CONVEYING SYSTEMS

Operating Instructions
Scraper Conveyor
with worm gear motor
2
Table of contents

Page

1.00 Introduction 4

1.10 General 4

1.20 Use of the conveyor as directed 4

1.30 Safety instructions 4

2.00 Transportation 5

3.00 Assembly 5

3.10 Conveyor housing (at delivery in sectional lengths) 5

3.20 Insertion of the scraper belt 6

.21 Closing of the scraper belt 8

.22 Tensioning of the scraper belt 9

3.30 Conveyor drive 10

3.40 Overload safety devices 10

3.50 Electric connection 10

4.00 Commissioning 11

4.10 First operation 11

.11 Drive 11

.12 General 11

4.20 Control during normal operation 12

5.00 Maintenance of the conveyor 12

5.10 Maintenance of the drive 13

.11 Lubricants 13

.12 Change of lubricants 14

.13 Filling amounts of lubricants 14

.14 Table of lubricants 15

5.20 Maintenance of the scraper belt with side chains

and chain wheels 16

.21 Nachspannen des Kratzerbandes 16

.22 Changing the scraper belt 16

5.30 Maintenance of the conveyor hou 16

5.40 Standstill of the conveyor 17

5.50 Elimination of faults 17

6.00 Spare parts 17

3
 1.00
Introduction
1.10
General
The purpose of these operating instructions is to assist you during
assembly and maintenance of KABELSCHLEPP conveyors, so that
expensive machine down-times can be avoided, and malfunctions can
be eliminated as quickly as possible.

The operating instructions are primarily intended for persons

whoare in charge of the assembly, maintenance and operation of
KABELSCHLEPP conveyors.

Therefore it is very important that these operating instructions are

handed over to these persons.

1.20
Use of the conveyor as directed
The scraper conveyor is intended for the transportation of chips and
coarse separation of chips and cooling lubricants during wet
machining.
It is suitable for short broken chips in dry and wet machining.
The amount of chips introduced must not exceed the continuous
carrying capacity specified in the technical data sheet. Otherwise
there is a risk of chip blockage or jamming of the conveyor belt.

Attention:
Do not put any large parts or pieces of waste on the
conveyor belt! This can jam the conveyor belt,
resultingin damage.

1.30
Safety instructions
- Observe accident prevention regulation VBG 10.
- Observe operating instructions.
- Maintenance and repairs may only be carried
out by qualified personnel.

- Work on electrical installations may only be carried out by

qualified electricians.
- Never bypass safety devices (e.g. overload protection)! Their
proper functioning must always be ensured.
- Never touch the conveyor belt or the ejection hole when
the conveyor is in the operating mode!
Not even when the conveyor is stopped! (Danger of automatic
start-up when coupled to the controller of the machine tool)

- Do not walk on the conveyor belt when the conveyor is in the

operating mode!
(Danger of automatic start-up)
- Do not remove existing covers during operation of the con
veyor.
- If the conveyor should become jammed, first turn off the
main power switch, then remove chips, using a suitable tool
(chip dog) and protective clothing (gloves).
Non-compliance with the safety instructions may
result in material damage and personal injuries.

4
2.00
Transportation
Small KABELSCHLEPP conveyors (up to a total length of 6 m) are
delivered ready for operation.
For transport by crane, the provided lifting elements must be used.
Otherwise there is a risk of damage to the conveyor, as well as an
increased danger of accidents.

Attention: Do not stand underneath the lifted conveyor!

Danger!
Transportation by forklift truck
only in original packing and with extreme caution!
Observe accident prevention regulations!

For large conveyors, the tail, feeding part, inclined section with moun-
ted bow-shaped connections (sectional length 2 ...... 3 m), drive unit
and support structure are delivered as separate elements.

The conveyor belt is delivered in sectional lengths of max. 10 m

(rolled).

3.00
Assembly

3.10
Conveyor housing
(with delivery in sectional lengths)

All individual elements are numbered consecutively. They are screwed

to the adjoining points or welded in exceptional circumstances.
During assembly it must be ensured that the flange screws are tightened
uniformly. For conveyors which are also used to convey cooling agents,
the screwable adjoining points must be sealed. (Under no circumstances
may cooling lubricants be allowed to leak! Environmental hazard!)

Sealing and sealing material is supplied with the conveyor.

The conveyor housing must be adjusted during assembly, because

otherwise the conveyor belt will not be guided properly. During assembly
it must be ensured that the adjoining points of the sliding rails and the
floor of the housing are at the same height.

Corrections can be made by releasing the flange screws and if

necessary readjusting, or by re-bending the slideway connectors.

Before inserting the conveyor belt, check that the conveyor

housing is set up firmly and securely.

