MC600 Modular Conveyor: Revision 12 January 2014 Document Number: PCM-03-02-02

MC600 Modular Conveyor
Operators and Spare

Parts Manual
Revision 12
January 2014
Document Number: PCM-03-02-02
MC600 MODULAR CONVEYOR MC600 Modular Conveyor
Operators and Spare Parts Manual
REVISION HISTORY
Doc No. PCM-03-02-02
REVISION HISTORY
Document MC600 Modular Conveyor Operators and Spare Parts

Information Manual
Revision History Date Revision Comments Author Signature

number
14/02/2012 10 Revise Lubricants AK
24/02/2012 11 Revise page 27 AK
09/01/2014 12 Revised page 49 MS
MARCH 2014 13 REMOVED SPARE DS

SECTION
Revision 11 Page 2 of 84
COPYRIGHT
COPYRIGHT
No copies or reproductions may be made from this manual, parts lists or illustrations
without written prior consent of Pilot Crushtec (SA) (Pty) Ltd. This manual complete
or in part must not be loaned to a third party.
The MC600 Modular Conveyor is a registered trademark for a portable crushing plant
manufactured by Pilot Crushtec (SA) (Pty) Ltd.
ISSUE 050202/01
Pilot Crushtec (SA) (Pty) Ltd.

POSTAL ADDRESS: P.O. BOX 30032, JET PARK, 1469, GAUTENG, SOUTH AFRICA
PHYSICAL ADDRESS: 26 YALDWYN ROAD, JET PARK, GAUTENG, SOUTH AFRICA
TEL: +27 (011) 842 5600
FAX: +27 (011) 842 5610
EMAIL: [email protected]
WEBSITE: www.pilotcrushtec.com
TABLE OF CONTENTS
Table of Contents
REVISION HISTORY 2
COPYRIGHT 3
CHAPTER 1: SAFETY 7
1. SAFETY INTRODUCTION 7
1.1. GENERAL 7
1.2. SAFETY SIGNS 7
1.3. ELECTRICAL SAFETY 9
1.4. HYDRAULIC SAFETY (IF FITTED WITH THE HYDRAULIC MOTOR) 10
1.5. SAFETY BEFORE AND DURING OPERATION 11
1.6. SAFETY BEFORE AND DURING MAINTENANCE 12
1.7. SAFETY BEFORE AND DURING TRANSPORT 13
1.8. SAFETY SIGNS IN THIS MANUAL 14
1.9. SAFETY SIGNS ON THE MC600 MODULAR CONVEYOR 15
1.10. NOISE LEVELS AROUND YOUR CONVEYOR 16
CHAPTER 2: TECHNICAL 17
2.1. INTRODUCTION AND SYSTEM OVERVIEW 17
2.2. KEY COMPONENTS 17
2.2.1. SYSTEM OVERVIEW 17
2.2.2. POWER UNIT 19
2.2.3. FEED BOOT 20
2.2.4. FEED BELT/CONVEYOR 21
2.2.5. SLEWING AXLE 21

2.2.6. HEIGHT ADJUSTABLE LEGS 22
2.3. TECHNICAL DATA 23

2.3.1. STANDARD EQUIPMENT 23
2.4. WORKING DIMENSIONS 24

2.5. TECHNICAL INFORMATION 25
TABLE OF CONTENTS
CHAPTER 3: INSTALLATION 27
3.1. SAFETY INTRODUCTION 27
3.2. INSTALLATION 27
3.3. ELECTRICAL SAFETY 27
3.4. CONNECTING UP THE ELECTRIC MOTOR 28
3.5. BEFORE STARTING 29
3.5.1. STARTING AND CHECKING THE CONVEYOR 29
3.6. SHUTTING DOWN 29

3.7. ADJUSTING THE CONVEYOR ANGLE 30
3.8. CONVERTING AXLE TO SLEWING POSITION 34
CHAPTER 4: OPERATION 36
4.2. SAFETY BEFORE AND DURING OPERATION 36
4.3. RECOMMENDED CHECKS BEFORE START-UP 37
4.3.1. STARTING AND CHECKING THE CONVEYOR 38
4.3.2. INTRODUCING MATERIAL TO THE CONVEYOR 38
4.3.3. FEED SIZE SPECIFICATION 38
4.3.4. SHUTTING DOWN THE CONVEYOR 39
CHAPTER 5: MAINTENANCE 40
5.2. RECOMMENDED MAINTENANCE CHECK LIST 40
5.3. RECOMMENDED MAINTENANCE SCHEDULE 40
5.4. BELT TRACKING ON YOUR CONVEYOR 41
5.5. BELT TRACKING 43
5.6. BELT TENSIONING ON YOUR CONVEYOR 44
5.7. TROUGHING IDLER ANGLE ADJUSTMENT 45
5.8. REMOVING THE DRIVE GEARBOX 46
5.9. TAIL DRUM GUARD 47
TABLE OF CONTENTS
5.10. LUBRICATION 47
5.11. RECOMMENDED BOLT TIGHTENING TORQUES 47
CHAPTER 6: SPARE PARTS 48

6.1. SPARE PARTS ORDERING PROCEDURE 48
6.2. SPARE PARTS ORDER FORM 49
6.3. PARTS LIST 50
CHAPTER 7: TRANSPORTATION 51
7.2. STOPPING THE CONVEYOR 51
7.3. PREPARING FOR TRANSPORTATION 51
7.4. READY FOR TRANSPORTATION 52
7.5. PRIOR TO HAULAGE 53
7.5.1. MC600 LENGTHS AND WEIGHTS 53
7.6. ON SITE TRANSPORT 53

CHAPTER 8: FAULTFINDING 54
8.1. CONVEYOR NOT WORKING WHEN MOTOR IS RUNNING 54
8.2. SCREECHING NOISE WHEN CONVEYOR IS RUNNING 54
8.3. CONVEYOR BELT NOT RUNNING 55
8.4. CONVEYOR COLLAPSED 56
WARRANTY 58
Chapter 1: SAFETY
CHAPTER 1: SAFETY
1. SAFETY INTRODUCTION
1.1. GENERAL
Operators should be trained in the correct and safe use of all equipment.
ONLY QUALIFIED AND TRAINED PERSONNEL SHOULD ATTEMPT TO OPERATE THIS CONVEYOR.
Before operation the operator(s) must:
 Have received specific and adequate training in the task to be carried out.
 Have read and understood the Operators Manual and the Safety Signs in this manual and around
the machine(s).
 Know the location and function of controls and safety features such as emergency stop buttons
(if fitted) and safety guards.
 Be aware of all moving parts of the machine.
 OTHER SAFETY PRECAUTIONS i.e. place the protection covers over rotating parts of the
electric motor.
1.2. SAFETY SIGNS

In this section are listed all the safety signs used throughout this manual and on your machine.
Take time to familiarize yourself with the symbols and explanations. These signs are used frequently
throughout this manual to indicate any potential warning or danger when operating this machine.
Chapter 1: SAFETY
Chapter 1: SAFETY
SAFETY SIGNS (cont)
1.3. ELECTRICAL SAFETY

