: All electrical wiring must be completed by a qualified electrician according to local electrical
codes
Note: Before starting the conveyor for the first time, ensure there are no foreign objects (nuts, bolts,
tools etc.) on the frame or belt
Partially Assembled Conveyors
 Unpack the conveyor and check for damage.
 Ensure the installation area is flat and free of debris.
 Assemble the horizontal infeed section(s). Once the infeed section is assembled, move
conveyor body into position, check that it is level in both directions, and attach the incline
section to the infeed section of the conveyor.
Note: Some conveyors have welded joints and some have bolted joints, depending on the
construction type. If your conveyor is ‘liquid tight’, then any bolted joints will need to be sealed with
the sealant supplied.

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Operation & Maintenance Manual
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 Conveyors are supplied with one of three leg options:
o Fixed legs
o Adjustable legs
o Castors
 For fixed legs, drill through the holes in the feet and use suitable anchors to fasten the
conveyor to the floor
 For adjustable legs, slacken the clamping bolts on the legs and adjust the leg length. Re-
tighten the clamping bolts and check the in-feed for level. Drill through the holes in the feet
and use suitable anchors to fasten the conveyor to the floor
 For castors, lock the wheels with the wheel locks (if fitted)
 Remove the incline cover and the two chain guards located under the discharge area.
 Assemble the idle shaft as follows. See Fig. 1
o Place the idle sprockets on the idle shaft with the hubs to the inside.
o Place the idle shaft into the brackets on the tail end of the conveyor and secure with
the set screws.
Fig. 1
No.
Description
1
Infeed Section
2
Idle Shaft
3
Idle Sprockets
4
Tail End Cover

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Operation & Maintenance Manual
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Note: On a sectional belt, all mating sections are clearly identified, and the leading section has a
special pan with a welded hook attachment
 For belt supplied in sections, assemble as shown in Fig. 2
o Locate the mating ends of each belt section.
o Remove the cotter pins from the axle and pull the axle from the pan.
o Mate the tabs on the end pans, the side wings, and draw bars. Replace the axle and
cotter pins. Bend up both legs of the cotter pins to secure the axle.
o Repeat these steps for each belt section.
Fig. 2
 To assist in the installation of the belt, it is recommended that you temporarily remove the
drive shaft as follows. See fig. 3
Fig. 3
No.
Description
1
Draw Bar
2
Roller
3
Side Wings
4
Pan
5
Axle
6
Cotter Pins
No.
Description
1
Chain Guard
2
Drive Chain
3
Motor Drive Sprocket
4
Torque Limiter Assembly
5
Keys
6
Drive Shaft
7
Backplate
8
Belt Drive Sprockets
9
Conveyor Belt (Note: insert upside down

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o Remove the chain guard.
o Loosen all the set screws in the motor drive sprocket, torque limiter, belt drive
sprockets, and pillow block bearings.
o Slide the belt drive sprockets off their keys and remove the keys.
o Partially withdraw the drive shaft from the drive chain end and remove the belt
drive sprockets from the shaft. Continue to withdraw the shaft until the end of the
shaft is clear of the belt area but still supported by the pillow block bearing.
 Feed the belt into the lower track at the discharge end of the conveyor, starting with the
special lead pan with the welded hook.
Note: The belt must be inserted upside down (i.e., with cleats facing down). For correct belt
orientation see Fig. 4.
Fig. 4
 When the lead end of the belt reaches the idle shaft, position the idle sprockets so that the
teeth on the sprockets line up with the rollers on the belt.
 Wrap the lead end of the belt around the idle sprockets and insert it into the upper track.
Note: It may be necessary to use a small pry bar to gently ease the belt around the curve.
 Attach one end of a ‘come along’ style winch to the hook on the lead belt pan. Attach the
other end of the winch to a suitable location on the conveyor and begin to pull the belt up
the incline. See Figs. 5-7.

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Fig. 5 Fig. 6
Fig. 7
Note: It may be necessary to reposition the winch several times, depending upon the length of the
incline, size of winch, etc. See Figs 8-9.
Fig. 8 Fig. 9

