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Created by: JJU-IN

Approved by: GVG-IN

FLSmidth, 13-May-2011 70015175-01

SHIP UNLOADER FOR COAL

VUNG ANG 1 CSU-700-RT - 00EAA01

Operation and maintenance instructions


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The information transmitted by this document is the proprietary and confidential property of FLSmidthand may not be duplicated, disclosed or utilized without written consent from FLSmidth.

ForewordThe present instructions are concerned with the situations which, according to the

experience of FLSmidth, are the most likely to occur during manufacture, installa-

tion, operation and maintenance of the equipment. An exhaustive enumeration of

all conceivable situations, which may occur, cannot be provided.

Consequently, if a situation should arise, the occurrence of which is not foreseen in

the instructions, and which the operator is/or feels unable to handle, it is recom-

mended that FLSmidth is contacted without undue delay for advice on appropriate

action.

All references to relevant safety standards are given at the EC declaration of con-

formity if required.

Reference by seller to any international or national standard does not incur an

obligation on seller to provide any recipient, reader or user of the documentation

with samples or copies of the said standard(s).Hence, any recipient, reader or user of the documentation is expected at his own

cost to obtain necessary knowledge of the contents of any of the standards

referred to.

Safety

Potential safety risks, and correct mode of conduct subject to such risks, are con-

tinuously described in the text in relation to specific actions.

See instructions 32031 for general safety rules and the separate equipment-specific

safety instructions for a complete list of all unforeseen risks in connection with the

installation, operation and maintenance of the equipment.

Definitions and abbreviations

Authorized person A person who is qualified and who, by the responsible man-

ager, is entrusted with certain tasks.

Skilled person A person who, after an education as a craftsman, is capable of

doing skilled work.

SDS Safety Data Sheet (in US known as MSDS)

MSDS Material Safety Data Sheet

OM Operation and Maintenance

Legend

WarningThis symbol indicates dangers which, in case of non-observance, may cause fatal or

serious personal injuries!

Warning text is concluded with a filled black triangle to symbolize end of warning

text.

Attention

This symbol indicates important information where specific attention and caution is

needed. For example to avoid damage to or destruction of the equipment and/or

parts of the installation.

Attention text is concluded with a filled black square to symbolize end of attention

text.


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Table of contents

1.0 Introduction ............................................................................................ 51.1 Material Flow ..................................................................................... 5

1.2 Feeding Device [00EAA01AF003] .......................................................... 5

1.2.1 Auto Control .............................................................................. 51.2.2 Manuel Control........................................................................... 5

1.3 Vertical Conveyor [00EAA01AFOO1] ..................................................... 51.4 Horizontal Conveyor [00EAA01AF002] ................................................... 61.5 Diverter gate and discharge chute [00EAA01BR001] ............................... 61.6 Slewing ............................................................................................. 61.7 Travelling and Motion .......................................................................... 61.8 Hydraulic Equipment ........................................................................... 61.9 Electrical System ................................................................................ 71.10 Manoeuvring .................................................................................... 71.11 Inspection and Maintenance ............................................................... 71.12 Lubrication ....................................................................................... 71.13 Auxiliary Hoist .................................................................................. 8

2.0 Safety instructions ................................................................................... 92.1 General notes .................................................................................... 9

2.1.1 Introduction .............................................................................. 92.2 General notes on safety for Ship Unloader ............................................. 9

2.2.1 General ..................................................................................... 92.2.2 Acoustic and visual alarm signal .................................................. 102.2.3 Interlocking .............................................................................. 102.2.4 Marking of equipment ................................................................ 112.2.5 Personal protective equipment .................................................... 112.2.6 Foreseen hazards to personnel .................................................... 112.2.7 Foreseen hazards to equipment .................................................. 122.2.8 General notes relating to the posting of signs ............................... 122.2.9 Permission to work .................................................................... 122.2.10 Harmful media ........................................................................ 13

2.3 Specific safety precautions concerning erection ..................................... 132.4 Specific safety precautions concerning OM ............................................ 13

2.4.1 Completion of erection or maintenance procedures ........................ 132.4.2 Isolation of energy sources ......................................................... 132.4.3 Cleaning of equipment ............................................................... 13

3.0 Operation ...............................................................................................143.1 Pre-starting procedure. ...................................................................... 143.2 Start the unloader. ............................................................................143.3 Unloading. ........................................................................................153.4 Change hold / Temporary stopping. .....................................................163.5 Cleaning up. .....................................................................................163.6 Reversing the vertical conveyors. ........................................................ 173.7 Alarm. ..............................................................................................173.8 Flood light. ....................................................................................... 173.9 Emergency stop. ............................................................................... 173.10 Stopping the unloader ...................................................................... 183.11 Auxiliary hoist .................................................................................183.12 Manoeuvring movements .................................................................. 18


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3.12.1 Luffing horizontal arm .............................................................. 193.12.2 Pendulum vertical arm ............................................................. 203.12.3 Slewing the turret.................................................................... 203.12.4 Travelling. ..............................................................................223.13 Remote Control. .............................................................................. 23

3.14 Operators Panel Service Mode ........................................................... 253.15 Storm Lock and Parking Position ........................................................26

4.0 Maintenance ...........................................................................................284.1 Before every start .............................................................................. 284.2 After every 100 operation hours .......................................................... 294.3 After the first 100 operation hours ....................................................... 294.4 After the first 200 operation hours ....................................................... 294.5 After each 200 operation hours ........................................................... 304.6 After the first 400 operation hours ....................................................... 304.7 After each 400 operation hours ........................................................... 304.8 After each 500 operation hours ........................................................... 304.9 After each 800 operation hours ........................................................... 304.10 After each 2.000 operation hours ....................................................... 304.11 After each 4.000 operation hours ....................................................... 314.12 After each 8.000 operation hours ....................................................... 314.13 After each 10.000 operation hours ..................................................... 324.14 After each 15.000 operation hours ..................................................... 324.15 Lubrication Chart .............................................................................32

4.15.1 Oil and grease specification. .....................................................324.15.2 First Fill amounts ..................................................................... 334.15.3 Vertical Arm ............................................................................ 334.15.4 Horizontal Arm ........................................................................ 344.15.5 Slewing Table .........................................................................34

4.16 Vertical Screw Conveyor VSC-700 ...................................................... 354.16.1 Technical specification .............................................................. 354.16.2 Description .............................................................................35

4.17 Horizontal Screw Conveyor HSC-1050 ................................................ 454.17.1 Technical specification .............................................................. 454.17.2 Description .............................................................................45

4.18 Central Chute .................................................................................. 565.0 Appendix - A ..........................................................................................58

5.1 Bolt Torque ....................................................................................... 586.0 Appendix - A ..........................................................................................59

6.1 KKS Numbering ................................................................................. 597.0 Appendix - B ..........................................................................................64

7.1 Drawings showing KKS Number ........................................................... 648.0 Appendix - C ..........................................................................................71

8.1 Drawings ..........................................................................................71


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1.0IntroductionThe unloader consists of a series of screw conveyors, which enclosed and continu-

ously convey the coal from bulk ship to the terminal.

1.1Material FlowThe material flow starts at the feeding device. The feeding device rotates counter

clock-wise (seen from above), and feeds the material into the vertical screw con-

veyor.

The vertical screw conveyor feeds the coal up to the horizontal screw conveyor.

