Documente Academic
Documente Profesional
Documente Cultură
Discharge belt
GSSF 2000 x 47.7
Shougang Hierro II
Shougang Hierro S.A.A.
San Juan de Marcona, Peru
2-492-20980
11/2013 Rev 0
Revision level
Revision
status
0
Date
11.11.2013
28.11.2013
Changes
Original created (German)
Translation from the original
Made by
Ritterbecks
Ritterbecks
1
2
3
11/2013 Rev 0
Table of Contents
1
11/2013 Rev 0
User's guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 1
1.1
User groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 1
1.2
1.3
Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 2
1.4
General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3
1.5
1.6
Copyright - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4
1.7
Technical modifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 4
1.8
Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 1
2.1
2.2
2.3
2.4
2.5
Safety devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 4
Principles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 1
3.2
3.3
Personnel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 2
3.4
Noise hazard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 2
3.5
3.6
Fire protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 3
3.7
4.2
Main components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 2
2-492-20980 (Item 02)
IVZ - 1
TOC - 2
Operating principle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 4
4.4
Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 6
Transport instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1
5.2
5.2.1
Lifting gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3
5.2.2
Lifting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3
5.2.3
Lifting ropes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 6
5.2.4
5.2.5
Lifting chains - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 10
5.2.6
Hook - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 11
5.2.7
5.2.8
Shackles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 13
5.2.9
5.2.10
5.3
Storage requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 17
5.3.1
General requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 17
5.3.2
5.3.3
Special requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 20
5.4
Installation planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 23
5.5
5.6
5.7
5.8
5.8.1
5.8.2
5.8.3
5.8.4
5.8.5
5.8.6
5.8.7
5.8.8
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4.3
5.9
6
11/2013 Rev 0
General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1
6.2
Operator training - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 1
6.3
6.4
Test run - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 3
6.5
6.5.1
6.5.2
Misalignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 6
6.5.3
6.6
Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6
6.6.1
Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6
6.6.2
Emergency-stop system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6
6.6.3
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 1
7.1
7.1.1
Notes on cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 3
7.1.2
7.1.3
7.2
7.2.1
Maintenance intervals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 8
7.2.2
Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 10
7.2.3
Bearings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 10
7.2.4
7.2.5
Wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 12
7.3
Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 14
7.3.1
7.3.2
7.3.3
7.3.4
Conveyor belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 24
7.3.5
Carrying idlers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 26
7.3.6
Front scraper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 27
7.3.7
Plough-type scraper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 28
7.3.8
IVZ - 3
TOC - 4
7.3.10
7.3.11
7.3.12
7.4
7.5
7.5.1
Machine structures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 39
7.5.2
Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 1
8.1
8.2
Storage of lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3
8.3
8.3.1
Oil groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3
8.3.2
Lubricant lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 4
8.3.3
8.4
8.4.1
Standard lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 6
8.4.2
Special lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 9
8.5
Lubricating instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 12
ANNEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 - 1
9.1
Drawings
9.2
Drive unit
9.3
9.4
9.5
Scrapers B6C
9.6
9.7
9.8
Safety devices
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7.3.9
User's guide
The technical documentation (Assembly and Operating Instructions) is designed to
familiarise the user with the machine / plant and its designated use.
The Assembly and Operating Instructions must always be available at the service location
of the machine / plant.
1.1
User groups
Necessary or expected user skills (competence):
Use personnel qualified for the machine / system with special knowledge of the machine/
plant and the processes.
Qualified personnel are persons who, on account of their training, experience and
instruction as well their knowledge of the relevant standards, provisions, accident
prevention regulations and service conditions, are authorised to carry out the necessary
tasks and can recognise and avoid any potential hazards.
The operating personnel receive special instruction from the owner/operator of the
machine / plant. Operators must be conscious of the fact that they are in a hazardous area
during some manual tasks.
Two people always work temporarily on the machine / plant in accordance with the rules
of proper use. All operating, monitoring and servicing work is always carried out by at least
two people working together.
Those working on the machine / plant must be made familiar with the safety instructions
and layout of the emergency-stop systems as well as the related emergency-stop circuits.
11/2013 Rev 0
To exclude danger to other people, access to the machine / plant is prohibited for
unauthorised people. These people are not familiar with the process workflow and cannot
recognise potential hazards.
1-1
1.2
SIGNAL WORD
Type and source of danger
Possible consequence(s) of non-observance.
Measure(s) for prevention of the danger.
The following table shows the classification and significance of the signal words for safety
notes.
Pictogram
Signal word
Significance
Consequences of nonobservance
DANGER
Imminent danger
WARNING
Possible danger
CAUTION
Possible danger
CAUTION
INFORMATION
!
!
General danger
!
Special danger, e.g.
electrocution
1-2
Definitions
right
left
or
2-492-20980 (Item 02)
11/2013 Rev 0
1.3
1.4
General information
Dear Customer,
1.5
Incorrect operation
Faulty maintenance
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In addition, the conditions for liability and warranty as specified in the General Conditions
of Supply of ThyssenKrupp Resource Technologies are applicable.
1-3
1.6
Copyright
We reserve all rights in connection with this documentation, including those relating to
patent registration or provisional patent registration. This documentation may not be
disclosed to third parties or reproduced or used in any other way without our previous
consent in writing.
1.7
Technical modifications
ThyssenKrupp Resource Technologies reserves the right to change designs in the course
of technical developments. Recent modifications may not yet have been included in the
drawings and texts of these Assembly and Operating Instructions.
1.8
CAUTION
The use of non-original spare parts
Damage to the machine/plant or its environment is possible
Only use original spare parts that are approved by ThyssenKrupp
ResourceTechnologies.
Damage caused by using products other than the original spare parts and
accessories is excluded from the liability and warranty.
We expressly point out that we cannot assume any liability for spare parts and
accessories which have not been supplied by us. In some cases the installation of
such products may alter and negatively affect the structural characteristics of the
machine / plant and therefore impair safety.
Continuous operation and operational readiness of the machine / plant can only be
ensured if important spare and wear parts are held in stock.
Please order spare parts using the information contained in the spare parts list. The spare
parts drawings listed in the spare parts list furnish additional information.
Please note that parts manufactured by us and non-company products are often subject
to special production and delivery specifications.
1-4
11/2013 Rev 0
Technical data
Basic data
Feed material:
Iron ore
0 - 250 mm
max. 2%
Bulk density:
2,3 t/m3
Performance data
Conveying capacity:
2.1
3660 t/h
Belt width:
2000 mm
Centre distance:
47,7 m
Belt speed:
approx. 5
11/2013 Rev 0
Figure 1
2-1
2.2
2.3
Type of gear:
Transmission:
1:96
Oil quantity:
Flange coupling:
FC 775/275-S-M
Flexible coupling:
ADR 125
Electric motor:
approx. 9,500 kg
Model:
Working temperature:
- 40 + 80C
Accuracy:
+/- 0,03%
Weight recorded:
Evaluation electronics:
2.4
Model:
RS 485 for remote control or PLC via Profibus
11/2013 Rev 0
Interface:
2-2
11/2013 Rev 0
Figure 1
2-3
Safety devices
PT100 41/5-3B
NTS 002
SLS 011
BLS 011
DI0001
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2.5
2-4
11/2013 Rev 0
Figure 2
2-5
11/2013 Rev 0
Blank page
2-6
11/2013 Rev 0
3.1
Principles
The machine/plant has been manufactured in accordance with the recognised safety
regulations. However, this does not preclude danger to life and limb for the user or
others, nor does it prevent harm to the machine/plant and/or other property.
These safety instructions must be observed by all persons responsible for the
transport, installation, commissioning, operation, maintenance as well as the
dismantling and disposal of consumables and process materials. We recommend
that the owner obtains a signed confirmation that the safety instructions have been
read and understood by his personnel.
The machine/ plant may only be used in technically perfect condition in accordance
with its designated use and the instructions set out in the manual, and only by safetyconscious persons who are fully aware of the risks involved in operating the machine/
plant! Any malfunctions, especially those affecting the safety of the machine/plant,
should therefore be rectified immediately.
In addition to the manual, observe and instruct the user in all other generally
applicable legal and other mandatory regulations relevant to accident prevention and
environmental protection!
These compulsory regulations may also deal with the handling of hazardous
substances, issuing and/or wearing personal protective equipment (safety helmet,
safety boots, safety goggles, hearing protection, respiratory protection).
Observe all safety instructions and warnings attached to the machine/ plant!
Ensure that safety instructions and warnings attached to the machine/plant are
always complete and perfectly legible!
Never make any modifications, additions or conversions to the machine/ plant which
might affect safety without the supplier's approval! This also applies to the mounting
and adjustment of safety devices and safety valves as well as to welding work on
load-bearing elements.
Comply with the prescribed intervals or those specified in the operating instructions
for routine checks and inspections!
For the execution of maintenance work, tools and workshop equipment adapted to
the task on hand are absolutely indispensable.
The personnel must be familiar with the location and operation of fire extinguishers!
3-1
3.2
3.3
3.4
For safety reasons, conversions and modifications are prohibited unless previously
approved by ThyssenKrupp Resource Technologies.
Personnel
Personnel entrusted with work on the machine/ plant must have read the manual and
in particular the chapter on safety before beginning work. Reading the Instructions
after work has begun is too late. This applies especially to persons working only
occasionally on the machine/plant, e.g. during setting up or maintenance.
For reasons of security, long hair must be tied back or otherwise secured, garments
must be close-fitting and no jewellery - such as rings - may be worn. Injury may result
from being caught up in the machinery or from rings catching on moving parts.
Any work on and with the machine/plant may only be carried out by reliable
personnel. Statutory minimum age limits must be observed!
Employ only trained or instructed staff and set out clearly the individual
responsibilities of the personnel for operation, set-up, maintenance and repair!
Define the machine operator's responsibilities - also with regard to observing traffic
regulations - giving the operator the authority to refuse to carry out instructions by
third parties which compromise safety!
Work on the electrical system and equipment of the machine/plant may only be
carried out by a skilled electrician or by instructed persons under the supervision and
guidance of a skilled electrician and in accordance with electrical engineering rules
and regulations.
Work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment!
Noise hazard
3-2
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INFORMATION
3.5
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3.6
Fire protection
The legal requirements regarding fire protection and fire prevention have to be
complied with and supplemented with in-company regulations. The fire-fighting
experts of the insurance companies should also be consulted in this process.
Appoint supervisors who are in charge of all the matters related to fire prevention and
fire fighting and provide them with the knowledge required for this task.
The management staff and the engineers have to support them in their task by
providing consultation to them.
The supervisor must check the fire extinguishing equipment at regular intervals, in
order to ensure that the equipment is always ready for use.
Rooms which are easily flammable require particular attention in this context!
3-3
The persons commissioned with supervision and fire fighting must have attended a
first aid course. First aid stations must be provided.
The fire protection regulations must be posted at different locations in the plant.
The personnel must be informed about the fire protection measures. Any case of fire
must be reported immediately.
The units and the assembly groups which heat up more strongly during operation on
account of the electrical and/or mechanical stress to which they are exposed must
be monitored by the responsible personnel. This applies e.g. to compressors, gear
units, bearings, motors, oil/hydraulic units.
The fire extinguishers must be easily accessible and may not be obstructed by
objects.
The personnel must be familiarised with the use of the fire extinguishers to such a
degree that they are capable of fighting fire outbreaks with the appropriate fire
extinguishers.
Fire-fighting rules
3.7
Use fire-fighting water for burning wood, waste, fabric, jute, paper, belts, etc.
In case of burning liquids (mineral oil, petrol, oil, petroleum, paints, tar, etc.), always
use CO2 extinguishers and powder type fire extinguishers.
