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Assembly and Operating Instructions

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

Year of manufacture 2013

2-492-20980 (Item 02)

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

ThyssenKrupp Resource Technologies GmbH


P.O. Box 1463 D - 59306 Ennigerloh
Schleebergstrae 12 D - 59320 Ennigerloh
Telephone: +49 2524 30 0
Fax: +49 2524 2252
www.thyssenkrupp-resource-technologies.com/
All parts protected by copyright. All rights reserved including those of translation into other languages. This
document may not be processed, reproduced or distributed by any means, including electronic systems, in
whole or in part without our express permission in writing.
2-492-20980 (Item 02)

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

Structure of the safety notes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 2

1.3

Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 2

1.4

General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3

1.5

Liability and warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3

1.6

Copyright - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4

1.7

Technical modifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 4

1.8

Stocking of spare parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4

Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 1
2.1

Discharge conveyor (1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 1

2.2

Drive unit (2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 2

2.3

Belt weigher (3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 2

2.4

Metal detector (4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 2

2.5

Safety devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 4

General safety notes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 1


3.1

Principles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 1

3.2

Modifications and spare parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 2

3.3

Personnel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 2

3.4

Noise hazard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 2

3.5

Information regarding residual risks during daily operation - - - - - - - - - - - - - - - - - -3 - 3

3.6

Fire protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 3

3.7

Disposal of consumables and process materials - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 4

Design and operating principle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4 - 1


4.1

Scope of application and designated use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 1

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, storage and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1


5.1

Transport instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1

5.2

Hoisting devices and slinging equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3

5.2.1

Lifting gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3

5.2.2

Lifting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3

5.2.3

Lifting ropes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 6

5.2.4

Wire rope clamps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 8

5.2.5

Lifting chains - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 10

5.2.6

Hook - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 11

5.2.7

Screw-type lifting eyes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 11

5.2.8

Shackles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 13

5.2.9

Slinging equipment and load protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 15

5.2.10

Substructures for loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 16

5.3

Storage requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 17

5.3.1

General requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 17

5.3.2

Storage facilities & other details - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 18

5.3.3

Special requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 20

5.4

Installation planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 23

5.5

Preparation for installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 24

5.6

Delivery parts and weights - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 26

5.7

General information on assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 27

5.8

Mount belt conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29

5.8.1

Assembling the conveyor frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29

5.8.2

Assemble idler supports - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 30

5.8.3

Assembling the idler supports - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

5.8.4

Assembling the material guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

5.8.5

Assembling the plough-type scraper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.8.6

Assembling the front scrapers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34

5.8.7

Assembling the drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 35

5.8.8

Assembling the resistance thermometer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 36

2-492-20980 (Item 02)

11/2013 Rev 0

4.3

5.9
6

11/2013 Rev 0

Assembling and tensioning the conveyor belt - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 38

Commissioning and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1


6.1

General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1

6.2

Operator training - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 1

6.3

Safety notes for operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1

6.4

Test run - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 3

6.5

Commissioning under load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 5

6.5.1

Before initial commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 5

6.5.2

Misalignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 6

6.5.3

After initial commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 6

6.6

Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6

6.6.1

Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6

6.6.2

Emergency-stop system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6

6.6.3

Pull-rope emergency switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 7

Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 1
7.1

Important information on maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 1

7.1.1

Notes on cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 3

7.1.2

Information on maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 4

7.1.3

Notes relating to repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 5

7.2

Maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 6

7.2.1

Maintenance intervals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 8

7.2.2

Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 10

7.2.3

Bearings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 10

7.2.4

Conveyor belt/tensioning device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 11

7.2.5

Wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 12

7.3

Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 14

7.3.1

Replacement of the tensioning pulley with C-hooks - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 14

7.3.2

Replacing the tensioning pulley with a C-hook - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 16

7.3.3

Replacing the driving pulley - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 22

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

Material guiding mechanism and feeding shoe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 29

2-492-20980 (Item 02)

IVZ - 3

TOC - 4

Pull-rope emergency switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 30

7.3.10

Belt tracking switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 31

7.3.11

Monitoring of the torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 32

7.3.12

Belt break monitoring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 33

7.4

Bearings with adapter sleeves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 34

7.5

Screwed and bolted connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 39

7.5.1

Machine structures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 39

7.5.2

High-tensile bolted joints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 40

Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 1
8.1

Introduction and technical instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 1

8.2

Storage of lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3

8.3

General information on lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3

8.3.1

Oil groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3

8.3.2

Lubricant lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 4

8.3.3

Open toothed gears - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 5

8.4

Table of lubricants (Index 8) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 6

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

Driving pulley and tensioning pulley

9.4

Belt weigher with evaluation electronics

9.5

Scrapers B6C

9.6

Hydraulic cylinder ENERPAC CLL-508

9.7

Hydraulic hand pump

9.8

Safety devices

11/2013 Rev 0

7.3.9

2-492-20980 (Item 02)

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.

2-492-20980 (Item 02)

1-1

1.2

Structure of the safety notes


The safety notes in the Assembly and Operating Instructions are highlighted as follows:

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

Death or severe bodily injuries

WARNING

Possible danger

Death or severe bodily injuries

CAUTION

Possible danger

Minor bodily injuries

CAUTION

Possible property damage

Damage to the machine / plant or


its environment

INFORMATION

Useful information or tip:


Simplifies the handling

!
!
General danger

!
Special danger, e.g.
electrocution

1-2

Definitions
right

on the right-hand side looking in conveying direction

left

on the left-hand side looking in the conveying direction

Instructions for action (in the stated order)

Listing in the text

or
2-492-20980 (Item 02)

11/2013 Rev 0

1.3

1.4

General information
Dear Customer,

These Assembly and Operating Instructions are prepared by ThyssenKrupp Resource


Technologies and have to be observed in every detail by those responsible for the
transport, installation, commissioning, operation, maintenance as well as the disposal of
all consumables and process materials. Only if the responsible individuals follow the
instructions in these Assembly and Operating Instructions will errors in operating and
servicing the machine / plant be avoided and trouble-free operation ensured.
The Assembly and Operating Instructions contain important information on how to operate
the machine / plant safely, properly and efficiently. Observing this information helps to
avoid danger, to reduce repair costs and downtimes and to increase both the reliability and
the life of the machine / plant.
The Assembly and Operating Instructions include numerous instructions referring to
possible hazards. The user is responsible for training the operating staff at the machine /
plant or on site and ensuring that the safety regulations are observed.
The Assembly and Operating Instructions do not include instructions and guidelines for
major repair work.
ThyssenKrupp Resource Technologies can provide skilled and qualified personnel to
carry out inspections and repairs if required.

