Training Manual For Mechanical Maintenance Personal: STACKER STD 4500/29,5x1,2

Training Manual for Mechanical
Maintenance Personal
STACKER STD 4500/29,5x1,2
Chapter 2 : DESCRIPTION OF MACHINE AND ASSEMBLY GROUPS
September 2016
thyssenkrupp Industrial Solutions AG, Business Unit Resource Technologies, Mining –
Materials Handling
Training Manual for Mechanical Maintenance Personal
Stacker STD 4500/29,5x1,2
Training Programme
for
Mechanical Maintenance Personnel
Chapter 2:
Description of machine
and assembly groups
thyssenkrupp Industrial Solutions AG, Business Unit Resource Technologies, Mining – Materials Handling
2
2.1 Operating conditions
2.2 Design and function
2.3 General safety instructions
3
Material data:
Material Density () Grain size Moisture Angle of

t/m3 (mm) content repose
Iron ore 2.5 < 40 max. 3-9 % 36 °
Handling capacity:
4500 t/h (rated)
4800 t/h (max)
Designated use:
− Machine constitutes risk if improperly used by unskilled personnel
− specifically designed for transportation of limestone / clay, sandstone and iron ore
− specifically designed in accordance with the specifications of this stockyard
− manufacturer’s confirmation needs to be obtained if other materials are to be handled
− Operation only within the specific limits and for the operation time provided for per
annum
− Overload may endanger personnel and cause considerable damage
4
2.2 Design and function
• Layout – Stockyard
• Main assembly units
5
Layout – Stockyard
1 1
The stacker ( 1 ) with all its appertaining equipment serves to stack the specific bulk material into
a pile or a transfer chute (2) feeding further conveyors.
6
Main assembly units
3
( 1 ) Travel gear
( 2 ) Hoisting gear
( 3 ) Boom
( 4 ) Boom conveyor
2
1
( 5 ) Tripper car
4
5
7
Main assembly units
Travel gear
1 2 3 4 5 4 5
 2-six-wheel bogie (1)
 2 four-wheel bogie (2) 5
 6 two-wheel bogie, driven (3)

7
7 6
 4 non driven two-wheel bogie (4)
 4 single wheel bogie (5)
 removing of foreign matter from

the
 rails by rail cleaners (6)
 equipped with buffers (7)
8
Main assembly units
4
Travel drive unit
2
− E-motor (1) 1
− brake unit (2) with drum brake
− gearbox (3)
− whole unit is connected to the

respective two-wheel bogie 5
− working area of brake secured by 3

means of a protective hood (4)
− The planetary gearbox is

connected by the shrink disk ( 5 )
to the drive shaft
9
Hoisting gear
1
− hydraulic cylinder (1) ensures

the hoisting- and lowering
movements of the boom
− respective power pack (2) is

installed
on the portal platform situated
opposite to the power cable reel
10
Boom
1 2
4
− liftable and lowerable boom
(1), supported in
maintenance-free hinge 5
bearings (2)
− counterweight (3) for

compen-sating the dead load 5 3
of the boom as well as a part
of the useful load 4
− stairs (4) and walkways (5) to

allow a safe access to the 4
mechanical- and electrical
parts 4
11
Stacker STD 4500/29,5x1,2 1 2
Boom conveyor
− at transfer point from tripper car (1)
to boom conveyor (2), there is
installed a transfer chute (3)
− transfer chute equipped with 4

adjustable baffle gate (4) to be set
in a way that the arrival material
flow is fed to the centre of the
boom belt 3
− skirting (5) in the material feeding 5

zone minimizing dust development
− discharging of the bulk material at

the top of the boom
12
Boom conveyor
− idlers are arranged in
such a way that the
desired troughing of the
conveyor belt will be
obtained.
− The belt is running over
idler stations (1), each
consisting of three plain
idlers, and within the
feeding zone there are 3 1 5 1
2 7 4
impact idlers (2) mounted.
− In front of the drive (3)-
and discharge pulley (4),
the belt will be troughed
off.
− The latter is ensured by
idler brackets (5) having a 6
reduced troughing angle.
− In the return strand, the
conveyor belt is running
over idler stations (6)
each equipped with one
idler.
− To guide the belt,
provision has been made
for one negatively
troughed idler station (7),
13 consisting ofthyssenkrupp
two plain Industrial Solutions AG, Business Unit Resource Technologies, Mining – Materials Handling
idlers.
4 5 2 1
Boom conveyor drive unit