In case of burning cables, motors, electric plants, etc. only use powder type fire
extinguishers or CO2fire extinguishers.
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3-4
4.1
DANGER
Risk of injury through operating the machine/plant with unauthorised
modifications, conversions or spare parts
Imminent danger of death or severe bodily injuries
ThyssenKrupp Resource Technologies explicitly excludes all liability and
warranty claims if modifications/conversions are made without the express
permission in writing of the manufacturer.
Only operate the machine/plant in its original condition. Any deviations from the
original condition must be reported by the operator to the responsible
department.
CAUTION
System damage through use of the machine/plant contrary to its designated
use
Damage to the machine/plant or its environment is possible
The intended use of the machine/plant is regulated by contract. Any other use
contrary to its designated use is prohibited. ThyssenKrupp Resource Technologies
cannot be held liable for damage resulting from such misuse. The risk of such
misuse lies entirely with the user.
The machine/plant must be used exclusively for the intended purpose agreed
upon with the manufacturer.
Observe the Assembly and Operating Instructions.
11/2013 Rev 0
Prior to the use of the machine/ plant beyond this scope of application, consult the aftersales service. Otherwise the warranty will lapse.
4-1
4.2
Main components
See Figure 3
1
(2)
Drive unit
(3)
Drive station
(4)
Driving pulley
(5)
Tensioning unit
(6)
Tensioning pulley
(7)
Conveyor belt
(8)
Carrying idlers
(9)
Impact rollers
(10)
Transfer rollers
(11)
Hold-down rollers
(12)
Return rollers
(13)
Feeding shoe
(14)
Material guiding
(15)
(16)
Plow-type scraper
(17)
Pre-scraper
(18)
Belt weigher
(19)
Needle slide
(20)
Chute
(21)
10
11
12
13
14
15
16
17
18
19
20
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21
4-2
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Figure 3
4-3
4.3
Operating principle
The ore broken by the crusher passes through the needle slide (21) on the transfer chute
(20) to the discharge conveyor. The feeding shoe (14) is used to guide and steady the
material.
The conveyor belt (8) of the belt conveyor runs on carrying idlers (9-13) which are
fastened to the conveyor frame with mounting brackets. The conveyor belt is guided by
the driving pulley (5) and the tensioning pulley (7).
The conveyor belt is endless. The drive power is transmitted from the driving pulley to the
conveyor belt by friction contact.
In order to induce the friction contact tension the conveyor belt on the tensioning unit (6)
using tensioning spindles and hydraulic cylinders.
The function of the belt conveyor is controlled with speed monitors and belt tracking
switches.
In addition, a device is installed, which detects if the belt is broken.
If there is an emergency the discharge conveyor can be stopped by the operating
personnel with pull rope emergency switches which are installed on the sides of the belt
conveyor.
The driving pulley (5) in the drive station (4) is driven by a drive unit (motor and gear unit).
The discharge conveyor is equipped with a belt weigher (20).
The front scrapers (18) remove cakings on the outside of the conveyor belt in the area of
the driving pulley.
A plough-type scraper (17) is located upstream of the tensioning pulley and removes
cakings on the inside of the conveyor belt.
11/2013 Rev 0
The material guiding strips (15) attached above the conveyor belt prevents material from
falling off the sides of the conveyor belt.
4-4
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Figure 3
4-5
4.4
Drive
See Figure 4
The belt conveyor is driven on the driving pulley by an electric motor (6) with a bevel spur
gearbox (1).
The bevel spur gearbox (1) is connected via a flange coupling (3) with the driving pulley.
A flexible coupling (5) is located between the electric motor (6) and the bevel spur gearbox
(1).
The bevel spur gearbox (1) is equipped with a back stop (4). The built-in backstop (4)
prevents the running back of the conveyor belt during standstill.
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The drive is fastened on a base frame and connected to the conveyor frame with a torque
support (2).
4-6
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Figure 4
4-7
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Blank page
4-8
5.1
Transport instructions
The machine/plant is transported in component parts or as assembly groups. Make sure
that suitable lifting tackle is used to unload the parts from the transport vehicles and move
them to the storage location.
The machine/plant must be transported with adequate care in order to prevent damage
and not endanger staff. In addition to the following information, the general and local
safety and accident prevention regulations must be observed. Overhead gantries and
mobile cranes or lifting tackle with a sufficient load bearing capacity must be available to
carry out the unloading, transport/loading safely and correctly.
11/2013 Rev 0
The transport and storage symbols on the machine packaging must be heeded.
Keep dry
Caution! Glass!
This way up
Sling here
Centre of gravity
Stacking limitation
Clamp here
Permitted
temperature range
Electrostatic sensitive
device
Do not roll
When transporting the machine by crane, only use suitable loading devices.
When packing the machine, loading devices may only be attached at the marked points.
5-1
DANGER
Risk of injury due to the improper transport of the machine/plant
Imminent danger of death or severe bodily injuries
Only transport the machine/plant on the designated slinging devices (lugs) and
slinging points.
The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
Make sure to use proper transportation equipment.
Do not walk under suspended loads.
Secure moveable components.
CAUTION
System damage from improper transport of the machine/plant
Damage to the machine/plant or its environment is possible
Do not attach any additional slinging points to the machine through welding,
torching or drilling (notching effects and the corresponding risk of crack
formation).
Do not push together the side walls or the attachment parts of the machine by
pulling lifting gear at an angle!
If transport securing devices have been furnished do not remove them until
installation has been completed.
11/2013 Rev 0
Check all components for transport damage after delivery to the site.
5-2
5.2
WARNING
Risk of injury through components that are improperly secured during
installation
Death or severe bodily injuries are possible
Make sure that moveable components are properly secured during installation
5.2.1
Lifting gear
Usually, cranes and lifting gear is used for transporting heavy assembly groups and
components. Slinging equipment such as ropes and hooks are critical elements between
the load and lifting equipment.
Safe lifting requires adequately dimensioned and suitably designed lifting gear and
slinging equipment to be used, as well as correct attachment and fixing to the load.
The weight of assembly groups and components is specified in the spare parts catalogue
/ in the Operating Instructions, so that equipment such as e. g. hoisting devices, winches,
cranes, lifting chains can be selected accordingly.
Check hydraulic winches for proper function before use. Only use winches with
adjustment ring. This allows loads to be supported mechanically and prevents their
lowering.
5.2.2
Lifting
INFORMATION
Before lifting heavy loads, attach a load cell to check the load.
Determine the size and shape of the load; two criteria which determine the following:
the type of load securing, e. g. with slings, baskets or slings with special fixtures,
11/2013 Rev 0
the slinging equipment / load securing fixtures, e. g. lifting rope, lifting chain, screw
eyes, yokes (see following chapters),
the load angle of the slinging equipment.
Determine the thickness of the slinging equipment to be used. Do not exceed the
permissible load bearing capacity of the slinging equipment.
5-3
If any of the following points are unclear, consult the assembly supervisor
responsible:
correct attachment method,
selected thickness of slinging equipment,
type of slinging equipment.
Check the slinging equipment for damage / faults. Make sure that any faulty slinging
equipment is discarded immediately.
Do not overload slinging equipment and protect it against sharp corners and edges
of the load e. g. through edge/corner protection made of sacking or metal, boards
etc.
After attaching the slinging equipment, tighten it as far as possible by hand. If the
slinging equipment has to be tightened by crane, make sure that no body parts get
between the load and the slinging equipment, and keep hands and fingers safe.
Give the crane driver fixed/agreed clear signals for moving the load.
5-4
Make sure that the slinging equipment cannot damage the load (and vice versa).
11/2013 Rev 0
After the weight of the load has been picked up completely by the lifting tackle and
the load has been lifted a little:
Remove slinging equipment from the load and check both for damage.
11/2013 Rev 0
5-5
5.2.3
Lifting ropes
The number of sling points is equal to the number of rope strands connecting the crane
hook with the load. A load angle i. e. an angle between the horizontal surface of the load
and the lifting ropes is formed by several strands. The smaller the load angle, the smaller
the permissible load bearing capacity of the lifting ropes and thus the effectiveness.
Effectiveness of the load angle
Load angle
Load bearing
capacity
%
30
50,0
(500 kg)
45
70,7
(707 kg)
60
86,6
(866 kg)
90
100,0
(1000 kg)
5-6
11/2013 Rev 0
General wear
Use:
Although the weight of lifting ropes is lower than that of lifting chains of the same load
bearing capacity, they have a few disadvantages. They can become damaged more easily
and are more difficult to handle since their bending radius is smaller.
Lifting ropes are suitable for vertical lifting operation or for lifting operation where ropes
must be routed in a large radius around corners.
The thickness of a wire rope is given in relation to its outer diameter.
Protect lifting ropes from the influences of the weather, solvents, high temperatures
and chemicals.
Avoid knots forming in wire ropes. In the event of a knot, do not use the rope again.
Protect ropes against sharp-edged corners by enlarging the corner radius. This can
be by means of metallic corner protection devices or blocks. Sacking and wooden
boards can also be used.
The correct procedure for securing lifting ropes to the hook is as follows:
Secure each individual strand on the hook to prevent hitching at the hook.
Never use one single slinging rope strand since this could lead to the load rotating.
The wire rope could be untwisted and thus the splice pulled out.
Never wind the wire rope completely around the crane hook (i. e. by 360 degrees).
The low bending radius would damage the rope.
11/2013 Rev 0
damaged eyes
5-7
5.2.4
When securing loads by winding the lifting ropes around the load, use shackles (1).
Once the rope has been put into operation and is tensioned, tighten the clamping nuts
again. Check the clamping nuts regularly and tighten if necessary. This compensates rope
expansion and the related reduction of rope radius.
Diameter of the clamping
yoke
Required minimum
number of clips
Inches
mm
Inches
mm
Inches
mm
3/16
4,76
11/32
8,73
76
1/4
6,35
7/16
11,11
3-1/4
83
5/16
7,94
1/2
12,70
3-1/4
83
3/8
9,53
9/16
14,29
102
7/16
11,11
5/8
15,88
4-1/2
114
1/2
12,70
11/16
17,46
127
5-8
11/2013 Rev 0
Rope diameter
Rope diameter
Required minimum
number of clips
mm
Inches
mm
Inches
mm
5/8
15,88
3/4
19,05
5-3/4
146
3/4
19,05
7/8
22,23
6-3/4
172
7/8
22,23
25,40
203
25,40
1-1/8
28,58
8-3/4
222
1-1/8
28,58
1-1/4
31,75
9-3/4
248
1-1/4
31,75
1-5/16
36,51
10-3/4
273
1-3/8
34,93
1-1/2
38,10
11-1/2
292
1-1/2
38,10
1-23/32
43,66
12-1/2
318
1-5/8
41,28
1-3/4
44,45
13-1/4
337
1-3/4
44,45
1-15/16
49,21
14-1/2
368
50,80
2-1/8
53,98
16-1/2
419
2-1/4
57,15
2-5/8
66,68
16-1/2
419
2-1/2
63,50
2-7/8
69,85
17-3/4
451
11/2013 Rev 0
Inches
5-9
5.2.5
Lifting chains
Use:
Lifting chains are made of alloyed steel and are sturdier and more flexible than lifting
ropes, but they are not as resistant to impact loads as ropes are. The thickness of a chain
is determined in relation to the diameter (1) of a chain link.
Avoid knots forming in lifting chains. They weaken the chain strand and can lead to
deformation or other damage to the chain links.
Shorten lifting chains by hooking them back into the chain or into the main line with
the aid of a gripper hook. Never shorten a chain by twisting, knotting or through bolts.
Protect lifting chains against sharp corners and edges that could deform the chain
links. Use suitable flexible boards or metallic corner protection devices.
