Grizzly feeder-users-manual

TABLE OF CONTENTS
TERMS AND CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SETTING UP YOUR GRIZZLY FEEDER PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SITE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
UNLOADING YOUR MASABA EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATING YOUR GRIZZLY FEEDER PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
POWER CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CRIBBING YOUR GRIZZLY FEEDER PLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
IDENTIFYING YOUR GRIZZLY FEEDER PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATING YOU GRIZZLY FEEDER PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONVEYOR PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONVEYOR OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ADJUSTING DISCHARGE CONVEYOR HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
GRIZZLY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BELT TRACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TROUBLESHOOTING BELT CONVEYORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
VENDOR SPECIFIC MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLING/TENSIONING V-DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CHECK CONDITION OF SHEAVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CHECK SHEAVE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
V-BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
BELT SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
GENERAL RULES OF TENSIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
APPENDIX A. . . . . . . . . . . . . . . . . . . . . . . . . . . .Fenner Dunlop Belt Storage and Installation
APPENDIX B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flexco Bolt Solid Plate Belt Splice
APPENDIX C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fenner Dunlop Belt Tracking
APPENDIX D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fenner Dunlop Belt Maintenance
APPENDIX E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fenner Dunlop Trouble Shooting
APPENDIX F . . . . . . . . . . . . . . Dodge Torque-Arm Shaft Mount Speed Reducer Lubrication
APPENDIX G. . . . . . .Dodge Installation and Parts Replacement Manual for Speed Reducers
APPENDIX H. . . . . . . Dodge Instruction Manual for Torque-Arm Speed Reducer Backstops
APPENDIX I . . . . . . . . . . . . . . . . . . . . Dodge Instruction Manual for Mounted Ball Bearings
APPENDIX J . . . . . . . . . . . . . . . . . . . . . . . . . Dodge Instruction Manual for Type E Bearings
APPENDIX K. . . . . . . . . . . .Dodge Instruction Manual for S-2000 Spherical Roller Bearings
APPENDIX L . . . . . . . . . . Rexnord Instructions for 2000, 5000, 9000 Series Roller Bearings

TABLE OF CONTENTS
APPENDIX M . . . . . . . . . . . . . . . . . . . . . .WEG Electric Motor Installation and Maintenance
APPENDIX N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASABA Hydraulic System Service
APPENDIX O. . . . . . . . . . . . . . . . . . . MASABA Hydraulic System Schematic (If Equipped)
APPENDIX P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Allied Oil and Supply Material Safety

1
MASABA, INC. (d/b/a MASABA Mining Equipment)
TERMS AND CONDITIONS
1. OFFER & ACCEPTANCE: MASABA, Inc. (“Seller”) acceptance of Buyer’s order to purchase products is expressly made conditional on assent to these
Terms and Conditions, which along with the Sales Order constitute a binding “Contract” between the parties. This Contract constitutes the complete and final
agreement between Seller and Buyer for the products. Any additional or different terms or conditions contained in any document furnished by Buyer, including
but not limited to, any purchase order or any acknowledgement, are deemed to be material and are herby objected to and rejected by Seller. If such agreement
shall be deemed an offer or counter-offer by Buyer, Seller expressly rejects such offer or counter-offer and limits acceptance to these Contract terms and expressly
objects to any different or additional terms proposed by Buyer. Any actually performance by Buyer or Seller thereafter shall be deemed a renewal of the offer
contained in this Contract and acceptance of this Contract without change. In the event of a conflict between the terms of this Contract and the terms of any other
document, the terms of this Contract shall control. This offer to purchase Seller’s products is valid for thirty (30) days form the date of the Sales Order.
2. PAYMENT TERMS: All prices specified in this Contract are FOB Seller’s designated location which constitutes delivery. All risk of damage to or loss of the
products from any cause whatsoever shall pass to Buyer upon delivery, even if Seller arranges for shipment of the product. Unless otherwise expressly provide on
the reverse hereof, payment shall be made within thirty (30) days form the earlier of the date of delivery or the date of an invoice, without discount. Any discount
which may be expressly provide on the reverse hereof applies to the sale price of the products at the shipping point, and does not apply to any charges made for
taxes, storage, loading or transportation. All payments shall be made in United States dollars. Interest will be charged at the rate of eighteen percent (18 %) per
annum, or the maximum interest rate allowable by applicable law, whichever is lower, on all unpaid invoices. Buyer shall pay all taxes and charges of any nature
imposed by any federal, state, or local governmental authority by reason of the sale or delivery of the products whether levied or assessed against Seller, Buyer, or
the products. Such applicable taxes or charges, if not included in this Contract, shall be invoiced separately. If, in Seller’s opinion, reasonable doubt exists as to
Buyer’s financial condition, Seller may, at any time and without prejudice to any other remedies, suspend or terminate performance of any order, decline to ship,
stop any material in transit, or require full or partial payment by Seller in advance.
3. DELIVERY: Any delivery of promise date indicated on the Sales Order is an estimate of the date Seller believes the products will be available for delivery, pro-
vided, however, Seller shall not be responsible for any delays in delivery.
4. WARRANTY:
• Limited Warranty; Exclusion of Third Party Components: Subject to the terms, conditions and limitations contained herein, Seller warrants only to the orig-
inal Buyer that (a) Seller’s new equipment products and Seller’s new component products will not fail to operate in accordance with their respective specifica-
tions due to the defects in material or workmanship during the period which ends two (2) years form the date of delivery, normal wear and tear excluded, and (b)
Seller’s new equipment products will not incur a failure of their respective structural components (i.e. , trusses) due to defects in material or workmanship at any
time during the period which ends five (5) years form the date of delivery, normal wear and tear excluded. The foregoing periods are sometimes referred to as
“original warranty periods.” THE FOREGOING LIMITED WARRANTY DOES NOT APPLY TO ANY PART, PORTION OR COMPONENT OF ANY
PRODUCT WHICH IS MANUFACTURED BY A THIRD PARTY (“Third -Party Component”).
• DISCLAIMER OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED OR STATUTORY: THE LIMITED WARRANTY SET FORTH IN THE FORE-
GOING PARAGRAPH IS THE SOLE AND EXCLUSIVE WARRANTY. WITH RESPECT TO THE PRODUCTS, SELLER MAKES NO OTHER EXPRESS
WARRANTY OF ANY KIND OR NATURE AS TO THE PRODUCTS OR THEIR PERFORMANCE EXCEPT FOR THOSE LIMITED WARRANTIES
EXPRESSLY SET FORTH IN THE FOREGOING PARAGRAPH AND SPECIFICALLY DISCLAIMS ANY AND ALL REPRESENTATIONS OR WAR-
RANTIES OF ANY KIND OR NATURE CONCERING THE PRODUCTS, INCLUDING, BUT NOT LIMITED TO, ANY REPRESTATIONS OR WAR-
RANTY THAT THE PRODUCTS COMPLY WITH ANY LAW, RULE OR REGULATION. SELLER MAKES NO WARRANTIES WITH RESPECT TO
ANY THIRD PARTY COMPONENT AND SELLER SPECIFICALLY SELLS SUCH THIRD-PARTY COMPONENTS “AS IS” WITHOUT ANY WAR-
RANTY. FURTHER, SELLER MAKES NO IMPLIED WARRANTY OF ANY KIND OR NATURE WITH RESPCT TO ITS PRODUCTS OR ANY
THIRD-PARTY COMPONENTS AND SPECIFICALLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES, INCLUDING, BUT NOT LIM-
ITED TO, ANY AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, NON-INFRINGE-
MENT, OR COMPLIANCE WITH ANY FEDERAL, STATE OR LOCAL LAW, RULE OR REGULATION. IN ADDITION, SELLER EXPRESSLEY
DISCLAIMS TO THE FULLEST ALLOWED BY LAW, RULE OR REGULATION ANY WARRANTY PROVIDED UNDER ANY FEDERAL, STATE OR
LOCAL LAW, RULE OR REGULATION.
• Terms and Conditions of Warranty; Voiding of Warranty; Notice Requirements: The limited warranties set forth above shall be null and void if (a) any
alternations or modifications are made to a product, (b) a product is not maintained in strict compliance with the maintenance requirements set forth in the main-
tenance manual for such product or otherwise provided to Buyer of such product, (c) any repairs are made to a product which are not authorized by Seller in writ-
ing, (d) any failure of a product to comply with the above limited warranty is not reported to Seller in writing within thirty (30) days of the date such failure first
occurs, (e) a product is operated after the failure covered by warranty first occurs, (f) a product is used for any purpose other than for the purpose for which it was
manufactured, (g) a product is not operated in strict compliance with the terms and conditions set forth in any operating manual for the product (including, but not
limited to exceeding the load bearing capacity of the product), (h) a product is abused or damaged, (i) Buyer fails to deliver the product to Seller for inspection
and testing if requested by Seller or Buyer disposes of the product or any part of component on or before the sixtieth (60th) day after sending a written claim to
Seller, or (j) such failure of the limited warranty results from a failure of any Third-Party Component.
• Course of Dealing; Course of Performance; Usage of Trade: No course of dealing or course of performance of Seller with respect to the products sold under
this Contract or with respect to any of its products to whomever sold and no usage of trade shall be considered in interpreting this Contract or any part thereof and
none of the foregoing shall be considered a waiver or modification of any such terms, conditions, disclaimers, or limitation of the limited warranties or disclaim-
ers contained in this Contract. No statement, whether written or oral, made by any employee, sales person, distributor, agent or contractor of Seller which is not
set forth in this Contract shall be considered a representation or warranty with respect to any product, its specifications or its performance sand all such statements
are hereby disclaimed.
• Exclusive Remedies for Breach of Warranty: The sole and exclusive remedy for any failure of any product to comply with the limited warranty set forth above
or any other warranty imposed upon Seller by law, if any, shall, at the election of Seller, in its sole discretion, be either (a) the repair or replacement of the product
or component which failed to comply with such warranty or (b) the refund of the purchase price of the product. Buyer is responsible for all labor costs in connec-
tion with the repair or replacement of any equipment or component product; however, Seller will be responsible for its own labor performed in connection with
any repair of equipment products at Seller’s location. Except as provideD below, any repair or replacement shall carry the same warranty as the original product
but only for the remainder of the original warranty period. Buyer’s exclusive remedy with respect to any claim arising out of or as a result of Third-Party Com-
ponent shall be against the third-party manufacturer.
• Warranty Claims; Notice Requirement; Limited Time to ring Claims: Any and all claims under the above limited warranty shall be made to Seller only in
writing and not later than thirty (30) days after the date the product first fails to comply with the above limited warranty but in no event later than the expiration
of the original warranty period with respect to which the claim is being made. Any claim under the above limited warranty made after such period for making a
claim shall be null and void. After receipt of written notice of the warranty claim, Seller shall determine whether to (a) repair or replace the product or part or (b)