− E-motor (1)
− Hydr.Coupling (2)
− Drum brake with lifting device (3)
− gearbox with fan (4)
− working area of brake is secured by
means of a protective hood (5)
− entire drive unit is mounted on a
base frame (6)
− torque support (7) to absorb the
reaction power resulting from the
driven end torque
14
Pulleys, Belt cleaners1 4 6
2 7
5 6,7
− drive pulley (1) provided with − the discharge pulley (4) is supported in
friction lagging is supported in take- sliding
up blocks (2) at the take-up device pillowblocks (5) at the boom structure.
− at the discharge pulley, a main and
− safety scraper (3) on the material- secondary
free side of the belt, which prevents scraper ( 6,7 ) are arranged for cleaning
foreign particles from being drawn the dirt side
in between pulley and belt. of the belt.
15
2
Take-up device 1
− frame (1)
− take-up pulley (2), fixed by
take-up block bearings (3)
− nuts (4) and screws (5)
− as soon as required tension of

the belt has been obtained by 3 4,5 ´6
activating the two take-up screws,
the take-up pulley does become
arrested in this position.
− Tensioning can be controlled and symetrically
adjusted by using of hydraulic jacks (6) see O&M

Manual Chapter 4- Page 53: 4.1.4.2.4. Tensioning the
belt
16
Tripper Car
− tripper car (1) is designed as
welded sectional steel construction 1
− access from tripper car to 2

− boom is ensured by a platform (2)
− tripper car runs on supports (3)

equipped with non-driven runner 7
wheels arranged in single-wheel /
double wheel supports 8 3 5 3 3
− E-house (4), power cable reel (5)
− stairs (7) and walkways (8) to allow

safe access to the mechanical and
electrical parts
4 7
17
General safety instruction
• General safety instructions for structural steelwork /

mechanical engineering
• General safety instructions for electrical system
• General hydraulic safety instructions
• Fire prevention
• Fire fighting
18
General safety instructions for structural steelwork /
Mechanical engineering
− stacker must be kept clean; spillage, accumulations of grease and other soiling must be
removed immediately; all drives, motors, bearing points and electrical equipment must
be kept clean
− belt conveyors, scrapers and material transfer points must be kept clean
− access to service walkways and other sealed off areas only when stacker is stationary,
and with particular attention to the safety regulations
Danger! It is prohibited to leave the walkways and step onto the machine structure
and/or belt conveyors. Life may be at risk if this rule is not observed!
− brakes must be kept clear of dirt, rust, oil and grease; Clear any soiling immediately!
Caution !
Brakes which are not in perfect condition are a hazard to personnel and
the stacker!
− sufficient illumination of the stacker is needed during hours of darkness
19
General safety instructions for structural steelwork /
Mechanical engineering
− Damage, cracked paintwork, loose screws and deformation of load bearing components
must be immediately reported to TKIS. Deformation of and cracks in the load-bearing
components may be repaired only upon consultation with TKIS and with the express
approval of TKIS.
Caution! Cracks and deformation are an indication of overloading of the

component in question. To prevent further damage, the cause of overload must
be determined and rectified without delay.
− Welding, flame-cutting and grinding work on load-bearing components may impair the
stability of the stacker. Such work is prohibited without the express written approval
from and instruction by TKIS.
Caution! TKIS absolves itself of all responsibilities and liability for short
and/or long- term damage to the stacker resulting from contravention of
the rules and regulations.
20
General safety instructions for electrical system
− It is prohibited to work on the stacker when it is in a non-interlocked condition,
except for repair and maintenance purposes.
− The interlocking system may be rendered inoperative by bridging switches only in
exceptional cases, for example during repair work, and not during normal operation.
Caution! Measures must be taken to ensure the safety of the personnel and
the stacker when working in a non-interlocked condition.
Starting the drive will be announced by special optical and audible
signals.
− It is prohibited to disable and/or to carry out unauthorized modifications or settings

on safety equipment.
− No changes may be made to the software (PLC).
21
General hydraulic safety instructions (see subcontractor O &M
Manual)
− Work on the hydraulic equipment is only to be carried out by people who have
special knowledge and experiences of hydraulics!
− All lines, hoses and screwed joints regularly have to be checked for tightness and
for visible damage!
Caution!
Oil spouting out, can lead to injury or fire!
− Before starting any repair work on open sections and pressure lines, the relevant
assembly group areas must be depressurized!
− Hydraulic lines must be professionally routed and checked! Connections must not
be mixed up! Take care when replacing hoses that they have the correct length and
quality!
− Valves are only to be repaired by authorized and qualified personnel!
22
Fire prevention
− Inflammable materials such as oil, grease, paint and wire wool must be stored
somewhere fire proof.
− It is also advisable to avoid situations and conditions that could cause fire, such as
the overheating of bearings and belts, and the build up of dirt and dust on electric
motors etc.
− Any type of damage to a fire extinguisher as well as their deficiency must be reported
immediately to the relevant supervisory staff.
− Welding and flame-cutting work must be carried out with extreme care. The work
must be supervised by someone with a hand-operated fire extinguisher.
− To guarantee a continuous supervision of the stacker, inspections must be carried out