The following electrical safety instructions are to be adhered too when work is to be carried out on the
electrical system:
 Never work on the electrical system of any equipment unless you are thoroughly familiar
with system details.
 Work on the electrical system must only be carried out by a qualified electrician.
 The electrical equipment of the conveyor should be inspected at regular intervals.
 Damaged cables or loose connections must be corrected immediately. Use only original
fuses with the specified current rating.
 Lock out the Conveyor according to a Lock out procedure before commencing any work on
the conveyor.
Chapter 1: SAFETY
1.4. HYDRAULIC SAFETY (IF FITTED WITH THE HYDRAULIC MOTOR)

The following hydraulic safety instructions are to be adhered too when work is to be carried out on the
hydraulic system:
 Never disable or alter any hydraulic circuit or component without consulting with Pilot
Crushtec or your local dealer.
 Any work carried out on a hydraulic system must be performed by an engineer with special
knowledge and experience in hydraulics.
 Relieve all pressure in hydraulic system by returning controls to the neutral position. Turn
machine off and isolate power supply before any pipes, filter caps, filters, or hydraulic
fittings are disconnected or removed.
 Ensure replacement hydraulic components are the same standard and quality as the original
parts. Ensure they are fitted correctly.
 Beware of hydraulic oil leaks. Hydraulic fluid under pressure can penetrate the skin or
damage eyes. Fluid leaks under pressure may not be visible. Use a piece of cardboard to
find leaks but do not use bare hand.
 Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical
attention.
 Replace any damaged hydraulic pipe. Leaks can cause fires. Always ensure a replacement
pipe has the same specification as the original pipe, length, fittings, orientation, and
diameter. Ensure pipes are laid and fitted correctly.
 Do not exceed safe limits. Never set a pressure relief valve to a pressure higher than that
set at the factory.
Chapter 1: SAFETY
1.5. SAFETY BEFORE AND DURING OPERATION

The following instructions are to be adhered too before starting up the machine.
 Read and understand the Operators Manual before you start the conveyor. Study the
DANGER, WARNING, CAUTION AND IMPORTANT safety signs on your conveyor.
 Check your conveyor and have all systems in good operational condition.
 Check for broken, missing, or damaged parts. Replace and make necessary repairs.
 Ensure all safety guards and emergency stops (if fitted) are fitted and in working order.
Refer to the detailed checklist before start-up.
 Before starting, walk completely around the conveyor. Make sure no one is under it, on it or
close to it. Let other workmen and bystanders know you are starting up and do not start
until everyone is clear of the conveyor.
 Check bolts and nuts for looseness. A loose bolts or nuts may cause serious damage and
injury.
 Ensure that the Lock Pins have been inserted (refer to Chapter 6: Spares List).
 During operation, do not climb onto, over or under or tilt the conveyor moving conveyor
belts and rollers. Always use ladders, steps, and walkways when mounting and dismounting.
 All the hole alignments on the mechanical supports must be checked and
secured with bolts provided and in accordance with safety signs.
 Never check the tension of ‘V’ belts, drive chains, and conveyors when
the conveyor is running.
 Never work or stand beneath conveyor or attachments as it is raised or

lowered.
 Never work / stand beneath conveyor as they are loaded with

discharging material.
 Follow safe operating practices. Operate the conveyor controls smoothly.

Avoid sudden stops, starts, or changes in direction.
 Only use emergency stop buttons (if fitted) or emergency stop lines (if
fitted) in emergency situations or during safety drills.
Chapter 1: SAFETY
 After each day’s operation, always run the conveyor empty; never leave material on the
conveyor belt. Starting a conveyor with a full load will cause strain problems in your
conveyor.
Never alter any parts of the conveyor without consulting Pilot Crushtec.
1.6. SAFETY BEFORE AND DURING MAINTENANCE

TRAINED AND QUALIFIED PERSONNEL SHOULD ONLY CARRY OUT MAINTENANCE.
Whenever maintenance or service is being carried out a minimum of two (2) persons
should be present at all times. NEVER WORK ALONE.
WARNING
MAINTENANCE SHOULD BE CARRIED OUT
BY QUALIFIED AND TRAINED PERSONNEL
 Prepare yourself. Wear a hard hat, safety goggles, hearing protection and
other protective equipment as required by job conditions. Do not wear loose
clothing or jewellery that can catch on controls or moving parts. Long hair
must be tied back.
 Follow the suggested LOCKOUT PROCEDURE (see safety sign) on the machine
before performing any repairs or maintenance.
 Never attempt repairs or adjustments to the machine while it is running.
 Remove only guards or covers that provide access. Wipe away excess grease
and oil.
 Never leave guards off or access doors open when unattended. Keep
bystanders away if access doors are open.
 When working beneath raised equipment, always use blocks, jack-stands or other rigid and
stable supports. Never work under unsupported equipment.
 Performing work above 6ft 6” (2m) always use an approved (EN/ANSI) safety harness.
 Clean or replace damaged, missing, or painted over safety signs that cannot be read.
 Rotating and moving parts must be inspected during maintenance and replaced if cracked or
damaged. Excessively worn or damaged parts can fail and cause injury or death.
 After maintenance, tighten all bolts, fittings, and connections. Install all guards, covers and
shields. Replace or repair any damaged ones.
Chapter 1: SAFETY
 Start the electric motor and check for vibration. Operate all controls and make sure the
conveyor is functioning properly. After testing, shut down, check the work you performed (any
missing cotter pins, washers, locknuts, etc.) Recheck all bolts before releasing conveyor for
operation.
 Operate all controls and make sure the machine is functioning properly.
 After testing, shut down, check the work you performed (any missing cotter pins, washers,
locknuts, etc.). Recheck all fluid levels before releasing machine for operation.
 Isolate at all times before carrying out any work. Also isolate if the conveyor is not to be used
for an extended period of time
1.7. SAFETY BEFORE AND DURING TRANSPORT

The preparations to move or load equipment should be supervised by a minimum of two (2) persons.
 Ensure persons transporting the machine adhere to all Safety Signs and procedures.
 Before transportation on public roads, ensure the machine has been properly secured with no
loose material left in or on the machine.
 Extreme caution is required when transporting machinery on site. Soft or uneven ground may
cause accidents.
 When transporting a machine on a truck or trailer, know the overall height to avoid contacting
overhead obstructions such as bridges, power lines etc.
 Ensure wheel nuts are torque to approx. 150lbf.ft (200N.m) prior to transport.
Also inspect your tyres for:
 Correct pressure (4.0 bar)

 Cuts or bulges
 Nails or spikes
 Uneven or excessive wear
 Missing valve cap
 Have cuts or punctures repaired by authorised personnel before adding air. Beware an over-
inflated tyre can explode and cause serious injury or death.
Also inspect your wheels for:
 Damaged rims
 Missing or loose wheel nuts or bolts
 Obvious misalignment
Chapter 1: SAFETY
1.8. SAFETY SIGNS IN THIS MANUAL

Safety signs throughout this manual are identified by the safety alert symbol. When you see this symbol
always be alert to the possibility of personal injury or death.
Please take time to familiarise with each of the signs and what they mean.
Always follow the instructions in the Safety message.
This indicates an imminently hazardous situation

which if not avoided, will result in death or serious
injury.
This indicates a potentially hazardous situation

which, if not avoided, could result in death or serious
injury.
This indicates a potentially hazardous situation

which, if not avoided, may result in minor or
moderate injury.
It may also be used to alert against unsafe practices.
This indicates a statement of company policy, which

if not adhered to will result in damage to your
machine and/or other people’s property.
Chapter 1: SAFETY
1.9. SAFETY SIGNS ON THE MC600 MODULAR CONVEYOR

