As A s s emb em b l y and an d Oper Op erat atii n g Ins In s t r u c t i o n s Discha Disch arge rg e belt GSSF 2000 x 47.7 Shougang Hierro II Shougang Hierro Hierro S.A.A. S.A.A. San San Juan J uan de d e Marco Marcona, na, Peru Peru 2-492-20980 Year Year of manufacture 2013 2013
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
Revision evisio n l evel evel
Revision status 0
Dat e 11.11.2013 28.11.2013
Ch an g es Original created (German) Translation from the original
Mad e b y Ritterbecks Ritterbecks
1 2 3 4
ThyssenKrupp Resource Technologies GmbH P.O. Box 1463 – D - 59306 Ennigerloh Schleebergstraße 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)
0 v e R 3 1 0 2 / 1 1
Table bl e of Conte Cont ents nt s 1
2
3
0 v e R 3 1 0 2 / 1 1
4
User's User's guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 1 1.1
Us er g r o u p s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 1
1.2
St r u c t u r e o f t h e s af et y n o t es - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 2
1.3
Def i n i t i o n s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 2
1.4
Gen er al i n f o r m at i o n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3
1.5
L i ab i l i t y an an d w ar r an t y - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 3
1.6
Co p y r i g h t - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4
1.7
Tec h n i c al m o d i f i c at i o n s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4
1.8
S t o c k i n g o f s p ar e p ar t s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4
Technical Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 1 2.1
Di s c h ar g e c o n v ey o r (1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 1
2.2
Dr i v e u n i t (2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 2
2.3
B el t w ei g h er (3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 2
2.4
Met al d et ec t o r (4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 2
2.5
Saf et y d ev i c es - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 4
Genera Generall safety safety notes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 1 3.1
Pr i n c i p l es - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 1
3.2
Mo d i f i c at i o n s an an d sp sp ar e p ar t s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 2
3.3
Per s o n n el - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 -3 - 2
3.4
No i s e h azar d - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 2
3.5
Infor nforma mati tion on rega regardi rding ng resi residu dua al risk risks s duri during ng dail daily y ope opera rati tion on - - - - - - - - - - - - - - - - - -3 - 3
3.6
F i r e p r o t ec t i o n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 3
3.7
Di sp sp os os al al of of co co ns ns um um ab ab le les an an d p ro ro ce ces s m at at er er ia ial s - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 4
Design Design and operating operating principle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4 - 1 4.1
Sc op op e o f ap pl pl ic ic at at io io n an d d es es ig ig na nat ed ed us us e - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 1
4.2
Mai n c o m p o n en t s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4 - 2 2-492-20980 (Item 02)
IVZ - 1
5
TOC - 2
4.3
Op er at i n g p r i n c i p l e - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 4
4.4
Dr i v e - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 6
Transport, Transport, storage storage and and assembly assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1 5.1
Tr an s p o r t in in s t r u c t i o n s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1
5.2
Ho is is ti ti ng ng de dev i ce ces an an d s lili ng ng in in g eq ui ui pm pm en en t - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3
5.2.1 5.2.1
Liftin Lifting g gear gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3
5.2.2 5.2.2
Liftin Lifting g - - - - - -- - - -- - - -- - - -- - - -- - -- - - -- - - -- - - -- - - -- - -- - - -- - -- - - -- - -- 5 - 3
5.2.3 5.2.3
Liftin Lifting g ropes ropes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 6
5.2.4 5.2.4
Wire rope clamps clamps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 8
5.2.5 5.2.5
Liftin Lifting g chain chains s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 10
5.2.6 5.2.6
Hook Hook - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 11
5.2.7 5.2.7
Screw-t Screw-type ype lift lifting ing eyes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 11
5.2.8 5.2.8
Shackle Shackles s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 13
5.2.9 5.2.9
Slingin Slinging g equip equipmen mentt and load load protec protectio tion n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 15
5.2.10 5.2.10
Substru Substructu ctures res for loads loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 16
5.3
St o r ag e r eq u i r em en t s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 17
5.3.1 5.3.1
General General requir requireme ements nts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 17
5.3.2 5.3.2
Storage Storage facilit facilities ies & other other detail details s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 18
5.3.3 5.3.3
Special Special require requiremen ments ts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 20
5.4
In s t al l at i o n pl pl an n i n g - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 23
5.5
Pr ep ar at i o n fo fo r in in s t al l at i o n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 24
5.6
Del i v er y p ar t s an d w ei g h t s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 26
5.7
Gen er al al i n fo fo r ma mat i o n o n as s em b ly ly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 27
5.8
Mo u n t b el t c o n v ey o r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29
5.8.1 5.8.1
Assemb Assemblin ling g the the conve conveyor yor frame frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29
5.8.2 5.8.2
Assembl Assemble e idler idler support supports s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 30
5.8.3 5.8.3
Assemb Assemblin ling g the idler idler suppo supports rts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32 32
5.8.4 5.8.4
Assemb Assemblin ling g the the mater material ial guide guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.8.5 5.8.5
Assembl Assembling ing the ploughplough-typ type e scrape scraperr - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33
5.8.6 5.8.6
Assemb Assemblin ling g the the front front scraper scrapers s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34
5.8.7 5.8.7
Assembl Assembling ing the drive drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 35
5.8.8 5.8.8
Assembl Assembling ing the resist resistanc ance e thermo thermomet meter er - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 36
2-492-20980 (Item 02)
0 v e R 3 1 0 2 / 1 1
5.9 6
7
0 v e R 3 1 0 2 / 1 1
A ss ss em em bl bl in in g an d t en en si si on on in in g t he he c on on ve vey or or be bel t - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 38
Commissioning and and operation operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 1 6.1
Gen er al i n f o r m at i o n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1
6.2
Op er at o r t r ai n i n g - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1
6.3
Saf et y n o t es f o r o p er at i o n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 1
6.4
T es t r u n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 3
6.5
Co m m i s s i o n i n g u n d er l o ad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 5
6.5.1 6.5.1
Before Before init initial ial commis commissio sionin ning g - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 5
6.5.2
Mis alig nm ent - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6
6.5.3
Af ter in it ial co mm is si on in g - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6
6.6
Sh u t t i n g d o w n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6
6.6.1 6.6.1
Normal Normal operati operation on - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6
6.6.2 6.6.2
Emergenc Emergency-s y-stop top syst system em - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 6
6.6.3 6.6.3
Pull-rop Pull-rope e emerge emergency ncy switch switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 7
Maintena Maintenance nce - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 1 7.1
Im po po rt rt an an t i nf nf or or ma mat io io n o n m ai ai nt nt en en an an ce ce - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 1
7.1.1 7.1.1
Notes Notes on on clean cleaning ing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 3
7.1.2 7.1.2
Informa Informatio tion n on mainten maintenanc ance e and and inspe inspecti ction on - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 4
7.1.3 7.1.3
Notes Notes rela relatin ting g to repai repairs rs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 5
7.2
Mai n t en an c e an d i n s p ec t i o n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 6
7.2.1 7.2.1
Mainten Maintenanc ance e inter interval vals s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 8
7.2.2 7.2.2
Drive Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 10 10
7.2.3 7.2.3
Bearing Bearings s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 10
7.2.4 7.2.4
Convey Conveyor or belt belt/te /tensi nsioni oning ng devi device ce - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 11 11
7.2. 7.2.5 5
Wear Wear part parts s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 12 12
7.3
Rep ai r s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 14
7.3.1 7.3.1
Replac Replaceme ement nt of the tension tensioning ing pulley pulley with with C-hoo C-hooks ks - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 14 14
7.3.2 7.3.2
Replac Replacing ing the tension tensioning ing pulley pulley with with a C-hoo C-hook k - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 16 16
7.3.3 7.3.3
Replac Replacing ing the drivin driving g pulle pulley y - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 22
7.3.4 7.3.4
Convey Conveyor or belt belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 24
7.3.5 7.3.5
Carryi Carrying ng idle idlers rs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 26 26
7.3.6 7.3.6
Front Front scrape scraperr - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 27
7.3.7 7.3.7
PloughPlough-type type scrape scraperr - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 28
7.3.8 7.3.8
Materia Materiall guidin guiding g mecha mechanis nism m and and feedi feeding ng shoe shoe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 29
2-492-20980 (Item 02)
IVZ - 3
8
9
7.3.9 7.3.9
Pull-r Pull-rope ope emerge emergency ncy switch switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 30
7.3.10 7.3.10
Belt Belt track tracking ing switch switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 31
7.3.11 7.3.11
Monito Monitorin ring g of the the torque torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 32
7.3.12 7.3.12
Belt Belt break break monit monitori oring ng - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 33 33
7.4
B ea ear i n gs gs w i t h ad ap te ter s l ee eev es - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 34
7.5
Sc r ew ed an d b ol ol t ed c o nn nn ec t io io n s
7.5.1 7.5.1
Machine Machine struct structures ures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 39
7.5.2 7.5.2
High-ten High-tensil sile e bolte bolted d joints joints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 40
Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 1 8.1
In tr tr od od uc uc ti ti on on an d t ec ec hn hn ic ic al al i ns ns t ru ru ct ct io io ns ns - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 1
8.2
St o r ag e o f l u b r i c an t s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3
8.3
Gen er al al in in f o rm rm at at i o n on o n lu lu br br ic ic at i o n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3
8.3.1 8.3.1
Oil groups groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3
8.3.2
Lu br ic ant li nes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 4
8.3.3 8.3.3
Open Open toothe toothed d gears gears - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 5
8.4
Tab l e o f lu lu b r i c an t s (I (In d ex 8) 8) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 6
8.4.1 8.4.1
Standar Standard d lubri lubrican cants ts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 6
8.4.2 8.4.2
Special Special lubric lubricant ants s - -- - -- - -- -- - -- -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - 8 -9
8.5
L u b r i c at i n g i n s t r u c t i o n s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 12
ANNEX ANNEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 - 1 9.1
Dr aw i n g s
9.2
Dr i v e u n i t
9.3
Dr i v i ng ng pu p u l l ey an an d t en s i on on i ng ng pu p u l l ey
9.4
B el el t w ei ei gh gh er er wi w i th th ev ev al ua uat io io n el ec ec tr tr on on ic ic s
9.5
Sc r ap er s B 6C
9.6
Hy dr dr au au lili c c yl yl in in de der EN ENERPA C CL LL-508
9.7
Hy d r au l i c h an d p u m p
9.8
TOC - 4
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 39
0 v e R 3 1 0 2 / 1 1
Saf et y d ev i c es
2-492-20980 (Item 02)
1
Us er ' s g u i d e 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
Us er g r o u p s 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. 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.
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
1-1
1.2
St r u c t u r e o f t h e s af et y n o t es The safety notes in the Assembly and Operating Instructions are highlighted as follows:
SIGNAL WORD Type and and sou rce of danger Possible consequence(s) of non-observance. • Measur Measure(s) e(s) for for preven preventio tion n of the dange danger. r. The following table shows the classification and significance of the signal words for safety notes.
Pi c t o g r am
Si g n al w o r d
Si g n i f i c an c e
Co n s eq u en c es o f n o n observance
DANGER
Imminent danger
Death or severe bodily injuries
WARNING
Possible danger
Death or severe bodily injuries
CAUTION
Possible danger
Minor bodily injuries
CAUTION
Poss Possib ible le pro prope perrty dam damag age e
Dama Damage ge to the the mach machin ine e / plan plantt or its environment
INFORMATION
Useful information or tip: Simplifies the handling
!
! General danger
!
Special dang er, e.g. e.g. electrocution
1.3
1-2
Def i n i t i o n s 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)
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1.4
Gen er al i n f o r m at i o n 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 informatio n 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
L i ab i l i t y an d wa war r an t y ThyssenKrupp Resource Technologies explicitly exclude all liability and warranty claims for damage or operational malfunctions originating from: •
Non-co Non-compl mplian iance ce with with instru instructi ctions ons in the the Assem Assembly bly and Operati Operating ng Inst Instruct ruction ions s
•
Incorrect operation
•
Any Any use use of the the mac machi hine ne othe otherr tha than n the the spec specif ifie ied d use use
•
Faulty ma maintenance
•
Use of cons consumab umables les (in partic particula ularr lubri lubrican cants) ts) not explic explicitl itly y permi permitte tted d by the manufacturer
•
Use Use of spar spare e par parts ts not appr approv oved ed by the manu manufa factu cture rer r
•
Conv Conver ersi sion ons s and and modif modific icati ation ons s not not approv approved ed by by the the manu manufac factu turer rer..
In addition, the conditions for liability and warranty as specified in the General Conditions of Supply of ThyssenKrupp Resource Technologies are applicable. 0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
1-3
1.6
Co p y r i g h t 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
Tec h n i c al mo m o d i f i c at i o n s 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
St o c k i n g o f s p ar e p ar t s
CAUTION The use of non-origin al spare parts Damage to the machine/plant or its environment is possible • Only use use original original spare spare parts that are approved approved by ThyssenKr ThyssenKrupp upp 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. Our warranty only covers genuine spare parts supplied by us. 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)
0 v e R 3 1 0 2 / 1 1
2
Tec h n i c al d at a 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
Di s c h ar g e c o n v ey o r (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
Figure 1
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2-492-20980 (Item 02)
2-1
2.2
2.3
Dr i v e u n i t (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
Moun Mounti ting ng posi positi tion on - Drive rive::
Conv Convey eyin ing g dire direct ctiion RIGHT
B e l t w e i g h e r ( 3)
Model: Working temperature:
- 40 + 80°C
Accuracy:
+/- 0,03%
Weight recorded:
hermetic sealed, temperature-compensating strain gauges
Evaluation electronics:
2.4
Met al d et ec t o r (4)
Model: Interface:
RS 485 for remote control or PLC via Profibus 0 v e R 3 1 0 2 / 1 1
2-2
2-492-20980 (Item 02)
Figure 1
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2-492-20980 (Item 02)
2-3
2.5
Saf et y d ev i c es
(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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Figure 2
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3
Gen er al s af et y n o t es
3.1
Pr i n c i p l es •
The machine machine/pl /plant ant has been manufac manufactur tured ed in accorda accordance nce with with the the recog recognis nised ed safe safety ty 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 These safe safety ty inst instruc ructio tions ns must must be obser observed ved by all all perso persons ns respons responsibl ible e for for the 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 mach machine ine// plant plant may may only only be used used in in techni technical cally ly perfe perfect ct cond conditi ition on in in accord accordance ance 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 addi addition tion to the the manu manual, al, observ observe e and and instr instruct uct the user user in all other other gene generall rally y applicable legal and other mandatory regulations relevant to accident prevention and environmental protection!
