V 2172 0070 0045 - Rev - 2 (3257241)

Precision Pulley & Idler

An Employee Owned Company

300 SE 14TH STREET
PELLA, IA 50219
641‐628‐3115

HUDBAY PERU PO 2172‐0070
CONSTANCIA PROJECT

PPI JOB NO. 380721‐22‐23

CONVEYOR IDLERS

INSTALLATION, O&M MANUAL INDEX

Equipment Specifications & Data Sheets
Idler Drawings
Recommended Spare Parts List
Idler Operation & Maintenance Manual

®
OPERATION
&
MAINTENANCE
BELT CONVEYOR IDLER INSTRUCTIONS
Important - Safety Instructions
Compliance with safety standards, including OSHA and other Federal, State, and local codes or
regulations is the responsibility of the user of the conveyor installation. Placement of guards and other
safety equipment in accordance with safety standards is dependent upon the area and use of the
system. A safety study should be made of the conveyor application and guards should be installed
wherever appropriate. “Safety Standards for Conveyors and Related Equipment” ANSI B20.1 is a guide
for safe construction, installation, operation and maintenance of conveyors and related equipment.
The stated purpose of ANSI Standard B20.1 is to present certain guidelines and safety practices
that will be assistance in establishing a safe work place. It is important to realize that the best design
and safety features can be useless in conjunction with faulty maintenance and operating practices.
The broad scope of ASME/ANSI Standard B20.1 precludes its inclusion in this manual.
However, it is highly recommended that those responsible for assuring safety in the installation,
operation and/or maintenance of belt conveyors and equipment, acquire and use Standard B20.1 as a
reference and guide.
Storage and Preparation Establishing the Conveyor Centerline

Belt conveyor idlers are usually shipped to the job site Before proceeding with the installation of the idlers, a
mounted on skids. As idlers often arrive well in advance of centerline of the conveyor must be established. A
their installation, they should be stored under cover to recommended method is to stretch piano wire the entire
protect them from exposure to the weather and other length of the conveyor frame (or segments of the frame on
adverse conditions. long conveyors.)
Prior to installation, check all idlers for evidence of 1. Anchor the wire at convenient points on the conveyor
damage to the rolls or frame due to mishandling. Check all frame by attaching an eyebolt to a piece of steel.
rolls to make sure that they turn freely. Idlers should be
cleared of any foreign matter that may have accumulated 2. Locate the eyebolt at the center of the conveyor.
during transit or storage. Foreign matter on idler rolls can Remember to keep the eyebolt about 1” to 2” (2.5 cm to
cause damage to the belt. 5 cm) above the troughing idlers center roll.
3. Fasten the eyebolt bracket to the conveyor frame.
Reliable operation and long service life of these idlers
depends upon the care taken during installation and 4. Install a similar eyebolt bracket at the opposite end (or
operation. Periodic inspection and maintenance are at a convenient intermediate point if the conveyor has a
required. The following information can be considered to be bend, slope or curve).
the minimum care recommended. Local environment,
working conditions, and regulations may require more 5. String the piano wire, adjust to the centerline of the
frequent servicing. conveyor, pull the wire taut, and secure the wire.
Copyright © 2007, Precision Pulley & Idler, All Rights Reserved Subject to change without notice Rev, 04/07
Corporate Office West Coast SouthWest Northeast Southeast
®
Service Center Service Center Service Center Service Center
PO Box 287 800.247.1228 Sacramento, CA Fort Worth, TX Lewisberry, PA Cleveland, TN
®
E m p lo y e e O w n e d
800.247.1228
Pella, IA 50219 Copyright © 2007, Precision
641.628.3115 Pulley & Idler,800.247.1228
800.821.9798 All Rights Reserved 800.247.1228 800.247.1228
www.ppipella.com fax 641.628.3658 fax 916.386.0545
Subject fax 641.628.3658
to change without notice PPI Idler OM
fax 641.628.3658 Manual - Page 1
fax 641.628.3658
ELEVATION OF CENTER LINE OF 1/3 OF
HEAD & TAIL PULLEYS CONVEYOR & IDLER TROUGH DEPTH
EQUAL EQUAL
CONVEYOR AND IDLERS LEVEL
Idler Installation Checklist from the centerline of the tail pulley equal to one (1) belt
width for 20 degree troughed idlers, one and one half (1 1/2)
Remove mud, stones, or any other debris from times belt width for 35 degree troughed idlers, and twice (2)
conveyor stringers and deck plate. Remove all burrs, dents the belt width for 45 degree troughed idlers.
and bumps caused by excessive weld spatter to allow the
belt conveyor idler frame to be securely positioned level with It is good practice to use a 20 degree troughing idler as
the plane of the conveyor and perpendicular to the line of a transition idler for the first and last idler when using 35
conveyor belt travel. degree troughing idlers and a 35 degree idler when using 45
degree troughing idlers.
Rotate each roller to verify that it turns freely.
Thoroughly inspect for any blocking or shipping wires that Place idlers in a position by sliding them in the direction
have not been removed. Visually inspect for any shipping or of belt travel until the footpads seat against the mounting
installation damage to the idler frame or rolls. bolts. Tighten bolts by hand. Final alignment requires that
the centers of all idlers are in a straight line, perpendicular
Check for and remove any tools or other foreign objects to the line of belt travel, properly spaced, and level. When
on the belt, particularly on the return side where these items alignment is complete, tighten all idler mounting bolts
may get between the terminal pulleys and belt. Any grease
on the belt should be removed immediately as belt
deterioration will occur.
Head and tail shafts need to be parallel to each other.
All bolts should be properly tightened.
Troughing Idlers
When installing a conveyor system the troughing or
carrying idlers should be installed first. Alignment of the
structure is critical, if the belt is to train properly on the idlers.
Idler and pulley supports must be an equal distance from the
conveyor centerline and level across the conveyor width
When installing troughing idlers, sling the units by their

frames. If welding on the conveyor frame is necessary,
never ground through a roll as bearing damage may result.
Starting at the tail end of the conveyor, the first standard

troughing idler should be located an approximate distance
®
800.247.1228 Copyright © 2007, Precision Pulley & Idler, All Rights Reserved
www.ppipella.com Subject to change without notice PPI Idler OM Manual - Page 2
Troughing idlers are shipped completely assembled
less the mounting bolts. Four bolts are normally suggested
and they must be securely tightened after the idler frame is
correctly positioned.
Return Idlers
After the carrying idlers have been set in place, the
return idlers should be installed. The return idlers must be
installed perpendicular to the conveyor centerline and level.
Leave the training idlers out until the belt has been properly
trained.
Hanger brackets and shaft retainer clips are shipped

unassembled and without mounting bolts. Normally four (4)
mounting bolts are required.
First, install bolt hanger brackets loosely into place

securely with a wrench. below belt conveyor frame side stringer.
Next, insert the roller assembly into the slot of each

hanger bracket and allow the shaft slots to seat firmly into
the brackets, and then attach the clips as detailed below.
The shaft clip slides over the end of the shaft. The holes
in the clip and bracket will align when properly installed.
Install self-tapping screw. Do not over tighten.
Self-Aligning Troughing Idlers

