Belt Stacker BS

Machine manual
en-23210.001-F
Belt stacker BS
Code word
Order number
POLYSIUS Order Code (POC)

Machine manual Contents
Belt stacker BS
Contents
1 Technical data......................................................................................... 1-1

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-2
3.2 Mode of functioning................................................................................3-13
4 Transport and assembly........................................................................4-1
4.1 Transport and storage instructions...........................................................4-1
4.2 Assembly.................................................................................................. 4-1
4.3 Assembly connections..............................................................................4-2
4.4 Sequence of assembly.............................................................................4-7
5 Lubrication..............................................................................................5-1
6 Preparation for the test run...................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
6.2 Setting and adjustment.............................................................................6-2
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-2
7.3 Trouble shooting.......................................................................................7-4
7.4 Repair....................................................................................................... 7-5
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers’ documentation...................................................................9-1
en-23210.001-F
Machine manual Technical data
Belt stacker BS 1
1 Technical data
NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers'
documentation.
Information on the intended use

Bulk material.......................................................................................
Bulk density................................................................................. t/m3
Grain size...................................................................................... mm
Max. moisture content.................................................................... %
Angle of repose..................................................................................°
Machine
Model...................................................................................................
Year of manufacture............................................................................
Basic data
Usable storage capacity.................................................................. t
Maximum storage capacity.............................................................. t
Stacking method.................................................................................
Rail spacing..................................................................................... m
Stacking rate................................................................................. t/h
Voltage............................................................................................. V
Mains frequency............................................................................. Hz
Feeding conveyor
Width of belt................................................................................. mm
Belt troughing....................................................................................°
Conveying speed.......................................................................... m/s
2
Belt conveyor boom (1)

Jib length........................................................................................ m
Position up / down.......................................................................+° / -°
Width of belt................................................................................. mm
Type of belt..........................................................................................
Belt troughing....................................................................................°
Conveying speed (approx.)........................................................... m/s
Max. lifting speed (at discharge pulley) approx...................... m/min
Belt pretensioning......................................................................... kN
Calibration pressure of lifting cylinder for exact determination of
ballast........................................................................................... bar
Belt scraper
Model...................................................................................................
Belt drive (1.21)
Motor
Model...................................................................................................
Type of construction...........................................................................
Construction size................................................................................
Power............................................................................................. kW
Speed at supply frequency........................................................ min-1
Type of brake................................................................holding brake
.............................................................................................................
Soft starting unit......................................................................yes/no
Coupling
Type.........................................................................................flexible
Model...................................................................................................
Coupling
Type.........................................................................................flexible
Model...................................................................................................
Gear unit
Type.....................................................shaft-mounted spur gear unit
Belt stacker BS 3
Model...................................................................................................
4
Tripper carriage (2)

Height of the belt loop................................................................. mm
Centre distance of the travel carriages...................................... mm
Maximum gradient of the conveyor belt...........................................°
Travel carriage (5)

Located point end
Model...................................................................................................
Diameter of crane wheels........................................................... mm
Number of wheels...............................................................................
of which driven....................................................................................
number of open gearings....................................................................
Floating point end

Model...................................................................................................
Diameter of crane wheels........................................................... mm
Number of wheels...............................................................................
of which driven....................................................................................
number of open gearings....................................................................
Hand rail clamp (5.4)................................................................yes/no
Travel speed
Travel speed............................................................................. m/min
Transmission ratio of back gear....................................................1 :
Number of drive units.........................................................................
Travel drive
Motor (5.9)
Model...................................................................................................
Type of construction...........................................................................
Construction size................................................................................
Power............................................................................................. kW
Speed at supply frequency........................................................ min-1
Coupling (5.11)
Belt stacker BS 5
Type.........................................................................................flexible
Model...................................................................................................
Gear units (5.10)

Type....................................................................bevel spur gear unit
Model...................................................................................................
Number................................................................................................
General equipment (7)
Central lubrication system for individual lubrication points (optional extra). no

Model...................................................................................................
Number of lubrication points..............................................................
Tank volume..................................................................................litre
Lubrication time
(at least 1 x per machine startup).......minutes per 8 hrs. operation
Lifting device (7.10)

Design........................spindle lifting drive / hydraulic lifting system
Hydraulic lifting system

Maximum working pressure......................................................... bar
Volume of the tank...................................................................... litre
Hydraulic pump
Type.....................................................................................................
Model...................................................................................................
Delivery rate............................................................................. cm3/U
Motor power.................................................................................. kW
Hydraulic cylinder
Model...................................................................................................
Retracted length.......................................................................... mm
Extended length........................................................................... mm
Machine manual Safety
Belt stacker BS 1
2 Safety
NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.
Use
 Be sure to comply with the information concerning the
intended use of the machine in the section Technical data.
 Any use other than the intended use, such as the stacking of
bulk material which is too coarse and too moist, is forbidden.
ThyssenKrupp POLYSIUS AG is not responsible for damage
resulting from any use other than the intended use.
All other use is at the owner’s own risk.
 The intended use also includes observance of the instructions
in the machine manual and compliance with the maintenance
instructions.
Transport and assembly

 All transportation instructions in this machine manual refer
exclusively to transportation of the machine at the plant site.
 Only use suitable hoisting and lifting equipment which is in
serviceable order and has a sufficient load bearing capacity.
 Take special care with the transportation of gear units already
equipped with oil pumps and piping. Before transporting the
gear unit, remove the piping and close all pipe connections and
openings with weather and impact-proof sealing covers to
prevent ingress of foreign bodies.
 Never work under a suspended load.
Operation
 Do not make any changes (software) to programmable control
systems.
 Any safety checks before or during operation depend on the
relevant national regulations. The plant management is
responsible for the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, shut down the machine immediately.
Safety Machine manual
2 Belt stacker BS
Maintenance
 Ensure that all machines and motors whose operation might
endanger persons or equipment are switched off and
safeguarded against restarting for the entire duration of the
maintenance work.
 In the case of open-air storage facilities, close the hand rail
clamps on the travel carriages before starting any repair work.
 Ensure that all rotating parts of the machine have come to a
standstill before you remove protection devices or open flaps.
 Keep the machine free of oily and combustible substances and
materials. Never use gasoline or other easily inflammable
substances for cleaning the machine.
 Switch off the power supply to the electrical components
before commencing any maintenance work.
 Make sure that the pneumatic piping is relieved of pressure
before disconnecting it.
 Before carrying out work on the central lubrication system
with pneumatically operated barrel pump, you must disconnect
the barrel pump from the compressed air supply system.
 Make absolutely sure that the piping of the central lubrication
system has been relieved of pressure.
 The hydraulic system is specially designed for the delivered
machine and must not be used for other purposes without the
consent of ThyssenKrupp POLYSIUS AG.
 Use only hydraulic oil complying with the requirements in the
section Lubrication.
 Make sure that the hydraulic piping is depressurised before
disconnecting it.
 Never use the pumps of the hydraulic system for emptying or
filling the oil tank.
 If you drain hydraulic oil at operating temperature, you risk
scalding yourself.
 After all maintenance work, check that there are no leaks in
connecting points and connections.
 Strictly observe the welding instructions when performing any
welding work.
Machine manual Safety
Belt stacker BS 3
 If you carry out electrical welding on any part of the machine,

never conduct the welding current through plain or antifriction
bearings, other movable connections or measuring equipment.
Always directly connect the welding current return lead to the
part being welded.
 Remount all protection devices and properly close all
inspection and service covers when maintenance work has
been finished.
Machine manual Components and mode of functioning
Belt stacker BS 1
3 Components and mode of functioning