The horizontal screw conveyor transports the material, via the turret, into the

diverter gate and to the dock belt conveyor. There is an hour counter on the control

panel inside the electrical control room, showing the unloading time for the latestship. There is also one hour counter showing the total running time for the ship

unloader.

1.2Feeding Device [00EAA01AF003]One electric motor and gear is installed on the lower parts of the vertical screw

conveyor drives the feeding device.

The feeding device feeds the vertical screw with coal and controls the filling of the

same screw.

The speed of the feeding device can either be controlled by Manual Control or Auto

Control.

1.2.1Auto ControlThe control of the feeding device is normally set in auto position. The capacity will

be set by two push buttons (+/-) in % of full capacity. The feeding device will then

keep the filling efficiency as close as possible to the pre-set capacity.

1.2.2Manuel ControlThe control of the feeding device can be set manually and the speed can be set by

two push buttons (+/-). The display will show the actual capacity.

If there is an alarm of level A, the feeding device will automatically stop.

1.3Vertical Conveyor [00EAA01AFOO1]The main vertical conveyor is driven by two electric motors via a gear box to a

variable screw speed.

The power consumption can be read at the control display in % of installed power.


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The vertical arm can Pendle in a range of 30 (in all 60) from its vertical position

when horizontal luffing range -20 to 0. During Horizontal Luffing range of 0 to

+20 the inside pendulum movement is limited by the stroke of the pendulum

cylinder.

1.4Horizontal Conveyor [00EAA01AF002]An electrical motor with a gearbox drives the horizontal conveyor with a constant

speed. The conveyor is dimensioned for a higher capacity than for the vertical

conveyor to avoid overfilling.

The horizontal arm, where the horizontal conveyor is situated, is movable in a

vertical direction (luffing).

The luffing range is 20 (from horizontal) during unloading and +25 duringpositioning.

1.5Diverter gate and discharge chute [00EAA01BR001]The coal is falling down from the horizontal conveyor, through an outlet chute in

the turret to a diverter gate. The diverter gate diverts the material to the desired

belt conveyor. Diverter gate is connected with the linear actuating device. This

device will rotate the flap to the desired location.

1.6SlewingA slewing bearing [00EAA01HD001] is mounted between the slewing table and the

turret and allows slewing of the arm system. The slewing motion is performed by

four Electric Motors with gear unit [00EAA01AE009, 00EAA01AE010,

00EAA01AE011, 00EAA01AE012].

The slewing degree is 309 for Unloader 00EAA01 and 290 for Unloader

00EAA02.

1.7Travelling and MotionThe unloader is mounted on a gantry with eight bogies [00EAA01AE001,00EAA01AE002, 00EAA01AE003, 00EAA01AE004, 00EAA01AE005, 00EAA01AE006,

00EAA01AE007, 00EAA01AE008]. On each of the bogies there are two wheels.

On the seaside and the landside one wheel on each bogie is driven by an electrical

gear motor.

1.8Hydraulic EquipmentThe unloader is equipped with its own hydraulic system.

A hydraulic container [00EAA01AP001] contains the motors and pumps and ismounted on the horizontal arm.


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The hydraulic system is provided with a safety function, which leaves the pendulum

cylinder [00EAA01AP003] and the luff cylinder [00EAA01AP002] on their positions

in case of a power malfunction or, if a pipe or a fitting would burst.

For more information about the hydraulic system, see sub suppliers instructions

manual.

The hydraulic equipment can be manually controlled by levers at the panel inside

the container.

In case of cut off in power supply the petrol driven motor, installed in the hydraulic

container can be used to move the arm system of the unloader out of the barge.

1.9Electrical SystemAll electrical equipment is installed in an air-conditioned electrical control room on

the gantry of the unloader.

Main power supply 3 x 400V, 50Hz

Motor voltage 3 x 400V, 50Hz

For more information and wiring diagram see the electrical manual.

1.10ManoeuvringThe unloader can be manoeuvred from radio remote control box. The radio remote

control box is intended to be used by the operator when standing at the hatch area

on the ship.

1.11Inspection and MaintenanceWith a system of ladders and platforms it is possible to reach frequently used and

important areas of the unloader for inspection and maintenance.

However, it is not allowed to enter the horizontal or vertical arm during operation ofthe unloader.

1.12LubricationTo lubricate the bearings of the horizontal conveyor, slewing ring and feeding

device, the unloader is equipped with an automatic lubrication system

[00EAA01AP004]. The grease will be supplied from a barrel situated at the inside of

one of the end carriers on the gantry.

However, those are not the only details, which need to be greased on the unloader.

The other greasing points are pointed out in the lubrication chart. See the mainte-nance manuals for further instructions and the lubrication types.


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Inside the electrical control room, on the control panel, an hour counter is installed.

On this the operator can read the total amount of operating hours for the unloader.

The hour count is based on the operation hours of the screws. The hour countershould be used to make sure that the maintenance is done on time.

1.13Auxiliary HoistBottom of the horizontal arm an auxiliary hoist [00EAA01AE013] with two speeds is

installed.

This is a rope hoist for 10Tons and it is electrically driven.

The hoist could be manoeuvred from the radio controlled remote box and, it can be

used for lifting front-end loaders in and out of the holds.

The hoist is equipped with an overload safety system.


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2.0Safety instructions

2.1General notes2.1.1IntroductionThe Ship Unloader must only be used under the intended technical circumstances

as defined in current instructions manuals.

It is a prerequisite for the safety that all relevant rules and regulations for the

prevention of accidents are held available at all times.

FLSmidth will not assume responsibility for any damage resulting from abuse or

improper operation or inadequate maintenance of the Ship Unloader or resulting

from its operation or maintenance by unqualified personnel, including personnelwho have not acquired the skills required to operate or maintain the equipment on

the basis of the directions provided in the technical documentation.

2.2General notes on safety for Ship Unloader2.2.1GeneralAt the unloader certain safety devices are included.

An anemometer is situated on the highest position of the horizontal arm. This will

alarm the operator, when the wind speed reaches a peak level, which could causeproblems during the operation. Then the operator must then immediately stop the

operation and park the unloader.

An electronic movement restriction is preventing the operator to overload the

unloader during the digging movement.

Limit switches are built into the system to avoid false movements.

Overload protection valves are mounted in both the hydraulic and the lubrication

system.

Overload protection device is installed on the auxiliary hoist.

Warning

Devices for switching off for the prevention of unexpected start-up shall be used

(e.g. where, during maintenance or trial run, a start up of the machine may create

a hazard).

Devices must be provided for disconnecting (isolating) electrical equipment to

enable work to be carried out without any attendant risk of electrical shock or

burn.


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Warning

The safety equipment must not under any circumstances be by-passed, discon-

nected or modified relative to its original function.

2.2.2Acoustic and visual alarm signalIn connection with operation in the automatic mode, an alarm signal having dura-

tion of 15 seconds will sound before the unit is put into operation. The visual alarm

starts when the motor is started and will keep flashing until the machine is stopped.

Manual operation of the Ship Unloader will be preceded by a 5-second alarm signal

before the machine is started.

The visual alarm will be activated simultaneously with the machine, flashing con-

tinuously throughout the operation.

Warning

Alarm signals must be performance-tested once a month.

When an emergency stop on the Ship Unloader or on the preceding conveyor is

activated, the Ship Unloader will stop.

All emergency stops must be reset manually and must be zero-set from the control

panel prior to any re-starting of the Ship Unloader.