•
These These comp compuls ulsory ory regula regulatio tions ns may also also deal deal with with the the hand handlin ling g of of hazar hazardou dous s substances, issuing and/or wearing personal protective equipment (safety helmet, safety boots, safety goggles, hearing protection, respiratory protection).
•
Observ Observe e all all safet safety y instr instruct uctions ions and warnin warnings gs attac attached hed to the the mach machine ine// plant! plant!
•
Ensure Ensure that that safety safety inst instruc ructio tions ns and and warni warnings ngs attach attached ed to to the the machi machine/ ne/pla plant nt are are always complete and perfectly legible!
•
In the the even eventt of safety safety-rel -releva evant nt modi modific ficati ations ons or chan changes ges in the the beha behaviou viourr of the machine/ plant during operation, stop the machine/ plant immediately and report the malfunction to the responsible department!
•
Never Never make make any modifica modificatio tions, ns, additi additions ons or conv convers ersions ions to the the mach machine ine// plant plant which 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.
•
Replac Replace e hydra hydrauli ulic c hoses hoses within within at approp appropria riate te inter interval vals s even even ifif no safe safetyty-rel relevan evantt defects have been detected!
•
Comply Comply with with the prescr prescribe ibed d interv intervals als or those those speci specifie fied d in the the opera operatin ting g instru instructi ctions ons for routine checks and inspections!
•
For the executio execution n of mainten maintenanc ance e work, work, tools tools and and works workshop hop equipm equipment ent adapted adapted to the task on hand are absolutely indispensable.
•
The pers personn onnel el must must be famil familiar iar with with the the locat location ion and oper operati ation on of fire fire extin extinguis guishers hers!!
•
Obse Observ rve e all all firefire-wa warn rnin ing g and and firefire-fi figh ghti ting ng proce procedu dure res! s!
2-492-20980 (Item 02)
3-1
3.2
3.3
3.4
Mo d i f i c at i o n s an d s p ar e p ar t s •
For safe safety ty reas reasons ons,, conver conversio sions ns and and modi modific ficatio ations ns are are proh prohibi ibited ted unless unless previou previously sly approved by ThyssenKrupp Resource Technologies.
•
Use of access accessorie ories s and and spare spare parts parts not not appro approved ved by Thys Thyssen senKrup Krupp p Reso Resourc urce e Technologies can lead to unforeseeable dangers.
Pe r s o n n e l •
Personne Personnell entrus entrusted ted with with work work on on the the machin machine/ e/ plan plantt must must have have read read the manual manual and 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 For rea reaso sons ns of secu securi rity ty,, lon long g hai hairr mus mustt be be tied tied back or otherwise secured, garments must be close-fitting and no jewellery - such as rings - may be worn. I njury may result from being caught up in the machinery or from rings catching on moving parts.
•
Use protect protective ive equipm equipment ent wherev wherever er requ require ired d by the circum circumsta stance nces s or by law! law!
•
Any work work on and with with the the machi machine/p ne/plan lantt may may only only be be carri carried ed out out by by relia reliable ble personnel. Statutory minimum age limits must be observed!
•
Employ Employ only only trained trained or inst instruc ructed ted staff staff and and set set out out clea clearly rly the indivi individua duall responsibilities of the personnel for operation, set-up, maintenance and repair!
•
Define Define the the machi machine ne operat operator's or's respon responsib sibili ilitie ties s - also also with with rega regard rd to obse observi rving ng traff traffic ic regulations - giving the operator the authority to refuse to carry out instructions by third parties which compromise safety!
•
Work on the the elec electri trical cal system system and equipm equipment ent of the the mach machine ine/pla /plant nt may may only only be carried out by a skilled electrician or by instructed person s under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.
•
Work on the the hydr hydraul aulic ic syst system em must must be carri carried ed out out only only by perso personne nnell with with speci special al knowledge and experience of hydraulic equipment!
No i s e h azar d Information Information on the emissions level level which is specific to the work station 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 main tenance and checking, control station) immediately after commissioning.
3-2
2-492-20980 (Item 02)
0 v e R 3 1 0 2 / 1 1
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
Infor nforma mati tion on rega regard rdin ing g re r esidu sidua al ris r isks ks duri during ng dail daily y 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
3.6
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–
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 crus hing procedure, the material discharge.
Fi r e p r o t ec t i o n •
The legal legal require requirement ments s regard regarding ing fire fire protec protectio tion n and and fire fire prev prevent ention ion have 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 Appoint supe supervi rvisor sors s who are in charg charge e of all all the the matters matters related related to fire fire preve preventi ntion on and 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 supe supervi rvisor sor must must check check the the fire fire extingu extinguish ishing ing equi equipme pment nt at regula regularr interv intervals als,, 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 persons commis commissio sioned ned with with supervi supervision sion and fire fightin fighting g must must have have atten attended ded a first aid course. First aid stations must be provided.
•
The fire fire protec protectio tion n regula regulatio tions ns must must be be poste posted d at diff differe erent nt loca locatio tions ns in in the the plant. plant.
•
The pers personn onnel el must must be be informe informed d about about the the fire fire prote protecti ction on measur measures. es. Any case case of fire fire must be reported immediately.
•
The units units and and the the asse assembl mbly y group groups s which which heat heat up more more stron strongly gly during during operati operation on on 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 fire extin extingui guishe shers rs must must be easi easily ly acce accessi ssible ble and may not be obstr obstruct ucted ed by 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-f fire-figh ighting ting water water for for burni burning ng wood wood,, waste waste,, fabric fabric,, jute, jute, paper, paper, belt belts, s, etc. etc.
•
In case case of burn burning ing liqu liquids ids (min (mineral eral oil, oil, petrol petrol,, oil, oil, petrole petroleum, um, pain paints, ts, tar, tar, etc. etc.), ), alway always s use CO2 extinguishers and powder type fire extinguishers.
•
In case case of of burni burning ng cable cables, s, moto motors, rs, elec electri tric c plant plants, s, etc. etc. only only use use powd powder er type type fire fire extinguishers or CO 2fire extinguishers.
Dispo isposa sall of of con consu suma mabl ble es and and proc proce ess mate materi ria als •
The safe safe and and enviro environme nment-f nt-frie riendl ndly y disp disposa osall of of all all cons consuma umable bles s and and proces process s materials should be ensured. You should also make sure that all respective national regulations for the protection of the environment are complied with.
0 v e R 3 1 0 2 / 1 1
3-4
2-492-20980 (Item 02)
4
Des i g n an d o p er at i n g p r i n c i p l e
4.1
Sc op op e o f ap pl pl ic ic at io io n an d d es es i gn gn at at ed u se se
DANGER Risk of inju ry thro ugh operating the machine/plant machine/plant with unauthorised unauthorised modifications, conversions or spare parts parts Imminent danger of death or severe bodily injuries • ThyssenKrupp ThyssenKrupp Resource Resource Technolo Technologies gies explicitl explicitly y excludes excludes all liabilit liability y and warranty claims if modifications/conversions are made without the express permission in writing of the manufacturer. • Only operate operate the machine/p machine/plant lant in its original original conditio condition. n. Any deviations deviations from from the original condition must be reported by the operator to the responsible department.
CAUTION System damage thro ugh use of the machine/plant contr ary to its design ated us e 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/pla machine/plant nt must be used used exclusively exclusively for for the intended intended purpose purpose agreed agreed upon with the manufacturer. • Observe Observe the the Assembl Assembly y and and Operating Operating Instructions. Instructions. Prior to the use of the machine/ plant beyond this scope of application, consult the aftersales service. Otherwise the warranty will lapse. 0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
4-1
4.2
Mai n c o m p o n en t s See Figure 3 Conveyor frame, 4-part with supports and carrying idler( 1)
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)
2
3
4
5
6
7
8
9
Impact rollers
(10) 10)
Transfer rollers
(11) 11)
Hold-down rollers
(12) 12)
Return rollers
(13) 13)
Feeding shoe
(14) 14)
Material guiding
(15) 15)
Cover with injection system
( 16) 16)
Plow-type scraper
(17) 17)
Pre-scraper
(18) 18)
Belt weigher
(19)
Needle slide
(20) 20)
Chute
(21) 21)
10
11
12
13
14
15
16
17
18
19
20
21
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Figure 3
2-492-20980 (Item 02)
4-3
4.3
Op er at i n g p r i n c i p l e The ore broken by the crusher passes through the needle slide (21) on the tr ansfer chute (20) to the discharge conveyor. The feeding shoe (14 ( 14)) is used to guide and steady the material. The conveyor belt (8 ( 8) of the belt conveyor runs on carrying idlers ( 9-13) 13) which are fastened to the conveyor frame with mounting brackets. The conveyor belt is guided by the driving pulley (5 (5) and the tensioning pulley (7 ( 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 ( 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). 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. The material guiding strips (15) attached above the conveyor belt prevents material from falling off the sides of the conveyor belt.
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Figure 3
2-492-20980 (Item 02)
4-5
4.4
Dr i v e 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 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. The drive is fastened on a base frame and connected to the conveyor frame with a torque support (2).
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Tr an s p o r t , s t o r ag e an d as s em b l y
5.1
Tr an s p o r t in in s t r u c t i o n s The machine/plant is transported in component parts or as assembly groups. Make sure that suitable lifting tackle is used to unload the part s 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. The transport and storage symbols on the machine packaging must be heeded.
0 v e R 3 1 0 2 / 1 1
Ke K eep 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 o f the machine/plant machine/plant Imminent danger of death or severe bodily injuries • Only transport transport the the machine/plant machine/plant on on the designated designated slinging slinging devices devices (lugs) (lugs) and slinging points. • The fastening fastening of of loads and the instruction instruction of crane operator operators s should only be entrusted to experienced persons! The marshaller must be within eyesight of the operator or have verbal communication with him. • Make Make sure to use proper proper trans transport portati ation on equipme equipment. nt. • Do not not walk walk unde underr suspe suspended nded loads. loads. • Secure Secure moveab moveable le compone components nts..
CAUTION System damage from improper transport of the machine/plant Damage to the machine/plant or its environment is possible • Do not attach attach any additiona additionall slinging slinging points points to the machine machine through through welding, welding, torching or drilling (notching effects and the corresponding risk of crack formation). • Do not push push together together the side walls walls or the attachment attachment parts parts of the the machine machine by pulling lifting gear at an angle! • If transport transport securing securing devices devices have been been furnished furnished do do not remove remove them until installation has been completed.
Check all components for transport damage after delivery to the site.
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2-492-20980 (Item 02)
5.2
Ho is is t in in g d ev ev i ce ces an d s l in in gi gi ng ng eq ui ui pm pm en en t
WARNING Risk of injury thro ugh components that are improperly improperly secured during installation Death or severe bodily injuries are possible • Make sure that that moveable moveable components components are are properly properly secured secured during installa installation tion
5.2.1
L i f t i n g g ear 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.
•
Befo Before re lif lifti ting ng,, dete determ rmin ine e the the weig weight ht of of the the load load..
•
Determ Determine ine the the size size and and shape shape of of the load; load; two two criter criteria ia which which determi determine ne the the follow following ing:: – the type of load securing, e. g. with slings, baskets or slings with special fixtures,
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– the slinging slinging equipment / load securing fixtures, e. g. lifting rope, lifting chain, screw screw eyes, yokes (see following chapters), – the load angle of the slinging equipment. •
Determ Determine ine the thickn thickness ess of the the slin slingin ging g equipm equipment ent to be be used. used. Do not not exce exceed ed the the permissible load bearing capacity of the slinging equipment.
2-492-20980 (Item 02)
5-3
•
If any any of of the the follo followin wing g point points s are are unclea unclear, r, cons consult ult the assemb assembly ly super supervis visor or responsible: – correct attachment method, – selected thickness of slinging equipment, – type of slinging equipment.
•
Check Check the the sling slinging ing equipme equipment nt for for damage damage / faults faults.. Make Make sure sure that that any any faulty faulty slingi slinging ng equipment is discarded immediately.
•
Do not not overl overload oad slingi slinging ng equip equipmen mentt and and protec protectt it agai against nst sharp sharp corn corners ers and and edge edges s of the load e. g. through edge/corner protection made of sacking or metal, boards etc.
•
Protect Protect high-g high-glos loss/f s/fini inishe shed d surfac surfaces es of of the the load load against against damage damage caused caused by the 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 When att attac achin hing g sli sling ngin ing g equ equipm ipment ent at great great heigh heights: ts: – 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 After attach attaching ing the slingi slinging ng equi equipme pment, nt, tigh tighten ten it as far as poss possibl ible e by hand. hand. If 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 Give the the cran crane e driv driver er fix fixed/ ed/ag agre reed ed cle clear ar sign signal als s for mov movin ing g the loa load. d.
Before lifting the load:
5-4
•
Remo Remove ve any any mat mater eria iall lyi lying ng loos loosel ely y on on the the loa load. d.
•
Secure Secure unuse unused d rope/c rope/chai hain n ends, ends, e. g. g. by hookin hooking g them them to to the the main main ring ring/co /colle llecti cting ng them in the shackle.
•
Inst Instru ruct ct staf stafff to leav leave e the the haz hazar ard d area area..
•
Chec Check k that that the the loa load d is secu secure red d symm symmet etri rica call lly y at all all poin points ts..
•
Make Make sure sure that that the slingi slinging ng equi equipme pment nt canno cannott damag damage e the the load load (and (and vice vice versa versa). ).
2-492-20980 (Item 02)
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Af ter th e weigh wei gh t of o f the t he l oad has been pi ck ed u p co mp let ely by th e li ft in g tack t ack le and an d the load has been lifted a little: •
Check the load brake.
•
Chec Check k aga again in whet whethe herr the the load load is secu secure red d at at all all poin points ts..
