32

CAUTIONS, WARNINGS AND HAZARDS

CAUTIONS, WARNINGS AND HAZARDSINTRODUCTIONThis manual was prepared as a “how-to-guide” for installers, end-users and main-tenance personnel. It is also intended to educate both owner (purchaser) and all individuals working around the unit, of potential hazards.

With proper installation and main-tenance, conveyors are essential for achieving a variety of functions essential in today’s industrial marketplace. By fol-lowing a simple, periodic maintenance schedule, the life of a typical conveyor (or, most any type of machinery--including our automobiles!) will increase when com-

pared to a similar unit in an application receiving little or no maintenance. You may find that a conveyor can become your best workplace friend by following simple safety guidelines. Failure to follow even the most basic safety suggestions can result in serious personal 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 reference. It should be placed where appropriate personnel may main-tain proper maintenance and records.

This manual must be read by all new users before operating or working near this unit.

DO NOT OPERATE BEFORE READING THIS MANUAL! KEEP IN SAFE PLACE--DO NOT DISCARD!

Before conveyor is placed into operation, all operators and other personnel coming in contact with conveyor must be prop-

erly trained and must have read accompanying Tech Handbook.

Never move MCP conveyor by holding ANY part of conveyor other than handles. Handles are provided at both ends and both sides of MCP conveyors.

DO NOT wear loose clothing or unprotected long hair around MCP conveyors, powered conveyors or machinery with moving parts.

When MCP conveyor is being moved, set up or when conveyor is being adjusted by expanding or contracting overall unit length, keep hands, clothing, long hair or other objects clear of scissor

grid framework on conveyor to avoid serious injury.

Never connect belt conveyors directly to gravity conveyors, MCP conveyors, machinery or fixtures without using connector brackets

& pop out roller.

It is the responsibility of the customer and installation person-nel 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.

Only trained personnel shall perform maintenance functions. Before maintenance operations are performed, shut conveyor

“OFF” and lock out power source to prevent unauthorized start-up. When maintenance is completed, only authorized personnel shall be permitted to start conveyor following maintenance or other emergency shut-off.

TECH HANDBOOK FOR MCM CONVEYORSTABLE OF CONTENTS

WARNING LABELS

--All specifications are subject to change without notice----Drawings are intended for illustration ONLY and are not to scale--

ABOVE: Label attached to all protective guards (drives, spool guards, etc.)

ABOVE: Label placed near all drive assemblies and at 30’ intervals

TECH HANDBOOK FOR MCP CONVEYORS 2 - Drive Bands 13

-Warning Label 2 - Gear Reducer Adjustments 14

CAUTIONS, WARNINGS AND HAZARDS 3 TROUBLE SHOOTING AND REPLACEMENT PARTS 15

- introduction 3 - Trouble Shooting/Serial Plate 15

- Cautions Warnings and Hazards 3 - Ordering Replacement Parts 15

SAFETY INFORMATION/RECEIVING AND INSPECTION 4 ELECTRICAL DIAGRAMS 16

- Important Safety Guidelines 4 - Conveyor Control System MCP Wiring Diagram 16

- Shortages, Damages, Returns and Uncrating 4 - Conveyor Control System MCPC Wiring Diagram 17

GENERAL INSTALLATION INFORMATION 5 - Conveyor Control System Gate Wiring Diagram 18-19

- Set-up/Connection of intermediate sections 5 PARTS LIST 20

- Motor Removal and Installation 6-7 - Parts List For MCP 36BF 20

- Raising and Lowering Gate 8 - Parts List For MCP 48BF 21

MAINTENANCE SAFETY PRECAUTIONS 9 - Parts List For MCPC 36BF 22

- Before Performing Maintenance 9 - Parts List For MCPC 48BF 23

- Maintenance and Follow-Up Details 9 - Parts List For MCP GATE 48BF 24

MAINTENANCE AND LUBRICATION 10 - Parts List For MCP Herringbone 25

- Daily Preventative Maintenance 10 - Parts List For 1096 MCI 48BF 26

- Maintenance Schedule 11 WARRANTY 31

- Preventing Unnecessary Repairs 11

- Report on Miscellaneous Maintenance Performed 11

START-UP PROCEDURES 12

- Sequence of Operation 12-14

54

GENERAL INSTALLATION INFORMATIONSET-UP / CONNECTION OF INTERMEDIATE SECTIONSOnce initial inspection and uncrating are completed, unlock casters and swivel lock and move conveyor into actual operational area. While moving, be sure to keep hands, clothing, hair and other objects clear to avoid serious injury. Once relocated, lock casters and swivel lock to secure conveyor.