Belt Self-Aligning Idlers are intended to aid in
maintaining alignment when conditions such as temporary
off-center loading, unusual side winds, or misalignment of a
transient nature, due to lump concentration, disturbs the
alignment of a properly installed conveyor belt. A correctly
Important aligned, loaded, and spliced conveyor belt will not require
corrective action from the belt self-aligning idlers.
After the return roller has been properly assembled and
aligned so that it is square and horizontal with the Self-Aligning Troughing Idlers are installed along the
centerline of the conveyor frame, securely tighten the conveyor length, as required, but no closer than 50’ (15 m)
return hanger bracket bolts. from a pulley. Positive arm type units are used on belts
traveling in one direction only. Actuating type trainers
BELT TRAVEL
®
without arms are used on reversing belts and on belts with Place the trainer assembly on the conveyor frame and
traveling trippers or stackers. slide the frame in the direction of belt travel until the
footpads seat against the mounting bolts. Remove any
CEMA B, C, & D Self-Aligners, TESA, RSA, & FSA are blocking or shipping wires so the trainer frame can pivot
shipped completely assembled less the mounting bolts. freely. Check for squareness and level the trainer frame as
Pivot and guide roller bearings are factory lubricated and required to complete the installation. Verify the type of roll
ready for operation. The guide roller arms are bolted parallel relationship, i.e. be sure that both trainer and trougher have
to the frame for shipment. the same troughing angle, and same belt width.
The Self-Aligning Troughing Idler is designed to provide

an elevated roll height as compared to standard troughing
A idlers. This arrangement provides the greatest training
effect, but also increases the load that the frame and rolls
have to withstand. NOTE: the TESA is ½” higher than a
standard troughing roll.
Return Self-Aligning Idlers

A Return Self-Aligning Idlers are installed along the length
of the conveyor is required, but no closer than 50’ (15 m)
from a pulley.
TESA as shipped
Return Self-Aligning Idlers are shipped completely
assembled and ready for mounting. Mounting bolts are not
To set up the frame for operation, remove the bolt (A) at supplied. Four bolts are required to secure a training idler.
the base of the guide roller arm and reinstall it 90° to the
frame. (NOTE: The bolt is designed inserted up from the Return Self-Aligning Idlers have the same features as
bottom of the frame.) Before tightening the guide arm pivot the self-aligning troughers, (except they do not have an
bolt (A), check the alignment of the guide roll with the elevated roll height).
troughing rolls (With the belt centered, there should be NOTE: The Guide Roll Arm Assembly Replacement
about 1 inch between the guide roll and the belt.) The guide Part Number for all Self-Aligners is #30145.
roll should be positioned so that it will come in contact with
the belt BEFORE the belt can come to the end of the wing Side Guide Idlers - GRT, GRF, GRR
roll. Tighten bolt (A) to 100 ft-lbs.
Side guide idlers do not train a belt, but can prevent a
A belt from running off the pulleys and damage itself against
the conveyor structure or other objects.
Side guide idlers should be installed so that they do not

l
ve
touch the edge of the belt when it is running normally. If the

belt runs against the side of a guide idler roll continually,
ra
even though the rolls rotate freely, wear to the belt edge will
T
occur.
lt
A
Conveyor Start-up
e
B
Before actual startup of a conveyor system, electrical

TESA ready controls should be checked to ensure that the entire system
for installation can be stopped quickly in case of an emergency.
Carefully check self-aligning idler position to be certain During initial startup, the conveyor should be jogged on
that the guide roller assemblies are properly located so that and off until the belt has made several complete revolutions.
if the conveyor belt shifts, the belt edges will contact the During this time, make a complete check of all equipment to
guide rollers. The guide roller brackets extend in the determine proper adjustment and function.
direction opposite the belt travel. NOTE: for TESA & FSA
the guide roll arms should be pointing to the tail of the
conveyor. For RSA, they should be pointing towards
the head of the conveyor.
®
Belt Training belts traveling one direction only. This remedy cannot be
used for reversing belt conveyors.
A misaligned conveyor will cause the belt to run-off to
one side. The belt will tend to creep to the side that first The return side should be adjusted first, starting at the
makes contact with the idler roll. This condition can usually head end. Note the run-off point and adjust a few of the
be corrected by adjusting a few idlers to change the contact preceding idlers. The adjustments are made by shifting the
points. idlers so that the belt contacts the roll opposite the run-off.
Training Empty Belt

After the idlers and belt have been installed, the system
should be started while empty and check for alignment. A
properly aligned conveyor has the belt running evenly in the
center of the idlers and, consequently, prevents injury to the
ADVANCED
belt edges from contact with supporting structures or other
AND
objects. If a misalignment problem exists, it is not advisable RAISED
to attempt correction by readjusting the head or tail pulley,
as undue strains on the pulleys, bearings, belt, belt spice or
joint, or the conveyor may result. Pulleys should be carefully
aligned when installed and should not be disturbed for
purposes of belt training.
If one section of a belt runs true and another section

runs out of line, either the belt is bowed from improper PULLEY
storage, handling, or the belt is not properly spliced. If the
belt runs out of line consistently at one point in the conveyor,
the condition can be attributed to misaligned idlers. Usually
the idlers that require adjustment will be located upstream of
the point at which the belt runs out of line.
Proper alignment is achieved by loosening the mounting

bolts on several idlers on the upstream side and skewing
them slightly. When one side of an idler is shifted ahead of A slight adjustment on a number of idlers is
the other, the belt shifts to the side that is behind. recommended.
ADJUSTMENT BELT RUN-OFF
PERPENDICULAR TO BEFORE ADJUSTMENT Repeat this procedure at other points along the belt, if
BELT LINE necessary, until the return side is running true.
The carrying side can then be adjusted by using this

same procedure starting at the tail end and proceeding to
the head end.
Tilting the troughing idlers forward (not over 2 degrees)