For the operation of a storage facility for bulk material (blending
bed) a stacker and a reclaimer are necessary.
The usual forms are belt stackers and bridge scrapers.
The reclaimer (bridge scraper) is not further described in this
machine manual.
The belt stacker can be operated according to the following
methods:
 Cone-shell stacking,
 Chevron stacking.
The essential functions are homogenisation of the bulk material
to be stored and formation of a bulk material buffer between the
feeding equipment and the material preparation process.
Homogenisation is achieved by reclaiming the bulk material
transverse to the stacking direction.
Components and mode of functioning Machine manual
2 Belt stacker BS
3.1 Components
NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract.
Main assemblies of the belt stacker
1 Belt conveyor boom

2 Tripper carriage
5 Travel carriage
7 General equipment
Belt stacker BS 3
Figure 1
4 Belt stacker BS
Items shown in the drawing of the belt conveyor boom (1)
1.1 Front section of belt conveyor boom

1.2 Middle section of belt conveyor boom
1.3 End section of belt conveyor boom
1.4 Walkway
1.5 Bar grate
1.6 Counterweight
1.7 Drive pulley
1.8 Drive pulleybearing
1.9 Snub pulley
1.10 Take-up pulley
1.11 Feed idler stand
1.12 Troughing idler stand
1.13 Return strand idler
1.14 Bracket for return strand idler stand
1.15 Rubber belt
1.16 Take-up station
1.17 Roof station
1.18 Belt scraper
1.19 Plough-type belt stripper
1.21 Conveyor belt drive
Belt stacker BS 5
Figure 2
6 Belt stacker BS
Items shown in the drawing of the tripper carriage (2)
2.1 Structural steelwork of the tripper carriage

2.2 Upper platform of the tripper carriage
2.3 Walkway
2.4 Discharge pulley
2.5 Deflection pulley
2.6 Holding-down roller
2.7 Troughing idler stand
2.8 Return strand idler
2.9 Belt scraper
2.10 Dirt deflector
2.11 Transfer hood with impact plate
2.12 Transfer chute
Belt stacker BS 7
Figure 3
8 Belt stacker BS
Items shown in the drawing of the travel carriages (5)
5.1 Drive bogie

5.2 Bogie
5.3 Link
5.4 Hand rail clamp
5.5 Track clearer
5.6 Buffer stop
5.7 Single wheel travel carriage
5.8 Travel drive (consists of items 5.9 to 5.11)
5.9 Motor
5.10 Coupling
5.11 Gear unit
Belt stacker BS 9
Figure 4
10 Belt stacker BS
Items shown in the drawing of the general equipment (7)
7.1 Bearing assembly of belt conveyor boom

7.2 Torque arm for belt drive
7.3 Belt skew monitoring switch
7.4 Rope pull emergency switch
7.5 Speed monitor
7.8 Probe on the belt conveyor boom tip
7.10 Lifting device
7.11 Travel distance switch
7.12 Cable drum
7.14 Central lubrication system
7.15 Control cabin
7.16 Travel distance pulse generator
Belt stacker BS 11
Figure 5
12 Belt stacker BS
Belt conveyor boom (1)

The belt conveyor boom is a welded, solid-web girder
construction and is used for transporting the bulk material to the
stockpile ridge.
Due to the structural statics, the boom conveyor is provided with
a rear drive unit. The feed idler stands (1.11) are located under
the rubber belt (1.15) in the area of the throw-off-end station.
The take-up station (1.16), where the belt tension is set by means
of threaded spindles, is located at the belt conveyor boom tip.
The belt scrapers are also located here (1.18). A roof station is
located in the lower strand to guide the belt.
Upstream of the snub pulley (1.9), which causes a belt wrap of
approx. 210° at the drive pulley, the plough-type belt stripper
(1.19) is installed for rejecting foreign bodies.
To allow maintenance of the mechanical equipment, there are
walkways (1.4) at both sides of the belt conveyor boom. The
vertical angular movement of the belt conveyor boom is effected
by a lifting device (7.10).
A counterweight (1.6) is located at the end of the belt conveyor
boom to compensate for unilateral masses and relieve the load
on the lifting device.
Tripper carriage (2)

The tripper carriage is a framework structure which carries the
conveying equipment for feeding the bulk material to the boom
conveyor belt. The bearing assembly is also located in the front
section of the belt conveyor boom (1).
The feeding conveyor belt is guided via troughing idler stands
(2.7) to the discharge pulley (2.4) and is then returned to the
conveyor framework of the feeding conveyor via two deflection
pulleys (2.5).
The equipment of the transfer station ensures that the bulk
material is safely transferred to the rubber belt (1.15) of the belt
conveyor boom (1). The belt scraper (2.9) for cleaning the feeding
conveyor belt is also located at this point.
Travel carriages (5)

The belt stacker is supported on 4 travel carriages. The drive
travel carriages are located under the bearing component of the
belt conveyor boom. The single wheel travel carriages (5.7) are
located under the rear end of the tripper carriage (2).
Belt stacker BS 13
Depending on the size of the belt stacker, and thus on the loading
of the individual track wheels, the drive travel carriages are
executed as single bogie or double bogie travel carriages. In the
case of the double bogie travel carriage, the loading is uniformly
distributed via a link (5.3) to two bogies (5.2).
Every drive travel carriage is provided with a travel drive. The
track wheels of a drive bogie (5.1) are driven via a pinion which is
mounted in the gearbox of the travel drive. The back gear formed
by the gear rims of the track wheels and the pinion is contained
in the bogie casing.
In the case of open-air storage facilities, every drive travel
carriage is equipped with a hand rail clamp (5.4). When the belt
stacker is shut down, the rail clamp secures it against any
movement caused by an external application of force, such as
wind.
On both sides of the belt stacker, the travel carriages are
equipped with flanged wheels. The wheel flanges ensure proper
lateral guidance of the belt stacker.
To compensate for expansion, one travel carriage group is pivot
mounted in the steel structure of the stacker.
Track clearers (5.5) are fitted in front of and behind each travel
carriage on the bogie casings or travel carriage casings to
remove foreign bodies from the rail while the belt stacker is
moving.
General equipment (7)

The general equipment comprises all components that ensure the
operation of the main assemblies.
3.2 Mode of functioning