11/2013 Rev 0
5 - 10
If the chain for lifting operation is to be wound around the load to be lifted, always turn
the hook opening away from the direction in which the slings are to be pulled. This
prevents the hook slipping out when the slings are tightened.
5.2.6
If all the strands of a lifting chain can be hooked back into the main line, the
permissible load bearing capacity of the whole sling can be increased by 50 %.
Hook
The load bearing capacity is usually stamped into the hook.
11/2013 Rev 0
5.2.7
If possible, use a hook with spring-loaded snap-in locking devices. If such hooks are
not available, the hook has to be secured temporarily as shown in the diagram.
For vertical lifting operation, use simple screw-type eyes (without shoulder).
Screw-type eyes with shoulder are used when loads are to be lifted at certain angles
(e. g. lifting operation with several lifting ropes).
5 - 11
The permissible load bearing capacity that has already been reduced by the load angle,
is reduced even further by the use of screw-type eyes.
A screw-type eye with shoulder that is used e. g. at an angle of 45, can only used for up
to a load of about 10 % of the permissible load for vertical lifting operation.
Permissible loads for screw-type lifting eyes with shoulder:
Shank diameter
Vertical lifting
operation
Tension at 60 to
the shoulder level
Tension at 45 to
the shoulder level
Tension at 90 or
loose side pull
mm
Pounds
kg
Pounds
kg
Pounds
kg
Pounds
kg
1/4
6,4
300
136
50
23
30
14
40
18
1/2
12,7
1300
590
200
91
140
64
150
68
3/4
19,3
3000
1361
400
181
250
113
300
136
25,4
6000
2722
800
363
500
227
600
272
1-1/4
31,8
9000
4082
1300
590
800
363
900
408
1-1/2
38,1
13000
5897
1800
816
1200
544
1300
590
50,8
23000
10433
3300
1497
2100
953
2300
1043
2-1/2
63,5
37000
16783
6000
2722
3500
1724
4300
1950
11/2013 Rev 0
Inches
5 - 12
5.2.8
Check the condition of the thread to make sure the screw-type eye fits tightly and that
there is flush and complete contact between the shoulder and the load. Never use
screw-type eyes with cracked or flawed threads.
Only use screw-type eyes the load bearing capacity of which is suitable for the load,
i. e. shanks with threads that fit exactly in standard boring holes.
Use hardened washers to make sure the edges of the screw-type eye are a tight fit.
The washers must not be thicker than two threads.
Shackles
DANGER
Danger caused through the use of improper slinging equipment
Imminent danger of death or severe bodily injuries
11/2013 Rev 0
5 - 13
Diameter
Do not expose the main part of the shackle to side tensile loads.
The permissible load for anchor load and chain load shackles as well as for screwtype or socket pin is always the same.
If shackles are used at load angles other than 90, the permissible load bearing
capacity is reduced; see table:
Single shackle
vertical
Two shackles 60
Two shackles 45
Two shackles 30
Inches
mm
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
1/4
6,4
1/3
0,3
3/4
0,7
1/2
0,5
1/3
0,3
5/16
7,9
1/2
0,5
0,9
0,7
1/2
0,5
3/8
9,5
3/4
0,7
1-1/4
1,1
0,9
3/4
0,7
7/16
11,1
0,9
1-3/4
1,6
1-1/2
1,4
0,9
1/2
12,7
1-1/2
1,4
2-1/2
2,3
1,8
1-1/2
1,4
5/8
15,9
1,8
3-3/4
3,4
2,7
1,8
3/4
19,3
2,7
5-1/2
4-1/2
4,1
2,7
7/8
22,2
5-1/2
25,4
5-1/2
10
7,2
5,4
1-1/8
28,6
6-1/2
5,9
11-1/2
10,5
9-1/2
8,5
6-1/2
5,9
1-1/4
31,8
7,2
14
12,7
12
10,8
7,2
5 - 14
11/2013 Rev 0
Shackles are closed safety devices that cannot be hooked out. Their size is determined in
relation to the diameter of the main part (1) and not in relation to the diameter of the bolt.
A distinction is made between anchor load shackles (on the left of the diagram) and chain
load shackles (on the right).
Diameter
Single shackle
vertical
Two shackles 60
Two shackles 45
Two shackles 30
Inches
mm
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
1-3/8
24,9
10
17
15,4
14
12,7
10
1-1/2
38,1
12
10,8
20
18,1
17
15,4
12
10,8
1-3/4
44,5
16
14,5
28
25,4
23
20,9
16
14,5
50,8
21
19
36
32,6
30
27,1
21
19
2-1/4
57,2
27
24,5
46
41.7
38
34,5
27
24,5
2-1/2
63,5
34
31
58
52,6
48
44
34
31
2-3/4
70,1
40
36,2
69
62,9
57
51,9
40
36,2
76,2
80
45,3
87
78,8
71
64.4
50
45,3
101,6
100
90,7
173
156,9
142
128,7
100
90,7
5.2.9
11/2013 Rev 0
5 - 15
5 - 16
Make sure that the base has a sturdy and level surface and can bear the whole
weight of the load. Only use hard wood with (approx.) square cross-section as a
base.
Use wedges to prevent the load rolling away or moving (e. g. handles, round forged
parts and rings). When using wedges be careful with your hands and make sure they
do not get crushed if the load moves.
When using several supports as substructures, only use supports of the same height.
Place supports under the load so that they are stable and level. Do not use supports
that have rounded edges, are fragile or damaged.
Use the supports to create a cavity under the load, enabling the slinging equipment
to be attached and removed easily.
11/2013 Rev 0
5.2.10
Protect lifting chains against sharp edges/corners. Use materials to enlarge the
radius, e. g. metallic corner protection devices (left and right), belts, wooden blocks,
sacking, steel bushings/sleeves. This protects finished load surfaces from the chain
too.
5.3
Storage requirements
5.3.1
General requirements
CAUTION
System damage from improper storage/assembly of the machine/plant
Damage to the machine/plant or its environment is possible
If the machine/plant is to be stored, it has to be left in the delivery condition. The
manufacturer is not liable for damage caused by improper repeated assembly of
the machine/plant.
CAUTION
System damage from improper storage of the machine/plant
Damage to the machine/plant or its environment is possible
All the delivered machine and plant components must be stored on suitable
supports to keep them dry. The storage place must be free from vibration.
The stored machine and plant components must be protected from water, sea
water, aggressive vapour or gas and increased ozone concentration.
If the storage time is exceeded by a lengthy period (i.e. more than 2 months), all the
bearings of the machine and plant components must be completely filled with suitable
grease. The shafts in the bearings must be turned several times once a month. They must
be subsequently topped up with grease. The bearings and housings are thereby protected
from condensation water and rust. After storage, i.e. before the plant component is
commissioned, the grease must be removed and the bearings cleaned and regreased
(approx. 1/3 of the volume of bearing and housing).
11/2013 Rev 0
All the machine and plant components must be stored at temperatures between + 5 C
and + 45 C. Electrical equipment is to be stored dry and frost-free, temperatures between
minimum + 5 C and maximum + 45 C.
All unpainted surfaces must be provided with suitable protection against corrosion.
The storage location must be dry. If equipment is stored in a shipping container, a
"desiccant material" must be placed in the container prior to storage. The equipment must
be covered and good ventilation provided in the storage place.
The packing climate must be protected from environmental influences, in order to maintain
rust prevention and the effectiveness of siccatives.
5 - 17
The storage area must be clean and free from dust and other contaminants.
Equipment must be stored in the original crates or on the original transport skids provided
by TKF. Equipment on transport skids must be loosely covered with tarpaulins, in order to
keep it clean and to allow the air to circulate.
Stored equipment may not be exposed to direct sunlight.
Plant components made of plastic or rubber may not be exposed to direct sunlight. The
storage temperature must be + 5 C minimum and + 45 C maximum. It must be protected
from contamination by grease or oil. Rubber parts, such as the belts of troughed belt
conveyors and the filter belts of vacuum belt filters, are normally delivered on coils. The
coils must be stored vertically and not horizontally. Furthermore, the coils may not be
stored directly on the floor. They must be stored vertically on a firm base surface. Pallets
or similar must be used for moisture protection. The coils may not be stacked.
The stored equipment must be secured against damage and loss. Secured storage areas
may only be accessed by authorised personnel.
Insurance with sufficient coverage for damage caused by third parties, transport and
weather damage (lightning, flooding, and storms) and theft must be concluded for the
entire handling/storage period until the machine/plant has been accepted.
5.3.2
5.3.2.1
"Open-air" storage
Please note that roofed storage (Chapter 5.3.2.2 ""Roofed" storage") is to be preferred,
however large-volume, painted plant components showing a small proportion of
mechanically machined surface compared to the volume as well as wear-out parts, where
surface corrosion does not affect the function, could be stored in the open air (provided
that there is no indication to the contrary on the packing, as e.g. protect from heat,
protect from moisture or similar.) See Chapter 5.1 "Transport instructions".
5 - 18
Mills (mechanically machined parts such as bearings, retaining flanges on the gear
rim must be provided with protection against corrosion and mechanical damage e.g.
by anti-corrosive grease, plastic foil and wooden banding)
Chutes
Crusher frame
Bed plates
11/2013 Rev 0
Examples: "Wear parts whose surface has no effect on the functional capability"
Slotted plates and rear panel plates for intermediate and discharge diaphragms
5.3.2.2
"Roofed" storage
Plant components which have to be protected from direct sunlight as well as those which
have to be protected from rain as a result of mechanically machined surfaces, rubber or
plastic seals, ventilation holes, or similar.
11/2013 Rev 0
Examples:
Rubber belts for troughed belt conveyors. Please note that the belts are delivered on
coils and must be stored in a vertical position.
Rubber and plastic seals (e.g. for gear rim protection cover, mill outlet casing,
material guide bar of troughed belt conveyors, etc.).
Idlers for troughed belt conveyors, drive stations and pulleys, mechanical parts of
belt weighers.
Plant components with ventilation holes e.g. gear units, gear motors and bearings
equipped with openings for air pressure compensation.
All compact hydraulic units and compressors which have to be protected against dirt
by plastic foil. The covering on the bottom must remain open, in order to prevent the
accumulation of condensation water.
Operating fluids such as lubricants, grease and oil as well as sealants such as
silicone, paints, thinners and cleansers.
Items must always be stored on a support such as timber planks, pallets, or similar,
preferably on a level, drained and gravelled base surface. Contact with surface water and
the ground must be avoided.
2-492-20980 (Item 02)
5 - 19
5.3.2.3
5.3.2.4
Anchor bolts
Filter bags for dust collectors and the corresponding solenoid valves
Measuring instruments
Sensors
PCs
Screens
5.3.3
Special requirements
5.3.3.1
Electric motors
Motors must be stored in the original crates if they are not mounted on the equipment.
The storage area must be free of vibration.
5 - 20
Balls and rollers (regreasable roller bearings). Bearings going into extended storage
must be completely greased beforehand. Motor shafts must be manually rotated
once a month and bearing grease must be topped up. Rotate the shaft by hand
before putting it into service.
Balls (roller bearings, regreasing not possible). No other provisions are necessary for
the bearings.
11/2013 Rev 0
Bearings:
All drain openings must be operable and the drain plugs removed during storage. The
motors must be stored so that the drain opening is at the lowest point. All breathers and
automatic drains must be operable via T-safety screws, so that breathing can take place
at a different location from the bearing seats.
Windings must be measured when they are put into storage. When they are removed from
storage, the resistance reading may not be more than 50 % below the original value. Any
values below this value necessitate electrical or mechanical drying. Where a large quantity
of motors is stored, an inspection or sampling should be made by removing the end
brackets and visually inspecting for the presence of water in the grease or rust on the
bearing. If present, replace the bearings and relubricate.