1.5

Liability and warranty


ThyssenKrupp Resource Technologies explicitly exclude all liability and warranty claims
for damage or operational malfunctions originating from:

Non-compliance with instructions in the Assembly and Operating Instructions

Incorrect operation

Any use of the machine other than the specified use

Faulty maintenance

Use of consumables (in particular lubricants) not explicitly permitted by the


manufacturer

Use of spare parts not approved by the manufacturer

Conversions and modifications not approved by the manufacturer.

11/2013 Rev 0

In addition, the conditions for liability and warranty as specified in the General Conditions
of Supply of ThyssenKrupp Resource Technologies are applicable.

2-492-20980 (Item 02)

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

Stocking of spare parts

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

2-492-20980 (Item 02)

11/2013 Rev 0

Our warranty only covers genuine spare parts supplied by us.

Technical data
Basic data
Feed material:

Iron ore

Size of the feed material:

0 - 250 mm

Moisture content of material:

max. 2%

Bulk density:

2,3 t/m3

Performance data
Conveying capacity:

2.1

3660 t/h

Discharge conveyor (1)

Belt width:

2000 mm

Centre distance:

47,7 m

Belt speed:

max. 1.06 m/s

Angle of incline of belt:

approx. 5

Steel cord belt:

2000 DIN 22102-EP2500/4 25:10 Y open - GI

11/2013 Rev 0

Figure 1

2-492-20980 (Item 02)

2-1

2.2

2.3

Drive unit (2)

Type of gear:

Bevel spur gearbox with back stop


X4KR260HH/B

Transmission:

1:96

Oil quantity:

approx. 270 litres, ISO VG 320 HC

Flange coupling:

FC 775/275-S-M

Flexible coupling:

ADR 125

Electric motor:

355 L4, 400 kW, 1800 min-1, B3

Weight drive complete,


with motor:

approx. 9,500 kg

Mounting position - Drive:

Conveying direction RIGHT

Belt weigher (3)

Model:
Working temperature:

- 40 + 80C

Accuracy:

+/- 0,03%

Weight recorded:

hermetic sealed, temperature-compensating strain


gauges

Evaluation electronics:

2.4

Metal detector (4)

Model:
RS 485 for remote control or PLC via Profibus
11/2013 Rev 0

Interface:

2-2

2-492-20980 (Item 02)

11/2013 Rev 0

Figure 1

2-492-20980 (Item 02)

2-3

Safety devices

(1) Resistance thermometer:

PT100 41/5-3B

(2) Pull-rope emergency switch:

NTS 002

(3) Belt tracking switch:

SLS 011

(4) Belt-break monitoring switch:

BLS 011

(5) Speed control:

DI0001

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2.5

2-4

2-492-20980 (Item 02)

11/2013 Rev 0

Figure 2

2-492-20980 (Item 02)

2-5

11/2013 Rev 0

Blank page

2-6

2-492-20980 (Item 02)

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General safety notes

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!

In the event of safety-relevant modifications or changes in the behaviour of the


machine/ plant during operation, stop the machine/ plant immediately and report the
malfunction to the responsible department!

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.

Replace hydraulic hoses within at appropriate intervals even if no safety-relevant


defects have been detected!

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!

Observe all fire-warning and fire-fighting procedures!


2-492-20980 (Item 02)

3-1

3.2

3.3

3.4

Modifications and spare parts

For safety reasons, conversions and modifications are prohibited unless previously
approved by ThyssenKrupp Resource Technologies.

Use of accessories and spare parts not approved by ThyssenKrupp Resource


Technologies can lead to unforeseeable dangers.

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.

Use protective equipment wherever required by the circumstances or by law!

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

No permanent work station has been assigned to the plant/machine.


Depending on the material to be processed, noise emissions will occur: these may only
be measured during operation. The user has to ensure the measurement of the sound
power level of all operation positions (e.g. for maintenance and checking, control station)
immediately after commissioning.

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2-492-20980 (Item 02)

11/2013 Rev 0

Information on the emissions level which is specific to the work station

INFORMATION

Directive 2003/10/EC of the European Parliament and of the Council dated 6


February 2003 (17th individual directive in terms of Article 16 Paragraph 1 of the
Directive 89/391/EEC).
If other measures fail to prevent from risks due to noise hazards, a suitable and
properly adapted personal ear protection must be made available to the employee
and need be used by the employee.
Personal ear protection must be worn by the personnel if the noise hazard
reaches the threshold value (85 dB (A)).

3.5

Information regarding residual risks during daily


operation
The safety requirements specified in the EC Machines Directive have been taken into
account in the machine/plant.
Residual risks can nevertheless still occur during operation.
Residual risks, which remain even after careful shutting off and with platforms
corresponding to the applicable safety requirements, are pointed out below.
Mechanical hazard/material

11/2013 Rev 0

3.6

Overcharging of the crushing area/ crusher discharge


Overcharging and discharge of crushing material on account of upstream conveying
equipment and/or congestion of material in the feed hopper.

Dusty operating conditions


on account of the type of feeding material, material feeding, the crushing procedure,
the material discharge.

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!

2-492-20980 (Item 02)

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.

Disposal of consumables and process materials


The safe and environment-friendly disposal of all consumables and process
materials should be ensured. You should also make sure that all respective national
regulations for the protection of the environment are complied with.

11/2013 Rev 0

3-4

2-492-20980 (Item 02)

Design and operating principle

4.1

Scope of application and designated use

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.

2-492-20980 (Item 02)

4-1

4.2

Main components
See Figure 3
1

Conveyor frame, 4-part with supports and carrying idler(1)


Servicing platform

(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)

Cover with injection system

(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

11/2013 Rev 0

21

4-2

2-492-20980 (Item 02)

11/2013 Rev 0

Figure 3

2-492-20980 (Item 02)

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

2-492-20980 (Item 02)

11/2013 Rev 0

Figure 3

2-492-20980 (Item 02)

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.

11/2013 Rev 0

The drive is fastened on a base frame and connected to the conveyor frame with a torque
support (2).

4-6

2-492-20980 (Item 02)

11/2013 Rev 0

Figure 4

2-492-20980 (Item 02)

4-7

11/2013 Rev 0

Blank page

4-8

2-492-20980 (Item 02)

Transport, storage and assembly

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 away from heat

Keep dry

Caution! Glass!

This way up

Sling here

Centre of gravity

Do not use hand


hooks

No hand truck here

Stacking limitation

Clamp here

Permitted
temperature range

Do not use fork lift


truck here

Electrostatic sensitive
device

Do not destroy barrier

Tear off here

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.

2-492-20980 (Item 02)

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

2-492-20980 (Item 02)

5.2

Hoisting devices and slinging equipment

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.

Before lifting, determine the weight of 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.

2-492-20980 (Item 02)

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.