2.2.3InterlockingThe control system of the Ship Unloader incorporates a number of interlocking

which will ensure trouble-free operation of the machine in relation to the associated

equipment. The control system and its function are described in the electrical

documentation.

The following interlocking are of crucial importance to safety and, therefore, all

persons working on and around the machine must be familiarized with the inter-

locking.

When the machine is operating in the automatic mode, the outgoing belt conveyormust be in operation before the screw conveyor of the Ship Unloader is put into

operation.

In the automatic mode of operation the screw system of the Ship Unloader and

the preceding equipment will stop if the outgoing conveyor is stopped (Process

shutdown and emergency stop).

The Ship Unloader cannot be started if an emergency stop is activated.

Warning

Interlocking in the control system of the Ship Unloader must not under any circum-

stances be changed or by-passed.


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2.2.4Marking of equipmentThe Ship Unloader is marked as follows:

CE stamp according to Machinery directive.Manufacturer : F. L. Smidth A/S, Vigerslev All 77, DK 2500 Valby

Year : 2010

Series and type : Ship Unloader, type CSU-700-RT

Serial number : 50041935 for 00EAA01 & 50042625 for 00EAA02

2.2.5Personal protective equipmentAll persons working on or anywhere near the Ship Unloader must as a minimum be

wearing personal safety equipment in strict compliance with the signs posted at the

entrances of Ship Unloader and also in compliance with local requirements. Addi-

tional safety equipment may be required for specific jobs.

Warning

In case of substantial dust loads, personnel working inside the store building must

use respiratory protection equipment.

Ear protectors must be used when the noise level (sound pressure) is above 85

dBA.

2.2.6Foreseen hazards to personnelDuring normal operation the Ship Unloader is controlled by the operator on themachine which is done from the control panel. It is essential to ensure that the

personnel are familiarized with the contents of the present instruction manual and

the specifically applying safety regulations.

There is a risk of personal injury when performing work on the Ship Unloader

and/or conveyor is in operation.

Warning

Personnel must not ride on or in material-carrying elements of the Ship Unloader.

Platforms on the Ship Unloader are considered as working areas, because the ShipUnloader is operated from here, e.g. when shifting ship or hatches.

Warning

Since unauthorized use of the machine involves the risk of personal injury, only

authorized personnel is allowed access to the Ship Unloader.

Warning

Due to the risk of getting jammed between machine and fixed obstacles, a mini-

mum clearance of 0.5m must be ensured between a fixed obstacle and the ma-

chine.


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Warning

All working areas must be kept clear and free of obstacles.

Warning

Due to the risk of serious bodily injury, movable components must not be touched

during operation.

Warning

Due to the risk of serious bodily injury if the screw conveyor or other movable parts

of the machine are touched, guards and inspection hatches must not be removed or

opened during operation.

Warning

Due to the risk of personal injury if persons are hit by the machine when operatingit, the operator must ensure during ship shifting that no one is in the danger zones

on or around the machine before it is moved to a ship or hatches.

2.2.7Foreseen hazards to equipmentThe Ship Unloader is designed for continuous handling of the specified nominal

capacity and the specified maximum capacity during short-term peak load.

Attention

The specified maximum capacity of the machine must not be exceeded.

The machine is designed to handle a certain volume. The specified max. Capacities

have been calculated on the basis of a theoretical density.

Attention

If the actual density is lower than the theoretical one, the permissible max. Capac-

ity will become correspondingly lower.

Attention

The maximum lump size of the handled material must not be exceeded.

2.2.8General notes relating to the posting of signsSigns must not be removed or moved and must be kept clean and readable.

2.2.9Permission to workIt is the responsibility of the erection supervisor or maintenance supervisor to

ensure that all personnel involved have studied and fully understand:

The permission given to perform work in the specific area. All relevant instructions concerning health and safety and the contents of this

instructions manual.


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2.2.10Harmful mediaThe process media and the lubricants may cause danger to health. The material

safety data sheet (MSDS) informs any danger and precautions.

2.3Specific safety precautions concerning erectionSee separate instructions manual.

2.4Specific safety precautions concerning OMWarning

Any operational or maintenance activity must be carried out by skilled persons and

is subject to the supervision of authorized personnel.

2.4.1Completion of erection or maintenance proceduresAttention

Before any operation or test activity commences an authorized person must declare

that erection or maintenance has been completed and that the equipment has been

released for operation or test.

2.4.2Isolation of energy sourcesWarning

It is dangerous to perform test or maintenance activities before it is ensured that it

will be impossible to restart the Ship Unloader or any adjacent equipment in theprocess e.g. locally or by means of a remote control unit.

Gravity force may constitute a risk. It must be ensured that neither mechanical

components nor media may constitute a risk to any person.

See shut down procedure in sub-section 2.2.1.

2.4.3Cleaning of equipmentWarning

Mechanical equipment, steel structures and surfaces of compartments must be kept

clean from dust, scrap and dirt.

In particular all kinds of combustible material constitute a risk of fire or dust explo-

sion.


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3.0Operation

3.1Pre-starting procedure.See Chapter 4 before every start.

3.2Start the unloader. Main power 400 V turned on. Main power 400 V turned on in E&l-cabin. Reset all Emergency stop push buttons. Start the unloader by setting the switch (S15) to On. This will start the supply-

ing units.

Check that lamp (H1) Alarm A and lamp (H2) Alarm B are not lit. Make sure that the surrounding working area is free from obstacles. Pull the left-hand joystick (S10) towards you and raise the feeding device to a

position approximately 0.5 m over the rail. The first stop of the lever will be at

30% of full luffing speed. At the second stop the max speed can be adjusted with

button (S26) and (S27). The operator can set his own preferred speed at the end

of each lever. Between the first and the second stop the speed will gradually be

adjusted to the set maximum.

Move the unloader to a position, by pulling the left hand lever (S10) to the left orright, to enable centring the feeding device over the hold that shall be unloaded.

Centre the feeding device. Set the feeding device switch (S21) to manual or automatic If you have chosen manual mode then set the capacity (on the operators panel

or on the remote control if selected) on desired value by pressing the in-

crease or decrease button. We recommend that you start with approximately

50%.

Start up the screw conveyors as described in Operating Manual E&l Chapter 6. It is important not to let the vertical conveyors run empty for a longer time. 1

minute is maximum, because this will increase the wear of the support pads and

they will be over heated.

Start the unloading as soon as the conveyor system is running. Lamps (H3 andH4) will light up.


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3.3Unloading.Lower the feeding device into the material until it is covered.

Depending of the coals flow ability the digging depth of the feeding head has to beadjusted. Unloading the coal by travelling of 13 m/minutes and if the coal are not

floating, the capacity will be approximate 1410 m3/hour or 1200 ton/hour if the

density is 850 kg/m3 for digging dept of 0.65 meter.

Move the unloader through the material by 1.travelling which is recommended,

next by 2.slewing and last if not possible to use travelling or slewing then use

3.pendulum. Unloading with the pendulum motion the digging dept will change

depending of the vertical arm position.

This will also change the capacity of the unloading. The same digging depth can be

achieved by compensate using the luffing cylinder.

After a while, when the chosen pattern feels convenient, the capacity could be

increased or decreased with the push button on the operators panel, or be switched

over to automatic capacity control by using switch (S21).

The value for automatic capacity control could be increased or decreased with the

same push button on the operators panel, where 100% approximately means 1200

tph.

The actual rated capacity of the vertical conveyors will be shown on the operators

panel in % of 1200 tph.


