Roach Conveyors 638CALR User manual

TECH HANDBOOK FOR BELT DRIVEN LIVE ROLLERS
TABLE OF CONTENTS
CAUTION LABELS
TECH HANDBOOK FOR BELT DRIVEN LIVE ROLLERS ....................................... 2
-Caution Labels ....................................................................................................... 2
CAUTIONS, WARNINGS AND HAZARDS .......................................................... 3
-Introduction ........................................................................................................... 3
-Cautions, Warnings and Hazards........................................................................... 3
SAFETY INFORMATION......................................................................................... 4
-Important Safety Guidelines .................................................................................... 4
-Understanding Pop Out Rollers ............................................................................... 4
RECEIVING AND INSPECTION ............................................................................. 5
-Shortages, Damages and Return Authorizations....................................................... 5
-Uncrating and Storage ........................................................................................... 5
GENERAL INSTALLATION INFORMATION.......................................................... 6
-Couplings / Attaching Bed Sections ........................................................................ 6
-Unit Squareness..................................................................................................... 6
-Squaring Bed Sections............................................................................................ 7
-Identifying / Installing Permanent Floor Supports...................................................... 7
KNEE BRACES, CASTERS AND CEILING HANGERS........................................... 8
-Installing Knee braces and Casters .......................................................................... 8
-Installation of Ceiling Hangers ................................................................................ 8
UNDERTRUSSING AND POLYTIER SUPPORTS................................................... 9
-Installation of Undertrussing.................................................................................... 9
-Installation of Polytier Supports ............................................................................... 9
INSTALLATION OF BELTING ............................................................................... 10
-Belt Connections................................................................................................... 10
-Maintaining Proper Belt Tension............................................................................ 10
BELT PATH............................................................................................................. 11
-Illustrations for Units With End Drive ..................................................................... 11
-Illustrations for Units With Center Drive ................................................................. 11
START-UP PROCEDURES ..................................................................................... 12
-Drive Chain and Sprocket Alignment..................................................................... 12
-Drive Chain and Sprocket Tension......................................................................... 12
-Gear Reducer Vent Plug ....................................................................................... 13
-Preparing for Initial Start-Up................................................................................. 13
BELT TRACKING.................................................................................................... 14
-General Information............................................................................................. 14
-Pop Out Rollers and Installation of Tread Rollers .................................................... 14
-Erratic Tracking at Start-Up................................................................................... 15
-Advanced Tracking Adjustments............................................................................ 15
SETTING PRESSURE ROLLER TENSION.............................................................. 16
-Model 638CALR Pressure Roller Adjustment........................................................... 16
-Model 796CALR / 251CALR Pressure Roller Adjustment......................................... 16
MAINTENANCE SAFETY PRECAUTIONS............................................................ 17
-Before Performing Maintenance ............................................................................ 17
-Maintenance and Follow-Up Details ...................................................................... 17
MAINTENANCE AND LUBRICATION ................................................................. 18
-Maintenance Schedules ........................................................................................ 18
-Recommended Lubricants...................................................................................... 19
-Report on Miscellaneous Maintenance Performed................................................... 20
TROUBLE SHOOTING AND REPLACEMENT PARTS ......................................... 21
-Trouble Shooting / Serial Plate ............................................................................. 21
PARTS LISTS FOR 638CALR................................................................................ 22
-Units With 4” and 8” End Drive............................................................................ 22
-Units With 4”, 8” and 12” Center Drive ................................................................ 23
-Units With 4” and 8” End Side Mount Drive.......................................................... 24
PARTS LISTS FOR 796CALR................................................................................ 28
-Units With 4” and 8” End Drive............................................................................ 28
-Units With 4”, 8” and 12” Center Drive ................................................................ 29
-Units With 4” and 8” End Side Mount Drive.......................................................... 30
PARTS LISTS FOR 251CALR................................................................................ 31
-Units With 8” and 12” End Drive.......................................................................... 31
-Units With 4”, 8” and 12” Center Drive ................................................................ 32
-Units With 8” and 12” End Side Mount Drive........................................................ 33
NOTES.................................................................................................................... 34
WARRANTY .......................................................................................................... 35
ABOVE: Label attached to all protective guards (drives, roller guards, etc.)
ABOVE: Label placed near all drive assemblies and at 30’ intervals

