A-P - 2.0 - EN (45345) - Unlocked

Operation Manual
Pivoting Pan Conveyor SPB

F.L.Smidth document no: 60045466
Customer: F.L.Smidth INC. Proj.-no.: ............................................ 45343

2040 Avenue C * Bethlehem (AUMUND)
PA 18017-2188
USA Conveyor-no.
AUMUND: .............................................. 45345
Operator: Cementos Argos S.A. FLS EQ. no.: ..................................... 471.DB210

Colclinker Plant
Cartagena, Colombia Cem. Argos EQ. no.: 00704ALM113.DB210
Year of manufacture: .................................. 2008

Order-no.: ................ 4-0720001-143077
(customer) ..........................................................
PN-gb Deck-gb 09/07
Revision: Rev. 02 / 08. May 2008
AUMUND Fördertechnik GmbH • Saalhoffer Straße 17 • D-47495 Rheinberg

Tel.: + 49 2843 72-0 • Fax: + 49 2843 60270 • E-Mail: aumund@aumund.de
Structure of the operation manual
BHB-AUFB 06/97 GB
Operation manual
Contents
Table of Contents
General 1
Safety 2
Operation 3
Faults 4
Maintenance and Servicing 5
Lubrication 6
Spare Parts 7
Annex 1
Documentation and information concerning individual 8
components such as gear boxes, couplings etc.
Annex 2 - Drawings 9
Erection 10
Package Lists 11
--- 12
15.02.97/GB/G-INH.tbl
PN G-IN-A 02/97 GB 1
Operation Manual
Chapter 1 / General Survey
Table of contents
1.1 Preface ........................................................................ 2

1.2 Copyright ..................................................................... 3
1.3 Warranty, Guarantee, Liability ................................... 3

1.4 Standards, System of units ...................................... 3
1.5 Transport, Storage ..................................................... 4
1.5.1 Transport ...................................................................... 4
1.5.2 Storage ......................................................................... 6
1.6 Service, Maintenance ............................................... 10
1.6.1 Service address for USA and Canada .................... 12
1.7 Description ................................................................ 13

1.7.1 General outline ........................................................... 13
1.7.2 Project 45345 /
item 471.DB210 / 00704ALM113.DB210
SPB 1600/200/5 ......................................................... 14
1.7.3 Flat valve
item 471.DG130 / 00704ALM113.DG130
item 471.DG140 / 00704ALM113.DG140 .................. 18
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Operation Manual
1.1 Preface
Dear customer,
The present operating instructions contain the information required for the
assembly, operation and maintenance of your system.
A safe and trouble-free operation may be expected, if
• the system will be operated according to its purpose and if only the
specified material will be conveyed.
• the information and instructions given in this manual will be strictly

adhered to.
The owner or responsible persons authorized by him must have read and
understood the complete operating manual.
All persons put in charge of the assembly, the operation or maintenance of
the system must at least have been instructed with regard to:
• Safety instructions
• Information and instructions concerning their task
The safety instructions in this operating manual only consider the

dangers resulting from the system supplied as well as its operation.
May be they are a supplement, however, in no case a replacement for
the safety instructions valid on site.
The owner is responsible for the adherence to the safety instructions

valid on site and the proper operation of the system.
Illustrations in this operating manual are normally only schematic diagrams

and their details may deviate from the design supplied. The enclosed draw-
ings are decisive for the design supplied.
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Operation Manual
1.2 Copyright
The copyright for these operating instructions remains with the company:
AUMUND Fördertechnik GmbH
The present operating instructions are only meant for the owner and his
personnel. Complete reproductions or parts thereof are only admissible for
the use of the owner. Handing over to third parties, complete or in parts is
forbidden.
1.3 Warranty, Guarantee, Liability
Basically, the contract concluded between the contracting partners to the

system supplied applies.
Start, duration and scope of the warranty, guarantee and liability as well as
all further conditions may be noted from the present contract. For points
which are not contractually determined the relevant legal regulations apply.
In case of application beyond the intended purpose any guarantee and

liability become null and void.
1.4 Standards, System of units
Upon design and engineering of the system the relevant German and Euro-
pean standards as well as contractual agreements, if any, were considered.
Basing on the SI unit system we exclusively apply the metrical system of
units in our whole documentation including drawings and parts lists.
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Operation Manual
1.5 Transport, Storage
1.5.1 Transport
Type of transport and packing depend on the transport goods and the trans-
port conditions. The transport conditions can only be considered by us in so
far, as they are known to us as part of the order. Therefore, generally valid
remarks cannot be made to the kind of transport and packing.
The goods should be carefully inspected immediately upon arrival at the
final destination.
Transport damage must be immediately notified to the forwarding

agents, i.e.:
• in case of unpacked goods immediately upon transfer with
entry into the consignment note.
• in case of packed goods within one week after receipt.
You will find information with regard to the transport of individual

components during assembly in the assembly instructions.
However, the following principles are to be observed for the transport on

site:
CAUTION!
Only assign instructed personnel to carry out transport
work. All hoisting and lifting gear must comply with the lo-
cally applicable safety regulations and be in operationally
reliable condition.
Failure to observe this may lead to accidents causing dam-
age to property and personal injuries.
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Operation Manual
• Transport all components in a way that avoids deforming or damaging

them.
• Do not put steel ropes or chains around machined or painted surfaces.
CAUTION!
The existing standard attaching points are only designed
for the transport of the related component. The complete
conveyor or component modules assembled to form larger
units may only be transported, if this has been contractually
stipulated so that the construction will have been designed
accordingly.
CAUTION!
The following points may never be used as attaching
points:
• Handles on covers and doors
• Bearing housings
• Shafts, axles, spindles
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Operation Manual
If a component does not feature any identified attaching points, it will

also be possible to pute sling bands around it for lifting.
In such a case, observe the following:
• Do not put the sling bands around sharp edges, or protect the bands by
intermediate layers.
• Mount the bands so that they do not slip off or secure them against
slip-off.
• Lift the component in its center of gravity. If need be, determine the
appropriate attaching point during an lifting attempt.
1.5.2 Storage
Unless any special agreements have been concluded, the components sup-
plied are protected against corrosion as follows:
AUMUND components
All structural steel elements have been steel-shot blasted (Sa 2 1/2).
All surfaces not treated with an anticorrosive agent, feature a primer coat of
zinc-phosphate paint (colour RAL 3009 or RAL 7032, min. 40 µm thick).
An additional coat of paint will only exist, if it has been ordered.
All surfaces where other parts need to be attached in an exactly fitting
position, such as shaft journals or borings, are provided with a waxlike
anticorrosive. In addition, shaft journals are wrapped in with a fabric tape to
protect them against mechanical damage.
Anticorrosive agent: Hölterol MF 1424 (for information refer to Chapt. 8)
The surface of conveyor sections, bucket strands or chains are sprayed with
a waxlike anticorrosive agent. Hollow spaces and clearances are only par-
tially protected against corrosion.
Anticorrosive agent: Rivolta K.S.P.317 (for information refer to Chapt. 8)
Applies to all components: A long-time outdoor storage without

having taken any additional measures is not permissible.
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Operation Manual
Supplier components
We can only influence the corrosion protection of supplier components such

as gearboxes or couplings, if this has already been specified correspondingly
in the order. Details on the standard corrosion protection can normally be
found in the documentation of the relevant supplier.
Prior to storing compoments, their corrosion protection shall be

checked for damage and, either touched up or fully renewed, if re-
quired.
Only use those anticorrosive agents for touch-up work that have
been used by us. The application of other agents may lead to unfore-
seeable reactions, as e.g. considerably complicating the later remov-
al of the agent. If an anticorrosive agent other than the one used by
us is planned to be applied, the existing corrosion protection shall be
removed completely beforehand.
Anticorrosive agents may not be applied on rubber or plastic parts or
on shaft seal rings.
The climatic conditions and the ambient influences may considerably

vary. Possibly, this requires further measures to be introduced in
addition to the ones mentioned below. In case of doubt, the required
measures should be agreed with us. In that case, however, we will
need detailed information on the local storage conditions.
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Operation Manual
Storage < 3 months
The manufacturer's instructions on individual components such as

gearboxes, electric motors or the like may contain requirements that
are more demanding than the subsequently listed instructions. In such
instances the manufacturer's instructions will have higher priority.
• Protect all components against the direct impact of weather, soiling

and aggressive ambient influences.
• The storage of the components in a closed or roofed in space is always

preferrable to outdoor storage.
• Ensure an adequate venting of closed spaces.
• The foundation must be dry.
• Store all components so as to prevent their twisting, tilting or slipping.
• Always store components which are unprotected or inadequately

protected against corrosion under weatherproof conditions or provide
them with a reliable protection against corrosion.
• Adequately vent waterproof covers to avoid the condensation of water.
• Always provide for a weatherproof, dust-proof and vibration-free

storage of gearboxes, electric motors, and other assemblies equipped
with roller bearings.
• Store gearboxes and electric motors in accordance with their installa-

tion position and do not stack them above each other.
• Ensure a dry storage of all electric devices and equipment.

If there is no appropriate place available, ensure the airtight packing of
the devices, also providing it with desiccants.
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Operation Manual
• Protect bucket elevator belts against the following impacts:

- solar radiation
- UV radiation (fluorescent lamps)
- ozone (sparking electrical apparatuses)
- direct heat impact
- oil, grease, benzene, acids, solvents
• Deposit the rolled-up bucket elevator belts on an axle on stands so that

they are stored in a suspended position.
Make sure to turn the belt rolls by 90 degrees at least once per month.
We recommend a monthly check of the condition of the components

in storage and of the safety measures.
Storage >3 months up to 18 months
Further to the measures already mentioned, the below listed additional or

amended rules should be considered.
• Ensure storage in a closed or roofed in place. Outdoor storage is not

permissible.
• Thoroughly inspect all components every two months for corrosion

and / or damaged corrosion protection. In case of high humidity reduce
the inspection interval to one month.
• Immediately eliminate corrosion. Immediately touch up any damaged

corrosion protection or apply it anew.
• Rotate gear units, electric motors and other shafts supported by roller
bearings at least every three months by several turns.
This will newly distribute the grease in the roller bearings and improve
the corrosion protection.
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Operation Manual
1.6 Service, Maintenance
A regular, carefully carried out maintenance will have considerable in-

fluence on the operational safety of your system. We recommend to keep a
record, in which all regular inspections and the work carried out will be
entered.
Our service employs expert personnel and will gladly carry out for you
• all regular maintenance work
• all repairs required
• consulting, supervision and implementation of assembly and retrofit

jobs
Do you have any questions about

- our conveying systems?
- this manual?
Do you need
- spare parts?
- or any assistance?
Please feel free to contact one of the following addresses:
AUMUND Fördertechnik GmbH

Saalhoffer Straße 17
D-47495 Rheinberg
Phone: +49-2843-720
Fax: +49-2843-60270
E-mail: aumund@aumund.com
Service, Assembly
Phone: +49-2843-72304
Fax: +49-2843-72479
E-mail: Radmacher@aumund.de
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Operation Manual
Spare parts
Phone: +49-2843-72301
Fax: +49-2843-60902
E-mail: schoeps@aumund.de
For information on the Aumund Group please visit our website:

www. aumund.com
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Operation Manual
1.6.1 Service address for USA and Canada
AUMUND Corporation
1825 Barrett Lakes Blvd
Suite 520
Kennesaw GA 30144
USA
Telefon: 001-770-226-9578
Fax: 001-770-953-484
E-Mail: sales@aumundusa.com
Managing director: Mr. G. Conroy

E-Mail: gconroy@aumundusa.com
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Operation Manual
1.7 Description
The installation supplied has been designed according to the conditions of

application known to us.
The individual conveyors have been designed for their transport task and the
material to be conveyed, which are specified in the contract. Each conveyor
may only be applied for the contractually agreed transport task and the speci-
fied material to be conveyed.
All design details, such as track guiding, kind of drive, details about the
material to be conveyed as well as further technical data are to be
found in the installation drawing to the corresponding project.
The following description only gives a survey about the installation supplied
and its design. If further information is requested, you may refer to the en-
closed drawings.
1.7.1 General outline
The plant supplied consists of:
Quantity Project Item Conveyor type Designation

471.DB210 /
1 45345 SPB 1600/200/5 pivoting pan conveyor
00704ALM113.DB210
471.DG130 /
1 45345 Flat valve 700/700 Flat valve
00704ALM113.DG130
471.DG140 /
2 45345 Flat valve 700/700 Flat valve
00704ALM113.DG140
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Operation Manual
1.7.2 Project 45345 /

item 471.DB210 / 00704ALM113.DB210
SPB 1600/200/5
The deep drawn pan conveyor mainly consists of:

• drive station
with:
drive unit
drive shaft with sprocket wheels
• runway
• conveyor safety guards
• conveying elements
• take-up station
with:
guide sprockets
sprockets for turning point
tensioning device
• intermediate discharges
with:
gear motor
The drive station mainly consists of:

• station steel structure
• bracket to accommodate the drive elements
(not existing in case of a shaft-mounted gearbox)
The station steel structure is a sectional steel sheet structure being bolted
and/or welded to the supporting surface. Chain idlers within the drive station
ensure the precise guidance of chain strands.
The drive set has been designed according to the technical and contractual
requirements. Thus, different types and combinations of motors, couplings
and gear boxes are applied. The exact design as well as information to the
individual components are included in the installation drawing and in
chapter 8.
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Operation Manual
The drive shaft is supported in self-aligning roller bearings being equipped

with two dust-tight flanged bearing housings. The bearing housings are
bolted to the drive station. The sprocket wheels have parted toothed rims
(toothed segments) which can be replaced without separating the conveying
elements.
Between the two sprockets, idlers are arranged as support for the carrier
plates of the conveying elements.
The runway mainly conisists of:

• runway rails in the upper and lower run
• runway supports
The runway rails are standard rail sections being connected by means of
special fishplates and screws (rail joints) in order to form the runway. In
order to take into account any thermal expansions and/or movements of
structure, expansion joints are provided, if required. The place of installation
is shown on the respective general arrangement drawing.
The runway supports are of tubular sectional steel structure on which the
runway rails are mounted and fixed.
Conveyor safety guards consisting of individual wire mesh elements are

arranged in the entire accessible area of conveyor.
The conveying elements mainly consist of:

• carrier plates with carrier axle
• chains
• rollers
The carrier plates are trough-shaped, bent plates with a straight bottom.
Tubes for the carrier axle and roller brackets are welded to the carrier plate
bottom. The chains are bolted to the end of the carrier axle with projects
over the carrier plate. The link chains are provided with surface-hardened
bolts and bushes. Consequently, wear is reduced and the service life is
increased.
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Operation Manual
At their ends, the carrier plates overlap like scales. At the return stations, the
carrier plates lift off; thus, wear can be reduced to a minimum. When the
runway rails are lowered, the conveying elements permit an intermediate
discharge at any point.
At the return points, the carrier plates are turned; conveying can thus be
effected in the upper as well as in the lower run.
Take-up station
The station’s steel structure is made of sectional steel plates; the structure is
bolted to a base frame.
The base frame with skids is arranged on rails.
For tensioning, the complete station can be moved by means of tension
spindles (1).
The station is provided with four deflection wheels (2) which are supported
in roller bearings and provided with exchangeable toothed segments.
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Operation Manual
Two so-called turn points (3) serve to turn over the carrier plates (4).
Forced discharge of the carrier plates in the take-up station is ensured by a
special rail guidance. Therefore, the take-up station will always be the last
discharge station.
Chain idlers (5)within the take-up station ensure the precise guidance of
chain strands.
Automatic discharge station in the upper run

The side plates for the taking up of the inlet point as well as the rail guidan-
ce with non-return latch are connected to the runway supports and screwed
to the substructure. The inlet points are arranged on a switch shaft which is
supported in the side plates.
The points are actuated via a lever assembly by a geared motor.
The final position of the inlet point’s actuating shaft are controlled by proxi-
mity switches. The inlet point can be actuated during operation. A signal
transmitted by a proximity switch mounted at the drive station or the di-
scharge station determines the right switching instant
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Operation Manual
1.7.3 Flat valve

item 471.DG130 / 00704ALM113.DG130
item 471.DG140 / 00704ALM113.DG140
The flat valve is used for opening and closing the material storage (clinker
silo, hopper, etc.), and also for material take-off.
The flat valve mainly consists of:

• the frame
• the valve element
• the geared motor
• rack and pinion
The frame is a profile steel construction with guides for the valve element.
The pinion shaft is supported on flange bearings which are equipped with
articulated bearings.
A geared motor is installed as adjusting drive. The drive automatically will
be switched off in the respective final position.
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Operation Manual
Chapter 2 / Safety
Contents
2. Safety ........................................................................... 3
Introduction................................................................. 3
2.1 General ........................................................................ 4
2.1.1 Standards ..................................................................... 6
2.2 Symbols, Warning Signs ........................................... 7