Safety Signs are important features of the MC600 Modular Conveyor. Please take time to familiarise
yourself with their meaning and locations on the conveyor as seen below.
Figure 1: Safety Signs on the MC600 Modular Conveyor
Chapter 1: SAFETY
1.10. NOISE LEVELS AROUND YOUR CONVEYOR

The noise levels generated by the standard MC600 conveyor working on its own does not exceed 85dB
per dose and therefore ear protection would not normally be required. Noise Levels around the MC600
in its working environment could however exceed 85dB per dose as a result of other conveyor working
with or near the MC600 conveyor.
It is recommended that a Risk Assessment program of the conveyor in its particular working
environment be conducted and the noise levels of plant be addressed in this Risk Assessment.
Ear Protection must be worn when operating this conveyor in an environment where the noise levels
exceed 85dB per dose.
Chapter 2: TECHNICAL
CHAPTER 2: TECHNICAL
2.1. INTRODUCTION AND SYSTEM OVERVIEW
The MC600 Modular Conveyor is comprised of a range of key components which are primary intended
for use as a feed conveyor as well as a discharge stock piling conveyor.
Each key component item is shown and described in more detail in this system overview and shown on
the break down illustration on page 19.
The MC600 Modular Conveyor varies in four lengths; these are 7m, (fixed support legs on the 7 metre
and 13 metre picking conveyor refer to Section 6), 10m, and 13m and 16 metres.
2.2. KEY COMPONENTS

The key components are as follows:
 Power Unit drive consisting of a 3kW electric motor(3-phase Electric Motor 380V/525VAC), c/w
gearbox on the 7m, 10m, and 13m conveyors and on the 16m uses a direct 4kW drive
 Feed Boot
 Feed Belt/Conveyor (600mm)
 Slewing Axle (but fixed support legs on 7m conveyor)
 13m picking conveyor (optional) fitted with a speed variator with a minimum and maximum
speed selections and a 1.5kW electric motor
 Height Adjustable Legs
 Hydraulic motor (optional)
2.2.1. SYSTEM OVERVIEW

The standard modular conveyor is driven by a 3-phase electric motor and gearbox assembly/Hydraulic
motor above the conveyor structure. The motor gearbox combination can be easily removed/
exchanged.
The 13m picking conveyor (optional) electric motor 1.5kW is fitted with a speed variator for minimum
and maximum speed selections.
1
1
5 2
Figure 2: Break down of the MC600 10m, 13m, and 16m Modular Conveyor
COMPONENT No. DESCRIPTION
1 DRIVE SECTION ASSEMBLY
2 CENTRE SECTION ASSEMBLY
3 TAIL SECTION ASSEMBLY
4 4M SLEW AXLE
5 REAR BOOT ASSEMBLY
6 REAR PIVOT
7 SUPPORT LEG
2.2.2. POWER UNIT

The standard conveyor is driven by an electric motor and gearbox /Hydraulic motor (optional)
assembly above the conveyor structure. The motor gearbox combination can be easily removed/
exchanged.
Drive consisting of a 3kW electric motor, c/w gearbox on the 7m, 10m, and 13m conveyors and on the
16m uses a direct 4kW drive
The 13m picking conveyor (optional) electric motor 1.5kW is fitted with a speed variator for minimum
and maximum speed selections.
Electric Motor /Gearbox Assembly Hydraulic Motor
Figure 3: Picture of the Power Unit Assembly
Conveyor Belt
Electric Motor
Gearbox
Assembly
Figure 4: Picture of the key components

2.2.3. FEED BOOT
The Feed Boot is fitted as standard to the tail end of the conveyor. It has tapered sides for greater
efficiency. A Rubber skirting (refer to (1) Back Skirting and (2) Side Skirting) fitted on the rear and
sides prevent spillage of the loaded material.
1
2
Figure 5: Feed Boot
2.2.4. FEED BELT/CONVEYOR

The conveyor uses a 600mm (24”) wide conveyor belt. The speed of the conveyor belt is set by the
chosen motor/ gearbox combination/or a set control on the picking conveyor. Belt tracking is done
with the adjustable belt tensioners at the back of the assembly as well as on the troughing idlers.
600mm Conveyor Belt Troughing Idlers
Figure 6: Troughing Idlers and Conveyor Belt
2.2.5. SLEWING AXLE

A slew axle with pneumatic tyres is fitted as standard to the conveyor. This allows for kidney shaped
stockpiling. The wheels can easily be straightened for towing the conveyor on site. A drawbar is fitted
to the tail drum section for this purpose.
Figure 7: The Slewing Axle
2.2.6. HEIGHT ADJUSTABLE LEGS

The conveyor legs on the MC600 are fitted with hanger brackets, so they can be adjusted on either side
of the section to the height/angle required.
Fit hanger bracket
in new position
Figure 8: Adjustable height/angle positions
2.3. TECHNICAL DATA

2.3.1. STANDARD EQUIPMENT
 Modular construction in 7m, 10m, 13m, and 16m

 600mm (24”) wide conveyor
 Box type frame
 Drive consisting of a 3kW electric motor, c/w gearbox on the 7m, 10m, and 13m conveyors and
on the 16m uses a direct 4kW drive
 Height adjustable support legs with pneumatic tyres
 Fixed support legs on 7m
 Belt speed 1.5m/s
 Feed boot with rubber skirting
 Tail drum guarding
 Plough scraper on tail drum
 Angle adjustable troughing idlers
 Rubber lagged drive drum
 Class 315/3 ply 3.2mm top cover and 1.6mm bottom cover belting
 Slewing axles on 16m, 13m, and 10m conveyor
 13m picking conveyor (optional) with a minimum speed (7.6 metres/min) and maximum
speed (40.6 metres/min) variator control and fitted with a 1.5kW electric motor
 Self tensioning belt scraper on drive drum
 Base plate on 7m conveyor
 Hydraulic motor (optional)
2.4. WORKING DIMENSIONS

The working dimensions of the MC600 are below.
Figure 9: Working Dimensions
2.5. TECHNICAL INFORMATION
LENGTH ANGLE DISCHARGE ELECTRIC RPM WEIGHT CONVEYOR SPEED

(METRES) (MIN/MAX) HEIGHT MOTOR (KG)
(MM) (KW)
METRES/MIN FEED/MIN
7 11° 1701 3.0 1450 940 90 295
20° 3657 3.0 1450 1262 90 295

10
16° 3047
13° 2542
* 13 00° N/A 1.5 1450 1480 7.6 (min)

40.6 (max)
20° 4570 3.0 1450 1460 90 295

13
16° 3870
13° 3300
20° 5671 4.0 1450 1660 90 295

16
16° 4575
13° 4050
* 13m Picking Conveyor (optional)
2.6. CORRECT USE OF YOUR CONVEYOR