3
CAUTIONS, WARNINGS AND HAZARDS
INTRODUCTION
This manual was prepared as a “how-to-
guide” for installers, end-users and mainte-
nance personnel. It is also intended to educate
both owner (purchaser) and all individuals
working around the unit, of potential hazards.
With proper installation and maintenance, con-
veyors are essential for achieving a variety of
functions essential in today’s industrial market-
place. By following a simple, periodic mainte-
nance schedule, the life of a typical conveyor
(or, most any type of machinery--including our
automobiles!) will increase when compared to
a similar unit in an application receiving little
or no maintenance. You may find that a con-
veyor can become your best workplace friend
by following simple safety guidelines. Failure
to follow even the most basic safety
suggestions can result in serious per-
sonal injury.
Conveyors contain many moving parts--pulleys,
belting, chains, sprockets, shafts, rollers, etc.
Therefore, it is imperative to become familiar
with basic unit operation and know all points
of potential hazards.
Remember, when working around or near
conveyors (and any industrial machinery) it
is your responsibility to become familiar with
the unit, to know potential hazards (many are
noted with caution labels) and to operate unit
in strict accordance with the safety guidelines
in this manual.
Keep this manual in a safe place for future ref-
erence. It should be placed where appropriate
personnel may maintain proper maintenance
and records.
This manual must be read by all new
users before operating or working
near this unit.
CAUTIONS, WARNINGS AND HAZARDS
Always anchor permanent supports to floor (or mounting
surface). Use 3/8” x 2-1/2” (or longer) wedge anchors for
permanent installation in concrete flooring.
It is the responsibility of the customer and installation
personnel to supply and install net or mesh guarding on
overhead mounted conveyors to prevent product and/or debris
from falling to floor in areas where required.
To check drive sprocket alignment, shut “OFF” and lock out
power source before attempting any adjustments.
To check drive sprocket tension, shut “OFF” and lock out
power source before any adjustments are attempted.
Center drive guards MUST be replaced after installation
or maintenance.
Electrical controls must be designed by a qualified
electrical engineer to ensure that appropriate safety fea-
tures (emergency stops, pull cords, switches, etc.) are installed on
unit for safe operation. Before conveyor start-up, all operators
and other personnel coming in contact with unit must be properly
trained and must have read accompanying Tech Handbook.
Only trained personnel shall perform maintenance func-
tions. Before maintenance operations are performed, shut
conveyor “OFF” and lock out power source to prevent unauthor-
ized start-up. When maintenance is completed, only authorized
personnel shall be permitted to start conveyor following mainte-
nance or other emergency shut-off.
DO NOT OPERATE BEFORE READING THIS MANUAL!
KEEP IN SAFE PLACE--DO NOT DISCARD!

4
SAFETY INFORMATION
IMPORTANT SAFETY GUIDELINES
UNDERSTANDING POP OUT ROLLERS
In most instances, live roller conveyor
frames are equipped with slots in the frame
for tread rollers. Why is this necessary?
When installed below 7’-0” elevation,
tread rollers must be designed to pop out
of the frame to prevent injury to operator
or individuals coming in contact with tread
rollers. However, when installed at 7’-0”
and greater elevation, tread rollers must
NOT be allowed to pop out. Individuals
stationed below the conveyor could be
injured by rollers that inadvertently become
free from conveyor frame. Therefore, a
belt driven live roller originally supplied
with slotted frame and pop out rollers, must
be modified if it is moved to 7’-0” or high-
er elevation. A special hold-down angle
must be installed to eliminate pop out roll-
ers. Also, when a live roller conveyor that
does not feature pop out rollers,
is used in an application below 7’-0”
elevation, conveyor MUST be modified to
include safety pop out rollers.
Contact Roach national sales at
870-483-7631 with conveyor serial
number for additional information.
WARNING: Belt driven live roller con-
veyors must have safety pop out tread
rollers when installed below 7’-0” eleva-
tion. Conversely, when installed at 7’-0”
or greater elevation, tread rollers must
NOT be allowed to pop out of frame.
Shut conveyor OFF and lock out power
source until above safety considerations
are completely adhered to.
*NOTE: Guard rail may be used to hold
rollers in frame when installed at 7’-0” or
higher elevations.
SLOTTED FRAME ALLOWS
ROLLERS TO EASILY POP OUT
(rollers removed for clarity)
WHEN GUARD RAIL IS ADDED,
DO NOT COVER POP OUT SLOTS
IN CONVEYOR FRAME*
GUARD
RAIL
WARNING: All personnel coming in contact with this conveyor should be aware of the following safety guidelines
BEFORE USING OR WORKING AROUND CONVEYOR. NOTE: ALWAYS notify Roach Manufacturing
®
whenever any
conveyor is used in an application or condition other than was originally intended. Failure to notify Roach
®
may
allow conveyor to be operated in a hazardous operating condition. Injuries resulting from negligence or violation of
safety instructions hereby removes responsibility of product liability claims from Roach
®
.
Do not operate conveyor with
protective guards removed. This
includes chain guards, belt guards, snub
roller guards, center drive guards and
any other safety guard.
Do not walk, ride, climb, or touch
moving parts on a conveyor in
operation.
Do not wear loose clothing or
uncovered hair around conveyor.
Do not work near conveyor with-
out knowing how & where to shut
power “OFF” and lock out power source.
Do not remove jammed product
with conveyor running.
Do not replace parts or perform
maintenance on conveyor, or mov-
ing conveyor parts, without first shutting
“OFF” power to conveyor and locking out
power source.
Do not connect gravity to powered
conveyor without safety gravity
connector brackets.
To prevent electrical shock, conveyor
must be grounded, and have proper
electrical connections in accordance with
federal, state, and local codes.
Safety pop out rollers in conveyors
installed above 7’-0” elevation must
be retained by guard rail, clips, etc. Safety
pop out rollers must be allowed to pop out
when conveyors are installed at or below
7’-0” elevation.
It is the responsibility of conveyor
end-user to comply with all safety
standards including OSHA and other fed-
eral, state, and local codes or regulations.
Install protective guarding and other relat-
ed safety precautionary equipment to elimi-
nate hazardous operating conditions which
may exist when two or more vendors sup-
ply machinery for related use.
Any violation of above safety
instructions hereby removes all
product liability claims from Roach
Manufacturing Corporation ® .