2.3 Lockout / Tagout ......................................................... 9
2.3.1 Definitions ..................................................................... 9
2.3.2 Lockout Conditions ..................................................... 11
2.3.3 Assignment of Responsibility...................................... 11
2.3.4 Lockout Procedure .................................................... 12
2.3.5 Installing, Servicing, Maintaining
or Repairing Equipment .............................................. 13
2.3.6 Startup Procedures .................................................... 14
2.3.7 Training and communication ...................................... 14
Periodic inspection ..................................................... 15
2.3.8 Lockout device requirements ...................................... 16
2.3.9 Group lockout and Shift Changes .............................. 16
Shift or personnel changes ......................................... 17
2.4 Safety Regulations ................................................... 18
2.4.1 General ....................................................................... 18
2.4.2 Selection and qualification of personnel ..................... 19
2.4.3 Working Places For the Operating Personnel ............ 20
2.4.4 Sound Emissions / Noise ........................................... 20
2.4.5 Regulations and instructions for operation ................. 20
2.4.6 Regulations and instructions on
maintenance and service............................................ 22
2.4.7 Regulations and instructions for lubrication ................ 26
2.4.8 Safety Information for hydraulics ................................ 27
2.5 Accident prevention regulations ............................. 28
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Operation Manual
Chapter 2 / Safety
2.6 Safety and Protection Equipment .......................... 28

2.7 Employee Training ................................................... 29
2.8 Safety Label Replacement ....................................... 29
2.9 Note: The Machine May Not Match
That Shown in This Manual ..................................... 29
Appendix
Typical Minimal Lock-Out Procedure (Example)
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Appendix A
TYPICAL MINIMAL LOCKOUT PROCEDURES
OSHA - 1910.147 App A

Regulations (Standards - 29 CFR)
Table of Contents
• Part Number: 1910

• Part Title: Occupational Safety and Health Standards
• Subpart: J
• Subpart Title: General Environment Controls
• Standard Number: 1910.147 App A
• Title: Typical Minimal Lockout Procedures
LOCKOUT PROCEDURE
Purpose
This procedure establishes the minimum requirements for the lockout of energy isolating devices whenever main-
tenance or servicing is done on machines or equipment. It shall be used to ensure that the machine or equipment
is stopped, isolated from all potentially hazardous energy sources and locked out before employees perform any
servicing or maintenance where the unexpected energization or start-up of the machine or equipment or release of
stored energy could cause injury.
Compliance with the Program
All employees are required to comply with the restrictions and limitations imposed upon them during the use of
lockout. The authorized employees are required to perform the lockout in accordance with this procedure. All
employees, upon observing a machine or piece of equipment which is locked out to perform servicing or mainte-
nance, shall not attempt to start, energize, or use that machine or equipment.
Type of compliance enforcement to be taken for violation of the above: decided by the employer.
Sequence of Lockout
1. Notify all affected employees that servicing or maintenance is required on a machine or equipment and
that the machine or equipment must be shut down and locked out to perform the servicing or mainte-
nance.
Table 1: Name(s)/Job Title(s) of Affected Employees and How to Notify
Name Job Title How to Notify
1/4
2. The authorized employee shall refer to the company procedure to identify the type and magnitude of
the energy that the machine or equipment utilizes, shall understand the hazards of the energy, and
shall know the method to control the energy.
Table 2: Type(s) and Magnitude(s) of Energy, Its Hazard, and the Methods to
Control the Energy
Type and Magnitude of Energy Hazard Method to Control the Energy
3. If the machine or equipment is operating, shut it down by the normal stopping procedure (depress the
stop button, open switch, close valve, etc.).
Table 3: Type(s) and Location(s) of Machine or Equipment Operating Controls
Type of Controls Location of Controls
4. Deactivate the energy isolating device(s) so that the machine or equipment is isolated from the energy
source(s).
Table 4: Type(s) and Location(s) of Energy Isolating Devices
Type of Energy Isolating Devices Location of Energy Isolating Devices
5. Lock out the energy-isolating device(s) with assigned individual lock(s).
2/4
6. Stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating fly-
wheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or
restrained by methods, such as grounding, repositioning, blocking, bleeding down, etc.
Table 5: Type(s) of Stored Energy - Method(s) to Dissipate or Restrain
Type of Stored Energy Method to Dissipate or Restrain
7. Ensure that the equipment is disconnected from the energy source(s) by first checking that no person-
nel are exposed, then verify the isolation of the equipment by operating the push button or other nor-
mal operating control(s) or by testing to make certain the equipment will not operate.
Return operating control(s) to neutral or OFF position after verifying the isolation of the equipment.
Table 6: Method of Verifying the Isolation of the Equipment
Method of Verifying the Isolation of the Equipment
8. The machine or equipment is now locked out.
Restoring Equipment to Service
When the servicing or maintenance is completed, and the machine or equipment is ready to return to normal oper-
ating condition, the following steps shall be taken:
1. Check the machine or equipment and the immediate area around the machine to ensure that nones-
sential items have been removed and that the machine or equipment components are operationally
intact.
2. Check the work area to ensure that all employees have been safely positioned or removed from the
area.
3. Verify that the controls are in neutral.
4. Remove the lockout devices and reenergize the machine or equipment.
3/4
NOTE
The removal of some forms of blocking may require reenergization of the machine before safe removal.
5. Notify affected employees that the servicing or maintenance is completed and the machine or equip-
ment is ready to be used.
[54 FR 36687, Sept. 1, 1989 as amended at 54 FR 42498, Oct. 17, 1989; 55 FR 38685, Sept. 20, 1990; 61 FR
5507, Feb. 13, 1996]
4/4
Operation Manual
Chapter 3 / Operation
Table of contents
3 Operation..................................................................... 2
3.1 General ........................................................................ 2
3.2 Operation and control devices
Pivoting pan conveyor (SPB) .................................... 4
3.2.1 Emergency Switch ........................................................ 4
3.2.2 Speed control ............................................................... 4
3.3 Commissioning of the conveying system ................ 5
3.3.1 Use of soft start devices ............................................... 6
3.3.2 Checks prior to first commissioning .............................. 7
3.3.3 Checks prior to each further commissioning ................ 8
3.3.4 Checks after extended periods of non-use ................... 9
3.3.5 Commissioning ........................................................... 10
3.4 Operation................................................................... 11
3.4.1 Pivoting pan conveyor (SPB) ...................................... 12
3.4.1.1 Operating Temperatures of Rollers ............................ 12
3.5 Shutdowns of plant .................................................. 13

3.5.1 Shutdown procedure (at the end of work) .................. 13
3.5.2 Emergency shutdown ................................................. 13
3.5.3 Shutdown in the event of faults and repairs ............... 14
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Operation Manual
3 Operation
This chapter has always to be used in combination with chapter 2 -

safety. This chapter deals only with special safety instructions being
not included in chapter 2. If this chapter is removed from the user’s
manual or copied, chapter 2 - safety - has always to be added.
3.1 General
This chapter is intended to familiarize the user (operator) with all require-
ments for a proper and safe use of plant.
The following is assumed:
• the plant is in a proper, safe and ready to use condition
• the user (operator) is prepared for his relevant duties, instructed and
familiarised with all requirements relating to safety and accident
prevention.
• the user (operator) is suitably qualified to use the plant (see chapter 1).
• the local conditions, particularly the working area of plant permit

commissioning.
It should be noted that this chapter deals only with the operation of such
sub-assemblies which can be locally operated and whose control- and oper-
ating elements are an integral part of AUMUND’s scope of supply.
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Operation Manual
The interlocking conditions are mostly tailored to the respective plant

and prescribe control- and switching sequences which have always
to be observed. They are automatically taken into account during
assembly by AUMUND or made known to customer for his assembly
work.
If the plant is commissioned without taking into account the interlock-
ing conditions inadmissible functions with consequential damages at
the own or other plants can result.
In cases where Aumund plants, sub-assemblies or parts thereof are

integrated in the works plant concept and operation, control and
monitoring are subject to a centralised control, the operator is respon-
sible for the preparation and/or provision of related operating instruc-
tions.
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Operation Manual
3.2 Operation and control devices

Pivoting pan conveyor (SPB)
The following information only concerns the AUMUND scope of supply.

Any further information vital for a safe operation of the conveyor has to be
added to the manual by the operator.
3.2.1 Emergency Switch
In the accesible areas of the conveyors pullrope emergency switches are

arranged in certain distances. These emergency switches are connected to
each other through ropes (pullropes) or with fixed points at the conveyor.
For the actuation of a pullrope emergency switch: draw pullrope
Thereby, in case of emergency, the conveyor stoppage can be effected from

all points in the accessible area. The emergency switches are normally
locked after actuation and have to be released prior to a new commissioning
of the conveyor. There can be differences in operation depending on the
make of emergency switch. If the emergency switches belong to the
AUMUND scope of supply, please refer to the corresponding information in
chapter 8.
3.2.2 Speed control
During operation impulses are transmitted to a proximity limit switch. These

impulses are recorded by an evaluation device and compared to the specified
minimum number of impulses. If the actual number of impulses (number of
rotations) deviates from the specified values, the conveyor including feed
has to be shut down immediately.
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Operation Manual
3.3 Commissioning of the conveying system
The following text concerns the conveying system in general, since the checks
and procedures apply to the commissioning of all design types.
If a type of design requires particular or additional checks or procedures,
this will be mentioned in the following description.
CONVEYING DIRECTION
Operating the conveying system in the wrong conveying direction may
damage it, and leads to the loss of warranty.
• Only operate conveying systems in the conveying direction
specified on the general arrangement drawing.
• Not even a short run into the direction opposite to
the conveying direction is permitted, regardless of the reasons
involved.
• An operation involving running in two conveying directions
will only be permissible in case of conveying systems
which we explicitly declared to be suited for
this purpose.
DUAL DRIVE
( = two drives on one common drive shaft)
Non-observance of the following provisions can cause damage to
various drive elements.
• Do not switch on dual drives individually or with a delay.
• The power consumption figures of both drive motors must
be identical. Check the power consumption prior to
the first loading of the conveyor.
In case of different power consumption figures, the oil filling of one of
the two hydraulic couplings needs to be changed to reach identical
power consumption figures.
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Operation Manual
3.3.1 Use of soft start devices
Dual drive
UNEVEN LOADS
Uneven loads of the two drives can result in damage or destruction of
individual drive elements.
• Do not operate dual drives in combination
with soft start devices.
It's very difficult to correctly adjust the soft start devices. For this
reason, damage to the drives due to wrong adjustments or malopera-
tions would be very likely.
Single drive
In case of single drives, soft start devices may be used.

In this case, compliance with the following is mandatorily required:
• The permissible starting torque may not exceed twice the amount of the
nominal motor torque for a duration of max. 5 seconds.
• After start-up, the running torque is to be limited to the nominal motor

torque.
When soft start devices are used, no D.O.L. start-up of the motor
may occur. Such a D.O.L. start-up shall be excluded technically.
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Operation Manual
3.3.2 Checks prior to first commissioning
Before the conveying system is switched on for the first time, its readiness for
operation must be determined by the following checks:
Check that:
1. All tools, screws and other loose parts are removed from the
conveyor(s)
2. All lifting gear, ropes and chains required for assembly are removed.
3. The direction of rotation of drive motors and geared motors is correct.
WARNING!
The operation of drive and geared motors in the wrong direc-
tion of rotation may cause serious or even lethal injuries and
considerable damage to property.
Check the direction of rotation as specified in
chapter 5.
4. Gears, hydraulic couplings, backstops, bearings, drives and other parts

to be lubricated are sufficiently filled and lubricated with the correct
lubricant (see chapter 6)
UNEVEN LOADS
If hydraulic couplings are filled with different quantities of oil, overload-
ing and damage to a drive can occur.
• In the case of dual drives, both hydraulic couplings
must be filled with exactly the same quantity of oil.
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Operation Manual
5. All protective devices (hoods, protective screens in front of rotating

parts etc.) are fitted and functional.
6. All limit switches are fitted, correctly adjusted and functional.
7. All monitoring devices are correctly adjusted and functional.
8. All inspection and assembly openings are closed and locked.
Before the conveying system is switched on for the first time, the
"Checks prior to each further commissioning" must have been finalised.
3.3.3 Checks prior to each further commissioning
Prior to each commissioning the operator has to make sure:
• that the conveying system is safe to operate and has no apparent faults.
The following must be observed in particular:
- defects at electric lines
- faults in the supporting structure
- damaged warning and monitoring devices (flashlamps, horns,
hanging lamps)
- faulty safety switches
- faulty control elements (switches, buttons)
- tripping hazards, loose parts and dangerous coverings (e.g.
grease, ice) on all ways in the conveyor area, especially on stairs
and walkways
- dirt caused by conveying material
- faulty lamps and luminaires
- complete fitted protective devices
- unclosed doors and inspection openings
• no person is present in the working area of the conveying system or in

its hazardous zone
• no objects are present on the conveying system or lean against the same
which could loosen during operation of the conveying system and thus
constitute a danger to man or system.
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Operation Manual
Where safety and operational reliability are impaired, shut down the
conveying system and inform the service department (see also chapter 2
- safety). For all other faults, inform the service department and initiate
repair.
3.3.4 Checks after extended periods of non-use
This chapter must be observed in addition to the checks specified in the

above chapters before the conveying system is restarted after an extended
period of non-use (several days and weeks).
Check:
• whether possible repair and maintenance work (assembly, adjustments)

have really been completed. Familiarize yourself with any changes and
new conditions.
• the conveying system with regard to:

- loose or loosened parts
- missing parts
- mechanical damage
- heavy fouling of moving parts and sub-assemblies
- corrosive damage
• whether possibly loose parts (e.g. tools and disassembled spare parts)
are present on the conveying system which could fall down during
movement or cause damage to subsequent conveying systems as a result
of their further transport.
• whether all ways in the conveyor area, especially stairs and walkways
are without oil, grease and other dirt.
• whether all safety and warning signs are still completely available
(see chapter 2 - safety).
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Operation Manual
• the functionality of the following safety devices:

- emergency stop switches
- limit switches
- protective screens
- protective covers
3.3.5 Commissioning
The conveying system may be commissioned, if
• the checks described above have been carried out successfully.
• the safety regulations valid in situ have been fulfilled.
• the operator's prescriptions have been adhered to.
Commissioning at low temperatures
Even, if the system is designed for very low temperatures, the following
temperature limits apply for the starting in cold condition:
• -40° C / -40° F for gear units
• -30° C / -22° F for hydraulic couplings

If the pour point of the used oil is above -30°C / -22°F, this
pour point will be the temperature limit for the start-up of the
hydraulic coupling.
DAMAGE AT GEAR UNITS AND COUPLINGS!

If gear units and couplings are colder than indicated above, they must
be preheated. The oil fillings must at least have the a.m. tempera-
tures.
For preheating apply e.g. the installed gear unit heating, fan heaters,
radiant heaters or electric blankets.
Do not use open flames!
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Operation Manual
3.4 Operation
Please read the following chapters as regards information and instructions for
the operation of the equipment.
Contents and scope of this information, however, depend on the AUMUND
scope of supply.
Scope of Supply 1 (Rule)
The electric control is not included in the AUMUND scope of supply. In this
case, we cannot give any instruction concerning the operation and procedure.
Scope of Supply 2
The electric (local) control is included in the AUMUND scope of supply,

however, does not consider its integration in the total equipment
(e.g. loading device).
Our instructions only refer to the handling and procedure of the AUMUND
part of the control.
Scope of Supply 3 (Exception)
The complete electric control is included in the AUMUND scope of supply.