All external parts and motors subjected to corrosion to be protected by corrosive resistant
coating.
Where motors are not stored in the original containers, but are removed and mounted on
other pieces of machinery, the mounting must be such that the drains and breathers are
fully operable. In this respect, the drains must be located at the lowest point of the motor
and the drain plugs removed, so that condensation water can drain out by itself. All other
storage conditions apply, including rotation of the motor shafts. If such conditions cannot
be complied with, the equipment must be treated as if it were mounted in its normal
position and all protective devices such as heaters, breathers and drains were fully
operable.
5.3.3.2
Gear unit
Oil and grease lubrication:
The oil recommended by the manufacturer must be used for the oil change.
11/2013 Rev 0
All gear openings such as flanges for oil lubrication, openings for holding thermometers
and pressure and flow sensors must be checked for proper sealing. Replace the sealing
if necessary. Breathing or venting: Pressure compensation between the pressure inside
the gear unit and the atmosphere must be provided. The inside of the gear must be
protected against humidity and/or nesting insects or birds.
5 - 21
5.3.3.3
Gear motors
If gear motors, e.g. SEW, are placed in storage, a volatile corrosion inhibitor (VCI) is
added to the lubricant of these gear units.
Some of the gear units are delivered with a higher oil level for long-time storage.
The storage period is a maximum of 3 years in compliance with the documentation
supplied by the manufacturer.
CAUTION
Gear damage from improper storage of the machine/plant
Damage to the machine/plant or its environment is possible
Gear units must be kept sealed until commissioning, in order to prevent
volatilisation of the VCI corrosion inhibitor.
Before these gear motors are commissioned, the operating oil level must be
restored using dipstick/oil-inspection glass/oil-level plug.
5.3.3.4
Cover the motor control centre with heavy duty plastic or similar material to prevent
the ingress of foreign matter.
Motor control centres which are not installed and used immediately must be stored
in a clean dry area. The storage temperature should be constant and between + 5 C
and + 45 C. If the storage temperature fluctuates or if humidity exceeds 60 %,
space heaters must be used to prevent condensation. Control centres must be
stored in an air-conditioned building with adequate air circulation and be protected
from dirt and water.
Control centres which are designed for indoor applications do not have packaging
which is suitable for outdoor storage. They should therefore be provided with
additional packaging for protection from outside elements and a temporary electric
heater to prevent condensation. A space heater rated at 200 watts per section is
adequate for the average control centre. All loose packaging or flammable material
must be removed before switching on space heaters.
Control centres which are for outdoor use and are not being used must be kept dry
internally by installing temporary heaters or by means of self-contained space heaters.
Drive motors are enclosed. Ensure that all covers are tightly fitted.
Keep the temperature between + 5 C and + 45 C.
Drive housing and operator's station -- Keep the housing and the operator's station
dry by means of siccatives. Ensure that both are closed. If any openings are cut, they
must be sealed with duct sealant or duct tape.
Keep the temperature between + 5 C and + 45 C.
11/2013 Rev 0
DC drives:
Control valves:
The normal storage conditions are valid for all products. "Normal" is defined as conditions
free from heat or cold (+ 5 C to + 45 C storage temperature), and where the products
are kept dry and protected from dust. Other products may not be stacked on them.
5.3.3.5
5.4
Installation planning
11/2013 Rev 0
Please refer to the relevant foundation and installation drawings for the main
dimensions of the machine/plant and the associated secondary units.
Provide additional ladders, walkways, platforms and safety railings for maintenance
work and indicate the permissible traffic loads.
Provide suitable lifting gear for the installation and for the exchange of spare and
wear parts. It should be possible to position the lifting tackle/load hook vertically on
top of the machine/plant.
Comply with the specified loading values for the design of foundations and the
calculation of the girder/platform structures.
The movement of the machine/plant generates horizontal and vertical forces which
must be absorbed by suitable shear braces.
5 - 23
If the conditions at the place of installation vary from those in the installation drawing,
please consult ThyssenKrupp Resource Technologies.
INFORMATION
5.5
WARNING
The use of untrained personnel or equipment that does not comply with
safety standards poses additional danger
Death or severe bodily injuries are possible
The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
When carrying out overbelt assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms. Never use machine
parts as a climbing aid! Wear fall protection when carrying out maintenance work
at a higher level.
5 - 24
11/2013 Rev 0
WARNING
WARNING
Danger from working on electrical systems without proper technical
knowledge
Death or severe bodily injuries are possible
Work on the electrical systems or equipment may only be carried out by a skilled
electrician or by specially trained personnel under the supervision of an
electrician and in compliance with the applicable regulations required for
electricians.
INFORMATION
11/2013 Rev 0
5 - 25
5.6
5 - 26
1 x Plough-type scraper, 75 kg
Electrical switches, mounting brackets, pull cord, extension springs, egg shape
clamps, company sign, nameplate, warning signs
11/2013 Rev 0
INFORMATION
The list of these subassembly groups coincides with the sequence of assembly
steps.
5.7
WARNING
Risk of injury through improper assembly and transport
Death or severe bodily injuries are possible
Make sure that moveable components are secured, also during installation
Use proper transportation equipment
Do not walk under suspended loads
Fasten and lift components properly
Only transport the machine/plant on the designated slinging devices (lugs) and
slinging points.
WARNING
Risk of injury during assembly work at great heights
Death or severe bodily injuries are possible
When carrying out overbelt assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms.
Never use machine parts as a climbing aid!
11/2013 Rev 0
Wear fall protection when carrying out maintenance work at a higher level.
5 - 27
WARNING
Risk of injury when working on electrical systems
Death or severe bodily injuries are possible
Work on the electrical system or equipment may only be carried out by a skilled
electrician or by specially instructed personnel under the control and supervision of
a skilled electrician and in accordance with the applicable electrical engineering
rules.
CAUTION
System damage through improperly executed welding work
Damage to the machine/plant or its environment is possible
Never conduct welding current through slide or roller bearings or other moveable
connections or measuring equipment.
Carry out welding work on individual machine components prior to their
installation.
INFORMATION
Careful selection of the tools and appliances used and the installation personnel
is important for correct execution of the assembly work.
The respective layout plan and assembly drawings must be carefully studied. All
guidelines and notes must be observed.
5 - 28
11/2013 Rev 0
5.8
5.8.1
Install pontoons, supports, carrying idlers (1) and mount in the ground.
Align and bolt the individual parts of the conveyor frame (1) to the drive station (4)
and the tensioning station (2).
CAUTION
System damage from uncontrolled off-track running of the conveyor belt
Damage to the machine/plant or its environment is possible
11/2013 Rev 0
The carrying idlers and feed-zone idlers are to be aligned at right angles to the
belt centre in order to avoid misalignment of the conveyor belt.
Figure 5
5 - 29
5.8.2
5.8.2.1
Figure 6
5.8.2.2
The Idlers are connected to each others by a steel profile to prevent the idler stations from
tilting.
Impact rollers 219/133 x 900 / 25 (3 rollers)
5 - 30
11/2013 Rev 0
The impact rollers are arranged on the elastomer spring elements, which reduces the
shock force of material falling down.
Figure 7
5.8.2.3
Return rollers
See Figure 8
The return rollers consist of two rollers and the roller mounting bracket of the conveyor
belt. The idlers are provided with rubber tyres to avoid sticking of material on the idler shell.
Return rollers 89/159 x 1400 / 10 (2 rollers)
Figure 8
5.8.2.4
Pressure Idlers
See Figure 9
These hold-down rollers are located on the lower strand at the head and tail of the
conveying system and upstream of the inverted V return roller.
11/2013 Rev 0
Figure 9
5 - 31
5.8.3
5.8.4
Bolt on the guide strips (1) on the lateral supports (3) of the conveyor frame.
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Figure 10
5 - 32
5.8.5
Install plough-type scrapers (1) in the lower strand in front of the tensioning pulley (2)
and adjust the height.
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Figure 11
5 - 33
5.8.6
Install and adjust both of the front scrapers (2) on the driving pulley (1).
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Figure 12
5 - 34
5.8.7
Assemble coupling (5) gear unit (2) coupling (4) and motor (3) on both sides of the
driving pulley.
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Figure 13
5 - 35
5.8.8
Install one resistance thermometer PT100 41/5-3B in the bore holes (2) on both of
the bearing housings of the driving pulley.
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5 - 36
11/2013 Rev 0
Figure 14
5 - 37
5.9
CAUTION
System damage from improper installation of conveyor belt
Damage to the machine/plant or its environment is possible
Pay attention to the carrying side of the conveyor belt.
Vulcanising of the conveyor belt is to be executed by an expert company.
CAUTION
System damage from incorrect tensioning of the belt conveyor
Damage to the machine/plant or its environment is possible
The conveyor belt has to be tensioned so far that the driving pulley does not slip
when starting up.
Two hydraulic cylinders (3) are used to tension the conveyor belt. They are supported on
retaining plates (2) and press against both of the bearing housings (4) of the tensioning
pulley. The top and bottom retaining plates (2) are inserted and screwed into the grooves
by two rails (1).
A hand pump (8) and hoses are also delivered for building up pressure in the hydraulic
cylinders.
Several steps are required for tensioning because the stroke of the hydraulic cylinder (3)
is small. The hydraulic cylinders must be moved between the steps.
Before the actual tensioning process, the nuts (7) on the tensioning screws (5) are
unscrewed until the tensioning screws can be adjusted in the retaining plates (6).
The hydraulic cylinder (3) are extended with the hand pump (8) which then also move the
tensioning pulley.
Now the retaining plates (6) of the tensioning screws (5) are assembled after a one groove
shift and the nuts (7) of the tensioning screws (5) are tightened to hold the tensioning
pulley in this position.
5 - 38
11/2013 Rev 0
Then the retaining plates (2) and the hydraulic cylinders (3) are assembled on both sides
of the tensioning pulley and as close as possible to the bearing housings (4).
The hydraulic cylinders (3) are then removed from both sides of the tensioning pulley. The
pressure in the hydraulic cylinders (3) is lowered so that the pistons can be pushed back.
The hydraulic cylinder (3) are moved and re-assembled as close as possible to the
bearing housings (4).
Thereafter the nuts (7) on the tensioning spindle (5) are loosened again and unscrewed
until the tensioning spindle can be moved for the second tensioning process.
These steps, described so far, are carried out in sequence until the conveyor belt is
sufficiently tensioned.
Finally, the nuts (7) on the clamping screws (5) are tightened and locked to fix the
tensioning pulley in this position.
11/2013 Rev 0
Figure 15
5 - 39
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Blank page
5 - 40
6.1
General information
For many reasons we highly recommended you call for the assistance of
ThyssenKrupp Resource Technologies staff in the commissioning process. This is not
only for reasons relating to the warranty, but also for the purpose of:
For the initial commissioning routine note the instructions relating to the components
included in the ANNEX 9.
6.2
Operator training
These Assembly and Operating Instructions for the operation of the machine/system is not
a replacement for training and instruction!
Previous technical and safety knowledge is required for operation of the machine/plant!
The owner must prepare a directive for regulating the internal operation, maintenance and
repair of the machine/plant.
These Assembly and Operating Instructions provides the operator with the information
required for operating the equipment.
Always make sure to observe the intended use of the machine/system (see Chapter 4.1).
The operating staff must be familiar with the arrangement and function of the safety
devices.
6.3
11/2013 Rev 0
DANGER
Risk of injury from damaged insulation on the connecting cable and
missing terminal box covers
Imminent danger of death or severe bodily injuries
The electrical connections of the drive must be adequately protected.