BELT TRAVEL in the direction of belt travel produces an aligning effect.
AFTER This may be accomplished by placing a tilting book or steel
ADJUSTMENT
washer under the rear feet of the idler stand. If the angle of
tilt exceeds two degrees, excessive wear may occur on the
pulley side of the belt and on the troughing rolls themselves,
due to the rotation of these rolls on an axis not at the right
angle to the path of belt travel. This method has the
advantage over shifting idlers in that it will correct movement
on the belt before and after the idler, consequently, this
technique can be useful for training erratic belts. See above.
Return idlers cannot be tilted, but by shifting their axis or

See drawing for a visual description. Re-tightening the height a return idler can provide a corrective effect.
mounting bolts before restarting the conveyor.
This method of belt adjustment should be done on a
Shifting or tilting of idlers for belt training can be used for temporary basis in cases requiring immediate attention.
®
alignment.
Angled loading or off-center loading will result in the

following conditions.
Both shifting and tilting idlers are one directional

adjustments. They are not effective on a reversible belt.
If the area you are attempting to train continues to be a

problem, a self-aligning training idler should be installed just
upstream of the problem area. INCORRECT LOADING
Off-center or angled loading causes the belt to move
Training Loaded Belt laterally on the idlers, resulting in spilled material and belt
damage.
Once constant central alignment has been achieved on
the return and carrying runs with an empty belt the belt
conveyor should be checked while carrying a load.
A properly trained belt will run true under loaded

conditions. A loaded belt that runs off-center is usually
caused by improper loading. Chutes should distribute the
load evenly and on the center of the belt.
INCORRECT LOADING
The loading point of a belt conveyor is the critical point.

Here the conveyor belt receives the majority of impacts or
abrasions. The ideal solution is to have the material pass
from chute to belt with a minimum amount of impact and to
load on the center of the belt.
The skirts should be adjusted to prevent spillage of

CORRECT LOADING material and to keep the load central on the belt. The
Start with a light load and gradually work up to the load maximum distance between skirtboards customarily is two-
the conveyor was designed to handle. Check chutes to see thirds the width of a troughed belt. It is advisable for
that the material is being directed onto the center of the belt. centering that when possible the skirtboard distance be
Off-center loading will affect belt alignment by causing the reduced to one half the width of the troughed belt, especially
belt to run off center. A centrally loaded belt will maintain belt for free flowing materials.
When setting the steel for the loading skirts, use a board materials should be reviewed for changes in maintenance
3/4” (19 mm) thicker than the belt as a gage for clearance procedures.
66% BELT WIDTH Though impact idlers are designed to minimize belt and
TYPICAL roll damage due to impact conditions, the rolls should be
50% BELT WIDTH observed carefully and may require replacement due to
FOR FREE FLOWING
MATERIAL some applications. Reducing idler spacing, grizzlies, or
stone boxes can further increase idler and belt life in these
cases.
3/4" Observe the edge of the belt for any wear. If such a
(19 mm)
MIN. GAP
condition is observed, locate the area of contact and
misalignment and adjust the idlers or install a training idler.
Replace any worn or damaged rolls, rubber discs or any

other components not functioning properly.
between the idler roll and the bottom of the steel skirting. Idler Inspection
After installation of the conveyor belt, install the rubber Regularly scheduled inspections of conveyor systems
skirting. The rubber should lay on the conveyor belt with a are the best preventative maintenance possible. Problem
minimum of pressure. areas can be detected and corrected before damage occurs
If continued belt damage is observed from misalignment to the belt or equipment.
or from severe impacts from loading material, additional A check of the loading area is the best place to start.
framing or impact (rubber disc) idlers should be installed. Loading chutes should be delivering material to the belt
evenly and centered on the belt. Uneven or off-centered
Idler Maintenance loading is the greatest cause of problems on any belt
conveyor.
All idlers are prelubricated at the factory and are ready
for operation. Reliable operation and long service life of PPI Noticeable vibrations should be located and eliminated
idlers depend upon the care taken during installation and as this may loosen mounting bolts and cause the idlers to
operation. Periodic inspection and maintenance are shift. Misalignment problems must be corrected at once.
required. Local environment, working conditions, and Check idler alignment and adjust as required, remember to
regulations may require more frequent servicing. retighten mounting bolts. If off-centered loads occur, make
corrections to chute work. Watch for unusual wear patterns
A “walking inspection” of a belt conveyor system is a
on the idler rolls, which can be caused by off-centered
good method to detect potential problems from any unusual
loading or idler misalignment.
sounds made by such components as idlers, shafts,
bearings, rolls or other items. Check for material build-up on idler rolls, particularly the
return rolls as these are in direct contact with the carrying
Excessive build up on idler rolls will cause damage to
side of the belt. If build-up occurs, check the belt cleaner to
the belt. Shut down the conveyor, locking out the power
be sure that it is operating correctly. If a belt cleaner has not
switch and clean up, repair, or replace immediately. Review
been installed, it is recommended that one is placed in
the type of material being conveyed and the type of rolls
operation as soon as possible.
being used. Rubber disc or polymer coated rolls can reduce
or eliminate some roll build-up problems. Check all training idlers to see that they are pivoting
freely. Remove any accumulated dirt and debris from the
PPI idlers are designed to be self-cleaning.
frame.
Accumulation of material must not interfere with roll rotation
or training idlers from pivoting. Clean up any material that Walk the length of the conveyor installation and verify
could restrict polls or pivot arms. A stalled roll will cause that the idler rolls are turning freely and smoothly with no
excessive roll shell and belt wear. Remove and replace any excessive endplay.
stalled or frozen rolls to prevent belt damage from a worn
roll. An inspection maintenance program is essential for low
maintenance cost and dependable operation.
At no time should the conveyor idlers be used to handle
material loads or speeds other than originally specified.
Capacity and belt speed ratings should not be exceeded.
Any changes in environmental conditions or conveyed
®
Appendix A Conveyor Problem Solving
Any belt conveyor installation can be subject to a Belt runs to one side throughout entire length
wide variety of difficulties that may become costly at specific idlers.
in terms of replacement and plant downtime 1. Idlers/pulleys not square: Realign, install limit
unless the problem is quickly diagnosed and switches or safety.
2. Idlers improperly placed: Relocate or insert
corrected. This guide is intended to point out the additional idlers for support.
majority of belt conveyor problems and to set forth 3. Material build-up: Remove accumulation. Install belt
their probable causes and cures. cleaners.
Belt runs off tail pulley. Belt slip.