A complete operating instruction is included.
As regards the scopes of supply 1 and 2 we could either not prepare

any operation instruction or the same is not complete. At this place,
however, we urgently recommend to describe the necessary
operating steps as detailed as possible in order to guarantee at least
a safe and trouble free operation.
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Operation Manual
3.4.1 Pivoting pan conveyor (SPB)
3.4.1.1 Operating Temperatures of Rollers
As a standard the supporting of our rollers allows operating temperatures up

to 125° C. The lubricant may be applied up to 150° C.
Above 80° C the rollers must by all means be lubricated subsequently.
Please consider the information in chapter 6.
According to our experience temperatures above 80° C are not achieved in
normal operation. In case of doubt, the actually achieved roller temperatures
must be determined by the operator. In case of temperatures above 125° C
other suitable rollers must be used according to the advice of our enginee-
ring department.
Before stopping the conveyor, it should be emptied by all means in order to

avoid heating of the rollers through hot conveying material.
When the rollers are situated in covered areas of the conveyor, when it is
stopped, the danger of excessive heating is especially high. If rollers were
heated excessively in case of unexpected standstill (disturbance), the relative
rollers must be checked for their smooth running. Stuck or very sluggish
rollers must be exchanged. In case of rollers which are only slightly more slug-
gish than a new roller, the complete grease filling must be exchanged.
For hints to the lubrication please refer to chapter 6.
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Operation Manual
3.5 Shutdowns of plant
3.5.1 Shutdown procedure (at the end of work)
We recommend to empty all conveyors prior to the shutdown, as problems

during restarting could occur under certain circumstances.
For the plant described herein there are no special regulations or rules of
conduct to be observed for shutdown procedure. If special rules and regula-
tions should result from the integration into the overall plant these have to
be made known by the operator.
3.5.2 Emergency shutdown
Emergency shutdown must only take place in emergency situations (e.g.

danger to the life and limb of persons, danger to the plant, fire hazard). This
function is initiated by actuating an emergency stop switch.
After initiation of the “Emergency Stop” operator must switch on and start
the plant only when it is ensured that the cause of initiation of this function
has been eliminated and the operation of plant no longer constitutes a haz-
ard.
The electric control of plant is not part of AUMUND’s scope of

supply so that this chapter includes no and/or only restricted informa-
tion on the emergency shutdown.
We, however, strongly recommend to include at this juncture the
information required on the type of emergency shutdown equipment
and its functioning.
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Operation Manual
3.5.3 Shutdown in the event of faults and repairs
In the event of a fault, individual or all functions can be shutdown automati-

cally by the built-in safety devices.
As far as provisions for these shutdowns are made in the operating sequence
(e.g. in the event of overload), the measures to be taken are noted in
chapter 4 - faults.
All malfunctions (as indicated, e.g. by the respective pilot lamps on the
control panels of control stand), may only be cleared by “authorised, quali-
fied personnel”.
The machine must be shutdown for repair work.
Switch off main current supply of plant and secure against uninten-
tional restart.
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Operation Manual
Chapter 4 / Faults
Table of contents
4 Faults ........................................................................... 2
4.1 General ........................................................................ 2
4.2 Faults, cause, remedy ................................................ 2
4.2.1 Pivoting pan conveyor (SPB) ....................................... 3
4.2.2 Flat valve ...................................................................... 4
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Operation Manual
Chapter 4 / Faults
4 Faults
4.1 General
Faults cannot be prevented even with the most careful selection of compo-
nents and assemblies.
To avoid unnecessary idle and downtimes in the event of a fault, the follow-
ing provides helpful advice and assistance in fault recognition and
clearance.
Detailed information permit the operator to localize the source of fault and
to take the required steps to avoid and to clear faults.
Reference is also made to the additional information in chapter 8 - Annex.
When undertaking repairs, the instructions in chapter 1-general, 2-

safety and 5-maintenance and repairs must be observed.
The clearance of faults on electrical equipment requires specialised know-

ledge.
This work may only be carried out by specially trained service personnel or
Aumund engineers or their authorised representatives.
4.2 Faults, cause, remedy
The following tables show possible faults, their causes as well as remedy
measures.
Furthermore, our After-Sales-Dpt. will assist you, if required.
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Operation Manual
Chapter 4 / Faults
Fault Possible cause Possible remedy

Conveyor starts Speed control faulty Readjust speed indicator or replace
briefly and then in the event of damage
switches off or Clean sensor field
stops during Check fuse
operation Readjust or replace speed monitor
Check lines and connection points
Turbo-coupling transmits no Check safety fuse and oil filling and
or not sufficient power replace safety fuse and fill in correct
oil quantity, if required
Conveyor is blocked Eliminate blocking of conveyor
Conveyor switches Emergency switch was Determine and eliminate cause of
off during opera- actuated emergency stop, then unlock actuated
tion emergency switch
Fuse released Replace fuse or switch on overload
release. In the event of repeated
occurence determine and eliminate
cause.
Thermal motor detector has Motor(s) to be cooled, probable dirt
been released to be eliminated
Thermal control element of Eliminate overcharge and blocking
turbo-coupling released of conveyor,
check correct oil filling
Level indicator released Eliminate overfilling and cause such
as reduction and deviation of
material feed
Stopping distance Brake is not correctly Right adjustment of braking torque
of conveyor is too adjusted, brake linings are and reserve stroke, renewal of the
long, brake does worn or oiled-up, brake linings, repair or exchange of
not stop Eldro-device is defect Eldro-device (see special
information, chapter 8)
Rims of rollers Straight-run has changed - Adjust straight run
touch rails screwed connection conveyor Tighten screws,
plate/chain has loosened , Straighten or replace conveyor plates
conveyor plate or roller axle Straighten or replace roller axle
is bent
Runway rails are bent Straighten or replace runway rails
Discharge station Contact maker is defect or Exchange or right adjustment of
does not open/does wrongly adjusted contact maker (see chapter 5)
not open punctually
Limit switch at the inlet point Exchange of limit switch
is defect
01.00/GB/4ST1B.tbl
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Operation Manual
Chapter 4 / Faults
4.2.2 Flat valve
Fault Possible cause Possible remedy
Adjusting drive Limit switches are not Adjust limit switches correctly or
does not switch off correctly adjusted or defective replace them
in one or both final
positions
Locking element Locking element blocks Empty flat valve, remove caking
does not reach because flat valve is filled
final position with conveying material or Switch on adjusting drive only with
conveying material caked or flowing conveying material or empty
froze flat valve
Drive motor switched off by Look for and eliminate reasons for
protective motor switch motor overload,
e.g. blocked locking element
15.07.96/4FL10.tbl
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Operation Manual
Chapter 5 / Maintenance and servicing
Table of contents
5 Maintenance and servicing ........................................ 2

5.1 General ........................................................................ 2
5.2 Inadmissible activities ............................................... 3
5.3 Responsibilities .......................................................... 4
5.3.1 Inspection and repair work ........................................... 4
5.3.2 Acceptances ................................................................. 4
5.3.3 Official and statutory acceptances ............................... 4
5.4. Maintenance materials ............................................... 4
5.5 Spare parts .................................................................. 5
5.6 Disposal ...................................................................... 5
5.7 Tools and auxiliary aids ............................................. 5
5.8 Maintenance and servicing schedule ....................... 6

5.8.1 Plant in general ............................................................ 8
5.8.2 Pivoting pan conveyor (SPB) ...................................... 9
5.8.3 Flat valve .................................................................... 11
5.9 Maintenance and servicing ...................................... 12
5.9.1 Notes on cleaning ..................................................... 13

5.9.2 Replacement of spare parts ....................................... 14
5.9.3 Limit switches-Functional check ................................. 15
5.9.4 Test of sense of rotation - drive motor ........................ 16
5.10 Pivoting pan conveyor (SPB) .................................. 18

5.10.1 Tensioning the chain .................................................. 18
5.10.2 Sprockets ................................................................... 19
5.10.3 Link chain - Wear, Exchange ..................................... 22
5.10.4 Checking for wear of the rollers .................................. 27
5.10.6 Switch point control .................................................... 28
5.11 Tightening torques for bolts .................................... 29
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Operation Manual
5 Maintenance and servicing
This chapter has always to be used in combination with chapter 2-

manual or copied, chapter 2-safety has always to be added.
5.1 General
A precondition for perfect operation of the machine in addition to its use for
the intended purpose is proper maintenance, i.e:
• Regular inspections
• Regular lubrication
• Prompt replacement of wearing parts
• Immediate elimination of defects
When undertaking servicing and maintenance work, the applicable regula-

tions for prevention of accidents and official requirements must be observed.
This applies similarly to the avoidance of environmental nuisances and
damage such as:
• Unnecessary noise emission
• Inadmissible disposal of lubricants, paints and other toxic harmful

substances
• Unnecessary smoke and exhaust emission
When undertaking cleaning, maintenance and repair work, the machine or

individual components must not be damaged or their specific functional
characteristics altered.
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Operation Manual
5.2 Inadmissible activities
All conveyors shall only be operated in accordance with the convey-

ing direction indicated on the installation drawing. Even a short run of
the conveyor into opposite direction shall not be permissible, regard-
less of the reasons for such an operation.
A two-way operation will only be permissible in case of conveyors
which we have expressly stated to be designed for this purpose.
Non-observance can result in damage to the conveyor and leads to
the loss of warranty.
The following sub-assemblies are adjusted for optimal operation and func-
tion. It is therefore essential that settings are not altered; always restore the
same values and initial preconditions:
• Brakes
• Limit stop devices
• Overload protection devices
• Safety and protective devices
Refer any faults and problems to Aumund under the applicable service
address (see chapter 1 - general).
Operating limit switches, emergency stop switches, speed indicators, speed
monitors and level limit switches must not be rendered inactive or their
location and position altered.
All replaced switches must be checked for proper functioning directly after
their installation.
Protective covers must not be removed permanently. If protective covers

have to be removed for maintenance purposes, these must be replaced
properly on completion of work.
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Operation Manual
5.3 Responsibilities
5.3.1 Inspection and repair work
Regular inspections and maintenance and repair work must only be under-
taken by responsible, authorised persons (in-house service personnel, Au-
mund service personnel).
5.3.2 Acceptances
Repair and maintenance work must be supervised and accepted by an “in-

spector” with the necessary expertise.
5.3.3 Official and statutory acceptances
All official and statutory acceptances must only be carried out by officially
recognised experts.
Note
Acceptances may be subject to different regulations and procedures depend-

ing on the particular country concerned.
Requirements of the individual country are applicable.
5.4. Maintenance materials
Recommended are all maintenance materials approved by Aumund and/or

specified in chapter 6 - lubrication instructions and chapter 7 - Spare parts
list.
This includes all maintenance materials which can be found in the additional
information on sub-assemblies and components (see chapter 8 - annex).
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Operation Manual
5.5 Spare parts
As far as standard or DIN parts are not concerned, only the original or
recommended spare parts shown in the spare parts list (chapter 7 - spare
parts list) must be used.
Parts being not shown in the spare parts list can be procured by us upon
request.
Spare parts other than those mentioned above may only be used with the
express permission of Aumund. In this case, the applicable Aumund service
address should be contacted (see chapter 1 - general).
5.6 Disposal
All replaced materials and parts must be disposed of in a proper manner.
In addition to locally applicable, pertinent, statutory and other requirements

and guidelines, the following applies:
Prevent oils, greases and other liquid harmful substances from contaminat-
ing soil and do not discharge to the sewerage system.
Always fill used oil and grease into the containers provided.
Dispose of metal parts, plastics and glass separately, as far as possible.
5.7 Tools and auxiliary aids
For normal maintenance work, no special tools are generally necessary apart
from the tools normally used for fitters and electricians.
In cases were heavy parts have to be moved, suitable lifting gear, pressing
equipment or winches, e. g. crane, chain winch, hydraulic presses, etc., with
adequate bearing-, pressing- or tractive force must be used.
Where special tools have to be used for repairs on sub-assemblies such as

motors ,gears, etc., these are usually specified in the associated documents
of the sub-assembly, see chapter 8 - annex.
If this is not the case, please contact AUMUND.
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Operation Manual
5.8 Maintenance and servicing schedule
Necessary repairs result from inspection and test results.
The inspections and checks to be carried out are subdivided in the following
plan according to operating hours and maintenance intervals.
The following mean:
daily / weekly / monthl / yearly (examples)
X daily
X weekly
X monthly
X yearly
2 every 2 weeks
3 every 3 months (quarterly)
6 every 6 months (half yearly)
2 every 2 years
1.5 every 1 1/2 years (18 months)
each with each commissioning
beg with each beginning of shift
req as required
Category (Cat.) B = Work can (or must) be carried out during operation.
Category (Cat.) S = Work must be carried out with the machine

shutdown.
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Operation Manual
The following applies in principle:
1. First carry out all work necessary after lapse of the number of speci-
fied operating hours.
2. If an inspection interval is reached prior to lapse of the number of

specified operating hours, the specified work must be carried out and
the operating hours counted from zero.
For the inspection intervals, 24-hour daily operation of the machine was
taken as a basis.
WARNING!
Where functional tests, visual inspections or sounding
checks have to be carried out in individual cases during
operation of the machine, no persons must enter the haz-
ardous area.
Operating safety and reliability of the machine are subject to wearing parts
being changed before their wear limits are reached and adjustable compo-
nents are set to optimal values.
If a component is found to be worn during an inspection without

replacement having to be made, the inspection interval must be
reduced.
If additional explanations to the information in the maintenance and servic-

ing schedule are required, refer to the additional information in chapter 8 -
annex.
Normally additional information on the individual sub-assemblies is includ-
ed in chapter 8 - annex.
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Operation Manual
For maintenance and servicing it is absolutely required to refer to this addi-

tional information.
If any information supplied elsewhere deviates from the information in
chapter 8, the additional information in chapter 8 will be binding unless
otherwise specified.
For any further information on the individual tests contact Aumund under
the applicable service address, see chapter 1 - general.
5.8.1 Plant in general
N D W M Y
u a e o e
m Operating i e n a Further in-
b Sub-assembly l k t r Cat. formations Work to be undertaken
e hours y l h l see
r y l y
y
Complete plant X B/S Visual inspection, check for:
- leakages
- fouling
- rust
- mechanical damages
All Protective devices
Safety guards, X S Check condition

safety hoods fixing
protective effect
Emergency X B Check function and condition
switches and all
other switchgear
being required for
the protection of
persons
All switchgear X Check function and condition
being required for
the protection of
plant (speed-,
straight run control
etc.)
Warning-and X B Completeness, legibility

information signs
03.07.95/GB/5AL3.tbl
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Operation Manual
Maintenance and servicing
N D W M Y
u a e o e
m i e n a Further in-
b Operating l k t r
Sub-assembly hours Cat. formations Work to be undertaken
e y l h l see
r y l y
y
* Drive elements The drive elements contained in the conveyor and the documentation belonging to it are
(e.g. motor, gear listed in chapter 8. The necessary maintenance work may be learnt from the manufacturer's
unit, coupling, documentation and must be carried out in the time intervals indicated there.
brake)
1 Torque support 3 S Check fixture
Check for damage
1/all Drive shaft / 3 S/B Check bearings for:
axles in all stations - excess grease
(drive, take-up and - abnormal noise
discharge stations) - abnormal heating
Check bolted connections for:
- completeness
- tight fit
all Sprocket wheel After commissioning, after exchange Check bolted connections for:
(drive shaft, of the toothed segments - completeness
guide wheels, 100 h - tight fit
turning point) After the first inspection chapter 5 Check for wear:
3 S - tooth shape
- functioning
3 S chapter 5 Check bolted connections for:
- completeness
- tight fit
all Conveying elements 6 S Check bolted connections for:
- completeness
- tight fit
X B Check conveyor plates for damages
(visual inspection), adjust or replace
damaged conveyor plates
Chain X B Check for wear and damages (visual
inspection)
X S/B Check clamp rings for
- completeness
- tight fit
X S chapter 5 Check tension of chain
6 S chapter 5 Check wear (measurements)
all chain pulley X B Check for:
- completeness
- cakings
- smooth running
all Roller X B Check for:
- completeness
- cakings
- smooth running
- damages of stirrups
X S chapter 5 Check for wear (measurements)
* Number depends on type of design - see installation drawing 11.04/GB/5ST9A-1.tbl
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Operation Manual
N D W M Y
u a e o e
b Operating l k t r
Sub-assembly hours Cat. formations Work to be undertaken
e y l h l see
r y l y
y
all No-return latch X B Functional check
(take-up station,
3 S Check stop buffers for wear, exchange
discharge station)
them, if necessary.
all Input switch point X B Functional check
(discharge station)
Input switch point 3 S/B Functional check
control If necessary, correct adjustment of the
contact makers.
Steel structure 6 S Check bolted connections for:
- completeness
- tight fit
Check for:
- corrosive or other damages
Repair or replace deformed or worn parts
* Number depends on type of design - see installation drawing 01.00/GB/5ST9A-2.tbl
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5.8.3 Flat valve
N D W M Y
u a e o e
b Sub-assembly Operating l k t r Cat. formations Work to be undertaken
e hours y l h l see
r y l y
y
1 Housing 6 S Check for wear:
- in- and outlet openings
- locking element
- wear linings
1 Locking element 6 S Check bearing:
- bearing play
- smooth running
- bolted connections
1 Adjusting drive chapter 8 Acc. to separate maintenance instruction
(geared motor)
2 Limit switch X Functional check
X Wear (only in case of mechanical limit
switches)
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Operation Manual
5.9 Maintenance and servicing
The following chapters contain general and special information on underta-

king maintenance work. Wear limits and adjustment values are only specified
if not included in chapter 8. It is absolutely required to refer to the additional
information on the individual sub-assemblies and components included in
chapter 8 - annex.
During all maintenance and repair work the conveyor must be

reliably protected against unauthorised and/or unintentional set-
ting into operation. All parts of the conveyor, which will be loo-
sened, assembled or disassembled must be secured in such a way
that people cannot be endangered.
If the conveyor is equipped with a locking device for mainte-
nance work, the application will be as described in chapter 3.
If the conveyor starts operating during the course of work unin-
tentionally, severe injury or even death of people might result.
Switch-off, locking and resetting into operation during mainte-

nance- and repair work are to be determined by the owner in a
service instruction. Authorised service personnel and the safety
measures required are to be stated. The safety regulations valid at
site are to be followed.
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Operation Manual
5.9.1 Notes on cleaning
The following applies in principle:

If possible mechanical cleaning should be given the preference over cleaning
with chemical auxiliary agents.
Always wear protective clothing when working with solvents and

cleaning agents.
Casings, cooling ribs, openings and covers of components not only give
protection but also have additional functions such as cooling, insulation,
noise reduction, splash protection, etc.
Some of these functions can be significantly impaired or even rendered
ineffective through dirt deposits.
Several remedies for removing fouling:

• Stubborn fouling through crust formation, e.g. scraping, brushing.
• Slight fouling such as dirt layers and fine deposits, e.g. wiping, removal
by suction, brushing, sweeping.
• Grating sections, screens and other openings; if possible remove or
dismantle and subsequently, e.g. blow-out, brush-off, wash out or
brush-out.
• Oil and grease films, e.g. wiping, removal by suction, removal with
binder (e.g. sawdust). Always change contaminated lubricant (e.g. sand
deposits or contamination through foreign substances).
Loose dirt must not come into contact with rotating components
from where it can be hurled out. Non-observance can result in
personal injury or material damage.
PN-gb 5-9N 05/06 13

Operation Manual
Unscrew vent screws for inspection and inspect the thread and seal ring for
damage.
Always replace damaged screws and seal rings.
Sliding contacts and brushes are cleaned appropriate to the type of fouling:
Wipe off deposits and dust to prevent arcing.
Smooth rough surfaces with carborundum linen using a suitably adapted
grinding block.
Turn out-of-true slip rings with fine chip.
Do not blow-out moist or wet electrical apparatus and components (e.g.

motors, switches) with compressed-air, since water particles may enter
unprotected areas and impair or even damage insulation and the functional
characteristics.
Electrical machine parts or components which are not energized

in a dry condition can be live when moist or wet.
Before touching a moist or wet electrical component, check whe-
ther exposed parts are live by measurement.
5.9.2 Replacement of spare parts
The components of the Aumund equipments are hard-wearing and designed

for a long service life.
Should it be necessary to replace a component this work can be carried out
without any additional explanations or by means of the drawings supplied.
Should you have any questions please contact the Aumund service address
(see chapter 1).
PN-gb 5-9N 05/06 14

Operation Manual
5.9.3 Limit switches-Functional check
At the beginning of check it must be ensured that the plant or the functional
sequence can be switched off in case of overrunning of a faulty switch before
any damages will occur.
Always observe the safety regulations for work which has to be carried out
during operation.
Limit switches provided in the normal operational sequence are checked

during operation for reasons of expediency. This means that if during a nor-
mal complete operating cycle all functions are properly fulfilled the corre-
sponding limit switches are in order.
Limit switches which are not approached during operation must be manually
checked or by using a testing instrument.
As far as required refer for any further information to the wiring diagrams
and/or to the additional information in chapter 8 - annex.
PN-gb 5-9N 05/06 15

Operation Manual
5.9.4 Test of sense of rotation - drive motor
Gearboxes with back stop must not be operated with the wrong sense of
rotation. A wrong sense of rotation may result in a destruction of back stop.
This also applies to short-time starting. For the test of sense of rotation the
following instructions have to be observed.
Gearboxes with attached auxiliary drive must also not be operated

with the wrong sense of rotation in case no back stop is installed.
The motor of auxiliary drive may explode due to overspeeding.
Non-compliance with these instructions may lead to severe perso-
nal injury or to death.
The sense of rotation of the gearbox input shaft is marked.
For drives without backstop and/or without auxiliary drive the sense of
rotation of drive motor can be tested with the motor being installed.
If an auxiliary drive is attached, auxiliary drive and main gearbox are con-
nected by means of a freewheel-overriding clutch. Consequently the sense of
rotation of auxiliary drive motor can be tested with the motor being installed.
The conveyor only moves in case the sense of rotation is correct.
For drives with back stop and/or auxiliary drive the sense of rotation of
drive motor has always to be tested:
• prior to the first start of installation
• after a replacement of motor
• after disconnecting and reconnecting of electrical lines
• after work has been carried out at the electrical installation which
might result in a change of the rotary field
PN-gb 5-9N 05/06 16

Operation Manual
1st possibility
The sense of rotation can be tested by skilled personnel by means of a rotary

field instrument without starting the motor.
In this case the motor can already be connected with the gearbox.
2nd possibility
The sense of rotation is tested by a short start of motor.
In this case gearbox and motor must not be connected with each other or have
to be disconnected prior to starting.
• With turbo-couplings the oil must only be filled in after having carried
out the test of sense of rotation. With installations being in operation the
oil must be drained off prior to test and subsequently be filled in again.
• With flexible couplings the joining element must be fitted only after
having carried out the test of sense of rotation. With installations being
in operation it has to be removed prior to the test and subsequently be
fitted again. Since different makes of couplings are used please refer to
the additional information in chapter 8 for the disconnection of cou-
pling.
• If under special circumstances a disconnection of motor and gearbox
should not be possible in the way described above, the motor has to be
disassembled before testing the sense of rotation.
• With gearboxes without attached geared motor the back stop can be
disassembled as well. We, however, advise against this possibility
since this might affect warranty claims.
PN-gb 5-9N 05/06 17

Operation Manual
5.10 Pivoting pan conveyor (SPB)
5.10.1 Tensioning the chain
Trouble-free operation of the chain only will be possible with a correctly

pre-tensioned chain. A chain, not being pretensioned correctly or not being
pretentioned at all, might seriously damage the conveyor.
After the first assembly or after having exchanged the chain or having
carried out other working for which the chain had to be released, the con-
veyor must restart operation only after having re-tensioned the chain.
Only tension the chain when the conveyor is empty and when the chain is
cold (max. 30°C).
The correct chain tension has to be adjusted by means of 2 tension spindles.

In order to prevent the one-sided load of the conveyor, both tension spindles
have to be adjusted equally.
Concerning conveyors without curve, the correct chain tensioning can be

determined by measuring the chain slack. The chain is correctly tensioned
when sagging in the lowest tension area between two rollers by 10 – 20 mm.
Please note:
When measuring the chain slack, the two rollers, between which the slack is
measured, must lie on the runway rails.
The area of lowest chain tension is :

• in the lower run behind the drive station in case of even conveyor
course
• in the lower run in front of the take-up station in case of ascending
conveyor course
Additional Tests with the Pivoting Pan Conveyor

Operating the unloaden conveyor, the heel of the take-up station can lift
slightly from the guide rails (max. 5 mm). If this will not be the case, tighten
the tension spindles in small steps.
SPB-gb 5-9-2a 11/04 18

Operation Manual
5.10.2 Sprockets
Toothed rims must be replaced once the hardened zone of the tooth spaces
has been worn away. It is not possible to give precise dimensions as a limit
for permissible wear due to the shape of the teeth and the tooth spaces.
Instead, compare the wear against a new toothed rim or a template, or make
an assessment on the basis of the running behaviour of the conveyor.
Considerable wear of the toothed segments occurs:
• if the tooth shape differs by more than 6 mm at any point from the
shape of a new toothed rim when a comparison is made against a new
toothed rim or a template (see Fig. SPB1 and SPB2)
• if the chain does not leave the tooth space of the sprocket wheel
smoothly, but jerkily.
• if the edges of the tooth spaces are abraded.
The toothed segments have to be replaced:

1. if wear acc. to the above symptoms can be observed.
2. if the chain is exchanged against a new one.
Without a chain exchange, the toothed segments must only be exchanged, if
the chain elongation has not yet exceeded the dimension X50 .
SPB-gb 5-9-2a 11/04 19

Operation Manual
Fig. SPB1a Tipical wear at the drive wheel
Fig. SPB1b Tipical wear at the tension wheel
In normal situations it is possible to replace the toothed segments while the

chain is still in place. In special cases where there is little room, it may be
necessary to open the chain and remove the conveying elements of the
sprocket wheel or to dismantle the conveyor plates.
All the toothed segments of all the sprocket wheels on one shaft or axle
must be replaced at the same time. Always use new fixing materials (see the
spare parts list for dimensions and quality). Tighten up bolts and screws to
the correct torque. The seatings of screw head and nut as well the thread
must always be clean and free of grease.
The conveyor must be operated several times during the work

described below. Ensure that there is nobody in the danger zone,
especially within the conveyor itself while the conveyor is mo-
ving. Ensure during this work that the conveyor cannot be star-
SPB-gb 5-9-2a 11/04 20

Operation Manual
ted up accidentally or by an unauthorized person.
Work steps:
Only the principle is shown. The exact procedinghas to be stipulated under
consideration of the local conditions.
1. Empty conveyor if possible.
2. Conveyor to be moved until the toothed segment to be exchanged are
not in the meshing area.
3. Remove the screws and the toothed segment.
4. Insertnew tooth segment and fix with new srews.
Do not yet tighten the srews with the necessary torque and do not yet
screw on safety nuts.
Note:
The toothed segments are marked by engraved figures in the inter-
sections.
The same figures = matching intersections
5. Carry out steps 2, 3 and 4 for the other toothed segments.
6. Once all the new toothed segments have been installed, tighten up all
the screws to the correct torque.
7. Run the conveyor for one or two hours and check the torque, making
any corrections needed.
Screw on safety nuts and tighten fast!
Further tests as per maintenance schedule.
SPB-gb 5-9-2a 11/04 21

Operation Manual
Vis Tightening torque*

[10.9] Nm ft-lb
M 16 310 228
M 20 610 450
M 24 1050 774
M 30 2100 1550
* Friction figures microns total: 0,14
11.04/GB/5ST5.tbl
Fig. SPB2 How the segments are fastened together
5.10.3 Link chain - Wear, Exchange
The individual chain sections of the link chain are connected by head bolts
that are held in place by locking rings. The link chain can be opened at any
desired point.
Fig. SPB3 Construction of the link chain

1 - Head bolt, 2 - Outer link, 3 - Inner link, 4- Bush,
5- lLocking ring
Please observe the correct position of the flights upon installation (Fig. SPB4
and SPB5). Incorrect installation leads to damage at the conveyor sections.
SPB-gb 5-9-2a 11/04 22

Operation Manual
Fig. SPB4 View upper run

Installation position of flights and fixing to the link chain.
1 = Carrier axle, 2 = Flight, 3 = Link chain
Fig. SPB5 View lower run

Installation position of flights and fixing to the link chain.
1 = Carrier axle, 2 = Flight, 3 = Link chain
Wear of the chains becomes apparent, if the chain starts to lengthen. The
extent of wear can be determined by measuring the length over two bushes.
The following table shows two different dimensions of wear:
X50 Up to this dimension, individual chain parts and/or toothed segments

may be exchanged.
SPB-gb 5-9-2a 11/04 23

Operation Manual
Xmax If this dimension is reached or exceeded, the complete chain and the
wheel/toothed segments will have to be exchanged.
For the chaine Ø Bush Ø Bolt X50 Xmax

Chaintype
type installed in (mm) (mm) (mm) (mm)
the respective 160 x 30 / 50 x 8 32 20 194 196
conveyor, 160 x 45 / 70 x 10 40 26 202 204
please refer to
the general 160 x 60 / 80 x 10 40 26 202 204
arrangement 160 x 60 / 90 x 12 44 30 206 208
drawing. 160 x 60 / 90 x 12 V 54 36 216 218
15.06.97/GB/5ST6C.tbl
Note concerning measurement:

In the case of link chains, do not measure across two bushes that are in one
inner link pair, but instead measure across the bushes of two adjacent inner
link pairs (Fig. SPB6)!
The measurement must be done with a chain tensioned normally. Measure-
ments of a chain not under tension will yield false values.
SPB-gb 5-9-2a 11/04 24

Operation Manual
Fig. SPB6 Link chain
The bolts or bushes must be replaced together if they are damaged or worn.
Always replace the links in pairs!
In the case of conveyors with two chain strands, always replace the same
number of link pairs on both chain strands.
Positioning of conveying elements on the drive wheel (Ill. SPB7)

Chain must be put into its exact position on the drive sprocket.
The position of the support plate/chain is correct when the centre of the
support plate (1) and the centre of the roller (2) have a distance of 230 mm.
The position of the support plate (1) shall be checked at the highest setting.
Please observe the conveying direction.
Ill. SPB7 Positioning of conveying elements on the drive wheel
If the conveying elements are not mounted properly (correct position!), the
SPB-gb 5-9-2a 11/04 25

Operation Manual
conveyor may be badly damaged.
Opening linkchain:
1. Release the tension on the conveying elements
Loosen the nuts of the tensioning spindles enough to fully decompress
the springs.
2. Support the conveying elements to the left and right of the point that is
to be opened (dismantle the rollers if roller intervals are very short).
3. Open the locking rings and remove them.
4. Knock out the bolts.
Hold a heavy object (such as a long piece of steel rod) against the
chain to prevent it from springing or deforming!
Please use the pressing in/out device for chain 90x12.
Closing linkchain:
1. Line up the drilled holes of the chain sections to be joined and knock
in the chain bolts.
Hold a heavy object (such as a long piece of steel rod) against the
chain to prevent it from springing or deforming!
Please use the pressing in/out device for chain 90x12.
Note:
In the case of conveyors with two chain strands, always make sure
that the locking rings are on the outside.
2. Put the locking rings in place and close them (press the ends together).
Always use new locking rings each time! (Fig. SPB8)
Fig. SPB8
3. Remove the support for the conveying elements (reassemble any

rollers that had been removed).
4. Tension the chain again (see above).
SPB-gb 5-9-2a 11/04 26

Operation Manual
5.10.4 Checking for wear of the rollers
The rollers must be replaced once the hardened zone of the roller body has
been worn away.
Fig.KZB12
Note:
The size of roller installed in your conveyor can be taken from the technical
data in the installation drawing.
Diameter (mm) Roller flange thickness (mm)

Roller size
D D min S S min
108 108 98 17,5 13,5
140 140 130 18,7 14,7
160 160 150 21,0 17,0
10.98/GB/5ST4.tbl
Pn-gb 5-10-4nur-für-Laufrollen 12/06 27

Operation Manual
5.10.6 Switch point control
The inlet switch point to the discharge station may only be switched if there
is no roller on the inlet rail. When passing, a roller triggers an inductive
proximity switch, sending out signals to the point control.
During erection the correct setting was already made, however, sometimes
the setting might change during operation.
Setting of the contactor for switch point control
1. Conveying elements moved so, that one roller on the first discharge
station is located 50 mm behind the end of the inlet rail
2. Position the proximity switch so that it is masked completely by the
roller.
For Position and dimensions, see drawing in chapter 9, annex 2.
Fig.SPB8
SPB-gb 5-9-2-5a 10/00 (Kont. Laufr.) 28

Operation Manual
5.11 Tightening torques for bolts
Tightening torques for electrolytically galvanized hex bolts

[Nm / lbf ft] Coefficient of friction = 0,125
Standard thread Strength class
metric
5.6 8.8 10.9 12.9
M6 4.3 / 3.2 9.9 / 7.3 14 / 10.3 16.5 / 12.2
M8 10.5 / 7.8 24 / 17.7 34 / 25 40 / 29.5
M 10 21 / 15.5 48 / 35.5 67 / 49.5 81 / 59.5
M 12 36 / 26.5 83 / 61 117 / 86 140 / 103
M 16 88 / 65 200 / 147 285 / 210 340 / 250
M 20 171 / 126 390 / 287 550 / 406 660 / 486
M 24 295 / 217 675 / 497 960 / 708 1140 / 840
M 30 590 / 435 1350 / 995 1900 / 1401 2280 / 1681
01.07/GB/7al1.tbl
PN-gb 5-11N 11/07 29

Operation Manual
Chapter 6 / Lubricating instructions
Table of contents
6 Lubricating instructions ............................................ 2

6.1 General ........................................................................ 2
6.2 Disposal ...................................................................... 3
6.3 Basic information ....................................................... 3
6.3.1 Project 45345 /
item 471.DB210 / 00704ALM113.DB210
SPB 1600/200/5 ........................................................... 5
6.3.1.1 Discharge station - lower run ........................................ 8
6.3.1.2 Flat valve
item 471.DG130 / 00704ALM113.DG130
item 471.DG140 / 00704ALM113.DG140 .................. 10
6.4 Lubricants ................................................................. 11
6.4.1 Temperature depending choice of lubricant ............... 11
6.4.2 Flender Geared Motors .............................................. 13
6.4.3 Special lubricants ....................................................... 14
6.5 List of Lubricants ..................................................... 15
6.6 Lubrication of the rollers ......................................... 17
6.6.1 Standard rollers .......................................................... 17
6.6.2 Hot material rollers ..................................................... 18
6.6.3 Regular subsequent lubrication .................................. 18
Flender list of lubricants
F.L.S. Summary of Lubrication Requirements
By double-clicking on the symbol beside the designation or

number of a document the corresponding file will open.
After closing the file you will return to this page of the operation
manual.
PN-gb 6IN-A(f) 10/06 1

Operation Manual
6 Lubricating instructions
This chapter has always to be used in combination with chapter 2-

manual or copied, chapter 2-safety has always to be added.
6.1 General
The following lubricating instructions are intended to provide the user of the
machine with information on the necessary lubrication procedures in order
to protect the machine from premature and excessive wear.
Optimal lubrication maintains operating reliability and the life of the ma-
chine.
For lubrication, the applicable regulations for prevention of accidents and

official requirements must be observed
This applies particularly to the avoidance of environmental nuisances and

damage such as:
• Unnecessary noise emission
• Inadmissible disposal of lubricants such as oils and greases
• Unnecessary fouling of the machine.
The machine parts to be processed, gears, joints or other sub-assemblies

must not be damaged or their functional characteristics altered as a result of
lubrication.
PN-gb 6N(f) 07/01 2

Operation Manual
All lubricating points must be provided with the necessary oil filling
prior to commissioning. The operator is responsible for ensuring that
the necessary checks are carried out.
Delivery condition:
Grease lubricating points (except for gears), so far as they are delivered
assembled, are filled with lubricant.
Oil lubricating points (gears, geared motors, hydraulic installations and

similar) are delivered only in a few cases with oil filling. The oil filling must
be checked in any event.
6.2 Disposal
All replaced greases and oils must be disposed of in a proper manner.