Protect high-gloss/finished surfaces of the load against damage caused by the


slinging equipment. Protective material that is intended to prevent the load/lifting
means slipping must be attached in such a way that it cannot slip if the slinging
equipment becomes loose.

When attaching slinging equipment at great heights:


Use the climbing aids provided. If no climbing aids have been provided or these
are not available, use an approved ladder.
Secure the ladder to prevent it slipping or falling over.
Use both hands for climbing. Have the slinging equipment to be attached brought
up by lifting tackle (e. g. crane).

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

Remove any material lying loosely on the load.

Secure unused rope/chain ends, e. g. by hooking them to the main ring/collecting


them in the shackle.

Instruct staff to leave the hazard area.

Check that the load is secured symmetrically at all points.

Make sure that the slinging equipment cannot damage the load (and vice versa).

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11/2013 Rev 0

Before lifting the load:

After the weight of the load has been picked up completely by the lifting tackle and
the load has been lifted a little:

Check the load brake.

Check again whether the load is secured at all points.

Transport the load over free areas as far as possible.

Warning signals must be given if there is anyone in the hazard zone.

Setting the load down:


Set the load down slowly on a respectively sturdy base. Align the base again before
the load is set down.

Remove slinging equipment from the load and check both for damage.

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2-492-20980 (Item 02)

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

max. permissible load per strand in


relation to 1000 kg

%
30

50,0

(500 kg)

45

70,7

(707 kg)

60

86,6

(866 kg)

90

100,0

(1000 kg)

The load bearing capacity/wire rope strength is reduced by:


Splitting rope loops in the lifting ropes and splitting lifting ropes into continual
strands
Bending round corners
Using lifting ropes for clamping
Acceleration and slowing during lifting and lowering operation
High and low temperatures
Vibration
Corrosion

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2-492-20980 (Item 02)

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.

Check the lifting ropes for:


broken or cut strands,
rust and corrosion,
knots and kinked spots,

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damaged eyes

2-492-20980 (Item 02)

5-7

5.2.4

Do not bend the eyes of lifting ropes over corners.

When securing loads by winding the lifting ropes around the load, use shackles (1).

Wire rope clamps


Attach wire rope clips in such a way that the lower part of the clip (6) is pushed against the
long end (5) of the rope, and the yoke of the clip (2) against the dead end (4) of the rope.
Always attach a rope thimble (1). The correct number of clips and distance (3) between
them is given in the following table.
Tighten clamping nuts using the given torques.

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

Distance between clips

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

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2-492-20980 (Item 02)

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Rope diameter

Rope diameter

Diameter of the clamping


yoke

Distance between clips

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

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Inches

2-492-20980 (Item 02)

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.

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5 - 10

2-492-20980 (Item 02)

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.

Check lifting chains for:


notches, cracks, exact dimensions and wear
deformed chain links, welding burr, bent or open hooks, elongation
rust and corrosion

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.

Screw-type lifting eyes


The size of screw-type lifting eyes is determined in relation to the diameter of the shank of
the threaded section. A distinction is made between simple screw-type eyes and screwtype eyes with shoulder.

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).

2-492-20980 (Item 02)

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

per screw-type eye

per screw-type eye

per screw-type eye

per screw-type eye

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

2-492-20980 (Item 02)

Eyes must be screwed in completely to prevent the shank becoming bent.

5.2.8

Use screw-type eyes of a suitable size.

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.

Check shanks of the screw-type eyes for deformation or crack formation.

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

Never replace shackle bolts by conventional bolts. Danger of breaking!

2-492-20980 (Item 02)

5 - 13

Diameter

Do not expose the main part of the shackle to side tensile loads.

Ensure the shackle bolt is a perfect fit.

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

2-492-20980 (Item 02)

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

Slinging equipment and load protection


Protect lifting ropes 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 wire
rope too.

11/2013 Rev 0

2-492-20980 (Item 02)

5 - 15

5 - 16

Substructures for loads

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.

Protect finished surfaces by cushioning the base, e. g. with sacking, pressboard,


belts.

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.

Compensate unevenness under the supports.

Use the supports to create a cavity under the load, enabling the slinging equipment
to be attached and removed easily.

2-492-20980 (Item 02)

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.

2-492-20980 (Item 02)

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

Storage facilities & other details

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)

Gear rim cover

Mill outlet case

Chutes

Ducts for material transport and dedusting

Crusher frame

Apron conveyor supporting frame/chain conveyor supporting frame (without drive


units)

Supporting frame for troughed belt conveyor

Bed plates

Structural steelwork elements

2-492-20980 (Item 02)

11/2013 Rev 0

Examples: "Large-volume plant components"

Examples: "Wear parts whose surface has no effect on the functional capability"

Grinding media, rods and balls

Mill and shell lining

Slotted plates and rear panel plates for intermediate and discharge diaphragms

Crusher rolls for RollSizer

Systematic organisation of the material warehouse is strongly recommended, i.e. storage


should correspond to the assembly planning (Example: bed plates and base plates should
be placed at the outer edge of the storage area, etc). Route plans must be provided in
the store. The store must also be accessible to heavy trucks, mobile cranes and forklifts.
Drainage systems for discharge of surface water must be present.
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. All parts must be stored in such a way that no water can
accumulate.
The effectiveness of the protection of machined surfaces (protection against corrosion
and mechanical damage) must be checked and repaired or renewed if necessary.
Markings on plant components must be readable without the part having to be moved. If
water accumulates on a plant component through visible markings, the component must
be provided with new visible markings at suitable points.

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.).

Components with a high proportion of mechanically machined surfaces, e.g. gear


rims, pinions with bearings, gear units, gear motors, motors, fans, parts of filter plant
housings, rotary gate valves, control and shut-off valves, large-volume couplings,
bearing housings and bearing segments for the slide shoe bearings.

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

Storage in enclosed inside areas with partial air conditioning


Partially air-conditioned means reduction of air humidity and temperature limit. All
components whose functional capability is adversely affected by high temperatures and
high air humidity, especially electrical equipment, but also other components.
Examples:

5.3.2.4

Bolts/nuts for mounting the gear rim

Anchor bolts

All types of instruments/measuring instruments

Hydraulic pipes, gear rim lubrication

Switches, control centres (MCC = motor control centre)

Transmitters, frequency control

Separators for hydraulic and lubricating units

Filter bags for dust collectors and the corresponding solenoid valves

Measuring instruments for the belt weigher and misalignment monitoring

Filter cloth for bag filter installations

Storage in closed lockable rooms


High-quality, sensitive and valuable components.
Examples:

Measuring instruments

Sensors

PCs

Screens

Laboratory equipment e.g. test screens, scales, etc.

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.

2-492-20980 (Item 02)

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.

2-492-20980 (Item 02)

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

Electrical control systems


Control centres (MCC):

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.