1. Counterweight too light: Recalculate weight and 1. Insufficient traction between belt and pulley:
adjust counterweight or take-up accordingly. Increase wrap with snub pulleys, lag drive pulley,
2. Idlers/pulleys not square: Realign, install limit install belt cleaners.
switches or safety. 2. Counterweight too light: Recalculate weight and
3. Frozen idlers: Free idlers, lubricate, and improve adjust counterweight or take-up accordingly.
maintenance. 3. Material build-up: Remove accumulation. Install belt
4. Spillage at loading point: Control flow with chutes, cleaners.
feeders, center load. 4. Frozen idlers: Free idlers, lubricate, and improve
5. Material build-up: Remove accumulation. Install belt maintenance.
cleaners. 5. Pulley lagging worn: Replace worn lagging.
Entire belt runs off at all points of the line. The following causes are listed for each problem in order of
1. Side loading: Load in center and direction of travel. probable occurrence and how to correct them. The cures
2. Spillage at loading point: Control flow with chutes, will correct the majority of belt conveyor problems. However,
feeders, center load. some remedies require lengthy procedures that should be
3. Idlers/pulleys not square: Re-align, install limit referred to your PPI representative.
switches or safety.
4. Material build-up: Remove accumulation. Install belt Belt slip on starting.
cleaners. 1. Insufficient traction between belt and pulley:
5. Belt strained on one side: Remove strained section Increase wrap with snub pulleys, lag drive pulleys,
and splice in new piece. install belt cleaners.
6. Idlers improperly placed: Relocate or insert 2. Counterweight too light: Recalculate weight and
additional idlers for support. adjust counterweight or take-up accordingly.
3. Pulley lagging worn: Replace worn lagging.
One belt section runs off at all points of the 4. Drive underbelted: Recalculate maximum belt
line. tensions and select correct belt.
1. Bad fasteners or splice: Use correct fasteners;
resplice belt. Excessive belt stretch.
2. Edge worn or broken: Repair belt edge. 1. Excessive tension: Recalculate and adjust tension.
3. Bowed belt: Avoid telescoping belt rolls or storing in 2. Drive underbelted: Recalculate maximum belt
damp locations. tensions and select correct belt.
3. Material build-up: Remove accumulation. Install belt
Belt runs off at head. cleaner.
1. Idlers/pulleys not square: Realign, install limit 4. Counterweight too heavy: Recalculate weight and
switches or safety. adjust, reduce take-up tension to slip point, and
2. Pulley lagging worn: Replace worn lagging. then tighten slightly.
3. Material build-up: Remove accumulation. Install belt 5. Wrong differential speed: Make required
cleaners. adjustment.
4. Idlers improperly placed: Relocate or insert 6. Damage by abrasives, acid, chemicals, heat, oil,
additional idlers for support. etc.: Use belt designed for specific conditions, make
spot repairs, install rubber disc idlers, do not over
lubricate idlers.
.
Belt breaks at or behind fasteners; fasteners Cover swells in spots or streaks.
tear loose. 1. Damage by abrasives, acid, chemicals, heat, oil,
1. Bad fasteners or splice: Use correct fasteners; etc.: Use belt designed for specific conditions, make
resplice belt. spot repairs, install rubber disc idlers, do not over
2. Pulleys too small: Use large diameter pulleys. lubricate idlers.
3. Excessive tension: Recalculate and adjust tension.
4. Pulley lagging worn: Replace worn lagging. Belt hardens or cracks.
5. Material between belt/pulley: Use skirtboards, 1. Damage by abrasives, acid, chemicals, heat, oil,
remove accumulation, improve maintenance. etc.: Use belt designed for specific conditions, make
6. Drive underbelted: Recalculate maximum belt spot repairs, install rubber disc idlers, do not over
tensions and select correct belt. lubricate idlers.
2. Pulleys too small: Use larger diameter pulleys.
Vulcanized splice separation. 3. Pulley lagging worn: Replace worn lagging.
1. Excessive tension: Recalculate and adjust tension. 4. Improper storage/handling: Refer to your PPI
2. Pulleys too small: Use larger diameter pulleys. representative for methods.
3. Drive underbelted: Recalculate maximum belt
tensions and select correct belt. Excessive wear, including rips, gouges,
4. Material between belt/pulley: Use skirtboards, ruptures and tears.
remove accumulation, improve maintenance. 1. Extreme material impact: Use correctly designed
5. Bad fasteners or splice: Use correct fasteners; chutes or baffles, install impact idlers, adjust
resplice belt. skirting, load fines first.
6. Wrong differential speed: Make required 2. Relative loading velocity too high or low: Adjust
adjustment. chutes or speed.
3. Spillage at loading point: Control flow with chutes,
Excess bottom cover wear. feeders, center load.
1. Material build-up: Remove accumulation, install belt 4. Material build-up: Remove accumulation and/or
cleaner. install belt cleaners.
2. Frozen idlers: Free idlers, lubricate, improve 5. Damage by abrasives, acid, chemicals, heat, oil,
maintenance. etc.: Use belt designed for specific conditions, make
3. Breaker strip missing: When service is lost, install spot repairs, install rubber disc idlers, do not over
new breaker strip. lubricate idlers.
4. Insufficient traction between belt and pulley: 6. Breaker strip missing: When service is lost, install
Increase wrap with snub pulleys, lag drive pulley, new breaker strip.
install belt cleaners.
5. Material between belt/pulley: Use skirtboards, Covers become checked or brittle.
remove accumulation, improve maintenance. 1. Damage by abrasives, acid, chemicals, heat, oil,
6. Pulley lagging worn: Replace worn lagging. etc.: Use belt designed for specific conditions, make
Excessive edge wear, broken edges. lubricate idlers.
1. Side loading: Load in center and in the direction of 2. Improper storage/handling: Refer to your PPI
travel. representative for methods.
2. Belt strained on one side: Remove strained section
and splice in new piece. Longitudinal grooving or cracking of top
3. Spillage at loading point: Control flow with chutes, cover.
feeders, center load. 1. Skirting rubbing belt: Install skirting correctly.
4. Damage by abrasives, acid, chemicals, heat, oil, 2. Frozen idlers: Free idlers, lubricate, improve
etc.: Use belt designed for specific conditions, make maintenance.
spot repairs, install rubber disc idlers, do not over 3. Material build-up: Remove accumulation and/or
lubricate idlers. install belt cleaners.
5. Bowed belt: Avoid telescoping belt rolls or storing in 4. Extreme material impact: Use correctly designed
damp locations. chutes or baffles, install impact idlers, adjust
6. Material build-up: Remove accumulation and/or skirting, load fines first.
install belt cleaners
®
Longitudinal grooving or cracking of bottom
cover.
1. Frozen idlers: Free idlers, lubricate, improve
maintenance.
2. Material build-up: Remove accumulation and/or
install belt cleaners.
3. Pulley lagging worn: Replace worn lagging.
Fabric decay, carcass cracks, ruptures,