(see illustration on the right)

CONNECTING MCP/MCPC SECTIONS TOGETHER

SHORTAGES, DAMAGES, RETURNS AND UNCRATINGNOTE: Do not return goods to factory without prior, written return authoriza-tion. Unauthorized returns are subject to refusal at factory.

Before uncrating, check quantity of items received against bill of lading to confirm that all material has been received. Examine the condition of equipment to determine if any damage has occurred.

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 damage 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.

Carefully remove crating and look for essential components and specific

accessories that may have been boxed and attached (or ‘banded’) to crating material. Save all hardware for subse-quent use by installation personnel.

It is possible that some items may become separated from original shipment. Check bill of lading (or, accompanying freight documentation) to ensure receipt of ALL units ordered including ALL accessories.

SAFETY INFORMATION / RECEIVING AND INSPECTIONIMPORTANT SAFETY GUIDELINES

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 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 operat-ing condition. Injuries resulting from negligence or violation of safety instructions hereby removes responsibility of product liability claims from Roach.

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 replace parts or perform maintenance on conveyor, or moving

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.

It is the responsibility of conveyor end-user to comply with all safety stan-

dards including OSHA and other federal, state, and local codes or regulations. Install protective guarding and other related safety precautionary equipment to eliminate hazardous operating conditions which may exist when two or more vendors supply machinery for related use.

Any violation of above safety instructions hereby removes all

product liability claims from Roach

To connect up to 6 sections the conveyors must be spliced together. Follow the steps below to splice conveyors together. Repeat steps 1-3 for both sides of the conveyors.

DO NOT OPERATE UNTIL ALL SPLICE PLATES HAVE BEEN SECURED

Align the discharge end of the 1st section with the infeed end of the 2nd section.

Using the “Guide Flare” move the units together. The 2 units should be butted together.

Note: Casters must be unlocked

Bolt the 2 units together.Step 1 Step 2 Step 3

UNLOCKED LOCKED

UNLOCKED

SWIVEL LOCKSWIVEL LOCK

6 7

GENERAL INSTALLATION INFORMATIONMOTOR REMOVAL AND INSTALLATION

Follow the steps below to remove and install a new motor in your MCP conveyor.

DO NOT OPERATE UNTIL NEW MOTOR IS INSTALLED

Unplug conveyor from power

Remove motor leads

Unbolt motor from motor base with 7/16 wrench

Remove sheave from shaft Place sheave on new motor flush with shaft, remove set screws

Add 1 drop of blue Loctite to set screws

Remove black motor lead from fuse holder

Remove motor from conveyor

Loosen chord grip, pull wires from motor box

Loosen sheave set screws with 1/8” allen wrench

Remove rollers Remove motor box coverStep 1:

Step 4:

Step 7:

Step 10: Step 11: Step 12:

Step 5:

Step 8:

Step 6:

Step 9:

Step 2: Step 3:

To see this in action, enter this link into your web browser: https://youtu.be/4L3YIwzLLSc

GENERAL INSTALLATION INFORMATIONMOTOR REMOVAL AND INSTALLATION

Reinstall set screws with 1/8” allen wrench

Run wires through chord grip and tighten chord grip

Insert remaining wires into correct wago

Replace rollers

Place new motor on motor base

Crimp new spade terminal onto black wire

Reinstall gasket and motor box lid

Plug conveyor back into power

Attach new motor to motor base with 7/16 wrench

Attach spade terminal to fuse holder

Stretch bands over sheave

Step 13:

Step 16:

Step 19:

Step 22:

Step 14:

Step 17:

Step 20:

Step 23:

Step 15:

Step 18:

Step 21:

Follow the steps below to remove and install a new motor in your MCP conveyor.