In addition to locally applicable, pertinent, statutory and other requirements
and guidelines, the following applies:
• Prevent oils, greases and other toxic chemical substances from con-
taminating soil and do not discharge to the sewerage system.
• Always fill used oil and grease into the containers provided.
6.3 Basic information
Kindly learn all information concerning the lubrification from the following
paragraphs under this chapter as well as the information to the individual
components in chapter 8.
The following applies in general:

Lubricating intervals depend on the operating conditions of the parts to be
lubricated.If these parts are exposed to dusty, moist, hot or corrosive atmos-
pheres, they must be lubricated more frequently.
PN-gb 6N(f) 07/01 3

Operation Manual
• Never use too much grease, since this will cause bearings to overheat.
• Turn shafts slowly while relubricating if possible.
• Always keep grease nipples clean and cover if necessary.
The specified lubricants have been selected taking into account the operat-
ing conditions known to us and based on the order. If these conditions
should change, particularly the ambient temperatures, Aumund cannot
warrant for correct lubricant selection.
The lubricating intervals, so far as Aumund components are not concerned,

are taken from the instructions of the manufacturer concerned. Depending
on the individual operating conditions, these intervals are often variable. It is
recommended to observe the additional information in chapter 8 - annex.
The lubricant changing intervals can sometimes be optimised.
In all cases where lubricating intervals and lubricant quantities mainly

depend on the operating conditions no reliable information can be supplied
in the lubrication schedule. The optimum values have to be determined
during operation. For this purpose lubricating points have to be checked first
in short (weekly) intervals and then in longer ones. The final lubricating
interval has to be determined in such a way that the respective component
can be lubricated in a proper manner at any time.
Many lubricant manufacturers provide a free lubricant analysis service. It is

recommended to make regular use of this service.
Lubricant analysis provides exact information on the lubricant properties
and degree of ageing of the lubricant and so enables optimal utilisation and
cost reduction.
PN-gb 6N(f) 07/01 4

Operation Manual
6.3.1 Project 45345 /

item 471.DB210 / 00704ALM113.DB210
SPB 1600/200/5
Sub-assembly: Appurtenant lubricating point drawing: fig. SPB1

Pivoting pan conveyor - 45345
Item Designation Code Kind of Num- Q'ty of grease / Intervals Re-
no. no. lubrication ber of lubrication point mark
* lubri- **
cating Q'ty of Q'ty Q'ty Relubri- Change of lubricant
points first of for cation
filling refilling change first following
1 Drive shaft
1a fixed bearing Grease gun 1 0.7 kg 0.2 kg
III 3,600 h
1b loose bearing 1 1.1 kg 0.3 kg
or 1/2
yearly
2 Supporting pulley III Grease gun 8 0.15 kg 0.05 kg
(drive wheel)
3 Chain bogie wheel V Grease 6 0.15 kg Life lubrication up to 80° C 4)
(drive station) filling
4 Guide sprocket III Grease gun 4 0.15 kg 0.05 kg 3,600 h
(bearings) or 1/2
yearly
5 Sprocket for turning III Grease gun 2 0.7 kg 0.2 kg 3600 h or
points (bearings) 1/2
yearly
6 No-return latch III Grease gun 2 0.13 kg 0.05 kg 3,600 h
(tail station) or 1/2
yearly
7 Chain bogie wheel V Grease 20 0.15 kg Life lubrication up to 80° C 4)
(take-up station) filling
8 Roller V Grease 232 0.2 kg Life lubrication up to 80° C 4)
filling
9 Chain used Drop 2 20 L acc. to requirement 5)
(greasing pot) oil lubrication
* Under this code number you will find the exact designation of lubricant in the lubricant list or in the chapter
‘Special lubricants’ (code number with the sign S...).
** Remarks: 1) Please observe the additional information in chapter 8 -annex- since the present
chapter partly indicates only standard values.
2) The lubricant identification number refers to the lubricant list of the manufacturer of
constructional parts.
3) Please observe the information of pragraph 6.4 concerning Flender geared motors.
4) The intervals for relubrication exclusively depend on the operating conditions and
must be determined during operation (see hints in this chapter).
5) The chain has to be lubricated in order to avoid any creaking only. Therefore, the
lubrication should be limited to the actually required scope.
6) The lubricant might have to be selected depending on the temperature.
Make sure to observe the information supplied in section 6.4.
07.07/GB/6ST3A-1!.tbl
SPB-gb 6-3-1A(f) 07/07 5

Operation Manual
Sub-assembly: Appurtenant lubricating point drawing: fig. SPB1

Pivoting pan conveyor - 45345
* lubri- **
Drive unit > B4DH 10 - NEMA 256T
10 Gear A14 splash 1 ~50 L ~50 L 400h 10,000 h 1)
lubrication max. 2)
2 years
10.1 Gear (shaft seals) III grease gun 3 0.03 kg 3,000 h 1)
max. 6
months
11 Backstop A14 Splash 1 0.5 L 0.5 L 400 h 10,000 h 1)
lubrication max. 2)
2 years
12 Turbo coupling 3 oil filling 1 ~2.9 L ~2.9 L max. 10,000 h 1)
or max. 5 years
13 Motor grease 1)
(bearings) filling
14 Brake S1 oil filling 1 1.6 L 1.6 L 1)
(electro-hydraulic
lifting device)
4) Penetration of dirt into inside of the bearing shall be avoided by regreasing at such
short intervals.
07.07/GB/6ST3a2!.tbl
SPB-gb 6-3-1A(f) 07/07 6

Operation Manual
10.1 10 10.2 14 12 13
11
4
10.3
1a(1b) 2 3 8 9 St30j.drw 5 6 7
fig. SPB1
SPB-gb 6-3-1A(f) 07/07 7

Operation Manual
6.3.1.1 Discharge station - lower run
Sub-assembly: Discharge station (UT) Appurtenant lubricating point drawing: fig. SPB2
* lubri- **
1 Drive shaft III grease gun 2 0.05 kg 0.02 kg 3,600 h
(inlet point) or 1/2
yearly
2 Inlet rail III grease gun 2 0.02 kg 0.01 kg 3,600 h
or 1/2
yearly
3 No-return latch III grease gun 2 0.13 kg 0.05 kg 3,600 h
or 1/2
yearly
4 Chain pulley III grease 12 0.15 kg life lubrication
filling
Geared motor > CAD68 - M80S4
5 Gear C23 gplash 1 1.5 L 1.5 L 10,000 h 20,000 h 1)
lubrication max.2 max.4 2)
years years 3)
6 Motor (Bearing) IV grease 2 life lubrication 1)
filling
07.07/GB/6ST3B!.tbl
SPB-gb 6-3-1-1A(f) 07/07 8

Operation Manual
fig. SPB2
SPB-gb 6-3-1-1A(f) 07/07 9

Chapter 6 / Lubricating instructions Operation Manual
6.3.1.2 Flat valve

item 471.DG130 / 00704ALM113.DG130
item 471.DG140 / 00704ALM113.DG140
Sub-assembly: Flat valve Appurtenant lubricating point drawing: fig.FL1

* lubri- **
filling refilling chang first following
1 Bearings III grease gun 2 0.02 kg 0.01 kg 3,600 h
or half
yearly
2 Pinion and toothed III to be 1 acc.to 3,600 h
rack applied with require- or half
paint brush ment yearly
Geared motor > CAD88 - M90S4
3 Motor IV grease 1 life lubrication 1)
(bearings) filling
4 Gear C23 splash 1 1.7 L 1.7 L 10,000 h 20,000 h 1)
lubrication max. max. 2)
2 years 4 years 3)
07.07/6FL6!.tbl
fig. FL1
FL-gb 6-3-1A(f) 07/07 10
Operating Manual
6.4 Lubricants
In this chapter you find the Aumund list of lubricants and as far as necessary a
special lubricant list and lubricant information of individual manufacturers of
By means of the lubricant identification numbers stated in the lubrication
diagram you will find the suitable lubricants in the enclosed information.
If the lubricant information of the individual manufacturers is not noted
here, you may find it in chapter 8.
6.4.1 Temperature depending choice of lubricant
The choice of lubricant depends apart from other conditions also on the
operating temperatures. Basically, the lubricants indicated in the table of
lubricants consider the operating temperatures known to us. Extremely low or
high temperatures may, however, require further measures or temperature
depending changes of lubricant.
Oil lubricated components
Temperatures below -20° C / -4° F
• Usually, gear units are equipped with a heating and a suitable oil
is provided. Normally, a temperature depending oil change is not
required.
• For hydraulic couplings a hydraulic oil is provided with suitable
viscosity. The pourpoint should at least be -30° C /-22° F.
Attention: The pourpoint of the different oil makes differs consid-
erably, even in case of an identical viscosity class.
Temperature limits and rules of behaviour exist for the starting in cold
state. They are included in Chapter 3 Operation.
PN-gb 6-4-A-FL(f) 07/07 11

Operating Manual
Greased components
Our grease used as a standard is permanently applicable between

-20° C / -4° F and +40° C / +104° F grease temperature.
For a short time (max. 1 day) grease temperatures up to -30° C / -22° F and
+60° C / +140° F are also possible.
If the grease temperatures are permanently below -20° C / -4° F or above
+40° C / +104° F, the grease must be exchanged.
In case of a very high temperature difference, only one kind of grease may no
longer be enough and two different kinds of grease may have to be used. If the
temperatures will be regularly exceeded, e.g. in summer and in winter time,
we recommend to exchange the grease by shortened subsequent lubricating
intervals divided to three subsequent lubrications.
Alternative greases:
Service temperature *)
Supplier Designation
permanent for a short-time period
-50° C - 20° C -50° C - 40° C Berutox FB 48/1
-58° F - 68° F -58° F - 104° F Berutox FB 48/2
-20° C - 60° C -20° C - 80° C Carl Bechem
High-Lub FA67-400
-4° F - 140° F -4° F - 176° F GmbH
-30° C - 80° C -30° C - 110° C
Berutox FH28 EPK2
-22° C - 176° F -22° C - 230° F
*)
The above mentioned service temperatures do not result from a standard test,
but were determined on the basis of the low speeds and the kinematic
viscosity at the relevant temperature.
07.07/GB/6AL7
We indicated greases of the Bechem company on behalf of other suitable

greases. Your lubricant supplier will surely be in a position to mention
alternatives from his grease program upon requirement.
PN-gb 6-4-A-FL(f) 07/07 12

Operating Manual
6.4.2 Flender Geared Motors
The oil change intervals and the oils suitable for Flender geared motors
CAVEX and MOTOX essentially depend on their actual running time.
1. Actual running time / year in excess of 20 hours:

The specifications in the Flender operating instructions apply.
2. Actual running time / year up to 20 hours:

Filling with synthetic oil = lifetime Iubrication
Filling with mineral oil = oil change according to operating
instructions
If not otherwise agreed, the following is generally provided for:
• synthetic oil for worm gear
• mineral oil for spur wheel and bevel spur gears
• maintenance drives at the bucket elevators =

running time / year up to 20 hours
In principle, worm gears can also be run on mineral oil. However, this
must be expressly stipulated in the order, otherwise it will not be
considered when designing the gear. A subsequent change from
synthetic oil to mineral oil requires our prior consent.
PN-gb 6-4-A-FL(f) 07/07 13

Operating Manual
6.4.3 Special lubricants
Please find below lubricants which are not included in our standard list of
lubricants. If required, additional information is given in this chapter or in
chapter 8 (see column "remark")
Mainten Designation/Data Remark

S1 Hydraulic oil MorLina 10 look data sheet about
of class HL 10, DIN 51524 Operating Fluid,
Maintenance for ELDRO
Thrusters (*)
(*) Please observe the additional information in chapter 8 -annex
25.10.95/GB/6AL6!.tbl
PN-gb 6-4-A-FL(f) 07/07 14

Operating Manual
6.5 List of Lubricants
PN-gb 6-5n(f) 12/06 15

Operating Manual
PN-gb 6-5n(f) 12/06 16

Operating Manual
6.6 Lubrication of the rollers
6.6.1 Standard rollers
Standard rollers can be applied up to a maximum temperature of 125° C .

The following type of grease is used in these rollers:
Type of thickening agent: Calcium Complex Sulphonate Soap
Class: KP2N-30
For subsequent lubrication of the rollers only the same sort of grease and
thickening agent may be used. If other greases will be used for subsequent
lubrication, the rights of warranty claims will become invalid.
Rollers supplied before 06/2002 and thus still filled with a lithium soap
grease, may be subsequently greased with the a.m. new grease. However, a
complete replacement of grease in two subsequent lubrication procedures
should be carried out. For this purpose, the complete initial quantity must be
filled in during each of these two subsequent lubrication procedures accor-
ding to the lubricating schedule via the lubricating nipple.
Hint:
In case of rollers having been used for quite some time already, it may be
that the exchange of grease via the lubricating nipple is not possible. Especi-
ally in case of rollers which were subject to high temperatures, lubrication
borings or the sealing labyrinth may be jammed by deposits. In those cases
either the change of grease may be given up or the rollers must be disassem-
bled, cleaned and then filled with new grease.
On principle, only use grease guns to regrease the standard rollers.

Due to the narrow holes and seals make sure to inject the grease only very
gradually.
If the grease is injected under too much pressure or shocklike, this might
result in pressing out the seals and the roller will no longer be in an operable
condition.
PN-gb 6-6nur-für-Laufrollen 06/05 17

Operating Manual
6.6.2 Hot material rollers
At temperatures above 125° C to 200° C special hot material rollers will be

applied.
The following type of grease is used in these rollers:
Bechem Ceritol PA 1 MO
For subsequent lubrication of the rollers only the same sort of grease may be
used. If other greases will be used for subsequent lubrication, the rights of
warranty claims will become invalid.
6.6.3 Regular subsequent lubrication
In case of roller temperatures of up to max. 80° C the rollers are mainte-

nance-free and need not be lubricated subsequently.
According to our experience temperatures above 80° C are not achieved in
normal operation.
However, the roller temperature cannot be determined theoreti-

cally, it must be measured by the operator under the actual ope-
rational conditions at site.
Depending on the roller temperature the following lubrication intervals

result:
Standard rollers
Roller temperature(°C) Lubrication interval
> 80 - < 90................................. per year or 8000 h
> 90 - < 100............................... 4 months or 2500 h
> 100 - < 110............................. 2 months or 1250 h
> 110 - < 125 ............................. 1 month or 600 h

Operating Manual
Hot material rollers:
Roller temperature(°C) Lubrication interval

< 120 .......................................... 10000 h
> 120 - < 135................................ 5000 h
> 135 - < 150................................ 2500 h
> 150 - < 165................................ 1250 h
> 165 - < 180.................................. 625 h
> 180 - < 195.................................. 312 h
> 195 - < 210.................................. 156 h
> 210 - < 225.................................... 78 h
> 225 - < 240.................................... 39 h
Rollers which are subject to high temperatures, must by all means be lubrica-
ted again in the intervals indicated. In case of additional strong dust load and/
or wet surroundings we recommend to reduce the lubrication intervals by
50% and to lubricate the rollers subject to temperatures below 80° C once a
year.