6-1
WARNING
Risk of injury from larger oscillation amplitudes
Death or severe bodily injuries are possible
Do not reach into the spaces between fixed components and oscillating
components.
Repair incorrect oscillation before feeding material.
CAUTION
Risk of injury when operating the drive units without protective clothing.
Bodily injury possible
6-2
Operate the machine / plant only if all protective and safety-oriented devices, such
as removable safety devices and emergency shut-off equipment, sound-proofing
elements and exhausters, are in place and fully functional!
Check the machine/ plant at least once every shift for obvious damage and defects!
Report any changes (including changes in the operating performance) to the
responsible department immediately! If necessary, stop the machine/ plant
immediately and lock it!
In the event of malfunctions, stop the machine/ plant immediately and lock it!
Have any defects remedied immediately!
Follow the start-up and shutdown procedures and control displays as set out in the
manual!
Before starting up/actuating the machine/ plant, make sure that nobody is at risk!
Only work with the prescribed lighting under darkness and with poor visibility.
Switch off the machine/plant immediately if people's lives are at risk, e.g. due to
careless working near belt conveyor systems and material transfer points.
Work may only be carried out if the worker is properly qualified and/or has been
authorised to do so.
Do not carry out maintenance and repair work without authorization.
11/2013 Rev 0
The machine must never be operated without the guards in position over the
drive units.
6.4
Test run
Before the test run is started, the following checks are to be carried out:
Pretension of the conveyor belt,
Adjustment of the belt tracking limit switch,
Adjustment of the pull-rope emergency switch,
Adjustment of the belt tear switch,
Adjustment of the speed monitor,
Proper functioning of the scrapers,
Afterwards, all mechanical and electrical parts are separately checked according to their
operational sequence.
If these checks did not reveal any defects, a test run of the crusher discharge belt can be
started.
During the test run, check:
CAUTION
System damage from actuating the safety devices for normal operating
interruptions
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6-3
CAUTION
Plant damage caused by increased belt tension
Damage to the machine/plant or its environment is possible
The belt tension must not be increased under any circumstances.
The conveyor belt has to be tensioned so far that the driving pulley does not slip
when starting up.
The tensioned conveyor belt must run smoothly and straight during test run. If the
conveyor belt runs out laterally, it can be aligned by adjusting the carrying idlers.
The carrying idler causing the misalignment of the conveyor belt is usually the
second or third one behind the point where the belt is running out of line.
If the conveyor belt is running to the left-hand side looking in conveying direction, the
left-hand side of the idler mounting is to be moved towards conveying direction.
If the conveyor belt is running to the right-hand side looking in conveying direction,
the right-hand side of the idler mounting is to be moved towards conveying direction.
Experience has shown that a belt running very well during test run may run out of line
at first material feed.
Thus a few corrections may prove necessary.
During the test run, all plant components are to be run at no-load for at least 4 hours.
After the test run, the following activities are to be carried out:
Check the tension of the conveyor belt. For re-tensioning see Chapter 5.9.
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6-4
6.5
DANGER
Risk of injury through the removal of blockages during operation
Imminent danger of death or severe bodily injuries
This work may only be carried out when the discharge conveyor is at a standstill
and secured against restarting.
WARNING
Danger from insufficient barrier around the plant
Death or severe bodily injuries are possible
Close off a large area around the general danger zone of the conveyor belt.
CAUTION
Plant damage caused by starting up with conveyor belt loaded
Damage to the machine/plant or its environment is possible
In the normal case: The discharge conveyor must only be switched on when
empty.
After "emergency stop": Before starting make sure that the feed zones and
transfer points are absolutely free from material.
6.5.1
11/2013 Rev 0
INFORMATION
The discharge conveyor must be fed with material uniformly, to avoid overloading.
The maximum volume capacity can be achieved only at uniform feeding.
After all machines and the downstream conveying systems have been checked for proper
functioning, the discharge conveyor can be fed with material.
6-5
6.5.2
Misalignment
Possible causes for misalignment of the conveyor belt:
6.5.3
Abrasion of the conveyor belt on the bearing structure or trapped pieces of material.
In case of misalignment of the conveyor belt the information in Chapter 6.4 must be
observed.
Adjusting the rubber strips of the material guide and the feeding shoe.
6.6
Shutting down
6.6.1
Normal operation
The material feed must always be interrupted before the crushing plant is stopped. The
crushing plant can then run "empty."
6.6.2
Emergency-stop system
CAUTION
System damage from material overfilling when using emergency-stop
switch
6-6
11/2013 Rev 0
6.6.3
In order to restart the plant after having rectified the emergency case, the actuated
switch is to be unlocked by turning the impact surface to the right-hand side.
CAUTION
Plant damage caused by uncontrolled switch-off of plant parts
Damage to the machine/plant or its environment is possible
Only actuate the pull-rope emergency switch in an emergency. The belt and all of
the connected system components are shutoff in accordance with the control
concept when it is actuated.
Belt tracking switches must not be used for normal shutdown.
The belt cannot be switched back on until the local switch is unlocked.
11/2013 Rev 0
6-7
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Blank page
6-8
Maintenance
7.1
WARNING
Risk of injury through cleaning, inspection, maintenance and repair work
during operation
Death or severe bodily injuries are possible
Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off and secured against restarting.
Inform the operating personnel before starting service and maintenance work!
Appoint a person to supervise the work!
When carrying out any work concerning the operation, conversion or adjustment of
the machine/ plant and its safety-oriented devices or any work related to
maintenance, inspection and repair, always follow the start-up and shutdown
procedures described in the Operating Instructions and the information on
maintenance work!
As a general principle, all work on the machine/ plant should only be carried out when
the machine/ plant is at a standstill.
If the machine/ plant has been completely shut down for maintenance and repair
work, it must be secured against inadvertent restart by:
Locking the main control elements and removing the key and/or
11/2013 Rev 0
Before restarting the machine/plant after repair work, check that all safety devices
have been attached.
After electrical installation or repair work, test the protection systems (e.g. earth
resistance).
To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting gear and secured. Only
use suitable and technically perfect lifting gear and suspension systems with an
adequate carrying capacity! Never work or stand under suspended loads!
7-1
7-2
The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
When carrying out overbelt assembly work, always use specially designed or other
suitable and safe climbing aids and working platforms. Never use machine parts as
a climbing aid! Wear fall protection when carrying out maintenance work at a higher
level.
Keep all handles, steps, handrails, platforms, landings and ladders free of dirt, snow
and ice!
Always tighten up any bolted connections which have been loosened during
maintenance and repair work!
Any safety devices removed for setting up, maintenance or repair purposes must be
refitted and checked immediately upon completion of the maintenance and repair
work.
Ensure that all consumables and process materials and replaced parts are disposed
off safely and in an environmentally friendly manner!
Only use original fuses with the specified current rating! Shut down the machine/
plant immediately if faults occur in the electrical power supply!
Work on the electrical system or equipment may only be carried out by a skilled
electrician or by specially instructed personnel under the control and supervision of
a skilled electrician and in accordance with the applicable electrical engineering
rules.
If prescribed, the power supply to parts of machines and plants on which inspection,
maintenance and repair work is to be carried out must be disconnected. Check that
the isolated parts have been disconnected from the supply, then earth and shortcircuit them and insulate any adjacent live parts!
If work on live parts is necessary, it may only be carried out in the presence of a
second person who can disconnect the power supply in an emergency by actuating
the emergency stop button or main power switch. Cordon off the working area with
a red-and-white safety chain and a warning sign. Only use insulated tools!
Before starting work on high-voltage assemblies and after disconnecting the power
supply, the supply cable must be earthed and components such as capacitors shortcircuited with an earthing rod!
Carry out welding, flame-cutting and grinding work on the machine/ plant only if this
has been expressly authorised, as there may be a risk of explosion and fire!
Before carrying out welding, flame-cutting and grinding work, clean dust and other
inflammable substances from the machine/ plant and its surroundings and provide
adequate ventilation (risk of explosion)!
Check all lines, hoses and bolted connections regularly for leaks and obvious
damage. Repair any damage immediately! Splashing oil may cause injury and fires.
11/2013 Rev 0
7.1.1
Depressurise all system sections and pressure pipes which are to be opened in
accordance with the instructions for the assembly group concerned before carrying
out any repair work!
Hydraulic lines must be laid and connected in line with good professional practice!
Do not mix up any exchange connections! The fittings, lengths and quality of the
hoses must comply with the technical requirements.
Follow the applicable safety regulations when handling oil, grease and other
chemical substances!
Be careful when handling hot consumables and process materials (risk of burning or
scalding)!
Notes on cleaning
CAUTION
Risk of injury when working without personal safety equipment
Bodily injury possible
Always wear a face protector when carrying out cleaning work with highpressure or steam jet cleaners.
Check the degree of soiling of the machine/plant every day. Do not allow material to
accumulate or cake. The mechanical interaction of the plant components may be
interfered with and malfunctions and increased wear occur.
Always clean the assembly group in question before commencing maintenance work.
Before cleaning the machine/ plant with water or steam jet (high-pressure cleaners) or
other cleaning agents close/tape up all openings into which water, steam and detergents
should not be allowed to penetrate for safety or operational reasons. Electric motors and
switch cabinets are at particular risk.
Do not use corrosive detergents.
Do not direct the spray jet at electrical devices, relay boxes and switch cabinets, intake
and breather filters or greased surfaces.
Always hold the spray jet a sufficiently large distance away from the surface being cleaned
and do not direct the spray jet at these surfaces at right angles.
Clean places which are difficult to reach with suitable equipment e.g. special brooms.
11/2013 Rev 0
7-3
7.1.2
WARNING
Risk of injury by neglecting proper maintenance intervals
Death or severe bodily injuries are possible
All pending maintenance work must be completed according to schedule. The
manufacturer does not accept liability for damage resulting from maintenance
work which has not been carried out or has not been carried out according to
schedule.
CAUTION
System damage through improper maintenance
Damage to the machine/plant or its environment is possible.
Check the machine / plant at least once per shift for obvious damage and
defects! Report any changes (including changes in the operating performance)
to the responsible department immediately!
In the event of malfunctions, stop the machine / plant immediately and lock it!
Have any defects remedied immediately!
Failures arising from inadequate or improper maintenance may cause high repair costs
and long downtimes. Regular maintenance is therefore indispensable.
Check the paintwork for corrosion at regular intervals but no later than every 6
months. Touch up all damaged areas in line with good professional practice.
Have the function of all instrumentation and control devices/ electrical interlocks
checked by qualified personnel at regular intervals.
INFORMATION
Downtimes for repairs can also be used for scheduled maintenance work.
7-4
11/2013 Rev 0
Functional safety, trouble-free operation and the service life of the machine/ plant depend
on proper cleaning, inspection and maintenance.
The required frequency of checks for wear, inspection, maintenance and repair cannot be
specified beforehand owing to the variety of service conditions. An appropriate routine
inspection schedule must be prepared making allowance for the operating conditions.
The maintenance table (Chapter 7.2.1) is a guideline for inspection and maintenance
work.
For maintenance and repair work strictly follow the general safety notes included in
(Chapter 3).
INFORMATION
7.1.3
WARNING
Risk of injury due to improper fastening
Death or severe bodily injuries are possible
To avoid the risk of accidents, individual parts and large assemblies being
moved for replacement purposes should be carefully attached to lifting gear and
secured. Only use suitable and technically perfect lifting gear and suspension
systems with an adequate carrying capacity! Never work or stand under
suspended loads!
The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
11/2013 Rev 0
When carrying out overbelt assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms. Never use machine
parts as a climbing aid! Wear fall protection when carrying out maintenance work
at a higher level.
7-5
7.2
Do not re-use seals and safety elements that have been removed.