gouges, soft spots.
1. Extreme material impact: Use correctly designed
chutes or baffles, install impact idlers, adjust
skirting, load fines first.
2. Material between belt/pulley: Use skirtboards,
remove accumulation, improve maintenance.
3. Breaker strip missing: Install new breaker strip
when service is lost.
4. Driver underbelted: Recalculate maximum belt
tensions and select correct belt.
5. Damage by abrasives, acid, chemicals, heat, oil,
etc.: Use belt designed for specific conditions, make
lubricate.
6. Radius of convex vertical curve too small: Increase
radius by vertical realignment of idler to prevent
excessive edge tension.
Ply separation.
1. Excessive tensions: Recalculate and adjust tension.
2. Pulleys too small: Use larger diameter pulleys.
3. Edge worn or broken: Repair belt edge.
4. Damage by abrasives, acid, chemicals, heat, oil,
etc.: Use belt designed for specific conditions, make
lubricate.
5. Belt speed too fast: Reduce belt speed.
®
Precision Pulley & Idler

An Employee Owned Company
RECOMMENDED SPARE PARTS LIST
Quantity Part #
31 E6-35TE-66SBG
1 38177-66G
11 E6-10VR-66SBG-7
1 E6-35TESA-66SBG
1 E610VRSA66SBG-7
1 E6-35TET-66SBG
1 E7-35TISLZ-66RG
1 E7-35TISL-66RKG
18 D5-35TE-42SBG
2 D5-FL-42SBG w/14206G
5 D5-10VR-42SBG-4
1 D5-35TESA-42SBG
D5 35TESA 42SBG
1 D510VRSA42SBG-4
2 D5-35RETI-42G
1 D5-35TET-42SBG
1 D5-RSA-42SBG
11 E6-35TE-72SBG
1 38177-72G
4 E6-10VR-72SBG-7
1 E6-35TESA-72SBG
1 E610VRSA72SBG-7
1 E6-35TET-72SBG
1 E7-35TISL-72RKG
1 E7-35TISLZ-72RG
2172-3000-DS-070_0.xls
HUDBAY PERU S.A.C
CONSTANCIA PROJECT
DATA SHEET
CONVEYOR IDLERS
Document No.
2172-3000-DS-070
REV DATE DESCRIPTION AUTHOR ENGINEERIN ELECTRICAL PROCESS APPROVED CLIENT
G
A 6/26/2012 Issued for Review FB CG FS JD BB
T1 7/18/2012 Issued for Tender JLG CG FS JD BB
0 12/31/2012 Issued for Purchase CC BA - - NM
Coversheet Page 1
2172-3000-DS-070_0.xls
HUDBAY PERU S.A.C

CONSTANCIA PROJECT
Rev
DATA SHEET
DOCUMENT No: 2172-3000-DS-070
PACKAGE TITLE: CONVEYOR IDLERS
EQUIPMENT No: 3121-CV-001
EQUIPMENT NAME: Stockpile Feed Conveyor
The Stockpile feed conveyor transfers crushed material P80 = 145 mm from the Primary crusher
EQUIPMENT DESCRIPTION AND FUNCTION:
to the stockpile.
VENDOR: *
1.00 CONVEYOR GENERAL INFORMATION
1.01 MATERIAL TYPE Primary crushed copper/molybdenum
1.02 HIGH BULK DENSITY (t/m³) 1.8
1.03 DESIGN FEED RATE / CAPACITY (t/h) 6000
1.04 BELT SPEED (m/s) 3.5
1.05 DISTANCE BETWEEN PULLEY CENTRES (HORIZONTAL) (m) 178
1.06 ELEVATION (m) 23.16
1.07 CONCAVE CURVE RADIUS (m) 318
1.08 BELT WIDTH (mm) 1800
1.09 REQUIRED MINIMUM L10 BEARING LIFE (h) 60,000

Bearings shall be factory greased and permanently sealed. Rolls shall be fitted with end shields
1.10 BEARING LUBRICATION/SEALING
to protect the bearings and seals.
1.11 CARRY TOTAL LOAD LOAD PER METRE OF BELT
1.12 NORMAL (kg/m) 528.80
1.13 FLOADED (kg/m) 931.14
1.14 RETURN TOTAL LOAD LOAD PER METRE OF BELT (BELT MASS)
1.15 NORMAL (kg/m) 52.65
2.00 CARRY IDLERS (FIXED)
2.01 QUANTITY REQUIRED 183 (TBC)
2.02 DESCRIPTION Plain steel equal rolls
2.03 NUMBER OF ROLLS PER IDLER SET 3
2.04 TROUGH ANGLE (°) 35
2.05 DIAMETER (mm) 152
2.06 IDLER SPACING (m) 1.2
3.00 CARRY IDLERS (RETRACTABLE)
3.01 QUANTITY REQUIRED Not Required
3.02 DESCRIPTION Not Required
3.03 NUMBER OF ROLLS PER IDLER SET Not Required
3.04 TROUGH ANGLE (°) Not Required
3.05 DIAMETER (mm) Not Required
3.06 IDLER SPACING (m) Not Required
4.00 RETURN IDLERS (FLAT)
4.02 DESCRIPTION Plain steel rolls (Flat)
4.03 NUMBER OF ROLLS PER IDLER SET 2 (vendor to confirm)
4.06 IDLER SPACING (m) 3
3121-CV-001 Page 2
2172-3000-DS-070_0.xls
5.00 RETURN IDLERS (VEE)
5.02 DESCRIPTION Plain steel rolls (Vee)
6.00 CARRY TRAINING IDLERS
6.02 DESCRIPTION Carry Tracking idler assembly
7.00 RETURN TRAINING IDLERS (VEE)
7.02 DESCRIPTION Return Tracking idler assembly
8.00 RETRACTABLE IMPACT IDLERS
9.00 TRANSITION IDLERS (5-20 degrees)
Adjustable transition idlers.