Belt stackers are used as stacking machines in bulk material
storage facilities and blending beds.
These storage facilities mainly serve the following purposes:
 separation of the stacking and reclaiming cycles,
 homogenisation of the stored bulk material,
 formation of a material buffer store between the inward
conveying equipment (quarry) and the preparation process
(grinding plant).
14 Belt stacker BS
The most commonly used stacking methods are the cone-shell

stacking method and the chevron stacking method.
The cone-shell stacking method is mainly employed in stores with
several components, if side scrapers or portal scraper reclaimers
are being used for reclaiming the material.
The chevron stacking method is employed in blending beds if it is
necessary to achieve a homogenisation effect. Bridge scrapers
are mainly used for reclaiming the material in this case.
Cone-shell stacking method

The belt stacker is moved in local operating mode (manually by
the operator) up to the stockpile area which is to be stacked.
There are two possible modes of operation for the storage facility
machines. In the case of short stockpiles, it is only possible for
either the stacker or the reclaimer to work at any one time. In the
case of long stockpiles, it is possible for both machines to work
at the same time (mainly in coal stores).
For this mode of operation it is necessary for the collision
interlock system to be working on the basis of a travel
measurement and for the stacking and reclaiming to take place in
accordance with fixed rules.
This mode of operation minimises the storage space requirement.
To allow a stockpile area to be approached, the belt conveyor
boom has to be moved into the cross over position (highest
position). It is only possible for the stacker to travel over
stockpile boundaries if the belt conveyor boom is in this position.
At the same time, the reclaimer must enable passage of the
stacker, if it is to travel through the stockpile area where the
reclaimer is working.
The stacker reaches the selected area of the stockpile (any
desired position)
 Changeover to automatic operation (local or control room)
 Start-up warning
 Lowering of the belt conveyor boom from the cross over
position to the upper stacking position (only necessary in the
case of operation with portal scraper reclaimer)
 If the stockpile is not detected:
 Travel drives started in direction of starting cone
 Travel drives stopped if
the stockpile is detected or
Belt stacker BS 15
the starting cone position (start of stockpile) is reached.

 Boom conveyor belt started
 Inward conveying equipment enabled
 If the stockpile is detected:
 Travel drives started in direction of free space, until the belt
conveyor boom is free
 If the stockpile is not detected in the starting cone position:
 Lowering of the belt conveyor boom until the stockpile is
detected or the lower belt conveyor boom position is
reached.
When the stacked bulk material reaches the probe at the belt
conveyor boom tip, the boom is raised for a certain time. When
the upper position of the belt conveyor boom is reached and the
stacked material subsequently reaches the probe, the stacker
moves away from the stockpile until the boom is free. This
procedure is repeated until the stacker reaches the end of the
stacking area (stockpile end).
When the stacked bulk material now reaches the probe at the
belt conveyor boom tip, the message ”Stockpile full” is sent. The
material feeding (from the crusher) is then stopped and the
inward conveying equipment is emptied (enough space must still
be available for this material).
16 Belt stacker BS
Chevron stacking method

The belt stacker is moved in local operating mode (manually by
the operator) up to the stockpile area which is to be stacked.
 Changeover to automatic operation (local or control room)
 Start-up warning
 Boom conveyor belt started
 Inward conveying equipment started
Lowering of the belt conveyor boom until the stockpile is
detected or the lower boom position is reached. Travel carriages
started in any desired direction. The stacker moves to and fro
between the defined stockpile end points. A stockpile is thus
created. When the stacked bulk material reaches the probe at the
belt conveyor boom tip, the boom is raised for a set time. This
again creates space for a new layer.
When the boom has reached its upper position and the bulk
material reaches the probe, the stockpile is full. The material
feeding is then stopped and the inward conveying equipment is
emptied (enough space must still be available for this material).
Usually, the stacker travels between the end points of the
stockpile ridge when working by the chevron stacking method.
This produces conical superimposed layers at the stockpile ends.
In this end zone the homogenisation effect is therefore very
limited.
To improve the homogenisation effect, the following method is
applied at the cut face of the stockpile:
Stockpile stacking control system

When building up the lowest layer the travel carriages are not
stopped at the end point of the stockpile ridge, but the stacker
travels to the foot point of the stacked stockpile and then
reverses. This has the result that the bridge scraper already
encounters the material of this layer when making the first
reclaiming cut.
As the stockpile grows, the point at which the stacker reverses
moves back step by step along the slope, so that the shape of the
end cone is maintained.
Belt stacker BS 17
Figure 6
Machine manual Transport and assembly
Belt stacker BS 1
4 Transport and assembly
4.1 Transport and storage instructions

The machine is transported in individual parts or in
subassemblies. Make absolutely sure that suitable lifting
equipment is employed in removing the parts from the transport
vehicles and transferring them to the storage area.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against moisture, soiling and
damage. Never place the parts directly on the ground.
Make absolutely sure that motors, couplings, gear units and
measurement and control equipment are stored in well-ventilated
rooms and protected against moisture.
Gear units
Make absolutely certain that carrying ropes are only fastened at
the envisaged points.
Take special care with the transportation of gear units already
equipped with oil pumps and piping. Prior to any transportation,
remove the piping and close all sockets and openings with
weather and impact-proof sealing covers, to prevent ingress of
foreign bodies. Make sure that all sealing covers can be easily
removed.
4.2 Assembly
General notes
The following assembly instructions do not detail the individual
steps for assembling the units, but rather give an overview of the
work to be performed.
Changes in the planning of the plant during the processing of the
contract may lead to deviations from these assembly
instructions.
Transport and assembly Machine manual
2 Belt stacker BS
NOTE
It is a prerequisite of our warranty that final assembly and
assembly inspection are undertaken by an assembly specialist
from ThyssenKrupp POLYSIUS AG.
We recommend that the assembly work is supervised from start

to finish by specialists from ThyssenKrupp POLYSIUS AG.
Careful selection of tools and appliances used and of the
personnel is important for the correct execution of the assembly
work.
For assembly of the belt stacker, the assembly area must be
accessible with transport vehicles and motor cranes. The rails in
this area must be ready-laid, measured and capable of bearing
loads.
4.3 Assembly connections
Bolted connections
Depending on the design, the subassemblies are either welded
together or bolted together with highly pretensioned joints. To
bolt the parts together you must use torque wrenches, impact
screwdrivers or similar tightening devices. Be sure to comply
with the pretensioning forces or tightening torques stated below
unless other values are given on the drawings.
The following specifications apply to the data in the table:
 The specified values are applicable to standard threads
 Threads and contact surfaces are slightly oiled (no Molykote!)
 The slotted headless screws have a coefficient of friction of
µtotal = 0.14
 The specified values only apply to the property classes 8.8,
10.9 and 12.9.
Bolt Tightening torque (Nm) Pretensioning force (kN)

8.8 10.9 12.9 8.8 10.9 12.9
M 10 45 67 78 26 39 45
M 12 78 117 135 39 56 66
M 14 126 184 216 53 77 90
M 16 193 279 333 72 106 124
Belt stacker BS 3
M 18 270 387 459 91 129 151