2
refund the purchase price of the product. Seller may require Buyer to return any product or part thereof which Buyer claims to be defective to Seller at Buyer’s
cost for inspection as a condition to any claim under the above limited warranty. No product or part may be returned to Seller without Seller’s prior written autho-
rization. If a product which is returned is determined by Seller in its sole discretion not to have failed to comply with the limited warranty, Buyer shall pay costs
of removal, repair and/or replacement for such product. If a product which is returned is determined by Seller in its sole discretion to have failed to comply with
the limited warranty, Seller shall pay for all repair and/or replacement costs for such product (or refund the purchase price if so elected by Seller) and Seller shall
reimburse Buyer for the reasonable costs of shipping the product or component to Seller.
• Limitation on Liability for Breach of Warranty and Other Claims: If the warranty and the remedy for any failure of any product to comply with any war-
ranty are deemed for any reason to fail their intended purpose, Seller’s liability for any failure of any product to comply with any such warranty, together with any
and all other liability, if any, arising out of or in connection with such product, including, but not limited to, all claims, whether in Contract, tort, or otherwise,
arising out of, connected with, or resulting for the manufacture, sale, delivery, resale, repair, replacement, or use of the product, shall not exceed the purchase
price for such product. In no event shall Seller be responsible or liable to Buyer or any third party under any circumstances for any indirect, consequential, spe-
cial, punitive or exemplary, damages or losses, including, but not limited to, damages for loss of profits, goodwill, use of the product or any other equipment or
other intangible losses which may be incurred in connection with the product regardless of the type of claim or the nature of the cause of action, even if Seller has
been advised of the possibility of such damage or loss. Any and all claims that Buyer has against Seller, whether or not Buyer is aware of such claims, must be
brought by Buyer within the applicable thirty (30) days after the date that such claim first arose, but in any event within the applicable warranty period set forth
above. Any claim not brought by Buyer within the applicable thirty (30) day period shall be deemed null and void.
5. IMDEMNIFICATION: Buyer will indemnify and hold harmless Seller, its affiliates and their respective officers, directors, employees, agents and other repre-
sentatives and defend any action brought against same with respect to any claims, judgments, actions, suites, demands, damages, liabilities, costs or expenses
(including, but not limited to, reasonable attorneys’ fees and legal expenses) associated with or arising from the ownership, use or operation of the products by
Buyer or any third party, including without limitation, product liability, an international, federal or state occupational safety and health statute, or any other gov-
ernmental regulations or laws, and also with respect to any fault or negligence of the seller. If buyer fails to fulfill any of its obligations under this paragraph or
any other part of this agreement, buyer agrees to pay seller's costs, expenses, and attorney fees incurred by seller to enforce or establish its rights under this para-
graph or any other part of this agreement.
6. TERMINATION OF PERFORMANCE: Buyer may cancel its order only with the written consent of Seller and upon terms that will indemnify Seller for any
loss, damage and expense arising from such cancellation. Seller may terminate this Contract pursuant to Sections 2 and/or 11 hereof, and in such event, Seller
shall have no further reliability to produce or ship any products hereunder and shall have no liability for damages to Buyer or any third party.
7. TECHNICAL ADVICE: No obligation or liability shall arise out of Seller’s rendering of technical advice in the connection with Buyers’ order or products.
Any technical advice furnished, or recommendation made by Seller or any employee or representative of Seller, concerning any use or application of any prod-
ucts or parts furnished under this Contract is believed to be reliable, but Seller makes no warranty, express or implied of results to be obtained. Buyer assumes all
reasonability for loss or damage resulting form the handling or use of any such products or part is accordance with such technical advice or recommendation. The
selection of the products ordered, or design of any customer products, shall be Buyer’s sole and ultimate responsibility, and Seller shall have no liability whatso-
ever for any design defects of custom products, or if the products ordered are unsuitable for Buyer’s intended use. Any advice or assistance provided by Seller to
Buyer in connection with Buyer’s selection or design of the products is at Buyer’s risk, and Seller makes no representation or warranty whatsoever in connection
with such advice or assistance.
8. ASSIGNMENT: Buyer shall not assign its rights or obligations under this Contract without the prior written consent of Seller, which consent may be withheld
for any reason in the sole discretion of Seller. Any attempt at such assignment by Buyer without the prior written consent of Seller shall be deemed null and void.
This Contract will be binding upon the parties hereto, and the successors and permitted assigns.
9. SECURITY INTEREST OF SELLER: Title to the products will not pass to Buyer until all required payments have been made to Seller. Until the purchase
price and all other applicable costs and expenses are paid in full, Seller reserves a purchase money security interest in the products and the proceeds therefrom,
and Seller thereby possesses the rights of a secured party under the Uniform Commercial Code. Upon Seller’s request, Buyer shall execute all necessary financ-
ing statements and other documents evidencing this security interest with the appropriate sate and local authorities. Seller is entitled to and is hereby granted rea-
sonable access to Buyer’s locations as necessary to exercise its remedies as a secured party.
10. GOVERNING LAW: This Contract shall be construed, interpreted, and governed by the laws of the State of South Dakota without regard to its conflict of laws
principles. The exclusive forum for any disputes arising out of or relating to this Contract shall be any federal or state court sitting in the State of South Dakota.
The parties irrevocably consent to such exclusive jurisdiction in such courts and to the proper venue therein.
11. FORCE MAJEURE: Seller does not assume the risk of and shall not be liable for failure to perform any obligation relating to the products caused by civil
insurrection, war, fire, strike, labor disturbances, acts of God, acts or omissions of Buyer, acts or omissions of the United States Government, floods, epidemics,
freight embargoes, shortages of fuel, energy or materials, failure of suppliers or subcontractors to satisfactorily meet scheduled deliveries, or any other cause
beyond the reasonable commercial control of Seller
12. NOTICES: Any notices, consents or other communications required or permitted under this Contract must be in writing and delivered personally, overnight air
courier, registered or certified mail or facsimile. Unless otherwise stated in this Contract, notices, consents or other communication will be deemed received (a)
on the date delivered, if delivered personally or by facsimile transmission; (b) on the next business day if sent via overnight air courier; or (c) three (3) business
days after being sent, if sent by registered or certified mail.
13. SEVERABILITY; WAIVER: The invalidity or unenforceability of any provision of this Contract shall not affect the validity or enforceability of any other pro-
vision of this Contract. No waiver of any of the provisions of this Contract shall be deemed, or shall constitute a waiver of any other provision, whether or not
similar, nor shall any waiver constitute a continuing waiver. No waiver shall be binding unless executed in writing by the party making the waiver. The Section
headings included herein are for the convenience of the parties only and no way alter, modify, amend, limit or restrict the contractual obligations of the parties.
14. NO THIRD PARTY BENEFICIARIES; SETOFF: Nothing in this Contract is intended to, or shall, create any third-party beneficiaries, whether intended or
incidental and neither party shall make any representations to the contrary. Seller shall have the right to deduct from any sums it owes to Buyer, and sums or the
value of any obligation owed by Buyer to Seller.
15. ENTIRE AGREEMENT: The terms set forth herein constitute the sole terms and conditions of the Contract between Buyer and Seller. Notwithstanding the
foregoing or any other term of this Contract, to the extent this Contract conflicts with the terms or conditions of any written distributor agreement between the
parties, the written distributor agreement shall control. No other warranty, term, condition or understanding, whether oral or written shall be binding upon Seller,
unless hereafter expressed in writing, approved and signed by Seller.
16. SURVIVAL: The provisions of Sections 3, 4, 5, and 7 through 16 shall survive the termination and performance of this Contract.

3
SAFETY RULES
READ CAREFULLY BEFORE OPERATING EQUIPMENT
WHEEL LUGS MUST BE CHECKED AND RE-TORQUED AFTER FIRST 30 MILES
IMPORTANT
Wheel lugs must be properly torqued before using your conveyor in radial travel mode.
Safety must be a primary consideration when operating any type of machinery. Accidents
are the result of carelessness or negligence on the part of the operator. The following safety
considerations are not meant to cover every possible condition or situation that may occur.
Common sense and precaution must be practiced at all times when installing, operating and
maintaining any MASABA machinery.
IMPORTANT
It is the responsibility of the owner to establish and maintain a safety training program that
covers equipment operation and maintenance in accordance with all MSHA, OSHA, and
local, state, and federal guidelines. All personnel operating this equipment MUST read and
understand this Owner’s Manual and all warnings and safety precautions. Be aware of all
posted warning, caution, or danger decals on your equipment. Compliance with these
warnings is mandatory to prevent serious injury or death.
IMPORTANT
Guards and safety devices have been factory installed. Any additional guards or safety
devices required to meet local, state or federal guidelines are the responsibility of the end
user.
• ALWAYS RESPECT HEAVY MACHINERY FOR WHAT IT IS.
• ONLY QUALIFIED PERSONNEL MAY OPERATE OR MAINTAIN EQUIPMENT.
ALL PERSONNEL OPERATING THIS EQUIPMENT MUST READ AND UNDER-
STAND THIS OWNER’S MANUAL AND ALL WARNINGS AND SAFETY PRECAU-
TIONS.
• NEVER OPERATE ANY MACHINERY WITHOUT ALL GUARDS AND HOUSINGS
PROPERLY INSTALLED AND IN GOOD WORKING CONDITION. NEVER OPER-
ATE ANY EQUIPMENT WHILE UNDER THE INFLUENCE OF DRUGS OR ALCO-
HOL.
• NEVER LEAVE THE MACHINE RUNNING AND UNATTENDED.
• NEVER ATTEMPT TO ADJUST, LUBRICATE, REPAIR, MAINTAIN, ETC. ANY
MACHINERY WHILE IT IS MOVING OR OPERATING. ALWAYS USE “LOCK-

