Superior Dozer Trap Installation instructions

WARNING!
Read manual before
operating equipment.
Operator’s and Maintenance Manual
Dozer Trap
WO# 1171768 02-2018

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Table of Contents
General Safety .............................................................. 1
Signal Words and Symbols ...................................... 1
Owner Responsibilities ............................................. 1
Safety Rules ............................................................. 1
Lockout/Tagout/Blockout ............................................ 3
Lockout/Tagout ......................................................... 3
Blockout .................................................................... 3
Dozer Trap Decal Identification .................................. 4
General ..................................................................... 4
Conveyor .................................................................. 5
Discharge Hood (If Applicable) ................................. 6
Dozer Trap Carbody Overview .................................... 7
Overview ................................................................... 7
Diesel Engine Control ............................................... 8
Gauges, Panel & Diesel Fuel Fill Point ..................... 9
Tracks ....................................................................... 9
Dozer-Trap Site Prep ................................................. 10
Site Preparation ...................................................... 10
Pit Transporting Dozer-Trap ..................................... 11
Prepping Equipment for Pit-Transport .................... 11
Pit Transporting Dozer-Trap ................................... 11
Conveyor Load Area Components ........................... 13
Load Area ............................................................... 13
Weld-In Hopper ...................................................... 13
Flow Control ........................................................... 13
Conveyor Skirtboard Overview ............................... 14
Take-Ups ................................................................ 15
Material Loading ........................................................ 17
Guidelines ............................................................... 17
Loading Belt ............................................................ 17
Conveyor Belt ............................................................. 19
Belt Installation ....................................................... 19
Belt Travel .............................................................. 20
Belt Tracking ........................................................... 20
Checking Belt and Components for Squareness .... 20
Belt Run Off ............................................................ 21
Check Belt Splice Squareness ............................... 21
Belt Re-Splicing ...................................................... 21
Belt Length ............................................................. 21
Belt Tension ............................................................ 21
Belt Repair .............................................................. 22
Storage ................................................................... 22
Maintenance ........................................................... 22
Troubleshooting ...................................................... 23
Operation Checklist ................................................... 25
Before Starting Conveyor for First Time ................. 25
Before Starting Conveyor Each Time ..................... 25
Preparing Conveyor for Operation .......................... 25
Conveyor Operation ................................................... 26
Control Panel Overview .......................................... 26
Operating Conveyor ................................................ 26
Conveyor Remote ................................................... 27
Drive Components (Dodge) ....................................... 28
Reducer .................................................................. 28
Maintenance ........................................................... 28
Reducer Oil Capacities ........................................... 29
Oil Recommendations ............................................ 29
V-Belt ...................................................................... 30
Bushings ................................................................. 30
Dodge Bearing Torque Settings ............................. 30
Dodge Ball Bearing Lubrication .............................. 31
Long Term Storage ................................................. 31
Taking Reducer Out of Storage .............................. 31
Exterra® Primary Belt Cleaner .................................. 32
Safety Information ................................................... 32
Overview ................................................................. 32
Installing Belt Cleaner ............................................. 32
Maintenance ........................................................... 33
Specifications .......................................................... 34
Troubleshooting ...................................................... 34
DozerTrap Maintenance Schedule ............................ 35
Maintenance Log ........................................................ 36
Warranty ...................................................................... 38

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General Safety
Read and understand equipment operators manual
before operating or performing maintenance. Failure to
do so could result in serious injury or death.
Signal Words and Symbols
This is the safety alert symbol. It is used to alert
you to potential physical injury hazards. Obey
all safety messages that follow this symbol to
avoid possible injury or death.
DANGER indicates a hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous
situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a hazardous
situation which, if not avoided, could
result in minor or moderate injury.
NOTICE is used to address practices
not related to physical injury.
Safety instructions (or equivalent)
signs indicate specific safety related
instructions or procedures.
Superior Industries cannot anticipate every possible
circumstance which involves potential hazard. The warnings and
notifications in the manual are not all inclusive.
Owner Responsibilities
• Operate and maintain equipment in a safe manner and in
accordance with all applicable local, state, and federal
codes, regulations and/or laws; and in compliance with
equipment safety labeling and manual instructions.