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3.4Change hold / Temporary stopping.Lift the feeding device out of the material with the left-hand lever (S10)

Let the conveyors run for 15 sec to empty the vertical arm conveyor

Stop the vertical conveyor by turning the switch (S17) to Off

Change the unloader position or move to the next hold.

After moving, Start the conveyors again by turning the switch (S17) to On

Lower the feeding device into the material and your unloading sequence is re-

started.

3.5Cleaning up.There is a special method to unload the last 0.5 metre (bottom layer) in the ship

hold.

Stop the unloading temporarily (see chapter 3)

Lift down a front-end loader into the hold by using the auxiliary hoist installed on

the horizontal arm.(max capacity10 ton)

Build up piles of material with the front-end loader for the feeding device to work

in.

Set the feeding device in manual mode with switch (S21).

The operator must control the capacity of the vertical conveyor very carefully inorder to prevent the conveyor to run empty during the sequence.


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3.6Reversing the vertical conveyors.It is possibly to reverse the vertical conveyors if a foreign object has entered the

system or if it is necessary to empty the conveyors through the feeding device.

Lift the feeding device out of the material

Stop the vertical conveyors with switch (S17)

When the conveyors have stopped, turn switch (S17) to reverse

Both the main vertical conveyor and the feeding head will now reverse for 10

seconds and then automatically stop. For a new reverse you have to wait for approx

30 seconds and then turn switch (S17) once more.

Restart the conveyors to the correct direction by turning on switch (S16).

3.7Alarm.There are two alarm levels on the unloader

Alarm A - stop of the unloader

Alarm B - warning

In case of a system error, either lamp (H1) alarm A or lamp (H2) alarm B will lit up.

See Operation Manual EL (separate manual) for further instructions.

3.8Flood light.There are three floodlights on top of the vertical arm. They are operated from the

control panel with switch (S20).

3.9Emergency stop.There are 14 emergency stops on the Ship Unloader and they are situated as

follows:

Bogie seaside

Bogie landside

Turret outside electrical control room

On horizontal arm

1 pcs. Inside electrical control room

On the remote control

Be familiar with the locations of the emergency stops.

This will stop the unloader immediately regardless if the conveyor system is filled

up with material or not. When the reason for the emergency stop has been cleared,the conveyors must be emptied.


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To reset the unloader after an emergency stop you have to reset the control panel

by pressing the Acc fault button on the remote control.

3.10Stopping the unloaderWhen the working shift is over or the ship is unloaded, the unloader shall be

stopped and parked.

Lift the feeding device out of the hold.

Let the vertical conveyor run for 15 seconds.

Stop the conveyors by turning switch (S16) off.

The feeding device, vertical, and horizontal screw conveyors stops in a sequence.

There is a time delay to make sure that the conveyors are emptied. The light (H3)

Screw system running goes out.Move the unloader to its parking position.

Set the vertical arm down at the support and hook on the wire.

Stop the unloader by turning switch (S15) off.

Shut down the Panel PC.

3.11Auxiliary hoistThe auxiliary hoist will be manoeuvred from the control panel according to Operat-

ing Manual E&l Chapter 2.

3.12Manoeuvring movementsThe speed of the following movements could be set manually for each sequence.

The first step of the lever is fixed to 30% of maximum speed. At the second step

(end position) the speed can be adjusted to a set maximum by pressing the lever

to the max end position and changing the speed, with button (S26) for increasing

or (S27) for decreasing.

Between the first and the second stop, the speed of the movement will be set

according to your position between the two joystick positions.


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3.12.1Luffing horizontal arm

Pull the left-hand joystick (S10) for lifting the horizontal arm.

Push the left-hand joystick (S10) for lowering the horizontal arm.


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3.12.2Pendulum vertical arm

Push the right-hand joystick (S11) for pendulum of the vertical arm outwards

Pull the right-hand (S11) joystick for pendulum of the vertical arm inwards.

3.12.3Slewing the turret


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Move the right-hand joystick (S11) to the right for slewing the turret clockwise.

Move the right-hand joystick (S11) to the left for slewing the turret counter clock-

wise.


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3.12.4Travelling.

Move the left-hand joystick (S10) to the right for travelling to the right.

Move the left-hand lever (S10) to the left for travelling to the left.


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3.13 Remote Control.


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Object number Item Data Equipment Note-S3-11 Emergency Stop

-S10 Joystick

-S11 Joystick

-S15 Switches Unloader On / Off

-S16 Switches Conveyors On / Off

-S17 Switches Vertical screw Off / Reverse

-S18 Switches Winch Up / Down

-S20 Switches Flood Light On

-S21 Switches Feeding device Manuell / Auto-S22 Switches Winch High / Low

-S25 Push Button Accept Fault Acc Fault

-S26 Push Button Set Speed Increase

-S27 Push Button Set Speed Decrease

-H1 Signal Light Alarm A Alert

-H2 Signal Light Alarm B Warning

-H3 Signal Light Running System

-H4 Signal Light Running Feeding Device

-H6 Signal Light Allow Start Feeding Device

-H7 Signal Light Allow Start Terminal Idle


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3.14Operators Panel Service ModeIt is possible, in connection with maintenance work, to operate each one of the

individual conveyors separately via the service mode on the Operators panel. Aspecial service mode user has to log on.

See also Operating Manual El.


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3.15Storm Lock and Parking PositionIn case of winds exceeding the allowed working limit (indicated by alarms) or when

the Ship Unloader is to be off-duty, the Ship Unloader has to be secured and

parked in the storm and parking position according to (02.01.01.01).

Position the Ship Unloader over the Storm Lock Gantry (02.01.02.01).

Secure the Ship Unloader with the Parking Pin (02.01.02.04).

Manoeuvre the storm lock of the vertical arm in to the storm lock/parking sup-

port (02.01.01.03).


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Secure the vertical arm on the parking position by attaching the chain from the

parking support on to the lug of the vertical arm.

Unlocking done in reverse way.


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4.0Maintenance

To keep the FLSmidth Ship Unloader in good condition and long-term trouble free

operation, a proper maintenance is required.

Therefore we recommend you to follow this manual as well as those of our sub-

contractors.

Its important that all maintenance is conducted by skilled personnel

Before any kind of service it is important to break the electrical power as follows:

If you have any work on the power transformer break the LBS main switch If you have any work on the cable reel break LBS main switch and land main

switch and discharge the conductive load. For other works on the Unloader break the main switch in MCC on the Ship

Unloader.

Make it a normal routine to check the machine as follows:

Pay attention to unusual sounds Check for oil or grease leakages Check lights, emergency stops and limit switches Watch out for damages or corrosion Watch out for material dust around drive end bearing. If dust appears replace the

sealing ring before operating the machine (described in Chapter 8.2.3).

Make sure that the cable reels have a good function Keep the manoeuvring room and the instruments as clean as possible Every maintenance step should carefully be written down in a separate mainte-

nance book in order for you to get some statistic information about the wear time

of your Unloader.

4.1Before every startLubricate the slewing tooth wheel on slewing table through 3 openings.

Lubricate the bottom bearing through the roller (11.02.01.22) grease nipple

(15.01.01.11) Drawing 13024513 by removing the plug(15.01.01.12), remember to

tighten the plug after lubrication.

Check level in grease barrel by looking at the Filling pump station (see vendor

instruction)

Check level in grease pumps container, which is located in the lubrication pilot

stations on the vertical arm, horizontal arm and gantry. (See vendor instruction for

detail)

Check oil level in hydraulic oil tank.