The MC600 Modular Conveyor can be used for the feeding of sand, gravel, aggregates, rock, coal, and
any other hard core material. This does not include hot materials, which may damage the belt of the
conveyor. To avoid long term damage to the conveyor do not feed rock exceeding 200mm.
Should you have any doubt about feeding a type of material not listed, contact Pilot Crushtec or your
local dealer for guidance or any authorisation.
The following procedures must be carried out before operating this equipment.
 Appropriate space should be allowed for material stockpiles and loading of conveyor.
 This conveyor should only be loaded via its feed boot.
 Before operating, ensure proper conveyor installation. (Refer to Chapter 3 - Installation).
 Before operating, the conveyor should be levelled, ensuring that the weight of the conveyor is
evenly distributed.
Before operation the operator(s) must:
 Have received specific and adequate training in the task to be carried

out.
 Have read and understood the safety instructions in Chapter 1.
 Know the location of controls and safety features.
 Be aware of all moving parts of the conveyor.
 All safety guards must be in place.
Before transportation on public roads, ensure the conveyor has been properly
secured with no loose material left in or on the conveyor. (Refer to Chapter 7 -
Transportation).
After each day’s operation, always run the conveyor empty. Starting a conveyor
with a full load will cause strain problems in your conveyor.
Do not climb on the conveyor while it is running
Chapter 3: INSTALLATION
CHAPTER 3: INSTALLATION
3.1. SAFETY INTRODUCTION
Read and fully understand CHAPTER 1: Safety before continuing any further. The MC600 Modular
Conveyor is designed to operate under many different conditions and in diverse applications; it is
therefore recommended that a customised Hazard Risk Assessment be performed for the specific task /
operation.
3.2. INSTALLATION
The MC600 belt conveyor can be received as a complete section or as the following parts / sections:
 Subdivided conveyor with Drive section folded onto tail section
 Feed Boot
 Slew Axle
 Support Legs: Rear axle support & Front axle support (rear & front extensions)
 Tail Stand
 Tail Section Guards (refer to Chapter 6.3.8.- Tail Section Assembly)
 Walkways (if fitted)
TO HAVE THE MC600 MODULAR CONVEYOR READY FOR OPERATION, THE ABOVE MENTIONED
PARTS/SECTIONS MUST BE ASSEMBLED TOGETHER ACCORDINGLY. QUALIFIED PERSONNEL MUST
CARRY OUT THE INSTALLATION AND TESTING PROCEDURE.
THE CONVEYOR MUST BE UNFOLDED AND ASSEMBLED ACCORDINGLY. QUALIFIED PERSONNEL MUST
COMPLETE THE INSTALLATION AND TESTING OF THE MACHINE. AN EXTERNAL ELECTRICAL POWER
SOURCE MUST BE CONNECTED TO THE MC600 BY A QUALIFIED ELECTRICIAN TO PROVIDE POWER TO
THE MODULAR CONVEYOR. THE ELECTRIC MOTOR MUST PROVIDE SMOOTH POWER DELIVERY TO THE
MACHINE.
3.3. ELECTRICAL SAFETY

The following electrical safety instructions are to be adhered too when work is to be carried out on the
electrical system:
 Never work on the electrical system of any equipment unless you are thoroughly familiar with
system details.
 Work on the electrical system must only be carried out by a qualified electrician.
 The electrical equipment of the conveyor should be inspected at regular intervals.
 Damaged cables or loose connections must be corrected immediately. Use only original fuses
with the specified current rating.
 Lock out the Conveyor according to a Lock out procedure before commencing any work on
the conveyor.
3.4. CONNECTING UP THE ELECTRIC MOTOR

The following electrical safety instructions are to be adhered too when connecting up the electric
motor.
ONLY A QUALIFIED AND TRAINED ELECTRICIAN SHOULD ATTEMPT TO CONNECT THIS ELECTRIC
MOTOR.
The terminal connections for the 3-phase Squirrel Cage motor are as illustrated below.
DELTA (∆) STAR (Y)
W2 U2 V2 W2 U2 V2
U1 V1 W1
U1 V1 W1
L1 L2 L3 L1 L2 L3
Frames 63-100L 220VAC 380VAC
Frames 112M-355 380VAC 660VAC
Frames 112M-355 400VAC 690VAC
All Frames 525VAC 950VAC (1000VAC)
All Frames 550VAC
NOTE: Can be used on Star Delta NOTE: Can be used direct on line
Starters or direct line
Figure 10: 3-phase Squirrel Cage Motor connections
3.5. BEFORE STARTING

The machine must be on a level, compacted area with firm stable underfoot conditions.
Ensure all emergency stop buttons / latching switches (if fitted) are not switched to the STOP position.
Ensure all electrical controls are in the off position.
3.5.1. STARTING AND CHECKING THE CONVEYOR

The following procedure must be carried out before starting the MC600.
 Announce to all relevant personnel that the conveyor is going to be started.

 An external power source must be connected to the MC600 by a qualified electrician to
provide power to the modular conveyor.
 Start the electric motor to check smooth power delivery to the machine.
 Check if the direction of the conveyor is correct, as can be seen from the illustration below.
Check that the tracking of the conveyor belt is correct. The tracking of the belt can only be
checked whilst it is in motion. Absolute care must be taken when tracking the belt to avoid
injury (Refer to Chapter 5.4 - Belt Tracking).
3.6. SHUTTING DOWN

The following procedure must be carried out when shutting down the MC600.
 Stop the material feeding into the feed boot.

 Wait for all the material to pass over the length of the machine, then stop the conveyor by
switching the electric motor off.
 Lock Out the machine in accordance with the relevant procedures when not in use.
 It is very important to note that the feed boot of your conveyor should not be left under load
for extended periods of time.
3.7. ADJUSTING THE CONVEYOR ANGLE

The MC600 has a telescopic support leg on front. Adjustments to the angle of the conveyor can easily
adapted by using these legs.
Slight adjustments in the angle of the conveyor can be performed by loosening the retaining bolts on
the hangers and sliding them along the length of the centre section. This is potentially a dangerous
operation. Make sure that the conveyor is adequately supported and that there is no risk of it falling
nor toppling forward. Remember to tighten all the fasteners after any adjustments.
Changing the conveyor angle is potentially a dangerous operation. Make sure that the conveyor is on
level ground and that there is no risk of it falling or toppling forward. Remember to replace all the
locking pins after any adjustments.
NOTE: When adjusting the conveyor angle be careful not to tip the conveyor over to the front.
Always take care that the centre of gravity of the assembly is between the axle and the tail section
to prevent tipping. Tipping over will damage your machine and/or cause injury to personnel.
ALWAYS ENSURE THAT THE CONVEYOR IS

ADEQUATELY SUPPORTED BEFORE LOOS-
ENING ANY FASTENERS ON THE SUPPORT
STRUCTURE. FAILURE TO DO SO COULD
RESULT IN DEATH OF SERIOUS INJURY.
Figure 11: Angle Adjustment
There is a correct way and an incorrect way of adjusting the angle of the conveyor, which are
illustrated in the drawings below. The decal sign indicates where approx. the centre of gravity is.
CORRECT WAY
The axle must be well in the front of the centre of gravity (approx. in the middle of the conveyor)
to reduce the load on the legs as well as to ensure that the conveyor does not tip forward.
Centre of gravity
Axle in front of the

centre of gravity
INCORRECT WAY
In the drawing below, the position of the axle is shown behind the centre of gravity and with the
added stress from having the support legs spread apart to accommodate the shallow angle can
cause serious damage with the possible collapse of the conveyor.
Centre of gravity
Axle behind the centre of

gravity
Figure 12: Centre of gravity of the conveyor
A typical recommended example can be seen in the illustration below, of the distance (A) between the
centre of the axle and the centre of the base plate is approx. 8822 mm set at an angle of 13º with the
16 metre MC600 conveyor.
To adjust the angle of the MC600 the following procedure must be adhered too:
 Ensure that suitable rigging equipment and qualified personnel are available to support the
conveyor. A minimum of two people are required to perform this operation with appropriate
scaffolding / platforms.
 Lock Out the machine in accordance with the relevant procedures.
 Temporarily support the weight of the conveyor using appropriate rigging equipment.
 Loosen the retaining bolts on the top hangers.
 Slowly lift or lower the conveyor to the desired angle. This may require that the hanger brack-
ets be removed if the travel between cross-braces is not enough.
 Tighten the hanger brackets.
 Slowly lower the temporary support and check that the conveyor support legs and the hanger
brackets can support the weight of the conveyor.
 Before removing the temporary support completely, check that the centre of gravity is
between the axle and the tail pulley. If unsure, repeat the procedure and move the axle fur-
ther away from the tail pulley.
Length Angle Discharge Electric Rpm Weight Conveyor Speed