• All personnel must read this manual and throughly
understand safe and correct installation, operation, and
maintenance procedures.
• Install equipment correctly before placing in service and
then follow recommended maintenance schedule and
procedures to service equipment thereafter.
• Fulfill all warranty obligations so as to not void warranty.
Complete description of obligations is found on back of
sales contract under terms and conditions. Warranty policy
is located on inside back cover of this manual.
Safety Rules
These are general safety considerations. Additional precautions
may be necessary to operate your equipment in a safe manner.
• Follow all applicable local, state, and federal codes,
regulations and/or laws; OSHA rules and regulations;
insurance requirements; and in compliance with equipment
safety labeling and manual instructions in regards to
operating and maintaining your equipment.
• Do not allow anyone to operate equipment until he/she has
read manual and is familiar with safety precautions.
• Do not allow unauthorized persons unfamiliar with
equipment to operate or perform maintenance.
• Do not operate or maintain equipment while under the
influence of alcohol, medications, or other drugs which can
impair judgment or cause drowsiness.
• Required PPE (personal protective equipment) will vary
depending on equipment usage and location. It is operators
responsibility to wear correct PPE for the situation and when
required.
• It is operators responsibility to be aware of hazardous areas
and follow safety signs and label instructions.
• It is operators responsibility to be aware of equipment
operation and work area hazards at all times. Keep work
areas clear and clean.
• Loose clothing, long hair or jewelery can get caught in
moving parts. Remove or restrain when necessary.
• Do not smoke while servicing the equipment.
• Do not perform maintenance while equipment is running
unless noted otherwise in a procedure within this manual.
• Lockout/Tagout/Blockout equipment before performing
maintenance.
• It is operators responsibility to know all locations, and
periodically check, all guards and shields are in place before
operating equipment.
• Watch for adequate overhead clearance and power lines
before setting up and operating equipment.
• Operators are responsible to know location and function of
all controls and indicators.
• Be sure area is clear of persons before starting equipment
for operation or maintenance.
• Equipment requires an operator at all times. Never leave
machine running unattended.
• The equipment should not be used to handle materials other
then what it was designed for. Refer to specifications.
ã
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ãDANGER
ãWARNING
ãCAUTION
NOTICE
SAFETY
INSTRUCTIONS

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• Buildup of materials on idlers and pulleys will lead to belt
misalignment and damage. Lockout/Tagout/Blockout before
removing material.
• When equipment is operating, belt travels at a speed
sufficient to cause injury. Be sure no persons are exposed to
moving parts or to material discharging at end of belt.
• Do not use equipment if safety devices are not working
properly. Remove from service until repaired.
• Modifying equipment or using unapproved factory
recommended service parts may result in injury, death,
voided warranty, and/or decrease equipment effectiveness.
• Be sure equipment is in lowest position before transporting.
Do not exceed 55 mph on paved roadways. Reduce speed
in adverse conditions or uneven terrains.
Conveyors with Undercarriage (if equipped)
• Lower conveyor undercarriage to lowest position in winds of
30mph or higher. If lowering is not an option, tie down
(anchor) conveyor at axle. Failure to do so could cause
injury or equipment damage.
Hydraulic Safety (if equipped)
• Hydraulic components are hot and can cause serious injury.
Let equipment cool before servicing.
• Hydraulic system is under high pressure. Escaping hydraulic
fluid has enough force to penetrate skin and cause serious
injury. Never check for leaks using body parts.
Engine and Battery Safety (if equipped)
• Always stop engine and remove key when leaving
equipment unattended.
• Never operate engine in an enclosed area. Proper
ventilation is required under all circumstances.
• Hot coolant can spray out if radiator cap is removed while
system is hot. To remove radiator cap, let system cool, turn
to first notch, wait until all pressure is released. Scalding can
result from fast removal of radiator cap.
• Do not make sparks or use open flame near battery.
• When disconnecting battery terminals, remove negative (-)
cable first; then remove positive (+). When connecting
cables, connect positive (+) first, then connect negative (-).
• Disconnect battery (both terminals) before welding on any
part of equipment. Failure to do so may cause damage to
sensitive electrical components (if equipped).
• Batteries contain acid which burns eyes and skin on contact.