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OUT/TAGOUT” PROCEDURES ESTABLISHED BY YOUR COMPANY BEFORE
WORKING ON ANY EQUIPMENT.
• NEVER ATTEMPT TO RIDE ON A MOVING PIECE OF MACHINERY.
• DO NOT WALK ON MACHINERY GUARDS, GRATINGS, OR COVERS.
• DO NOT PLACE HANDS, FEET OR ANY PART OF THE BODY NEAR MOVING
PARTS.
• NEVER WEAR LOOSE CLOTHING, NECKTIES, OR JEWELRY AROUND MOV-
ING PARTS. LONG HAIR SHOULD BE SECURED UNDER A CAP OR HAT.
• ALWAYS WEAR EYE PROTECTION, HEARING PROTECTION, RESPIRATORS,
GLOVES, HARD HATS, SAFETY SHOES AND OTHER PROTECTIVE CLOTHING
WHEN REQUIRED. MATERIAL CAN AND WILL FALL OFF AT ANY POINT AND
CAN CAUSE SERIOUS INJURY.
• KEEP ALL OPERATING PERSONNEL ADVISED OF THE LOCATION AND
OPERATION OF ALL EMERGENCY STOPS AND CONTROLS. CLEAR ACCESS
MUST BE PROVIDED TO THESE STOPS AND CONTROLS MUST BE MAIN-
TAINED AT ALL TIMES.
• FREQUENT INSPECTIONS OF ALL EMERGENCY STOPS, CONTROLS,
GUARDS, GRATINGS OR COVERS MUST BE MAINTAINED AT ALL TIMES.
• ALWAYS FOLLOW “LOCKOUT/TAGOUT” PROCEDURES ETABLISHED BY
YOUR COMPANY WHEN PERFORMING ANY TYPE OF MAINTENANCE OR
REPAIR.
• BEFORE STARTING ANY EQUIPMENT, MAKE SURE THAT THE OPERATOR
HAS READ AND UNDERSTANDS ALL OPERATION AND SAFTEY GUIDELINES.
VERIFY THAT THE AREA AND EQUIPMENT ARE SAFE FOR OPERATION AND
ALL GUARDS ARE IN PLACE AND SECURE. OPERATORS MUST PERFORM A
PRE-OPERATION SAFETY INSPECTION.
• NEVER ALTER, MODIFY OR ATTEMPT TO USE THE CONVEYOR FOR ANY-
THING OTHER THAN ITS INTENDED USE.
• NEVER ATTEMPT TO MOVE OR RELOCATE A CONVEYOR WITH THE SLIP
TUBE EXTENDED (CONVEYOR RAISED). THE SLIP TUBE MUST BE FULLY
RETRACTED AND SECURED BEFORE MOVING A CONVEYOR.
HYDRAULIC SYSTEMS SAFETY (IF EQUIPPED)

5
• CHECK ALL HOSES FOR SIGNS OF WEAKNESS OR CRACKS BEFORE USING
EQUIPMENT.
• CHECK FLOW DIAGRAM TO BE CERTAIN THE SYSTEM IS DEPRESSURIZED
BEFORE ATTEMPTING REPAIRS. SEE APPENDIX O FOR THE HYDRAULIC
SCHEMATIC.
• BE AWARE OF HEAT BUILDUP IN SYSTEM AND ALLOW COOLING BEFORE
BEGINNING REPAIR OR MAINTENANCE.
• SQUEEZE OR FLEX FLEXIBLE HOSES TO CHECK FOR PRESSURE BEFORE
LOOSENING FITTINGS.
• USE “WHIP-CHECKS” TO MOUNT AND SECURE HYDRAULIC LINES TO PRE-
VENT INJURIES FROM WHIPPING OR FLAILING HOSES.
GENERAL
Successful operation of a machine depends upon good maintenance. Machinery must be
inspected regularly to make sure that all moving parts are in good operating condition and that all
bolts are tight. During the first week of operation, check the bolts for tightness daily and then
periodically thereafter. This procedure also applies to parts and components that have been disas-
sembled and reassembled during normal maintenance periods.
Caution must be used when operating your equipment in high winds. If possible lower your con-
veyor to its lowest setting during periods of high wind. If lowering you conveyor is not possible,
secure it to the ground at the axle. High winds can blow your conveyor over causing serious
injury and equipment damage.
Statements used throughout this user manual to draw attention to important safety measures
include but are not limited to the following:
IMPORTANT
IMPORTANT is used to identify a procedure that needs to be followed to prevent machine dam-
age or personal injury.
The instructions that follow this level of warning draw attention to a safe operating procedure. If
the instructions are ignored the possibility of personal injury may exist.

6
The instructions that follow this level of warning draw attention to the possibility of a serious haz-
ard. Failure to follow these instructions may put an individual at risk of serious injury or death.
The instructions that follow this level of warning are the most serious. Failure to follow these
instructions will most likely result in serious injury or death.
SAFETY DECALS
The decals shown below are a representation of the types of decals you may find on your equip-
ment. It is the responsibility of the operator to replace any worn, torn, hard to read or missing
decals.

7
SETTING UP YOUR GRIZZLY FEEDER PLANT
SITE PREPARATION
• Location of the Feeder Plant is generally determined by the location of discharge of material
to be conveyed. Improper site conditions can adversely affect the operation and maintenance
of your Feeder Plant.
• The area around the Feeder Plant should be kept clear and level to make the loading of dis-
charge material as convenient as possible.
• The Feeder Plant must have adequate clearance all around to allow for maintenance and the
removal of material spillage.
• The discharge conveyor work site must have solid compacted ground with no more than one
degree slope to ensure proper operation. This will prevent the Feeder Plant from rolling down
hill.
UNLOADING YOUR MASABA EQUIPMENT
It is recommended that you unload your Feeder Plant at the site it will be used.
Your Feeder Plant was delivered fully assembled and can be disconnected from the delivery truck
at the designated site.
To disconnect your Feeder Plant from the delivery truck:
1. Set the air brakes or block the wheels on the Feeder Plant.
2. Your Feeder Plant is equipped with manual landing legs. Lower the landing legs until the
Feeder Plant king pin is high enough to take pressure off the delivery truck.

8
Landing legs can crush hands and feet. Make sure the area beneath the landing leg is clear
before operating the manual crank to lower the landing legs. Failure to do so can result in
serious injury.
3. Disconnect the air brakes from the tractor.
4. Disconnect the king pin from the tractor.
5. Drive tractor away from the Feeder Plant.
OPERATING YOUR GRIZZLY FEEDER PLANT
POWER CONNECTION
PROPER “LOCKOUT/TAGOUT” PROCEDURES SHOULD BE FOLLOWED BEFORE
ATTEMPTING TO CONNECT YOUR GRIZZLY FEEDER PLANT TO ANY POWER
SOURCE. FAILURE TO FOLLOW YOUR COMPANY DESIGNED “LOCKOUT/
TAGOUT” PROCEDURE CAN RESULT IN SERIOUS INJURY OR DEATH.
Before operating your Feeder Plant you will need to connect it to an external power supply. Be
sure your power supply has the proper voltage. Improper voltage and/or power surges can dam-
age the electronic systems and will void warranty.
IMPORTANT
It is important to inspect the power supply cord for cuts or other damage. Use of a damaged
cord can result in equipment damage and/or personal injury.
CRIBBING YOUR GRIZZLY FEEDER PLANT
Use the following procedures to properly crib your Grizzly Feeder Plant. These procedures may
vary depending on the style of Grizzly Feeder Plant you purchased.

9
1. If you purchased your Feeder Plant equipped with a discharge conveyor, it arrived with the
front cribbing legs in travel position. They must be unbolted from the Feeder Plant chassis
before use.
2. Locate the four (4) holes near the front of the Feeder Plant chassis on each side.
3. Bolt the cribbing legs to the chassis on both sides of the Feeder Plant using the supplied hard-
ware.
4. Lift the Feeder Plant with either the landing legs or by chain/cable attached to the front lifting
eyes so the plant can be leveled.

10
Be sure to inspect all lifting equipment for extreme wear or damage and maintain according
to manufacturer’s guidelines.
5. Cross crib all cribbing points on both sides of the Feeder Plant.

11
6. Once the Feeder Plant is properly cribbed and level, retract the Feeder Plant landing legs.
7. Attach a chain/cable to the two attachment points on the folding Feeder Plant skirts.
8. Remove the two bolts that secure the skirt to the Feeder Plant and slowly lower the skirt into
position.
IMPORTANT
Never attempt to lower the Feeder Plant skirt by hand. Always use a chain/cable for this
procedure.

12
Make sure all personnel are clear of the unfolding skirt. Pinch points exist along the entire
length of the hinged area. Failure to do so can result in serious injury.
IDENTIFYING YOUR GRIZZLY FEEDER PLANT
Your Grizzly Feeder Plant is equipped with an electrical panel and a hydraulic system for control-
ling material discharge functions. Depending on the Feeder Plant you purchased, the electrical
panel consists of either six (6) or eight (8) buttons that control designated functions, one (1)
hydraulic manual over-ride switch, and the emergency stop button.
The function buttons are identified as follows:

13
• DISCHARGE START: Press this button to start the discharge conveyor.
IMPORTANT
It is important to start the discharge conveyor prior to starting the feeder conveyor. Failure
to do this may result in material spillage or equipment damage.
• DISCHARGE STOP: Press this button to stop the discharge conveyor.

14
IMPORTANT
It is important to stop the feeder conveyor prior to stoping the discharge conveyor. Failure
to do this may result in material spillage or equipment damage.
• FEEDER START: Press this button to start the feeder conveyor.
• FEEDER STOP: Press this button to stop the feeder conveyor.

15
• FEEDER + SPEED: Push this button to increase the belt speed of the feeder conveyor.
• FEEDER - SPEED: Push this button to decrease the belt speed of the feeder conveyor.

16
• HYDRAULIC MANUAL OVER-RIDE: Turn this switch clockwise from “off” to “on” to
allow for the use of the manual hydraulic levers.
• HYDRAULIC UNIT START: Press this button to start the hydraulic unit to allow for the
use of the manual hydraulic levers.

17
• HYDRAULIC UNIT STOP: Press this button to stop the hydraulic unit.
• EMERGENCY STOP: Pull this button to start and Push it to stop all functions in case of
emergency.
OPERATING YOU GRIZZLY FEEDER PLANT
CONVEYOR PREPARATION
Prior to running your conveyor for the first time perform the following tasks:
• Confirm that all shipping brackets and straps have been removed and that there are no
obstructions to impede the operation of the conveyor belt.
• Always track belts prior to running material, belts may need to be adjusted once material starts
running. See Appendix C for belt tracking instructions.
• Minimize side load/feed of belt in hopper area to minimize tracking issues.
• Make sure material is being fed on the center of the belt as much as possible.
• Check all conveyor flashing to make sure it is in the proper position and fully tightened to
reduce spillage.
• Check “V-Belts” on belt drive for proper tensioning.