9.02 DESCRIPTION
Angles to be as specificed below, or incorporate these angles in the range of adjustment.
9.04 TARGET ANGLE (INCLUDING ADJUSTMENT) (°) 5 to 20

10.02 DESCRIPTION
11.00 IMPACT BED
11.01 QUANTITY REQUIRED 1

Designed for ease of maintenance, swift replacement of wear components and ease of removal
11.02 DESCRIPTION
and installation
11.03 LENGTH (m) 2.2 (Vendor to confirm)
CONVEYOR COMPONENTS SCHEDULE OF TECHNICAL INFORMATION - (Supplier to complete data)

12.01 MANUFACTURER - PPI
3121-CV-001 Page 3
2172-3000-DS-070_0.xls
12.02 COUNTRY OF MANUFACTURE - USA
12.03 PROTECTIVE COATING DETAILS - ROLLS- 1 MIL DF OF HIGH SOLIDS ALKYD ENAMEL, FRAMES-GALVANIZED
12.04 SERIES / MODEL - E6-35TE-72SB
12.05 OVERALL DIAMETER (mm) 152
12.06 BEARING SIZE - 6307
12.07 ROLLER MASS (kg) 18
12.08 ASSEMBLY MASS (kg) 102
12.09 IDLER MOUNTING
12.10 BOLT CENTRES mm 2057
12.11 BOLT SLOT SIZE mm 21
12.12 BOLT SIZE / GRADE 19.05 / 8.8
13.01 MANUFACTURER - N/A
13.02 COUNTRY OF MANUFACTURE - N/A
13.03 PROTECTIVE COATING DETAILS - N/A
13.04 SERIES / MODEL - N/A
13.05 OVERALL DIAMETER (mm) N/A
13.06 RANGE OF ADJUSTMENT, Vendor to provide details. (mm) N/A
13.07 BEARING SIZE - N/A
13.08 ROLLER MASS (kg) N/A
13.09 ASSEMBLY MASS (kg) N/A
13.10 IDLER MOUNTING N/A
13.11 BOLT CENTRES mm N/A
13.12 BOLT SLOT SIZE mm N/A
13.13 BOLT SIZE / GRADE N/A
14.04 SERIES / MODEL - E6-2R-72SB
14.07 ROLLER MASS (kg) 27 & 35
14.12 BOLT SIZE / GRADE 19.05 / 8.8
15.04 SERIES / MODEL - E6-10VR-72SB-7
15.12 BOLT SIZE / GRADE 19.05 / 8.8
3121-CV-001 Page 4
2172-3000-DS-070_0.xls
16.04 SERIES / MODEL - E6-35TESA-72SB
16.12 BOLT SIZE / GRADE 19.05 / 8.8
17.00 RETURN TRAINING IDLERS
17.04 SERIES / MODEL - E610VRSA72SB-7
17.12 BOLT SIZE / GRADE 19.05 / 8.8
19.00 TRANSITION IDLERS
19.04 SERIES / MODEL - E6-35TET-72SB
19.09 NOMINAL ANGLE AND ADJUSTMENT (°) 5 - 35 WITH 2.5° INCREMENTS
3121-CV-001 Page 5
2172-3000-DS-070_0.xls
19.13 BOLT SIZE / GRADE 19.05 / 8.8
20.00 IMPACT BED
20.04 SERIES / MODEL - E7-35TISL-72RK WITH SRAIL5 & TISKIT / E7-35TISLZ-72SB WITH SRAIL2
20.05 OVERALL LENGTH (mm) 2134
20.07 WEAR BAR MATERIAL UHMW
20.08 WEAR BAR METHOD OF ATTACHEMENT TO BED BOLT & LOCKING NUT
21.00 NOTES
21.01 Fields marked with an asterisk (*) are to be completed by the equipment supplier.
21.02
3121-CV-001 Page 6
2172-3000-DS-070_0.xls
HUDBAY PERU S.A.C

CONSTANCIA PROJECT
Rev
DATA SHEET
EQUIPMENT NAME: SAG Mill Feed Conveyor - Line 1
The SAG mill feed conveyors reclaim material from the stockpile via apron feeders and transport
EQUIPMENT DESCRIPTION AND FUNCTION: the material to the SAG mills. There are two parallel grinidng lines which are fed by these
conveyors. The Conveyors are identical but with opposite drive handings.
VENDOR: *

1.12 NORMAL (kg/m) 430.39
1.13 FLOADED (kg/m) 735.66
1.15 NORMAL (kg/m) 24.10
2.01 QUANTITY REQUIRED (Sets) 256
3.01 QUANTITY REQUIRED (Sets) Not Required
4.01 QUANTITY REQUIRED (Sets) 4 (TBC)
3213-CV-002 Page 7
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5.02 DESCRIPTION Plain steel equal rolls (Vee)

9.02 DESCRIPTION

10.02 DESCRIPTION
11.00 IMPACT BED
11.02 DESCRIPTION
and installation
11.03 LENGTH (m) 2 (Vendor to confirm)

3213-CV-002 Page 8
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12.12 BOLT SIZE / GRADE 19.05 / 8.8
14.04 SERIES / MODEL - E6-R2-66SB
14.12 BOLT SIZE / GRADE 19.05 / 8.8
15.12 BOLT SIZE / GRADE 19.05 / 8.8
3213-CV-002 Page 9
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16.12 BOLT SIZE / GRADE 19.05 / 8.8
17.12 BOLT SIZE / GRADE 19.05 / 8.8
3213-CV-002 Page 10
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19.13 BOLT SIZE / GRADE 19.05 / 8.8
20.00 IMPACT BED
20.04 SERIES / MODEL - E7-35TISL-66RK WITH SRAIL5 & TISKIT / E7-35TISLZ-66R
21.00 NOTES
21.02
3213-CV-002 Page 11
2172-3000-DS-070_0.xls
HUDBAY PERU S.A.C