M 20 387 558 648 117 166 194
M 22 522 747 873 146 208 243
M 24 666 954 1116 168 239 280
M 27 990 1395 1665 221 315 370
M 30 1350 1890 2250 270 385 450
Weld joints
CAUTION
If you carry out electrical welding on any part of the machine, never conduct
the welding current through plain or antifriction bearings, other moving
connecting elements or measuring equipment, in order to prevent damage
to such parts.
Always directly connect the welding current return lead to the part being
welded.
Inspection instructions for welds in steel structures
Scope
Unless any other written agreements are made, these inspection
instructions apply to all welds on blending beds of ThyssenKrupp
POLYSIUS AG and its subsidiaries.
These inspection instructions form an integral part of the
relevant design drawings and parts lists.
Standards
National or international standards which are equivalent to those
specified in these instructions may be used. (This is to be
considered in each individual case.)
Welding method
For the welding of steel structures for blending beds, only manual
arc-welding is permissible. It may be performed by hand or
automatically or semi-automatically with direct and alternating
current. Other welding methods are only permissible in
exceptional cases.
Filler rods and welding electrodes

4 Belt stacker BS
Filler rods and welding electrodes must be suitable for the base
metal in question and approved for the materials concerned by a
renowned classification authority (e.g. Germanischer Lloyd,
Norske Veritas or Deutsche Bundesbahn).
Weld execution
Welder qualification
The welders performing welding work must hold valid
certifications according to DIN 8560. The qualification
certificates must be valid for the qualification class of the
materials specified in the drawings and parts lists. As an
alternative, the welder’s qualification can be demonstrated by the
welding of test pieces in the presence of the responsible welding
supervisor of ThyssenKrupp POLYSIUS AG.
Cleaning the welding point before welding

The parts to be welded must be completely free from
contaminations, rust, roll scale, paint and slag.
Support of parts to be welded

The parts to be welded together must be so supported and held
that they can freely follow the shrinking process. After the
welding, the structures should have the shape shown in the
drawing without any additional treatment being necessary.
Belt stacker BS 5
Protection against climatic influences

All welding rods and welding electrodes as well as the
components must be completely dry during the welding. To
ensure good welding results, adequate measures must be taken
to protect the welders and welding areas against wind, rain, snow
etc. and in particular against cold. At air temperatures below 0 °C
at the workplace, all welding work has to be stopped. Only in
exceptional cases may this be ignored, provided ThyssenKrupp
POLYSIUS AG give their consent and provided special protective
measures (e.g. preheating) are taken.
Spatters and welding droplets

Special care must be taken that neither spatters nor welding
droplets come onto the structure. The arc may only be initiated at
points where welding beads are to be deposited. If the surface of
any load-bearing parts has been contaminated with spatter or
welding droplets in spite of all care, these must be ground off.
Rewelding is not permissible. It is permissible to prevent the
bonding of spatters and welding droplets by the use of prepared
chalk or other parting compounds in the vicinity of the welds. Any
weld beads and slag must be cleaned off the workpiece and
welds. Prior to the application of the prime coat, all welds and the
adjacent areas must be brushed clean.
Inspection
The purchaser’s inspectors, as well as any additional third party
inspectors must be granted access to the manufacture or welding
site at any time after prior notification.
On this basis, the purchaser’s quality control department must be
notified in due time of the individual inspection stages.
The supplier is obliged to provide all the equipment, tools and
qualified personnel required for the inspection.
Required quality of weld joints

All welds must be performed according to the quality classes
BS/BK of DIN 8563. The edge misalignment must not exceed the
maximum value of 2 mm.
6 Belt stacker BS
Non-destructive material testing
Ultrasonic testing
All butt welds must be subjected to ultrasonic testing.
Calibration of the ultrasonic test equipment

The testing is performed to the Distance-Gain-Size (DGS) method.
For calibration, standard reference blocks according to DIN 54120
and DIN 54122 respectively can be used.
The use of special calibration blocks which in material
composition and heat treatment correspond with the workpiece
is acceptable. To determine the equivalent flaw size,
DGS diagrams, as well as DGS scales can be used.
Requirements for the workpiece and test equipment

The properties of the test surfaces must be such that a proper
coupling of the test probes used is ensured.
The ultrasonic test is to be performed by the Impulse-Echo-
Method with angle probes. The use of a test frequency of 4 MHz is
preferred.
Testing by magnetic particle inspection

Additionally, all assembly weld seams must be subjected to a
magnetic particle test.
Test method
Magnetising must be by direct current saturation or, if burn marks
on finish-machined surfaces are anticipated, a magnetising yoke.
Only the wet process (fluorescent or black-white) is acceptable.
The intensity of the tangential field strength must be within the
range of 2000 to 3000 A/m. This value has to be checked with a
tangential field intensity meter.
Belt stacker BS 7
Permissibility of indications
Assessment of indications in ultrasonic testing

For inclusions and pores an equivalent flaw size of 4 mm í is
acceptable. For indications with longitudinal extension, the
product of the determined equivalent flaw size and the indication
length must not exceed the numerical surface value of 4 mm EFS
(12.6 mm2) and not be longer than 20 mm. With a series of indications, the sum
of the lengths of individual, acceptable indications may not exceed the numerical
value of the material thickness in a reference faulty weld length of 12 x the
material thickness.
Example:
Plate thickness 10 mm
Reference faulty weld length 12 x 10 mm = 120 mm
Faulty lengths found in this sector: 3 + 4 + 2 = 9 mm
Acceptable sum: 10 mm
With sequentially located discontinuities, the distance between
two adjacent indications must not be shorter than 6 (six) times
the length of the longest indication. Lack of fusion, root
imperfections and/or cracks are not permissible.
Assessment of indications in magnetic particle inspection

Cracks are not permissible.
Elimination of defects
If tests in accordance with sections Weld quality and
Permissibility of indications reveal unacceptable defects, you can
eliminate these by excavations with smooth transitions, as long
as the plate thickness in this area is not weakened by more than
5 %, or by deep excavations down to the sound base material with
subsequent repair welding.
It is always necessary to prove that the area to be welded is free
from defects by performing a magnetic particle test and/or dye
penetration test before starting the welding and also after
completing the repair work. After the repair welding, you must
inspect all areas subjected to weld repair by non-destructive
testing in accordance with sections Weld quality and Acceptance
criteria.
Welding diary
8 Belt stacker BS
The welding supervisor has to record the results of all random

tests performed during the welding work in a welding diary.
These records must state the names of the welders performing
the welding work and must include protocols of all interim tests
performed. ThyssenKrupp POLYSIUS AG must be notified
immediately of any deviations from the drawing specifications
and/or larger faults.
4.4 Sequence of assembly
Preassembly of the belt conveyor boom (1)