18
CONVEYOR OPERATION
To start using your Grizzly Feeder Plant using the electric control panel, perform the following
steps:
1. Pull the “Emergency Stop” button to the start position.
2. Push the “Discharge Start” button to engage the discharge conveyor.
3. Push the “Feeder Start” button to engage the feeder conveyor.
ADJUSTING DISCHARGE CONVEYOR HEIGHT (IF EQUIPPED)
If you purchased a Grizzly Feeder Plant that has an adjustable height discharge conveyor, use the
following steps to adjust the conveyor height.
1. Turn the “Hydraulic Manual Over-Ride” switch to the “ON” position.
2. Push the “Hydraulic Unit Start” button to activate the hydraulic unit.
3. Locate the hydraulic handle labeled “CONV HEAD” and operate it in the direction of the
“U”. As the slip tube raises (or lowers), watch for adjustment holes in the undercarriage. Stop
the slip tube when the holes appear at the desired discharge height.
4. Insert the supplied retention pins into the undercarriage holes to secure the slip tube.
Failure to insert slip tube retention pins properly can result in conveyor damage and possi-
ble injury.
IMPORTANT:
When inserting the slip tube retention pins, it is important that the tab on the pin faces away
from the raised slip tube as indicated below. Do not use the pin tab to get more height, tube
damage may result.

19
GRIZZLY OPERATION
Your Grizzly Feeder Plant is equipped with two (2) hydraulic cylinders that are used to tilt the
Grizzly to remove oversized material. These functions can also be performed through the use of
an OPTIONAL remote control unit. See the remote control unit User’s Manual for more details
on its operation.
THE AREA AROUND THE TILTING GRIZZLY HOPPER MUST BE KEPT CLEAR OF
PERSONNEL DURING THE OPERATION OF THE HYDRAULIC CONTROLS OR
REMOTE CONTROLS (IF EQUIPPED). FAILURE TO DO SO CAN RESULT IN SERI-
OUS INJURY OR DEATH. IT IS IMPORTANT THAT ANYONE OPERATING THE
OPTIONAL REMOTE CONTROL HAVE LINE OF SIGHT VISION TO THE AREA
AROUND THE TILTING GRIZZLY HOPPER.
Use the following procedures to tilt the Grizzly.
1. If the hydraulic unit is not on, locate the “Hydraulic Manual Over-Ride” switch and turn it to
the “ON” position.
2. Push the “Hydraulic Unit Start Button” to activate the hydraulic unit.
3. Locate the hydraulic lever labeled “GRIZZLY” and operate it in the direction of the “U”.
After oversized material has been removed, return the Grizzly to it’s starting position by oper-
ating the hydraulic lever in the “D” direction.
The Grizzly has the ability to operate at a variety of angles to allow oversized material to be
removed during normal operation. Use the following procedures to set the desired operating
angle of the Grizzly.

20
1. With the hydraulic unit running, operate the hydraulic lever labeled “GRIZZLY” in the direc-
tion of the “U” until the desired operating angle is achieved. Insert the stop pins in the slip
tubes at both ends at the desired angle..
2. Operate the “GRIZZLY” lever in the direction of the “D” until the Grizzly comes to rest.
3. Resume normal operation.

20
MAINTENANCE
BELT TRACKING
Prior to running the conveyor loaded with material, the belt tracking should be checked. Belt
training is the process of adjusting idlers to insure that the belt travels over the center of the idlers,
return rollers, and pulleys.
DO NOT ATTEMPT TO TRAIN THE BELT BY ADJUSTING THE SCREW TAKE-UPS. The
take-ups are used for belt tension, and to keep the tail pulley square with the frame.
A normal sequence of training is to start with the return run working toward the tail pulley and
then follow with the top run in the direction of belt travel. The primary rule which must be kept in
mind when tracking a conveyor belt is simply: “THE BELT MOVES TOWARD THAT END OF
THE ROLL/IDLER IT CONTACTS FIRST”.
The following steps should be taken to properly train the belt to run over the center of the pulleys,
troughing idlers, and return rollers:
• Ensure that all frames are level. If the frames are not level, the belt will be forced to one side
or the other.
• Square the tail pulley by measuring from a fixed point on both sides of the conveyor.

21
• Check the belt splice for squareness. The belt ends should be squared from a center line at
least 15 feet long and accurately derived from center point measurements along the belt. Do
not use the edge of the belt for reference.
• Square all troughing and return rollers with the frame and tighten the attachment bolts.
• Run the conveyor empty and at reduced speed if possible. Look for a side creep at any point
along the frame. Check the return travel for side creep. Make adjustments where side creep
occurs as follows:
The conveyor must be powered off before attempting to adjust any return rollers or idlers.
Failure to do so can result in serious injury.
1. The point of maximum side creep requires adjustment of a preceding roller when you are fac-
ing in the direction toward which the belt is moving.
2. Loosen the bolts and pivot the roller around its midpoint, making these adjustments in small
increments. Tighten the bolts and make a test run after each adjustment to see the effect on
side creep. If the point of maximum side creep changes, adjust the roller that precedes that
new point.
3. When the slow running belt is centered, change to normal speed. Load the belt with material
and continue testing until belt is running centered.

22
4. If the belt should show a side creep only at the splice point as it runs along the conveyor,
rather than at one point, the splice is not square and should be re-done. See appendix B for
detailed instructions on proper belt splicing.
TROUBLESHOOTING BELT CONVEYORS
1. ALL PORTIONS OF CONVEYOR BELT RUNNING TO ONE SIDE AT A GIVEN POINT
ON STRUCTURE.
PROBLEM CORRECTION
One or more idlers immediately preceding Advance, in the direction of belt
trouble point not at right angles to direc- travel, the end of the idler toward
tion of belt travel. which the belt has shifted.
One or more idler stands not centered Center them.
under belt.
Belt runs off terminal pulley. Check terminal pulley alignment.
Check alignment of idlers
approaching terminal pulley.
Buildup of material on idlers. Improve maintenance. Install brushes
or other cleaning device.
Structure not level and belt tends to Level Structure.
shift to low side.
2. PARTICULAR SECTION OF BELT RUNS TO ONE SIDE AT ALL POINTS OF CON-
VEYOR.
PROBLEM CORRECTION
Belt not joined squarely. Square ends & re-splice.
Cambered belt. Tension it or replace it.
3. CONVEYOR BELT RUNS TO ONE SIDE FOR LONG DISTANCE ALONG BED.

23
PROBLEM CORRECTION
Load being placed on belt off-center. Adjust chute and loading conditions so
as to place in center.
Conveyor frame or structure crooked. Straighten it.
4. SEVERE WEAR ON PULLEY SIDE OF CONVEYOR BELT.
PROBLEM CORRECTION
Slippage on drive pulley. Increase tension if belt
construction permits.
Lag drive pulley (groove if wet)
Spillage of material between belt and Improve loading conditions with
pulley, or material builds up at loading chutes.
point until belt is dragging. If belt loaded too full, increase
belt speed or decrease feed.
Install plows or scrapers in front of tail pulley
on return run.
Excessive tilt to troughing idlers. Adjust to not more than 2 degrees
from line perpendicular to belt.
Sticking idlers. Improve maintenance and lubrication.
5. PRODUCT SLIPS ON INCLINE.
PROBLEM CORRECTION
Belt dirty. Clean it.
Incline too steep. Decrease incline.
6. COVER BLISTERS OR SAND BLISTERS.
PROBLEM CORRECTION
Cover cuts or very small cover punctures Make spot repair with vulcanizer
allow fine particles of sand to work or repair dough, after removing
under the cover and cut cover away from and cleaning the carcass.
underneath blister area.
Oil either in material or from outside Remove source of oil, if possible.
source. Check lubrication.
VENDOR SPECIFIC MAINTENANCE SCHEDULES
For maintenance schedules that are specific to the parts installed on your MASABA Equipment,
please refer to the corresponding appendix.

26
INSTALLING/TENSIONING V-DRIVES
CHECK CONDITION OF SHEAVES
Before installing a new set of V-Belts, examine the sheaves. Dirty or rusty sheaves impair the
drive’s efficiency and abrade the belts, which results in pre-mature failure. Worn sheaves shorten
V-Belt life by as much as 50%. If the grooves are worn to where the belt bottoms, slippage may
result and burn the belts. If the sidewalls are “dished out”, the bottom shoulder ruins the V-Belts
pre-maturely by wearing off the bottom corners.
The conveyor must be powered off before removing safety guards and must remain off while
performing any maintenance function. Failure to do so can result in serious injury.
CHECK SHEAVE ALIGNMENT
Sheave adjustment should be checked by placing a straight edge across the sheave face so that it
touches all four points of contact.
Improper sheave alignment produces:
• Uneven wear on one side of the V-Belt
• The V-Belt to roll over in the sheaves
• Puts the entire load on one side of the V-Belt, stretching or breaking the cords on that side.

27
V-BELT INSTALLATION
Shorten the center distance of the drive until the V-Belts can be put on the sheaves without
stretching. Stretching the V-Belts can cause internal damage to the belts. Center distance can be
decreased by adjusting the motor height as shown below.
BELT SELECTION
For maximum service, replace V-Belt drives with a complete new matched set of belts. Never
employ a used V-Belt as a replacement for one of a set of new V-Belts. Used belts normally are
worn in cross-section and stretched, and will cause the new belts to accept its load. A new belt
used with old belts will ride higher in the sheave, travel faster and operate at a much higher ten-
sion than the used belts. The cord center may be ruptured, allowing the new belt to elongate.
Shortly after this occurs it will cease to accept its full share of the load, leaving the drive under-
belted. Belts of different manufactures should not be mixed for the same reasons.
GENERAL RULES OF TENSIONING
• IDEAL TENSION IS THE LOWEST TENSION AT WHICH THE BELT WILL NOT SLIP
UNDER PEAK LOAD CONDITIONS.
• CHECK TENSION FREQUENTLY DURING THE FIRST 24-48 HRS OF RUN-IN OPER-
ATION.
• OVER TENSIONING SHORTENS BELT AND BEARING LIFE.
• TENSION BELTS WHEN SLIPPING. NEVER APPLY BELT DRESSING AS THIS WILL
DAMAGE THE BELT AND CAUSE EARLY FAILURE.