DO NOT OPERATE UNTIL NEW MOTOR IS INSTALLED

To see this in action, enter this link into your web browser: https://youtu.be/4L3YIwzLLSc

98

MAINTENANCE SAFETY PRECAUTIONSBEFORE 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 dur-ing 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 MCP conveyor warning labels (see “WARNING LABELS” at front of handbook). If labels have been destroyed or are not clearly legible, contact Roach Corporation® to receive replacement labels. Placement of warning labels is critical to avoid unauthorized unit operation which may result in hazardous working conditions for all related personnel coming in contact with conveyor.

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” (if applicable) and disconnects locked in the “OFF” position to prevent unit from unauthorized start-up during main-tenance. All personnel should be informed of the safety proce-dures 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 adjustment, lubrication or other maintenance function. Only experienced, trained personnel possessing advanced hazards-training should attempt such critical operations.

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.

Only trained personnel shall perform maintenance functions. When maintenance is completed, only authorized per-sonnel shall be permitted to start conveyor following maintenance or other emergency shut-off.

GENERAL INSTALLATION INFORMATIONRAISING AND LOWERING GATE

Follow the steps below to raise and lower gate sections.

TO RAISE GATE

TO LOWER GATE

DO NOT OPERATE UNTIL GATE SECTION HAS BEEN SECURED

With a person on each side, hold

handles and lift up.

Find lever to unlock gate latch. Move lever up to unlock gate from raised position.

With a person on each side, hold

handles and slowly pull down.

Continue raising gate until it locks

into the raised position.

Step 1

Step 1 Step 2 Step 3

Step 2

Continue lowering gate section to floor.

Make sure that gate is fully lowered into position.

Step 4 Step 5

To see this in action, enter this link into your web browser: https://youtu.be/N0cPL89vXw0

1110

MAINTENANCE AND LUBRICATIONMAINTENANCE SCHEDULES

MODEL NO.__________

*All charts are for guidelines in normal operating or ‘as noted’ conditions. Severe applications will warrant additional maintenance.

PREVENTING UNNECESSARY REPAIRSYour MCP conveyor is one of the most durable MCP models manufactured in the world today. However, even the most durable conveyors may be damaged when abused or neglect-ed. Impact or “shock” loading will surely damage models not designed for such loading conditions.

When MCP models are moved across uneven surfaces, floors, mezzanines, etc., even the best designed models are subject to additional maintenance. Floor supports must be monitored daily when used in such terrain to ensure that they are properly adjusted and that damaged component parts are immediately replaced to promote safe work environment.

Heavy fork truck traffic creates another notable hazard in loca-tions where MCP conveyors are used. Monitor all MCP convey-ors located near fork truck traffic and locate pylons or pillars to prevent damage to MCPs.

Remember that conveying the product is NOT what causes the most damage to your MCP conveyor. Hazards, neglect and operator mis-use are responsible for the vast majority of replacement parts required to maintain your MCP conveyor.

RECOMMENDED MAINTENANCE SCHEDULE*FREQUENCY DETAIL OF MAINTENANCE

Daily

Check for damage to conveyor and for worn parts and replace immediately; Inspect floor supports and adjust as required to maintain proper product flow; Remove dirt,

grease, and other contaminates which reduces product life

Monthly

Confirm that hardware is adjusted as intended (i.e. bolts and nuts may have become loose during operation or

adjustment). Adjust as necessary. However, do not over tighten since over tightening will not allow unit to be closed

or adjusted properly.

REPORT ON MAINTENANCE

CONVEYOR REPAIRED INSPECTION DETAIL OF MAINTENANCE COMPLETED (OR INSPECTION) MARK NO. BY DATE LIST PARTS REPLACED OR REPAIRS

MAINTENANCE AND LUBRICATIONDAILY PREVENTATIVE MAINTENANCE

DAILY PREVENTATIVE MAINTENANCE - MCP/MCPC/HERRINGBONE

DAILY PREVENTATIVE MAINTENANCE - GATE

1. Turn conveyor on.

2. Run conveyor.

3. Check for any rollers that are not turning at set speed. Check drive bands for wear, replace if needed.

4. Listen for any abnormal noises.

1. Turn conveyor on.

2. Run conveyor.

3. Check gate latch for proper function (up and down).

4. check photo eye alignment, realign photo eye if out of

alignment.