Wear PPE to keep acid off body. In case of acid contact,
wash immediately with water. In case of eye contact, get
prompt medical attention and wash eye with clean, cool
water for at least 15 minutes. If electrolyte is taken internally,
drink large quantities of water or milk. Do not induce
vomiting. Get prompt medical attention.
• When working around batteries, remember all exposed
metal parts are “live”. Never lay a metal object across
terminals. A spark, short circuit, explosion, or personal injury
may result.
• Battery post, terminals, and related accessories contain
lead and lead components. Wash hands after handling.

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Lockout/Tagout/Blockout
Read and understand equipment operators manual
before operating or performing maintenance. Failure to
do so could result in serious injury or death.
Lockout/Tagout
Placement of a lock and tag(s) on an energy isolating device, in
accordance with a procedure, ensuring that the energy isolating
device and equipment being controlled cannot be operated until
lock and tag(s) are removed.
Lockout/Tagout/Blockout protects against:
• Unexpected or accidental start up or movement of
equipment and/or parts.
• Notifies other personnel when equipment is unsafe to
operate.
• To prevent injury from stored energy in equipment even
when it is shutdown.
Procedure
Figure 1
1. Identify energy source(s).
2. Isolate energy source(s).
3. Lock and tag energy source(s).
4. Prove equipment isolation is effective.
According to 29CFR part 1910 of OSHA regulations, the
employer must establish a lockout/tagout system of procedures,
training, and periodic inspection before any employee operates,
services, or maintains a piece of equipment.
Follow employers policies and recommendations for Lockout/
Tagout procedures.
Lockout/Tagout when:
• Repairs or maintenance is required on equipment.
• Cleaning or lubricating equipment.
• Cleaning blocked or jammed mechanisms.
• Equipment is left unattended.
Lockout/Tagout Rules
• Maintenance person, foreman, team leader, or anyone
working on equipment can apply a lock and tag to
equipment.
• Each person working on equipment applies their own tag.
• Only the person who applied lock and tag can remove it.
Blockout
In addition to lockout/tagout blockout secures belt movement
from stored energy.
Belt may be under high tension and could move even when
system is locked out.
Procedure
Figure 2
1. Place belt clamp before area being serviced.
2. Remove belt tension by pulling chain or cable come along in
opposite direction of belt travel.
ã=WARNING
Heed to the following warnings. Failure to do so could result in
death or serious injury.
• Follow correct Lockout/Tagout/Blockout procedures.
• Follow all applicable local, state, and federal codes,
regulations and/or laws; OSHA rules and regulations;
insurance requirements; and in compliance with
equipment safety labeling and manual instructions in
regards to operating and maintaining your equipment.
ã

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Dozer Trap Decal Identification
Read and understand equipment operators manual before operating or performing maintenance. Failure to do so could result
in serious injury or death.
Note: Inspect decals every time equipment is cleaned, keep free of debris and replace if decal becomes faded, worn or is peeling.
General
Figure 1
1. 19-00157 Danger Keep Off (Figure 1)
• Top of truss: both sides every 20 feet (6.1 m), Qty- varies
2. 19-00158 Warning Moving Parts (Figure 1)
• Tail Pulley Guard, Qty-1
• Take-up Guards, Both sides, Qty-2
• Head Pulley Guard, Qty-1
• Return Roll Guards: all guards 8 ft (2.44 m) and under, Qty-Varies
3. 19-00159 Warning Pinch Point (Figure 1)
• Landing Jacks, Qty-2
4. 19-00049 Extra Large Superior Decal (Figure 1)
•Qty-2
5. 19-01236 Shut Machine Off and Lockout/Tagout Prior To Entering Track Area (Figure 1)
• On each plate hanging from chain, Qty-2
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SHUT MACHINE OFF AND
LOCKOUT/TAGOUT PRIOR TO
ENTERING TRACK AREA.
19-01236
FAILURE TO DO SO WILL RESULT IN SERIOUS
INJURY AND/OR DEATH.