•
Trans Transpo port rt the load load over over free free area areas s as as far far as poss possib ible le..
•
Warni Warning ng sig signal nals s must must be be given given if ther there e is any anyon one e in the the haz hazar ard d zone zone..
Setting the load down: •
Set the the load load down down slowly slowly on a respect respective ively ly stur sturdy dy base. base. Align Align the the base base again again before before the load is set down.
•
Remo Remove ve sli sling nging ing equi equipm pmen entt from from the the loa load d and and check check both both for for dam damag age. e.
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2-492-20980 (Item 02)
5-5
5.2.3
L i f t i n g r o p es 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 Effectiveness of the load angle L o ad an g l e
L o ad b ear i n g capacity
max. permissi permissi ble 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 – General wear – High and low temperatures – Vibration – Corrosion
5-6
2-492-20980 (Item 02)
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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 Protect liftin lifting g ropes ropes from from the infl influen uences ces of the the weathe weather, r, solv solvent ents, s, high high tempera temperature tures s and chemicals.
•
Avoid Avoid knots knots forming forming in wire wire rope ropes. s. In In the event event of of a knot, knot, do not not use use the the rope rope again. again.
•
Protect Protect ropes ropes agai against nst sharp-e sharp-edge dged d corne corners rs by by enlar enlarging ging the corner corner radius radius.. This This can can be by means of metallic corner protection devices or blocks. Sacking and wooden boards can also be used.
•
The correc correctt proce procedur dure e for for secur securing ing liftin lifting g ropes ropes to the the hook hook is as as follo follows: ws: – 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 Never wind wind the wire wire rope rope comp complet letely ely around around the crane crane hook hook (i. e. by by 360 360 degre degrees) es).. The low bending radius would damage the rope.
•
Check the the lilifting ropes for: for: – broken or cut strands, – rust and corrosion, – knots and kinked spots, – damaged eyes
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2-492-20980 (Item 02)
5-7
5.2.4
•
Do not not ben bend d the the eyes eyes of lift liftin ing g rop ropes es over over corn corners ers..
•
When securi securing ng loads loads by by windin winding g the the lifti lifting ng ropes ropes around around the load, load, use use shack shackles les (1). (1).
Wi r e r o p e c l am p s 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. Ro p e d i am et er
Di am et er o f t h e c l am p i n g yoke
Di st st an an ce ce be bet we ween c lili ps ps
Req ui ui re red m in in im im um um number of clips
In c h es
mm
In c h es
mm
In c h e s
mm
3/16
4,76
11/32
8,73
3
76
2
1/4
6,35
7/16
11,11
3-1/4
83
2
5/16
7,94
1/2
12,70
3-1/4
83
2
3/8
9,53
9/16
14,29
4
102
2
7/16
11,11
5/8
15,88
4-1/2
114
2
1/2
12,70
11/16
17,46
5
127
3
5-8
2-492-20980 (Item 02)
0 v e R 3 1 0 2 / 1 1
Ro p e d i am et er
Di am et er o f t h e c l am p i ng ng yoke
Di st st an an c e b et et we ween c lili ps ps
Req ui ui re red m in in im im um um number of clips
I n c h es
mm
In c h es
mm
In c h e s
mm
5/8
15,88
3/4
19,05
5-3/4
146
3
3/4
19,05
7/8
22,23
6-3/4
172
4
7/8
22,23
1
25,40
8
203
4
1
25,40
1-1/8
28,58
8-3/4
222
4
1-1/8
28,58
1-1/4
31,75
9-3/4
248
5
1-1/4
31,75
1-5/16
36,51
10-3/4
273
5
1-3/8
34,93
1-1/2
38,10
11-1/2
292
6
1-1/2
38,10
1-23/32
43,66
12-1/2
318
6
1-5/8
41,28
1-3/4
44,45
13-1/4
337
6
1-3/4
44,45
1-15/16
49,21
14-1/2
368
7
2
50,80
2-1/8
53,98
16-1/2
419
8
2-1/4
57,15
2-5/8
66,68
16-1/2
419
8
2-1/2
63,50
2-7/8
69,85
17-3/4
451
8
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
5-9
5.2.5
L i f t i n g c h ai n s 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 Avoid knots knots forming forming in lifti lifting ng chai chains. ns. They They weaken weaken the chai chain n strand strand and can lead lead to deformation or other damage to the chain links.
•
Shorten Shorten lifti lifting ng chai chains ns by by hooki hooking ng them them back back into into the chain chain or or into into the the main main line line with with the aid of a gripper hook. Never shorten a chain by twisting, knotting or through bolts.
•
Protect Protect lift lifting ing chains chains agains againstt sharp sharp corne corners rs and and edges edges that that could could defo deform rm the the chai chain n links. Use suitable flexible boards or metallic corner protection devices.
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5 - 10
2-492-20980 (Item 02)
•
If the the chain chain for for lifti lifting ng opera operation tion is to be woun wound d around around the the load load to be lifte lifted, d, alway always s turn 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 lilifting ch chains fo 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 all the the stra strands nds of a lifting lifting chain chain can can be be hooke hooked d back back into into the main main line, line, the permissible load bearing capacity of the whole sling can be increased by 50 %.
Ho o k The load bearing capacity is usually stamped into the hook. •
5.2.7 0 v e R 3 1 0 2 / 1 1
If possi possible, ble, use a hook hook with with spri spring-l ng-load oaded ed snap snap-in -in locking locking devi devices ces.. If such such hook hooks s are are not available, the hook has to be secured temporarily as shown in the diagram.
Sc re rew -t -t yp yp e l i ft ft in in g ey es es The size of screw-type lifting eyes is determined in relatio n 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 vertic vertical al lift lifting ing operat operation ion,, use use simple simple screwscrew-typ type e eyes eyes (wit (withou houtt shoul shoulder der). ).
•
Screw-t Screw-type ype eyes eyes with with shou shoulde lderr are are used used when when loads loads are are to be lift lifted ed at at certai certain n angle angles s (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 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:
Sh an k d i am et er
Ver t i c al l i f t i n g operation
Tension at 60° to the should er level
Tension at 45° to the should er level
Tension at 90° or loose side pull
p er er s cr cr ew ew -t -t yp yp e ey e
p er er s cr cr ew ew -t -t yp yp e ey e
p er er s cr cr ew ew -t -t yp yp e ey e
p er er s cr cr ew ew -t -t yp yp e ey e
In c h es
mm
Po u n d s
kg
Po u n d s
kg
Po u n d s
kg
Po u n d s
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
1
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
2
50,8
23000
10433
3300
1497
2100
953
2300
1043
2-1/2
63,5
37000
16783
6000
2722
3500
1724
4300
1950
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5 - 12
2-492-20980 (Item 02)
Eyes must be screwed in completely to prevent the shank becoming bent.
5.2.8
•
Use Use scre screww-ty type pe eyes eyes of a suit suitab able le size size..
•
Chec Check k the the cond condit itio ion n of of the the thre thread ad to make make sure sure the 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 Only use screwscrew-type type eyes eyes the load load bearin bearing g capaci capacity ty of of which which is is suitab suitable le for for the load, load, i. e. shanks with threads that fit exactly in standard boring holes.
•
Check Check shanks shanks of the the scre screw-t w-type ype eyes eyes for for deforma deformatio tion n or or crack crack formati formation. on.
•
Use harden hardened ed wash washers ers to to make make sure sure the edges edges of of the the screw screw-ty -type pe eye eye are are a tight tight fit. fit. The washers must not be thicker than two threads.
Sh ac k l es
DANGER Danger Danger caused through th e use of impr oper slingi ng equipment Imminent danger of death or severe bodily injuries Danger of breaking! • Never replace replace shackle bolts by conventional conven tional bolts. Danger
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2-492-20980 (Item 02)
5 - 13
Shackles are closed safety devices that cannot be hooked out. Their size is d etermined 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 left of the diagram) and chain load shackles (on the right).
Di am et er
•
Do not not exp expos ose e the the main main par partt of the the shac shackl kle e to side side ten tensi sile le loa loads ds..
•
Ensu Ensure re the the sha shack ckle le bolt bolt is a per perfe fect ct fit. fit.
•
The permi permissi ssible ble load load for for anchor anchor load load and chain chain load load shackl shackles es as as well well as as for for screw screw-type or socket pin is always the same.
•
If shac shackle kles s are are used used at at load load angl angles es other other than than 90°, 90°, the the permi permissi ssible ble load load bearin bearing g capacity is reduced; see table:
S i n g l e s h ac k l e vertical
Tw o s ha hac kl kl es es 60°
Tw o s ha hac kl kl es 45°
Tw o s ha hac kl kl es es 30°
In c h es
mm
A m er i c . tonnes
t o n n es
A m er i c . tonnes
t o n n es
A m er i c . tonnes
t o n n es
A m er i c . 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
1
0,9
¾
0,7
1/2
0,5
3/8
9,5
3/4
0,7
1-1/4
1,1
1
0,9
3/4
0,7
7/16
11,1
1
0,9
1-3/4
1,6
1-1/2
1,4
1
0,9
1/2
12,7
1-1/2
1,4
2-1/2
2,3
2
1,8
1-1/2
1,4
5/8
15,9
2
1,8
3-3/4
3,4
3
2,7
2
1,8
3/4
19,3
3
2,7
5-1/2
5
4-1/2
4,1
3
2,7
7/8
22,2
4
3
6
7
6
3
5-1/2
5
1
25,4
5-1/2
5
10
9
8
7,2
6
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
8
7,2
14
12,7
12
10,8
8
7,2
5 - 14
2-492-20980 (Item 02)
0 v e R 3 1 0 2 / 1 1
Di am et er
Si n g l e s h ac k l e vertical
Tw o s ha hac kl kl es es 60°
Tw o s ha hac kl kl es es 45°
Tw o s ha hac kl kl es es 30°
In c h es
mm
A m er i c . tonnes
t o n n es
A m er i c . tonnes
t o n n es
A m er i c . tonnes
t o n n es
A m er i c . tonnes
tonnes
1-3/8
24,9
10
9
17
15,4
14
12,7
10
9
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
2
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
3
76,2
80
45,3
87
78,8
71
64.4
50
45,3
4
101,6
100
90,7
173
156,9
142
128,7
100
90,7
5.2.9
Sling lingin ing g equ equip ipme ment nt and loa load pro prote tect ctio ion n •
Protect Protect lifting lifting ropes ropes agai against nst sharp sharp edge edges/c s/corn orners. ers. Use materi materials als to enla enlarge rge the radius, e. g. metallic corner protection devices (left and righ t), belts, wooden blocks, sacking, steel bushings/sleeves. This protects finished load surfaces from the wire rope too.
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
5 - 15
•
5.2.10
5 - 16
Protect Protect lift lifting ing chains chains agains againstt sharp sharp edge edges/c s/corne orners. rs. Use Use mate materia rials ls to to enlarg enlarge e the radius, e. g. metallic corner protection devices (left and r ight), belts, wooden blocks, sacking, steel bushings/sleeves. This protects finished load surfaces from the chain too.
Substr ubstruc uctu ture res s for for loa loads •
Make Make sure sure that that the base has a sturdy sturdy and level level surfa surface ce and and can can bear bear the whole whole weight of the load. Only use hard wood with (approx.) square cross-section as a base.
•
Protect Protect fini finishe shed d surfa surfaces ces by cushi cushioni oning ng the the base base,, e. g. with with sack sacking ing,, pressb pressboar oard, d, belts.
•
Use wedges wedges to prev prevent ent the load load rolli rolling ng away away or movi moving ng (e. (e. g. handle handles, s, roun round d forged forged parts and rings). When using wedges be car eful with your hands and make sure they do not get crushed if the load moves.
•
When using using seve several ral support supports s as substr substruct ucture ures, s, only only use suppo supports rts of the the same same height. height.
•
Place Place suppo supports rts unde underr the the load load so that that they they are stable stable and and leve level. l. Do Do not use supp support orts s that have rounded edges, are fragile or damaged.
•
Comp Compen ensa sate te unev uneven enne ness ss unde underr the the supp suppor orts ts..
•
Use the suppor supports ts to to create create a cavit cavity y under under the load, load, enab enablin ling g the the sling slinging ing equipm equipment ent to be attached and removed easily.
2-492-20980 (Item 02)
0 v e R 3 1 0 2 / 1 1
5.3
St o r ag e r eq u i r em en t s
5.3.1
Gen er al al r eq eq ui ui re rem en ts ts
CAUTION System damage from impro per storage/assembly storage/assembly o f the machine/plant Damage to the machine/plant or its environment is possible • If the machine/p machine/plant lant is to to be stored, stored, it has to be left left in the deliver delivery y condition. condition. The manufacturer is not liable for damage caused by improper repeated assembly of the machine/plant.
CAUTION System damage from im prop er storage of the machine/plant machine/plant Damage to the machine/plant or its environment is possible • All the deliver delivered ed machine machine and plant plant component components s must be be stored on suitable suitable supports to keep them dry. The storage place must be free from vibration. • The stored stored machine machine and plant plant component components s must be protected 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). All the machine and plant components must be stored at temperature s between + 5 °C and + 45 °C. ° C. Electrical equipment is to be stored dry and frost-free, temperatures between minimum + 5 °C and maximum + 45 °C. 0 v e R 3 1 0 2 / 1 1
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)
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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
Stora torage ge faci facili liti tie es & othe otherr de detail tails s
5.3.2.1
" Op Op en en -a -ai r" r" s to to ra rag e Please note that roofed storage (Chapter ( Chapter 5.3.2.2 ""Roofed" storage") 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". instructions" . Examples: "Large-volume plant components"
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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)
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Gear rim cover
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Mill outlet case
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Chutes
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Ducts for material transport and dedusting
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Crusher frame
–
Apron conveyor supporting frame/chain conveyor supporting frame (without dr ive units)
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Supporting frame for troughed belt conveyor
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Bed plates
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Structural steelwork elements
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Examples: "Wear parts whose surface has no effect on the functional capability " –
Grinding media, rods and balls
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Mill and shell lining
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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
" Ro Ro of of ed ed " s t or or ag ag e 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. Examples:
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Rubber belts for troughed belt conveyors. Please note that the belts are delivered on coils and must be stored in a vertical position.