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.

Only trained personnel shall perform maintenance functions. When maintenance is completed, only authorized per-sonnel shall be permitted to start conveyor following maintenance or other emergency shut-off.

12 13

Once the power cord is connected the unit is ready to power on. The controls are on the side of the infeed end. The power switch is OFF in the down position and ON in the up position. Turning the switch ON the amber power light should illuminate indicating the unit has been

activated and is ready to run.

The conveyor speed can be adjusted by rotating the SPEED DIAL left to right from 0 - 100. 0 being the slowest speed and 100 the maximum.

A START/STOP switch is located on the right side of the conveyor at the infeed end and a second switch on the left side at the discharge end allowing operators to control the conveyor from either side. Both switches need to be in the START position to run. The conveyor will not run if any of the switches are in the STOP position.

START-UP PROCEDURESSEQUENCE OF OPERATION

There are 2 types of drive bands for the MCP conveyor. The first is a red band for the rollers driven by the motor. The second is a blue band which is for the rollers that are slave driven.

Should one of these drive bands break, extra bands have been included with each conveyor. These bands are zip tied to the frame at the infeed end of the conveyor.

DRIVE BANDS

Finally, the infeed end Power On button must also be pressed and illuminated for the converyor to run.

START-UP PROCEDURESSEQUENCE OF OPERATION

The power cord for the unit is at the infeed end of the conveyor. This input is a twist lock connector (see twist lock connector at bottom of the page) and should only be connected by authorized personnel. The power cord should be connected to a dedicated 120v power source.

If multiple units are latched together the power supply and the yellow MDC Cord for each unit must be connected. The individual units have male pronged connectors and female MDC cord connectors at the infeed end. The discharge end has a female connector used for docking the male connector when

the unit is last in line. Connect the male of one unit to the female of the second unit to provide power to the subsequent conveyor and interface all of the Start/Stop switches.

The MDC cable should be connected by aligning the pins and screwing the ends together.

MDC AND POWER CONNECTED

DO NOT CONNECT MORE THAN 6 CHILDREN TO A SINGLE 48” PARENT!

DO NOT CONNECT MORE THAN 6 CHILDREN TO A SINGLE 36” PARENT!

START / STOP SWITCHPOWERSWITCH

POWER LIGHT

SPEED DIAL(UNDER GUARD)

BLUE DRIVE BANDS

REDDRIVE BANDS

EXTRA DRIVE BANDS

FORWARD/REVERSESWITCH

TWIST LOCK CONNECTOR

Align the connector blades with the plug inlets. Insert blades into inlets Twist connectors to lock in place

POWER CORD

MDC CORD

POWER CORDMDC CORD

INFEED END

DISCHARGE END

1514

TROUBLE SHOOTING AND REPLACEMENT PARTSTROUBLE SHOOTING / SERIAL PLATE

ORDERING REPLACEMENT PARTS

TROUBLESHOOTINGTROUBLE PROBABLE CAUSE REMEDY

Product stops on conveyor or will not flow smoothly

A. Floor supports out of adjustment

B. Wheels are locked

C. Conveyor damaged

A. Adjust supports as previously outlined in the Owners Manual.B. Remove debris from wheels and/or replace wheels as necessary.C. Visual inspection required to identify worn or damaged parts. Replace worn or damaged parts as necessary.