Process control equipment:


Process control equipment should be stored indoors in a heated/air-conditioned room.
5 - 22

2-492-20980 (Item 02)

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

Other mechanical equipment


Belts and seals:
These components must be protected from moisture and stored in a dry environment. The
environment must be ozone free and the belts and seals kept out of direct sunlight, in order
not to adversely affect the performance characteristics.
Bare metal components (e.g. pistons, bushes or the sealing surfaces of valves) must be
rust-proofed by rubbing them with a VCI corrosion inhibitor such as rust-inhibiting oil or
wrapped in oiled paper (these additives are referred to internally as VCI = volatile
corrosion inhibitors). Volatile corrosion inhibitors permanently emit small amounts of
protective additives. Rust-inhibiting oil or oiled paper therefore protect surfaces with or
without metal contact and are particularly suitable for irregular shapes such as hollow
parts, tapped holes, pipes and machines.
VCI additives can be used for steel, iron, chrome, cast iron and aluminium. There are also
special VCI additives for copper and copper alloys and for both materials. The VCI method
is not applicable for the conservation of zinc, tin, cadmium, magnesium, lead and alloys of
these metals.

5.4

Installation planning

11/2013 Rev 0

When planning the installation, please note the following:

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 sufficient space to accommodate the periphery equipment as well as to


arrange the feeding units and conveyors to unload the material to be crushed.

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.

Ensure that the machine is accessible for cleaning.

Initiate measures against dangerous environmental influences, e.g. dangerous


dusts, uncontrolled oil leaks, noise.

Integrate the machine/plant in the existing/planned control system, including


interlocking system, protective and monitoring devices, e.g. emergency stop
switches, local switches, speed monitors, filling level monitors. Integrate optical and
acoustic starting alarms in the control system.

2-492-20980 (Item 02)

5 - 23

If the conditions at the place of installation vary from those in the installation drawing,
please consult ThyssenKrupp Resource Technologies.

INFORMATION

The construction contractor is responsible for the correct dimensioning of


foundations, steel platforms, load-bearing ceilings and their supports as well as
for the execution of the construction work and compliance with the official
regulations, even if an erecting engineer of ThyssenKrupp Resource
Technologies erects the machine/plant.
Align the machine / plant with a level.
For installation on a concrete foundation, grout the foundation bolts and the base
frame by concrete mortar 1:2 (1 portion cement; 2 portions sand) after alignment.
Prior to this, carefully clean the surface of the foundation and saturate it with
water.

5.5

Preparation for installation

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.

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 - 24

2-492-20980 (Item 02)

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

The manufacturer accepts no liability for damage resulting from incorrect


installation of the machine!
A careful selection of the tools and appliances used and the assembly personnel
employed is important for the correct execution of the assembly work.
It is recommendable to have the assembly work supervised from start to finish by
assembly specialists from ThyssenKrupp Resource Technologies.

11/2013 Rev 0

Our warranty is based on the assumption that an assembly specialist from


ThyssenKrupp Resource Technologies will carry out the assembly and assembly
inspection.

2-492-20980 (Item 02)

5 - 25

5.6

Delivery parts and weights

5 - 26

6 x Pontoon 405 high, each approx. 730 kg

1 x Carrying idler diameter 1200, approx. 3,800 kg

2 x Supporting blocks, 2017 high, each approx. 1,500 kg

1 x Support, 3910 high, approx. 4,400 kg

1 x Conveyor frame, part 1, approx. 12,000 kg

1 x Conveyor frame, part 2, approx. 10,300 kg

1 x Conveyor frame, part 3, approx. 7,500 kg

1 x Conveyor frame, part 4, approx. 11,000 kg

1 x Idler supports, upper strand and lower strand, approx. 8,700 kg

63 x Carrying idler padded, each approx. 33 kg

114 x Carrying idler top, each approx. 23 kg

12 x Carrying idler bottom rubber, each approx. 43 kg

28 x Carrying idler bottom, each approx. 23 kg

42 x Elastomer spring elements, each 3.2 kg

1 x Cantilever conveyor frame drive, approx. 990 kg

1 x Driving pulley, approx. 7,100 kg

1 x Bevel spur gearbox with motor, approx. 9.500 kg

1 x Discharge hood, approx. 2,000 kg

1 x Tensioning pulley, approx. 3,400 kg

1 x Tensioning unit, approx. 276 kg

1 x Feeding shoe, approx. 6.400 kg

2 x Front scraper, each approx. 175 kg

1 x Plough-type scraper, 75 kg

1 x Belt weigher, XXX kg

1 x Hydraulic pump with hoses, approx. 35 kg

2 x Hydraulic cylinder for tensioning, each approx. 30 kg

1 x Conveyor belt, approx. 9.400 kg

1 x Material guide, approx. 12.000 kg

1 x Protective grating, approx. 1,800 kg

1 x Servicing platform, 13,000 kg

1 x Needle slide, approx. 6,300 kg

1 x Chute, approx. 2,000 kg

Electrical switches, mounting brackets, pull cord, extension springs, egg shape
clamps, company sign, nameplate, warning signs

2-492-20980 (Item 02)

11/2013 Rev 0

The discharge conveyor is delivered in the following assembly groups:

INFORMATION

The list of these subassembly groups coincides with the sequence of assembly
steps.

5.7

General information on assembly

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.

2-492-20980 (Item 02)

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

The manufacturer accepts no liability for damage resulting from incorrect


installation of the machine!

Careful selection of the tools and appliances used and the installation personnel
is important for correct execution of the assembly work.

It is recommendable to have the assembly work supervised from start to finish by


assembly specialists from ThyssenKrupp Resource Technologies.

Our warranty is based on the assumption that an assembly specialist from


ThyssenKrupp Resource Technologies will carry out the assembly and assembly
inspection.

The respective layout plan and assembly drawings must be carefully studied. All
guidelines and notes must be observed.

5 - 28

2-492-20980 (Item 02)

11/2013 Rev 0

Initial assembly must be carried out by trained personnel.

5.8

Mount belt conveyor


See ANNEX 9.1 "Drawings"

5.8.1

Assembling the conveyor frame


See Figure 5 and drawing 4612258

Install pontoons, supports, carrying idlers (1) and mount in the ground.

Assemble the four separate parts of the conveyor frame (2).

Assemble cantilever conveyor frame/drive (3).

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

2-492-20980 (Item 02)

5 - 29

5.8.2

Assemble idler supports


This section describes the types of idler supports on which the conveyor belt is running.