When re-using assembly groups and parts, always use new bolts, nuts and washers.
Observe the welding instructions for the prevention of accidents whenever carrying
out welding work.
During electric welding, secure the earthing cable near the part being welded. Do not
route the welding current return line over movable machine elements (e.g. shafts,
bearings). For bridging, fit a cable with a cross-section adequate for the strength of
the welding current and for the length over which current must be carried.
Restore the machine/plant to its original state on the completion of the repair work.
Re-assemble protective and safety devices. Make sure that the machine/plant is
working properly by carrying out a test run.
CAUTION
Risk of injury from working with the belt conveyor open
Bodily injury possible
The maintenance and inspection work described below may only be carried out
when the belt conveyor has been shut down and secured against being restarted.
Maintenance work should be organised in such a way that downtimes are also used on
other parts of the plant.
For maintenance and repair of the components see ANNEX 9.
The following parts of the conveyor are subject to maintenance at regular intervals:
Drive unit (1)
7-6
11/2013 Rev 0
Figure 16
7-7
7.2.1
Maintenance intervals
The maintenance intervals represent the suggestions and recommendations of
ThyssenKrupp Resource Technologies.
However the frequency with which maintenance work should be carried out depends on
the particular operating conditions existing on site, such as
Operating time,
Operating state,
Wear.
Therefore the operating conditions must be observed and taken into account. It may prove
necessary to change or adapt the maintenance intervals.
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7-8
for the
first time
after
Conveyor belt
Check tension of belt
Check belt tracking
Check for wear and damage
Maintenance interval
... Operating
hours
... Weeks
10 h
... Months
6
1
1
Carrying idlers
Check for caking
Check for smooth running
1
1
Pulleys
Check for caking
Belt scraper
Check the function
Check the strips
Feeding shoe
Check the function
Check sealing rubber
Material transfer
Check centre feeding and discharge
Fastening bolts
Check bolt torque
50 h
Bearings
Clean, change grease
Drive unit
Check for leaks
Check oil level, top up if required
Check bolt torque
Oil change
50 h
500 h
10 h
12
6000
24
17500
1
1
12
60
11/2013 Rev 0
cracks,
loose/missing bolts,
corrosion,
.
Interval: at least once a year
7-9
7.2.2
Drive
The maintenance instructions in ANNEX 9.2 must be followed for the drive.
For oil change periods see Chapter 8.5 "Lubricating instructions".
7.2.3
Bearings
The bearings of the driving pulley and tensioning pulley are to be checked for smooth
running at regular intervals, particularly during the run-in period.
High temperatures or noisy and irregular running may be caused by:
Overloading
Bearing failures.
Re-lubrication
The lubricating nipples are to be cleaned prior to re-lubrication. For bearing housings
without lubricating nipples, relubrication is to be performed when the machine is out of
operation. In doing so, exchange the old grease for fresh grease.
Even for bearing housings with lubricating nipples, the old grease is to be removed after
repeated relubrication before fresh grease is filled in.
The bearings of the driving shaft (1) and the reversing shaft (2) are maintenance-free
except for the lubricating intervals in Chapter 8.5 "Lubricating instructions".
Immediately after relubrication the temperature may rise but only for a short period of time.
11/2013 Rev 0
For mounting and dismounting see Chapter 7.4 "Bearings with adapter sleeves".
7 - 10
7.2.4
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Figure 17
7 - 11
7.2.5
Wear parts
The following parts are to be controlled at regular intervals for tight seat and state:
Scraper (6)
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7 - 12
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Figure 18
7 - 13
7.3
Repairs
WARNING
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation
Death or severe bodily injuries are possible
Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off and secured against restarting.
INFORMATION
7.3.1
Pull the tensioning pulley across the entire length of the belt to bring it into position 2
below the hoisting device (1).
11/2013 Rev 0
Figure 19
7 - 14
Lift the conveyor belt (3) under the platform of the discharge hopper and attachto
thecorrespondingsuspensionpoints (4) with rope or chain hoists (see also
Chapter 5.2 "Hoisting devices and slinging equipment").
Dismantle the protective grating (6) and the upper tensioning guide (guide support).
Mount the tensioning pulley with lifting straps on a C-hook. Make sure the pulley is
suspended properly in the C-hook (see also Chapter 5.2 "Hoisting devices and
slinging equipment").
Lift the pulley (5) out of the guide, move it to the side, rotate it by 90 and set it down.
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Figure 20
7 - 15
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7.3.2
Figure 21
7 - 16
Carry out the following steps when removing the tension drum (4):
Figure 22
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Figure 23
7 - 17
INFORMATION
Place a wooden board (10) under the belt on the floor in order not to damage the
belt (6).
Relax the tension on the conveyor belt (6) with tensioning pulley (4),
Pull the tensioning pulley (4) across the entire length of the belt to bring it into position
M below the hoisting device (8).
11/2013 Rev 0
Figure 24
7 - 18
Figure 25
Lift the tensioning pulley (4) under the platform of the discharge hopper with the chain
hoist (8). (See also Chapter 5.2 "Hoisting devices and slinging equipment".)
Figure 26
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7 - 19
Lift the conveyor belt (2) under the platform of the discharge hopper and attachto
thecorrespondingsuspensionpoints (1) with rope or chain hoists. (See also
Chapter 5.2 "Hoisting devices and slinging equipment".)
In order to roll out the pulley later place round pieces of wood (3) on the belt which is
lying on the ground under the pulley.
Now the tensioning pulley is laying on the round pieces of wood in the belt.
Figure 27
For lifting the tensioning pulley out of the area of the steel structure:
Detach the tensioning pulley from the chain hoist (6) and pull out with the pulling tool
on the pontoon. Turn over the round pieces of wood (3) at the same time (B).
Pull out the tensioning pulley until it outside of the belt and can be lifted again with
the chain hoist (6) (C).
Detach the pulling tool (4), lift the tensioning pulley and rotate it by 90(D).
Place the tensioning pulley below the crane (7) on a support (E).
11/2013 Rev 0
The tensioning pulley can now be lifted from the area of the steel construction with the
crane (7).
7 - 20
11/2013 Rev 0
Figure 28
7 - 21
7.3.3
Lift the conveyor belt into the drive station with the lifting gear to provide the
maximum space between the belt and driving pulley. Fix the conveyor belt to the
suspension points in the steel structure of the drive station using rope or chain hoists
(4).
Mount the driving pulley (5) with lifting straps on a C-hook. Make sure the pulley is
suspended properly in the C-hook (see also Chapter 5.2 "Hoisting devices and
slinging equipment").
Use a mobile crane to lift the driving pulley out of the roof of the steel structure and
set down.
11/2013 Rev 0
7 - 22
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Figure 29
7 - 23
7.3.4
Conveyor belt
Removal
Lift the material guide (4) and the feeding shoe (5).
Cut the conveyor belt and pull it out using a rope winch. We recommend connecting the
new conveyor belt up to the belt to be removed before retracting it.
CAUTION
System damage through improper repairs
Damage to the machine/plant or its environment is possible.
Pay attention to the carrying side of the conveyor belt.
Vulcanising of the conveyor belt is to be executed by an expert company.
Installation
It is practical to prepare the new conveyor belt for vulcanising prior to mounting.
Afterwards the discharge conveyor is made ready for operation by carrying out the
operating steps mentioned above in reverse order.
11/2013 Rev 0
For tensioning the conveyor belt see Chapter 5.9 "Assembling and tensioning the
conveyor belt".
7 - 24
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Figure 30
7 - 25
7.3.5
Carrying idlers
Blocking carrying idlers cause damage to the conveyor belt (1) thus are to be exchanged
immediately.
Removing the carrying idlers
Lift the material guide (4) and the feeding shoe (5).
WARNING
Risk of injury from razor sharp edges on the worn-out carrying idlers.
Death or severe bodily injuries are possible
Wear suitable protective clothing,
Do not touch the edges of the carrying idlers.
Installation
11/2013 Rev 0
Figure 30
7 - 26
7.3.6
Front scraper
See also ANNEX 9.5 "Scrapers B6C"
Loosen the clamping strips (1) of the scraper in front of the driving pulley and adjust
or exchange the scraper fin (2).
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Figure 31
7 - 27
7.3.7
Plough-type scraper
Loosen the clamping strips (1) of the plough-type scraper (2) and adjust or exchange
the plastic plates (3).
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Figure 32
7 - 28
7.3.8
Loosen the clamping strips (3) of the feeding shoe (1) and the material guiding
mechanism (2) and then readjust the rubber strips (4) or replace them.
11/2013 Rev 0
Figure 33
7 - 29
7.3.9
Clean the pull-rope emergency switch (1) and check for proper functioning.
Foreign matter must not obstruct the pull-rope emergency switches. Pull ropes (2)
and tension springs (3) must move freely.
Set the spring tension high enough for the pull-rope emergency switch to be actuated
if the rope breaks.
11/2013 Rev 0
Figure 34
7 - 30
7.3.10
Clean the belt tracking switches (1) and check for proper functioning.
11/2013 Rev 0
Figure 35
7 - 31
7.3.11
Clean the pulse generator (1) of the speed control and check for proper functioning.
11/2013 Rev 0
Figure 36
7 - 32
7.3.12
Clean the Belt break monitoring (1) switch and make sure it functions properly.
11/2013 Rev 0
Figure 37
7 - 33
7.4
Unscrew the adapter sleeve nut by some turns. Place a drive cap or a tube section
against the adapter sleeve nut and loosen the bearing by strong, uniformly
distributed blows (fig. 2).
If the bearing is assembled on a bright shaft, the tool is to be put on the inner ring of
the bearing (fig. 3).
11/2013 Rev 0
Bearings that do not show indentations or other kinds of damages on the raceways, rolling
elements or on the cage and which run uniformly without excessive bearing clearance can
be fitted again.
7 - 34
Installation
Prior to fitting the bearing seats must be oiled slightly so as to avoid damage during fitting.
The following fitting sequence is to be adhered to:
Push the adapter sleeve up to the marked position on the shaft (fig. 4). This work is
facilitated by expanding the sleeve slot using a screw driver.
Unpack the bearings and check the radial bearing clearance in the state as delivered.
The bearings are identified correspondingly.
Marking means:
- Normal bearing clearance
C3
C4
Check the bearing clearance as shown in fig. 5 by putting a feeler gauge between
the outer ring and the unloaded roller.
11/2013 Rev 0
C0
INFORMATION
Do not over roll the measuring blade of the feeler gauge, rather pull it between the
roller and the outer ring.
Push the bearing onto the adapter sleeve, screw on the adapter sleeve nut and
tighten until the required clearance reduction is reached (fig. 6).
7 - 35
INFORMATION
11/2013 Rev 0
If it is not possible to measure the radial clearance, the axial displacement X of the inner
ring to the adapter sleeve may be used as a measure for the correct fit (fig. 8).
7 - 36
The following table shows the values for the clearance reduction, for the axial
displacement and for the minimum admissible final clearance.
After pressing on the bearing, the adapter sleeve nut must be removed, the locking
plate must be put in place and the nut must be screwed back on and tightened up.
The lug of the locking plate which is located opposite to one groove in the nut is bent down
(fig. 9).
In this way, the adapter sleeve nut is locked in place.
CAUTION
Plant damage through installation faults
11/2013 Rev 0
7 - 37
The hollow spaces of the bearings as well as those of the housings are to be filled
with grease.
See Chapter 8.5 "Lubricating instructions".