5
 3.20
Insertion of the scraper belt
In order to insert the scraper belt, the following steps must be performed:

Slacken fastening screws of the head plate.

Remove the head plate.

Roll up scraper belt in front of the conveyor discharge.

Projecting scraper sheet sides must be on the ground, and the fastening
brackets of the scraper sheets must be directed towards the conveyor
housing!

Before drawing the scraper belt into the conveyor housing, the centre
distance of the chain wheels to the drive shaft and to the
tail axle must be compared with the side chain centre distance (X).

If these dimensions do not correspond to each other, the chain wheels

must be moved axially. When doing so, ensure that the distance of both
chain wheels to the interior conveyor housing side is the same.

6
Put the front end of the scraper conveyor down on the lower
slideway of the conveyor and move against the chain wheels.

Lift the scraper conveyor to the height of the lower slideway of the
discharging section.

Switch the drive motor on and off briefly

(pre-assembled by KABELSCHLEPP)
in conveying direction.

The chain wheels then pull the scraper belt into the conveyor housing.

Attention:
Risk of injury!
Do not reach into crushing points and moving parts!
Only switch drive motor on in jog mode!
If the scraper belt jams, stop the motor immediately
and run it briefly in the reverse direction.

Attention:
Be careful when inserting the conveyor chain into the
tail! - Risk of injury!
Do not pull by hand, but use a suitable tool
(dog, pliers, etc.)

If several sectional parts of a scraper belt have to be inserted,

they can be connected using shackle-type connectors.

Continue switching motor on and off until the side chains

have been picked up by the chain wheels of the drive.

7
 3.21
Closing of the scraper belt

Connect the side chain ends using shackle-type connectors.

Push outer shackles from the outside into the chain links to be connected.

Attach individual shackles inside.

Secure using locking rings.

8
3.22
Tensioning of the scraper belt
(with the conveyor in operating mode)

The drive shaft is connected with a tensioning station mounted on the

conveyor housing; this can be used to tension the scraper belt.

Necessary job steps:

1. Release fastening screws for the pedestal bearings.

2. Release lock nuts.

3. Adjust the tensioning screws.

Attention!
Adjustment of the tensioning screws must be done gradually on
both sides. The drive shaft must never get into a diagonal position.

4. Once the scraper belt has been tensioned, re-tighten the fastening
screws and lock nuts.

During the first year after commissioning, inspections must be

carried out approximately every three months (corresponds to
approximately 500 working hours), and after that once a year.

9
 3.30
Conveyor drive

The scraper belt conveyor is driven by a side-mounted worm gear

motor pre-installed by KABELSCHLEPP.

For operation and maintenance see page 12 ff.

3.40
Overload safety devices
KABELSCHLEPP conveyors can be supplied with an overload
safety device, which responds to jamming of the conveyor belt and
protects the conveyor from damage.

Attention: Overload fuses which trip in normal circumstances

must be adjusted.
If a belt conveyor runs jerkily, the overload
fuse must not be adjusted, but rather the obstruction
must be found and eliminated.
Under no circumstances may the fuse be adjusted
in such a way that it no longer trips.

3.41
Overload protection
by means of a protective meter switch or current measuring relay
in the electric control
Normally a protective motor switch or a current meter relay mounted in
the electric control is sufficient as overload protection.
By means of the current meter relay, necessary signals (acoustic or
visual) and/or control actions can be triggered.

3.42
Overload safety
with torque arm and limit switch
The permissible torque is set at manufacture. If the conveyor belt
becomes jammed, the increased torque compresses a cup spring
package and the conveyor is switched off by limit switches and/or a
signal is triggered.

The safety device can be adjusted by repositioning the

limit switch attachment.

3.50
Electric connection
The electric connection of the conveyor must be carried out by specia-
lists according to the valid VDE regulations and in accordance with the
data on the rating label.

Attention:
Conveyors with return movement must be equipped
with a jogging skip gear.

10
4.00
Commissioning

4.10
First operation

Before the first operation, the following steps

have to be followed:

4.11
Drive
The worm gear motors are supplied with a suitable oil filling at the
factory.
Before commissioning, always check that the oil is at the proper
fill level using the oil-level plug (1).

Horizontal assembly:
When the gear unit is at rest, the oil level should reach the lower edge
of the oil level plug.

Assembly with inclination: If a worm gear motor of standard design with

an inclination of 150 C is installed, then when
the lubricant is changed, less than 0.1 litres of
the old lubricant remains in the gear unit
when the oil drain plug is removed. The
mixture ratio resulting from this
(0.9 l new / 0.1 l old) is sufficient to be
considered a proper change of lubricants.

At the same time, the supplied vent screw (2) must be used in place of
the locking screw used for transportation, or the seal cord in the vent
screw must be removed before commissioning (depending on make).