Check the aux. Hoist (27.01.01.03 drawing 13031701) see vendor instruction fordetail).


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Check oil levels in the following gear boxes

12.01.01.03 and 12.01.03.05 drawing 13024415.

22.01.01.03 drawing 13032442.34.01.01.05 drawing 13025744.

And also other gear boxes.

For further information regarding gearboxes see vendor instruction.

Watch out for material dust around drive end bearing. If dust appears replace the

sealing ring before operating the machine (described in chapter 9.2.3and 10.2.3).

4.2After every 100 operation hoursDrain the water separator in the hydraulic room.

Lubricate the top bearing with approximate 10 strokes at each grease nipple

(15.01.01.10 drawing 13023635).

Lubricate the bogie bearing and grease nipple

4.3After the first 100 operation hoursRetighten following screw connections:

Slewing bearing at slewing table see drawing 13024253, part no. 30.01.01.15 and

part no. 30.02.02.15.

Attachment pendulum cylinder, see drawing 13025391, part no. 07.01.02.01. See

drawing 13031241, part no. 24.01.06.21-22

Attachment luffing cylinder, see drawing 13024253, part no.30.02.01.07 and

30.02.01.09. See drawing, 13031241 part no. 24.01.06.18.

Horizontal arm hinge bearing see drawing 13024253, part no. 30.01.01.10, and

part no. 30.01.01.20 and 30.01.01.22.

Horizontal arm outer hinge bearing see drawing 13025391, part no. 07.01.02.01.

Cable reels tighten the bolts and check the collectors

4.4After the first 200 operation hoursCheck cable-, control reel according to service chart.

Lubricate all the Universal Joint Shafts

12.01.01.05

12.01.03.04

22.01.01.17

See vendor instruction for details.


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4.5After each 200 operation hoursCheck the collectors at the cable reels

Check that all nuts/screws at the intermediate and end bearings on vertical, hori-zontal conveyors are tighten according to specification.

4.6After the first 400 operation hoursChange oil in gearbox at vertical screw conveyor (12.01.01.03).

Change oil in gearbox at feeding head drive (12.01.03.05).

Change oil in gearbox at horizontal screw conveyor (22.01.01.03).

Change oil in gearbox at slewing drive (34.01.01.05).

4.7After each 400 operation hoursCheck wear rubber and wear plates and change when needed.

4.8After each 500 operation hoursAdjustment of Intermediate Bearing Support Pad clearance see 8.2.1

4.9After each 800 operation hoursCheck the aux. hoist according to the service chart.

Check all limit switches.

Check all wear plates.

Change oil, air and suction filter in the hydraulic system.

Check all the Universal Joint Shafts

12.01.01.05

12.01.03.04

22.01.01.17

See vendor instruction for detail.

Grease the top end bearing on the vertical arm through the nipples parts no

15.01.01.10 drawing 13024503

4.10After each 2.000 operation hours


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Check the lubrication system according to the service chart.

Check the aux. hoist according to service chart.

Check cable-, control reel according to service chart

Check all the Universal Joint Shafts

12.01.01.05

12.01.03.04

22.01.01.17

See vendor instruction for detail.

Grease outer end bearing horizontal screw conveyor through the nipples parts no

25.01.03.05 drawing 13031615.

Grease inner end bearing horizontal screw conveyor through the nipples parts no

25.01.03.05 drawing 13025643.

4.11After each 4.000 operation hoursGrease the Electrical. motors vertical screw conveyor

Grease the el. motor horizontal screw conveyor

Grease the el. motor feeding head drive

Grease the el. motor slewing table

Change oil in gearbox at vertical screw conveyor

Change the breather plug on the gearbox at vertical screw.

Change the oil filter on the gearbox at vertical screw.

Change oil in gearbox for feeding head drive

Change oil in gearbox at horizontal screw conveyor

Change oil in gearbox for slewing table

Change oil in gearbox at bogie


4.12After each 8.000 operation hoursCheck the aux. hoist according to service chart


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Check cable-control reel according to service chart

4.13 After each 10.000 operation hoursGrease auxiliary hoist el. Motor

4.14After each 15.000 operation hoursCheck the aux. hoist according to the service chart.

Change oil in the gear box at central lubricator pumps.


4.15Lubrication Chart4.15.1Oil and grease specification.Fabricate: Mobil Shell Type

Gear box oil:

Vertical screw Mobil gear 220 Omala oil 220 7346

Feeding head Mobil gear 320 Omala oil 220 7154

Horizontal screw Mobil gear 460 Omala oil 460 7155Slewing Mobil gear 320 Omala oil 220 7154

Fabricate: Shell Type

Hydraulic oil: Tellus TX68 7026

Fabricate: Mobil Shell Type

Grease:

Electric Motor Polyrex EM103 Alvania G3 C

Central lubrication Mobilux EP2 Alvania EP2 7425

Manual lubrication Mobilux EP2 Alvania EP2 7425Slewing ring tooth wheel Mobiltac 81 Grease S.8327 7265

Universal Joint Shaft Mobilux EP2 Alvania EP2 7425


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4.15.2First Fill amountsType Amount

7425 - 2 barrels

7026 - 1700 Litres

7154 - 102 Litres

7155 - 90 Litres

7265 - 6 Litres

7346 - 34 Litres

4.15.3Vertical ArmDetail Lubric.Type First Fill Amount PeriodSlewing ring Feeder 7425 See Centr.Lubr. Central Lubrication

Bottom Bearing 7425 Filled 15 strokes Before every unloading

Support Bearing 7425 Filled 10 strokes Each nippels.Each 100h

Gear box screw conv. 7346 16.6 litre 16.6 litre See separate instruction

Electrical motor C Filled 180g Each 4.000h

Universal Joint Shaft 7425 Filled First 200h then each 1000h

Pipe Fill 7026 300 litre See separate instruction

Feeder Gear Box 7154 21 litre See separate instruction

Top Bearing 7425 Filled 200g Each 800h, top nipple 150g,


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4.15.4Horizontal ArmDetail Lubric.Type First Fill Amount Period

Outer screw end greas seal 7425 See Centr.Lubr. Central Lubrication

Outer bearing screw conv. 7425 Filled 35g Each 2.000hIntermediate bearing 425 See Centr.Lubr. Central Lubrication See

vendor instruction

Auxiliary hoist bearing points 7425 50 g See separate vendor

instruction

Gear box Central lubr. 7154 0,1 litre 0,1 litre Each 15.000h

Auxiliary hoist gear box 7154 Filled See separate vendor

instruction

Auxiliary hoist el. Motor C Filled See separate vendor

instruction

Drive screw end grease seal 7425 See Centr.Lubr. Central Lubrication

Drive end bearing screw conv. 7425 Filled 35g Each 2.000hGear box screw conv. 7155 45 litre 45 litre First 400h/then each

4.000h

Electrical motor C Filled 120g Each 4.000h

Hydraulic container 7026 850 litre See separate vendor

instruction

Luffing cylinder 7026 Filled See separate vendor

instruction

4.15.5Slewing TableDetail Lubric.Type First Fill Amount Period

Slewing ring raceway 7425 See Centr.Lubr. Central Lubrication

Slewing ring tooth wheel 7265 3 litre Fill up Each 100h

Gearbox slewing motor 7154 4x7,3 litre

See separate vendor

instruction

Electrical motors C Filled 80g Each 4.000h


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4.16Vertical Screw Conveyor VSC-700

4.16.1Technical specificationDiameter of Screw 680 mm

Diameter of Housing (inner) 695 mm

Screw Length 22000 mm

Design capacity 1200 t/h

Drive Unit 2 x 355 kW

Gear Box 5,968:1

Revolutions of Screw 402 rpm

End Bearings FLS

Intermediate bearings FLS

Lubrication System Manual & Central Lubricator

4.16.2DescriptionVSC-700 is a Vertical Screw Conveyor consisting of multiple Screw Sections with

End Bearings and Intermediate Bearing Pads supporting the Screw on the outer

diameter. Each Screw Section has a weight of up to 1500 kg and the rotating mass

can be as high as 7-8 ton.