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Rubber and plastic seals (e.g. for gear rim protection cover, mill outlet casing, material guide bar of troughed belt conveyors, etc.).
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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.
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Idlers for troughed belt conveyors, drive stations and pulleys, mechanical parts of belt weighers.
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Plant components with ventilation holes e.g. gear units, gear motors and bearings equipped with openings for air pressure compensation.
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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.
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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.
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5.3.2.3 .2.3
Storage torage “ in enclos enclose ed inside inside are area as with partia partiall air air conditionin conditioning” g” “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
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Anchor bolts
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All types of instruments/measuring instruments
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Hydraulic pipes, gear rim lubrication
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Switches, control centres (MCC = motor control centre)
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Transmitters, frequency control
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Separators for hydraulic and lubricating units
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Filter bags for dust collectors and the corresponding solenoid valves
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Measuring instruments for the belt weigher and misalignment monitoring
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Filter cloth for bag filter installations
Stora torage in “ close closed d locka lockable ble rooms” rooms” High-quality, sensitive and valuable components. Examples: –
Measuring instruments
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Sensors
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PCs
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Screens
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Laboratory equipment e.g. test screens, scales, etc. …
5.3.3
Sp ec ec ia ial r eq eq ui ui r em em en en ts ts
5.3.3.1
El ec ec tr tr ic ic m ot ot or or s Motors must be stored in the original crates if they are not mounted on the equipment. The storage area must be free of vibration. Bearings: –
–
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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.
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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 mechan ical 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 u n i t Oil and grease grease lubrication : The oil recommended by the manufacturer must be used for the oil change. 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.
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5.3.3.3
Gear m o t o r s 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 supplied by the manufacturer.
CAUTION Gear Gear damage from i mpro per storage of the machin e/plant e/plant Damage to the machine/plant or its environment is possible • Gear units units must must be kept sealed until until commissi commissioning, oning, in in order to prevent prevent volatilisation of the VCI corrosion inhibitor. • Before these these gear gear motors are commissio commissioned, ned, the operating operating oil level level must must be restored using dipstick/oil-inspection glass/oil-level plug.
5.3.3.4
Elect lectri rica call con contro troll sys syste tems ms 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. DC drives: – –
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 Process control equipment: equipment: Process control equipment should be stored indoors in a heated/air-conditioned room. 5 - 22
2-492-20980 (Item 02)
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Control valves: The normal storage conditions are valid f or 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
Ot h er mechanical mechanical equipment Belts and seals: These components must be protected from moisture and stored in a dry envir onment. 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 a luminium. There are also special VCI additives for copper and copper alloys and for both materials. The VCI metho d is not applicable for the conservation of zinc, tin, cadmium, magnesium, lead and alloys of these metals.
5.4
In s t al l at i o n pl p l an n i n g When planning the installation, please note the following:
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Please refer to the relevant foundation and installation drawings for the main dimensions of the machine/plant and the associated secondary units.
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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.
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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, grou t 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
Pr ep ar at i o n f o r i n s t al l at i o n
WARNING The use of untrained personnel or equipment that does not comply with safety standards poses additio nal danger Death or severe bodily injuries are possible • The fastening fastening of of loads and the instruction instruction of crane operator operators s should only be entrusted to experienced persons! The marshaller must be within eyesight of the operator or have verbal communication with him. • When carrying carrying out overbelt overbelt assembl assembly y work, always always use special specially ly designed 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.
WARNING Risk of injury throu gh components that are improperly improperly secured during installation Death or severe bodily injuries are possible • Make sure sure that moveable moveable components components are are properly properly secured secured during installa installation. tion.
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2-492-20980 (Item 02)
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WARNING Danger Danger from working on electrical electrical systems witho ut prop er technical technical knowledge Death or severe bodily injuries are possible • Work on the electric electrical al systems systems or equipment equipment may only only be carried carried out by a skilled 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. Our warranty is based on the assumption that an assembly specialist from ThyssenKrupp Resource Technologies will carry out the assembly and assembly inspection.
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5.6
Del i v er y p ar t s an d w ei g h t s The discharge conveyor is delivered in the following assembly groups:
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6 x Pontoon 405 high, each approx. 730 kg
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1 x Carrying idler diameter 1200, approx. 3,800 kg
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2 x Supporting blocks, 2017 high, each approx. 1,500 kg
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1 x Support, 3910 high, approx. 4,400 kg
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1 x Conveyor frame, part 1, approx. 12,000 kg
–
1 x Conveyor frame, part 2, approx. 10,300 kg
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1 x Conveyor frame, part 3, approx. 7,500 kg
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1 x Conveyor frame, part 4, approx. 11,000 kg
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1 x Idler supports, upper strand and lower strand, approx. 8,700 k g
–
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
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1 x Driving pulley, approx. 7,100 kg
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1 x Bevel spur gearbox with motor, approx. 9.500 kg
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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
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1 x Conveyor belt, approx. 9.400 kg
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1 x Material guide, approx. 12.000 kg
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1 x Protective grating, approx. 1,800 kg
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1 x Servicing platform, 13,000 kg
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1 x Needle slide, approx. 6,300 kg
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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)
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INFORMATION
The list of these subassembly groups coincides with the sequence of assembly steps.
5.7
Gen er al i n f o r m at i o n o n as s em b l y
WARNING Risk of injury thro ugh improper assembly and and transport Death or severe bodily injuries are possible • Make sure sure that moveabl moveable e components components are secure secured, d, also during during installat installation ion • Use prop proper er trans transpor portat tation ion equi equipme pment nt • Do not not walk walk under under susp suspend ended ed loads loads • Fasten Fasten and and lift lift compon components ents properl properly y • Only transport transport the machine machine/plant /plant on the the designated designated slinging slinging devices devices (lugs) (lugs) and slinging points.
WARNING Risk of injury during assembly work at great heights Death or severe bodily injuries are possible • When carrying carrying out overbelt overbelt assembly assembly work, work, always always use speciall specially y designed designed or other suitable and safe climbing aids and working platforms. • Never use use machine parts as a climbing aid! • Wear fall fall protection protection when when carrying carrying out mainten maintenance ance work work at a higher higher level. level.
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WARNING Risk of injury when working on electrical 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 conduct welding welding current current through through slide slide or roller roller bearings bearings or other other moveable moveable connections or measuring equipment. • Carry out out welding welding work work on individua individuall machine machine components components prior 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. Initial assembly must be carried out by trained personnel. The respective layout plan and assembly drawings must be carefully studied. All guidelines and notes must be observed.
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2-492-20980 (Item 02)
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5.8
Mo u n t b el t c o n v ey o r See ANNEX See ANNEX 9.1 "Drawings"
5.8.1
A s se sem b lili ng ng th t h e c on on ve vey or or f ra ram e See Figure 5 and 5 and drawing 4612258 •
Instal Installl pont pontoon oons, s, support supports, s, carryin carrying g idle idlers rs (1) and mount mount in the ground ground..
•
Assem Assemble ble the the fou fourr sep separa arate te parts parts of the the conv convey eyor or frame frame (2). (2).
•
Asse Assemb mble le can canti tile leve verr conv convey eyor or fra frame me/d /dri rive ve (3) (3)..
•
Align Align and and bolt bolt the the indi individ vidual ual parts parts of of the convey conveyor or fram frame e (1) to the the drive drive statio station n (4) (4) and the tensioning station (2).
CAUTION System System damage from uncontroll ed off-track off-track running of the co nveyor belt Damage to the machine/plant or its environment is possible • The carrying carrying idlers idlers and feed-zone feed-zone idlers idlers are to be be aligned aligned at right angles angles to the the belt centre in order to avoid misalignment of the conveyor belt.
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Figure 5
2-492-20980 (Item 02)
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5.8.2
A s s em b l e i d l er su s u p p o r ts ts This section describes the types of idler supports on which the conveyor belt is running.
5.8.2.1
Car ry ry in in g i dl dl er er s t op op 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 ø159 x 900 / 25° (3 rollers)
Figure 6
5.8.2.2 .2.2
Carrying idlers idlers top, padde padded d (impa (impact ct rollers) rollers) See Figure 7 Impact Idlers are Carrying Idler with additional rubber tyres which are upholstered the idlers. The impact rollers are arranged on the elastomer spring elements, which reduces the shock force of material falling down. The Idlers are connected to each others by a steel profile to prevent the idler stations from tilting. – Impact rollers ø219/133 x 900 / 25° (3 rollers)
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2-492-20980 (Item 02)
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Figure 7
5.8.2.3
Ret ur ur n r ol ol le ler s 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 ø89/159 x 1400 / 10° (2 rollers)
Figure 8
5.8.2.4
Pr es es su su re re Id le ler s 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. – Hold-down rollers ø214/194 x 1250 with 10 mm covering / 0° (2 rollers)
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Figure 9
2-492-20980 (Item 02)
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5.8.3
A s se sem bl bl i ng ng th t h e i dl dl er su s u pp pp o rt rt s The idler supports are assemble according to the drawing 4612024 Sheet 1-2 on 1-2 on the conveyor frame.
5.8.4
Asse Assemb mbli ling n g the the mate materi ria al guid guide e See Figure 10 and 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 the guid guide e strip strips s (1) (1) on the latera laterall suppo supports rts (3) of the the conv conveyor eyor frame. frame.
•
Adju Adjust st the the hei heigh ghtt of of the the rubb rubber er stri strips ps (2). (2).
Figure 10
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2-492-20980 (Item 02)
5.8.5
Asse Assemb mbli ling ng the th e plou plough gh--type typ e sc scra rape per r See also drawing 2597871 •
Instal Installl ploughplough-typ type e scrape scrapers rs (1) (1) in the the lowe lowerr strand strand in in front front of the tension tensioning ing pulley pulley (2) and adjust the height.
Figure 11
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2-492-20980 (Item 02)
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5.8.6
A s se sem b lili n g t he he f ro ro n t sc sc ra rap er er s See Figure 12 •
Install Install and adjust adjust both both of the front front scrape scrapers rs (2) (2) on on the the driv driving ing pulley pulley (1). (1).
•
Read Read the the man manuf ufac actu ture rer' r's s doc docum umen enta tati tion on in ANNEX in ANNEX 9.5 "Scrapers B6C". B6C" .
Figure 12
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2-492-20980 (Item 02)
5.8.7
A s s em b l i n g th th e d r i v e Also see drawing 4612318 in 4612318 in ANNEX ANNEX 9.1. 9.1. •
Assem Assembl ble e the the cant cantil ilev ever er on the the conve conveyo yorr fram frame e (1) (1)..
•
Assemble Assemble coupli coupling ng (5) (5) gear gear unit unit (2) (2) coupl coupling ing (4) and motor motor (3) (3) on on both both side sides s of the driving pulley.
•
Read Read the the man manuf ufac actu ture rer' r's s doc docum umen enta tati tion on in ANNEX in ANNEX 9.2 "Drive unit". unit" .
Figure 13
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2-492-20980 (Item 02)
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5.8.8
Asse Assemb mbli ling ng the the resi resist sta ance nce the thermom rmome eter ter See Figure 14 •
Install Install one resista resistance nce thermom thermomete eterr PT100 PT100 41/5-3B 41/5-3B in in the the bore bore hole holes s (1) (1) on both of the bearing housings of the tensioning pulley.
•
Install Install one resista resistance nce thermom thermomete eterr PT100 PT100 41/5-3B 41/5-3B in in the the bore bore hole holes s (2) (2) on both of the bearing housings of the driving pulley.
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2-492-20980 (Item 02)
Figure 14 0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
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5.9
A ss ss em b lili ng ng an an d t en en si si on on in in g t h e c on on ve vey o r b el el t •
Appl Apply y and and vulc vulcan anis ise e the the conv convey eyor or belt belt..
CAUTION System damage from improper installation of conveyor belt Damage to the machine/plant or its environment is possible • Pay attention attention to the carrying carrying side side of the the conveyor conveyor belt. belt. • Vulcanising Vulcanising of of the conveyor conveyor belt belt is to be be executed executed by an expert expert company. company. •
Tension th the co conveyor be belt
CAUTION System damage from incorrect tensioning of the belt conveyor Damage to the machine/plant or its environment is possible • The conveyor conveyor belt belt has to be tension tensioned ed so far that the driving driving pulley pulley does does not slip 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). Then the retaining plates (2) and the h ydraulic cylinders (3) are assembled on both sides of the tensioning pulley and as close as possible to the bearing housings (4). 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)
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The hydraulic cylinders (3) are then removed from both sides of the tensioning p ulley. 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.
Figure 15
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2-492-20980 (Item 02)
6
Co m m i s s i o n i n g an d o p er at i o n
6.1
Gen er al i n f o r m at i o n 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: •
havi having ng the the mac mach hine ine/pl /plant ant che check cked ed
•
dete determ rmiining ning the the opti optimu mum m cap capac acit ity y
•
trai traini ning ng the the oper opera ating ting pers person onne nell
•
pass passin ing g on addit additio iona nall advic advice e on oper operat atio ion, n, main mainte tena nanc nce e and upk upkee eep. p.
For the initial commissioning routine note the instructions relating to the components included in the ANNEX the ANNEX 9. 9.
6.2
Op er at o r t r ai n i n g 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). 4.1). The operating staff must be familiar with the arrangement and function of the safety devices.
6.3
Saf et y n o t es f o r o p er at i o n
DANGER 0 v e R 3 1 0 2 / 1 1
Risk of injury from damaged damaged insulation on the connecting cable and and missing terminal box covers Imminent danger of death or severe bodily injuries • The electrical electrical connections connections of of the drive drive must must be adequately adequately protecte protected. d.
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6-1
WARNING Risk of injury from larger oscillation amplitudes Death or severe bodily injuries are possible • Do not reach reach into into the spaces spaces between between fixed fixed component components s and oscillat oscillating ing components. • Repair Repair incorrect incorrect oscillation oscillation before feeding material. material.
CAUTION Risk of injury when operating the drive units without protective clothing. Bodily injury possible • The machine machine must must never be operated operated without without the guards in position position over over the drive units.
6-2
•
Operat Operate e the machin machine e / plant plant only only if all protect protective ive and safety safety-ori -oriente ented d devic devices, es, such such as removable safety devices and emergency shut-off equipment, sound-proofing elements and exhausters, are in place and fully functional!