5
UNCRATING AND STORAGE
RECEIVING AND INSPECTION
SHORTAGES, DAMAGES AND RETURN AUTHORIZATIONS
NOTE: Do not return goods to factory
without prior, written return authorization.
Unauthorized returns are subject to refusal
at factory.
NOTE: Never store belt placed directly
on floor. Elevate belting to prevent contact
with floor moisture.
Before uncrating, check the quantity of items
received against bill of lading to confirm that
all material has been received. Examine the
condition of the equipment to determine if any
damage has occurred.
Also, it is possible that some items may
become separated from the original shipment.
Therefore, when receiving goods, it is impera-
tive that the bill of lading (or, accompanying
freight documentation) be checked to ensure
receipt of ALL units ordered including ALL
accessories.
Damage and/or shortage in shipment should
be reported immediately to both vendor and
carrier. Obtain a signed
damage report from carrier agent and send
copy to vendor. Do not repair any dam-
age before obtaining this report.
For damaged shipments, consult factory to
determine if entire shipment must be returned
to factory for repair or if an immediate order
should enter production to produce a new,
replacement shipment.
In illustration A above, model 796CALR is
shown pelletized with belting and return roll-
ers for all bed sections mounted to top of crate
which is prepared for shipment.
After receipt and initial inspection is
completed, carefully remove crating and
look for essential components and specific
accessories that may have been boxed and
attached (or ‘banded’) to crating material.
Pop out tread rollers, guard rails and hard-
ware are often packaged and shipped in
this manner. Save all hardware for subse-
quent use by installation personnel.
The drive section will be shipped mounted
to its actual operating bed section (see
illustration at top of page). Intermediate
bed sections are shipped mounted on top
of drive bed section with formed steel stiff-
ener (spacer) brackets.
Belting must be housed in dry quarters.
Do not store belt on edge (see illustration
above). Also, never store belt placed
directly on floor. Elevate belting to prevent
contact with floor moisture.
Some items (electric motors, gearbox,
etc.) may be shipped direct from their
manufacturer to final destination. Thus,
the conveyor may consist of two or more
separate shipments.
INCORRECT STORAGE CORRECT STORAGE
ILLUS. A

6
GENERAL INSTALLATION INFORMATION
COUPLINGS / ATTACHING BED SECTIONS
UNIT SQUARENESS
Use mechanical hoist (fork truck or other
available means) to raise bed sections to
approximate installed elevation. Mate
intermediate sections with splice plates
to join bed sections (see illustration at top
of page).
One of the most critical elements of proper
installation is unit squareness. Check drive
pulley, tail pulley, snub roller (if used in
drive assembly) and return roller assem-
blies to ensure these components are
square with unit bed. A framing square
can be utilized to confirm that conveyor
frame is square. Also, a diagonal mea-
surement across the conveyor frame may
be used to determine if the frame is out of
square. If measurement is not equal, the
frame is not square. Rollers will be skewed
and product will run to one side of the
conveyor or perhaps, off of the conveyor
in some cases. The importance of unit
squareness is perhaps the single most criti-
cal stage of installation with belt driven live
roller conveyors. If unit is out of square,
proceed to next section for adjustments
required to square frame and components.
NOTE: One of the most critical elements
of proper installation is unit squareness.
Check pulleys, snub and return rollers and
square each with unit bed.
NOTE: It is critical for bed sections to be
field assembled in proper sequence
following bed section labels.
When preparing to install conveyor, first
locate all component sections in the actual
installation area. After uncrating, place
unit bed sections conveying side up. Each
bed section is marked to indicate proper
sequence for mating (see illustration above
for typical bed section labels).
It is critical for bed sections to be field
assembled in proper sequence following
bed section labels. Refer to bed section
drawing for location of supports and
assemble as shown.
Conveyors are set up at the factory, bed
section labels are applied, unit is test run
and receives rigorous quality assurance
inspection. At this time unit becomes
field-ready. Therefore, it is critical that
field installation personnel re-assemble unit
by mating beds in accordance with bed
section labels (and bed section drawing).
Create a reference base line on floor by
marking a chalk line along the centerline of
conveyor. Follow base line when installing
unit.
SERIAL # 321654
BED JOINT # 2 MARK # P-1
SERIAL # 321654
BED JOINT # 2 MARK # P-1
BED SECTION LABELS