Top End Bearing, Bottom End Bearing and Support Bearing are manually lubricated.

The inlet device has a Feeding Head rotating in reverse direction to the screw.

The outlet device is provided with a mechanical swivel.

In order to get a smooth operation free from vibration it is essential that the sup-

ports of the screws are in good condition and adjusted to a proper clearance, thescrews are not worn to unbalance and there is no damage at any screw section. It


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is important that the centre line for screw is the same as for the housing due to

bearing lifetime. The screw should always be checked after replacing components.

All screws are balanced before delivery.

The Vertical Screw Conveyor is driven by two electrical motor with a mechanical

gearbox.

The gearbox is connected to the screw conveyor by a universal joint shaft with a

Safeset coupling.

Note! Do not open any conveyor before the line contactor is off.

Before taking any action on the vertical conveyor, run the screw without material

and in vertical position. Listen to any noise and check eventual vibration. Check run

out time when switching off current. Open all support cases and check the condition

of the parts. Following list can be a help if there is any disturbance:

SYMPTOM POSSIBLE REASON STEP TO DO

One side wear on

support

screw/shaft,

Support Pads even

worn. Vibrations.

One or several screw

section uneven worn and

out of balance.

Take out screws, replace dam-

aged parts or repair and rebal-

ance.

One side wear on

support

screw/shaft,

Support Pads evenworn. Vibrations.

A screw section is bent or

damaged.

Take out screws, replace dam-

aged parts or repair and rebal-

ance.

One side worn

Support Pad/bush

half

Conveyor out of align-

ment.

Take out screws and realign

casing.

One side worn

Support Pad/bush

half at several

supports in pendu-

lum direction.

Conveyor out of align-

ment.

Too much operating with

to much leaning vertical.


casing.

Inform and teach operators better

handling.

Short run out time Conveyor out of align-

ment. To tight adjustedSupport Pads.


casing.Readjust Support Pads.

Several other events might occur, e.g. anything got stuck between screw and

casing, but a single or combinations of mentioned symptoms are most frequent.

Adjustment of Intermediate Bearing Support Pad clearance

The Support Pads are situated in pendulum direction and perpendicular to pendu-

lum direction. The most wear will be in pendulum direction. Consider the Pads as

couples and measure, shim and replace them as couples. Make sure you have the

same number of Shims on each Pad in each couple.Check of clearance and eventual adjusting should be done each 500 h of operation.


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Replace Support Pads when they start getting spots with missing hard facing on the

internal hard faced surface.


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Take off one Pad (11.03.01.05) from the Support Case (11.03.01.04).

Measure the clearance at one side 90 degrees from the opened Pad. Measure by

following the pitch from end to end of the Support Screw (11.03.01.02) with a

thickness gauge. The clearance is the biggest gauge that can pass all the way.

Repeat at the opposite side without moving the screw.

Add the clearances from both sides and you have the total clearance.

If the total clearance is more than 6 mm take away one 2 mm shim (11.03.01.06

(set of shims)) (or more) from each of the measured Support Pads but do not make

the total clearance less than 2 mm.

Assemble the Pad (11.03.01.05) to the Support Case (11.03.01.04) with the same

number of Shims as before taking it off.

Measure the clearance at this couple of Pads according to above and take away

Shims if necessary.

Tighten all bolts and secure with the folding plate.

It is important that there is a clearance; the parts will otherwise be destroyed.

Check by turning the Screw by hand after all Pads on each Support Case have been

tightened. If the Screw is squeezed then you know which Support is the problem.

Also try to get as equal clearance as possible between the different couples. Use

the 1 mm shim if necessary.


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Replacing End Bearing

Place the Feeding Head on some wooden pieces so it will stay in vertical position.

Unscrew the bolts (11.02.03.08).

Lift up the Vertical Arm. The Feeding Head will be standing. Note when releasing

from the Feeding Head the Vertical Arm must be moved a little Pendulum in so

that the Screw clears from the Feeding Head.

Unscrew the bolts (11.02.03.16) and dismount the Bearing Holder (11.02.03.06).

Unscrew the bolts (11.02.03.18) and dismount the Sealing washer (11.02.03.04).Replace Bushing (2 half parts 11.02.03.05).


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Check Bearing Shaft (11.02.01.23) for wear and replace if necessary by unscrewing

the bolts (11.02.04.13).

Reassemble the Bearing and Feeding Head tightening the bolts with the specified

torques.

Replacing Screw Section

Place the Feeding Head on some wooden pieces so it will stay in vertical position.Take away bolts and lift up the Vertical Arm. The Feeding Head will be standing.


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Note when releasing from the Feeding Head the Vertical Arm must be moved a little

Pendulum in so the screw is getting free from the Feeding Head.

Place the uncovered screw end on a wooden piece or a piece of rubber and with the

Vertical Arm in vertical position. Dismount the Inspection Doors (11.05.01.12) inthe Top Screw Casing by unscrewing the bolts (11.05.02.08). Unscrew the bolts

(11.01.01.08) in the Top Flange to release the entire Vertical Screw.

Put an iron bar trough the opened lower Support Case, secure the screws with a

chain block and lift up the Vertical Arm to outmost vertical position (approx. 7 m

above ground) in order to take out the first Screw Section.

Place a fork lift (lifting capacity more than all screws together (approx. 4000 kg)

and lifting height 7 m) under the screw end. Take away iron bar and Chain Block

and lower the screws with the fork lift until the first screw section including the

Support Screw Shaft is clear of the Casing.

Place the iron bar in the lower Support Case and secure with Chain Block. It is now

possible to release and remove the first Screw Section. Unscrew the bolts

(11.03.01.18) and remove the Support Screw (11.03.01.02). Dismount the Screw

Section including the Support Screw Shaft by unscrewing the bolts (11.01.01.12).

Repeat from step 4 until all Screws and Support Screws are out.

Note all slings used for lifting or securing screws must be chain or steel wire.

Replace worn and damaged Screw Sections and Support Screws.

Insert screws in reversed order. Note it is very important not to bend any of the

Screw Sections and the most dangerous situation is when pushing them into the

Casing.

Make sure that the Screw Sections are rotated correctly to give the Flights a con-

tinuous running.

Repair of Screw Sections

A Vertical Screw Section might need repair for different reasons like abnormal

wear, buckled Flights, damaged hard facing. If you for any reason have to do

repairs contact FLSmidth, Materials Handling for information of correct material and

procedure.

Note after any welding on the screw the screw must be rotated and end planes

indicated and eventual machined and finally balanced in 3 planes.