Preassemble the belt conveyor boom on the ground without the
counterweight (1.6) in accordance with the assembly drawing.
First weld together the structural steel members of the belt
conveyor boom. During the subsequent assembly of the idler
stands for the upper and lower strands of the boom conveyor belt,
make sure that the stands are positioned at right-angles to the
longitudinal axis of the boom. In the case of the stands for the
upper strand, be sure to observe the marking of the direction of
conveyance on the stands. After you have mounted the tension
bearing, you can install all the pulleys. When mounting the
pulleys, make sure that they are positioned at right angles to the
boom axis. Also align the pulleys horizontally.
The rubber belt is supplied in open form and must be closed by
vulcanisation to form an endless loop. Knowledge or prior training
in this bonding technique are absolutely essential, as the
operating reliability of a belt conveyor largely depends on the
quality of its belt joint. If no plant personnel possess this
knowledge, the above-described bonding of the belt ends to form
a closed loop must be carried out by a special company.
Fit the plough-type belt stripper (1.19) into the structural
steelwork of the boom before mounting the rubber belt (1.16).
Final adjustment of the belt tension is not possible until the belt
stacker is operating under load conditions (see section Test run).
After fitting the rubber belt, adjust the plough-type scraper (1.19)
to ensure proper functioning and then mount the belt scraper
(1.18) on the tension bearing.
Mount the feed guide with cover on the belt conveyor boom; it
forms the lower part of the transfer station.
Belt stacker BS 9
Figure 7
A = direction of conveyance
B = direction of conveyance indication mark
10 Belt stacker BS
Further assembly
The arrangement of the side scraper is shown in the installation
drawing.
WARNING
Platforms, walkways and supporting structure are only designed for
maintenance work. They could collapse under heavy loads.
You could be seriously injured.
Never use platforms, walkways and supporting structures as auxiliary
mounting supports or storage areas for heavy parts.
Make absolutely sure that personnel only go on the platforms and walkways
to perform maintenance work.
 Place the travel carriages on the rails of the belt stacker

before mounting the tripper carriage.
 All travel carriages must be aligned parallel to the rails. The
travel carriages at the side of the belt stacker facing the
stockpile must be so placed on the rails that the clearance
between the wheel flanges and the rail head is identical on
both sides of the rail.
 The arrangement of the side scraper is shown in the
installation drawing.
 Use mounting supports to set the structural steelwork of the
tripper carriage on the travel carriage and to facilitate the
bolting together and alignment.
 Mount the bearing assembly of the belt conveyor boom (7.1) on
the belt conveyor boom and lift the assembled component into
the tripper carriage (2). After aligning the belt conveyor boom
(1), you can weld the bearing assembly of the belt conveyor
boom to the structural steelwork of the tripper carriage (2.1).
 To support the belt conveyor boom, install a scaffold under the
boom tip.
 After placing the tripper carriage and the bearing component
of the belt conveyor boom on the travel carriages, recheck the
alignment and correct if necessary.
After precisely aligning the travel carriages, in the case of
open-air storage facilities, mount the hand rail clamps (5.4) on
the drive bogies. The hand rail clamps are equipped with
different brake shoes in accordance with the respective rail
type.
Finally, mount the track clearers (5.5) on all the travel
carriages.
Belt stacker BS 11
 After mounting the walkways on the tripper carriage, you can

install the remaining troughing idler stands. When mounting
the troughing idler stands, make absolutely sure that they are
positioned at right angles to the axis of the tripper carriage
and observe the indication marks for the direction of
conveyance.
12 Belt stacker BS
 When mounting the discharge pulley (2.4), the deflection

pulley (2.5), the holding-down roller (2.6) and the return strand
idler, make absolutely sure that they are aligned horizontally
and are positioned at right angles to the axis of the tripper
carriage.
 After installing the feeding conveyor belt, mount the belt
scraper (2.9), the dirt deflector (2.10) and the transfer hood
(2.11) with impact plate.
 Attach the belt drive unit (1.21) to the drive pulley journal via
the hollow shaft. Mount the torque arm (7.2) in accordance
with the drawing and adjust its length. Be sure to carry out all
actions concerning the gear unit, motor and brake in
accordance with the manufacturer’s instructions.
 Using the adapter flange of the gear unit, bolt the travel drive
(5.8) onto the travel carriage casing.
 Before carrying out the direction of rotation tests of the
motors, fill the prescribed lubricants into the drive units.
Assembly of the general equipment (7)

 Install the control cabin (7.15) in accordance with the
information provided in the drawings and the manufacturer’s
instructions. Weld the base frame onto the structural
steelwork of the tripper carriage.
 Install the central lubrication systems in accordance with the
manufacturer’s instructions. You must fill the piping with
grease before starting the final assembly.
NOTE
Make absolutely sure that the lubricant distributors are
mounted in full conformity with the manufacturer’s
instructions. There must be no blockage of any of the outlets,
as this would destroy the overall functionality of this
component! Ensure maximum cleanliness during assembly;
the distributors are extremely sensitive to dirt.
 Install the safety devices such as rope pull emergency

switches, belt skew monitoring switches, speed monitors etc.
Belt stacker BS 13

The lifting device is a hydraulic lifting system with a hydraulic
cylinder. Install the hydraulic cylinder between the tripper
carriage and the belt conveyor boom (1) in such a way that the
movement takes place over the entire stroke distance without
tilting.
WARNING
If you fill too much ballast into the counterweight, the belt conveyor boom
may tip to the wrong side.
The belt conveyor boom could injure or kill somebody.
Secure the belt conveyor boom by attaching a safety rope to the tip of the
boom.
Installation of the hydraulic lifting system and calibration of the

belt conveyor boom
 Assemble the hydraulic cylinder and the associated hydraulic
system. Connect the hydraulic system and the hydraulic
cylinder by means of the provided hoses and hydraulic piping.
Cleanliness during assembly is an important prerequisite for
problem-free operation!
 Mount the counterweight (1.6) on the belt conveyor boom (1)
without balancing weights.
 Put the hydraulic system into operation in accordance with
the manufacturer’s instructions.
(For quantity and type of lubricant, see the section Lubrication
in this machine manual.)
 The belt conveyor boom is calibrated by adding additional load
ballast plates or balancing weights to the counterweight. A
pressure measuring device at the hydraulic cylinder of the
hydraulic lifting system informs you about the balancing
weight required for adjustment of the set calibration pressure
in the hydraulic cylinder (see section Technical data in this
machine manual). The aim of the calibration is to keep the
partly loaded belt conveyor boom in horizontal position while
the hydraulic cylinder is unloaded.
Machine manual Lubrication
Belt stacker BS 1
5 Lubrication
NOTE
The ThyssenKrupp POLYSIUS table of lubricants with the
lubricant reference numbers is contained in the supplement
Important notes on the documentation . The supplement is
contained in this folder or at the beginning of the overall
documentation. Each lubricant has a unique reference number
to which the lubrication instructions in this section relate. The
table gives a complete list of all suppliers and products
approved by ThyssenKrupp POLYSIUS AG.
It is the responsibility of the lubricant supplier to select
appropriate lubricants corresponding to the lubricant reference
numbers. ThyssenKrupp POLYSIUS AG accepts no liability for
the correctness of these data.
If you wish to use a lubricant that is not included in the table of
lubricants, you have to first obtain the express permission of
ThyssenKrupp POLYSIUS AG.
The supplement Important notes on the documentation also
contains the generally valid notes on lubrication.
CAUTION
Ensure that the environment is not polluted when lubricants are stored,
used and disposed of and carefully observe the relevant national
legislation for the protection of the environment when handling lubricants.
NOTE
The following lubrication points are supplied with lubricant by the
central lubrication system:
 Drive pulley bearings