7
IDENTIFYING/INSTALLING PERMANENT FLOOR SUPPORTS
GENERAL INSTALLATION INFORMATION
SQUARING BED SECTIONS
When conveyor section is determined to be
out of square, adjustments must be made
before proceeding to next section.
In illustration above, “x-bracing” or “squar-
ing rods”, are used to square a frame
that has become “racked” or is otherwise
out of square. It is common for bed sec-
tions to become racked during transit, thus
requiring adjustment during field assembly.
Squaring rods are supplied on the under-
neath side of bed sections and feature
a turnbuckle assembly which is used to
square accompanying bed sections. Adjust
the turnbuckle until the frame is squared.
Confirm by again taking a diagonal mea-
surement. The frame is then square when
diagonal measurements from opposite
sides are equal in measurement.
Next, tighten bolts in splice plates when
frame is square. Finally, conveyor must be
installed at level elevation across the width
to prevent erratic belt tracking or to prevent
package from travelling to one side of con-
veyor (which is especially possible on long
conveyor lines when unit is not installed
level across the width).
NOTE: Squaring rods are supplied on
the underneath side of bed sections and
feature a turnbuckle assembly which is
used to square accompanying bed sec-
tions. Adjust the turnbuckle until the frame
is squared.
CAUTION: Always anchor permanent
supports to floor (or mounting surface).
Use 3/8” x 2-1/2” (or longer) wedge
anchors for permanent installation in
concrete flooring.
Permanent supports may be installed on con-
veyors at various locations. However, it is
most common to use single tier permanent floor
supports at each end of a powered section (see
illustration A above) and where intermediate
bed sections are adjoined (see illustration B
above). Notice intermediate supports have two
lag bolts in a diagonal pattern while end (ter-
minal) supports have four lag bolts, one in each
of the four foot plate mounting holes.
When two (or more) powered conveyors are
placed end-to-end, a single tier permanent sup-
port may be used at the end junction commonly
supporting both units. Check load rating of
support before using this method of installation.
Adjust elevation to top of conveyor by loos-
ening bolts in support uprights, raising or
lowering conveyor and fully tightening bolts at
desired elevation. Tighten all bolts in supports
before unit operation. Complete support
installation by lagging support attachment
plates to floor. Confirm that unit is level across
width of conveyor before completing final sup-
port height adj.
*Supports are normally shipped at minimum
support height. See chart above.
*MINIMUM SUPPORT CHANNEL HEIGHT
MEDIUM DUTY HEAVY DUTY
SM-1 7-1/4” SM-7 34-1/4” SM-1 6-1/4” SM-7 25-3/4”
SM-2 10-1/4” SM-8 46-1/4” SM-2 7-3/4” SM-8 31-3/4”
SM-3 13-1/4” SM-9 58-1/4” SM-3 10-3/4” SM-9 43-3/4”
SM-4 16-1/4” SM-10 70-1/4” SM-4 13-3/4” SM-10 55-3/4”
SM-5 20-1/4” SM-11 80-1/4” SM-5 16-3/4” SM-11 67-3/4”
SM-6 24-1/4” SM-12 92-1/4” SM-6 19-3/4” SM-12 79-3/4”

8
KNEE BRACES, CASTERS AND CEILING HANGERS
INSTALLING KNEE BRACES AND CASTERS
INSTALLATION OF CEILING HANGERS
WARNING: It is the responsibility of the
customer and installation personnel to sup-
ply and install net or mesh guarding on
conveyors mounted overhead to prevent
product and/or debris from falling to floor
in areas where required.
Ceiling hangers are frequently used in
high-elevation applications for suspension
from ceiling. The 5/8” diameter (#11
UNC) all threaded rod is supplied to allow
infinite vertical adjustment along the length
of the suspension rod (see illustration
above).
Attach and firmly tighten U-shaped retainer
(“hat”) bracket to underneath side of lower
conveyor flange with hardware provided
to hold cross pipe (1” inside diameter)
against underneath side of conveyor.
Do not tighten cross pipe locking bolts
(these attach in the bottom of the U-shaped
retainer bracket) until threaded suspension
rods have been firmly secured to ceiling
structure.
To adjust conveyor elevation, tighten or
loosen lower nut and jam nut on threaded
suspension rods to desired elevation. A
lock washer must be used on suspension
rods to maintain unit at desired elevation.
When unit is at operating elevation and
unit has been levelled across bed width,
tighten locking bolts in U-shaped bracket
to secure position of cross pipe.
NOTE: Install knee brace (when supplied)
after final permanent support installation
and elevation adjustment.
Knee braces add strength to permanent
supports and stability to units in portable
applications. Install knee brace (when
supplied) after final permanent support
installation and elevation adjustment. Its
pivot bracket is bolted to underneath side
of lower conveyor flange and slotted end
is attached to outer side of support.
Casters (when supplied) are generally
installed at the factory. However, when
receiving casters direct from their supplier,
final attachment to support is necessary.
A special slotted pre-punched caster
attachment plate is supplied on supports
designed for casters.
A standard support is not designed for
attachment to casters. Field modification
or replacement of outside support
assemblies is required.

9
UNDERTRUSSING AND POLYTIER SUPPORTS
INSTALLATION OF UNDERTRUSSING
INSTALLATION OF POLYTIER SUPPORTS
When installing some conveyors, using a per-
manent support or ceiling hanger is simply not
practical. In this situation, three bed sections
(maximum) may be joined together utilizing
truss assembly, mounted underneath conveyor
(see illustration above).
Adjoin beds on floor using both connector rod
support assemblies and connector rods (5/8”
diameter-11UNC threaded rod). The diagonal
connector rod is used not only to support the
intermediate bed section joint but it is instru-
mental for setting and maintaining proper ten-
sion across intermediate spanned beds.
Use mechanical hoist (fork truck or other
means) to raise pre-assembled bed sections
(with undertrussing) to desired elevation
for final installation.
Use diagonal connector rods to level the under-
trussed beds both along and across the con-
veyor. Remember that the tension must provide
adequate for both dead load (conveyor weight)
and product load during unit operation.
WARNING: It is the responsibility of the
customer and installation personnel to sup-
ply and install net or mesh guarding on
conveyors mounted overhead to prevent
product and/or debris from falling to floor
in areas where required.
NOTE: To install, raise conveyor to
desired elevation, place cross pipe
underneath lower conveyor flange,
attach cross pipe to upright legs and use
U-shaped retainer (“hat”) bracket to con-
nect cross pipe to lower conveyor flange.
Polytier supports provide convenient
installation method for two or more tiers
of conveyor. To install, raise conveyor to
desired elevation (approximate). Place 1”
inside diameter cross pipe underneath
lower conveyor flange. Attach cross pipe
to upright legs. Use U-shaped retainer
(“hat”) bracket to connect cross pipe to
lower conveyor flange. Do not tighten
fully at this time.
There are two styles of attachment brackets
available for use with polytier supports.
Minimum elevation style (see TYPE “0”,
illustration above) offers lowest unit eleva-
tion, 0” + frame depth utilizing L-shaped
mounting bracket. Standard elevation style
offers unit elevation of 3-1/2” + frame
depth and includes bracket welded to cross
pipe which is bolted to upright legs during
installation.
When unit is at operating elevation and
unit has been checked across width for
level, tighten locking bolts in U-shaped
bracket. Add knee braces for unit rigidity.
*NOTE: Overall conveyor height is dic-
tated by type of drive assembly used--i.e.
underneath, center drive, sidemount, etc.
TYPE “0”
MIN. ELEVATION
IS 7-1/4” T.O.R +
0”*
STD. STYLE
MIN. ELEVATION
IS 3-1/2”
+ 7-1/4”*
POLYIER SUPPORT CHANNEL HEIGHT
PSM-1 23” PSM-6 53” PSM-11 83”
PSM-2 29” PSM-7 59” PSM-12 89”
PSM-3 35” PSM-8 65” PSM-13 95”
PSM-4 41” PSM-9 71” PSM-14 101”
PSM-5 47” PSM-10 77” PSM-15 107”