Chapter 7 / Spare parts list
Operation Manual
Table of contents
7 Spare parts list

7.1 Contacts and address of order
7.2 Ordering of spare parts
7.3 Time of delivery
7.4 Spare parts list for:
By double-clicking on the Item order conveyor-type register

symbol beside the 471.DB210 45345 SPB 1600/200/5 AA= 56,00m 1
designation or number of
00704ALM113.DB210 - Equipm-no. Cementos Argos
a document the
corresponding file will
open.
After closing the file you
will return to this page of
the operation manual.
Operation Manual
7 Spare parts list
In this chapter you will find a spare parts list for each conveyor. A spare
parts list contains a parts list for each structural component and the
illustration belonging to it so that normally you may find the parts
requested without problem.
Important hints
For technical reasons the parts lists may also contain parts which
are no spare parts. The corresponding illustration normally only
shows the spare parts.
All illustrations are sketches and may deviate in detail from the
actual designs.
7.1 Contacts and address of order
In case of all questions with regard to spare parts please refer to the contacts
in chapter 1.
You may also refer to our Internet page for further information.
Operation Manual
7.2 Ordering of spare parts
For ordering spare parts please proceed as follows:
Possibility 1
1. Kindly check in the table of contents of the spare parts list the
structural component you wish to replace completely or partly.
2. Copy the page of the spare parts list, on which you find the
requested structural component.
3. Kindly enter on the copy in the column "quantity to be ordered" the

number of parts requested before the component requested. Please
add this copy to your order.
We do recommend to order spare parts according to the a.m. possibility

1 in order to avoid faulty indications and misunderstandings.
Possibility 2
If you do not wish to use possibility 1 for your spare parts order for any
reason, we do need the following indications:
1. project number
2. Denomination and article number of the structural component
3. Number of parts requested
4. Item number of the requested part
5. Denomination of the requested part
Example:
Project-No.: 36848
Component: Drive shaft compl. - 30004952
Spare part: 1 piece Item 2 Drive ring
Operation Manual
7.3 Time of delivery
Most of the spare parts indicated in the following spare parts lists may be
supplied within 4 - 6 weeks.
Some special spare parts, however, which also depend on subsupplier

material, have considerably longer delivery times.
Toothed rims on request

Conveyor sections / buckets on request
Chains on request
Gear boxes on request
Couplings on request
Please consider the partly long delivery times for your stockkeeping
of spare parts.
Operation Manual
Chapter 8 / Annex 1
Table of contents
8.1 Project 45345 /

item 471.DB210 / 00704ALM113.DB210
SPB 1600/200/5 ........................................................... 2
8.1.1 Intermediate discharges on lower run...................... 4

8.1.2 Flat valve
item 471.DG130 / 00704ALM113.DG130
item 471.DG140 / 00704ALM113.DG140 .................... 5
PN-gb 8A(f) 10/06 1

Operation Manual
Chapter 8 / Annex 1
8.1 Project 45345 /

item 471.DB210 / 00704ALM113.DB210
SPB 1600/200/5
List of documents
Structural component Type Designation of document Register
/component No.
Drive:
By double-clicking on
the symbol beside the Motor NEMA 256T Operating instructions, 2
dimension drawing
designation or number
Turbo coupling with FLUDEX Technical data 6
of a document the control system EOC FADB 297 TD 441 3454-070
corresponding file will Operating instructions BA 4600 3
open. Drum Brake EBN200-23/5 Operating Instructions 4
Electro-hydraulic ELDRO ED 23/5 Operating instructions, 5
will return to this page Thruster Installation Instructions,
Operating Fluid, Maintenance
of the operation manual.
Bevel-helical gear unit B4DH 10 Dimensioned drawing: 6 168 130 6
Technical data
TD 441 3454-070
Operating instructions: BA 5010 7
Flender Recommended 8
Lubricants: BA 7300
Back stop RS FXM 100 Installation information see 7

50SX/H 55 Operating instructions
BA 5010 (gear unit)
Srink collar HSD 200-32
15.01.96/GB/8AL7!K1.tbl
PN-gb 8A(f) 10/06 2

Operation Manual
Chapter 8 / Annex 1
List of documents
/component No.
By double-clicking on Controlling devices:
the symbol beside the Thermal coupling control:
designation or number EOC - System EOC 230 / Operating instructions 11

125° + SS160 BA 4600.1
of a document the
EWD-Analyzing unit 20-250VUC
open. Inductive sensor BIM-G18-Y1/S926

will return to this page Emergency switch SPS-2D-3 Technical information 12
of the operation manual.

Speed monitor 7 MH 7- MFA4P Operating instructions 13
Technical information
Pre-amplifier 7 MH 7145-OA-
RMA
High Temperature MSP-3

Probe
Electrical control Pivoting pan Lists of electrical consumers 15

conveyor SPB and local instruments
Basic Circuit Diagram, 17

ID DOK 30024265
Protection against corrosion
Hölterhoff MF 1424 - Spray Safety data-sheet 19
Rivolta K.S.P.317 Safety data-sheet 20

15.01.96/GB/8AL7!üb.tbl
PN-gb 8A(f) 10/06 3

Operation Manual
Chapter 8 / Annex 1
8.1.1 Intermediate discharges on lower run
List of documents
/component No.
Intermediate discharges on lower run (4x)

By double-clicking on
Drive:
the symbol beside the
designation or number Gear motor CAD68-M80S4 Operating instructions, 9
Getriebe: BA 2010
of a document the
Operating instructions 10
corresponding file will Motor: BA 2310
open. Flender Recommended 8
After closing the file you Lubricants: BA 7300
will return to this page
of the operation manual. controlling devices:
Limit switch with 871L-B20E40-T2 Technical information 14

Mounting accessories with JS 025/037
Electrical Control Pivoting pan List of electrical consumers; 15

conveyor SPB List of local instruments

ID DOK 30024265
15.01.96/gb/8AL7!ZW.tbl
PN-gb 8A(f) 10/06 4

Operation Manual
Chapter 8 / Annex 1
8.1.2 Flat valve

item 471.DG130 / 00704ALM113.DG130
item 471.DG140 / 00704ALM113.DG140
List of documents
/component No.
By double-clicking on Drive:
the symbol beside the Gear-motor CAD88-M90S4 Operating Instructions 9

Gear box: BA 2010
designation or number
Operating Instructions 10
of a document the Motor: BA 2310
Recommended Lubricants 8
open. BA 7300
will return to this page Controlling devices:
of the operation manual. Limit switch with 871L-B20E40-T2 Technical Information 14
Mounting accessories with JS 025/037
Electrical Control Flat valve, List of electrical consumers; 16

motor operated List of local instruments

ID DOK 30024833

15.01.96/GB/8AL7!Fl.tbl
PN-gb 8A(f) 10/06 5

Operation Manual
Chapter 9 / Annex 2 - Drawings
9 Annex 2
Drawings and parts list
Table of contents
9.1 Systematic classification of parts'lists ..................... 2

9.2 Filing of parts lists and drawings ............................. 3
9.3 Project 45345 /
item 471.DB210 / 00704ALM113.DB210
SPB 1600/200/5 ........................................................... 4
PN-gb 9IN-A(f) 10/06 1

Operation Manual
Chapter 9 / Annex 2
9.1 Systematic classification of parts'lists
The following procedure will assist you to find

items of the installation drawing in the parts'list
and vice versa
PN-gb 9-1n(f) 12/03 2

Operation Manual
Chapter 9 / Annex 2
9.2 Filing of parts lists and drawings
The enclosed parts lists and drawings are listed in a table according to the
relative project.
The Operation Manual only contains one conveyor:

The parts lists and the GA drawing are filed immediately after the
table. All further drawings follow subsequently and are filed according
to their rising drawing numbers.
The Operation Manual contains several conveyors:

The parts list and the GA drawing are filed in an own register for each
separate project. All further drawings are commonly filed in a register
for all projects and sorted according to their rising drawing numbers.
You will find the register numbers above the drawing list of the
corresponding project.
Under "format" the size of the original drawing is indicated in the

drawing list. This manual may, however, also contain scaled down
drawings.
PN-gb 9-1n(f) 12/03 3

Operation Manual
9.3 Project 45345 /

item 471.DB210 / 00704ALM113.DB210
SPB 1600/200/5
By double-clicking on the symbol beside
the designation or number of a document
Parts lists and GA drawings: the corresponding file will open.
All further drawings: After closing the file you will return to this
page of the operation manual.
Drawing list
Project Item Conveyor type Customer
471.DB210 /
45345 SPB 1600/200/5 AUMUND Corporation
00704ALM113.DB210
Position in
Designation Article Drawing Index Size
GA-drawing
pivoting pan conveyor 30107365 30107365 Bl.1+2 F A0
1 product 30112240 30107365,Bl.1+2 F A0
1.1 drive station (assembly) 30112809 30025207 0 A3
1.2 tensioning station complete 30027922 30027922 A A1
1.3 support plate (gen. arrangem.) 00080551 00080551 D A0
1.5 runway 30112235 30112235 0 A0
1.6 discharge station (gen. arr.) 30112853 21022451 B A4
1.6.1 unloading station, ass., lower 30030569 30030567 A A1
1.11 point control 30011229 30011229 D A1
2 Drive Set 30112241 30107365,Bl.1+2 F A0
4 Peripheral Parts 30112242 30107365,Bl.1+2 F A0
flat valve,cpl
4.1 30113924 30049609 0 A3
(item 471.DG130 / 00704ALM113.DG130)
4.1.1 flat gate, assembly 30050401 30049612 0 A0
4.1.3 limit switch fixing 00881490 00881490 C A2
flat valve,cpl
4.2 30113923 30049608 0 A3
(item 471.DG140 / 00704ALM113.DG140)
4.2.1 flat gate, assembly 30050401 30049612 0 A0
4.2.3 limit switch fixing 00881490 00881490 C A2
4.8 feeding chute 30112221 30112221 A A0
4.13 discharge chute 30112222 30112222 0 A1
4.14 discharge chute 30112224 30112224 0 A1
4.15 chute 30112231 30112231 0 A0
4.16 chute 30112232 30112232 0 A2
4.17 chute 30112233 30112233 0 A2
4.40 spillage chute 30112227 30112227 0 A1
PN-gb 9-3A(f) 12/03 4

Operation Manual
Drawing list
Project Item Conveyor type Customer
471.DB210 /
45345 SPB 1600/200/5 AUMUND Corporation
00704ALM113.DB210
Position in
Designation Article Drawing Index Size
GA-drawing
5 accessories 30112243 30107365,Bl.1+2 F A0
5.3 cover hood 30113789 30113789 0 A1
5.3.12 dust curtain 30042943 30042943 0 A2
5.4 cover hood 30113804 30113804 0 A0
5.6 safety guards 30112238 30112238 0 A0
5.8 lube pot cpl 30008066 30008006 0 A2
5.10 emergency switch 30113849 30113849 A A0
5.20 safety labelling 30112954 30085005 A A2
6 assembly parts 30112244 30107365,Bl.1+2 F A0
By double-clicking on the symbol beside the designation or number of a

document the corresponding file will open.
After closing the file you will return to this page of the operation manual.
PN-gb 9-3A(f) 12/03 5

Operation Manual
Chapter 10 / Erection instructions
Information for Erection Work - Contents
For erection work, not only the erection instructions included in this chapter,
but also further documents and information will be required which are either
included in this chapter or in another chapter of this manual. Below you will
find a summary of this information/these documents:
Kind of information Included in
Safety instructions Chapter 2
Typical Minimal Lock-Out Procedure (Example) Kap. 2
Safety Labelling - Drawing Kap. 9
Important Notes to Safety Labelling Chapter 10
Erection instructions SPB Chapter 10

(Pivoting pan conveyor)
Instruction concerning to the package lists /

Package Lists Chapter 11
Installation drawings and other drawings Chapter 9
Functional description - Electrics

(Circuit manual) Chapter 8
Documentation regarding sub-suppliers parts Chapter 8
Lubrication instructions Chapter 6
m-PN-gb m10in 11/97 1

Safety Instructions
for the
Erection
of
Aumund Plants
Please Note
Prior to commencing any erection work
it is imperative to read the following
m-PN-gb m-sich-deck 11/97

Tel.: + 49 2843 72-0 • Fax: + 49 2843 60270
Operation Manual
Chapter 10 / Safety-Erection
Table of contents
1 Safety ........................................................................... 2
1.1 General ........................................................................ 2
1.2 Symbols, warning signs ............................................ 4
1.3 Safety regulations ...................................................... 5
1.3.1 General ......................................................................... 5
1.3.2 Selection and qualification of personnel ....................... 6
1.3.3 Working places for the operating personnel ................. 6
1.3.4 Sound emissions / noise .............................................. 7
1.3.5 Regulations and instructions for operation ................... 8
1.3.6 Safety information on electrical equipment
in electrical power installations ..................................... 9
1.3.7 Regulations and instructions for lubrication ................ 10
1.4 Accident prevention regulations ............................. 11
1.4.1 Behaviour in the event of accidents............................ 11
m-PN-gb m-sich-gb(f) 04/07 1

Operation Manual
1 Safety
1.1 General
The installation supplied by us was constructed in accordance with German

and European standards and regulations in line with the state of the art.
During all work with and on the installation, these regulations and the
general accident prevention regulations must be observed and complied
with.
The plant operator or person authorised by him is responsible for the
compliance with the valid safety regulations.
Nevertheless the installation can represent a hazard to life and limb if it is

operated by unqualified personnel or is operated by specially trained
personnel incorrectly or other than in the sense of its intended use.
This chapter must therefore, be read and understood by all persons entrusted
by the plant operator with the erection, commissioning, operation,
maintenance and repair of the installation before starting work.
The plant operator is recommended to convince himself of the level of

knowledge of the persons entrusted by him with respect to the following
points before assembly and commissioning:
• knowledge of these safety regulations
• knowledge of the statutory accident prevention regulations
Any failure to comply with these safety regulations can result in serious
personal injury or even death.
The plant operator must therefore ensure that the plant is only ever operated
when in safe, proper condition and that the relevant safety requirements and
regulations are observed.

Operation Manual
The plant operator can oblige the operating personnel to wear protective
clothing.
The plant operator is responsible for the necessary training and instruction
of the specialist personnel and/or other persons appointed by him.
The plant operator is required to draw up behaviour instructions and
guidelines for malfunctions and warning messages, to instruct the operators
and to ensure that the instructions are displayed at a clearly visible point.
To avoid danger and /or protect any person on site, anyone recognising
imminent hazards must take any immediate action to avert danger such as
sound warning, pressing the emergency stop switch etc..
If plant components are damaged, the entire plant has to be shutdown.
Particular local conditions or special applications can lead to situations

which were not known at the time this chapter was written.
In such cases, the plant operator must ensure the safe operation of the
installation or must shut down the installation until an agreement is reached
with Aumund or other competent authorities on the measures to be taken to
ensure safe operation, and until these measures have been implemented.
All modifications and changes to the installation are forbidden.

This does not apply to minor alterations which have no influence on the
structural safety, operational safety or general safety, or measures which
increase the safety of the installation.
The fundamental responsibility for these modifications and for the resulting
consequences lies solely with the plant operator.
In case of doubt, Aumund should be contacted and written approval
obtained before carrying out any modification.
If any installation or parts of it is supplied modified without taking safety

measures, the operator must ensure that before the commissioning the safety
of the installation is guaranteed.
This means, changes and modifications of the construction may only be
carried out in consideration and observance of the above regulations.

Operation Manual
1.2 Symbols, warning signs
These symbols will be used throughout the operator’s manual to mark

possible sources of danger.
DANGER!
Indication of a danger
Severe up to immediate fatal injuries may happen.
WARNING!
Severe up to mortal injuries may happen.
CAUTION!
Personal injuries or extensive equipment damage may
happen.
Danger to operational safety of the installation!

Failure to observe this instruction will impair the operational
safety of the installation and can result in damage.
This symbol marks all safety instructions of this manual which refer
to regulations, guidelines or processes which must be absolutely
complied with.

Operation Manual
1.3 Safety regulations
1.3.1 General
The plant may be assembled and operated only by the person authorized to
do so. Unauthorized persons must be forbidden to enter (fit prohibitive
signs).
If any faults are discovered with regard to operational safety or reliability,
any work must be stopped and/or the plant must be shut down or not started.
To avoid injury only the permissible and appropriate tools may be used
Safety and warning instructions in the form of signs, stickers and marks
must not be removed or defaced.
Safety equipment must not be bypassed or modifed and used in any manner
contrary to its original purpose.
Always keep the switch cabinets locked during normal operation and after
the end of work to prevent access by unauthorized persons.
Before working on rotating or moving parts, ensure that these are stationary
and cannot start to move during work.
Do not reach into rotating or moving parts and maintain an adequate
distance in order to avoid clothing or hair becoming caught up.
Avoid naked flames, extreme heat levels (e.g. welding) and sparks when
using cleaning agents and in the vicinity of inflammable or deformable parts
or materials (e.g. wood, plastic parts, oil, grease, electrical equipment).
Failure to observe these instructions may result in fires, whereby toxic gases
may be released and/or insulation materials damaged.
Before working on electrical equipment observe “Safety information on

electrical equipment in electrical power installations” !

Operation Manual
1.3.2 Selection and qualification of personnel
Employ only trained and instructed personnel. The operator must clearly
define responsibility and supervision of personnel.
Only qualified personnel may carry out any work.

For example:
Work on electrical equipment of plant must only be carried out by an
electrician as per the electro-technical rules.
Personnel to be trained, instructed or undergoing a general training must

only work on the plant under permanent supervision of an experienced
person.
Persons who are under the influence of drugs, alcohol or medicaments

which restrict reactivity are not allowed to operate, to maintain or repair the
plant.
1.3.3 Working places for the operating personnel
The electric control of plant is not part of Aumund’s scope of supply so that
this chapter does not include any information on working places for the
operating personnel.
Consequently the operator of the plant has to provide information on

working places, operating- and working sequences and inform the operating
personnel accordingly.