Guide values for the reduction of the radial clearance and the axial displacement when mounting
spherical roller bearings
Bearing bore
d
over
Axial displacement1
Reduction of
radial bearing
clearance
up to
min
mm
max
Cone
1:12
min
mm
max
Cone
1:30
min
mm
max
mm
C3
C4
mm
30
40
50
40
50
65
0,020
0,025
0,030
0,025
0,030
0,040
0,35
0,40
0,45
0,40
0,45
0,60
0,015
0,020
0,025
0,025
0,030
0,035
0,040
0,050
0,055
65
80
100
80
100
120
0,040
0,045
0,050
0,050
0,060
0,070
0,60
0,70
0,75
0,75
0,90
1,10
1,75
1,90
2,25
2,75
0,025
0,035
0,050
0,040
0,050
0,065
0,070
0,080
0,100
120
140
160
140
160
180
0,065
0,075
0,080
0,090
0,100
0,110
1,10
1,20
1,30
1,40
1,60
1,70
2,75
3,00
3,25
3,50
4,00
4,25
0,055
0,055
0,060
0,080
0,090
0,100
0,110
0,130
0,150
180
200
225
200
225
250
0,090
0,100
0,110
0,130
0,140
0,150
1,40
1,60
1,70
2,00
2,20
2,40
3,50
4,00
4,25
5,00
5,50
6,00
0,070
0,080
0,090
0,100
0,120
0,130
0,160
0,180
0,200
250
280
315
280
315
355
0,120
0,130
0,150
0,170
0,190
0,210
1,90
2,00
2,40
2,70
3,00
3,30
4,75
5,00
6,00
6,75
7,50
8,25
0,100
0,110
0,120
0,140
0,150
0,170
0,220
0,240
0,260
355
400
450
400
450
500
0,170
0,200
0,210
0,230
0,260
0,280
2,60
3,10
3,30
3,60
4,00
4,40
6,50
7,75
8,25
9,00
10,00
11,00
0,130
0,130
0,160
0,190
0,200
0,230
0,290
0,310
0,350
11/2013 Rev 0
7 - 38
7.5
7.5.1
Machine structures
Standard
Quality
DIN 7984
8 / 10 / 12
Washer
DIN 6916
C 45 hardened
DIN 609
10.9
10
12.9
12
11/2013 Rev 0
Screw quality:
Nut quality:
7 - 39
Bolt diameter
8.8
10.9
12.9
M6
11
15
18
M8
26
36
43
M10
51
71
86
M12
88
123
148
M16
211
300
358
M20
412
579
697
M24
711
1000
1196
M30
1422
2010
2403
M36
2481
3491
4197
M42
3991
5609
6727
M48
6021
8473
10150
M56
9650
13582
16279
M64
14416
20300
24320
INFORMATION
Only use the tightening torques listed in the table when no special tightening
torques are indicated in the relevant section.
7.5.2
7 - 40
Use bolts, nuts and washers from one manufacturer only. A uniform protection
against corrosion is compelling.
11/2013 Rev 0
Material data
Manufacturer
data
Marked HSFG
10.9
yes
HSFG
10
yes
HSFG
yes
HSFG
Washer
as per DIN 6916
Screw quality
Nut quality
10.9
10
12.9
12
Standard
Quality
Hexagon bolt
DIN 6914
10.9 / 12.9
Hexagon nut
DIN 6915
10 / 12
Washer
DIN 6916
C 45 hardened
Use the required pretensioning forces indicated in the table below or in the drawing.
Pretensioning forces and tightening torques applicable to torque methods for sets
corresponding to tensile strength class 10.9 according to table 5, DIN V 18800-7.
Torque method
Basic pretensioning
force Fv in kN
11/2013 Rev 0
Dimensions
As manufactured and
slightly oiled
M 12
50
100
120
M 16
100
250
350
M 20
160
450
600
M 22
190
650
900
M 24
220
800
1100
M 27
290
1250
1650
M 30
350
1650
2200
M 36
510
2800
3800
1)
Check the friction grip connection immediately following installation and at least once a year:
2-492-20980 (Item 02)
7 - 41
Measure
none, pretensioning is adequate
30 to 60
> 60
replace the bolt, check two adjacent bolts of the same connection
11/2013 Rev 0
< 30
7 - 42
Lubrication
8.1
WARNING
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation
Death or severe bodily injuries are possible
Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off.
Maintaining the operating reliability and an adequate service life calls for orderly
lubrication with lubricants which are most suitable for the individual application. It is not
possible to determine the complete characteristics of the lubricants by means of the
reference values stated in the table of lubricants. The supplier of the lubricant is solely
responsible for the correct selection of the lubricant with due consideration given to the
local conditions and conditions of application of such industrial systems as well as the
state-of-the art-in the field of lubrication engineering.
The lubricants are provided by the owner on-site.
We will not accept any claim for defects or damage which can be attributed to incorrectly
selected lubricants.
In summary, we recommend the exclusive use of high-quality lubricants which have been
selected by reputable companies in accordance with our guiding values.
INFORMATION
All of the mineral oil companies stated in the table of lubricants offer a lubrication
service, and their technicians are available to our customers to answer any
questions about appropriate lubrication.
11/2013 Rev 0
CAUTION
System damage through improper lubrication
Damage to the machine/plant or its environment is possible
Lubrication and any work in connection with lubrication must be carried out at
operating temperature with the machine/ plant at a standstill.
8-1
It goes without saying that this recommendation does not exclude lubricants of
another make with the same properties.
11/2013 Rev 0
8-2
8.2
Storage of lubricants
Carefully close the container immediately after removing lubricant. Store the
containers in enclosed dry indoor areas. You thereby avoid contamination of the
lubricants. Ensure that lubricants are stored, used and disposed of in an
environmentally friendly manner and comply with the relevant national environmental
regulations when handling lubricants.
Observe the relevant national occupational safety, health and fire protection
regulations when storing and handling lubricants.
Mark drums, canisters, oil cans and grease guns with different colours according to
their content. Mixing of lubricants is not allowed.
8.3
8.3.1
Oil groups
The oil types listed in Chapter 8.4 "Table of lubricants (Index 8)" are broken down into the
following oil groups:
Mineral oils
= CLP
Polyglycols
= HLP
Hydraulic oils
To select oils, refer to the viscosity indicated on the ID plate of the gear unit.
Comply with the oil quality required by the manufacturer. If necessary, have the
quality confirmed by your supplier. Every lubricant manufacturer or supplier is
responsible for the quality of its products.
The required quantity depends on the oil level measured on the inspection glass,
the dipstick or the oil overflow opening.
11/2013 Rev 0
Change the oil in accordance with the intervals stipulated by the gear unit
manufacturer. In addition, check the oil level regularly and top-up, if necessary.
When the oil type is changed, as little old oil as possible may remain in the gear
unit. As a rule, small residues do not cause any problems. Gear oils of different
types and from different manufacturers may not be mixed together. If necessary,
have the compatibility of the new oil with the residues of the old oil confirmed by
the manufacturer.
When changing from polyglycols to other gear oils or vice versa, always
thoroughly purge the gear unit with the new oil. Residues of the old oil must be
completely removed from the gear unit.
8-3
Carry out regular relubrication at appropriate intervals. Poor lubrication may cause
damage to the machine components.
When purging, use a low-viscosity oil type of the same basis and from the same
manufacturer; never mix mineral oil with synthetic oil.
Rinse out and dry the bearing and bearing housing if a grease with different soap
properties is to be used.
Completely fill the bearings with grease. Only partially fill the free space in the
housing with grease (around 30-50 %). Then mount the bearings.
After lubricating:
CAUTION
System damage from contamination in the grease
Damage to the machine/plant or its environment is possible
Work in a clean manner! Even minor contamination in the grease will affect the
service life of the bearing points.
8.3.2
Lubricant lines
11/2013 Rev 0
Ensure that the lubricant lines are thoroughly cleaned before commissioning and that they
are filled with the prescribed lubricant.
8-4
8.3.3
DANGER
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation
Imminent danger of death or severe bodily injuries. Open toothed rim drives and
toothed racks may draw in and crush parts of the body
Never lubricate the machine when the machine is running.
11/2013 Rev 0
Thoroughly clean open toothed rim drive units and toothed racks before lubrication. Apply
lubricant in a thin and even layer.
8-5
8.4.1
Standard lubricants
8.4.1.1
Lubricating oils
Index
numbe
r
Used for
Class
Aral
BP
ESSO
Fuchs
Europa
Mobil
Shell
Texaco
Klber
A1
Hydraulic
couplings and
hydraulic
systems
ISO VG 32
HLP
Vitam
GF 32
Energol
HLP-HM
32
Nuto
H 32
Renolin
B 10
DTE 24
Tellus 32
Rando
HD 32
LAMORA
HLP 32
ISO VG
46 HLP
Vitam
GF 46
Energol
HLP-HM
46
Nuto
H 46
Renolin
B 15
DTE 25
Tellus 46
Rando Oil
HD 46
LAMORA
HLP 46
A3
ISO VG
68 HLP
Vitam
GF 68
Energol
HLP-HM
68
Nuto
H 68
Renolion
B 20
DTE 26
Tellus 68
Rando Oil
HD C-68
LAMORA
HLP 68
B1
ISO VG
32 HVLP
Vitam
HF 32
Bartran
HV 32
Univis
N 32
Renolin
MR 32 MC
DTE 13 M
Tellus
T 32
Rando Oil
HD AZ 32
ISO VG
46 HVLP
Vitam
HF 46
Bartran
HV 46
Univis
N 46
Renolin
MR 46 MC
DTE 15 M
Tellus
T 46
Bartran
HV 68
Univis
N 68
Renolin
MR 68 MC
DTE 16 M
Tellus
T 68
Rando Oil
HD CZ 68
A2
Hydraulic
systems
B2
Hydraulic
systems
B3
ISO VG
68 HVLP
C1
ISO VG
150 CLP
Degol
BG 150
Energol
GR-XP
150
Spartan
EP 150
Renolin
CLP 150/
Plus
Mobilgear
600 x P150
Omala
150
Meropa
150
Klberoil
GEM
1-150 N
C2
ISO VG