10
INSTALLATION OF BELTING
BELT CONNECTIONS
MAINTAINING PROPER BELT TENSION
Maintaining proper belt tension is vital to
unit operation. Enough tension should be
maintained so that drive pulley does not
slip under fully loaded conditions.
It is perfectly normal for a belt to stretch
(in varying climatic conditions) under rated
loading. Therefore, a short belt insert or
“belt patch” (or patches) is provided for
future removal when belting has stretched
beyond means of conveyor take-up assem-
bly. For yet additional belt take-up, the
belt should be cut and re-laced to maintain
proper belt tension.
To adjust conveyor take-up, adjust posi-
tion of take-up rod (see illustration above)
as required. Remember to equally adjust
both sides to hold take-up pulley square (to
maintain unit squareness for belt tracking).
Operating unit with slipping belt will
decrease life of both belting and pulley
lagging. Also, do not operate unit with
too much tension on belt. This will
decrease belt life and may harm unit drive
and take-up bearings. Over tensioning
belt requires additional horsepower from
unit drive.
CAUTION: Belt lacing must be kept in
good condition for safe work environment.
Also, do not operate unit with improper
belt tension. Unit is subject to abnormal
wear and maintenance when operated
with belt incorrectly adjusted.
CAUTION: Belt lacing must be kept in
good condition for safe work environment.
Conveyor belting is cut to proper length, laced
and assembled on conveyor at the factory. It is
test run and inspected before it is shipped to its
final destination.
Before field installation of belting, the cor-
rect side to be placed down must be deter-
mined. 6” wide PVC belting is supplied as
“COS” (cover one side, friction surface other
side). The friction surface offers decreased
friction and less driving force. The friction
side appears dull and grainy; the cover side
darker and shiny. On model CALR, the cover
side is placed down with the friction surface
up which drives tread rollers. On LR models,
cover side of belt is placed up. Therefore, for
temporary accumulation, place friction surface
up; for transportation ONLY, place cover side
up.
If unit is shipped “knocked down,” belt must
be re-threaded on unit during installation (see
opposite page). Join ends of belt as shown
above with lacing pin. Loosen threaded take-
up rods (if necessary) at take-up pulley equal
amount on both sides and re-adjust when belt
is installed keeping pulley square with conveyor
bed. A belt puller can also be used to join
belting.
BELT LACING PIN
(protrudes belt width
for clarity only)
BELT LACING
BELT WIDTH LACING ANGLE
6” 10¯
12” 5¯

11
BELT PATH
ILLUSTRATION FOR UNITS WITH END DRIVE
ILLUSTRATION FOR UNITS WITH CENTER DRIVE
DRIVE PULLEY
SNUB ROLLER
BELT
RETURN ROLLER
PRESSURE ROLLER
TAKE-UP PULLEY
TAIL PULLEY
TAIL PULLEY
WARNING: Belt driven live roller conveyors must have safety pop out tread rollers when installed below 7’-0” elevation.
When installed at 7’-0” or higher elevation, tread rollers must NOT be allowed to pop out of frame.
WARNING: Belt driven live roller conveyors must have safety pop out tread rollers when installed below 7’-0” elevation.
When installed at 7’-0” or higher elevation, tread rollers must NOT be allowed to pop out of frame.
PRODUCT FLOW
TREAD ROLLERS
PRESSURE ROLLERS
DRIVE PULLEY
BELT
RETURN ROLLER
TAKE-UP PULLEY
PRODUCT FLOWBELT FLOW
BELT FLOW