Conveyor Belt Storage
and Installation
APPENDIX A

2
Receiving the Roll
Upon delivery, check the factory packaging for
damage, punctures, etc. Make any appropriate
claim against the carrier at that time.
Handling the Roll
Factory packaging is designed to protect your
conveyor belt during normal shipping and
handling. When a belt arrives, be careful
unloading it. Don’t drop it or handle it
roughly. This could break the packaging and
cause the belt to telescope. Once a belt tele-
scopes, it is almost impossible to re-roll.
Try not to roll it, but if you must, roll in the
direction the belt is wound. Rolling a belt in
the opposite direction can cause it to loosen
and telescope.
The best way to move a belt is to slip a sturdy
hoisting bar through the center core. Then, lift
it with a sling or with strong cables. Be careful
that these hoist cables don’t
damage the outer wraps at
the belt edges. Protect the
edges with special
“spreader bars,” or short
wooden planks. Never
apply a sling around the
circumference of a roll of
belting. . .it isn’t safe!
You can also move a
belt safely by
laying the roll
flat on a skid
and hoisting
the skid with
a forklift. Just
be sure the
forks on the
lift don’t
come in
contact with
the belt itself.
Storage
When storing a new conveyor belt, leave it
hoisted or stand it upright, preferably on a dry
surface (do not lay the roll on its side). A
wooden skid is best. Block it safely so it can’t
accidentally roll.
Extreme temperature variations can have an
adverse affect on a belt over long periods of
time. The ideal storage range is between 50°F
and 70°F.
Long exposure at temperatures even slightly
below 40°F can harden or stiffen the com-
pounds. If installed on a conveyor in this
stiffened state, the belt may not train well
until it adjusts or “warms up” to the system.
Neoprene, for example, is especially sensitive
to low temperatures and should never be
stored at less than 40°F. Stiffened neoprene
belting is different than other constructions. It
won’t loosen up until it’s had a lengthy expo-
sure to relatively mild temperatures.
Temperatures over 90°F have an adverse
effect, too, and should be avoided.
Sunlight and ozone can also deteriorate any
exposed rubber over time. Store your belt out
of the direct sunlight whenever possible.
Electrical generators or arc welders can
sometimes generate ozone. It is best to store
your belt some distance away from this type
of equipment.
In general, it’s wise to keep any unused belt
stored in its protective factory packaging until
it’s ready for installation.
Used belt should be thoroughly cleaned and
dried prior to storage.
A dry place out of direct sunlight is pre-
ferred for storage, excessive temperature
variations or extremes being avoided. Belts
should not be stored in excessively wet
places or in areas where oils, gasoline, paint
Conveyor Belt Storage and Installation
Index Page

3
materials, acids and chemicals are also stored
or used. Motor-control rooms, welding shops,
and other places where ozone is generated
should likewise be avoided. A belt should not
be permitted to rest on a concrete floor. If it is
necessary to lay a belt on the floor, use a
pallet or a cradle.
Belts which are not endless should be stored
in rolls. Once thoroughly cleaned and dried, it
is good practice to dust a belt with tire talc or
to insert kraft paper between the layers when
rolling it up. Care should be taken not to roll a
belt too tightly. Be sure the interior diameter
of the roll is sufficiently large to avoid any
possible carcass damage or warping.
The belt should be rolled evenly to
avoid telescoping and warping. Exces-
sive flexing or sharp bends of any sort
are to be avoided. Rolls should not be
stood on edge or leaned against a wall.
Small endless belts may be hung up on a
dowel or a peg for storage. It is advisable
to rotate the belt occasionally to avoid a
constant flex or bend at one point. Larger
endless belts may be stored flat, doubling
them over as necessary. It is advisable
when doubling a belt over to be sure that
the edges of the belt are in line to avoid
any warping. As above, it is good practice to
rotate and repile the belt occasionally to avoid
constant flexing or bending at any point.
Bends should be made as large as possible to
avoid cracking the carcass.
Installation
Once the roll of belting has been transported
to the point of installation it should be
mounted on a suitable shaft for unrolling and
threading onto the conveyor. Conveyor belt-
ing is normally rolled at the factory with the
carrying side out. Consequently, in mounting
the roll, the belt must lead off the top of the
roll if it is being pulled onto the troughing or
carrying idlers but off the bottom of the roll if
it is being pulled onto the return idlers. The
illustrations below represent suitable methods
of mounting and stringing belt for each case.
Note: Temporary flat roll at
bend point, as roll is pulled
onto troughing idlers
In some cases, such as in the mines where
head room does not permit maneuvering a
roll, the belt may have to be pulled off the roll
and reefed (Left). Extreme care should be
exercised to see that the loops have large
bends to avoid kinking or placing undue strain
on the belt. No weight should ever be placed
on the belt when it is in this position. Another
method of handling belting under such condi-
tions is to lay the roll on a turntable with a
vertical spindle.
No weight to be placed on top
Keep bends large to prevent
breaking carcass
Reefing the Belt
Left: Temporary flat roll at
bend point
Below: Threading through
return strand
Index Page

21 Laredo Drive
Scottdale, Georgia 30079 • USA
Phone: (404) 297-3170
Fax: (404) 296-5165
www.fennerdunlopamericas.com 10/03
IS O 9001:2000 Certified
C O N V E Y O R B E L T I N G A M E R I C A S
Index Page

Installing Flexco®
Bolt Solid Plate
1. Square belt ends using centerline method. Cut
belt ends using Flexco 840 Series Belt Cutter.
2. Support belt ends with wood plank. Nail
Flexco Templet in position with belt ends tight
against lugs.
3. Spray templet holes with Flexco Silicone
Lubricant. Punch or bore bolt holes. Remove
templet.
NOTE: A ½” square drive electric impact
wrench with Flexco 5552 Quick Change
Chuck will speed hole boring operation.
4.For 2-1/2, 3, 1-1/2FP, 2FP, RP1, and RP2, assemble
bottom plate. Insert 2 bolts and attach clip.
5. Fold one belt end back and insert bolts in one
row of holes.
6. Align bolts with templet teeth and place the other
belt end over bolts. Remove templet.
7.Place top plates over bolts using bolt horn.
Instructions for Installation
8. Start nuts on bolts by hand.
9. Cut Flexco-Lok® Tape 3-1/2 times the belt width
and feed tape under top plates, under the bottom
plates, then back under top plates.
10. Pull tape tight and hold in position by
en tighten all
other plates.
NOTE: A Flexco
11. Tighten all fasteners from edges to center.
Tighten all nuts uniformly.
Power Wrench used with an impact tool will
speed this step considerably.
12. Hammer plates in belt with wood block.
Retighten nuts.
13. excess bolt ends using two bolt
nish.
APPENDIX B

1
Table of Contents
I. Conveyor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Supporting Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pulleys, Rollers, Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Take-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
II. Non Structural Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Neutral Belt Stresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Skew (Bow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Square Belt Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
III. General Training Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IV. Training Package or Unit Handling Belting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
V. Training Bulk Haulage Belting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Index Page

2
“Tracking” or training is defined as the procedure required to
make the conveyor belt run “true” when empty and also when
fully loaded.
Tracking conveyor belt should be approached from a systems
point of view. We should first examine some of the compo-
nents of the conveyor system and see how they effect belt
tracking before we discuss the actual methods used to train a
belt.
We also need to look at a few non-structural components such
as conveyor house keeping, the belt itself and the splice,
before we discuss recommended training procedures.
Index Page

Supporting Structure
The supporting structure is designed to hold con-
veyor sections firmly and in proper alignment. If it
does not, for whatever reason, it is likely to have
an effect on belt tracking. Support structure should
be checked as a first step in belt tracking. Has a
forklift run into the supporting structure and buck-
led it? Are the anchors firm?
Conveyor sections are bolted to the supporting
structure. They should be “square” and “horizon-
tal” (side to side). If the section is “racked” it must
be straightened. Measure diagonals across the
frame. They should be equal. Repeat for total,
assembled bed.
Conveyor bed sections (slider or roller) must be
properly aligned with no vertical off-set between
sections. A taut line should be stretched over the
top surface of the bed and adjustments made so
that all points are in contact. The entire bed (and
each section) must be horizontal (across the
width). If they are not, the belt will be pulled by
gravity and will “drift” toward the low side unless a
compensating force of some kind is exerted on
that belt.
Pulleys/Rollers/Idlers
All pulleys, snub rollers, carrying idlers, and return
idlers must be square with the frame (perpendicu-
lar to belt center line), parallel to each other and
level.
“Squaring” with the frame is a good preliminary
adjustment. The final adjustment, however,
requires that this “squaring” be done with the belt
center line as the reference. All pulleys must be at
right angles to the direction of belt travel (belt cen-
ter line).
Crowns
Crowned pulleys for lightweight conveyor belt
can be trapezoidal or radial shaped. Georgia Duck
has products to accommodate both styles, howev-
er the amount of crown in either case should not
exceed 1/8" per foot on the diameter, and should
not exceed 1/8" total. The rate of crown seems to
be very important as well as the total amount of
crown
in the system.
On short center conveyors, we recommend no
crown on the drive (avoid crowns on drive in every
case, unless the drive is an end pulley), and to
crown the end pulleys. In a few cases we would
also crown additional pulleys, but that will depend
on the entire design and the amount of crown
used.
Remember, for crowns to be effective, there must
be enough free span/transition for the belt to elon-
gate and conform. Pretension to get pulley crown
conformation is very important, too much preten-
sion can cause pulley deflection and bearing prob-
lems. Georgia Duck has specific carcass construc-
tions to meet very short center, wide belt applica-
tions in the 1:1 ratio of length to width, and even
less. Please consult factory if you have needs in
this area.
Crowned pulleys are not recommended for high
modulus bulk haulage belting. Steel Cord belting
requires fully machined straight faced pulleys
through out the system. If a crowned pulley is used
on nylon, polyester or aramid style belting the
crown should only be placed in a low tension area
such as the tail on a conventional head drive con-
veyor. The tracking forces that the crown exhibits
does not effect high modulus bulk haulage belting
because the system lacks enough tension to make
the crown effective. If you could exert enough ten-
sion on the belt to force the belt to conform to the
crown, the belt would be subjected to excessive
stretch and splice failure could result.
3
I. Conveyor Components
Index Page

Take-up
The take-up device in a conveyor belt system has
three major functions:
1. To establish, and preferably to maintain a pre-
determined tension in the belt.
2. To remove the accumulation of slack in the belt
at startup or during momentary overloads–in
addition to maintaining the correct operating
tension.
3. To provide sufficient reserve belt length to
enable resplicing, if necessary.
Manual, as well as automatic, take-up devices are
normally used in a typical conveyor belt system.
The manual or screw take-up consists of a ten-
sion pulley (frequently the tail) which can be moved
to tighten the belt by means of threaded rods or by
steel cables which can be wound on a winch.
These give no indication of the tension they estab-
lish and are adjusted by trial methods until slip-
page is avoided. They are unable to compensate
for any length changes in the belt between adjust-
ments and thus, permit wide variation in belt ten-
sion. Use is generally restricted to short and/or
lightly stressed conveyors–widely used in unit
handling.
The manual take-up must be such that when ten-
sion is applied to the pulley, the pulley remains at
right angles to the direction of belt travel. Also the
tension must be high enough to allow elastic
recovery of elongation due to starting forces, load
changes, etc.
Automatic take-ups depend upon suspending a
predetermined weight (gravity), by activation of a
torque motor, by hydraulic pressure, or by spring
loading. These devices maintain a predetermined
tension at the point of take-up regardless of length
changes resulting from load change, start-up,
stretch, etc. This permits running the belt at the
minimum operating tension and should be used on
all long length conveyors and moderate to highly
stressed conveyors.
The automatic take-up alignment must be such
that the pulley or pulleys are maintained at right
angles to the direction of belt travel. In a gravity or
spring loaded take-up, the carriage must be guid-
ed to maintain the pulley axis on a line perpendicu-
lar
to the belt center line.
Adequate take-up is essential to satisfactory
operation of a belt conveyor. The amount required
depends on type of belting and on service con-
ditions. Please refer to belt manufacturer for
recommendations.
Normally, when a new belt has been properly
installed and tensioned, the take-up roll or pulley
(automatic take-up) will be initially set at a position
of 25% along the line of travel, leaving 75% of the
take-up area available for elongation.
4
Index Page