 Snub pulley bearings
 Take-up pulley bearings
 Belt conveyor boom bearing
 Deflection pulley of the tripper carriage
 Shackle toggle joints of the lifting device
 All wheel bearings of the travel carriages
Lubrication Machine manual
2 Belt stacker BS
Lubrication chart
Figure 8
Machine manual Lubrication
Belt stacker BS 3
Lubrication points Quantity (l, Lubrication intervals

kg) per (weeks)
lubrication
point
No. Qty Designation Lubricant Initial Topping First Further First Further
. ref. no. filling up topping topping change change
up up s
1 1 Drive unit for boom see manufacturer’s instructions

conveyor
[1]
2 Drive unit for travel see manufacturer’s instructions
carriage, located point
end
[1]
3 Drive unit for travel see manufacturer’s instructions
carriage, floating point
end
[4]
10 2 Drive pulley bearings 50 2.0 0.05 12 25
[4]
11 2 Snub pulley bearings 50 0.7 0.035 12 25
12 2 Take-up pulley bearings 50 1.0 0.035 12 25

[4]
13 6 Deflection pulley 50 0.7 0.035 12 25

bearings [4]
14 2 Holding-down roller 50 0.7 0.035 30 50

bearings [4]
[1] [4]
39 Crane wheel 50 3.0 0.1 8 16
[1]
40 Back gear of driven 92 0.3 as 8 16
track wheels [3] require
d
45 1 Hydraulic lifting system see manufacturer’s instructions
46 2 Shackle toggle joints of 50 0.03 0.02 8 16

hydraulic cylinder [4]
[4]
47 2 Boom bearing 50 0.03 0.02 8 16
56 1 Central lubrication 50 see Technical data, whether installed - top up as

system [2] necessary
58 1 Cable drum see manufacturer’s instructions
The different makes of lubricant corresponding to the lubricant reference numbers are shown in the table
Lubrication Machine manual
4 Belt stacker BS
of lubricants in the supplement Important notes on the documentation. The supplement is to be found in
this folder or at the beginning of the overall documentation.
Explanation of the numbers

[1]
For quantity see Technical data.
[2]
Weekly check of lubricant reservoir; top up at the latest when the Min. indication is reached.
[3]
Apply adhesive lubricant by hand, as required.
[4]
Is supplied by the central lubrication system, item 56, if this is installed (see Technical data).
Machine manual Preparation for the test run
Belt stacker BS 1
6 Preparation for the test run
NOTE
It is a prerequisite of our warranty that the first test run is
carried out in the presence of specialists from ThyssenKrupp
POLYSIUS AG and in accordance with their instructions.
6.1 Checks prior to the test run

After completion of the assembly work and prior to the first test
run, check all parts of the plant according to the list below. Take
particular care that all material remnants, tools and assembly
aids are removed.
 Have the track rails been laid in accordance with the rail-
laying instructions and have all bolted connections been
properly tightened?
 Are the hand rail clamps (5.4) open and is the monitoring
system in order?
(Only installed in the case of open-air storage facilities.)
 Has a check for proper functioning been carried out for
 Rope pull emergency switch (7.4)
 Belt skew monitoring switch (7.3)
 Speed monitor (7.5)
 Limit switches
 Emergency-off button
 Has the rubber belt conveyor (1.15) of the boom been
sufficiently tensioned?
For the belt pretensioning see section Technical data.
 Have all the protection devices been mounted?
 Have all lubrication points been supplied with lubricant in
accordance with the lubrication instructions in the section
Lubrication?
 Has the central lubrication system (7.14) been installed in
accordance with the manufacturer’s instructions and checked
for correct functioning?
 Have all drive units and couplings been mounted and set
according to the manufacturer’s instructions?
Preparation for the test run Machine manual
2 Belt stacker BS
 Has the direction of rotation check been carried out for all
motors?
 Have all platforms, ladders and protection devices been
properly mounted?
 Has crushed material with a grain size smaller than 80 mm
been placed in the blending bed below the scraping level of
the chain scraper?
Machine manual Preparation for the test run
Belt stacker BS 3
6.2 Setting and adjustment
NOTE
The end of the tripper carriage goes down under load.
Make sure that the end of the tripper carriage does not rub
against the conveyor framework of the feeding conveyor belt.
Belt stacker
At the first start-up, give a short switching pulse that makes the
rubber belt run for just a few metres. To ascertain correct
running, distribute personnel on the unit either within sight and
hearing of each other or equipped with radio telephones.
If skewing is ascertained, start the correction measures
upstream of the point of skewing, looking in the direction of
running.
The belt run can be influenced by the alignment of the take-up or
return pulleys, as well as the idlers. This correction is only
possible if the belt stacker is in operation. Only then can the
effect of the performed measure be observed.
If the skewing already starts at the take-up pulley, bring this into
the correct position by loosening or tightening the lateral
tightening spindle.
The rubber belt follows the reduction in tension, that is, it will run
to the pulley edge which has moved back due to the loosening of
the spindle.
If the skewing starts further down along the belt length, reset the
belt tracking by adjusting the idlers. This is made possible by the
adjustable mounting of the troughing idler stands (1.12). Pay just
as much attention to the lower strand as to the upper strand. The
troughing idler stand which causes the skewing is usually the
second or third before the point at which the skewing of the
rubber belt actually starts.
 Pull belt over - shift idler side against the run direction.
 Push belt over - shift idler side in the run direction.
This aligning work is another of those cases where only care and
patience can really help. You should only move 3 to 4 troughing
idler stands at the same time and then observe the effect. Mark
these troughing idler stands so that they can later be identified
more easily. The most important prerequisite for straight belt
running during operation is centric feeding of the material to be
conveyed.
Preparation for the test run Machine manual
4 Belt stacker BS

Lift the boom into its topmost position, which is stated in the
assembly drawing. Set the top limit switch for this position.
Proceed identically for its lowest position. If a lifting spindle is
installed as the lifting device, mount the emergency limit
switches directly after the height limiters.
Adjust the probe for limiting the height of the stockpile in
accordance with the manufacturer’s instruction so that with the
belt conveyor boom at maximum height the foot of the stockpile
reaches the dimensions defined in the assembly drawing. These
adjustments can only be carried out during operation with bulk
material.
Machine manual Maintenance
Belt stacker BS 1
7 Maintenance
7.1 Inspection
DANGER
The belt stacker could move.
There is danger of being crushed.
In the case of open-air storage facilities, close the hand rail clamps on the
travel carriages before starting any repair work.
Maintenance Machine manual
2 Belt stacker BS
No. Work to be performed Frequency Comments
1 Check the belt scrapers (1.18 and weekly