•
Check Check the the mach machine ine// plant plant at leas leastt once once every every shift shift for for obvio obvious us damag damage e and and defec defects! ts! 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 the even eventt of malfunc malfunctio tions, ns, stop stop the the machin machine/ e/ plan plantt immed immediat iately ely and lock lock it! it! Have any defects remedied immediately!
•
Follow Follow the the star start-up t-up and shutdow shutdown n proced procedure ures s and and contro controll displ displays ays as set set out out in in the manual!
•
Before Before start starting ing up/act up/actuat uating ing the mach machine ine// plant, plant, make make sure sure that that nobod nobody y is at risk! risk!
•
If abnor abnormal mal vibrat vibration ions s sudde suddenly nly occur occur in the equi equipmen pmentt suppo supporti rting ng stru structur cture e the the operation of which is corresponding with vibrations and unbalance s, these abnormal vibrations must be eliminated prior to feeding the machine with material.
•
Only Only work work with with the the presc prescrib ribed ed ligh lightin ting g under under dark darknes ness s and and with with poor poor visi visibil bility ity..
•
Switch Switch off the mach machine ine/pl /plant ant immedi immediate ately ly ifif peopl people's e's live lives s are at risk risk,, e.g. e.g. due due to careless working near belt conveyor systems and material transfer points.
•
Local Local oper operati ation on of indivi individua duall drives drives is allo allowed wed only only during during inspect inspection ion,, mainte maintenan nance ce and repair work.
•
Work Work may may only only be be carri carried ed out out ifif the the worke workerr is properly properly qualif qualified ied and/or and/or has been been authorised to do so. Do not carry out maintenance and repair work without authorization.
2-492-20980 (Item 02)
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6.4
Tes t r u n 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, •
Lubr Lubric icat atin ing g poi point nts s acc. acc. to lubr lubric icat atin ing g ins instr truc ucti tion ons s Chapter 8.5, 8.5,
•
Inst Instal alla lati tion on of safet afety y devi device ces, s,
•
Insp Inspec ectt the the whol whole e pla plant nt for for for forei eign gn bodi bodies es,,
•
Obse Observ rve e the the inst instru ruct ctio ions ns for for com compo pone nent nts s in the the ANNEX ANNEX 9. 9.
Afterwards, all mechanical and electrical parts are separately checked according to their operational sequence. If these checks did not reveal any defects, a t est run of the crusher discharge belt ca n be started. During the test run, check: •
Rota Rotati tion on dire direct ctio ion n of the the dri drive, ve,
•
Proper Proper functi functionin oning g and and smooth smooth runnin running g of of the the single single plant plant compon component ents, s,
•
Prop Proper er func functi tion onin ing g of the the belt belt weig weighe her, r,
•
Prope Properr funct functio ionin ning g and dis displ play ay of the the inst instal alle led d contro controll equip equipme ment nt:: – Speed monitor – Belt tracking limit switch – Pull-rope emergency switch – Belt tear switch
CAUTION System damage from actuating the safety devices devices for n ormal operating interruptions Damage to the machine/plant or its environment is possible
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• Belt tracking tracking limit limit switches switches and pull-rope pull-rope emergenc emergency y switches switches must be operated operated in case of emergency only. They must not be operated for normal shutdown. •
Obse Observ rve e the the inst instru ruct ctio ions ns for for com compo pone nent nts s in the the ANNEX ANNEX 9. 9.
•
Check Check direct direction ional al stabil stability ity of the convey conveyor or belt belt and correc correctt ifif neces necessar sary. y.
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Notes on the alignm alignm ent 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 caused by i ncreased belt tension Damage to the machine/plant or its environment is possible • The belt belt tension tension must must not be increased increased under any circumsta circumstances. nces. • The conveyor conveyor belt belt has to be tension tensioned ed so far that the driving driving pulley pulley does does not slip 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 carryi carrying ng idle idlerr causin causing g the the misal misalign ignmen mentt of the convey conveyor or belt belt is usual usually ly the the second or third one behind the point where the belt is running out of line.
•
Loos Loosen en the the out outer er bra brack cket et and and remo remoun untt it in in conve conveyi ying ng dir direc ecti tion. on.
•
If the the convey conveyor or belt belt is runnin running g to the the left-h left-hand and side side look looking ing in in convey conveying ing dire directi ction, on, the the left-hand side of the idler mounting is to be moved towards conveying direction.
•
If the the conve conveyor yor belt belt is running running to to the the rightright-han hand d side side look looking ing in conve conveyin ying g direct direction ion,, the right-hand side of the idler mounting is to be moved towards conveying direction.
•
Experie Experience nce has show shown n that that a belt belt runnin running g very very well well duri during ng test test run run may may run run out out of line 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. Af ter th e tes t r un , th e fo ll ow in g ac ti vi ti es ar e to be c arr ied ou t: •
Chec Check k the the tens tensio ion n of the the con conve veyo yorr belt belt.. For For re-te re-tens nsio ioni ning ng see see Chapter 5.9. 5.9.
•
Reti Retigh ghte ten n all all anch anchor or bol bolts ts and and fas faste teni ning ng bol bolts ts..
•
Check Check lubric lubricati ating ng points points accord according ing to the lubric lubricati ating ng instru instructi ctions ons Chapter 8.5. 8.5.
•
Obse Observ rve e the the inst instru ruct ctio ions ns for for com compo pone nent nts s in in the the ANNEX 9. 9.
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6.5
Co m m i s s i o n i n g u n d er l o ad
DANGER Risk of injury through th e removal removal of blockages blockages during operation operation Imminent danger of death or severe bodily injuries • This work work may only be carried carried out when when the discharge discharge conveyor conveyor is is at a standstill standstill and secured against restarting.
WARNING Danger Danger from ins uffic ient barrier around the plant Death or severe bodily injuries are possible • Close off off a large large area around around the general general danger zone of the the conveyor conveyor belt. belt.
CAUTION Plant damage damage caused by starting up wi th conv eyor belt loaded Damage to the machine/plant or its environment is possible • In the normal normal case: case: The discharge discharge conveyor conveyor must must only be switched switched on when when empty. • After "emergenc "emergency y stop": stop": Before starting starting make sure sure that the the feed zones zones and and transfer points are absolutely free from material.
6.5.1
B ef or or e i n it it ia ial co c o m mi mi s si si on on i ng ng
INFORMATION 0 v e R 3 1 0 2 / 1 1
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.
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6.5.2
Mi s al i g n m en t Possible causes for misalignment of the conveyor belt:
6.5.3
–
Insufficient alignment of conveyor frame, pulleys and carrying idlers.
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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 cas case e of mis misal alig ignme nment nt of of the the conve conveyo yorr belt belt the the inf infor orma mati tion on in in Chapter 6.4 must 6.4 must be observed.
A f te ter i n it it ia ial c om om mi mi s si si on on in in g Af ter co mm is si on in g t he f ol lo wi ng wo rk s ar e to be c arr ied ou t: •
Reti Retigh ghte ten n anc ancho horr bol bolts ts and and fas faste teni ning ng bolt bolts. s.
•
Adjus Adjusti ting ng the plou plough gh-ty -type pe scra scrape perr and and the the front front scrap scraper. er.
•
Adjus Adjusti ting ng the the rubb rubber er stri strips ps of of the mat mater eria iall guide guide and and the the feed feedin ing g shoe shoe..
6.6
Sh u t t i n g d o w n
6.6.1
No r m al o p er at i o n The material feed must always be interrupted before the crushing plant is stopped. The crushing plant can then run "empty."
6.6.2
Em er g en c y -s t op op s ys y s t em
CAUTION System damage damage from material overfilling when usin g emergency-stop switch Damage to the machine/plant or its environment is possible 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 emergencyemergency-stop stop switches switches must must not be be used for for normal shutdown. shutdown.
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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 The whol whole e elec electr tric ical al sys syste tem m is swi switc tche hed d off off by the the eme emerg rgen ency cy sto stop. p.
•
Dete Determ rmin ine e the the dang danger er or or dama damage ge and and pro provi vide de fir first st aid aid ifif nece necess ssar ary. y.
•
Have any defects rec rectif tified.
•
In order order to resta restart rt the the plant plant after after having having rectif rectified ied the the emer emergen gency cy case case,, the actuat actuated ed switch is to be unlocked by turning the impact surface to the right-hand side.
•
Acknowledge the fault.
•
Swit Switch ch on the the main main supp supply ly agai again. n.
Pullull-ro rope p e emerg merge ency ncy swit switch ch •
The The swi switc tch h is is tri trigg gger ered ed with with the the pul pulll-co cord rd..
•
PullPull-ro rope pe eme emerge rgenc ncy y swit switch ch auto automat matic ical ally ly loc locks ks when when act actua uate ted. d.
CAUTION Plant damage damage caused caused by uncont roll ed 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 tracking switches switches must must not be used used for normal normal shutdown. shutdown. •
The belt belt cann cannot ot be switch switched ed back back on on until until the local local switch switch is unlock unlocked. ed.
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Mai n t en an c e
7.1
Im p o r t an t in i n f o r m at i o n on o n ma m ai n t en an c e
WARNING Risk of injury t hroug h cleaning, inspection, maintenance and repair work during operation operation Death or severe bodily injuries are possible • Cleaning, Cleaning, inspection inspection,, maintenance maintenance and repair repair work work may only be be carried out out when the machine/plant is switched-off and secured against restarting. •
Note Note the the informa informatio tion n in the Operati Operating ng Inst Instruc ructio tions ns on on adjust adjusting ing,, maint maintenan enance ce and 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 Inform the operati operating ng pers personn onnel el befor before e start starting ing servic service e and and mainte maintenan nance ce work! work! Appoint a person to supervise the work!
•
When When carryi carrying ng out out any any work work concern concerning ing the operati operation, on, conver conversion sion or adju adjustm stment ent 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 gener general al princ principl iple, e, all all work work on on the machin machine/ e/ plant plant shou should ld only only be be carrie carried d out when when the machine/ plant is at a standstill.
•
If the the mach machine ine// plant plant has been comple completel tely y shut shut down down for mainten maintenanc ance e and and repai repairr work, it must be secured against inadvertent restart by: – Locking the main control elements and removing the key and/or – attaching a warning sign to the main switch.
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•
Before Before resta restartin rting g the machin machine/p e/plan lantt after after repa repair ir work, work, check check that that all safety safety device devices s have been attached.
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After After elect electric rical al inst install allati ation on or repair repair work work,, test test the the protec protectio tion n syste systems ms (e.g (e.g.. earth earth resistance).
•
To avoi avoid d the the risk risk of of accid accident ents, s, indi individ vidual ual parts parts and and large large asse assembl mblies ies being being moved 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)
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7-2
•
The fasteni fastening ng of of loads loads and the instruc instructio tion n of crane crane oper operato ators rs shoul should d only only be entrusted to experienced persons! The marshaller must be within eyesight of the operator or have verbal communication with him.
•
When carryi carrying ng out out overb overbelt elt asse assembly mbly work, work, alway always s use specia specially lly design designed ed or or other 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 handles,, steps steps,, handra handrails ils,, platf platforms orms,, landi landings ngs and and ladd ladders ers free of dirt, dirt, snow snow and and ice!
•
Always Always tighte tighten n up up any any bolt bolted ed connec connectio tions ns which which have have been been loosen loosened ed during during maintenance and repair work!
•
Any safety safety device devices s remove removed d for for settin setting g up, up, maint maintena enance nce or repa repair ir purp purpose oses s must must be be refitted and checked immediately upon completion of the maintenance and repair work.
•
Ensure Ensure that that all consum consumabl ables es and and proc process ess materia materials ls and and repl replaced aced parts parts are are disp dispose osed d off safely and in an environmentally friendly manner!
•
Only Only use use origin original al fuses fuses with with the the speci specified fied curren currentt rating rating!! Shut Shut down down the the machi machine/ ne/ plant immediately if faults occur in the electrical power supply!
•
Work on the the elec electric trical al syst system em or or equip equipmen mentt may may only only be be carrie carried d out out by a skill skilled ed 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 presc prescrib ribed, ed, the the powe powerr supply supply to to parts parts of of machi machines nes and and plant plants s on whic which h inspec inspectio tion, n, 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 elec electric trical al equi equipme pment nt of the mach machine ine/pl /plant ant must must be insp inspect ected ed at regular regular inte interva rvals. ls. Any defects such as loose connections or scorched cables must be rectified immediately.
•
If work work on live live parts parts is necess necessary ary,, it may only only be carri carried ed out out in the presen presence ce of 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 Before start starting ing work work on high high-vo -voltag ltage e assemb assemblie lies s and after after disco disconnec nnectin ting g the the power power supply, the supply cable must be earthed and components such as capacitors shortcircuited with an earthing rod!
•
Carry Carry out out weldi welding, ng, flame-c flame-cutt utting ing and grindin grinding g work work on on the the machi machine/ ne/ plan plantt only only ifif this this has been expressly authorised, as there may be a risk of explosion and fire!
•
Before Before carryi carrying ng out out weld welding ing,, flame flame-cut -cutting ting and grindi grinding ng work work,, clean clean dust dust and other other inflammable substances from the machine/ plant and its surroundings and provide adequate ventilation (risk of explosion)!
•
Check Check all all line lines, s, hose hoses s and and bolte bolted d conne connecti ctions ons regula regularly rly for leaks leaks and and obvi obvious ous damage. Repair any damage immediately! Splashing oil may cause injury and fires.
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7.1.1
•
Depres Depressur surise ise all system system sectio sections ns and and press pressure ure pipes pipes whic which h are are to be opene opened d in in accordance with the instructions for the assembly group concerned before carrying out any repair work!
•
Hydrau Hydraulic lic lines lines must must be laid laid and and connec connected ted in in line line with with good good profes professio sional nal practic practice! e! Do not mix up any exchange connections! The fittings, lengths and quality of the hoses must comply with the technical requirements.
•
Follow Follow the applic applicabl able e safety safety regulat regulation ions s when when hand handlin ling g oil, oil, grea grease se and and othe otherr chemica chemicall substances!