Especially during the run-in period, high temperatures may occur; this
is not a cause for alarm, since the lubricants used are suitable
for temperatures up to 100 0 C.

After run-in has been carried out, when the room temperature is 20 0C
the temperature on the surface of the housing must not exceed 70 0C.

4.12
General
Check that the conveyor is set up firmly, check screw connections and
the function of existing accessory parts.

Check tension of the scraper belt!

Check lubrication of the side chains and bearing points!

Check electric connection to the existing supply mains!

11
 4.20
Control during normal operation
Control of the scraper belt conveyor is by means of a machine
switch installed by the customer.
Walking on the conveyor during operation is forbidden.
It must in always be ensured that the material to be conveyed
is continuously charged!
Attention!
During installation of the conveyor into a machine
housing, the sheeting has to be executed in such a
way that it protects the conveyor during operation,
and the feeding point is not accessible.
Containers which are set up at the discharge of the
conveyor to receive the conveyed materials
must be designed in such a way that a risk of injury by
reaching inside the container is excluded. If necessary
a sheeting must be attached.
For conveyors with reverse movement there is a
feed device at the reversing point for troubleshooting.
In this case, the following items have to be taken into
consideration:
A jogging skip gear has to be provided for the return
movement. (see item 3.50)
In the case free mounting of the conveyor, there has
to be a raised area of the housing with a distance
of >120 mm to the dog.

5.00
Maintenance of the conveyor

Maintenance overview

Maintenance point Action Interval Page

Belt tension Check 500 h 9
Side chain Lubricate max.500 h 16
Conveyor housing Check screw connections 6 months 16
Conveyor housing Clean conveyor housing 6 months 16
Drive Gear oil and rolling-contact bearing greases Max. 36 months, see Diagram 5.12 14
Change

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5.10
Maintenance of the drive
In order to guarantee sufficient cooling, heavy deposits of dirt and dust
on the surface of the drive must be avoided.
The intakes of the ventilator hood of the motor and the interstices of the
radiator fins must be free of fouling.
The drive is of low-maintenance design. Maintenance is limited to
regular checks of the lubricants and changing the lubricants. The
changingintervals depend on the working hours and the working
temperature (see diagram on next page).

Independently of the working hours change:

J mineral lubricants (CLP): after 3 years at the latest
We recommend shortened changing intervals under severe operating
conditions like for example:
J high humidity
J corrosive environment
J large temperature fluctuations

Attention:

Do not mix synthetic lubricants with each other and do not

mix with mineral lubricants!

5.11
Lubricants
Unless a special arrangement has been agreed, every drive leaves our
factory with a gear-specific and type-specific lubrication filling. The
decisive factor here is the type specification (M1... M6) when the drive is
ordered. If the type is changed later, the lubricant filling must be adjusted
to the changed type (lubricant filling quantities)

The lubricants table for SEW drives on page 15 shows the permissible
lubricants for SEW gear units. Please note the following legend for the
lubricants table.

Abbreviations used, meaning of the shading and notes:

CLP = Mineral oil
CLP PG = Polyglycol (conforms to W-gear unit UDSDA-H1)
CLP HC = Synthetic hydrocarbons
E = Diester oil (water hazard class WGK1)
HCE = Synthetic hydrocarbons + diester oil (USDA - H1 approval)
HLP = Hydraulic oil
= Synthetic lubricant (= rolling-contact bearing grease, synthetic-based)
= Mineral lubricant (= rolling-contact bearing grease, mineral-based)
1) Worm gear unit with PG oil: please consult SEW
2) Special lubricant only for Spiroplan® gear units
3) Recommendation: select SEW fB > 1.2
4) Note critical start-up characteristics at low temperatures!
5) Low-viscosity grease
6) Ambient temperature

13
 Rolling-contact bearing grease
The rolling-contact bearings of the SEW gear units are filled at the factory
with the greases listed below. SEW recommends that when you change
the oil you also replace the grease filling.

Ambient temperature Manufacturer Type

Gear unit rolling- -20°C...+60°C Mobil Mobilux EP2
contact bearing -40°C...+80°C Mobil Mobiltemp SHC 100
-20°C...+80°C Esso Unirex EQ3
Motor rolling- -20°C...+60°C Shell Alvania RL3
contact bearing
+80°C...+100°C Klüber Barrierta L55/2
-45°C...-25°C Shell Aero Shell Grease 16

The following grease quantities are required:

- For fast-running bearings (Motor and gear unit input side):
Fill one third of the cavity between the rolling elements with grease.
- For slow-running bearings (inside the gear unit and
gear unit output side): Fill two thirds of the cavity between the
rolling elements with grease.