2.9) for correct contact and for wear
2 Check the take-up station (1.16) for weekly

soiling
3 Check for abnormal daily

noises,temperature, grease loss,
wear and caking at
 drive pulley (1.7)
 take-up pulley (1.10)
 snub pulley (1.9)
 discharge pulley (2.4)
 return pulleys (2.5)
 holding-down roller (2.6)
4 Check the idler stands daily

(1.11, 1.12, 1.13, 2.7 and 2.8)
for abnormal noises and for proper
functioning
5 Check the rubber belt (1.15) for daily

 straight running
 damage
 tension
6 Checking the plough-type belt daily

stripper (1.19) for wear and for
correct functioning
7 Check the seal at the feed guide of daily

the transfer chute (2.12) for wear
8 Check the chute lining and the monthly

impact plate in the transfer chute
(2.12) for wear
9 Inspection work on the drive units monthly in accordance

with the
manufacturer’s
instructions
10 Inspection work at the lifting device weekly in accordance

(7.10) with the
Belt stacker BS 3
manufacturer’s
instructions
11 Inspection work on the cable drums in accordance

(7.12 and 7.13) with the
manufacturer’s
instructions
12 Check the alignment of the travel weekly

carriages (5) and proper functioning
of the track clearers (5.5)
7.2 Servicing
WARNING
Make absolutely sure that personnel only go on the platforms and walkways
to perform maintenance work.

1 Belt scraper (1.18 and 2.9) as required
 Adjust
 Replace worn-out parts
2 Clean the take-up station (1.16) as required

3 Replace faulty bearings and seals at as required
 drive pulley (1.7)
 take-up pulley (1.10)
 snub pulley (1.9)
 discharge pulley (2.4)
 return pulleys (2.5)
 holding-down roller (2.6)
4 Replace faulty idlers at the idler as required
4 Belt stacker BS

stands
(1.11, 1.12, 1.13, 2.7 and 2.8)
5 Rubber belt (1.15) as required
 Repair any damage
6 Plough-type belt stripper (1.19) as required

 Readjust rubber strip; replace if necessary
7 Feed guide of the transfer chute as required

(2.12)
 Readjust the seal; replace if necessary
8 Pulleys with friction lining as required

 Remove cakings
 Replace worn-out pulleys
9 Transfer chute (2.12) as required
 Replace chute lining or impact plate
10 Maintenance work on the drive units in accordance

with the
manufacturer’s
instructions
11 Maintenance work on the lifting in accordance
device (7.10) with the
manufacturer’s
instructions
12 Maintenance work on the cable in accordance
drums with the
(7.12 and 7.13) manufacturer’s
instructions
13 Travel carriages (5) as required
 Repair the track clearers (5.5) or replace
them if necessary
Belt stacker BS 5
7.3 Trouble shooting

The most important functions of the belt stacker are monitored
during operation. If there are problems with these functions, an
alarm is activated and/or the unit is stopped.
Fault Cause Elimination

Material caking on Insufficient cleaning of Readjust the belt scraper
the pulleys the rubber belt (1.15) and/or plough-type belt
stripper;
if necessary replace the
scraper bars.
Skewing of the belt Material caking on the Readjust the belt scraper
pulleys and/or plough-type belt
stripper;
if necessary replace the
scraper bars.
Take-up pulley (1.10) Align the take-up pulley.

wrongly set
Only one side of the belt Readjust the impact plate
is carrying material in the transfer chute (2.12).
Drive pulley (1.7) Align the drive pulley.
wrongly set
Rubber belt (1.15) faulty Repair faulty area in rubber
belt.
Several idler stands are Align the roller stations.
not at right angles to
the direction of running
Snub pulley (1.9) Align the snub pulley.
wrongly set
Belt conveyor boom Inadequate belt tension Retension the rubber belt
Indication: (1.15)
Speed monitor (7.5) by means of the take-up
pulley (1.10).
Slipping clutch in the Replace the friction lining
drive unit is or the springs.
continuously slipping (see manufacturer’s
instructions)
6 Belt stacker BS
Belt conveyor boom Fault in the control Check the control system.
Indication: system (see documentation of the
Collision protection control system)
switch (7.9) responds Faulty brake motors in Check the brake motors.
the travel drive (see manufacturer’s
instructions)
If faults occur that are not described above, additional

information regarding the causes and eliminations of faults can
be found in the subsuppliers’ documentation.
Belt stacker BS 7
7.4 Repair
DANGER
The belt stacker could move.
There is danger of being crushed.
In the case of open-air storage facilities, close the hand rail clamps on the
travel carriages before starting any repair work.
If damage is observed during checks, you must repair the

damaged parts or replace them with new parts.
Before performing any repair work, switch off the power supply to
all electrical components.
Ensure the utmost cleanliness at all times during the repair work
in order to prevent dirt from entering the bearings, the drive
system, the hydraulic system or other sensitive parts of the
machine or plant.
WARNING
Replacing the tips of the belt scraper (1.18)

 Unscrew the set screw for the contact pressure.
 Unscrew the fixing bolts of the tips, remove the old tips and fit
new tips.
 Manually tighten the fixing screws and align the front edge of
the tips.
 Adjust the set screw for the contact pressure so that the
contact pressure per tip
at 150 mm tip width is 4 to 5 kg;
at 200 mm tip width is 6 to 7 kg.
Replacing the idlers

 Lift the rubber belt (1.15) slightly
 Remove the idlers from their brackets
8 Belt stacker BS
 Install new idlers

Belt stacker BS 9
WARNING
The hydraulic piping is subjected to a high system pressure.
If oil spurts out, it may injure you or cause a fire.
Be sure to depressurise the hydraulic system first via the lead-sealed
pressure valves, and then tighten the leaky connections and pipe unions.
Be sure to comply with the manufacturer’s instructions whenever

you carry out repair work on the drive units, the lifting device, the
cable drums and the central lubrication system.
For other repair work on the belt stacker, e.g. the replacement of
wearing parts, no special notes are necessary.
The drawings supplied under the contract, as listed in section 9.1
Technical drawings contain all the information required by trained
specialist personnel.
CAUTION
After you have completed the repair work, you must check the
machine/plant again according to the section Preparation for the test run.
Tools and auxiliary devices

No special tools are required for repair work on the belt stacker.
It is sufficient to have large torque wrenches and the tools
normally available in a well-equipped tool box.
Whether or not you need auxiliary equipment, (e.g. scaffolds or
hoists) depends on the conditions in your plant.
Machine manual Spare parts
Belt stacker BS 1
8 Spare parts
Suggestions for enquiries and orders of spare parts