(metres) (min/max) Height Motor (kg)
(mm) (kW)
Metres/Min Feed/min
7 11° 1701 3.0 1450 940 90 295
20° 3657 3.0 1450 1262 90 295

10
16° 3047
13° 2542
20° 4570 3.0 1450 1460 90 295

13
16° 3870
13° 3300
20° 5671 4.0 1450 1660 90 295

16
16° 4575
13° 4050
Note that for the angle of the conveyor to be changed, it is necessary that the wheels are straight and
free to move. The angle of the conveyor cannot be changed whilst the wheels are in a slewing
configuration.
If the conveyor is to be towed, the conveyor angle must be set to its minimum and all locking pins
fitted. The conveyor may only be towed on level and stable ground. Maximum towing speed is 12km/h
(7.5 miles/h).
ENSURE THAT THERE ARE NO PERSONS OR

STRUCTURES IN THE DIRECT VICINITY OF THE
CONVEYOR. THIS PROCEDURE IS TO BE
CARRIED OUT BY ADEQUATELY TRAINED
PERSONNEL ONLY.
3.8. CONVERTING AXLE TO SLEWING POSITION

The following procedure must be followed to convert the axle wheels from the straight position to the
slewing axle position.
Figure 13: Converting Axle to Slewing Position
The slewing axle configuration gives the user the option of stockpiling the product in kidney shaped
heaps.
Procedure is as follows:
 Only competent personnel may carry out this procedure.
 Place a 2 ton jack under the axle next to the slewing hub.
 Raise the wheel until it just clear the ground.
 Remove the retaining pin on the inside slewing axle pin (3), and pull the slewing axle pin out.
 Swing the wheel (2) by hand round on the remaining (outside) slewing axle pin.
 Lines the holes on the wheel mounts up with the back hole on the axle and push the slewing
axle pin through.
 Slowly lower the wheel and remove the jack.
 Repeat the procedure for the other wheel.
 Remember to replace the retaining pin.
Figure 14: Wheels shown in the Slew position
Note:
The Conveyor Angle may not be adjusted whilst the wheels are in the Slewing Position. First return the
wheels to the straight position. The wheels must be able to rotate when the angle of the conveyor is
changed.
Chapter 4: OPERATION
CHAPTER 4: OPERATION
Read and fully understand CHAPTER 1: Safety before continuing any further. The MC600 Modular
operation.
4.2. SAFETY BEFORE AND DURING OPERATION

Only qualified and trained personnel should attempt to operate this conveyor. The following procedure
must be adhered too before and during the operation of the conveyor.
 Read and understand the Operators Manual before you start the conveyor. Study the DANGER,
WARNING, CAUTION and IMPORTANT safety signs on your conveyor.
 Wear the appropriate Personal Protective Equipment (PPE) such as safety

boots, eye protection, ear plugs, hard hat, gloves and dust mask (as required).
 Check your conveyor and have all systems in good operational condition.
 Check for broken, loose, missing, or damaged parts. Replace and make
necessary repairs.
 Ensure all safety guards are fitted and in working order.

Refer to Chapter 4.3 - ‘Checks before Start Up’ for a detailed checklist before start-up.
 Before starting, walk completely around the conveyor. Make sure no one is under it, on it or
close to it. Let other workmen and bystanders know you are starting up and do not start until
everyone is clear of the conveyor.
 During operation, do not climb onto, over or under the conveyor. This can cause severe injury.
Always use ladders, or if fitted, steps and walkways, when mounting and dismounting.
 The hole alignment on the mechanical supports must be checked and secured with pins
provided and in accordance with safety signs.
 Never work or stand beneath the conveyor or attachments as it is raised or lowered.
 Never work or stand beneath the conveyor as they are being loaded with and/ or discharging
material.
 Follow safe operating practices. Operate the conveyor controls smoothly.

Avoid sudden stops, starts, or changes in direction.
 Only use emergency stop buttons or emergency stop lines (if fitted) in emer-
gency situations or during safety drills.
 After each day’s operation, always run the conveyor dry; never leave mate-
rial on the conveyor. Starting the conveyor with a full load will cause strain
problems in your conveyor.
4.3. RECOMMENDED CHECKS BEFORE START-UP

The following recommended inspection routine must be carried out before start-up. It is advised that
the Recommended Maintenance Checklist (Chapter 5.3) is also carried out after lengthy periods of non-
operation. These are the minimum recommended checks. Certain applications and conditions may
require additional checks or maintenance.
No. Description Dates Checked / fault repaired

1 Check that Decals are not damaged or missing
2 Check that the conveyor is on firm ground and stable
3 Check all electrical cables, wires & connections for

damage
4 Inspect bearings are not damaged
5 Ensure that nothing is restricting the movement of the

conveyor. i.e. obstructions hampering moving parts
6 Check there is no excessive material build up in and

around the machine
7 Check on the wear of the side and back rubber skirting

and that they are in place and not damaged in the feed
boot
8 Check that all safety guards in place and fixed
9 Check that all fasteners in place and tightened
Check that all support pins are in place- check that the
10 adjustment support pins are also in place
11 Inspect the condition of conveyor belt- any tears or

damage due to excessive material build-up
12 Check all emergency stops (where applicable)
13 Inspect the condition of the belt scrapper
Ensure that the axle is positioned well in front of the

14 centre of gravity before start up( refer to page 33)
Inspect the condition of the Hydraulic Hoses of the

15 motor (if fitted)
4.3.1. STARTING AND CHECKING THE CONVEYOR

Before starting, walk completely around the machine. Make sure no one is under it, on it or close to it.
Let other workmen and bystanders know you are starting up and do not start until everyone is clear of
the conveyor.
Note: If the 13m picking conveyor is being started up, ensure that the variator speed settings must
only be set with the electric motor powered up and operating. Operating the hand wheel or remote
control while the variator is stationary can irreversibly damage its internal components
Start up the conveyor via the start button on the external electrical panel. Check if the travel direction
of the conveyor belt is correct.
Check that the tracking of the conveyor belt is correct. The tracking of the belt can only be
checked whilst it is in motion. Absolute care must be taken when tracking the belt to avoid
injury (Refer to Chapter 5.4 - Belt Tracking).
Listen for any unusual sounds (seized rollers, belt rubbing on frame etc.).
If fitted with a hydraulic motor (optional) instead of the electric motor, then adjust the
hydraulic lever controls to start the conveyor.
4.3.2. INTRODUCING MATERIAL TO THE CONVEYOR

When starting to feed the conveyor, the following procedure should be followed to ensure full capacity
operation:
 Ensure that the electric motor is at operating speed; also check that the direction of the belt
and the tracking thereof is correct.
 Begin to feed the conveyor at a low rate, gradually increase the feed until your conveyor, and
the system it is operating in, can handle the load.
After an initial period stop the machine and check for obstructions. Check for material spillage and
excessive build up in the feed boot.
4.3.3. FEED SIZE SPECIFICATION

This conveyor can be used for the loading and feeding of sand, gravel, aggregates, rock, coal, and any
other hard core material to a maximum of 250mm. This does not include hot materials, which will
damage the conveyor belt on your conveyor.
4.3.4. SHUTTING DOWN THE CONVEYOR

When shutting down the feed to the conveyor, the following procedure should be followed to ensure
that no damage can be caused during this operation:
 Stop the material feeding into the feed boot.