Operation Manual
1.3.4 Sound emissions / noise
Sound emissions of our machines were measured acc. to DIN 45635. The
measured values apply to the use of machines as directed. Since working
places of operating personnel cannot be defined, always the highest sound
level is indicated.
Faktor of uncertainty
Sound level Lp K
Machine dB (A) dB (A)
Conveyors
(KZB, BZB, TKF, etc.) > 70
5
< 85
Centrex
Elevators
(BW-Z etc.) > 85 5
12.06/GB/2AL9.tbl
Dependent on the sound level the following protective measures have to be

taken:
> 70 dBA: Persons being permanently in this area must wear ear protectors.
>85 dBA: These areas must be marked by warning signs. In these areas all
persons must wear ear protectors, even for a short-time stay
All personnel working near sources of noise, such as hammering srewdriver,

compressor etc. during assembly, have to wear ear protection.

Operation Manual
1.3.5 Regulations and instructions for operation
Conditions for the operation are
• that the erection has been finished in accordance with the regulations
• that the operating staff is familiar with the operation of the equipment
As it is impossible for us to account for all possible dependencies on other

equipment or devices, they have to be assessed and considered by the
operator.
The transport of persons in this equipment is strictly forbidden at all times.
If the operator notices the presence of persons who could be endangered by

the operation, he must stop the plant immediately and must not start again
until the persons are out of the danger zone.
The operator must report even the slightest malfunction and any observation
which gives reason to anticipate a malfunction (e.g. unusual noises) without
delay to his superior.
This applies both to the mechanical and electrical equipment and to the steel
structure of the plant.
The plant must be shut down immediately in the event of one of the
following malfunctions:
• Damage to electrical equipment and lines.
• Failure of the brakes and safety equipment.
After an “emergency stop” the operator must not start the plant again until
he has convinced himself that the cause of the situation has been eliminated
and that the plant can be operated again without danger.
The plant may only be started again when all required protection measures
against accidential contact have been taken resp. a dangerous contact of all
dangerous surfaces has been prevented.

Operation Manual
Blown fuses must not be repaired or bridged; they must be replaced only by
fuses of the same rating.
Cooling equipment, such as fans and ventilation slots, must not be
permanently deactivated.
Before working on electrical equipment observe “Safety information on

electrical equipment in electrical power installations” !
1.3.6 Safety information on electrical equipment

in electrical power installations
The electric machines and/or equipment are intended for use in industrial
electrical power installations.
During operation, this equipment has hazardous live bare parts, possibly
together with moving or rotating parts.
Severe personal injury or extensive material damage can be caused by:
• incomplete erection
• unauthorized removal of covers
• improper use of machines
• incorrect operation
Always de-energize electrical plug-in connections before removing or

inserting the plug (with the exception of mains connections which do not
represent a shock hazard in the sense of the safety regulations).
Always protect open or exposed live leads and plug connectors against
accidental contact.

Operation Manual
Before any installation of or on electrical systems, these must be de-

energized.
Electrical parts which were stored for an extended period of time must only
be operated after an insulation test has been carried out.
1.3.7 Regulations and instructions for lubrication
Before first commisioning, lubricating points have to be checked for

suuficient lubrication to avoid damge to the plant.
Do not bring lubricants and oils into contact with naked flames or red hot
parts.
During all work on assemblies and components (e.g. motor, gearbox), their
specific regulations and lubrication instructions must be observed .
Before carrying out lubrication work, the plant should always be stopped
and switched off and protected against accidental and/or unauthorized
restarting (exception: lubrication work which is expressly stated as being
carried out during operation of plant).
Do not reach into rotating parts and maintain an adequate distance in order
to avoid clothing or hair becoming caught up.
Absolute cleanliness must be assured both during the initial fill and during
subsequent relubrication and lubricant changes to ensure that no foreign
particles can enter the lubrication point.
• Avoid overfilling and spilling of oil.
• Excessive grease which may be forced back out of the lubrication

point must be wiped away.
• Avoid skin contact with oils and greases - wear protective gloves and
clothing.
With certain lubricants, e.g. highly flammable hydraulic fluids, the special
safety regulations for these substances must be observed.
(See instructions printed on the packages and the manufacturers’
instructions.)

Operation Manual
1.4 Accident prevention regulations
In addition to the instructions mentioned in these regulations, the statutory

and general accident prevention regulations and guidelines in force at the
place of operation must also be observed and complied with.
The current regulations of the employer’s liability insurance associations
should generally be regarded as the basis for accident prevention guidelines.
1.4.1 Behaviour in the event of accidents
During the construction of plant and during preparation of the

documentation, we have paid great attention to all points contributing to
avoiding accidents.
Should an emergency situation nevertheless occur, seconds can often make
the difference between correct, logical behaviour and incorrect behaviour.
Training in good time for an emergency situation is therefore of the utmost
importance.
Here are a few tips:
• Avoid everything which could result in accidents
• Shut off the plant immediately in the event of an accident (emergency

stop)
• Distinguish between types of accident:

Personal injury
Fire
Material damage
• Draw up charts with behavioural rules and post these at clearly visible
points in- and outside the plant
• Train yourself in first aid
• Clearly define the signalling routes

Erection Instructions
Safety Labelling
Important Notes to Safety Labelling
Chapter 2 Safety contains information to safety labels. The product specific

drawing in chapter 9 contains all safety labels required and shows, where
they have to be fixed.
As far as possible, these labels are already fixed in our works. Some labels,
however, may only be fixed at site or after assembly, as e.g.:
• Safety labels for electrical equipment for control and energy supply.
(This equipment does not belong to our scope of supply and is only
known at site.)
• Labels, which are fixed on the conveyor in certain distances, e.g. safety
guards at the deep drawn pan conveyor.
• Labels at assemblies, which are manufactured at site and therefore are
not at disposal in our works.
These labels are supplied by us along with the product.

If labels should be missing for any reason, you may demand them from us.
With regard to addresses and further contact data please refer to chapter 1,
paragraph 1.6.
WARNING
Before commissioning it must be checked on the basis of the
drawing Safety Labelling, whether all safety labels have been
fixed.
Missing labels must be fixed.
m-PN-gb m-hinw-safety-label 10/06 1

Erection Instruction
for
Pivoting Pan Conveyor
SPB
Attention
The
m-SPB-gb m-SPBZ-deck 05/01
"Safety Instructions for the Erection of Aumund

Plants"
also apply to this instruction.

Tel.: + 49 2843 72-0 • Fax: + 49 2843 60270
Erection Manual
SPB
Contents
1 Preface .................................................................................. 2
1.1 Symbols Used ........................................................................ 2
2 Safety .................................................................................... 3
3. Transport and Storage ......................................................... 4

3.1 Delivery State ....................................................................... 4
3.2 Transport ............................................................................... 4
3.3 Storage .................................................................................. 4
4 Erection ................................................................................. 6
4.1 Site Survey ............................................................................ 6

4.2 Foundations and Anchoring of Components ........................ 7
4.3 Setting Up the Conveyor ...................................................... 8
4.3.1 Drive Station .......................................................................... 9
4.3.2 Discharge Station ................................................................. 10
4.3.3 Track .................................................................................... 10
4.3.4 Take-up station ..................................................................... 13
4.3.5 Conveying elements .............................................................. 14
4.3.5.1 Chain Tensioning .................................................................. 18
4.3.7 Feed and Discharge Chutes .................................................. 19
4.3.8 Safety Devices and Additional Equipment ........................... 20
4.4 Electrical Equipment ............................................................ 20
4.4.1 Point Control - Intermediate Discharge ................................ 21
4.4.2 Gear Motor Limit Stop ......................................................... 22
5 Start-up ............................................................................... 24
5.1 Trial Run without Material ................................................... 24
5.2 Trial Run with Material ........................................................ 25
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1 Preface
These assembly instructions are provided to assist our customers in erecting

AUMUND conveyor systems, however, they cannot substitute experienced
personnel. Normally, we do not have available exact information on the
installation site conditions so that it is only the general assembly work flow
that is described in the following. For this reason, we recommend to consult
one of our supervisors yet in the planning phase.
Important! As regards pivoting pan conveyor, errors in assembly may cause serious
damage yet on the occasion of the commissioning. For this reason, it is abso-
lutely required that the pivoting pan conveyor will be erected under the
supervision of an AUMUND supervisor. The erection of a pivoting pan
conveyor without the assistance of an AUMUND supervisor results in for-
faiting all warranty claims. Any deviations from this shall only be possible
upon corresponding contractual agreement.
If an AUMUND conveyor is going to be erected on a conveyor bridge or if

the conveyor is equipped with a self-supporting runway structure, the erection
of the conveyor bridge will form an independent assembly process which is
not described in the present instructions.
1.1 Symbols Used
Certain typographical emphasis in this Manual draws the reader's attention to

important information.
• Enumeration
Reference to drawings and figures
(reference to the erection plan is not included)
Ö Operating instructions, activities
12. Multiple activities are numbered consecutively
) Notes and explanations of particular importance.
Reference to required or recommended tools
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2 Safety
Caution The separate document "Safety Instructions for the Erection of

Aumund Systems" is part of this Manual. Read these safety in-
structions before you begin with the erection work described in
the following chapters.
At least the following symbols are used to denote safety in this Manual.
Hazard to the operating safety of the system

If the related instruction is ignored, the reliable operation of the system is
effected and damage to the system is possible.
Caution The Caution symbol precedes all safety alerts in this Manual which refer to
regulations, guidelines or work procedures that must be observed.
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3. Transport and Storage
3.1 Delivery State
Separate components, for example, stations, are mostly pre-assembled.

The conveying elements and the track are delivered in several components
and sub-components and must be assembled on site.
For details, refer to the packing lists (list of packages).
3.2 Transport
Ensure that components are not damaged during transport.

Attach ropes or chains to the stations only on the eyebolts provided for this.
Do not place steel rope or chain around unprotected metal parts
(e.g., shaft stub, etc.)
3.3 Storage
Put down all components so that no undue strain can deform or damage the
equipment.
All machines surfaces have a coat of wax-based corrosion inhibitor. The
corrosion inhibitor we use ensures protection of the protected equipment for
the following periods:
• 12 months indoors
• min. 3 months outdoors
Remove the corrosion inhibitor from all surfaces that require good fit with
other components, e.g., shaft journals on which a coupling is mounted, etc.
Remove the corrosion inhibitor with kerosine, petrol or diesel.
The above periods assume that unless agreed otherwise in the purchase
contract only machined surfaces are treated with the specified inhibitor. All
other parts are either untreated or painted as required for the respective
purpose. The above solvents to remove the anticorrosion chemical must not
be used on seals/gaskets or in bearings.
Solvents must never contaminate the earth or be disposed in the public sewer.
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Sub-supplier components
We can take care of corrosion protection of sub-supplier components, such
as gearing, couplings, etc. only if the protection is specified in the purchase
documents. If you need to know the type of standard corrosion protection
provided on sub-supplier units, please contact the respective supplier, unless
the information is already provided with the unit.
If it is decided that components must be warehoused on site and cannot be
installed immediately after arrival on site, extra corrosion protection is
needed, for which we should be contacted
Certain components, for example, gears, have warehousing instructions
included in the instruction manual.
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4 Erection
Make a check for short delivery and damage before starting erection.
The area for the conveyor track and the required transport routes should be
clean and all objects removed from them.
The dimensions and weights of all components are indicated on the attached
drawings and the part lists.
) The figures in this Manual are only for information and may not
show the actual design of the equipment.
Only the drawings on which the project is based and which are
supplied show the actual design of all components.
4.1 Site Survey
1. Checks and Inspections prior to Start of Erection Work:

• Location of platform and roof openings*
• Location of feeding and dumping points*
• Location and state of foundations**
• Location and state of the supporting and backup constructions**
* Dimensions in accordance with Aumund's installation plan

** These parts are not usually included in the Aumund scope
and as such only their location may be indicated on the Aumund drawing.
The required check must in this case be made with reference to other
drawings and specifications.
2. Conveyor Run (Conveyor Centerline)

The conveyor centerline is the connecting line between the take-up
station and the drive station and must be defined with extreme accuracy.
Except in case of a very short conveyor, define reference points at
distances of about 10 meters as guides for defining the conveyor line.
Then set up a straight wire to mark the conveyor centerline (between
the reference points). Several short sections of wire should be marked
because a long wire is not taught enough to avoid wind deflection and
similar effects.
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3. Location of Take-up station and Drive Station

The location of the drive station and the take-up station is defined by
the points of intersection of the tensioning centerline and the drive shaft
centerline respectively with the conveyor centerline.
These points must be defined with high accuracy.
4. Location of Track Supports
Track drawing
Once the track is defined and the straight wire set up, the conveyor
centerline must be copied on the ground with plumb lines (footprint of
the track supports). Mark the point on this line, where the track supports
are to be situated.
For avoiding the accumulation of measuring errors, control measure-
ments must be carried out with a long measuring tape from one point
(e.g. drive station).
4.2 Foundations and Anchoring of Components
Concrete foundations or steel structures must be constructed to ensure the

stability and anchor the different components, such as take-up station, drive
station, track supports, etc. The foundation heights and footprint tilt can be
seen in the AUMUND erection plan. The type of fastening of the component
must be considered when making the concrete foundation. The type of faste-
ning is specified in the erection plan. The most common types will be descri-
bed in the following paragraphs.
1. Fastening with anchor bolts
Special bolts are installed in prepared holes together with the component
they hold. After aligning the component the bolts are grouted with concrete.
As the bolts must not be tightened until after the concrete has set, the instal-
led component must be maintained in the required position.
2. Fastening with dowels
After aligning the component on the foundation, the holes for the dowels
can be marked through the bolt holes and drilled directly. The dowels
we use can be installed through the bolt holes without removing the
component.
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3. Welding
Welding for fastening is usually used with steel supporting structures,
such as for conveyor bridges.
In some cases steel plates are embedded in the concrete. The compon-
ents are welded to the steel plates after alignment on these plates. This
method is used, for example, if holes must not be drilled in the concre-
te.
4.3 Setting Up the Conveyor
All installation of AUMUND conveyors starts with one of the stations.

Which station is erected first, depends on the conditions on site (available
space, transport routes, etc.).
We recommend to start with the drive station and then erect the conveyor
section by section towards the take-up station.
We would not recommend at first to erect all stations, e. g., intermediate
dumps, and then construct the track between the stations. It may happen that
the track sections do not fit in between the stations.
Recommended Erection Sequence (overview)
• drive station
• track supports
• track to the first discharge station
• first discharge station
• track to the next discharge station
and so on until the take-up station
• take-up station
• assembly and installation of the conveyor
• chutes, grates, other accessory items
• electrical connection, setting the limit switches, function check
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4.3.1 Drive Station
There are two basic drive methods:

1. Shaft-mounting gear unit with hollow shaft
The drive - if part of the Aumund scope - is usually mounted when
delivered.
2. Gear unit with solid shaft and clutch between gear and drive shaft
The drive - if part of the Amund scope - is installed on a pad separate
of the drive station.
The drive station can be set up on the foundation as a complete unit. In case of
drive method 2, the drive is installed later.
The station must be aligned with extreme accuracy because any misalignment
can cause trouble and early failure.
Drive Station Alignment

The alignment of the drive station is correct if the drive shaft is positioned
horizontally, at right angles to the conveyor centerline and the conveyor
centerline (set up straight wire) runs in the center between the two driving
sprockets.
Ö Check drive shaft for horizontal position, align if necessary.
Bubble level with prism foot (machine bubble level)
If out of alignment, install shimming plates under the drive station until
the drive shaft is exactly horizontal.
Ö Check right angles between the drive shaft and the conveyor centerline
(set up straight wire), align if necessary.
Align the sprocket wheels to the conveyor centerline.
Steel straightrule min. 2 m
( )
(!) .
/2 ( . 1).
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Fig.1 (The figure is for orientation, the actual design can be different)
1 = Straight wire (conveyor centerline), 2 = Straightrule. 2m
Ö Fasten the drive station on the foundation after bringing it in exact

alignment and checking for correct position.
4.3.2 Discharge Station
Set up the discharge stations one after another as allowed by the progress of
the track erection.
Each discharge station can be set up on the foundation as a complete unit.
Ö Align the discharge station to the conveyor centerline
Ö Align the discharge station to the required height
The track rails must connect to the discharge station withput offset.
Ö Check to make sure that all drop latches function properly and with
ease and drop back to original position automatically.
) Set the limit switches. See the appropriate paragraph in this Manual.
4.3.3 Track
Track drawing
The track should be erected progressively from the drive station towards the
take-up station. Start with setting up the track supports, then place the track
rails on the supports. The intermediate discharge stations can already be set
up but should not be fastened at this point.
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Track Supports
All track supports are marked with the PO number and the position number
from the track drawing. These numbers are stamped in the top grate bracket.
Ö Before erection, inspect each track support for damage in transit.
Do not erect supports with bent or twisted legs.
Ö Repair the defect before erection of the support.
If a damaged track support is erected, not only is the erection of the track rails
difficult, the idlers can pump against the damaged support and cause extensi-
ve damage to the whole system.
Ö Align the track supports

• vertically
• at right angles to the track centerline
• to the required height (add shimming plates if necessary).
Ö Fasten the supports on their foundations.
Track Rails
Ö Place the track rails on the supports and align them roughly.
Fig. 2
Ö Connect the rails with each other
Connect the rails with brackets and bolts. Mount the nuts from outside.
Ensure to leave a gap of about 5mm between rail ends and no rail butt
shall be located on a track support.
Fig. 2 1 = Rail, 2 = Bracket, 3 = Bolt, nut, spring ring
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Fig. 3
Ö Align the track rails
Set the gauge with a fixed gauge tool.
Fix aligned rails to the track supports.
The installation of the track rails requires particular attention at the stations.
For dimensions, see the erection plan / track drawing.
Ö Check the alignment of the whole track.