CONSTANCIA PROJECT
Rev
DATA SHEET
EQUIPMENT NAME: SAG Mill Feed Conveyor - Line 2
The SAG mill feed conveyors reclaim material from the stockpile via apron feeders and transport
EQUIPMENT DESCRIPTION AND FUNCTION: the material to the SAG mills. There are two parallel grinidng lines which are fed by these
conveyors. The Conveyors are identical but with opposite drive handings.
VENDOR: *

1.12 NORMAL (kg/m) 430.39
1.13 FLOADED (kg/m) 735.66
1.15 NORMAL (kg/m) 24.10
3214-CV-003 Page 12
2172-3000-DS-070_0.xls

9.02 DESCRIPTION

10.02 DESCRIPTION
11.00 IMPACT BED
11.02 DESCRIPTION
and installation
11.03 LENGTH (m) 2 (Vendor to confirm)

3214-CV-003 Page 13
2172-3000-DS-070_0.xls
12.12 BOLT SIZE / GRADE 19.05 / 8.8
14.04 SERIES / MODEL - E6-R2-66SB
14.12 BOLT SIZE / GRADE 19.05 / 8.8
15.12 BOLT SIZE / GRADE 19.05 / 8.8
3214-CV-003 Page 14
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16.12 BOLT SIZE / GRADE 19.05 / 8.8
17.12 BOLT SIZE / GRADE 19.05 / 8.8
3214-CV-003 Page 15
2172-3000-DS-070_0.xls
19.13 BOLT SIZE / GRADE 19.05 / 8.8
20.00 IMPACT BED
20.04 SERIES / MODEL - E7-35TISL-66RK WITH SRAIL5 & TISKIT / E7-35TISLZ-66R
21.00 NOTES
21.02
3214-CV-003 Page 16
2172-3000-DS-070_0.xls
HUDBAY PERU S.A.C

CONSTANCIA PROJECT
Rev
DATA SHEET
EQUIPMENT NAME: Pebble Conveyor - Line 1
The Peeble conveyors take oversize material from the SAG mill trommel and transfer back to the
EQUIPMENT DESCRIPTION AND FUNCTION: SAG mill feed conveyor. There are two parallel grinidng lines which feed these conveyors. The
Conveyors are identical.
VENDOR: *
1.01 MATERIAL TYPE Pebbl;es from SAG mill discharge of primary crushed copper/molybdenum
1.05 DISTANCE BETWEEN PULLEY CENTRES (HORIZONTAL) (m) 78.2

1.12 NORMAL (kg/m) 158.00
1.13 FLOODED (kg/m) 277.30
1.15 NORMAL (kg/m) 19.10
3241-CV-004 Page 17
2172-3000-DS-070_0.xls
8.00 IMPACT IDLERS
8.02 DESCRIPTION Rubber Disc

9.02 DESCRIPTION
10.01 QUANTITY REQUIRED (kg/m) 4 (TBC)

10.02 DESCRIPTION (kg/m)
10.03 NUMBER OF ROLLS PER IDLER SET (kg/m) 3
10.04 TARGET ANGLE (INCLUDING ADJUSTMENT) (kg/m) 15 to 30
10.05 DIAMETER (kg/m) 127
10.06 IDLER SPACING (kg/m) 1
11.00 IMPACT BED
11.03 LENGTH (m) Not Required

3241-CV-004 Page 18
2172-3000-DS-070_0.xls
12.04 SERIES / MODEL - D5-35TE-42SB
12.12 BOLT SIZE / GRADE 15.88 / 8.8
14.04 SERIES / MODEL - D5-R-42SB
14.12 BOLT SIZE / GRADE 15.88 / 8.8
15.04 SERIES / MODEL - D5-10VR-42SB-4
15.12 BOLT SIZE / GRADE 15.88 / 8.8
3241-CV-004 Page 19
2172-3000-DS-070_0.xls
16.04 SERIES / MODEL - D5-35TESA-42SB
16.12 BOLT SIZE / GRADE 15.88 / 8.8
17.04 SERIES / MODEL - D5-10VRSA-42SB-4
17.12 BOLT SIZE / GRADE 15.88 / 8.8
18.04 SERIES / MODEL - D5-35RETI-42
18.06 RANGE OF ADJUSTMENT, Vendor to provide details. (mm) ENDS ARE COMPLETELY REMOVEABLE
18.13 BOLT SIZE / GRADE 15.88 / 8.8
19.04 SERIES / MODEL - D5-35TET-42SB
3241-CV-004 Page 20
2172-3000-DS-070_0.xls
19.13 BOLT SIZE / GRADE 15.88 / 8.8
20.00 IMPACT BED
20.05 OVERALL LENGTH (mm) N/A
20.07 WEAR BAR MATERIAL N/A
20.08 WEAR BAR METHOD OF ATTACHEMENT TO BED N/A
20.09 TROUGH ANGLE (°) N/A
21.00 NOTES
21.02
3241-CV-004 Page 21
2172-3000-DS-070_0.xls
HUDBAY PERU S.A.C

CONSTANCIA PROJECT
Rev
DATA SHEET
EQUIPMENT NAME: Pebble Conveyor - Line 2
VENDOR: *
1.05 DISTANCE BETWEEN PULLEY CENTRES (HORIZONTAL) (m) 78.2

1.12 NORMAL (kg/m) 158.00
1.13 FLOODED (kg/m) 277.30
1.15 NORMAL (kg/m) 19.10
3242-CV-005 Page 22
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8.00 IMPACT IDLERS

9.02 DESCRIPTION

11.00 IMPACT BED

3242-CV-005 Page 23
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12.12 BOLT SIZE / GRADE 15.88 / 8.8
14.12 BOLT SIZE / GRADE 15.88 / 8.8
15.04 SERIES / MODEL - D5-10VR-42SB-4
15.12 BOLT SIZE / GRADE 15.88 / 8.8
3242-CV-005 Page 24
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16.12 BOLT SIZE / GRADE 15.88 / 8.8
17.04 SERIES / MODEL - D5-10VRSA-42SB-4
17.12 BOLT SIZE / GRADE 15.88 / 8.8
18.06 RANGE OF ADJUSTMENT, Vendor to provide details. (mm) ENDS ARE COMPLETELY REMOVEABLE
18.13 BOLT SIZE / GRADE 15.88 / 8.8
3242-CV-005 Page 25
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19.13 BOLT SIZE / GRADE 15.88 / 8.8
20.00 IMPACT BED
21.00 NOTES
21.02
3242-CV-005 Page 26
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HUDBAY PERU S.A.C