12
START-UP PROCEDURES
DRIVE CHAIN AND SPROCKET ALIGNMENT
DRIVE CHAIN AND SPROCKET TENSION
Maintaining proper chain tension is
especially important. Again, a periodic
visual inspection is recommended to
ensure chain tension within a pre-deter-
mined operating range.
Remember, before any adjustments are
attempted, conveyor must be shut “OFF”
and power source locked out.
Before replacing chain guard cover, check
to see if drive chain is operating within
1/2” range (see above illustration). If unit
is out of tolerance, adjustment is necessary.
To adjust drive chain tension, tensioner bolt
located on reducer push plate should be
tightened (rotate clockwise) if chain tension
is loose. Tighten until proper operating
range is achieved. If chain tension is too
tight, loosen tensioner bolt (rotate counter-
clockwise) as required. When adjustment
is complete replace chain guard cover.
WARNING: Do not operate unit until
chain guard cover is replaced. Serious
operator or other personal injury could
result if protective guarding is not replaced.
WARNING: To check drive sprocket
tension, shut “OFF” and lock out power
source before any adjustments are
attempted.
WARNING: To check drive sprocket
alignment, it is imperative that conveyor
is shut “OFF” and power source is locked
out before any adjustments are attempted.
Set up and maintenance of drive sprocket
and drive chain alignment is critical. A
periodic visual inspection is recommended
to confirm alignment of drive components
(which includes both drive sprockets and
drive chain). Should set screws become
loose, drive sprockets are subject to
excessive wear and ultimately, to untimely
replacement.
To check drive sprocket alignment, it is
imperative that conveyor is shut “OFF”
and power source is locked out before
any adjustments are attempted. Remove
chain guard cover and place straight-edge
(see illustration above) across face of both
drive sprockets. If re-alignment is neces-
sary, loosen set screws and adjust drive
sprockets as required. Remember to
securely tighten set screws when
alignment is complete.
Before replacing chain guard cover,
check drive chain tension as described
in following section, “Drive Chain and
Sprocket Tension.”
CHAIN GUARD REMOVED FOR CLARITY
WARNING: DO NOT OPERATE CONVEYOR
WITH CHAIN GUARD REMOVED
CHAIN GUARD
REMOVED FOR
CLARITY
WARNING: DO NOT
OPERATE CONVEYOR
WITH CHAIN GUARD
REMOVED
DRIVE PULLEY SHAFT
STRAIGHT EDGE
TENSIONER BOLT
GEAR REDUCER SHAFT

13
START-UP PROCEDURES
®
GEAR REDUCER WITH POSIVENT
PREPARING FOR INITIAL START-UP
Before conveyor start-up, all operators and
other personnel coming in contact with unit
must be properly trained and must have
read accompanying Tech Handbook.
Provisions must be in order to instruct all
personnel coming in contact with conveyor
on the location of emergency stops,
pull cords, etc.
A routine maintenance program should
be implemented before unit is placed into
operation so that fundamental unit compo-
nents are attended to. This maintenance
program should include an inspection to
ensure that any dangerous or hazard-
ous operating conditions are noted and
IMMEDIATELY corrected, as well as
including electrical and mechanical unit
inspections and corrections.
Finally, when conveyor is initially started,
an immediate visual inspection should
include motor, gear reducer, belt track-
ing (discussed in following section under
“Belt Tracking”) and related adjustments
noted in handbook for unit/component
corrections.
WARN ALL PERSONNEL TO KEEP CLEAR
OF CONVEYOR DURING UNIT START-UP
Electrical controls must be designed by a
qualified electrical engineer to ensure that
appropriate safety features (emergency stops,
pull cords, switches, etc.) are installed on unit
for safe operation. Before conveyor start-up,
all operators and other personnel coming in
contact with unit must be properly trained
and must have read accompanying Tech
Handbook.
PosiVent Unique design incorporates a single
seam construction. Factory filled with
synthetic lubrication for universal mounting. Lubed
for life, no oil changes are required.
To expedite the installation and start-up process, all gear reducers are shipped filled with oil. The reducers are sealed and
lubed for life and require no oil changes.

14
BELT TRACKING
GENERAL INFORMATION
POP OUT ROLLERS & INSTALLATION OF TREAD ROLLERS
CAUTION: Upon initial operation the
belt will stretch. To maintain proper belt
tension, adjustment of the take-up pulley
or removal of belt patch will be required.
ONLY trained personnel should make belt
tracking adjustments.
CAUTION: ONLY trained personnel
should make belt tracking adjustments.
Shut unit “OFF” and lock out power
source before attempting adjustments in
belt tracking.
WARNING: Belt driven live roller
conveyors must have safety pop out tread
rollers when installed below 7’-0” eleva-
tion. Conversely, when installed at 7’-0”
elevation or greater, tread rollers must
NOT be allowed to pop out of frame.
Upon initial use belting will stretch after
a few days of operation. Remember that
maintaining proper belt tension is a crucial
element in belt tracking. Therefore, this
stretching of a belt when placed into
operation may affect its ability to track.
Adjustment of the take-up pulley will likely
adequately compensate for initial stretch.
However, depending on the overall unit
length, removal of a belt patch may be
necessary to correct.
The return direction of the belt must clear
supports, ceiling hangers, floor openings,
etc. Dragging on such components will
contribute to belt tracking problems and
is certain to damage belting at extended
intervals. Also, do not allow belt to rub
against conveyor side frame.
In a reversible application, a belt that runs
off to one side in one direction will likely
run off to the other side when operated in
the opposite direction.
Belt must be tracked in both unloaded and
loaded situations. See following step for
installation of tread rollers to track belt in
loaded situation.
In most instances, live roller conveyor
frames are equipped with slots in the frame
for tread rollers. When installed below
7’-0” elevation, tread rollers will pop out
of the frame to prevent injury to operator
or individuals coming in contact with tread
rollers. Live rollers installed at 7’-0” or
higher elevations, require tread rollers to
be installed in a NON pop out design to
prevent rollers from popping out and caus-
ing injury to individuals stationed below
the conveyor. Therefore, the frame should
be punched rather than slotted OR a hold
down angle must be used to eliminate pop
out rollers in high elevation applications.
(See “UNDERSTANDING POP OUT ROLL-
ERS”, page 4).
Remove tread rollers from shipping crate
and install in conveyor. Once installed,
confirm that belt will track under loaded
conditions. If belt does not track after
tread rollers are installed, further adjust-
ments will be required. Confirm that return
rollers, beds and all pulleys are squared.
Skewing of return rollers in small incre-
ments may complete belt tracking.
REMOVE BELT PATCH
SLOTS FOR TREAD ROLLERS TO POP OUT TREAD ROLLERS
PRESSURE ROLLERS
RETURN ROLLERS
BELT