Ö Electrically weld the track rails to the support angles.
Basic-coated electrodes
Fig. 3 Fixed gauge tool for setting the track gauge

1 = Gauge, 2 = Conveyor centerline (straight wire)
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4.3.4 Take-up station
The take-up station is largely pre-assembled and is placed on rails as a

complete unit. It can be moved for tensioning the chain.
Fig. 4 Take-up station overview

1 = Bottom strand extension rails, 2 = Chain carrier roller, 3 = Sprocket wheel
for rotary point , 4 = Chain carrier roller, 5 = Tensioning support,
6 = Tensioning spindle, 7 = Turn sprocket wheel , 8 = Top strand extension rail
Activities:
Complete take-up station
Fig. 4
Ö Align the rails for the take-up station centrally to the conveyor centerli-
ne and in accordance with the dimensions in the erection plan and
fasten the rails to the foundations .
Ö Put the take-up station on rails and set it up in exactly the required
position.
Ö Define the position for the tensioning supports and bolt them to the
foundation / beam.
Ö Install the tensioning spindles.
Ö Install the carrier rollers (2) on the take-up station.
Ö Install the extension rails on the top strand (8) and the bottom strand
(1).
Ö Check to make sure that all drop latches function properly and with
ease and drop back to original position automatically.
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4.3.5 Conveying elements
The conveying elements consists of the following supplied parts:

• pan
• catch axle
• catch link
• idler
• chain in part lengths
• fasteners
These parts must be assembled to a complete pan at a suitable location outsi-

de the conveyor.
Activities:
Pan overview
Fig. 5
Ö Install the catch axle (2) in the tubes in the pan (1).
Carrier axles should not be bent.

The supporting plate must be freely rotating on the carrier axle.
Fig. 5
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Fig. 6
Ö Install one catch link (3) each on either side of the catch axle (2).
Drive in the adapter sleeve (4).
Fig. 6
Fig. 7
Ö Install idlers (5) in the idler mount (6) on the pan (1) and tighten bolts.
Fig. 7
The chain lengths should not be bolted on the pans outside the conveyor. The
assembly can be handled only with much difficulty and will make the pro-
gress of erection unnecessarily complicated.
Do not pre-assemble units of several chain lengths and pans outside the
conveyor and then lift them on the track with a crane. In this case damage to
the pans and the chains cannot be avoided.
Whether the conveying elements are installed in the top strand or the bottom
strand depends on the conditions on site. In most cases it will be better to
install the conveying elements in the bottom strand.
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Activities: (installation in bottom strand)

Fig. 8
Ö Put the pan with the idlers on the rail.
Fig. 8 Pan in bottom strand
Fig. 9
Ö Bolt the chain (3) to the catch links (2) on either side of the pan.
Turn the catch links (2) to the correct position!
Apply two sets of lock washers (3) per screw connection.
(1 Set = 2 washers).
Tighten screw connection with a torque wrench.
Tightening torque for screw M12 (unlubricated) = 125 Nm
2 3
St32b.emf
Fig. 9 Position of catch links in bottom strand
Ö Install further pans and chain lengths.
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The chain bolts for connecting the individual chain strands may be beat with a
hand hammer. The chain bolts must be greased before application.
Support the chain during assembly in such a way that by no means a link plate
will be bent. The borings of the chain link plates must be aligned without
offset, before applying the bolt. Do not fix the bolts twisted or inclined.
Ö As permitted by the progress of erection, pull the ready conveying

elements towards the take-up station (direction of conveyance) and then
through the take-up station.
) The passage of the conveying elements through the take-up station
is illustrated in the erection plan.
The chain cannot be put on the sprocket wheels in the take-up station as you
like! The catch link and the catch axle must engage the recess in the sprocket
wheel to the rotary point. (Fig. 10)
Conveying elements that is wrongly installed causes extensive damage to
the conveyor.
Fig. 10 1 = Chain, 2 = Catch link/catch axle, 3 = Rail guide

4 = Sprocket wheel to rotary point, 5 = Chain carrier roller
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Ö Mount further conveying elements parts and pull them forward until the
drive station is reached.
Do not install the chain on the sprocket wheels in the drive station as you
like! Observe the following instructions and Fig. 11. Conveying elements
that is wrongly installed causes extensive damage to the conveyor.
Fig. 11
Fig. 11
) The position of the pan / chain is correct if the center of the carrier
roller (1) and the center of the idler (2) are at 230 mm distance from
each other. The carrier roller (1) must be at the extreme top position
when this measurement is made.
4.3.5.1 Chain Tensioning
The conveyor can only work smoothly with the required chain pretension. If
the chain is not pretensioned or the pretension is wrong, this can cause exten-
sive damage to the conveyor.
The conveyor shall not be started after first erection, chain change or other
work for which the chain must be slack unless the chain is tensioned.
Tension the chain only when the conveyor carries no material and the chain is
cold (max. 30° C).
The chain tension is to be set to correct tension with two tensioning spindles.
To avoid lopsided loading of the conveyor, both spindles must be adjusted
equally.
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If the conveyor has no curve the correct chain tension can be found by measu-
ring the chain sag. The chain tension is correct if the sag is 10 - 20 mm in the
zone of greatest slack between two idlers.
Note:
When the chain sag is measured, the idlers between which the sag is measu-
red must rest on the track rails.
The zone of least chain tension is:

• where the conveyor runs level - in the bottom strand behind the drive
station
• where the conveyor has upward gradient - in the bottom strand before
the drive station.
Extra Inspection for Pivoting Pan Conveyor

When the loaded conveyor is running the rear end of the take-up station can
slightly lift off the guide rails (max. 5mm).
We recommend to tighten the tensioning spindles evenly and in small amounts
while the conveyor is running until the take-up station just about lifts off the
rail.
4.3.7 Feed and Discharge Chutes
Chutes which are our scope are shown in the erection plan together with the
required erection dimensions.
Further drawings are attached if necessary.
As chutes are always made specific to a conveyor and the erection conditions
can vary widely, only general erection information can be provided here.
Basically, a distance of 50mm shall be maintained to all rotating or recipro-
cating components.
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4.3.8 Safety Devices and Additional Equipment
All safety devices should be installed prior the trial run unless they hamper
inspection or control during the trial run.
The following safety devices are provided:
• Protective grates Protective grate
• on either side of the conveyor
• on the stations
• in all walking areas
• Emergency stop Emergency stop switch
stopping the conveyor by means of rip cords. The conveyor can be
stopped from any position.
• Covers, e.g., on couplings
• Chain lubrication Lubricant bowl
If chain lubrication is provided, it is indicated in the drawing.
If the safety provisions in effect at the site of the equipment require more
protection, it must be provided.
4.4 Electrical Equipment
The electric control is not normally part of the Aumund scope. Therefore the
attached technical function description (basic circuit diagram) does not
generally reflect the concrete data of the project. The description is for a
typical electric control of a system described in this Manual. If the equipment
is other than the Aumund standard equipment (proximity limit switches, etc.),
the electric control must be adapted as required provided the interlinking
arrangement is not changed.
Some conditions and settings for certain functions of the conveyor are descri-
bed in the following paragraphs.
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4.4.1 Point Control - Intermediate Discharge
The entry point to the discharge station shall only be switchable if no idler is
present on the entry rail. An inductive proximity switch at the discharge is
actuated by the passing idler and sends a signal to the point control.
Setting the proximity limit switch for point control:

Point control
Fig. 12
Ö Move the conveying elements until an idler at the discharge station is
50 mm behind the end of the entry rail.
Ö Set the proximity switch to ensure that it is fully covered (dampened)
by the idler.
The switching function of proximity limit switches in our scope is
indicated by a light-emitting diode (LED).
Fig. 12 1 = Proximity limit switch, 2 = Entry rail,

3 = Roller at switching position
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4.4.2 Gear Motor Limit Stop
The gear motor of the intermediate discharge station shall be turned off at the
respective end position of the entry point. This is controlled by two proximity
limit switches. If the proximity limit switches are supplied by Aumund, they
are already installed and preadjusted in the factory.
The final setting must be carried out after installation of the intermediate
discharge station and before commisioning of the conveyor.
Function Check:
The gear motor must be turned off at the top or bottom extreme position of the
entry rail. The motor shall not be turned off before either stop is reached.
Figs. 13 and 14
Fig. 13 Entry rail in top extreme position,

setting lever at stop
Fig. 14 Entry rail in bottom extreme position,

entry rail at stop
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If the switching point setting is not correct or if the gear motor is not turned
off, the settings of the proximity limit switches must be adjusted. Fig. 15
illustrates the principle arrangement.
Fig. 15 1 = Mounting rail, 2 = Proximity limit switch - discharge,

3 = Actuator, 4 = Proximity limit switch - running
Fig. 15
Ö Make sure that the active control face of each proximity limit switch
(2 and 4) is directed to the actuator (3).
Proximity limit switches in our scope allow different settings of the
active face. The active face is marked, e.g. with concentric circles.
Ö Set the distance to the actuator (3) to about 10-11 mm.
Fig. 13
Ö Move the entry rail to top extreme position until the setting lever con-
tacts the stop.
Ö Shift the proximity limit switch in the mounting rail until the LED
signals the switching point in this position. Fix the limit switch in this
position.
Fig. 14
Ö Move the entry rail to bottom extreme position until the setting lever
contacts the stop.
Ö Shift the proximity limit switch in the mounting rail until the LED
signals the switching point in this position.
Fix the proximity limit switch in this position.
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5 Start-up
Before the system is started for the first time, make sure that:
• all dimensions are as indicated in the drawings.
• all instructions of the Erection Manual are followed.
• all gears and hydraulic couplings are filled with the prescribed oil.
• all sub-supplier instructions are followed.
• all tools and aids are removed from the hazard area of the conveyor.
• all guards are installed and safety devices functional.
• there are no persons in the danger area of the conveyor.
5.1 Trial Run without Material
At first run the conveyor without material and make a general function check.
The trial run shall extend over several hours.
• Start the conveyor briefly (jog mode).
Position persons at the stations to ensure that the conveyor is stopped as
soon as a fault occurs.
• Observe passage and turning of the pans in the stations.
• Test the intermediate discharge only if the passage in the drive and
take-up stations is in order.
• After test run check, wether the srew connection between
carrier axle / chain is tight.
) Refer as well to procedures to Fig. 9
Fig. 17
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5.2 Trial Run with Material
If the conveyor runs smoothly without material, make a trial run with materi-
al. Feed material to load the conveyor evenly. The material must be spread
evenly across the full width of the conveyor. If material is fed on one side, the
position of the feeding chutes must be adjusted.
The layer height shall be set as indicated in the erection plan to ensure that the
conveyor is not overloaded. If material is fed at several points, the layer
height controllers must be set to different height values to take care of the fact
that the layer on the conveyor is becoming higher from one feed point to the
next. The power consumption at maximum conveyor capacity shall not exceed
the rated current of the drive motor.
If a dust extraction system is provided at the feeding or dumping point, this
shall be checked for function. If the extraction rate is poor, check the housing
seal and the connections of the air piping for leaks.
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AUMUND Corporation
package list customer
2300 Windy Ridge Parkway
project date
11314 21.01.04
Atlanta GA 30339 LC-1-3-11252-00-127
packages weights measurements parts list contents Item-No. F 780
no. pos. quant kind net kg gross kg volume m³ length width height cm Pos. quantity unit family code / characteristics designation / comment
article / norm
110000 0N300-1641 drag chain conveyor

Parts list no.
30042358 30042358 Drawing no.
==================================================
1 1 03 1575 1575 You can find230
3,922 these 155 110 1 1 st 700001 2N810-1247 Drive station complete
parts in the above 30043249 ZB
-----------------------------------------------------------------------------------------------------------------------------
2 1 03 1514 1514 parts list and201
3,799 drawing
180 105 2 1 st 700002 2N820-1215 take up station complete
30043267 ZB
-----------------------------------------------------------------------------------------------------------------------------
807000 TKF1200/2-11314 complete trough section
Parts list no. 30043668 30042358 Drawing no.
==================================================
3 1 03 1165 1165 3,894 278 149 94 1 1 st 818000 0N009-5558 trough
30043842 VE
5 1 st 829092 2N180-1987 inlet flange
You can find these 30043707 VE LOSE
-----------------------------------------------------------------------------------------------------------------------------
parts in the above
4 1 03 1010 1010 3,502 250 149 94 2 1 st 818000 0N009-5559 trough
parts list and drawing 30043895 VE
6 1 st 829092 3N180-1988 inlet flange
30043708 VE lose
-----------------------------------------------------------------------------------------------------------------------------
5 1 03 1008 1008 3,502 250 149 94 3 1 st 818000 0N009-4354 trough
30007334 VE
-----------------------------------------------------------------------------------------------------------------------------
6 1 03 982 982 2,539 165 135 114 4 1 st 818000 0N009-5557 trough
Please note: First position above the double line 30043703 VE
191002 LF11314 drive set
always refers to the parts list and/or drawing no.. 30043831
In this parts list / drawing can you find the below ==================================================
parts. 5 1 st 829093 0N016-0770 drive platform
30043741 VE angebaut/attached
page
1 7254 7254 21,158 kind: 01 box 05 bundle 09 hobbock 13 sheet iron can
02 crate 06 cardboard box 10 sack 14 roll
03 unpacked 07 drum 11 pallet 15 coil
05 0160 06.99
04 skid 08 barrel 12 basket 16 container
21.01.04 14:56

A-P - 2.0 - EN (45345) - Unlocked

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Operation Manual

Pivoting Pan Conveyor SPB

Customer: F.L.Smidth INC. Proj.-no.: ............................................ 45343

Operator: Cementos Argos S.A. FLS EQ. no.: ..................................... 471.DB210

Year of manufacture: .................................. 2008

Revision: Rev. 02 / 08. May 2008

AUMUND Fördertechnik GmbH • Saalhoffer Straße 17 • D-47495 Rheinberg

Maintenance and Servicing 5

1.1 Preface ........................................................................ 2

1.3 Warranty, Guarantee, Liability ................................... 3

1.7 Description ................................................................ 13

PN-gb 1IN-A(f) 10/06 1

• the information and instructions given in this manual will be strictly

• Information and instructions concerning their task

The safety instructions in this operating manual only consider the

The owner is responsible for the adherence to the safety instructions

Illustrations in this operating manual are normally only schematic diagrams

Pn-gb \ 1n(f) 05/05 2

AUMUND Fördertechnik GmbH

1.3 Warranty, Guarantee, Liability

Basically, the contract concluded between the contracting partners to the

In case of application beyond the intended purpose any guarantee and

1.4 Standards, System of units

Pn-gb \ 1n(f) 05/05 3

1.5 Transport, Storage

Transport damage must be immediately notified to the forwarding

You will find information with regard to the transport of individual

However, the following principles are to be observed for the transport on

Pn-gb \ 1n(f) 05/05 4

• Transport all components in a way that avoids deforming or damaging

• Do not put steel ropes or chains around machined or painted surfaces.

Pn-gb \ 1n(f) 05/05 5

If a component does not feature any identified attaching points, it will

Applies to all components: A long-time outdoor storage without

Pn-gb \ 1n(f) 05/05 6

We can only influence the corrosion protection of supplier components such

Prior to storing compoments, their corrosion protection shall be

The climatic conditions and the ambient influences may considerably

Pn-gb \ 1n(f) 05/05 7

Storage < 3 months

The manufacturer's instructions on individual components such as

• Protect all components against the direct impact of weather, soiling

• The storage of the components in a closed or roofed in space is always

• Ensure an adequate venting of closed spaces.

• The foundation must be dry.

• Store all components so as to prevent their twisting, tilting or slipping.

• Always store components which are unprotected or inadequately

• Adequately vent waterproof covers to avoid the condensation of water.

• Always provide for a weatherproof, dust-proof and vibration-free

• Store gearboxes and electric motors in accordance with their installa-

• Ensure a dry storage of all electric devices and equipment.

Pn-gb \ 1n(f) 05/05 8

• Protect bucket elevator belts against the following impacts:

• Deposit the rolled-up bucket elevator belts on an axle on stands so that

We recommend a monthly check of the condition of the components

Storage >3 months up to 18 months

Further to the measures already mentioned, the below listed additional or

• Ensure storage in a closed or roofed in place. Outdoor storage is not

• Thoroughly inspect all components every two months for corrosion

• Immediately eliminate corrosion. Immediately touch up any damaged

Pn-gb \ 1n(f) 05/05 9

1.6 Service, Maintenance

A regular, carefully carried out maintenance will have considerable in-