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Clamp for Vertical Screw

The Clamp (11.01.01.06) for the Vertical Screw located at the Upper Support Case

is fitted with Polyamide Bushings (11.01.01.06 item 7, 2 pc.) to compensate for

different thermal expansion of the Screw Casing and the Vertical Arm steel struc-

ture.

To replace the bushings unscrew the bolts (11.01.01.14) and remove the outer rim

of the Clamp.

Replace the Bushings in both the inner and outer rim of the Clamp.

Reassemble the Clamp tightening the bolts with the specified torque.


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Safeset Torque Limiting Safety Coupling

The Vertical Screw Conveyor is driven by two motors via a Gear Unit (12.01.01.03).

The Gear Unit is connected to the Conveyor by a Universal Joint (12.01.01.05) and

a Safeset safety coupling (12.01.01.06).

The Safeset coupling has a hydraulic torque setting system. By adjusting the

hydraulic pressure the release torque can be set to the required level.

Set the pressure according to vendor instruction.

For maintenance see the Safeset coupling vendor instruction.


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Replacing Wear Plates

On the Vertical Screw Conveyor the Casing itself has a wear resistant inner surface.

When the Casings are worn they must be repaired or replaced.The Casings can be seen on the above figure.


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4.17Horizontal Screw Conveyor HSC-1050

4.17.1Technical specificationDiameter of Screw 1030 mm

Diameter of Housing (inner) 1050 mm

Length inlet-outlet 27000 mm

Design capacity 1200 t/h

Drive Unit 355 kW

Gear Box 12.5:1

Revolutions of Screw 120 rpm

End Bearings FLS

Intermediate Bearings FLS

Lubrication System Central Lubricator

4.17.2DescriptionHSC-800 is a Horizontal Screw Conveyor with End Bearings and Intermediate

Bearings.All bearings are automatically lubricated.

Both the inlet and the outlet devices are provided with a mechanical swivel.

It is important that the centre line for screw is the same as for the housing due to

bearings lifetime. The screw should always be checked after changing components.

All screws are balanced before delivery.

The Horizontal Screw Conveyor is driven by an electrical motor with a mechanical

gearbox.


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Replacing Intermediate Bearing


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Open both the Hatches (21.03.01.05) by unscrewing the nuts (21.03.03.03).

Unscrew the Grease Pipe.

Take out the lower half of the Bearing (21.03.02.04) by unscrewing the bolts

(21.03.02.07).

Unscrew the bolts (21.03.03.05).

Lift up the Bearing Holder (21.03.01.09) including the upper part of the Bearing

(21.03.02.03) and the Bearing Cover (21.03.01.08), the Bushing (21.03.02.10) and

the Sealings (21.03.02.11).

Reinsert the Bearing Holder while replacing the Bushing (21.03.02.10) and the

Sealings (21.03.02.11).

Mount the lower half of the Bearing (21.03.02.04). Tighten the bolts (21.03.02.07)

according to the specified torque.

Fasten the Bearing Holder by tightening the bolts (21.03.03.05) according to the

specified torque.

Reattach the Grease Pipe.

Close the Hatches (21.03.01.05) by tightening the nuts (21.03.03.03) according tothe specified torque.


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Replacing Intermediate Bearing Shaft

(

Remove the Intermediate Bearing according to Chapter 7.2.1 Item 1 to 5.

Unscrew the bolts (21.01.02.01) to dismount the Bearing Shaft (21.03.01.07).

Replace the Bearing Shaft and tighten the bolts (21.01.02.01) according to the

specified torque.

Reassemble the Intermediate Bearing according to Chapter 7.2.1 Item 6 to 10.


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Replacing End Bearing and Sealing Ring

Outer end

Unscrew screws and remove the Housing for the Speed Guard (26.01.01.08).

Unscrew screws and remove the Speed Guard (26.01.01.06).

Disconnect the lubrication system.

Unscrew the screws (21.01.02.04) that fixes the Shaft to the Screw.

Remove the screws (21.02.04.15) and bring the whole End Flange arrangement to

a workshop.

Remove Bearing House Cover (21.02.01.09) by unscrewing screws (21.02.04.12).

Press the Shaft (21.02.01.10) out of the Bearing House (21.02.01.08) in the direc-tion shown with an arrow above.


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Unscrew and remove the Lock Nut (21.02.01.21) and Lock Washer (21.02.01.22).

Remove the bearing (21.02.01.20).

Check for damage on the Shaft (21.02.01.10) and replace if necessary.

Control if the old grease contains water or material dust. Replace if so.Replace Sealing Rings (21.02.01.18 & 21.02.01.19).

Replace the Bearing (21.02.01.20)

Reassemble the End Flange.

Reassemble the Grease Pipe, Lock Washer and Nut, House Cover, Speed Guard and

Cover. Tighten bolts according to specified torques.

Fill up the Bearing House with grease before operating the equipment.

Test the Speed Guard function before operating the equipment.

Drive end

Break power to electrical motor and disconnect the electrical cable.

Dismount the Guard for the Drive Shaft (22.02.01.03) by unscrewing the screws

(22.02.01.09).


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Dismount the Universal Drive Shaft by unscrewing the screws (22.01.02.12).

Detach the Gear Unit (22.01.01.03) from the Torque Support by unscrewing the

screws (22.01.02.19).

Remove Gear Unit Cover and dismount the Shrink Disc by loosening the M16

hexagon head screws.

If necessary use two screws to push the Gear Unit off the Shaft.

Remove the Grease Pipe.


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Unscrew the screws (21.01.02.03), (21.05.04.14) and remove the Bearing House

and Shaft arrangement.

Take the Bearing arrangement to a workshop.

Remove the Bearing House Cover (21.05.01.11) by unscrewing screws

(21.05.04.08).

Press the Shaft (21.05.01.10) out of the Bearing House in the direction shown with

an arrow above.

Remove the Lock Nut (21.05.01.20) and Lock Washer (21.05.01.21).

Remove the Bearing (21.05.01.19).

Check for damage on the Shaft (21.05.01.10) and replace if necessary.Control if the old grease contains water or material dust. Replace if so.

Replace Sealing Rings (21.05.01.22 & 21.05.01.23) and the Bearing (21.05.01.19).

Reassemble the Bearing arrangement.

Reassemble the Grease Pipe, Lock Washer, Lock Nut and Bearing House Cover.

Tighten bolts according to specified torques.

Fill up the Bearing House with grease before operating the equipment.

Mount the Gear Unit on the Shaft. If necessary use two M24x75 screws to pull the

Gear Unit on to the Shaft.

Mount the Shrink Disc and tighten the M16 hexagon head screws according to

vendor specifications.

Mount the Gear Unit Cover.Reattach the Torque Support. Tighten the bolts according to specified torque.


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Reattach the Drive Shaft. Tighten bolts according to specified torque.

Mount the Drive Shaft Guard.

Connect the electrical cable to the motor and turn on the power.

Replacing middle Screw Sections

In order to lift up and lower in the Screw Sections first remove the Movable Brace

(20.01.01.20) by unscrewing the screws (20.01.02.21). See figure in Chapter

7.2.5.

Unscrew all the screws (21.01.02.05, 21.04.01.10 and 21.03.03.08) on the Upper

Cover for the Middle Screw Section and the top half of the Intermediate Bearing

(21.03.01.04).

Remove the Upper Cover (21.04.01.03).

Remove Bearing and Bearing Shaft according to Chapter 7.2.2 item 1 to 2.

Remove the top half of the Intermediate Bearing (21.03.02.05).