•
Be care careful ful when when handl handling ing hot consuma consumable bles s and and proce process ss mate materia rials ls (ris (risk k of burning burning or scalding)!
No t es o n c l ean i n g
CAUTION Risk of injury when working witho ut personal safety safety equipment Bodily injury possible • Always wear a face face protector protector when when carrying carrying out out cleaning cleaning work work with highhighpressure 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 jet a sufficiently large distance 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. The covers and tapes need be removed completely after cleaning. 0 v e R 3 1 0 2 / 1 1
After cleaning, check all lubricant and hydraulic oil lines for leaks, loose connections, friction areas and damage! Eliminate any deficiencies immediately!
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7.1.2
Infor nforma mati tion on on on main mainte tena nanc nce e and ins i nspe pect ctio ion n
WARNING Risk of injury by neglecting proper maintenance intervals Death or severe bodily injuries are possible • All pending pending maintenan maintenance ce work must be complete completed d according according to schedul schedule. e. 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 machine / plant plant at least least once per per shift for for obvious obvious damage damage and defects! Report any changes (including changes in the operating performance) to the responsible department immediately! • In the event event of malfunctions malfunctions,, stop the machine machine / plant plant immediately immediately and and lock it! 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. Functional safety, trouble-free operation and the service life of the machine/ plant depend on proper cleaning, inspection and maintenance. •
Check Check the the mach machine ine// plant plant at the the speci specifie fied d inter interval vals s (insp (inspect ection ion interv intervals als,, maintenance periods) for proper operation, lubrication condition and wear.
•
Repl Replac ace e or or rep repai airr all all dama damage ged/ d/ worn worn part parts. s.
•
Check Check the the paint paintwor work k for for corro corrosio sion n at regula regularr inter interval vals s but but no later later than than every every 6 months. Touch up all damaged areas in line with good professional practice.
•
Have Have the functio function n of all instrum instrumenta entatio tion n and and contro controll devic devices/ es/ electr electrica icall inter interloc locks ks checked by qualified personnel at regular intervals.
INFORMATION
Downtimes for repairs can also be used for scheduled maintenance work.
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The required frequency of checks for wear, inspection, maintenan ce 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 ( Chapter 7.2.1) 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). 3).
INFORMATION
For lubricating the machine/ plant see Chapter 8. 8. For maintenance and servicing of the components, see ANNEX 9. 9. As recommended during commissioning, you are advised 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
No te tes re r el at in in g t o r ep ep ai ai rs rs
WARNING Risk of injury due to improper fastening Death or severe bodily injuries are possible • To avoid the the risk of accident accidents, s, individual individual parts parts and large large assemblies assemblies being 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 fastening of loads loads and the instruct instruction ion of crane crane operators operators should should only be entrusted to experienced persons! The marshaller must be within eyesight of the operator or have verbal communication with him. • When carrying carrying out overbelt overbelt assembl assembly y work, always always use special specially ly designed 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.
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7.2
•
Imme Immedia diatel tely y repl replac ace e worn worn com compo pone nent nts s with with new new com compo ponen nents. ts. With worn components, strength is reduced and the risk of fracture is increased!
•
Do not not rere-use use seal seals s and and safe safety ty ele eleme ment nts s that that hav have e been been rem remov oved ed..
•
When re-usin re-using g assem assembly bly groups groups and and parts parts,, alway always s use use new new bolts bolts,, nuts nuts and and wash washers. ers.
•
Do not not leav leave e any any tool tool or other other devi device ce in the mach machin ine/ e/pl plan ant. t.
•
Observ Observe e the the weldi welding ng inst instruct ruction ions s for for the prevent prevention ion of acci acciden dents ts whene whenever ver carryi carrying ng out welding work.
•
During During elec electri tric c weldi welding, ng, secu secure re the the earthi earthing ng cable cable near near the the part part being being weld welded. ed. Do Do not 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 Restore the machin machine/p e/plan lantt to its origin original al state state on on the the compl completi etion on of of the the repair repair work. work. Re-assemble protective and safety devices. Make sure that the machine/plant is working properly by carrying out a test run.
Mai n t en an c e an d i n s p ec t i o n
CAUTION Risk of injury from working with the belt conveyor conveyor open Bodily injury possible • The maintenanc maintenance e and inspectio inspection n work describe described d below may may only be be carried 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. 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) 0 v e R 3 1 0 2 / 1 1
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Figure 16
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7.2.1
Mai nt nt en en an an c e i n te ter va v al s 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. Observe the instructions for components in the ANNEX 9. 9.
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2-492-20980 (Item 02)
Crusher discharge belt
for the first time after …
Maintenance interval ... Operating hours
... Week s
... Mo n t h s
Conveyor belt Check tension of belt Check belt tracking
10 h
6 1
Check for wear and damage
1
Carrying Carrying i dlers Check for caking Check for smooth running
1 1
1
Pulleys Check for caking
1
Belt scraper Check the function Check the strips
1 1
Feeding Feeding sho e Check the function Check sealing rubber
1 1
Material transfer Check centre feeding and discharge
1
Fastening Fastening bolt s Check bolt torque
50 h
12
Bearings Clean, change grease
6000
24
Drive unit Check for leaks Check oil level, top up if required
1 1
Check bolt torque
50 h
Oil change
500 h
Pull-rope emergency emergency switc h, belt tracking switch , speed speed monito r, belt break break monito r Functional test
12 17500
10 h
60
6
The belt conveyor must be checked regularly for
0 v e R 3 1 0 2 / 1 1
–
cracks,
–
loose/missing bolts,
–
Bolted/screwed connections (see Chapter 7.5), 7.5),
–
state of the weld seams and weld seam transitions,
–
corrosion,
–
changes in the condition of the protection and safety devices
. Interval: at Interval: at least once a year
2-492-20980 (Item 02)
7-9
7.2.2
Dr i v e The maintenance instructions in ANNEX in ANNEX 9.2 must 9.2 must be followed for the drive. For oil change periods see Chapter 8.5 "Lubricating instructions". instructions" .
7.2.3
B ear i n g s 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". instructions" . Immediately after relubrication the temperat ure may rise but only for a short period of time. For mounting and dismounting see Chapter 7.4 "Bearings with adapter sleeves". sleeves" .
0 v e R 3 1 0 2 / 1 1
7 - 10
2-492-20980 (Item 02)
7.2.4
Conve onveyo yorr belt belt//tens tensio ioni ning ng de device vice 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". belt".
Figure 17
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 11
7.2.5
Wear p ar t s 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 see ANNEX 9.5 "Scrapers B6C". B6C" . The control intervals are indicated in Chapter 7.2.1. 7.2.1.
0 v e R 3 1 0 2 / 1 1
7 - 12
2-492-20980 (Item 02)
Figure 18
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 13
7.3
Rep ai r s
WARNING Risk of injury through cleaning, inspection, maintenance, and repair work during operation operation Death or severe bodily injuries are possible • Cleaning, Cleaning, inspection inspection,, maintenance maintenance and repair repair work work may only be be carried out 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
Replace placeme ment nt of of the the tensi tensioni oning ng pull pulle ey with with CC-hooks hooks See Figure 19, 19, Figure 20 and 20 and ANNEX ANNEX 9.3 "Driving pulley and tensioning pulley" . For removal of the tensioning pulley: •
Use Use the the tensi tension onin ing g pull pulley ey to to rela relax x the the tensi tension on on on the the conv convey eyor or belt belt,,
•
Pull the tensioni tensioning ng pull pulley ey acro across ss the the entir entire e length length of the the belt belt to bring bring it into into posit position ion 2 below the hoisting device (1).
0 v e R 3 1 0 2 / 1 1
Figure 19
7 - 14
2-492-20980 (Item 02)
•
Lift the convey conveyor or belt belt (3) under under the the platfor platform m of of the the disc dischar harge ge hopper hopper and attach to the corresponding suspension points (4) with rope or chain hoists (see also Chapter 5.2 "Hoisting devices and slinging equipment" ).
•
Dismant Dismantle le the the prote protecti ctive ve grat grating ing (6) and and the the upper upper tension tensioning ing guide guide (guid (guide e suppo support). rt).
•
Mount Mount the the tensi tensioni oning ng pull pulley ey with with lifting lifting straps straps on a C-hook. C-hook. Make Make sure sure the the pulley pulley is suspended properly in the C-hook (see also Chapter 5.2 "Hoisting devices and slinging equipment"). equipment").
•
Lift the pull pulley ey (5) (5) out of the the guide, guide, move move itit to the the side side,, rotate rotate it by 90° and and set set it down down..
•
For For long longit itud udin inal al tran transp sport ort use use C-h C-hoo ook k wit with h pul pulle ley. y.
Figure 20
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 15
7.3.2
Replacin placing g the the tensi tensionin oning g pull pulle ey with with a C-hook hook
0 v e R 3 1 0 2 / 1 1
Figure 21
7 - 16
2-492-20980 (Item 02)
Carry out the following steps when removing the tension drum (4): •
Remo Remove ve the the pro prote tect ctiv ive e gra grati ting ng (1), (1),
Figure 22
•
Remove th the id idler suppo pports (2 (2),
0 v e R 3 1 0 2 / 1 1
Figure 23
2-492-20980 (Item 02)
7 - 17
INFORMATION
Place a wooden board (10) under the belt on the floo r in order not to damage the belt (6). •
Rela Relax x the the tens tension ion on on the con conve veyo yorr belt belt (6) (6) with with ten tensi sion onin ing g pull pulley ey (4), (4),
•
Pull the tens tension ioning ing pull pulley ey (4) (4) across across the the entire entire length length of of the belt belt to bring bring itit into into positi position on M below the hoisting device (8).
•
Dism Disman antl tle e the the conv convey eyor or fram frame e (3) (3) on the tens tensio ioni ning ng sta stati tion on
•
Secu Secure re tens tensio ioni ning ng pull pulley ey from from slip slippi ping ng
•
Remove the the tensioning un unit (5 (5)
Figure 24
0 v e R 3 1 0 2 / 1 1
7 - 18
2-492-20980 (Item 02)
Figure 25
•
Lift Lift the tensio tensionin ning g pulle pulley y (4) under under the the plat platform form of the the disch discharg arge e hopper hopper with with the the chain chain hoist (8). (See also Chapter 5.2 "Hoisting devices and slinging equipment" .)
Figure 26
•
Remove th the gui guid de ra rails (9) (9) (See Figure 24) 24)
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 19
•
Lift Lift the the conv convey eyor or belt belt (2) (2) unde underr the pla platf tfor orm m of the the discha discharge rge hop hopper per and attach to the corresponding suspension points (1) with rope or chain hoists. (See also Chapter 5.2 "Hoisting devices and slinging equipment" .)
•
In order order to roll roll out the the pull pulley ey later later place place roun round d piece pieces s of wood wood (3) on on the belt belt which which is is lying on the ground under the pulley.
•
Lowe Lowerr the the tensi tension onin ing g pul pulle ley y ont onto o the the rou round nd piece pieces s of of woo wood. d.
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: • Attach the rope or chain hoists (4) on the pontoon (5) (see also Chapter 5.2 "Hoisting devices and slinging equipment") equipment" ) ( A). A ). •
Detach Detach the the tensi tensioni oning ng pulle pulley y from from the chain chain hoist hoist (6) and and pull pull out out with with the the pullin pulling g tool tool on the pontoon. Turn over the round pieces of wood (3) at the same time ( B ).
•
Pull out the tension tensioning ing pulle pulley y until until it outs outside ide of the the belt belt and and can can be be lifted lifted again again with with the chain hoist (6) (C ( C).
•
Detach Detach the pullin pulling g tool tool (4), (4), lift lift the the tensi tensioni oning ng pull pulley ey and and rotate rotate itit by 90°( 90°( D).
•
Place Place the the tens tensio ioni ning ng pul pulle ley y belo below w the the cran crane e (7) (7) on a supp suppor ortt (E (E).
The tensioning pulley can now be lifted from the area of the steel construction with the crane (7). 0 v e R 3 1 0 2 / 1 1
7 - 20
2-492-20980 (Item 02)
Figure 28 0 v e R 3 1 0 2 / 1 1
The tensioning pulley is installed in the reverse order of sequence.
2-492-20980 (Item 02)
7 - 21
7.3.3
Repla placing cin g the the driv drivin ing g pull pulle ey For removal of the driving pulley: •
Use the tension tensioning ing pulley pulley to rela relax x the the tensi tension on on on the convey conveyor or belt belt (1) (1) acros across s its entire length (Figure (Figure 19, 19, Item 2).
•
Dism Disman antl tle e the the dust dust and and the the disc discha harg rge e hoo hood. d.
•
Dism Disman antl tle e the the plough plough-t -typ ype e scr scrap aper er (3) (3) and and swin swing g it off. off.
•
Lift Lift the the convey conveyor or belt belt into into the drive drive stat station ion with with the the liftin lifting g gear gear to provide 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).
•
Remo Remove ve the the cou coupl plin ing g guar guard d hood hood and and cou coupl plin ing g con conne nect ctio ion. n.
•
Remo Remove ve the bear bearing ing bolt bolts s (2) (2) on the the dri drivi ving ng pull pulley ey (5). (5).
•
Mount Mount the the drivi driving ng pull pulley ey (5) (5) with with lifti lifting ng stra straps ps on on a C-ho C-hook. ok. Make Make sure sure the the pulle pulley y is suspended properly in the C-hook (see also Chapter 5.2 "Hoisting devices and slinging equipment"). equipment").
•
Use a mobil mobile e crane crane to lift lift the drivi driving ng pull pulley ey out out of of the the roof roof of the the stee steell struc structure ture and set down.
0 v e R 3 1 0 2 / 1 1
7 - 22
2-492-20980 (Item 02)
Figure 29
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 23
7.3.4
Co n v ey o r b el t Removal •
Rele Releas ase e the the conv convey eyor or bel beltt (1) (1) usin using g tens tensio ioni ning ng spi spindl ndles es (2). (2).
•
Lift Lift the the mat mater eria iall gui guide de (4) (4) and and the the fee feedi ding ng shoe shoe (5). (5).