5.8.2.1

Carrying idlers top


See Figure 6
The carrying idlers consist of three idler rolls of equal length and the idler stand.
All idler rolls will shell of special tubing into which deep drawn bearing holding ends are
pressed and welded, thus ensuring smooth run and preventing unbalance.
Grease-pre-packed precision ball bearings is mounted on continuous axle. They are
lifetime lubricated with narrow labyrinths and a large grease chamber with sealing cap, to
protect the idler bearing from the environment.
The bearings are sealed by a sealing disc on the inside so that grease should not enter
the idler interior from the bearing.
Carrying idlers 159 x 900 / 25 (3 rollers)

Figure 6

5.8.2.2

Carrying idlers top, padded (impact rollers)


See Figure 7
Impact Idlers are Carrying Idler with additional rubber tyres which are upholstered the
idlers.

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)

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2-492-20980 (Item 02)

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

Hold-down rollers 214/194 x 1250 with 10 mm covering / 0 (2 rollers)

Figure 9

2-492-20980 (Item 02)

5 - 31

5.8.3

Assembling the idler supports


The idler supports are assemble according to the drawing 4612024 Sheet 1-2 on the
conveyor frame.

5.8.4

Assembling the material guide


See Figure 10 and drawing 4612052
The chutes are covered with 20 mm wear plates (HARDOX 400) to protect the structural
plates.
Guide strips (1) equipped with adjustable rubber strips (2) are located on the contact
points with the conveyor belt. The rubber strips prevent the falling of material down.
The guide strips (1) are made of of Hardox 400.

Bolt on the guide strips (1) on the lateral supports (3) of the conveyor frame.

Adjust the height of the rubber strips (2).

11/2013 Rev 0

Figure 10

5 - 32

2-492-20980 (Item 02)

5.8.5

Assembling the plough-type scraper


See also drawing 2597871

Install plough-type scrapers (1) in the lower strand in front of the tensioning pulley (2)
and adjust the height.

11/2013 Rev 0

Figure 11

2-492-20980 (Item 02)

5 - 33

5.8.6

Assembling the front scrapers


See Figure 12

Install and adjust both of the front scrapers (2) on the driving pulley (1).

Read the manufacturer's documentation in ANNEX 9.5 "Scrapers B6C".

11/2013 Rev 0

Figure 12

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2-492-20980 (Item 02)

5.8.7

Assembling the drive


Also see drawing 4612318 in ANNEX 9.1.

Assemble the cantilever on the conveyor frame (1).

Assemble coupling (5) gear unit (2) coupling (4) and motor (3) on both sides of the
driving pulley.

Read the manufacturer's documentation in ANNEX 9.2 "Drive unit".

11/2013 Rev 0

Figure 13

2-492-20980 (Item 02)

5 - 35

5.8.8

Assembling the resistance thermometer


See Figure 14
Install one resistance thermometer PT100 41/5-3B in the bore holes (1) on both of
the bearing housings of the tensioning pulley.

Install one resistance thermometer PT100 41/5-3B in the bore holes (2) on both of
the bearing housings of the driving pulley.

11/2013 Rev 0

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2-492-20980 (Item 02)

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Figure 14

2-492-20980 (Item 02)

5 - 37

5.9

Assembling and tensioning the conveyor belt

Apply and vulcanise the conveyor belt.

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.

Tension the conveyor belt

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.

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2-492-20980 (Item 02)

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

2-492-20980 (Item 02)

5 - 39

11/2013 Rev 0

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5 - 40

2-492-20980 (Item 02)

Commissioning and operation

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:

having the machine/plant checked

determining the optimum capacity

training the operating personnel

passing on additional advice on operation, maintenance and upkeep.

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

Safety notes for operation

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.

2-492-20980 (Item 02)

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!

If abnormal vibrations suddenly occur in the equipment supporting structure the


operation of which is corresponding with vibrations and unbalances, these abnormal
vibrations must be eliminated prior to feeding the machine with material.

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.

Local operation of individual drives is allowed only during inspection, maintenance


and repair work.

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.

2-492-20980 (Item 02)

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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,

Lubricating points acc. to lubricating instructions Chapter 8.5,

Installation of safety devices,

Inspect the whole plant for foreign bodies,

Observe the instructions for components in the ANNEX 9.

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:

Rotation direction of the drive,

Proper functioning and smooth running of the single plant components,

Proper functioning of the belt weigher,

Proper functioning and display of the installed control equipment:


Speed monitor
Belt tracking limit switch
Pull-rope emergency switch
Belt tear switch

CAUTION
System damage from actuating the safety devices for normal operating
interruptions
11/2013 Rev 0

Damage to the machine/plant or its environment is possible


Belt tracking limit switches and pull-rope emergency switches must be operated
in case of emergency only. They must not be operated for normal shutdown.

Observe the instructions for components in the ANNEX 9.

Check directional stability of the conveyor belt and correct if necessary.

2-492-20980 (Item 02)

6-3

Notes on the alignment of the conveyor belt:


Basically the driving pulley and the tensioning pulley are to be positioned at right angles
to the conveyor frame. The conveyor belt must not be regulated by adjusting the pulleys.

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.

Loosen the outer bracket and remount it in conveying direction.

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.

Retighten all anchor bolts and fastening bolts.

Check lubricating points according to the lubricating instructions Chapter 8.5.

Observe the instructions for components in the ANNEX 9.

11/2013 Rev 0

6-4

2-492-20980 (Item 02)

6.5

Commissioning under load

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

Before initial commissioning

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.

2-492-20980 (Item 02)

6-5

6.5.2

Misalignment
Possible causes for misalignment of the conveyor belt:

6.5.3

Insufficient alignment of conveyor frame, pulleys and carrying idlers.

One-sided caking of the pulleys or carrying idlers.

Feed and guide of the conveyor belt out of belt centre.

Scrapers put transversely into the material flow.

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.

After initial commissioning


After commissioning the following works are to be carried out:

Retighten anchor bolts and fastening bolts.

Adjusting the plough-type scraper and the front scraper.

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

When using an emergency-stop switch, there is a danger of material overfilling at


the transfer points, as all upstream and downstream parts of the plant are switched
off with no specific shutdown sequence.
The emergency-stop switches must not be used for normal shutdown.

6-6

2-492-20980 (Item 02)

11/2013 Rev 0

Damage to the machine/plant or its environment is possible

Several emergency-stop switches must be installed on the machine/plant.


The emergency-stop switches are identified by red impact surfaces on yellow background.
The switches engage on actuation.

6.6.3

The whole electrical system is switched off by the emergency stop.

Determine the danger or damage and provide first aid if necessary.

Have any defects rectified.

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.

Acknowledge the fault.

Switch on the main supply again.

Pull-rope emergency switch

The switch is triggered with the pull-cord.

Pull-rope emergency switch automatically locks when actuated.

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

2-492-20980 (Item 02)

6-7

11/2013 Rev 0

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6-8

2-492-20980 (Item 02)

Maintenance

7.1

Important information on maintenance

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.