Cleanliness
Cleanliness is essential to good belt tracking. A
buildup (of whatever material) on pulleys and rolls
can easily destroy the “perpendicularity” of the roll
or pulley face. Foreign matter in essence creates a
new roll or pulley crown–adversely affecting
tracking.
Likewise, cleanliness is essential to slider bed
operation. A buildup of foreign materials (or a
roughened portion of the slider bed face) can very
easily throw a belt off-center since this will result in
a differential of warp tensions across the width of
the belt. This can seriously effect training.
Scrapers can be applied directly to bend rolls at
the take-up area, on a gravity take-up system, to
keep the rolls free from build up. Ploughs installed
prior to the tail roll, under the loading section, will
prevent belt and pulley damage due to carry back.
Balanced/Neutral
It is extremely important that the final belt con-
struction be “balanced” or “neutral” in terms of the
internal stresses imparted to the belt during manu-
facture. Any unbalanced stress remaining in the
belt will likely cause problems in tracking.
Typical belt carcass designs usually utilize a plain
weave or twill weave. The “crimp” imposed upon
the warp yarns (length-wise yarns) in these types
of weaves, as well as the warp tension necessary
at the loom are difficult to control. Unbalanced
stresses can result. Georgia Duck has a patented
tensioning system to minimize this problem.
The resulting “straight/balanced” carcass is kept
straight by tensioning during the impregnation and
curing steps of manufacture, resulting in a straight
belt which is balanced and therefore, easy to track.
Camber
If unbalanced warp tensions exist in a conveyor belt,
that belt will usually assume a “crescent” or
“banana” shape when laid flat upon a horizontal
surface. This deviation from a straight line is here-
by defined as “camber.”
To measure belt camber, it is recommended that
the belt be unrolled on a flat surface like the ware-
house floor, a flat horizontal driveway, etc. Next,
one end of that belt should be grasped (and one end
only) and the belt dragged in a perfectly straight
line for approximately 10 feet. If the belt is too
heavy for one man to move, then one end should
be clamped to
a forklift and the same procedure performed. At
this point, the belt should lie flat. Unequal and
unresolved warp tensions in the belt will cause
it to assume a “crescent” or “banana” shape.
Camber is measured by drawing a taut line along
one edge of the belt and measuring maximum
deviation from that taut line to the belt at the point
of maximum deviation. Compute % camber as
follows:
% Camber =
Maximum Deviation (Inches)
x 100
Length of taut line (Inches)
It is recommended that if the percent camber
exceeds one-half of 1%, the belt manufacturer
be contacted. In lightweight, unit/package handling
.25% is the maximum.
Camber can be instilled into a belt during the slitting
operation if one of the slitting knives is dull. A dull
slitting knife will tear the fill yarns (cross-wise yarns)
rather than cut them. (While the belt is in roll form
the side of the belt which had gone through the dull
knife will exhibit a “fuzzy” appearance due to the
torn fill yarns.) Usually this type of camber will be
less than one-quarter of 1% and can be pulled out
handily when the belt is properly tensioned.
5
II. Non Structural Components
Index Page

Skew (Bow)
The fill yarns (weft yarns) in the belt carcass will
usually lie along the perpendicular to the belt cen-
ter line. Any deviation from this perpendicular line
by the fill yarn is hereby defined as “skew” or
“bow.”
A skewed pick in a plain weave or twill weave is
cause for concern since it is generally indicative
of unbalanced warp tensions and will usually go
hand-in-hand with a significant camber.
In a straight warp or solid woven carcass
design, however, skew is of little significance.
It is a cosmetic defect and is not indicative of a
cambered belt.
Belt Tension
Belt tension must be great enough to prevent slip-
page between the drive pulley and belt. Tension
must also be enough to cause the belt to conform
to the crowns, if present.
Slippage will cause excessive wear to both drive
pulley lagging and the belt. Further, an excessive
heat buildup on the drive pulley lagging can result
in rubber reversion. (Reversion is the softening of
vulcanized rubber when it is heated too long or
exposed to elevated temperatures. It is a deteriora-
tion in physical properties, and frequently results in
tackiness.) Once the pulley lagging has reverted,
it frequently will offset onto the bottom side of the
conveyor belt which will then distribute the reverted
rubber throughout the slider or roller bed of the
system. The resulting tackiness between the bed
and the belt will certainly drive horsepower con-
sumption up; can actually result in a stalled sys-
tem, and can cause severe tracking problems.
Square Ends
Accurate squaring of the belt ends prior to splicing
is essential to belt tracking, and helps distribute
stress evenly throughout the splice.
To properly square the belt ends, we recommend
the center line method.
To establish the belt center line, start near the belt
end as shown on the next page. Measure the belt
width at seven points approximately 1 foot apart.
Divide each measurement in two and mark these
center points as shown.
Using these seven “center points,” pop a chalk line
to form the belt’s center line. Next, using a carpen-
ter square or “T” square, draw a “cut line” across
the width of the belt near the belt end as shown.
Repeat this for the other belt end.
Using the “cut line” as the guide, cut off the end of
the belt with a sharp razor knife. Make sure that
the cut is clean and vertical. This operation should
then be repeated on the other end of the belt.
(Keep in mind that the final belt length may need to
include an allowance for such things as diagonal
splice, skive taper length, skive overlap, finger
punching loss, fastener extension, etc.–depending
upon what kind of splice is being performed.)
6
Index Page

7
BELT CENTER LINE
MARKING OF CUT LINE AND OTHER
RIGHT ANGLE GUIDE LINES
T-SQUARE
OR FRAMING SQUARE
BELT
END
BELT
END
CUT LINE
1 FOOT1 FOOT1 FOOT 1 FOOT 1 FOOT 1 FOOT
Index Page

An alternative method of squaring belt ends is
called the “double intersecting arc” method.
First establish the center line as indicated previ-
ously. Once that center line has been established,
pick a point on the center line and approximately 2
or 3 times the belt width from the belt end. An arc
is now struck, as shown in the following sketch.
On bulk haulage belting, a nail can be used as the
pivot point and an arc is struck with a steel tape.
Always mark the edge of the belt with the same
side of the tape.
A second arc is now struck as shown. The pivot
point in this case is on the center line and is close
to the belt end. The arc length is slightly less than
one-half of the belt width. Now draw a line from one
pair of intersecting arcs to the other. This is the “cut
line.” This line is perpendicular to the center line of
the belt. The reason for this may be edge wear or
damage or to eliminate slitting alignment errors.
Never assume both edges are straight and parallel.
Double Check Squareness
It is always a good idea to double-check the accu-
racy of the squared and cut end. Measure 5 feet
along each edge from the end of the belt, then
utilizing a tape measure, check the two diagonals.
They should be equal and further, should intersect
on the belt center line.
8
PIVOT
NAIL
PIVOT
NAIL
STEEL TAPE
LONG ARC
SHORTER
ARC
ALTERNATIVE ARC METHOD OF SQUARING ENDS
JOINING OF THE POINTS WHERE THE ARCS INTERSECT
GIVES THE RIGHT ANGLE CUT LINE
5’
5
A
C
D
B
PROVING ACCURACY OF SQUARED-CUT END
LENGTH OF DIAGONAL AB IS EQUAL TO LENGTH OF DIAG-
ONAL DC. ALSO AB AND DC INTERSECT ON THE BELT
CENTER LINE.
CUT
LINE
CUT
LINE
BELT
END
Index Page

Tracking the belt is a process of adjusting idlers,
pulleys, and loading conditions in a manner that
will correct any tendencies of the belt to run other
than true.
A normal sequence of training is to start with
the return run working toward the tail pulley and
then follow with the top run in the direction of belt
travel. Start with the belt empty. After tracking is
completed, run the belt with a full load and
recheck tracking.
Tracking adjustment is done while the belt is run-
ning and should be spread over some length of
the conveyor preceding the region of trouble. The
adjustment may not be immediately apparent, so
permit the belt to run for several minutes and at
least three full belt revolutions after each idler
adjustment to determine if additional “tracking”
is required.
After adjustment, if the belt has overcorrected, it
should be restored by moving back the same idler,
and not by shifting additional idlers or rollers.
If the belt runs to one side at a particular point or
points on the conveyor structure, the cause will
probably be due to the alignment, or leveling of the
structure, or to the idlers and pulleys immediately
preceding that particular area, or a combination of
these factors.
If a section or sections of the belt run off at all
points along the conveyor, the cause is possibly in
the belt itself, in the belt not being joined squarely,
or in the loading of the belt. With regard to the belt,
this will be due to camber. Its condition should
improve after it is operated under full load tension.
It is a rare occasion when a cambered belt (less
than 1/2%) needs to be replaced.
These basic rules can be used to diagnose a belt
running poorly. Combinations of these rules some-
times produce cases which do not appear clear-
cut as to cause, but if there is a sufficient number
of belt revolutions, the running pattern will become
clear and the cause disclosed. In those unusual
cases where a running pattern does not emerge, it
is quite likely that at some point the belt is running
so far off that it is fouling structure or mounting
brackets, bolts, etc. This results in highly erratic
performance and can be a real problem. We would
suggest that in this event the full tracking proce-
dure be employed. It is quite likely that the erratic
performance will be resolved in the process.
When replacing a used belt, go through the system
and square and level all rollers, idlers, pulleys and
bed before training a new belt.
Basic/Primary Rule of Tracking
The basic and primary rule which must be kept in
mind when tracking a conveyor belt is simple,
“THE BELT MOVES TOWARD THAT END OF
THE ROLL/IDLER IT CONTACTS FIRST.”
The reader can demonstrate this for himself very
simply by laying a small dowel rod or round pencil
on a flat surface in a skewed orientation. If a book
is now laid across the dowel rod and gently
pushed by one’s finger in a line directly away from
the experimenter, the book will tend to shift to the
left or right depending upon which end of that
dowel rod the moving book contacts first.
9
III. General Tracking/Training Procedures
BOOK MOVES LIKE SO
PENCIL
BOOK
PUSH
Index Page