5.12
Diagram – Change of lubricants
working hours

oil bath – constant temperature

average value depending on type of oil at 70° C

5.13
Filling amounts of lubricants
Filling amounts in litres

Gear unit type M1 M2 M3 1) M4 M5 M6

SA 37 0.25 0.4 0.5 0.5 0.4 0.4
SA 47 0.4 0.8 0.7/0.9 1.0 0.8 0.8
SA 57 0.5 1.1 1/1.5 1.5 1.2 1.2
SA 67 1 2 1.8/2.6 2.9 2.5 2.5
SA 77 1.8 3.9 3.6/5 5.8 4.5 4.5
SA 87 3.8 7.4 6/8.7 10.8 8 8
SA 97 7 14 11.4/16 20.5 15.7 15.7

14
5.14 Table of lubricants for SEW drives

01 805_692

15
 5.20
Maintenance
of the scraper belt, the side chains
and the chain wheels
Every 500 working hours the side chains of the scraper
conveyor have to be checked for proper lubrication.

Attention:
When a dry run is carried out, the side chains must be
manually re-greased with viscous oil.

At the same time

the chain wheels should be checked for firm fit and possible wear.

5.21
Re-tensioning of the scraper belt
Because of the tensile forces applied to the side chains of the scraper
belt causes the belt to stretch during operation, they must be
re-tensioned regularly. (see item 3.22 - page 9)
Do not tension the scraper belt and side chains too much, since other-
wise they wear out too quickly.
If the tensioning distance is insufficient, the scraper belt and side
chains may have to be shortened.

5.22
Changing the scraper belt
The scraper belt must be changed if the scraper belt shows very
heavy wear and its function is called into question.
The belt change is carried out in the same manner as the drawing-in
of the scraper belt (item 3.20) when removing the worn belt, but in the
reverse order.

5.30
Maintenance of the conveyor housing
The screw connections of the conveyor housing have to be checked at
regular intervals (approximately every 6 months) and tightened
if necessary. At the same time the housing should be inspected
for rust formation. Damages should be repaired if necessary.
The cleaning of the conveyor housing should be carried out as follows:
Separate scraper belt at the end member. Procedure as shown under
item 3.21 - page 8, but in reverse order. Then re-insert end member
axle into the side chain of the carrying run.
Let the drive run the scraper belt out of the conveyor housing.
Remove cover plates in the inclination area, bow-shaped connections
and drive area.
Thoroughly clean scraper belt and housing.
After that assemble conveyor according to 3.20 to 3.22 and screw cover
plates on again.
For conveyors which are designed for dry operation:
Lubricate the scraper belt and side chains according to 5.20!

16
5.40
Standstill of the conveyor
Shorter rest periods of the conveyor normally require no special measures.
If the conveyor is deactivated for a longer period, be sure to carry out a
thorough cleaning and conservation.

5.50
Elimination of faults

Fault Reason Elimination

Excessive Belt tension Tension scraper belt
crowding without is too light! as described under
noticeable jamming. item 3.22 on page 9.

Deformed or Obstruction from Remove bent dogs

demolished dogs overloading or entry and screw on new
of coarse ones.
parts.

Protective motor Jamming from Reverse the

switch switches off. excessive chip gene- conveyor. Remove
ration or by coarse the jam.
parts.

6.00
Spare Parts

In order that we can quickly classify any spare parts required,

when you order spare parts please give us the
KABELSCHLEPP order number (rating plate) and the name of the part
(spare parts list).

17
18
Part no, Designation DIN Part no, Designation DIN
1 Worm gear motor assembly 21 Self-locking screw, serrated
2 Chain starwheel 22 Scraper belt assembly
3 Drive shaft 23 Locking ring 471
4 Feather key 24 Shackle type connector
5 Sealing ring 25 Side chain
6 Pedestal bearing 26 Scraper plate
7 Hexagon screw 931 27 Fastening bracket
8 Hexagon nut 934 28 Hexagon screw 931
9 Spring lock washer 127 29 Hexagon nut 934
10 Clamping piece with torque arm 30 Spring lock washer 127
11 Clamping piece 31 Chain starwheel
12 Insert 32 Deep-groove ball bearing
13 Self-locking screw, serrated 33 Adjusting ring 705
14 Head panel 34 Setscrew 916
15 Self-locking screw, serrated 35 Axle retainer
16 Square screw 479 36 Axle retainer
17 Hexagon nut (lock nut) 934 37 Return axle
18 Cover plate on drive section 38 Support frame
19 Cover plate on bow-shaped connection
20 Cover plate on inclined section

19
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KABELSCHLEPP GmbH
Marienborner Straße 75 · D-57074 Siegen
GB 06.2005 Subject to change.

Postfach 10 06 54 · D-57006 Siegen

Telephone +49 (+271) 5801-0
Telefax +49 (+271) 5801-220
info@kabelschlepp.de
www.kabelschlepp.de