Note the information in the Operating Instructions on adjusting, maintenance and


inspection work and observe the intervals set out, including information on the
replacement of parts and equipment! The work may only be carried out by qualified
personnel.

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

attaching a warning sign to the main switch.

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!

2-492-20980 (Item 02)

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!

The electrical equipment of the machine/plant must be inspected at regular intervals.


Any defects such as loose connections or scorched cables must be rectified
immediately.

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.

2-492-20980 (Item 02)

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

The covers and tapes need be removed completely after cleaning.


After cleaning, check all lubricant and hydraulic oil lines for leaks, loose connections,
friction areas and damage! Eliminate any deficiencies immediately!

2-492-20980 (Item 02)

7-3

7.1.2

Information on maintenance and inspection

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 machine/ plant at the specified intervals (inspection intervals,


maintenance periods) for proper operation, lubrication condition and wear.

Replace or repair all damaged/ worn parts.

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

2-492-20980 (Item 02)

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

For lubricating the machine/ plant see Chapter 8.


For maintenance and servicing of the components, see ANNEX 9.
As recommended during commissioning, you are advised to have initial repairs carried out
by ThyssenKrupp Resource Technologies staff. Your maintenance staff will have the
opportunity to take part in an intensive training course.

7.1.3

Notes relating to repairs

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.

2-492-20980 (Item 02)

7-5

7.2

Immediately replace worn components with new components.


With worn components, strength is reduced and the risk of fracture is increased!

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.

Do not leave any tool or other device in the machine/plant.

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.

Maintenance and inspection

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)

Bearings of the driving pulley (2)

Bearings of the tensioning pulley (3)

Conveyor/belt tensioning device (4)


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7-6

2-492-20980 (Item 02)

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Figure 16

2-492-20980 (Item 02)

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.

11/2013 Rev 0

Observe the instructions for components in the ANNEX 9.

7-8

2-492-20980 (Item 02)

Crusher discharge belt

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

Pull-rope emergency switch, belt tracking


switch, speed monitor, belt break monitor
Functional test

10 h

12
6000

24

17500

1
1
12
60

11/2013 Rev 0

The belt conveyor must be checked regularly for

cracks,

loose/missing bolts,

Bolted/screwed connections (see Chapter 7.5),

state of the weld seams and weld seam transitions,

corrosion,

changes in the condition of the protection and safety devices

.
Interval: at least once a year

2-492-20980 (Item 02)

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:

Insufficient or excessive lubrication

Contamination in the bearing

Overloading

Insufficient bearing clearance

Torsion and twisting,

High friction in the seals

Heat input from outside

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

2-492-20980 (Item 02)

7.2.4

Conveyor belt/tensioning device


The conveyor belt at the beginning of operation. It must be re-tensioned if it slips on the
drive drum.
The guide rails of the bearing housing must be cleaned and greased prior to tensioning
the conveyor belt, see Item 1.
For tensioning the conveyor belt see Chapter 5.9 "Assembling and tensioning the
conveyor belt".

11/2013 Rev 0

Figure 17

2-492-20980 (Item 02)

7 - 11

7.2.5

Wear parts
The following parts are to be controlled at regular intervals for tight seat and state:

Conveyor belt (5)

Scraper (6)

Material guiding skirtboards (7)

Carrying idlers (8)

For the scrapers (6) see ANNEX 9.5 "Scrapers B6C".

11/2013 Rev 0

The control intervals are indicated in Chapter 7.2.1.

7 - 12

2-492-20980 (Item 02)

11/2013 Rev 0

Figure 18

2-492-20980 (Item 02)

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

Observe Chapter 7.1.3 "Notes relating to repairs"

7.3.1

Replacement of the tensioning pulley with C-hooks


See Figure 19, Figure 20 and ANNEX 9.3 "Driving pulley and tensioning pulley".
For removal of the tensioning pulley:
Use the tensioning pulley to relax the tension on the conveyor belt,

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

2-492-20980 (Item 02)

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.

For longitudinal transport use C-hook with pulley.

11/2013 Rev 0

Figure 20

2-492-20980 (Item 02)

7 - 15

Replacing the tensioning pulley with a C-hook

11/2013 Rev 0

7.3.2

Figure 21

7 - 16

2-492-20980 (Item 02)

Carry out the following steps when removing the tension drum (4):

Remove the protective grating (1),

Figure 22

Remove the idler supports (2),

11/2013 Rev 0

Figure 23

2-492-20980 (Item 02)

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).

Dismantle the conveyor frame (3) on the tensioning station

Secure tensioning pulley from slipping

Remove the tensioning unit (5)

11/2013 Rev 0

Figure 24

7 - 18

2-492-20980 (Item 02)

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

Remove the guide rails (9) (See Figure 24)

11/2013 Rev 0

2-492-20980 (Item 02)

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.

Lower the tensioning pulley onto the round pieces of wood.

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:

Attachtheropeorchainhoists(4)onthepontoon(5)(see also Chapter 5.2

"Hoisting devices and slinging equipment") (A).

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

2-492-20980 (Item 02)

11/2013 Rev 0

Figure 28

The tensioning pulley is installed in the reverse order of sequence.

2-492-20980 (Item 02)

7 - 21

7.3.3

Replacing the driving pulley


For removal of the driving pulley:
Use the tensioning pulley to relax the tension on the conveyor belt (1) across its
entire length (Figure 19, Item 2).

Dismantle the dust and the discharge hood.

Dismantle the plough-type scraper (3) and swing it off.

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).

Remove the coupling guard hood and coupling connection.

Remove the bearing bolts (2) on the driving pulley (5).

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

2-492-20980 (Item 02)

11/2013 Rev 0

Figure 29

2-492-20980 (Item 02)

7 - 23

7.3.4

Conveyor belt
Removal

Release the conveyor belt (1) using tensioning spindles (2).

Lift the material guide (4) and the feeding shoe (5).

Detach the two front scrapers (6).

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

2-492-20980 (Item 02)

11/2013 Rev 0

Figure 30

2-492-20980 (Item 02)

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

Remove guard plates if necessary.

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

Installation is carried out in reverse order of sequence.

Figure 30

7 - 26

2-492-20980 (Item 02)

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).

Adjust the height of scrapers with set screws (3).

11/2013 Rev 0

Figure 31

2-492-20980 (Item 02)

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).

Adjust the height of plough-type scrapers using set screws.

11/2013 Rev 0

Figure 32

7 - 28

2-492-20980 (Item 02)

7.3.8

Material guiding mechanism and feeding shoe

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

2-492-20980 (Item 02)

7 - 29

7.3.9

Pull-rope emergency switch


See also ANNEX 9.8 "Safety devices"

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.

See Chapter 7.2.1 for details of the inspection intervals.