Unscrew the screws (21.01.02.01) binding the Screw Section to the Bearing Shaft

at the other end by removing the Bearing according to Chapter 7.2.1 item 1 to 5.

Lift up the Screw Section (21.04.02.01).

Replace and make sure that the Screw Sections are rotated correctly to give the

Flights a continuous running.Reassemble the Screw Conveyor and tighten all the bolts with the specified torques.


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Replacing Outer Screw Section

Dismount the Middle Screw Section according to Chapter 7.2.4 item 1 to 7.

Dismount Screw from the End Bearing by unscrewing screws (21.01.02.04)Pull out the Screw Section (21.02.02.01).

Replace the Screw Section. Make sure that the Screw Sections are rotated correctly

to give the Flights a continuous running.

Reassemble the Screw Conveyor and tighten all the screws with the specified

torques.

Replacing Inner Screw Section


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Replacing the Inner Screw Section is done just like described in the Outer Screw

Section above.

Replacing Wear plate

The wear plates for the Horizontal Screw conveyor can be seen on the above figure


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4.18Central ChuteThe Wear/Cover Plates for the Central Chute Inlet can be seen on the above figure.

The Wear Plates for the Central Chute can be seen on the above figure.


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The Wear Plates for the Dividing Chute can be seen on the above figure.


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5.0Appendix - A

5.1Bolt TorqueMetric Bolt Torque Table

Estimated with clamp load as 75% of proof load

as specified in ISO 898-1

Property

Class

8.8 10.9 12.9 Socket Head

Cap Screw

Minimum Tensile

Strength MPa

M6 - M16: 800

M20 - M30: 8301040 1220

Nominal Size

and

Thread Pitch

Bolt Torque Specs in N-m

Dry Lubed Dry Lubed Dry Lubed

M10 x 1.50 50 38 72 54 84 64

M12 x 1.75 88 66 126 94 146 110

M14 x 2.00 141 106 148 201 235 176

M16 x 2.00 218 164 312 233 365 274

M18 x 2.50 301 226 431 323 504 378

M20 x 2.50 426 319 609 457 712 534

M22 x 2.50 580 435 831 624 971 728

M24 x 3.00 736 552 1052 789 1231 923

M27 x 3.00 1079 809 1544 1158 1805 1353

M30 x 3.50 1463 1097 2092 1570 2446 1834

M33 x 3.50 1990 1493 2849 2137 3329 2497

M36 x 4.00 2557 1918 3659 2744 4276 3208

Lubed means cleaned dry bolts lubricated with a standard medium viscosity

machine oil. Lubricate all contact areas of the bolts and washers. Lubricating

the bolts is the suggested method.


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6.0Appendix - B

6.1KKS Numbering

Process-related identification

Equipment description PF Level 0 Level 1 Level 2 Level 3

Screw unloaders = 0 0 EAA 01

Long travel drive unit 1 = 0 0 EAA 01 AE 001

Long travel - E motor = 0 0 EAA 01 AE 001 -M 01

Long travel - Gearbox = 0 0 EAA 01 AE 001 MG 01

Long travel - Brake = 0 0 EAA 01 AE 001 MB 01









Long travel drive unit 4 = 0 0 EAA 01 AE 004Long travel - E motor = 0 0 EAA 01 AE 004 -M 01










Long travel - Brake = 0 0 EAA 01 AE 006 MB 01Long travel drive unit 7 = 0 0 EAA 01 AE 007








Slewing drive unit 1 = 0 0 EAA 01 AE 009

Slewing - E motor = 0 0 EAA 01 AE 009 -M 01

Slewing - Gearbox = 0 0 EAA 01 AE 009 MG 01


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Slewing drive unit 3 = 0 0 EAA 01 AE 011Slewing - E motor = 0 0 EAA 01 AE 011 -M 01





Slew Bearing = 0 0 EAA 01 HD 001

Luffing hoist system = 0 0 EAA 01 AE 013

Luffing hoist system - E motor = 0 0 EAA 01 AE 013 -M 01

Luffing hoist system - Gearbox = 0 0 EAA 01 AE 013 MG 01

Luffing hoist system - Brake = 0 0 EAA 01 AE 013 MB 01

Cable reel unit = 0 0 EAA 01 AE 014

Cable reel - Gearbox = 0 0 EAA 01 AE 014 MG 01

Cable reel - E motor = 0 0 EAA 01 AE 014 -M 01

Hydraulic Unit = 0 0 EAA 01 AP 001

Gate Valve SS2599-50-G2" = 0 0 EAA 01 AP 001 KA 01

Check Valve RHDI11/2"CF = 0 0 EAA 01 AP 001 KA 02

Check Valve RHDI11/2"-50 = 0 0 EAA 01 AP 001 KA 03

Ball Valve, 3-Way AVI-1352-DN20-PN10-

G3/4" = 0 0 EAA 01 AP 001 KA 04

Check Valve RHDI3/8"CF = 0 0 EAA 01 AP 001 KA 05

Ball Valve KHB-G3/8" = 0 0 EAA 01 AP 001 KA 06Gate Valve SS2599-50-G2" = 0 0 EAA 01 AP 001 KA 07

Check Valve RHDI1"CF = 0 0 EAA 01 AP 001 KA 08

Pressure Relief Valve, Proportional

AP02B2YR21ANL = 0 0 EAA 01 AP 001 KA 09

Ball Valve KHB-G1 1/4"-1-1-1-2-SW14-

01X-B-PN315 = 0 0 EAA 01 AP 001 KA 10


01X-B-PN315 = 0 0 EAA 01 AP 001 KA 11


01X-B-PN315 = 0 0 EAA 01 AP 001 KA 12

Ball Valve KHB-G1 1/4"-1-1-1-2-SW14-01X-B-PN315 = 0 0 EAA 01 AP 001 KA 13


01X-B-PN315 = 0 0 EAA 01 AP 001 KA 14

Valve Group L90LS-02-SE16-261 = 0 0 EAA 01 AP 001 KA 15

Gate Valve SS2599-50-G3/4" = 0 0 EAA 01 AP 001 KA 16

Hydraulic luffing - Hose1 (inlet) = 0 0 EAA 01 AP 001 MR 01

Hydraulic luffing - Hose2 (outlet) = 0 0 EAA 01 AP 001 MR 02

Hydraulic luffing - Hose3 (drain) = 0 0 EAA 01 AP 001 MR 03

Hydraulic Pending - Hose1 (inlet) = 0 0 EAA 01 AP 001 MR 04

Hydraulic Pending - Hose2 (outlet) = 0 0 EAA 01 AP 001 MR 05

Hydraulic Pending - Hose3 (drain) = 0 0 EAA 01 AP 001 MR 06Pump1 = 0 0 EAA 01 AP 001 KP 01


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Motor1 - 45 kW = 0 0 EAA 01 AP 001 -M 01

Pump3 = 0 0 EAA 01 AP 001 KP 02

Motor3 - 3 kW = 0 0 EAA 01 AP 001 -M 02

Pump2 = 0 0 EAA 01 AP 001 KP 03Motor2 - 5.5 kW = 0 0 EAA 01 AP 001 -M 03

Oil Cooler = 0 0 EAA 01 AP 001 KH 01

Hydraulic Pipe Dia 30 mm = 0 0 EAA 01 AP 001 MR 07

Hydraulic Pipe Dia 28 mm = 0 0 EAA 01 AP 001 MR 08

Boom hydraulic luffing system