Conveyor will not open or roll smoothly

A. Casters are lockedB. Casters are frozen due to debris or dirty environment

C. Bolts and nuts are over tightened

D. Conveyor is damaged

A. Unlock casters before moving conveyor.B. Clear debris from casters until casters are readily mobile. Replace damaged or worn casters as necessaryC. Loosen bolts and nuts that may have been over tightened during maintenance procedures.D. Replace ALL components damaged to return unit to proper operating condition. NOTE: All damaged parts should be replaced immediately to promote safe work environment

To order any replacement parts or when calling for assistance with any powered conveyor, ALWAYS provide the unit serial num-ber. Shown at actual size, this aluminum plate is placed on enclosure mount at the infeed end of the conveyor.To order replacement parts or add-on components, contact the Roach distributor who originally furnished the unit if possible. If this is not possible, contact the national sales office at 870.483.7631 for the name of the authorized Roach distributor in your area. Have unit model number and serial number BEFORE calling. Refer to unit drawings (in rear section of handbook) for part numbers if ordering replacement parts.

START-UP PROCEDURESGEAR REDUCER ADJUSTMENTS

DC MAGNET MOTORS BRUSH MAINTENANCE • Remove cap (shown at right) from both sides of motor to access the brushes. • With cap removed, brush may be removed by pulling on the spring. • Visually inspect brushes for chips or grooves. • The shunt wire should not have any frays. • Reinsert with the brass tabs facing the front and rear of the motor.

A fuse has been included at each motor for protection. The fuse is a 1amp 250v Bussman fuse. If a fuse is blown a qualified technician should determine the cause of the surge before replacing the fuse.

FUSE1amp 250v Bussman

Rollers have been removed for clarity

CAP

CAP

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 Owners Manual.

SERIAL NUMBER

16 17

ELECTRICAL DIAGRAMSCONVEYOR CONTROL SYSTEM MCPC WIRING DIAGRAM

ELECTRICAL DIAGRAMSCONVEYOR CONTROL SYSTEM MCP WIRING DIAGRAM

18 19

ELECTRICAL DIAGRAMSCONVEYOR CONTROL SYSTEM GATE WIRING DIAGRAM

ELECTRICAL DIAGRAMSCONVEYOR CONTROL SYSTEM GATE WIRING DIAGRAM

20 21

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731

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751

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761

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BF (2

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771

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781

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6073

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Item

#

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Item

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tion

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#

801

196G

-26

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6073

62-7

3

811

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2”BF

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6063

62-7

821

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G-5

2”BF

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ROO

VES

6073

62-7

5

831

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BF (2

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OVE

S60

7362

-76

841

196G

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BF (2

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S60

7362

-77

851

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BF (2

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S60

7362

-78

861

196G

-25

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6073

62-7

9

871

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5/16

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6073

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0

881

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7362

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6073

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901

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6073

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911

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6073

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6

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760

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944

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6073

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9514

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6073

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5

961

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PG 2

5

26 27

NOTES PARTS LISTPARTS LIST FOR 1096 MCI 48BF

Item

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6026

40-6

86

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3060

9216

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96

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3860

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1036

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APG

26

28 29

NOTES NOTES

30

--All specifications are subject to change without notice----Drawings are intended for illustration ONLY and are not to scale--

W ARRANTY• MaterialsusedbyRoachareofgoodquality.• AnypartprovingtobedefectiveinmaterialsorworkmanshipuponRoachinspec-

tion, will be replaced at NO cost, FOB, Trumann, Arkansas, for one year. Installation expense will be paid by others.

• Roachliabilityincludesfurnishingsaidpartorparts;Roachisnotliableforconse-quential damages, such as loss of profit, delays or expenses incurred by failure of said part or parts.

• Failureduetoabuse,incorrectadjustments,exposuretocorrosiveorabrasiveenvironment or operation under damp conditions does not constitute failure due to defects in workmanship or materials.

• ComponentpartsnotmanufacturedbyRoach(motors,gearreducers,etc.)will be repaired or replaced at the option of their manufacturer. Contact nearest authorized service center for all warranty claims. NOTE: Motors or gear reducers tampered with before inspection shall be con-sidered free of ALL Warranty Claims.

808 HIGHWAY 463 NORTHTRUMANN, ARKANSAS 72472-1310

Tel 870-483-7631 Fax 870-483-7049info@roachconveyors.com

roachconveyors.com

NOTES

808 HIGHWAY 463 NORTHTRUMANN, ARKANSAS 72472-1310

Tel 870-483-7631 Fax 870-483-7049info@roachconveyors.com

roachconveyors.com

1505-531038

3/25/20