Pulley Crown on Lightweight
and Monofilament Belt
A crowned pulley can be regarded as a special
case of our primary rule of tracking as stated
above. The right half of the belt is contacting the
center of the pulley sooner than it contacts the
right edge of that pulley and therefore will tend to
move toward the center. The reverse is true of the
left half of the belt. The two forces tend to balance
one another
by centering the belt.
In addition to this surface effect, however, there is
a strong internal “balancing of warp tensions
occurring.” Consider any warp yarn not directly on
the center line. If the belt is forced off-center and
this warp yarn is drawn toward the mid-point of
the crown, tension will be increased on that yarn.
As the belt revolves and that yarn seeks to move
back to its normal position, this tension will dimin-
ish. Yarns on both sides of the belt seek that posi-
tion which results in the least stress to themselves,
consistent with the physical structure across which
they are stressed and consistent with their individ-
ual position within the matrix of the belt carcass.
Accordingly, the belt will shift on the crowned pul-
ley until these stressing forces are balanced and
minimized
–centering the belt.
Experiment has shown that a crown is most effec-
tive when it has a long unsupported span of belt
approaching the pulley. The lateral position of the
belt can be influenced by the crown more easily
when there is a minimum of resistance being
offered by a supporting slider bed or by supporting
idlers.
Georgia Duck goes to great lengths to manufacture
balanced carcass belts so that the belt will self
center and track on the crown.
In most non-unit-handling conveyors this opti-
mum condition does not exist on the top run
and consequently, crown on the head pulley is
of little value in training the belt. Further, it is a
distinct detriment as far as lateral distribution
of tension in the belt is concerned. Head pul-
leys therefore, should be uncrowned in normal
circumstances. Tail pulleys and take-up pulleys
which may have a fairly long approaching span
without support can be crowned with some
beneficial results.
The effectiveness of the crown is increased to a
length of approximately 10 feet. Lengthening the
unsupported span beyond 10 feet does not seem
to increase the effectiveness of the crown.
Diminishing the length of the unsupported span on
the other hand, does diminish the effectiveness of
the crown. The shorter the unsupported span, the
less effective the crown will be. Snub pulleys can
reduce effectiveness by 50% or more.
We recommend a standard pulley crown of 1/16"
on radius per foot of pulley face. This results in an
increase in pulley diameter at a point 12" from the
edge of the pulley of 1/8" above the edge diame-
ter. A crown of 1/8" per foot should be considered
maximum. Crowns may be trapezoidal or radius.
It is further recommended that the crown not be
carried beyond a point 18" in from the edge of the
pulley. If the pulley width is greater than 36" it is
recommended that a trapezoidal pulley be used. In
other words, that pulley will have a flat face in its
center equivalent to the amount that the pulley
width exceeds 36". Radius crowns work, but may
take a few minutes longer to stabilize.
With the advent of CNC Machining, we see more
use of radial crowns, but the same rule regarding
maximum crown should apply. Special Note: The
belt must stretch to conform to the crown or it will
not be effective.
10
Index Page

Equipment Induced Camber
Camber can be induced into a perfectly straight
belt by the roll or rolls preceding the camber. If the
roll is cocked, the belt will react and will move
toward that end of the roll which it contacts first.
This, of course, throws the belt off-center. If now,
subsequent structural adjustments center that roll,
the belt installation will be left with a cambered
appearance. This camber may be removed by sim-
ply aligning the roll or rolls which are cocked.
Specific Training Sequence
Emergency
If the conveyor system, including the belt, has
been designed, built and installed according to
good engineering and manufacturing practice, the
belt should track at start-up. There may be minor
variations from the ideal because of manufacturing
tolerance–this will simply result in a system in
which the belt is not tracking absolutely perfectly,
but one in which the belt can be operated without
belt damage long enough for the tracking
sequence to take place. Normally belt width is less
than pulley face width and a small amount of belt
movement will
not cause any damage.
Occasionally, there may be a serious maladjust-
ment or defect in the system which will throw the
belt off to such a degree as to threaten belt dam-
age. It may actually be necessary to station men at
each end of the conveyor and physically force the
belt back in line by means of a smooth, steel bar.
In extreme cases it may even be necessary to shut
the conveyor down, make any adjustment indicat-
ed, and then restring and reposition the belt before
start-up. In any case, it is extremely important to
avoid belt damage. Once a belt is damaged, it will
not necessarily recenter itself.
If the conveyor structure has been checked,
appears to be true, and all rolls appear to be per-
pendicular to the system center line and severe
belt tracking problems still persist, it is advisable to
shut the system down and establish a belt center
line as
a frame of reference. (Use the technique outlined
previously in this discussion.) Now that a belt
center line has been established. Use this line as
the reference for the adjustment of each individual
pulley, snubber, roll, etc. Once all rolls are perpen-
dicular to the belt center line, the belt will track
well enough so that the specific training sequence
can commence.
(If it was necessary to establish the belt center line,
double-check the system structure. Normally, the
system center line and belt center line are equiva-
lent. A variance suggests that something has been
overlooked in examination of the structure, pulleys,
idlers, etc.)
11
Index Page

At this point, let us assume that we have a system
which is at least operating and with a belt running
well enough so that it is not a danger of being
damaged. For purposes of our study, let us use
the hypothetical conveyor design which follows.
Keep in mind that we will follow the general train-
ing sequence previously outlined, namely:
1. Return run-working from head toward tail, low
tension side.
2. Top run-working from tail toward head, high
tension side.
3. First empty, then full; with belt running.
Return Run
Considering the hypothetical conveyor system we
have outlined (See Figure #1, page 13), our first
consideration will be the first item in the return
run–namely, the head pulley snubber (roll #1). From
our previous discussion, it is obvious that cocking
the head pulley snubber will have very little effect
on the tracking since there is essentially no unsup-
ported belt span available to allow the belt to react.
However, cocking snubber #1 will tend to throw a
camber into the belt which will tend to throw the
belt off-center and become apparent at roll #2.
The return idler #2 does have a sufficiently long
unsupported span for belt reaction and therefore,
cocking idler #2 in a horizontal plane, can have a
beneficial tracking effect. (If after we have adjusted
idler #2 to the point where the belt is centered on
idler #2, examination shows a camber between
rolls 1 and 2, this is an indication that roll #1 is not
perpendicular to the belt center line and is impart-
ing the camber to the belt in this section.)
If it is necessary to adjust roll #2 to an off-perpen-
dicular position in order to center the belt on roll #2,
this off-perpendicular position of roll #2 can cause
a subsequent cambering effect. In this particular
conveyor design, this cambering effect will be
almost totally eliminated by the proximity of roll #3.
If the distance between roll #2 and roll #3 were
8 feet (let us say) this cambering effect could be
pronounced. Under these circumstances it may
be necessary to compromise and not cock the
roll quite as much as we would like. (“Tracking”
can be considered a physical embodiment of the
art of compromise.)
For purpose of completeness, it should be noted
that if one end of roll #2 is lower than the other, the
belt will favor that side due to the pull of gravity.
This effect may, or may not, be masked by the
tracking effect of roll #2.
Idler #3 has little or no tracking effect due to the
lack of unsupported span between itself and roll
#2. It can, however, be used to control the position
of the belt since it does have a cambering effect.
It is important to note at this point that virtually any
adjustment you make to these rolls will be slight.
Idler #4 is highly effective as a tracking roll
because it does have a good unsupported belt
span approaching it. It will induce very little, if any,
camber to the belt because of its proximity to roll #5.
Roll #5 on this particular conveyor is our drive
pulley and will be a high tension region for the belt.
This, coupled with the fact that there is little or no
unsupported belt span between itself and roll #4,
suggests that this is a poor tracking pulley and
should not be crowned. This pulley should be
squared to the belt center line and left there.
The same is true for roll #6–the snubber pulley.
Roll #7 will not be very effective for tracking pur-
poses because of the short unsupported belt span,
but can be a problem camber-wise if it is not per-
pendicular to the belt center line. This pulley
should be square and left there.
The take-up pulley (#8) does have potential for
tracking, as well as for camber, due to the unsup-
ported belt span between itself and rolls #7 and 9.
If, however, we adjust roll #8 so it is off-perpendicu-
lar in order to achieve a tracking effect on the belt
as it approaches roll #8 from roll #7, that same
adjustment will tend to impart camber to the belt as
it leaves roll #8 and approaches roll #9. Accordingly,
compromise is called for and roll #8 should be per-
pendicular to the belt center line. Unfortunately, this
12
IV. Training Belt on Package or
Unit Conveyors
Index Page

13
BELTTRAVELCARRYINGRUN
RETURNRUN
11
10
12131415
16
1234
8
9
7
8’8’6’4’
TRACKING
HYPOTHETICALCONVEYOR
FIGURE#1
6
5
Index Page