220 CLP
Degol
BG 220
Energol
GR-XP
220
Spartan
EP 220
Renolin
CLP 220/
Plus
Mobilgear
600 x P220
Omala
220
Meropa
220
Klberoil
GEM
1-220 N
ISO VG
320 CLP
Degol
BG 320
Energol
GR-XP
320
Spartan
EP 320
Renolin
CLP 320/
Plus
Mobilgear
600 x P320
Omala
320
Meropa
320
Klberoil
GEM
1-320 N
C4
ISO VG
460 CLP
Degol
BG 460
Energol
GR-XP
460
Spartan
EP 460
Renolin
CLP 460/
Plus
Mobilgear
600 x P460
Omala
460
Meropa
460
Klberoil
GEM
1-460 N
C5
ISO VG
680 CLP
Degol
BG 680
Energol
GR-XP
680
Spartan
EP 680
Renolin
CLP 680/
Plus
Mobilgear
600 x P680
Omala
680
Meropa
680
Klberoil
GEM
1-680 N
D1
ISO VG
150 CLP
HC
Degol
PAS 150
Renolin
Unisyn
CLP 150
Mobilgear
SHC XMP
150
Omala
HD 150
Pinnacle
EP 150
Klbersynth
GEM
4-150 N
D2
ISO VG
220 CLP
HC
Degol
PAS 220
Enersyn
EP-XF 220
(is no
longer
produced)
Renolin
Unisyn
CLP 220
Mobilgear
SHC XMP
220
Omala
HD 220
Pinnacle
EP 220
Klbersynth
GEM
4-220 N
ISO VG
320 CLP
HC
Degol
PAS 320
Enersyn
EP-XF 320
Renolin
Unisyn
CLP 320
Mobilgear
SHC XMP
320
Omala
HD 320
Pinnacle
EP 320
Klbersynth
GEM
4-320 N
D4
ISO VG
460 CLP
HC
Degol
PAS 460
Renolin
Unisyn
CLP 460
Mobilgear
SHC XMP
460
Omala
HD 460
Pinnacle
EP 460
Klbersynth
GEM
4-460 N
D5
ISO VG
680 CLP
HC
Renolin
Unisyn
CLP 680
Mobilgear
SHC XMP
680
Omala
HD 680
C3
D3
8-6
Klbersynth
GEM
4-680 N
11/2013 Rev 0
8.4
Index
numbe
r
Class
Aral
E1
ISO VG
150 CLP
PG
Degol
GS 150
E2
ISO VG
220 CLP
PG
Degol
GS 220
Enersyn
SG-XP
220
ISO VG
320 CLP
PG
Degol
GS 320
Enersyn
SG-XP
320
E4
ISO VG
460 CLP
PG
Degol
GS 460
Enersyn
SG-XP
460
E5
ISO VG
680 CLP
PG
Degol
GS 680
Enersyn
SG-XP
680
ISO VG
46 CL
Degol
CL 46
Energol
CS 46
ISO VG
100 CL
Degol
CL 100
Energol
CS 100
ISO VG
150 CL
Degol
CL 150
ISO VG
220 CL
E3
Used for
Non-return
devices
F1
G1
G2
G3
Neck bearings
and pinion shaft
bearings
G4
BP
ESSO
Fuchs
Europa
Mobil
Renolin
PG 150
Shell
Texaco
Klber
Tivela
S 150
Synlube
CLP 150
Klbersynth
GH 6-150
Renolin
PG 220
Glycoyle
HE 220
Tivela
S 220
Synlube
CLP 220
Klbersynth
GH 6-220
Renolin
PG 320
Glycoyle
HE 320
Tivela
S 320
Synlube
CLP 320
Klbersynth
GH 6-320
Renolin
PG 460
Glycoyle
HE 460
Tivela
S 460
Synlube
CLP 460
Klbersynth
GH 6-460
Renolin
PG 680
Glycoyle
HE 680
Tivela
S 680
DTE Oil
Medium
Tellus Oil
C 46
Rando
Oil 46
Renolin
DTA 100
Morlina
100
Rando
Oil EE
Energol
CS 150
Renolin
DTA 150
Morlina
150
Rando
Oil F
Degol
CL 220
Energol
CS 220
Renolin
DTA 220
Morlina
220
Ursa Oil
P 45
ISO VG
320 CL
Degol
CL 320
Energol
CS 320
Renolin
DTA 320
Morlina
320
Viscoma
Oil 144
Glycolub
e 220
Glycolub
e 460
Teresso
46
Klbersynth
GH 6-680
H1
Rollers
Motor oil
SAE 30
Kowal
Motoroil
- VanellusT
-Energol
HDS
ESSOLU
BE-XD-3HDX
TITAN
Universal
HD SAE 30
Delvac
Super
Rimula
X 30
Ursa
Super LA
Ursatex
Klberoil
GEM
1-100 N
J1
Gear unit
Chain links
API GL 4
SAE 90
EP
Gear Oil
Hyp 90
Gear Oil
EP SAE
90
Gear oil
GX-D 90
TITAN
Gear MP
SAE 90
Mobilube
HD 90-A
Spirax
G 80 W
90
Multigear
SAE
85 W-90
Klbersynth
GEM
4-220 N
Index
number
Pour point
- 24 C to - 27 C
- 42 C
- 9 C bis - 24 C
- 30 C to - 48 C
- 27 C bis - 45 C
F+G
11/2013 Rev 0
8-7
8.4.1.2
Lubricating greases
Marking to DIN 51502 / 51825
Base oil: Mineral oil
Saponification type: Lithium-12-hydroxystearate
Application temperature range: - 20 C to 120 C
Index
numbe
r
Used for
Class
Aral
BP
ESSO
K1
Grease lubrication
unit for spider
bearing
NLGI
000
Aralub
GFP 000
Energrease
HT 000 EP
Lowviscosity
grease
000
K2
Tooth couplings of
main shaft
bearings
NLGI
00
Aralub
FDP 00
Energrease
HT-EP 00
Lowviscosity
gear
grease
K3
Tooth couplings
and grease
lubrication systems
NLGI 0
KPO K-20
Energrease
LS 0
Beacon
EP 0
K4
Grease lubrication
systems
NLGI 1
KP1K-20
Energrease
LS-EP 1
Beacon
EP 1
Renolit
FEP 2
Mobilux
EP 1
Alvania
Fett EP 1
K5
Lubrication
systems and roller
bearings (heavyduty)
NLGI 2
KP2K-20
Aralub
H-LP 2
Energrease
LS-EP 2
Beacon
EP 2
Renolit
FEP 2
Mobilux
EP 2
Alvania
Grease EP
(LF) 2
Multifak
EP 2
CENTOP
LEX
2 EP
K6
Roller bearings
(normal-duty type)
NLGI 3
K3K-20
Aralub
HL 3
Energrease
LS 3
Beacon 3
Renolit
FWA 220
Mobilux 3
Alvania
Grease RL
3
Glissando
FT 3
CENTOP
LEX 3
8.4.1.3
Fuchs
Europa
Renolit
SO-D8024
Mobil
Shell
Texaco
Klber
Mobilux
EP 023
Simnia
Grease 000
Mobilplex
44
Alvania
GL 00
Marfak
00
MICROL
UBE
GB 00
Alvania
grease
EP ROEP1
Multifak
EP 0
MICROL
UBE
GB 0
CENTOP
LEX
GLP 500
MICROL
UBE
GL 261
Used for
Class
L1
Roller bearings
(high temperature
load)
NLGI 2
Aral
BP
ESSO
Fuchs
Mobil
Shell
Texaco
Klber
Mobiltemp
SHC 100
11/2013 Rev 0
Index
numbe
r
8-8
Index
numbe
r
Used for
Class
L2
Roller bearings
(high temperature
load)
NLGI 2
Aral
BP
ESSO
Fuchs
Mobil
Shell
Mobilith
SHC 220
Albida
PPS 2
Texaco
Index
numbe
r
Used for
Class
L3
Roller bearings
(high temperature
load)
NLGI 1,5
Aral
BP
ESSO
Fuchs
Mobil
Shell
Texaco
Mobiltemp
SHC 32
8.4.2
Special lubricants
8.4.2.1
11/2013 Rev 0
Index
numbe
r
M1
Klber
Fuchs
Lubritech
black
transparent
GRAFLOSCON
A - G1 ULTRA
Klberplex
AG 11-462
Ceplattyn 300
M2
Inlet process
GRAFLOSCON
B - SG-00 ULTRA
Klberfluid
B-F 2 ULTRA
Inlet Ceplattyn - RN
M3
Operating lubrication
(Adhesive lubricant with good EP
characteristics.)
FZG special test A/2, 76/50 > 12th degree of
load,
Wear < 0.2 mg/kWh
GRAFLOSCON
C - SG-0 Ultra
Klberfluid
C-F 8 ULTRA
Ceplattyn KG 10 HMF
M4
GRAFLOSCON
C - SG-1000 Ultra
Klberfluid
C-F 4 ULTRA
M5
GRAFLOSCON
C - SG-2000 Ultra
Klberfluid
C-F 3 ULTRA
8-9
8.4.2.2
Index
numbe
r
Used for
CASTROL
Class
CASTROL
ISO VG
32 HLP
Tribol 943 AW 32
ISO VG
46 HLP
Tribol 943 AW 46
N3
ISO VG
68 HLP
Tribol 943 AW 68
N4
ISO VG
100 CLP
Tribol 1100/100
ISO VG
150 CLP
Tribol 1100/150
ISO VG
220 CLP
Tribol 1100/220
N1
N2
N5
Hydraulic unit
axle adjustment and overload protection.
Pinion assembly of the V-belt drive
Oil unit
Oil circulating lubrication
N6
BIO TOP
Greases
Index
numbe
r
P1
P2
P3
8.4.2.3
Used for
Roller bearings
CASTROL
Class
CASTROL
NLGI 000
Tribol 3020/1000-000
GP 000K-40
NLGI 00
Tribol 3020/1000-00
GP 00K-40
NLGI 2
KP2K-20
Tribol 3020/1000-2
BIO TOP
Molub-Alloy
Bio Top 9488-1
Hydrodynamic couplings
Application range: Power transmission oils
Pour point: up to - 42 C
Used for
Class
Aral
BP
ESSO
Fuchs
Europa
Mobil
Shell
Texaco
Q1
Hydraulic couplings
(Voith)
ISO VG 32
HLP
Degol BG
32
Energol
HLP-HM 32
Torque
Fluid N 45
Renolin
MR 10
Mobilfluid
125
Tegula
32
Rando
HD 32
11/2013 Rev 0
Index
numbe
r
8 - 10
8.4.2.4
Index number
Used for
Class
Castrol
Klber
Mobil
Q2
Hydraulic couplings
(Voith)
ISO VG 32
Hyspin
AWH-M 32
Summit
HySyn
FG 32
SHC 524
Pour point - 42 C
Pour point - 45 C
Pour point - 63 C
8.4.2.5
Index number
Used for
Class
Shell
R1
Hydraulic systems
ISO VG 32
Tellus
Arctic 32
Used for
Class
Fuchs Europa
Quintolubric
S1
Hydraulic systems
ISO VG 46
PLANTOFLUX AT-S
VG 46
Quintolubric
888-46
S2
Hydraulic systems
ISO VG 68
PLANTOFLUX AT-S
VG 68
Quintolubric
888-68
11/2013 Rev 0
Index number
8 - 11
8.5
Lubricating instructions
CAUTION
System damage due to incorrect indications of oil quantities and/or oil
classes
Damage to the machine/plant or its environment is possible
The specifications on the type plates of gears, motors etc. referring to the oil
quantity and oil class to be filled take priority over the specifications in these
lubricating instructions.
Observe the lubricating instructions for components given in ANNEX 9.
Lubricating
point
Quanti
ty
Lubricant
acc. to
Chapter 8.
4 index
number
Lubricating intervals in
operating hours
Oil change
Relubricatio
n
Lubricant quantity
Oil change
Bevel spur
gearbox
D3
1. Oil change
after 500 h;
additional oil
changes after
8000 - 12000 h
but no later than
every 4 years
Driving pulley
bearing
K5
every
6000 hours or
every 2 years
approx.
7.7 kg each
Tensioning
pulley bearing
K5
every
6000 hours or
every 2 years
approx.
3.2 kg each
Carrying
idlers
Relubricatio
n
approx.
270 litres
11/2013 Rev 0
Lifetime-lubrication
8 - 12
11/2013 Rev 0
Figure 38
8 - 13
11/2013 Rev 0
Blank page
8 - 14
ANNEX
9.1
Drawings
9.2
Drive unit
9.3
9.4
9.5
Scrapers B6C
9.6
9.7
9.8
Safety devices
11/2013 Rev 0
9-1
11/2013 Rev 0
Blank page
9-2
9.1
Drawings
Name
Drawing No.
4601915 Sheet 1-3
4612052
Plough-type scraper
2597871
Feeding shoe
4612040
Conveyor frame
4612258
4612318
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9-3
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Blank page
9-4
Drive unit
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9.2
9-5
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Blank page
9-6
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9.3
9-7
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Blank page
9-8
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9.4
9-9
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Blank page
9 - 10
Scrapers B6C
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9.5
9 - 11
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Blank page
9 - 12
11/2013 Rev 0
9.6
9 - 13
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Blank page
9 - 14
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9.7
9 - 15
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Blank page
9 - 16
Safety devices
11/2013 Rev 0
9.8
9 - 17
11/2013 Rev 0
Blank page
9 - 18