 Wait for all the material to pass over the length of the machine, and then stop the conveyor by
switching the electric motor off/hydraulic motor.
 Lock Out the machine in accordance with the relevant procedures when not in use.
It is very important to note that the feed boot of your conveyor should not be left under load for
extended periods of time.
Chapter 5: MAINTENANCE
CHAPTER 5: MAINTENANCE
Read and fully understand CHAPTER 1: SAFETY before continuing any further. The MC600 Modular
operation.
It is recommended the maintenance personnel perform a Maintenance Check on the MC600 Modular
Conveyor at least once a week (every 5 shifts). Performing the maintenance checks and attending to
any fault/s will prolong the life of your machine and the safety of the operator and personnel working
around the machine.
5.2. RECOMMENDED MAINTENANCE CHECK LIST

This recommended Maintenance Checklist is in addition to the Pre-start Checklist that the operator
performs on a daily basis (Chapter 4.2). The Maintenance Checklist does not replace the Pre-start
Checklist.
These are the minimum recommended maintenance guidelines as seen in the chart below. Certain
applications and conditions may require more frequent maintenance. Never alter any parts on your
conveyor without consulting PILOT CRUSHTEC or your service provider.
Note: The bearings fitted to the drive and tail drums are sealed units that have sufficient grease for
the life of the bearing. No regular greasing of these bearings is required.
5.3. RECOMMENDED MAINTENANCE SCHEDULE
No. DESCRIPTION WHEN DAILY WEEKLY MONTHLY REFERENCE/COMMENTS
REQUIRED
8 45 250
HOURS HOURS HOURS
MODULAR CONVEYOR GENERAL MAINTENANCE

Complete Pre-start C
Checklist
1 Check for material build-up C
Check all safety Guards are C

2 in place
Check for loose parts, C

3 missing nuts and bolts
Check conveyor belts for C

4 tears
5 Check belt tension C
6 Check belt tracking C
Check all rollers are free C

7 turning
Check all rollers are free of

8 obstructions C
9 Check for general oil leaks C
Check tension of belt C

10 scrapers
Check feed boot skirting C

11 rubbers
Check all decals are visible C

12 and not missing
Check for Electrical cables,

13 wires and connectors for C
any damage
Ensure that the axle is

positioned well in front of
the centre of gravity C
14
before start up( refer to
page 33)
No. DESCRIPTION WHEN DAILY WEEKLY MONTHLY REFERENCE/COMMENTS

REQUIRED
8 45 250
HOURS HOURS
HOURS
Check for bearings for C
15 damage
Condition of tyres (wear

16 and tear) C
17 All support pins in place C
POWER UNIT/GEARBOX GENERAL MAINTENANCE

1 Electric Motor C
Inspect Speed Variator Every 1000 hrs for oil

2 (13m Picking conveyor) level and leaks
If the Hydraulic motor Use Shell Tellus 52V68

(option ) is to be used hydraulic
3 ensure that the hoses are C
not leaking
4 Gearbox Check oil level if not

C factory filled (refer to
Lubrication Chapter 5.10)
Key: A - Adjust
C - Check/Top Up
R – Replace
D – Drain
Figure 15: Recommended Maintenance Check List
5.4. BELT TRACKING ON YOUR CONVEYOR

Belt tracking is performed at the tail section of the conveyor. Before doing any adjustments to the Tail
drums first identify the cause for the belt running oblique (Refer to Chapter 5.5). Adjust the belt with
the tensioners (A) either side on the tail section
A small movement in the adjuster i.e. less than 20mm (0.8”) should be sufficient.
The adjustment depends on the length of the conveyor. A greater movement will affect the tension of
the belt.
5.5. BELT TRACKING

Oblique travel may cause fast deterioration of the belt. In order to assist you we have compiled some
of the reasons for oblique travel with appropriate remedies.
REASONS FOR OBLIQUE EXAMPLES OF OBLIQUE

REMEDIES
TRAVEL TRAVEL
1. Insufficient aligning of drums a. Align all drums, carrying idlers

and idlers and return idlers at right angles
to the travelling direction of
belt.
b. Check that all drums and idlers
are level to each other
If a & b are as above then carry out

the following:
Adjustments are made as indicated
on Figs 1, 2, 3, by turning drums
and carrying idlers in direction of
arrow until the belt is running
straight and centred on the
conveyor.
Also return idlers may cause oblique

belt travel and therefore they must
be aligned at right angles to the
travelling direction of the belt and
after that adjustment can be made
2. Misalignment of Frame Oblique travel can be reduced by

turning forward outer carrying idlers
1-3 degrees in travelling direction of
the belt. See Fig 4: If this does not
correct the oblique travel then align
the frame
3. Material built up on drums and Check idlers and drums.

idlers Check belt cleaners and replace if
necessary. Possibly change to more
efficient type.
Figure 16: Adjusting the Belt Tracking
5.6. BELT TENSIONING ON YOUR CONVEYOR

Belt tensioning on the conveyor is performed at the tail section. The following procedure should be
carried out:
 By adjusting the belt tensioners (A), Figure 17, equally on either side of the section, you can
either tighten or loosen the belt.
 The belt should be sufficiently tight to prevent slippage at the drive drum. If over tighten the
life of the belt will decrease
Figure 17: Belt Tensioner nut A
5.7. TROUGHING IDLER ANGLE ADJUSTMENT

The angle of the troughing idlers can be adjusted to cater for different materials and conveyor angles.
The angle of the 3 idlers closest to the return pulley should never be adjusted, they are factory set at
their lowest possible angle so that the skirts on the feed boot seal effectively.
Similarly the three idlers closest to the drive drum are also set at their minimum angle so that
conveyor belt does not slip on the drive drum. A steeper troughing idler angle assists in guiding the
conveyed material to the centre of the belt as well as preventing ‘roll back’.
The following procedure is as follows:
 Ensure that suitable scaffolding / platform is available to perform this operation.
 Loosen the L-bolt.
 Loosen the U-bolt.
 Slide the troughing idler up until the tube clears the L-bolt.
 Remove the L-bolt and re-insert it in the desired hole further down on the bracket.
 Slide the troughing idler down so the inside of the tube locates on the L-bolt.
 Tighten the L-bolt and the U-bolt.
Repeat the procedure for the other troughing idler. Note, the angles of left, and right troughing idlers
must be the same (i.e. the L-bolts must be in the same holes relative to each other).
L-Bolt
U-Bolt
Troughing Idler
Figure 18: Troughing Idler Angle Adjustment
5.8. REMOVING THE DRIVE GEARBOX