11/2013 Rev 0

Figure 34

7 - 30

2-492-20980 (Item 02)

7.3.10

Belt tracking switch


See also ANNEX 9.8 "Safety devices"

Clean the belt tracking switches (1) and check for proper functioning.

Foreign matter must not obstruct the belt tracking switches.

See Chapter 7.2.1 for details of the inspection intervals.

11/2013 Rev 0

Figure 35

2-492-20980 (Item 02)

7 - 31

7.3.11

Monitoring of the torque


See also ANNEX 9.8 "Safety devices"

Clean the pulse generator (1) of the speed control and check for proper functioning.

Foreign matter must not obstruct the pulse generator.


See Chapter 7.2.1 for details of the inspection intervals.

11/2013 Rev 0

Figure 36

7 - 32

2-492-20980 (Item 02)

7.3.12

Belt break monitoring

Clean the Belt break monitoring (1) switch and make sure it functions properly.

Foreign matter may not obstruct the function of the switch.


Pull ropes (2) and tension springs (3) must be freely movable.

11/2013 Rev 0

Figure 37

2-492-20980 (Item 02)

7 - 33

7.4

Bearings with adapter sleeves


Removal
Mark the position of the adapter sleeve on the shaft and unlock the adapter sleeve
nut by bending up the locking plate (fig. 1).

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

2-492-20980 (Item 02)

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

- Bearing clearance larger than normal

C4

- Bearing clearance greater than C3

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).

2-492-20980 (Item 02)

7 - 35

Required bearing clearance:


A tight fit of bearings with a tapered bore is achieved by driving the bearing onto the
adapter sleeve.
In doing so, the original bearing clearance is reduced.
Any intuitive pressing-on of the bearing is not permissible. When pressing the bearing on
the adapter sleeve, the reduction of the clearance must be checked continuously.
The weight of the outer ring must not affect the insertion of the measuring blade (fig. 7).

INFORMATION

Do not measure unless the rollers are unloaded.

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

2-492-20980 (Item 02)

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.

Check the clearance of the bearing once again.

Assemble the bearing housing.

CAUTION
Plant damage through installation faults

11/2013 Rev 0

Damage to the machine/plant or its environment is possible


If several bearings are removed at the same time, the parts are to be marked in
order to avoid parts of the loose and fixed bearing being mixed up.
Fixed rings must be inserted for the fixed bearings.

2-492-20980 (Item 02)

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

Min. permissible residual


clearance after mounting
bearings with initial
clearance
C0

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

Applicable only to solid steel shafts

11/2013 Rev 0

7 - 38

2-492-20980 (Item 02)

7.5

Screwed and bolted connections


Always protect all screwed and bolted connections against corrosion.

7.5.1

Machine structures

For machine structures:

Standard

Quality

Hexagon bolt (thread up to head)

DIN EN ISO 4017

8.8 / 10.9 / 12.9

Hexagon socket head cap bolt

DIN EN ISO 4762

8.8 / 10.9 / 12.9

DIN 7984

8.8 / 10.9 / 12.9

DIN EN ISO 4032

8 / 10 / 12

Washer

DIN 6916

C 45 hardened

Hexagon fitted bolts

DIN 609

8.8 / 10.9 / 12.9

Hexagon socket head cap bolt with short head


Hexagon nut

Use only the following bolts and nut qualities together:


8.8
8

10.9
10

12.9
12

11/2013 Rev 0

Screw quality:
Nut quality:

2-492-20980 (Item 02)

7 - 39

Tightening torques for machine structures


Calculated with k = 0.14 (new bolts, without post-treatment) in accordance with VDI 2230

Tightening torque Ma (Nm)


Class

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

High-tensile bolted joints

7 - 40

Use bolts, nuts and washers from one manufacturer only. A uniform protection
against corrosion is compelling.

Only use properly oiled bolts in perfect condition.

Use a torque wrench to produce the required bolt pretensioning force.

2-492-20980 (Item 02)

11/2013 Rev 0

In the case of high-tensile (friction-type bolted connections), the force is transmitted by


friction between the contact faces and depends on the pretensioning force of the bolts.
The contact faces must be bright. They must be cleaned by sandblasting, flame cleaning
or chemical detergents (DIN 18800, DIN V 18800-7 - Annex D.1.6).

Components are marked as


follows

Material data

Manufacturer
data

Marked HSFG

Hexagon bolt HSFG


as per DIN 6914

10.9

yes

HSFG

Hexagon nut HSFG


as per DIN 6915

10

yes

HSFG

yes

HSFG

Washer
as per DIN 6916

Use only the following bolts and nut qualities together:

Screw quality
Nut quality

10.9
10

For steel structures:

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

Required tightening torque to achieve the basic


pretensioning force
MA in Nm
Hot-galvanised and
lubricated 1)

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)

Nuts lubricated with molybdenum disulphide or equivalent lubricants

Check the friction grip connection immediately following installation and at least once a year:
2-492-20980 (Item 02)

7 - 41

Pre-stressed bolted connections (DIN V 18800-7 1.2.2.2)


(1216) When using the torque method, at least 5 % of the sets of the connection must be
checked (at least 2 bolted connections for connections with less than 20 bolts). A test
torque which is a maximum of 10% higher than the applied tightening torque is transmitted
to the set on the side on which it was tightened. Proceed as described in Table 7
depending on the angle of rotation that is achieved till the torque wrench is activated. If
necessary, retain the element not to be turned in order to prevent it from turning.
Checking the pre-stressing force according to the torque method
(DIN V 18800-7 Table 7)
Angle of additional
rotation

Measure
none, pretensioning is adequate

30 to 60

pretensioning is adequate, check two adjacent bolts of the same connection

> 60

replace the bolt, check two adjacent bolts of the same connection

11/2013 Rev 0

< 30

7 - 42

2-492-20980 (Item 02)

Lubrication

8.1

Introduction and technical instructions

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.

2-492-20980 (Item 02)

8-1

In particular, the following points must be noted:


For recommended lubricants, see table of lubricants (Chapter 8.4special lubricants,
Chapter 8.4.2).

Carry out lubrication at the lubrication intervals specified in the lubricating


instructions (Chapter 8.5) using the stated lubricants and quantities.

It goes without saying that this recommendation does not exclude lubricants of
another make with the same properties.

11/2013 Rev 0

8-2

2-492-20980 (Item 02)

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

General information on lubrication

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

= CLP PG (synthetic oils)

Poly-a-olefins = CLP HC (synthetic oils)


Hydraulic oils

= HLP

Hydraulic oils

= HVLP (improved viscosity-temperature relationship)

INFORMATION on the gear unit

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.

2-492-20980 (Item 02)

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.

Completely fill the labyrinth gaps with grease.

Relubricate the bearings and labyrinths.

After lubricating:

Do not wipe grease off lubricating nipples/lubricating heads!