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 Continue to pull the belt up the incline until the upper belt extends beyond the lower belt
by the width of one pan.
Note: In order to pull the belt around the final bend, the winch will need to be attached to an
immovable object, such as a fork lift. See Fig. 10.
Fig. 10
 Remove the cotter pins and axle from the special lead pan and store the pan in a safe place.
If you ever have to remove and reinstall the belt this pan will be required.
Note: The axle will have to be removed through the adjustment slots in the conveyor frame.
 Replace the drive shaft. Ensure that the keys are replaced in the keyways, the belt drive
sprockets are mounted with the hubs to the inside, the sprockets align with the rollers on
the belt, and the belt is centered between the inside faces of the conveyor. Once everything
is correctly aligned, tighten all the set screws in the belt drive sprockets and pillow block
bearings.
Note: Double check the tightness of the set screws holding the belt drive sprockets. These will not
be accessible once the ends of the belt are connected.
 Line up the belt draw bars, rollers, side wings, and pans and insert the axle through the
adjustment slots in the conveyor frame. Insert new cotter pins into the ends of the axle and
bend up both legs to secure.
 To tension the belt, slacken the bolts holding the pillow block bearings to the frame and the
locknuts on the belt adjusters. Use the nuts on the belt adjusters to apply tension evenly to
each side. The belt is correctly adjusted when there is slight up and down movement in the
underside of the belt at the discharge end and little to no up and down movement in the
belt at the tail end. Once the tension is correct, tighten the locknuts on the belt adjusters
and the bolts holding the pillow block bearings to the frame.
 Replace the key in the torque limiter and axially align the sprocket on the torque limiter
with the sprocket on the motor shaft. Tighten the set screws on the torque limiter.

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Note: It is important to ensure that the chain drive sprockets are axially aligned to prevent
premature chain wear and overloading of the drive motor.
 Adjust the tension in the drive chain using the threaded rods under the motor mount.
Slacken the locknuts and adjust the tension until there is approximately 1/8” of movement
in the chain at the mid-point between the sprockets. When the tension is correct, tighten
the locknuts on the adjuster.
 Check the oil level in the gear reducer.
 If your conveyor is supplied with its own control box, this now needs to be wired into a
suitable electrical supply. If your conveyor is supplied without a control box, then it will need
to be wired into the control system of your machine.
Note: All electrical wiring must be completed by a qualified electrician according to local electrical
codes.

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Starting the First Time
Make sure area is clear of people and foreign objects.
Note: Before starting the conveyor for the first time, ensure there are no foreign objects (nuts,
bolts, tools etc.) on the frame or belt. The area around the conveyor should be cleared of personnel
and ‘Caution’ tape or temporary fencing should be installed to prevent access to any moving parts.
 To start the conveyor, press the <Start> button on the control panel or issue the start
command from your machine control system.
 If the motor starts but the torque limiter slips, immediately stop the conveyor and lockout
the electrical system. Check the torque limiter for contamination with oil or grease. If it is
clean then it will have to be adjusted. Please refer to the safety considerations regarding
the torque limiter on Page 9 of this manual and the manufacturers information sheet in the
Appendix.
Note: Do not over-tighten the torque limiter. This will lead to premature failure or over-loading of
the drive motor. The torque limiter needs to be adjusted so that it will carry no more than the
weight of the belt and the required load.
 After cleaning or adjusting the torque limiter, re-start the conveyor and ensure that the
conveyor operates correctly.
 Run the conveyor for approximately 30 minutes to allow the components to ‘settle in’. Stop
the conveyor and lockout the electrical system.
 Check the tension on the belt and the drive chain and adjust if necessary. Re-check the
tightness of all nuts, bolts and set screws.
 After the initial run and all adjustments have been made, install the covers on the tail end,
incline, and motor drive.
 Replace the two chain guards located under the discharge area.

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OPERATING SAFETY
1. Read and understand all of this Operator’s
Manual and all safety signs before using.
2. Disconnect power supply and lock out before
removing any guards, attempting any
maintenance, trouble shooting, or making
adjustments.
3. Clear area of personnel and foreign objects
before starting the conveyor.
4. Keep hands, feet, hair, and clothing away from
all moving and/or rotating parts.
5. Do not operate conveyor when any guards are
removed.
6. NEVER attempt to free the belt while the
conveyor is still running, as it could suddenly
re-start and cause injury to personnel or
damage to the conveyor.
7. Secure mounting hardware before operating.
8. Use conveyor only for intended purpose.
9. Review safety related items annually with all
personnel who will be operating or maintaining
this conveyor.
TO THE NEW OPERATOR OR OWNER
The ChipMaster Conveyor is designed to
filter waste material from machining and
sort scrap that accumulates from metal
forming. Be familiar with the conveyor
before starting.
In addition to the design and configuration
of the conveyor, hazard control and
accident prevention are dependent upon
the awareness, concern, and prudence of
personnel involved in the operation and
maintenance of the conveyor or in the use
and maintenance of facilities. It is the
responsibility of the owner or operator to
read this manual and to train all other
operators before they start working with
this conveyor. Follow all safety instructions
exactly. Safety is everyone’s responsibility.
By following the recommended
procedures, a safe working environment is
provided for the operator, bystanders, and
the area around the worksite. Untrained
operators are not qualified to operate this
conveyor.
Many features incorporated into this
conveyor are the result of suggestions made
by customers like you. Read this manual
carefully to learn how to operate the
conveyor safely and how to set it to provide
maximum efficiency. By following the
operating instructions in conjunction with a
good maintenance program, your conveyor
will provide many years of trouble-free
service.