This section applies only to conveyors fitted with electric motor drives. The electric motor and drive
gearbox are directly coupled together and are removed off the machine as a unit.
The procedure to remove the Drive gearbox is as follows:
 Ensure that suitable rigging equipment and qualified personnel are available to support the
weight of the motor and gearbox assembly. A minimum of two people are required to perform
this operation with appropriate scaffolding / platforms.
 The electrical connection to the motor must be removed and isolated by a qualified
electrician.
 Remove the brass nut (1).
Brass Nut (1)
 Hold the lock nut (2) and remove the nut (3).
Lock Nut (2)
Nut (3)
 Support the gearbox and motor arrangement with appropriate slings and lifting equipment.
 Slide the gearbox off the Drive drum shaft. The torque arm bracket comes off with the
gearbox.
5.9. TAIL DRUM GUARD

The tail drum guard is fitted with expanded metal so the belt tracking can be checked without
removing it.
5.10. LUBRICATION
The BEARINGS are factory greased for life, so lubrication will not be necessary.
The GEARBOX is factory filled for life and does not require refilling with lubricates.
LUBRICATION REQUIREMENTS (GEARBOX /GREASE IF NOT FACTORY FILLED/GREASED FOR LIFE)
CAPACITY LUBRICANTS/ALTERNATIVES
GEARBOX OIL 2.4 LITRES S320 (LONG LIFE)
The HYDRAULIC OIL (if fitted with a hydraulic motor drive) - Use Shell Tellus 52V68 hydraulic oil.
5.11. RECOMMENDED BOLT TIGHTENING TORQUES

The following table displays the bolt tightening torques.
BOLT SIZE TIGHTENING TORQUE (Nm)
BOLT GRADE 8.8 10.9 12.9
M10 49 89 93
M12 86 120 145
M14 135 190 230
M16 210 295 355
M20 410 580 590
M22 550 780 930
M24 710 1000 1200
M30 1450 2000 2400
Chapter 6: SPARE PARTS
CHAPTER 6: SPARE PARTS

6.1. SPARE PARTS ORDERING PROCEDURE
When requiring any spare parts the Ordering Procedure is as follows:
To ensure delivery of your parts, when ordering please quote:
 Machine serial number
 Illustration number and item number
 Part number
 Part description
 Quantity required
EXAMPLE:
If you wanted to order SCRAPER BLADE, place your order in the following
fashion:-
 Machine serial number – MC600 XXXX
 Illustration number - 6.3.1.
 Item number - 1
 Part number – MC6-60-150
 Part description – HANGER SUPPORT
 Quantity required - 2
This information will enable us to supply the correct parts with the minimum of delay.
Before operating or working on the machine, read the operator’s manual.
6.2. SPARE PARTS ORDER FORM
6.3. PARTS LIST

RECOMMENDED WEARING PARTS AND CRITICAL SPARES ITEMS FOR MC600 CONVEYOR
WEARING PARTS AND CRITICAL SPARES ITEMS
WEARING PARTS
QTY PER DESCRIPTION PART No. PROPOSED
MACHINE CUSTOMER
STOCKHOLDING
2 FEED BOOT SIDE RUBBER SKIRT MC6-70-001 4
1 FEED BOOT REAR RUBBER SKIRT MC6-70-002 2
1 DRIVE SCRAPER BLADE MC6-20-403 2
1 TAIL SCRAPER BLADE MC6-30-003 2
7 METRE CONVEYOR
2 RETURN ROLLER 19.22.0685 2
7 CENTRE ROLLER 19.22.4018 3
14 WING ROLLER 19.22.4020 6
14 IDLER CLIP RETAINER 19.22.0000 6
10 METRE CONVEYOR
20 WING ROLLER 19.22.4020 6
13 METRE CONVEYOR
26 WING ROLLER 19.22.4020 10
16 METRE CONVEYOR
32 WING ROLLER 19.22.4020 10
CRITICAL SPARES PARTS
4 TAIL /DRIVE DRUM BEARING BM1-13-005 4
Chapter 7: TRANSPORTATION
CHAPTER 7: TRANSPORTATION
Read and fully understand CHAPTER 1: SAFETY before continuing any further.
7.2. STOPPING THE CONVEYOR

Before stopping the conveyor, ensure all material has been discharged through the conveyor belt by
following procedures:
 First stop the material feeding into the feed boot of the conveyor and wait for the all the
material on the conveyor belt to be discharged i.e. ensure that the conveyor is empty of all
materials
 Stop the conveyor after all the material has been discharged from the machine.
 Lock Out the conveyor according to the relevant procedure.
7.3. PREPARING FOR TRANSPORTATION

For preparing the conveyor for transportation the following procedures must be adhered too:
 A qualified electrician must disconnect the electrical power source from the machine. The
power cable to the electric motor on the machine must be disconnected from the stand alone
electrical panel to ensure that no shock hazards exist from the machine’s disconnected power
supply.
 Inspect the Feed Boot to ensure that the machine is clear of all material.
 Ensure that the electric cable running to the motor is disconnected and the entry into the
motor is adequately sealed.
 Wash the conveyor to remove all debris and material.
 Remove the slewing axle and supports by unbolting the hangers at the top of the legs. This is
a potentially dangerous operation; it requires appropriate rigging equipment to support the
conveyor and competent personnel.
 Should the conveyor be too long for transport, it will require to be disconnected into two or
more sections.
 Firstly slacken the conveyor belt by screwing the tensioning bolts on the tail section all the
way in.
 Remove the tail drum.
 Remove the bolts holding the two centre sections together. Slide the two sections apart.
 Fold the one section over the other section. Note, the packing blocks need to be placed
between the two sections to prevent damaging the troughing idlers.
 Lift the one section over the other section. Locate into the bottom sections with the inner
stops provided.
 Secure the two sections together using appropriate straps.
Secure the two sections together using appropriate straps.
7.4. READY FOR TRANSPORTATION

The conveyor should now be ready for transport. The conveyor can be lifted with a crane. Once loaded
on the transport vehicle, secure the conveyor with the vehicles’ locking devices as well as with chain
shackles to the loadbed.
Figure 19: MC600 ready for transporting
7.5. PRIOR TO HAULAGE

For preparing the conveyor for prior for haulage the following procedures must be adhered too:
 Recheck for loose parts or debris on the machine.
 Ensure all pins are secured with ‘R’ and Split pins.
 Ensure persons transporting the machine adhere to all safety signs and procedures.
7.5.1. MC600 LENGTHS AND WEIGHTS

The MC600 is available in four different lengths which are display in the table below.
Length (metres) Weight (kg)

7 940
10 1262
13 1460
*13 1480
16 1660
* 13m Picking Conveyor
7.6. ON SITE TRANSPORT