may not always be possible since roll #8 is a take-
up roll and in this case, is spring-loaded. Roll #8
will move from time to time as tensions increase
and decrease in the system due to the normal
operating cycle. Good engineering practice dictates
that roll #8 be constrained in some sort of carriage
construction designed to keep it perpendicular to
the belt center line at all times. However, there can
be tolerance differences, corrosion effects, lack of
lubrications, etc., as well as other problems which
may, at least momentarily, throw the take-up roll
off-square. To avoid the “mistracking effect” this
would have, it would be a good idea to impart a
self-aligning feature to the take-up roll by crowning
it. Further, it is in a low tension portion of the belt
circuit and does have a reasonably effective
unsupported belt span preceding it.
Roll #9 can exert a reasonable amount of tracking
force on the belt because of the unsupported belt
span preceding it, but it can also exert a consider-
able cambering effect since the unsupported belt
span between roll 9 and 10 is so large. Here again,
compromise is called for–the ideal situation being
to simply square pulley #9.
Roll #10 in this design is a snubber and is very
important from a tracking point of view. First of all,
it has a long unsupported belt span preceding it
and therefore is capable of exerting a strong cen-
tering influence on the belt. Secondly, the position
of this snubber means that it will feed the belt
immediately onto the tail pulley and will, in
essence, be responsible for positioning of the belt
relative to loading. Roll #10 will obviously have little
or no cambering effect.
Because of the importance of presenting the belt
in a centered manner to the tail pulley, it might be
wise to impart a self-aligning feature to roll #10 by
crowning it. (Incidentally, this is also a low tension
portion of the belt circuit.) Note that the crown will
not be as effective as normal due to close proximi-
ty of roll #11.
Unless a snub pulley is needed to maintain belt
within framework, a snub pulley doesn’t serve us
well. The snub causes loss of tracking effectiveness
with the tail, more belt flex and costs more. Avoid
if at all possible.
The tail pulley (roll #11) should be perpendicular to
the belt center line. In this particular design adjust-
ing the tail pulley will have very little, if any,
tracking effect due to the fact that there is no
unsupported belt span between itself and roll #10.
The snubber roll (#10) in this particular case has
taken over the tracking function of the system. If,
on the other hand, there were no roll #10, then the
tail pulley would in truth have a tracking function
and could effectively be crowned.
The tail pulley (#11) does have a marked camber-
ing effect because of the long span between itself
and roll #13. It’s true that this span is supported by
a slider bed which tends to modify the cambering
effect. However, since the loading point or points
will occur somewhere on this section of the belt
and probably quite close to the tail pulley, it is
important that the tail pulley be squared relative to
the center line so as to avoid any camber whatso-
ever.
The slider bed (#12) can have a marked effect on
belt tracking. The slider bed must be level (side to
side) since if it is not level the belt will tend to run
toward the low side as it is being pulled by gravity.
Further, the slider bed needs to be clean and
smooth. If it is rough on one side or it has a layer
of gummy, sticky, reverted rubber on one side, it
will tend to pull the belt toward that side. In this
event, the slider bed should be thoroughly cleaned
and buffed. The underside of the belt must also be
cleaned ( do not use solvent based cleaners on
belt).
Carrying idlers #13, #14 and #15 do have tracking
and cambering effects based upon their distance
from each other, and their distance relative to the
slider bed and head pulley. The standard roller bed
will have the carrying idlers so close together that
individually the rolls will have very little tracking or
cambering effects. If, however, they are all cocked
in one direction, the effect can be marked. Accord-
ingly, we would urge that carrying idlers not be
used for tracking unless absolutely necessary and
simply be squared relative to the belt center line.
The discharge pulley (#16) is located in a high ten-
sion portion of the belt circuit. Further, there is usu-
ally little or no unsupported belt span preceding it,
which severely limits any tracking effect which
can be obtained from the head pulley. Accordingly,
it is good practice not to crown the head pulley nor
use it for tracking adjustments. If you find that you
must adjust the head pulley in order to center the
belt, you will, in all likelihood, find that you have
merely realigned an off-square head pulley.
14
Index Page

15
Empty/Full
As each adjustment is made on the individual
components of the conveyor system, it is neces-
sary to wait a few minutes, and for a minimum of 2
belt revolutions, in order to give the belt time to
react and to observe the true effect of the adjust-
ment you have made. If the belt has over-reacted,
do not proceed to another adjustment until you
first modify the original adjustment and again,
observe its effect.
It is possible that once you have made the entire
circuit of the conveyor that adjustments made in
the latter part of the sequence may have modified
or effected adjustments made earlier in the
sequence. It is good practice to double-check by
going through the entire sequence again, until the
belt is tracking as you wish.
Now that the belt is tracking, the conveyor system
should run fully loaded and the tracking sequence
repeated.
Ideally, loading should be done in the center of the
belt. Unfortunately, however, system parameters
may prevent this. In this event, you may find it nec-
essary to modify the original adjustments, so as to
compensate for the off-center loading. Here again,
compromise is called for. The belt must track
empty, as well as full, with as little variation as pos-
sible. (Note: Expect some variation–full vs. empty.)
Reversible
In reversible conveyor systems, all idlers should be
kept at right angles to the direction of belt travel
and any correction necessary made with self-align-
ing idlers, designed for reversing operations.
It might be profitable to consider our hypothetical
conveyor, if the belt were now reversed. (See
Figure #2, page 16.)
First of all, our sequence would be altered, since
we would now start with roll #10, proceed to 9, 8,
etc.
Roll #10 would now be functioning as the head
pulley snubber. Any adjustment off the perpendicular
of roll #10 would have little tracking effect, because
there is no unsupported belt span between #11 and
#10. Further, such a deviation from the perpendicu-
lar would have a substantial cambering effect. Under
the circumstances, therefore, it should be set per-
pendicular to the belt center line.
Our comments relative to roll #9 through #5 inclu-
sive would be substantially the same as before.
Reaction of roll #4, however, would reverse. Pre-
viously, it had a tracking effect and no cambering
effect. Now, the reverse is true–it has no tracking
effect, but considerable cambering effect. Rolls #3
and 2, likewise, have reversed their actions on the
belt. Accordingly, all 3 of these rolls should be left
perpendicular to the belt center line.
Roll #1 is now the tail pulley snubber rather than
the head pulley snubber. Here, again, it has
reversed its role and will now exert a significant
tracking effect and little cambering effect.
Roll #16 and roll #11 have now reversed positions
and accordingly, comments made previously about
roll #11 would apply to roll #16 and vice versa.
Comments made previously on items 12 through
15 would essentially hold under these particular
conditions.
It is of course, recommended that rolls #11, 13, 14,
15 and 16 simply set perpendicular to the belt cen-
ter line.
Finally, if this particular conveyor were to be used
as a reversible conveyor, serious considerations
should be given to replacing return rolls #2 and 3
with a single self-aligning roll. Further, there might
be some advantage to crowning both snub rolls (#1
and #10). In this particular case, snub roll #1 would
offer considerable tracking effect and would help
center the belt on the tail pulley #16. When the belt
is reversed, #1 would lose it’s tracking capability,
but #10 would pick it up. Further, if #1 were indeed
perpendicular to the belt line, it would not cause a
camber problem. The same can be said for roll #10.
Index Page

16
BELTTRAVEL
RETURN
TAKE-UP
DRIVE
PULLEY
11
10
12131415
16
1234
68
7
TRACKING
HYPOTHETICALCONVEYOR
FIGURE#2
95
Index Page

Short Center-Wide Belt
Conveyors
Short center-wide belt conveyors offer a special
tracking challenge, simply because there usually
is not enough belt length to stretch the necessary
distance for crown conformation. If belt centers are
10 times belt width, these problems do not normal-
ly show up; below 5:1 ratio you must be aware of
several factors: (1) Amount and type of crown,
(2) belt stress/strain curve, (3) tension on belt and
(4) location of crowns in the system.
Georgia Duck has products for lightweight material
handling systems for length to width ratios of 1:1
and even below, but these are special and all
details of conveyors must be discussed with a
Georgia Duck distributor or Georgia Duck repre-
sentative.
Tracking Priority
Finally, we would like to suggest that when track-
ing a conveyor belt, number one priority should be
given to adjusting return idlers followed by adjust-
ment of snubber rolls. If there is no snubber on the
tail pulley, then adjusting the tail pulley does
become effective and should be used. The head
pulley is normally a flat pulley and should be set on
a perpendicular to the belt center line. The head
pulley should be adjusted for tracking purposes
only as a last resort.
17
Index Page

Training a heavy duty belt is similar in a lot of ways
to training a light weight belt.
The major difference is that the troughed idlers on
the carry side exert a natural gravitational training
force. The edges of the belt that are turned up
tend to gravitate toward the center of the conveyor,
thereby exerting a powerful training action. Many
bulk haulage conveyor operators do not attempt to
add any other training devices to the carry side of
the conveyor, as the troughers do a fine job by
themselves.
As with training light weight belt, all major pulleys:
head, tail, drive, snubs, bends, and take-up should
be parallel, level and square. All idlers and pulleys
need to be clean and functioning properly. All load-
ing stations have to be centered so that product is
introduced to the center of the belt. Any belt train-
ing idlers that are on the system must be in proper
working order and be installed in the proper direc-
tion. The lagging on the drive pulley should be
inspected and replaced, if the lagging is damaged
or if the surface is smooth and hard, which can
result in slippage. It is good practice to replace
rubber lagging when a new belt is installed, par-
ticularly if the lagging is old, as the rubber tends
to harden with age and become less effective.
The new belt may have some internal stresses from
manufacturing; therefore, the best procedure for a
new belt is to run it for a while before making any
adjustments. This run-in period will relieve most
manufacturing stresses that can occur during
weaving, treating, calendering, assembly, curing,
and slitting. Some belts, after installation, may run
perfectly from the beginning. If the new belt will
stay out of the frame on the return side, then run
it empty for an hour or two, then begin introducing
a load to the belt. The belt should be constantly
inspected during this break-in period. Full belt con-
tact with all carry side idlers is important due to the
training forces that are present with the troughed
idler sets.
As stated in the beginning of this brochure,
crowned pulleys are not required for bulk haulage
belting. Crowned pulleys may offer a minor contri-
bution towards training when the crowned face is
used on a low-tension pulley like the take-up or
the tail pulley. The crown will have no effect if used
on the high tension head pulley or drive pulley.
High modulus belt fabrics like nylon, polyester, and
aramid do not respond to the centering forces of
crowned pulleys; and in some cases, can actually
have an adverse effect on the belt. Steel cord belts
must have fully machined straight faced pulleys to
operate around, because a crown will create
adverse stresses in the belt and in the splice.
The theory of training a heavy duty belt is to feed
the carry side square, use the troughers to keep
the belt centered through the discharge, then train
the empty belt on the return (slack side).
Self-training idlers should be on 100' centers on
the return side, unless the conveyor is out of
square, then 50' centers may be required in areas
where the frame is out of square. The locations of
the self-trainers are very important, as they can not
function properly if installed in the wrong place.
The first self-training idler on the return should be
placed about 30' behind the head. This allows the
training idler to align the belt coming out of the head
(into the trainer). . .then 30' past the trainer. Self-
training idlers do not work when placed too close to
a terminal pulley, snub, bend or take-up. These pul-
leys have more belt wrap than the training idler,
which off-sets any training forces that the idler has.
You need at least 30' of free run on each side of the
training idler to make it effective. On slow-moving
belts, 20' of free area on each side
will work. At 800' per minute, the self-training idler
should be placed 40' from a major pulley. The trainers
can then be spread out over the return. If the take-
up is 80' behind the head, place one self-trainer
between the head and take-up areas, after the take-
up area (20' to 40'); then place the trainers on 100'
centers back to within 20' to 40' of the tail. If the
self-training return idlers are still not effective, shim
the return trainers up to present the trainer with
more belt surface area. Equally effective is to use
the next size up return run self-trainer–a 5" dia. to a
6" dia. trainer. A good rule of thumb is never skew
an idler that has over 90° of wrap, to ensure that the
high modulus belt fabric will not be stretched out of
square. This method will train the slack side belt,
18
V. Training Bulk Haulage Belting
Index Page

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