WARNING
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Conveyor
Figure 2
1. 19-00010 Serial Number Plate (Figure 2)
• Tail Panel Qty-1
2. 19-00323 Read Operator’s Manual Decal (Figure 2)
• Tail Panel, Qty-1
3. 19-00081 Superior Parts Decal (Figure 2)
• Tail Panel, Qty-1
4. 19-00311 Made in America (Figure 2)
• Tail Panel, Qty-1
5. 19-00046 Owner’s Manual Decal (Figure 2)
• Owner’s Manual Compartment, Qty-1
6. 19-00012 Small Superior Decal (Figure 2)
• Conveyor Truss, Qty-2
PARTS
OR
SERVICE
TO ORDER PARTS FOR THIS EQUIPMENT
19-00081
www.superior-ind.com
Call: Your Local Dealer or
Superior Industries: 1-800-321-1558 / 320-589-7547
Email: [email protected]
FOR SERVICE/PRODUCT SUPPORT
Call: 320-589-7585
Email: [email protected]
PROUDLY
USA
MADE
IN THE
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Discharge Hood (If Applicable)
Figure 3
1. 19-01173 Notice Lift Only During Part Installation (Figure 3)
• Both sides of discharge hood, below lifting eye. Qty: 2
LIFT ONLY DURING
PART INSTALLATION
19-01173
Lifting for purposes other than part
installation can cause damage to equipment.
NOTICE
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Dozer Trap Carbody Overview
Read and understand equipment operators manual before operating or performing maintenance. Failure to do so could result
in serious injury or death.
Overview
Figure 4
1. Exhaust Extension
2. Hydraulic Cooler
3. 142HP Diesel Engine
4. Hydraulic Piston Pump
5. Hydraulic Piston Pump
6. 105 Gallon Fuel Tank
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Diesel Engine Control
Overview
Figure 5
1. Diesel Engine Controller
2. Key
3. Up Arrow (Used to raise RPMs)
4. Down Arrow (Used to lower RPMs)
Operation
1. Turn key (2) (Figure 5) to “Crank” to start diesel engine.
2. Turn key to “Run” to place diesel engine in operating mode.
3. Use arrows (3) (4) (Figure 5) to set diesel engine to desired RPM’s.
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Gauges, Panel & Diesel Fuel Fill Point
Figure 6
1. Aux Pump PSI Guage
2. Tracks PSI Gauge
3. Diesel Fuel Fill Point (105 Gallon Capacity)
4. Tracks Panel
Tracks
Figure 7
1. Carbody Tracks
12
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Dozer-Trap Site Prep
Read and understand equipment operators manual
before operating or performing maintenance. Failure to
do so could result in serious injury or death.
Site Preparation
Note: Location of dozer-trap is determined by location of intake
and discharge of material.
Note: Improper site conditions can adversely affect operation
and maintenance of conveyor. Area around conveyor should be
kept clear and level to make loading conveyor as discharge of
material as convenient as possible.
Figure 8
1. Using remote control, position dozer trap (1) (Figure 8) in
desired location. See “Pit Transporting Dozer-Trap” on
page 11.
Note: Ensure dozer-trap’s undercarriage (1) (Figure 9) is in
raised position while transporting is taking place.
Figure 9
2. Once dozer-trap is in desired location, lower undercarriage
(1) (Figure 9) to dozer-trap into operating position.
Note: Ensure area is clear of all personnel prior to beginning
operation.
ã=WARNING
Heed to the following warnings. Failure to do so could result in
death or serious injury.
• Lockout/Tagout/Blockout before performing maintenance
or installation.
• Follow installation instructions completely. Failure to do so
may cause death or serious injury.
ã
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Pit Transporting Dozer-Trap
Read and understand equipment operators manual
before operating or performing maintenance. Failure to
do so could result in serious injury or death.
Prepping Equipment for Pit-Transport
Figure 10
1. Ensure conveyor is turned off, and not in operating mode.
2. Using remote, raise undercarriage (1) (Figure 10) up to lift
dozer-trap up and into transport position. See “Pit
Transporting Dozer-Trap” on page 11.
3. Remove all material from system.
4. Disconnect all power and signal wiring from dozer-trap.
5. Remove all material from sides and end of walls.
6. Clear area for transportation.
Note: Avoid large local changes in elevation and obstructions.
Pit Transporting Dozer-Trap
Figure 11
Note: Prep equipment and area prior to transporting dozer-trap.
1. Turn 12 VDC control panel (1) (Figure 11) on by turning
lever.