Dear Customer,
ThyssenKrupp POLYSIUS AG want to make spare part enquiries
and spare part order placement as easy and efficient as possible.
For this purpose we have prepared a table containing all data
required by our spare parts department to ensure optimum
processing in the most speedy and trouble-free manner.
Please copy the title page and the page with the table. Fill in the
columns Quantity and Unit. Please mark those parts which you
require with a cross in the column Order or Enquiry. Send the title
page together with the table to the Spare Parts Department of
ThyssenKrupp POLYSIUS AG.
If the table relates to more than one machine, please also inform
us of the POLYSIUS Order Code (POC) of the machine for which
you require the spare parts.
Spare parts Machine manual
2 Belt stacker BS
Figure 9
Belt stacker BS 3
Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry
1.7 Drive pulley with piece
rubber lagging and shaft
1.8 Drive pulley bearing piece
1.8.1 Pedestal bearing housing piece
1.8.2 V-seal piece
1.8.3 V-seal with splash plate piece
1.8.4 Self-aligning roller bearing with piece
clamping sleeve
1.8.5 Fixed ring piece
1.9 Snub pulley with piece
rubber lagging and shaft
1.9.1 Axle bearing piece
1.10 Take-up pulley with shaft piece
1.10.1 Axle bearing piece
1.11 Feed idler stand 45° piece
1.11.1 Feed idler piece
1.12 Troughing idler stand 45° piece
1.12.1 Idler piece
1.13.1 Return strand idler with piece
rubber lagging
1.13.2 Return strand idler with piece
supporting rings
1.17.1 Idler (roof station) piece
1.15 Rubber belt piece
1.16.1 Tightening spindle with nut piece
1.18 Belt scraper see manufacturer’s documentation
1.19.1 Scraper piece
NOTE
For conveyor belt drive (1.21), see manufacturer’s documentation
4 Belt stacker BS
Figure 10
Belt stacker BS 5
2.4 Discharge pulley piece
2.5 Return pulley piece
2.6 Holding-down roller piece
2.7 Troughing idler stand, piece

complete
2.8 Return strand idler piece
2.9 Belt scraper see manufacturer’s documentation
2.11.1 Baffle plate with piece

mounting material
2.12 Transfer chute, complete piece
2.12.1 Wear protection, complete set
2.12.2 Slewing chute piece
2.12.3 Rubber cloth piece
2.12.4 Seal set
2.12.5 Seal set
2.12.6 Seal set

6 Belt stacker BS
Figure 11
Belt stacker BS 7
5.4.1 Y-flanged bearing piece
5.4.2 Brake shoes set
5.5.1 Graphite bar piece
5.12.1 Pivoting bearing, complete piece
5.14 Crane wheel, complete piece
5.14.1 Carrier with cover and piece

mounting material
5.14.2 Gear rim with piece

mounting material
5.14.3 Self-aligning roller bearing piece
5.14.4 Shaft seal ring piece
5.14.5 Spacer ring piece
5.14.6 Bush piece
5.15 Crane wheel, complete piece
5.15.1 Carrier with cover and piece

mounting material
5.15.2 Self-aligning roller bearing piece
5.15.3 Shaft seal ring piece
5.15.4 Spacer ring piece
5.15.5 Bush piece
5.16 Self-aligning roller bearing, piece

complete
5.16.1 Axial spherical plain bearing piece
5.16.2 V-ring piece

8 Belt stacker BS
NOTE
For travel drive (5.8), see manufacturer’s documentation
Belt stacker BS 9
Figure 12
10 Belt stacker BS
7.3 Belt skew monitoring switch see manufacturer’s documentation
7.4.1 Rope pull emergency switch, piece

complete
(tripper carriage)
7.4.2 Rope pull emergency switch, piece

complete
(belt conveyor boom)
7.5 Speed monitor see manufacturer’s documentation
7.8 Probe on the belt conveyor see manufacturer’s documentation

boom tip
7.10 Lifting device see manufacturer’s documentation
7.11 Travel distance switch see manufacturer’s documentation
7.14 Central lubrication system see manufacturer’s documentation
7.16 Travel distance pulse see manufacturer’s documentation

generator
NOTE
For the cable drum (7.12) and the control cabin (7.15) see
manufacturer’s documentation
Belt stacker BS 11
Figure 13
7.1 Bearing assembly of the belt set

conveyor boom, complete
7.1.1 Pivoting bearing block piece
7.1.2 Axle with mounting material piece
7.1.3 Pivoting bearing - fixed bearing piece

end
7.1.4 Pivoting bearing - floating piece

bearing end
Machine manual Appendix
Belt stacker BS 1
9 Appendix
9.1 Technical drawings
NOTE
For drawing numbers, please refer to the table of contents of
this folder.
Designation Drawing no.
Belt stacker BS
Belt conveyor boom
Tripper carriage
Feed guide
Travel carriage – located point end
Travel carriage – floating point end
General equipment
9.2 Subsuppliers’ documentation
Travel drive
Boom conveyor belt drive
Hydraulic lifting system
Central lubrication system

Belt Stacker BS

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Belt Stacker BS

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Machine manual

POLYSIUS Order Code (POC)

1 Technical data......................................................................................... 1-1

Information on the intended use

Belt conveyor boom (1)

Belt drive (1.21)

Soft starting unit......................................................................yes/no

Tripper carriage (2)

Travel carriage (5)

Floating point end

Hand rail clamp (5.4)................................................................yes/no

Gear units (5.10)

General equipment (7)

Central lubrication system for individual lubrication points (optional extra). no

Lifting device (7.10)

Hydraulic lifting system

Transport and assembly

 If you carry out electrical welding on any part of the machine,

3 Components and mode of functioning

Main assemblies of the belt stacker

1 Belt conveyor boom

Items shown in the drawing of the belt conveyor boom (1)

1.1 Front section of belt conveyor boom

Items shown in the drawing of the tripper carriage (2)

2.1 Structural steelwork of the tripper carriage

Items shown in the drawing of the travel carriages (5)

5.1 Drive bogie

Items shown in the drawing of the general equipment (7)

7.1 Bearing assembly of belt conveyor boom

Belt conveyor boom (1)

Tripper carriage (2)

Travel carriages (5)

General equipment (7)

3.2 Mode of functioning

The most commonly used stacking methods are the cone-shell

Cone-shell stacking method

the starting cone position (start of stockpile) is reached.

Chevron stacking method

Stockpile stacking control system

4 Transport and assembly

4.1 Transport and storage instructions

We recommend that the assembly work is supervised from start

4.3 Assembly connections

Bolt Tightening torque (Nm) Pretensioning force (kN)

M 18 270 387 459 91 129 151

Inspection instructions for welds in steel structures

Filler rods and welding electrodes

Cleaning the welding point before welding

Support of parts to be welded

Protection against climatic influences

Spatters and welding droplets

Required quality of weld joints

Non-destructive material testing

Calibration of the ultrasonic test equipment

Requirements for the workpiece and test equipment

Testing by magnetic particle inspection

Assessment of indications in ultrasonic testing

Assessment of indications in magnetic particle inspection

The welding supervisor has to record the results of all random

4.4 Sequence of assembly

Preassembly of the belt conveyor boom (1)

 Place the travel carriages on the rails of the belt stacker

 After mounting the walkways on the tripper carriage, you can