every 2 hours during downtimes between repair and servicing work, and also on
Sundays and holidays.
− The device must be inspected immediately after welding or flame-cutting work is

finished. Then 1 hour later a further inspection should be carried out and thereafter
every 2 hours.
23
Fire prevention
− Inflammable materials such as oil, grease, paint and wire wool must be stored
somewhere fire proof.
− It is also advisable to avoid situations and conditions that could cause fire, such as
the overheating of bearings and belts, and the build up of dirt and dust on electric
motors etc.
− Any type of damage to a fire extinguisher as well as their deficiency must be reported
immediately to the relevant supervisory staff.
− Welding and flame-cutting work must be carried out with extreme care. The work
must be supervised by someone with a hand-operated fire extinguisher.
− To guarantee a continuous supervision of the stacker, inspections must be carried out

every 2 hours during downtimes between repair and servicing work, and also on
Sundays and holidays.
− The device must be inspected immediately after welding or flame-cutting work is

finished. Then 1 hour later a further inspection should be carried out and thereafter
every 2 hours.
24
Fire fighting
− In case of fire in an area of the stacker every available person must take part in
fighting the fire.
− Every fire must be fought with a suitable fire extinguish substance (supplied by client).
− Small fires are to be fought immediately; in case of bigger fires give fire alarm in the
first place and start fire fighting then.
− It must be checked whether ventilating-, air-conditioning- and dedusting units are

disconnected (Danger of fire extension).
− The responsible supervisory staff must be informed.
25
Fire fighting
− In case of fires in electrical equipment and/or cables, these are to be made dead.
− Should it be impossible to make the LV-systems dead immediately (up to 1000V),

such fires are only to be fought by using suitable fire fighting means (Powder / CO2).
When doing so a safety distance of 1m is to be kept.
Caution!
When using CO2-fire extinguishers in closed rooms, there is a danger of
suffocation. Such rooms are to be left upon fire fighting immediately.
− Every use of fire extinguishers must be reported to the responsible supervisory staff.
− Used fire extinguishers must be replaced immediately by full and operative ones.
26

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Training Manual for Mechanical

Chapter 2 : DESCRIPTION OF MACHINE AND ASSEMBLY GROUPS

2.1 Operating conditions

2.2 Design and function

2.3 General safety instructions

Material Density () Grain size Moisture Angle of

• Main assembly units

 6 two-wheel bogie, driven (3)

 removing of foreign matter from

 equipped with buffers (7)

− brake unit (2) with drum brake

− whole unit is connected to the

− working area of brake secured by 3

− The planetary gearbox is

− hydraulic cylinder (1) ensures

− respective power pack (2) is

− counterweight (3) for

− stairs (4) and walkways (5) to

− transfer chute equipped with 4

− skirting (5) in the material feeding 5

− discharging of the bulk material at

Boom conveyor drive unit

− as soon as required tension of

adjusted by using of hydraulic jacks (6) see O&M

− access from tripper car to 2

− tripper car runs on supports (3)

− E-house (4), power cable reel (5)

− stairs (7) and walkways (8) to allow

• General safety instructions for structural steelwork /

• General safety instructions for electrical system

• General hydraulic safety instructions

− sufficient illumination of the stacker is needed during hours of darkness

Caution! Cracks and deformation are an indication of overloading of the

− It is prohibited to disable and/or to carry out unauthorized modifications or settings

− No changes may be made to the software (PLC).

special knowledge and experiences of hydraulics!

− Valves are only to be repaired by authorized and qualified personnel!

− To guarantee a continuous supervision of the stacker, inspections must be carried out

− The device must be inspected immediately after welding or flame-cutting work is

− To guarantee a continuous supervision of the stacker, inspections must be carried out

− The device must be inspected immediately after welding or flame-cutting work is

− It must be checked whether ventilating-, air-conditioning- and dedusting units are

− The responsible supervisory staff must be informed.

− Should it be impossible to make the LV-systems dead immediately (up to 1000V),

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