Figure 12
2. Turn key (1) on diesel engine control (2) clockwise to start
diesel engine (Figure 12).
3. Set diesel engine at desired RPM’s using up arrow (3) o
down arrow (4) (Figure 12).
ã=WARNING
Heed to the following warnings. Failure to do so could result in
death or serious injury.
• Lockout/Tagout/Blockout before performing maintenance
or installation.
• Follow installation instructions completely. Failure to do so
may cause death or serious injury.
ã
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Figure 13
4. Turn remote control on (Figure 13).
5. Lift dozer-trap up into transport position using toggle switch
(4) (Figure 13).
6. Use dial (1) (Figure 13) to slowly increase track speed.
Note: Dial (1) (Figure 13) also used to decrease track speed.
7. Use switches (2) and (3) to control left and right tracks
(Figure 13).
8. Once in desired position and tracks have came to a
complete stop, lower undercarriage into operating position
using toggle switch (4) (Figure 13).
9. Turn remote control off.
10. Turn diesel engine control (2) off by turning key (1) to “Off”
position (Figure 12).
11. Turn handle on 12VDC control panel (1) (Figure 11) to off
position.
Note: E-Stop button (5) (Figure 13) used in case of emergencies
when all equipment needs to shut down immediately.
Transporting Specifications
• Maximum Engine RPM: 2200 RPM
• Minimum Engine RPM: 800 RPM
• 1400 RPMs = 48 FPM
• 2200 RPMS = 70 FPM
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Conveyor Load Area Components
Read and understand equipment operators manual
before operating or performing maintenance. Failure to
do so could result in serious injury or death.
Load Area
Figure 14
1. Load material onto load area (1) (Figure 14).
Note: Rectangle openings direct material onto belt.
Note: Hold-Back wing (2) (Figure 14) prevents material from
falling over-top onto tracks and conveyor.
Weld-In Hopper
Figure 15
1. Weld-In Hopper
2. Clamp Bars
3. Skirting
Flow Control
Figure 16
1. Adjust flow control slide gate (1) using crank handle (2)
(Figure 16).
ã=WARNING
Heed to the following warnings. Failure to do so could result in
death or serious injury.
• Lockout/Tagout/Blockout before performing maintenance
or installation.
ã
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Conveyor Skirtboard Overview
Figure 17
1. Side Clampbar
2. Side Skirtboard
3. Rear Clampbar
4. Rear Skirtboard
Adjustment
Note: As conveyor belt get worn, skirtboard will need to be
adjusted to keep material from spilling.
Figure 18
1. Open clampbar (1) by loosening nuts (3) (Figure 18).
2. Push on top of skirtboad (2) (Figure 18) until skirtboard
presses against conveyor belt.
3. Re-tighten nuts on clampbar.
Replacement
Figure 19
1. Open clampbar (1) by loosening nuts (2) (Figure 19).
2. Remove old skirtboard (3) (Figure 19).
3. Cut corners (4) (Figure 19) on new skirtboard to match
contour of conveyor belt.
4. Slide new skirtboard in.
5. Push on top of skirtboard until skirtboard presses against
conveyor belt.
6. Tighten nuts on clampbar.
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Take-Ups
Figure 20
• Conveyor is equipped with heavy duty take-ups (1) (Figure
20).
Adjusting Take-Ups
1. Adjust take-up bolts (2) (Figure 20) with wrench to maintain
proper belt tension.
Note: Adjustment bolts must be equally adjusted to tighten belt.
2. Using adjustment bolt (2) (Figure 20) equally adjust take-
ups to tighten belt.
Superior Industries does not recommend training belt by unequal
adjustment of take-ups. Take-ups should only be used for
tensioning belt and keeping tail pulley square with conveyor
frame.
NOTICE
• Take-ups must be kept square.
• Take-ups are not a belt tracking tool. Do not perform take-
up adjustments to track belt.
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Bearing Lubrication
Bearings come pre-lubricated from factory with NLGI Grade 2
EP grease.
Bearing should be re-lubricated at regular intervals depending
on usage and operating conditions.
Regreasing Intervals (Weeks)
Hours
Run
Per Day
1-250 RPM 251-500
RPM
501-750
RPM
751-
1000
RPM
1001-
1250
RPM
812121075
1612 7542
2410 5221