15
BELT TRACKING
ERRATIC TRACKING AT START-UP
ADVANCED TRACKING ADJUSTMENTS
When adjustments noted in previous sec-
tions have been completed and belt con-
tinues to track erratically, a final series of
tracking adjustments are necessary.
The following adjustments will be made
referring to the direction of belt flow and
not the product flow of the conveyor.
If belt tracks toward side “R” (see illustra-
tion above), skew return rollers in direction
“B” to shift belting toward side “L”. If belt
tracks toward side “L”, skew return rollers
in direction “A” to shift belting toward
side “R”.
Skewing head pulley (pulley at unit dis-
charge) in direction “A” moves belt toward
side “L”. Skewing head pulley in direction
“B” moves belt toward side “R”.
As a rule of thumb, do not use drive and
take-up pulley for belt tracking since this
will overly increase belt tension. When
adjusting take-up pulley, adjust both sides
an equal amount.
As a last resort, shift the tail pulley in
direction “B” to move belting toward side
“L”; shift head pulley in direction “A” to
move belting toward side “L”.
CAUTION: Upon start-up, if belt tracks
to one side of unit, turn unit “OFF”, lock
out power source and confirm that con-
veyor is square and that all prime tracking
components are square with bed. Belt
tracking adjustments should be performed
by trained personnel ONLY.
Improper tracking of conveyor belting
should be considered a “systems” problem
rather than solely a deficiency in the belt.
To explain, a belt is tracked with adjust-
ments made to the conveyor rather than
just the belting.
Upon start-up, if belt tracks to one side of
unit, turn unit “OFF”, lock out power source
and confirm that conveyor is square. All
prime tracking components must be square
with bed including drive pulley, tail pulley,
snub roller and return rollers. Both sides
of take-up should be adjusted exactly the
same amount. The conveyor should be
level across the width of the unit. Confirm
that the belt has been properly threaded
(see “Belt Path” section) and that belt lac-
ing is square with the belt edges. Make
adjustments as necessary; however, all
adjustments should be made in small incre-
ments.
Start conveyor again and operate for at
least ten minutes once initial phase of
adjustments are complete. If belt continues
to track erratically, turn unit “OFF” and
proceed to following section.
CHECK LEVEL ACROSS WIDTH OF UNIT
*SEE NOTE
AT RIGHT
CAUTION: Belt tracking adjustments
should be performed by trained personnel
ONLY. Read section on “Belt Tracking”
completely before attempting belt tracking
adjustments.
*NOTE: When making adjustments in
direction “A” or direction “B”, component
must pivot from side “L” with actual com-
ponent movement on side “R”.

16
SETTING PRESSURE ROLLER TENSION
CALR PRESSURE ROLLER ADJUSTMENT
NOTE: Do not apply too much pressure
to tread rollers. If too much tension is
applied, tread rollers may have tendency
to raise out of slotted frame.
Model CALR, cam adjusted live roller
conveyor, is set up and operational at
the factory prior to shipment with proper
drive tension pre-set by Roach assembly
personnel. The cam adjusted live roller
features the quickest and most simple
adjustment of drive tension on tread rollers.
The illustration above shows a typical
numbered cam and CALR frame. The
frame has openings where numbers on the
cam are visible. Therefore, at a glance,
the tread roller tension can be determined.
To readjust in field, return the cam on the
pressure rollers to zero by rotating the shaft
counterclockwise to reduce drive tension.
For quick adjustment use a hex socket. Use
a 5/16” for 638 CALR, a 7/16” for 796
CALR and an 11/16” for 251 CALR. Place
heaviest package at infeed. Beginning
at infeed, adjust cams by rotating shafts
clockwise until package begins to move.
Complete cam adjustment on entire unit
for minimum drive tension required to
convey.
NOTE: Apply adequate pressure to tread
rollers to convey heaviest box on conveyor.
If too much tension is applied, tread rollers
may have tendency to raise out of slotted
frame.
NOTE: For quick adjustment use a hex
socketl:
638 CALR..................5-16”
796 CALR..................7/16’
251 CALR..................11/16”
TO INCREASE DRIVE TENSION-ROTATE HEX SHAFT TO HIGHER
NUMBER ON CAM; LOWERING NUMBER DECREASES TENSION
CAMS (ROTATE TO ALTER DRIVE TENSION)