•
Deta Detach ch the two two fro front nt scrap crape ers (6). (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 attention to the carrying carrying side side of the the conveyor conveyor belt. belt. • Vulcanising Vulcanising of of the conveyor conveyor belt belt is to be be executed executed by an expert expert company. 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. For tensioning the conveyor belt see Chapter 5.9 "Assembling and tensioning the conveyor belt". belt".
0 v e R 3 1 0 2 / 1 1
7 - 24
2-492-20980 (Item 02)
Figure 30
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 25
7.3.5
Car r y i n g i d l er s Blocking carrying idlers cause damage to the conveyor belt (1) thus are to be exchanged immediately. Removing the carrying idlers •
Remo Remove ve guar guard d pla plate tes s ifif nec neces essa sary ry..
•
Lift Lift the the mat mater eria iall gui guide de (4) (4) and and the the fee feedi ding ng shoe shoe (5). (5).
WARNING Risk of injury from r azor azor sharp edges on the worn-out carrying id lers. Death or severe bodily injuries are possible • Wear Wear suitab suitable le prote protecti ctive ve cloth clothing ing,, • Do not not touch touch the edges edges of of the carry carrying ing idle idlers. rs. Installation Installation is carried out in reverse order of sequence.
0 v e R 3 1 0 2 / 1 1
Figure 30
7 - 26
2-492-20980 (Item 02)
7.3.6
Fr o n t s c r ap er See also ANNEX also ANNEX 9.5 "Scrapers B6C" •
Loosen Loosen the the clamp clamping ing strips strips (1) (1) of the scra scraper per in in front front of the driv driving ing pull pulley ey and and adjus adjustt or exchange the scraper fin (2).
•
Adju Adjust st the the hei heigh ghtt of scra scrape pers rs wit with h set set scre screws ws (3). (3).
Figure 31
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 27
7.3.7
Pl o u g h -t y p e s c r ap er •
Loosen Loosen the the clam clamping ping strips strips (1) (1) of the ploug plough-t h-type ype scra scraper per (2) (2) and and adjust adjust or exchan exchange ge the plastic plates (3).
•
Adjus Adjustt the the heig height ht of of plou plough gh-ty -type pe scr scrap aper ers s usin using g set set scre screws ws..
Figure 32
0 v e R 3 1 0 2 / 1 1
7 - 28
2-492-20980 (Item 02)
7.3.8
Materi teria al guid gu idin ing g mech mecha anism nism and and fee feeding ding shoe shoe •
Loosen Loosen the clampi clamping ng stri strips ps (3) (3) of of the the feedi feeding ng shoe shoe (1) and the materi material al guid guiding ing mechanism (2) and then readjust the rubber strips (4) or replace them.
Figure 33
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 29
7.3.9
Pullull-ro rope p e emerg merge ency ncy swit switch ch See also ANNEX also ANNEX 9.8 "Safety devices" •
Clean Clean the pull-r pull-rope ope emergen emergency cy switch switch (1) and check check for proper proper functi functionin oning. g.
•
Foreig Foreign n matte matterr must must not not obstr obstruct uct the pull pull-ro -rope pe emerg emergency ency switch switches. es. Pull Pull ropes ropes (2) (2) and tension springs (3) must move freely.
•
Set the the spri spring ng tensi tension on high high enough enough for the pull-ro pull-rope pe emer emergenc gency y switc switch h to be actu actuate ated d if the rope breaks.
See Chapter 7.2.1 for 7.2.1 for details of the inspection intervals.
Figure 34
0 v e R 3 1 0 2 / 1 1
7 - 30
2-492-20980 (Item 02)
7.3.10
Belt Belt tra track ckin ing g swit switch ch See also ANNEX also ANNEX 9.8 "Safety devices" •
Clean Clean the belt belt track tracking ing switch switches es (1) and check check for proper proper functi functioni oning. ng.
•
Forei Foreign gn mat matte terr must must not not obs obstr truct uct the the belt belt trac tracki king ng swi switch tches. es.
See Chapter 7.2.1 for 7.2.1 for details of the inspection intervals.
Figure 35
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 31
7.3.11
Monit onitor orin ing g of the the torq torque ue See also ANNEX also ANNEX 9.8 "Safety devices" •
Clean Clean the the puls pulse e gener generato atorr (1) of the the spee speed d control control and chec check k for for prope properr functi functioni oning. ng.
Foreign matter must not obstruct the pulse generator. See Chapter 7.2.1 for 7.2.1 for details of the inspection intervals.
Figure 36
0 v e R 3 1 0 2 / 1 1
7 - 32
2-492-20980 (Item 02)
7.3.12
Belt Belt bre br eak mon monit itor orin ing g •
Clean Clean the the Belt Belt break break monit monitorin oring g (1) (1) switc switch h and and make make sure sure it func function tions s prope properly rly..
Foreign matter may not obstruct the function of the switch. Pull ropes (2) and tension springs (3) must be freely movable.
Figure 37
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 33
7.4
B ear i n g s wi wi t h ad ad ap t er sl s l e ev e s Removal •
Mark Mark the positi position on of of the the adapte adapterr sleev sleeve e on the the shaft shaft and unlock unlock the adap adapter ter slee sleeve ve nut by bending up the locking plate (fig. 1).
•
Unscre Unscrew w the the adapt adapter er slee sleeve ve nut nut by by some some turns turns.. Place Place a drive drive cap or a tube tube secti section on against the adapter sleeve nut and loosen the bearing by strong, uniformly distributed blows (fig. 2).
•
If the the beari bearing ng is is assem assemble bled d on a bright bright shaft shaft,, the tool tool is to to be put put on the inne innerr ring ring of the bearing (fig. 3).
0 v e R 3 1 0 2 / 1 1
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 dam age during fitting. The following fitting sequence is to be adhered to: •
Push the adapte adapterr sleev sleeve e up to the the mark marked ed posi position tion on the the shaft shaft (fig. (fig. 4). 4). This This work work is facilitated by expanding the sleeve slot using a screw driver.
•
Unpack Unpack the bear bearing ings s and and check check the radial radial bearing bearing cleara clearance nce in the the state state as deli delivere vered. d. The bearings are identified correspondingly.
Markin Markin g means: C0
- Normal bearing clearance
C3
- Bearing clearance larger than normal
C4
- Bearing clearance greater than C3
•
Check Check the the beari bearing ng clea clearan rance ce as as shown shown in fig. fig. 5 by by putti putting ng a feeler feeler gaug gauge e betwe between en the outer ring and the unloaded roller.
0 v e R 3 1 0 2 / 1 1
INFORMATION
Do not over roll the measuring blade of the feeler gauge, rather pull it between the roller and the outer ring. •
Push the bearin bearing g onto onto the the adap adapter ter sleeve sleeve,, screw screw on the the adap adapter ter sleeve sleeve nut and tighten until the required clearance reduction is reached (fig. 6).
2-492-20980 (Item 02)
7 - 35
Required Required bearing cl earance: earance: 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.
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).
0 v e R 3 1 0 2 / 1 1
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 After press pressing ing on the the beari bearing, ng, the adapte adapterr sleev sleeve e nut nut must must be remove removed, d, the the lock locking ing 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 t o one groove in the nut is bent down (fig. 9). In this way, the adapter sleeve nut is locked in place.
•
Chec Check k the the clea cleara ranc nce e of the the bea beari ring ng once once agai again. n.
•
Ass Assemble ble th the be bearing ho housing. ng.
CAUTION Plant damage through installation faults Damage to the machine/plant or its environment is possible 0 v e R 3 1 0 2 / 1 1
• If several several bearings bearings are removed removed at the same same time, the the parts are are to be marked marked in order to avoid parts of the loose and fixed bearing being mixed up. • Fixed rings must be inserted inserted for the the fixed fixed bearings bearings..
2-492-20980 (Item 02)
7 - 37
•
The hollow hollow spac spaces es of of the bearin bearings gs as well well as those those of the housing housings s are are to be fille filled d with grease. See Chapter 8.5 "Lubricating instructions". instructions" .
Guide values for the reduction of the radial clearance and and the axial displacement when moun ting spherical roller bearings Bearing bore d o v er
Ax ial di sp lac emen t1
Reduction of radial bearing clearance
up to
min
mm
m ax
Cone 1:12 min
mm
m ax
Cone 1:30 m in
mm
m ax
Min. permissible residual clearance clearance after mounting bearings with initial clearance C0
mm
C3
C4
mm
30
40
0,020
0,025
0,35
0,40
-
-
0,015
0,025
0,040
40
50
0,025
0,030
0,40
0,45
-
-
0,020
0,030
0,050
50
65
0,030
0,040
0,45
0,60
-
-
0,025
0,035
0,055
65
80
0,040
0,050
0,60
0,75
-
-
0,025
0,040
0,070
80
100
0,045
0,060
0,70
0,90
1,75
2,25
0,035
0,050
0,080
100
120
0,050
0,070
0,75
1,10
1,90
2,75
0,050
0,065
0,100
120
140
0,065
0,090
1,10
1,40
2,75
3,50
0,055
0,080
0,110
140
160
0,075
0,100
1,20
1,60
3,00
4,00
0,055
0,090
0,130
160
180
0,080
0,110
1,30
1,70
3,25
4,25
0,060
0,100
0,150
180
200
0,090
0,130
1,40
2,00
3,50
5,00
0,070
0,100
0,160
200
225
0,100
0,140
1,60
2,20
4,00
5,50
0,080
0,120
0,180
225
250
0,110
0,150
1,70
2,40
4,25
6,00
0,090
0,130
0,200
250
280
0,120
0,170
1,90
2,70
4,75
6,75
0,100
0,140
0,220
280
315
0,130
0,190
2,00
3,00
5,00
7,50
0,110
0,150
0,240
315
355
0,150
0,210
2,40
3,30
6,00
8,25
0,120
0,170
0,260
355
400
0,170
0,230
2,60
3,60
6,50
9,00
0,130
0,190
0,290
400
450
0,200
0,260
3,10
4,00
7,75
10,00
0,130
0,200
0,310
450
500
0,210
0,280
3,30
4,40
8,25
11,00
0,160
0,230
0,350
1
Applicable only to solid steel shafts
0 v e R 3 1 0 2 / 1 1
7 - 38
2-492-20980 (Item 02)
7.5
Sc r ew ed an an d bo bo l t ed co c o n n ec t i o n s Al way s p ro tec t al l s cr ewed and bo lt ed c on nec ti on s ag ain st co rr os io n.
7.5.1
Mac h i n e st s t r u c t u r es
Fo r m a c h i n e s t r u c t u r e s :
St an d ar d
Qu al i t y
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
DIN 6916
C 45 hardened
DIN 609
8.8 / 10.9 / 12.9
Hexagon socket head cap bolt with short head Hexagon nut Washer Hexagon fitted bolts
•
Use Use only only the foll follow owin ing g bol bolts ts and nut nut qual qualit itie ies s tog toget ethe her: r:
Screw quality: Nut quality:
8.8 8
10.9 10
12.9 12
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
7 - 39
Tightening Tightening torques for machine structures Calculated with µk = 0.14 (new bolts, without post-treatment) in accordance with VDI 2230
Tightening torque Ma (Nm) Class
Bolt d iameter iameter 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
Hi gh gh -t en en si si l e b ol ol t ed ed jo j o in in ts ts 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).
7 - 40
•
Use bolts, bolts, nuts and washer washers s from from one one manu manufac facture turerr only. only. A unifo uniform rm prot protecti ection on against corrosion is compelling.
•
Only Only use use pro prope perly rly oiled oiled bolts bolts in perf perfec ectt con condi diti tion. on.
•
Use Use a torqu torque e wren wrench ch to to produ produce ce the the requ require ired d bolt bolt pret preten ensi sion onin ing g forc force. e.
2-492-20980 (Item 02)
0 v e R 3 1 0 2 / 1 1
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 Use only only the foll follow owin ing g bol bolts ts and nut nut qual qualit itie ies s tog toget ethe her: r:
Screw quality Nut quality
10.9 10
Fo r s t eel s t r u c t u r es :
12.9 12
St an d ar d
Qu al i t y
Hexagon bolt
DIN 6914
10.9 / 12.9
Hexagon nut
DIN 6915
10 / 12
Washer
DIN 6916
C 45 hardened
•
Use the requ require ired d preten pretensio sionin ning g forces forces indi indicat cated ed in the tabl table e below below or or in the the drawi drawing. ng.
Pretensioning forc es and and tightenin g torques applicable to torque method method s for sets corr esponding to tensi le strength class 10.9 accordin g to table 5, DIN DIN V 188 18800 00-7. -7. Torque method Basic pretensioning force Fv in kN
Dimensions
0 v e R 3 1 0 2 / 1 1
Required Required tigh tening torqu e to achieve the basic pretensioning force M A in Nm Hot-galvanised Hot-galvanised and lubricated 1)
As man uf act ur ed an d 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 frict ion grip c onnection i mmediately followi ng inst allation and at at least once a year: year:
2-492-20980 (Item 02)
7 - 41
Pre-stressed bolted connections (D connections (DIN IN V 18800-7 1.2.2.2) (1216) When using the torque method, at le ast 5 % of the sets of the conn ection 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-stressin pre-stressin g force accordin g to the torque method (DIN V 18800-7 Table 7) An gl e of add it io nal rotation
Measure
< 30°
none, pretensioning is adequate
30° to 60°
prete reten nsioning is adequate, check two adjacent bolts of the same connection
> 60°
replace the bolt, check two adjacent bolts of the same connection
0 v e R 3 1 0 2 / 1 1
7 - 42
2-492-20980 (Item 02)
8
L u b r i c at i o n
8.1
In tr tr od od uc uc t io io n an d t ec hn hn ic ic al al i n st st r uc uc ti ti on on s
WARNING Risk of injury through cleaning, inspection, maintenance, and repair work during operation operation Death or severe bodily injuries are possible • Cleaning, Cleaning, inspection inspection,, maintenance maintenance and repair repair work work may only be be carried out 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, service , and their technicians are available to our customers to answer any questions about appropriate lubrication.
CAUTION 0 v e R 3 1 0 2 / 1 1
System damage through improper lubrication Damage to the machine/plant or its environment is possible • Lubrication Lubrication and any any work in connecti connection on with lubricat lubrication ion must be carried carried out 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 (Chapter 8.4special 8.4special lubricants, Chapter 8.4.2). 8.4.2).