CONSTANCIA PROJECT
Rev
DATA SHEET
EQUIPMENT NAME: Pebble Transfer Conveyor - Line 1
VENDOR: *
1.06 ELEVATION (m) 0
1.07 CONCAVE CURVE RADIUS (m) Not Applicable

1.12 NORMAL (kg/m) 158.00
1.13 FLOADED (kg/m) 277.30
1.15 NORMAL (kg/m) 19.10
3243-CV-006 Page 27
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7.04 TROUGH ANGLE (°) Flat

9.02 DESCRIPTION

11.00 IMPACT BED

3243-CV-006 Page 28
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12.12 BOLT SIZE / GRADE 15.88 / 8.8
14.12 BOLT SIZE / GRADE 15.88 / 8.8
3243-CV-006 Page 29
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16.12 BOLT SIZE / GRADE 15.88 / 8.8
17.04 SERIES / MODEL - D5-RSA-42SB
17.12 BOLT SIZE / GRADE 15.88 / 8.8
18.06 RANGE OF ADJUSTMENT, Vendor to provide details. (mm) ENDS ARE COMPLETE REMOVEABLE
18.13 BOLT SIZE / GRADE 15.88 / 8.8
3243-CV-006 Page 30
2172-3000-DS-070_0.xls
HUDBAY PERU S.A.C

CONSTANCIA PROJECT
Rev
DATA SHEET
EQUIPMENT NAME: Pebble Transfer Conveyor - Line 2
VENDOR: *
1.06 ELEVATION (m) 0
1.07 CONCAVE CURVE RADIUS (m) Not Applicable

1.12 NORMAL (kg/m) 158.00
1.13 FLOADED (kg/m) 277.30
1.15 NORMAL (kg/m) 19.10
3244-CV-007 Page 1
2172-3000-DS-070_0.xls
7.04 TROUGH ANGLE (°) Flat

9.02 DESCRIPTION

11.00 IMPACT BED

3244-CV-007 Page 2
2172-3000-DS-070_0.xls
12.12 BOLT SIZE / GRADE 15.88 / 8.8
14.12 BOLT SIZE / GRADE 15.88 / 8.8
3244-CV-007 Page 3
2172-3000-DS-070_0.xls
16.12 BOLT SIZE / GRADE 15.88 / 8.8
17.04 SERIES / MODEL - D5-RSA-42SB
17.12 BOLT SIZE / GRADE 15.88 / 8.8
18.06 RANGE OF ADJUSTMENT, Vendor to provide details. (mm) ENDS ARE COMPLETE REMOVEABLE
18.13 BOLT SIZE / GRADE 15.88 / 8.8
3244-CV-007 Page 4
2172-3000-DS-070_0.xls
19.13 BOLT SIZE / GRADE 15.88 / 8.8
20.00 IMPACT BED
21.00 NOTES
21.02
3244-CV-007 Page 5

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Precision Pulley & Idler

Storage and Preparation Establishing the Conveyor Centerline

Head and tail shafts need to be parallel to each other.

All bolts should be properly tightened.

When installing troughing idlers, sling the units by their

Starting at the tail end of the conveyor, the first standard

Hanger brackets and shaft retainer clips are shipped

First, install bolt hanger brackets loosely into place

Next, insert the roller assembly into the slot of each

Install self-tapping screw. Do not over tighten.

Self-Aligning Troughing Idlers

The Self-Aligning Troughing Idler is designed to provide

Return Self-Aligning Idlers

Side guide idlers should be installed so that they do not

touch the edge of the belt when it is running normally. If the

Before actual startup of a conveyor system, electrical

Training Empty Belt

If one section of a belt runs true and another section

Proper alignment is achieved by loosening the mounting

The carrying side can then be adjusted by using this

Tilting the troughing idlers forward (not over 2 degrees)

Return idlers cannot be tilted, but by shifting their axis or

Angled loading or off-center loading will result in the

Both shifting and tilting idlers are one directional

If the area you are attempting to train continues to be a

A properly trained belt will run true under loaded

The loading point of a belt conveyor is the critical point.

The skirts should be adjusted to prevent spillage of

Replace any worn or damaged rolls, rubber discs or any

Belt runs off tail pulley. Belt slip.

Fabric decay, carcass cracks, ruptures,

Precision Pulley & Idler

HUDBAY PERU S.A.C

HUDBAY PERU S.A.C

1.01 MATERIAL TYPE Primary crushed copper/molybdenum

1.02 HIGH BULK DENSITY (t/m³) 1.8

1.03 DESIGN FEED RATE / CAPACITY (t/h) 6000

1.04 BELT SPEED (m/s) 3.5

1.05 DISTANCE BETWEEN PULLEY CENTRES (HORIZONTAL) (m) 178

1.06 ELEVATION (m) 23.16

1.07 CONCAVE CURVE RADIUS (m) 318

1.08 BELT WIDTH (mm) 1800

1.09 REQUIRED MINIMUM L10 BEARING LIFE (h) 60,000

1.12 NORMAL (kg/m) 528.80

1.13 FLOADED (kg/m) 931.14

1.15 NORMAL (kg/m) 52.65

2.00 CARRY IDLERS (FIXED)

2.01 QUANTITY REQUIRED 183 (TBC)

2.02 DESCRIPTION Plain steel equal rolls

2.03 NUMBER OF ROLLS PER IDLER SET 3

2.04 TROUGH ANGLE (°) 35

2.05 DIAMETER (mm) 152

2.06 IDLER SPACING (m) 1.2

3.00 CARRY IDLERS (RETRACTABLE)

3.01 QUANTITY REQUIRED Not Required

3.02 DESCRIPTION Not Required

3.03 NUMBER OF ROLLS PER IDLER SET Not Required

3.04 TROUGH ANGLE (°) Not Required

3.05 DIAMETER (mm) Not Required

3.06 IDLER SPACING (m) Not Required

4.00 RETURN IDLERS (FLAT)

4.01 QUANTITY REQUIRED 4 (TBC)

4.02 DESCRIPTION Plain steel rolls (Flat)