17
MAINTENANCE SAFETY PRECAUTIONS
BEFORE PERFORMING MAINTENANCE
MAINTENANCE AND FOLLOW-UP DETAILS
While performing maintenance do not wear loose clothing.
Immediately report any hazardous conditions--sharp edges,
pinch (or nip) points or other conditions that may result when
several manufacturers supply machinery which may create
operating hazards.
When using mechanical aids such as hoists, cables, or cranes
exercise extreme caution to prevent damage to conveyors or other
integrated machinery which may create a working hazard when
maintenance is completed and units are in operation.
Clean up any spilled lubricants or other materials used in the
maintenance process or those which may be deposited during unit
operation. Eliminating poor housekeeping practices increases unit
efficiency while creating safer personnel working conditions.
After maintenance, conduct visual inspection to ensure that all
safety devices and guards have been replaced. Confirm that all
units are clear of tools, debris or other items. Before starting
conveyor, check condition of unit caution labels (see
“CAUTION LABELS” at front of handbook). If labels have been
destroyed or are not clearly legible, call 870.483.7631 to receive
replacement labels. Placement of caution labels is critical to avoid
unauthorized unit operation which may result in hazardous work-
ing conditions for all related personnel coming in contact with
conveyor.
Warn personnel that conveyor is being prepared for start-up and
to stay clear of unit. Do not start conveyor until all personnel are
clear. When maintenance is completed, only authorized personnel
shall be permitted to start conveyor following maintenance or other
emergency shut-off.
One of the most important guidelines for maximizing conveyor
operation and personnel safety is to implement a regular mainte-
nance schedule and train personnel on the appropriate needs of
the specific unit.
Only trained personnel shall perform maintenance functions.
Before maintenance operations are performed, conveyor must
be shut “OFF” and disconnects locked in the “OFF” position to
prevent unit from unauthorized start-up during maintenance. All
personnel should be informed of the safety procedures associated
with unit maintenance and performance.
Do not perform any work on conveyors or conveyor system while
in operation unless it is impossible to otherwise conduct adjust-
ment, lubrication or other maintenance function. Only experi-
enced, trained personnel possessing advanced hazards-training
should attempt such critical operations.
CAUTION: Only trained personnel shall perform maintenance functions. Before maintenance operations are performed, conveyor must
be shut “OFF” and disconnects locked in the “OFF” position to prevent unit from unauthorized start-up.
CAUTION: Only trained personnel shall perform maintenance functions. When maintenance is completed, only authorized personnel
shall be permitted to start conveyor following maintenance or other emergency shut-off.

18
MAINTENANCE AND LUBRICATION
PERIODIC MAINTENANCE SCHEDULE
MODEL NO.__________
*All charts are for guidelines in normal operating or ‘as noted’ conditions. Severe applications may warrant additional maintenance.
MONTHLY RECOMMENDED MAINTENANCE SCHEDULE*
COMPONENT DETAIL OF MAINTENANCE
GEAR REDUCER Check for leaks
V-BELT DRIVE BELT Check for proper operating tension & overall wear
DRIVE SHEAVES Check & re-tighten set screws & check for overall wear
PILLOW BLOCK/FLANGE BEARINGS Lubricate (normal conditions)
DRIVE CHAIN Check for proper operating tension & for overall wear &
lubricate
DRIVE SPROCKETS Check for overall wear & re-tighten set screws
PERIODIC RECOMMENDED MAINTENANCE SCHEDULE*
COMPONENT DETAIL OF MAINTENANCE
GEAR REDUCER Check for leaks
DRIVE CHAIN Clean (brush in solvent) & re-lubricate by applying lubricant to
inside of chain with brush or spout can at 2000 hour intervals
MOTOR Check & clear motor ventilation openings at 500 hour intervals
Check misc. operating conditions (normal heat & noise)
WEEKLY RECOMMENDED MAINTENANCE SCHEDULE*
COMPONENT DETAIL OF MAINTENANCE
BEARINGS Lubricate in dirty, dusty or moist-wet conditions
UNIT SAFETY CHECK Confirm placement of all guards, warning labels &
check for loose bolts, nip points & other
hazards

19
MAINTENANCE AND LUBRICATION
RECOMMENDED LUBRICANTS
*NOTE: Temperatures listed indicate the nominal operational temperature for the specific lubricant listed. This does not imply that the bear-
ing housing, seals or any other conveyor unit component is rated to operate in this specific temperature range or environment. 250°F is the
maximum operating temperature for standard bearing lubricants and bearing components. Although various lubricants may enhance bearing
operation, special-order bearings may be required to achieve optimal bearing performance. For additional information, consult factory.
MISC. LUBRICANTS
LUBRICANT BRAND/DESCRIPTION
General Purpose Grease
(For -30¯F to 300¯operation)*
For extreme Temperature Operation
(-90¯F to 350¯F operation)*
Shell Dolium R (Shell Oil Co.)
(or Suitable equivalent)
Mobiltemp SHC-32 (Mobil Oil Corp.)
(or suitable equivalent)
Washdown Application*
(-30¯F to 225¯F operation)
(May require special consideration -- consult
factory)
Shell Alvania No. 3 (Shell Oil Co.)
(or suitable equivalent)
General Purpose Oil SAE 10; SAE 20 or SAE 30

20
MAINTENANCE AND LUBRICATION
REPORT ON MISCELLANEOUS MAINTENANCE PERFORMED
REPORT ON MAINTENANCE
CONVEYOR REPAIRED INSPECTION DETAIL OF MAINTENANCE COMPLETED (OR INSPECTION)
MARK NO. BY DATE LIST PARTS REPLACED OR REPAIRS
NOTES