–
Carry out lubrication at the lubrication intervals specified in the lubricating instructions (Chapter (Chapter 8.5) 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.
0 v e R 3 1 0 2 / 1 1
8-2
2-492-20980 (Item 02)
8.2
St o r ag e o f l u b r i c an t s •
Carefu Carefully lly close close the the contain container er imme immedia diatel tely y after after removi removing ng lubr lubrica icant. nt. Store Store the 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.
•
Observ Observe e the the relev relevant ant nation national al occu occupat pation ional al safet safety, y, heal health th and and fire fire protect protection ion regulations when storing and handling lubricants.
•
Mark drums, drums, canist canisters, ers, oil cans cans and and greas grease e guns guns with with differ different ent colour colours s accor accordin ding g to their content. Mixing of lubricants is not allowed.
8.3
Gen er al in in f o r m at i o n o n lu l u b r i c at i o n
8.3.1
Oi l g r o u p s 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
= CL CLP PG PG (synthetic oils)
Poly-a-olefins
= CLP HC (synthetic oils)
Hydraulic oils
= HLP
Hydraulic oils
= HVLP (improved viscosity-temperature relationship)
INFORM INFORMATION ATION on th e gear uni t
To select oils, oils , refer to the viscosity indicated on the ID plate of the gear unit. Comply with the oil quality required 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 quantity depends on the oil level measured on the inspection glass, the dipstick or the oil overflow opening. 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.
0 v e R 3 1 0 2 / 1 1
When the oil type is 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 Carry out out regula regularr relubr relubrica icatio tion n at appropr appropriate iate interv intervals als.. Poor Poor lubric lubricati ation on may may caus cause e damage to the machine components.
•
When purgin purging, g, use use a low-vi low-visco scosit sity y oil oil type type of of the the same same basis basis and from from the the same same manufacturer; never mix mineral oil with synthetic oil.
•
Rinse Rinse out out and and dry dry the the bear bearing ing and bearing bearing housin housing g if a greas grease e with with diffe different rent soap soap properties is to be used.
•
Comple Completel tely y fill fill the the beari bearings ngs with with grease grease.. Only Only parti partiall ally y fill fill the the free free spac space e in the housing with grease (around 30-50 %). Then mount the bearings.
•
Comp Comple lete tely ly fil filll the the laby labyri rint nth h gaps gaps wit with h grea grease se..
•
Relu Relubr bric icat ate e the the bear bearin ings gs and and lab labyr yrin inth ths. s.
After lubricating: •
Do not not wipe wipe grea grease se off off lub lubri rica cati ting ng nipp nipple les/l s/lubr ubric icat atin ing g head heads! s!
CAUTION System damage from c ontamination in the grease Damage to the machine/plant or its environment is possible • Work in a clean clean manner! manner! Even minor minor contaminatio contamination n in the grease grease will affect affect the service life of the bearing points.
8.3.2
L u b r i c an t l i n es Ensure that the lubricant lines are thoroughly cleaned before commissioning and t hat they are filled with the prescribed lubricant.
0 v e R 3 1 0 2 / 1 1
8-4
2-492-20980 (Item 02)
8.3.3
Op en to to o t h ed ge gear s
DANGER Risk of injury through cleaning, inspection, maintenance, and repair work during operation operation Imminent danger of death or severe bodily injuries. Open toot hed rim driv es and and toothed racks may draw draw in and crush parts of the body • Never lubricate lubricate the machine when the machine is running. running .
Thoroughly clean open toothed rim drive units and toothed r acks before lubrication. Apply lubricant in a thin and even layer.
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
8-5
8.4
Tab l e o f l u b r i c an t s (In d ex 8)
8.4.1
St an d ar d l u b r i c an t s
8.4.1.1
L u br br ic ic at at in in g o ilil s
Index numbe r
Us ed f o r
Cl as s
A r al
BP
ESSO
Fuchs Europa
Mo b i l
Sh el l
Tex ac o
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
K l ü b er
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
Klüberoil 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
Klüberoil 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
Klüberoil 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
Klüberoil 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
Klüberoil 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
Klübersynth GEM 4-150 N
D2
ISO VG 220 CLP HC
Degol P AS 220
Enersyn EP-XF 220 (is no longer produced)
Renolin Unisyn CLP 220
Mobilgear SHC XMP 220
Omala HD 220
Pinnacle EP 220
Klübersynth GEM 4-220 N
D3
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
Klübersynth 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
Klübersynth GEM 4-460 N
D5
ISO VG 680 CLP HC
Renolin Unisyn CLP 680
Mobilgear SHC XMP 680
Omala HD 680
C3
Gear units and gear motors
Synthetic gear oil
8-6
2-492-20980 (Item 02)
Klübersynth GEM GEM 4-680 N
0 v e R 3 1 0 2 / 1 1
Index numbe r
Cl as s
A r al
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
G3
ISO VG 220 CL
G4
E3
Us ed f o r
Synthetic gear oil Cannot be mixed with mineral oil.
Non-return devices
F1
G1
G2
Neck bearings and pinion shaft bearings
BP
ESSO
Fuchs Europa
Mo b i l
Renolin PG 150
Glycolub e 220
S h el l
Tex ac o
K l ü b er
Tivela S 150
Synlube CLP 150
Klübersynth GH 6-150
Renolin PG 220
Glycoyle HE 220
Tivela S 220
Synlube CLP 220
Klübersynth GH 6-220
Renolin PG 320
Glycoyle HE 320
Tivela S 320
Synlube CLP 320
Klübersynth GH 6-320
Renolin PG 460
Glycoyle HE 460
Tivela S 460
Synlube CLP 460
Klübersynth 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 460
Teresso 46
Klübersynth 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
Klüberoil 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
Klübersynth GEM 4-220 N
Index number
Mi n i m u m r eq u i r em en t t o DIN
Po u r p o i n t
A
=
Oil to DIN 51524-2 based on mineral oil
- 24 °C to - 27 °C
B
=
Oil to DIN 51524-3 based on mineral oil
- 42 °C
C
=
Oil to DIN 51517-3 based on mineral oil
- 9 °C bis - 24 °C
D
=
Oil to DIN 51517-3 based on poly-a-olefins
- 30 °C to - 48 °C
E
=
Oil to DIN 51517-3 based on polyglycols
- 27 °C bis - 45 °C
F+G
=
Oil to DIN 51517-2 based on mineral oil
—
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
8-7
8.4.1.2
L ub ub ri ri ca cat in in g gr gr ea eas es es 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
Us ed f o r
Cl as s
A r al
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 and grease lubrication systems
NLGI 0 KPO K-20
Energrease 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
Mo b i l
Sh e l l
Tex ac o
K l ü b er
Mobilux EP 023
Simnia Grease 000
Mobilplex 44
Alvania GL 00
Marfak 00
MICROL UBE GB 00
Alvania grease EP ROEP1 OEP1
Multifak EP 0
MICROL UBE GB 0
CENTOP LEX GLP 500
MICROL UBE GL 261
Heavy-dut vy-duty y lubri lubrica catin ting g gre greases ses Marking to DIN 51502 Base oil: Poly-alpha-olefin (PAO), fully synthetic Saponification type: Gel Gel t hickener Application temperature range: - 50 °C to 200 °C Application range: high-speed bearings (e.g. pinion assembly bearings, …)
Index numbe r
Us ed f o r
Cl as s
L1
Roller bearings (high temperature load)
NLGI 2
A r al
BP
ESSO
Fu c h s
Mo b i l
Sh el l
Tex ac o
K l ü b er
Mobiltemp SHC 100
0 v e R 3 1 0 2 / 1 1
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
Us ed f o r
Cl as s
L2
Roller bearings (high temperature load)
NLGI 2
A r al
BP
ESSO
Fu c h s
Mo b i l
Sh el l
Mobilith SHC 220
Albida PPS 2
Tex ac o
Marking to DIN 51502 Base oil: Poly-alpha-olefin (PAO), fully synthetic Saponification type: Gel Gel th ickener Application temperature range: - 50 °C to 180 °C Application range: slow-speed bearings (e.g. feed conveyor, chain scraper, ...)
Index numbe r
Us ed f o r
Cl as s
L3
Roller bearings (high temperature load)
NLGI 1,5
A r al
BP
ESSO
Fu c h s
Mo b i l
Sh el l
Tex ac o
Mobiltemp SHC 32
8.4.2
Sp ec i al l ub ub r i c an t s
8.4.2.1
Lubr Lubric ica ating ting oils oils for for tub tube e mill mills s Application range: Lubrication of toothed rim
0 v e R 3 1 0 2 / 1 1
Index numbe r
Lubrication of toothed rim (nozzle greasing greasing )
M1
Klüber
Fuchs Lubritech
b l ac k
t r an s p ar en t
Priming lubrication by hand
GRAFLOSCON A - G1 ULTRA
Klüberplex AG 11-462
Ceplattyn 300
M2
Inlet process
GRAFLOSCON B - SG-00 SG-00 ULTRA
Klüberfluid 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
Klüberfluid C-F 8 ULTRA
Ceplattyn KG 10 HMF
M4
Oper Operat atin ing g lub lubri rica cati tion on from from + 5 °C up to 100 100 °C °C
GRAFLOSCON C - SG-1000 Ultra
Klüberfluid C-F 4 ULTRA
Ceplattyn KG 10 HMF - 1000
M5
Operating lubricant from + 15 °C up to + 120 °C
GRAFLOSCON C - SG-2000 Ultra
Klüberfluid C-F 3 ULTRA
Ceplattyn KG 10 HMF - 2500
2-492-20980 (Item 02)
8-9
8.4.2.2
Lubric Lubrica ating ting oils oils for gyra gyratory tory crushe crushers rs Oils
Index numbe r
Us ed f o r
CASTROL
Cl as s
CA STROL
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
Us ed f o r
P1
CA STROL
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
Grease lubrication system for spider bearing P2
P3
8.4.2.3
Roller bearings
CASTROL
Cl as s
BIO TOP
Molub-Alloy Bio Top 9488-1
Hy dr dr od od yn yn am am ic ic c ou o u pl pl in in gs gs Application range: Power transmission oils Pour point: up to - 42 °C
Index numbe r
Us ed f o r
Cl as s
A r al
BP
ESSO
Fuchs Europa
Mo b i l
Sh el l
Tex ac o
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 0 v e R 3 1 0 2 / 1 1
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. .4.2.4
In d ex n u m b er
Us ed f o r
Cl as s
Cas t r o l
K l ü b er
Mo b i l
Q2
Hydraulic couplings (Voith)
ISO VG 32
Hyspin AWH-M 32
Summit HySyn FG 32
SHC 524
CAST CASTRO ROL L Hysp Hyspin in AWHAWH-M M 32
=
Pour Pour point oint - 42 °C
Klüber Summit HySyn FG 32
=
Pour point - 45 °C
Mobil SHC 524
=
Pour point - 63 °C
Hydraulic ydraulic oils for low tempe tempera rature ture applica pplications Application temperature range: min. - 40 °C up to max. + 70 °C Pour point: up to - 60 °C
8.4.2.5
In d ex n u m b er
Us ed f o r
Cl as s
Sh e l l
R1
Hydraulic systems
ISO VG 32
Tellus Arctic 32
Fireire-resis resista tant nt hydra hydrauli ulic c oils oils Flash point: 300 °C Fire point: 360 °C Pour point: down to - 20 °C
In d ex n u m b er
Us ed f o r
Cl as s
Fu c h s Eu r o p a
Qu i n t o l u b r i c
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
0 v e R 3 1 0 2 / 1 1
2-492-20980 (Item 02)
8 - 11
8.5
L u b r i c at i n g i n s t r u c t i o n s
CAUTION System damage damage due to inco rrect indic ations of oil qu antities and/or oil classes Damage to the machine/plant or its environment is possible • The specificat specifications ions on the type type plates plates of gears, gears, motors etc. etc. referring referring to the oil oil quantity and oil class to be filled take priority over the specifications in these lubricating instructions. • Observe Observe the lubricating lubricating instruc instructions tions for component components s given given in ANNEX in ANNEX 9. 9.
Lubricating point
1
Bevel spur gearbox
2
Driving pulley bearing
3
Tensioning pulley bearing
4
Carrying idlers
Quanti ty
1
2
2
Lubricant acc. to Chapter 8. 4 index number
Lubricating intervals in operating hours Oi l c h an g e
Rel u b r i c at i o n
Lubricant quantity Oi l c h an g e
D3
1. Oil change after 500 h; additional oil changes after 8000 - 12000 h but no later than every 4 years
K5
every 6000 hours or every 2 years
approx. 7.7 kg each
K5
every 6000 hours or every 2 years
approx. 3.2 kg each
Check the oil every day when the gear unit is at a standstill
Rel u b r i c at i o n
approx. 270 litres
Lifetime-lubrication
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Figure 38
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9
A NNEX
9.1
Dr aw i n g s
9.2
Dr i v e u n i t
9.3
Dr i v i n g pu pu l l ey an d te ten s i o n i n g pu p u l l ey
9.4
B el el t w ei g he her wi w i th th ev ev al ua uat i on on el el ec ec tr tr on on ic ic s
9.5
S c r a p e r s B 6C
9.6
Hydra ydraul ulic ic cy cyli lind nde er ENERPAC CLLLL-508
9.7
Hy d r au l i c h an d p u m p
9.8
Saf et y d ev i c es
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9-1
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9-2
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9.1
Dr aw i n g s
Nam e
Dr aw i n g No .
Discharge conveyor GSSF 2000x47.7
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
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9-3
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9-4
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9.2
Dr i v e u n i t
0 v e R 3 1 0 2 / 1 1
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9-5
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9-6
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9.3
Dr i v i n g pu pu l l ey an d te t e n s i o n i n g p u l l ey
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9-7
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9-8
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9.4
B el t w ei gh gh er er wi w i th th ev ev al al ua uat io io n el ec ec tr tr on on ic ic s
0 v e R 3 1 0 2 / 1 1
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9-9
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9.5
Sc r ap er s B 6C
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9.6
Hydra ydraul ulic ic cy cyli lind nde er ENERPAC CLLLL-508
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9.7
Hy d r au l i c h an d p u m p
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9.8
Saf et y d ev i c es
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