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

2-492-20980 (Item 02)

8.3.3

Open toothed gears

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.

2-492-20980 (Item 02)

8-5

Table of lubricants (Index 8)

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

Gear units and


gear motors

Synthetic gear oil

2-492-20980 (Item 02)

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

Synthetic gear oil


Cannot be mixed
with mineral oil.

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

Minimum requirement to DIN

Pour point

Oil to DIN 51524-2 based on mineral oil

- 24 C to - 27 C

Oil to DIN 51524-3 based on mineral oil

- 42 C

Oil to DIN 51517-3 based on mineral oil

- 9 C bis - 24 C

Oil to DIN 51517-3 based on poly-a-olefins

- 30 C to - 48 C

Oil to DIN 51517-3 based on polyglycols

- 27 C bis - 45 C

F+G

Oil to DIN 51517-2 based on mineral oil

11/2013 Rev 0

2-492-20980 (Item 02)

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

Heavy-duty lubricating greases


Marking to DIN 51502
Base oil: Poly-alpha-olefin (PAO), fully synthetic
Saponification type: Gel thickener
Application temperature range: - 50 C to 200 C
Application range: high-speed bearings (e.g. pinion assembly bearings, )

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

2-492-20980 (Item 02)

Marking to DIN 51502


Base oil: fully synthetic
Saponification type: Lithium complex
Application temperature range: - 40 C to 160 C
Application range: Crusher rotor bearings, RollSizer,

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

Marking to DIN 51502


Base oil: Poly-alpha-olefin (PAO), fully synthetic
Saponification type: Gel thickener
Application temperature range: - 50 C to 180 C
Application range: slow-speed bearings (e.g. feed conveyor, chain scraper, ...)

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

Lubricating oils for tube mills

11/2013 Rev 0

Application range: Lubrication of toothed rim

Index
numbe
r

Lubrication of toothed rim


(nozzle greasing)

M1

Klber

Fuchs
Lubritech

black

transparent

Priming lubrication by hand

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

Operating lubrication from + 5 C up to 100 C

GRAFLOSCON
C - SG-1000 Ultra

Klberfluid
C-F 4 ULTRA

Ceplattyn KG 10 HMF - 1000

M5

Operating lubricant from + 15 C up to +


120 C

GRAFLOSCON
C - SG-2000 Ultra

Klberfluid
C-F 3 ULTRA

Ceplattyn KG 10 HMF - 2500

2-492-20980 (Item 02)

8-9

8.4.2.2

Lubricating oils for gyratory crushers


Oils

Index
numbe
r

Used for

CASTROL

Class

CASTROL

ISO VG
32 HLP

Tribol 943 AW 32

Tribol BioTop 1448 / 32

ISO VG
46 HLP

Tribol 943 AW 46

Tribol BioTop 1448 / 46

N3

ISO VG
68 HLP

Tribol 943 AW 68

Tribol BioTop 1448 / 68

N4

ISO VG
100 CLP

Tribol 1100/100

ISO VG
150 CLP

Tribol 1100/150

Tribol BioTop 1418 / 150

ISO VG
220 CLP

Tribol 1100/220

Tribol BioTop 1418 / 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

Grease lubrication system


for spider bearing

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

2-492-20980 (Item 02)

Application range: Power transmission oils


Base oil: fully synthetic
Pour point: - 42 C to - 63 C

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

CASTROL Hyspin AWH-M 32

Pour point - 42 C

Klber Summit HySyn FG 32

Pour point - 45 C

Mobil SHC 524

Pour point - 63 C

Hydraulic oils for low temperature applications


Application temperature range: min. - 40 C up to max. + 70 C
Pour point: up to - 60 C

8.4.2.5

Index number

Used for

Class

Shell

R1

Hydraulic systems

ISO VG 32

Tellus
Arctic 32

Fire-resistant hydraulic oils


Flash point: 300 C
Fire point: 360 C
Pour point: down to - 20 C

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

2-492-20980 (Item 02)

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

Check the oil


every day
when the
gear unit is at
a standstill

Relubricatio
n

approx.
270 litres

11/2013 Rev 0

Lifetime-lubrication

8 - 12

2-492-20980 (Item 02)

11/2013 Rev 0

Figure 38

2-492-20980 (Item 02)

8 - 13

11/2013 Rev 0

Blank page

8 - 14

2-492-20980 (Item 02)

ANNEX

9.1

Drawings

9.2

Drive unit

9.3

Driving pulley and tensioning pulley

9.4

Belt weigher with evaluation electronics

9.5

Scrapers B6C

9.6

Hydraulic cylinder ENERPAC CLL-508

9.7

Hydraulic hand pump

9.8

Safety devices

11/2013 Rev 0

2-492-20980 (Item 02)

9-1

11/2013 Rev 0

Blank page

9-2

2-492-20980 (Item 02)

9.1

Drawings

Name

Drawing No.
4601915 Sheet 1-3

Idler supports, complete

4612024 Sheet 1-2

Material guide, complete

4612052

Plough-type scraper

2597871

Feeding shoe

4612040

Conveyor frame

4612258

Cantilever conveyor frame - drive

4612318

11/2013 Rev 0

Discharge conveyor GSSF 2000x47.7

2-492-20980 (Item 02)

9-3

11/2013 Rev 0

Blank page

9-4

2-492-20980 (Item 02)

Drive unit

11/2013 Rev 0

9.2

2-492-20980 (Item 02)

9-5

11/2013 Rev 0

Blank page

9-6

2-492-20980 (Item 02)

Driving pulley and tensioning pulley

11/2013 Rev 0

9.3

2-492-20980 (Item 02)

9-7

11/2013 Rev 0

Blank page

9-8

2-492-20980 (Item 02)

Belt weigher with evaluation electronics

11/2013 Rev 0

9.4

2-492-20980 (Item 02)

9-9

11/2013 Rev 0

Blank page

9 - 10

2-492-20980 (Item 02)

Scrapers B6C

11/2013 Rev 0

9.5

2-492-20980 (Item 02)

9 - 11

11/2013 Rev 0

Blank page

9 - 12

2-492-20980 (Item 02)

Hydraulic cylinder ENERPAC CLL-508

11/2013 Rev 0

9.6

2-492-20980 (Item 02)

9 - 13

11/2013 Rev 0

Blank page

9 - 14

2-492-20980 (Item 02)

Hydraulic hand pump

11/2013 Rev 0

9.7

2-492-20980 (Item 02)

9 - 15

11/2013 Rev 0

Blank page

9 - 16

2-492-20980 (Item 02)

Safety devices

11/2013 Rev 0

9.8

2-492-20980 (Item 02)

9 - 17

11/2013 Rev 0

Blank page

9 - 18

2-492-20980 (Item 02)