This section is only applicable to the conveyors fitted with pneumatic tires on an axle.
ALWAYS remember that this drawbar is only required for on- site use and NOT for long distance
towing. ALWAYS ensure that the tires are set to the towing position prior to transport (Refer to
CHAPTER 3.4). Do not under any circumstances exceed 12km/h (7.5 miles/h) while towing the
conveyor since it is top-heavy and could topple over when cornering. Always be aware of the machine
height when towing to prevent it striking overhead equipment / spans / cabling.
Chapter 8: FAULTFINDING
CHAPTER 8: FAULTFINDING
The following FAULTFINDING guide is intended to describe basic procedures to remedy some problems
that may arise.
8.1. CONVEYOR NOT WORKING WHEN MOTOR IS RUNNING
Inspect locking
Conveyor not working element could be too Yes Repair or replace
when motor is running loose or broken locking element
No
Is Drive Drum shaft Yes

Replace Key
key missing?
No
If fitted with a *speed No

Replace
variator, is the unit
operational?
Yes
No
Contact Pilot Crushtec
* 13m Picking Conveyor only
8.2. SCREECHING NOISE WHEN CONVEYOR IS RUNNING
Inspect if there is
Screeching noise Yes
a lack of bearing Replace bearing
when conveyor is
lubrication
running
No
Clear any
Is the conveyor belt Yes obstructions, check,
and adjust the
wedged or rubbing
tracking on the
against fixed parts? conveyor
No
Is the belt scraper too Yes

Ease pressure at
tight? scraper
No
Is there a roller Yes

Replace the relevant
seized? roller
No
Yes
Are the skirts over Readjust skirts
tight?
No
8.3. CONVEYOR BELT NOT RUNNING
Ensure that the Electric

Motor has been connected
correctly and checked for
any loose wiring and that
there is power available or
Is the Electric No the motor has seized
Conveyor Belt not
running /Hydraulic Motor OR
running? Is the Hydraulic motor
connected up and there are
no leaks in the hoses
Yes
Inspect the locking Yes

Replace or tighten
element is not loose
locking element
or broken
No
Yes
Has the bearing Replace bearing
collapsed or seized
No
Is there debris Yes

obstructing the Drive Remove obstruction
Drum?
No
8.4. CONVEYOR COLLAPSED
Has the position of

the axle been
Conveyor has correctly installed No
collapsed (refer to page 32 of
the manual)
Yes
Figure 20: Fault finding Guides
NOTE: Repair and maintenance work.

It is recommended that repair and maintenance work of an intricate nature, such as the hydraulic
system which contains safety components, is referred to qualified personnel in the field.
Never alter any equipment or parts of equipment without consulting with Pilot Crushtec (SA) (Pty) Ltd.
WARRANTY
WARRANTY
All conditions and warranties expressed or implied by any statute common law, trade usage or
otherwise are hereby excluded. No liability is accepted by Pilot Crushtec (SA) (Pty) Ltd for any loss,
damage or injury to property or persons arising directly or indirectly from any failure or defect in the
machinery supplied. The materials employed by Pilot Crushtec (SA) (Pty) Ltd in the manufacture of
their machinery, to the best of their knowledge, are the highest available quality of their respective
kinds. Pilot Crushtec (SA) (Pty) Ltd undertake to replace or repair free of cost any part supplied to
them direct to the customer of which they shall receive notice and which shall be proved to the
satisfaction of Pilot Crushtec (SA) (Pty) Ltd within a period of Twelve months or 2000 working Hours
whichever comes first, of delivery to be defective in workmanship or materials provided:
 The written note of complaint is given within seven days of the discovery of the defect.
 That on request by Pilot Crushtec (SA) (Pty) Ltd., the part is returned carriage paid to Pilot
Crushtec (SA) (Pty) Ltd and shall, in the event of replacement become their property.
 That Pilot Crushtec (SA) (Pty) Ltd shall not be liable for the cost of removal of the defective
part or the cost of fitting a new part unless agreed in writing by Pilot Crushtec (SA) (Pty) Ltd,
prior to commencement of the work
 That the defect has not been caused by the use of the machine outside of the operating limits
or parameters specified by Pilot Crushtec (SA) (Pty) Ltd.
 That the guarantee period shall be proportionally reduced if the machinery is run for more than
one eight hour shift per day, no unauthorized alteration, or modification has been made to the
plant or machine or component the subject of the claim.
 That the machinery is maintained and serviced in accordance with the instructions provided in
the operator’s manual and that a logbook detailing of service, type of service and all parts used
is kept and made available for inspection.
 That only wear and spare parts purchased from Pilot Crushtec (SA) (Pty) or an approved dealer
or agent are used in the servicing and maintenance of the machine.
The new part will be delivered by Pilot Crushtec (SA) (Pty) Ltd, carriage paid to the customers nearest
station in the RSA or F.A.S. port of exportation.
This understanding is in lieu of and excludes any other conditions, guarantees, or warranties expressed
or implied, statuary or otherwise. In no event shall Pilot Crushtec (SA) (Pty) Ltd be liable (except to the
extent if any of its undertaking as aforesaid) for any loss injury or damage howsoever caused or arising.
The guarantee contained aforesaid hereof is personal to the Pilot Crushtec (SA) (Pty) Ltd customer and
may not be assigned.
WARRANTY
WARRANTY CLAIM PROCESS

 All Warranty claims submitted to Pilot Crushtec (SA) (Pty) Ltd shall follow the process flow
defined in document SAL-07-02-06 (Copy available on Request).
 Pilot Crushtec (SA) (Pty) Ltd will make all applicable forms available to Customer upon request.
 All Warranty Claims must be E-mailed to [email protected] or Faxed to +27 11 842
5610
COVERAGE
Products Warranted
This Warranty Coverage, is specifically for machines manufactured and supplied by Pilot Crushtec
(SA) (Pty) Ltd and is an important part of the provider's continuing effort to provide "you" with
superior value and product support. Pilot Crushtec is not responsible for failures from the use of parts
not approved by Pilot Crushtec. The new or approved rebuilt part used to repair Warrantable Failure
assumes the identity of the part it replaced and is entitled to the remaining warranty coverage of the
failed part.
Engine Warranty
On machines where engines are fitted, the warranty is covered by the Engine Manufacturer Warranty. A
copy of the Engine Manufacturer’s Warranty can be requested from Pilot Crushtec. Owner is responsible
to ensure that the machinery is maintained and serviced in accordance with the instructions provided in
the operator’s manual and that a logbook detailing date of service, type of service and all parts used, is
kept and made available for inspection.
Spare Parts
Spare parts purchased for machines carry a Three month or 500 hour, whichever comes first warranty
coverage but does not include wear parts as described below.
Wearing Parts Warranty
Wearing parts are not covered for wear and tear, normal wear out of components, corrosion, or
physical or mechanical erosion. These parts include but are not limited to items that come into direct
contact with materials being conveyed or processed. The warranty for wearing parts covers failures of
the wearing parts under normal service as a result of faulty material or workmanship. Coverage of wear
parts supplied as part of a machine ends when the machine warranty period has expired or when there
is no more useful life left in the wear part, whichever occurs first. Useful remaining life of wearing
components will be taken into account in the event of any claim. Some parts deemed as wearing Items
are Castings, V-Belts, Filters, Bearings, Conveyor belts, Motor’s, gearboxes, Springs, Couplings, Meshes
etc.
WARRANTY
Components not Manufactured by Pilot Crushtec (SA) (Pty) Ltd
In case of parts or components not manufactured by Pilot Crushtec (SA) (Pty) Ltd the customer will be
entitled to the benefits in so far as they may be transmitted to the customer, of any guarantees
provided by the manufacturer in respect thereof and Pilot Crushtec (SA) (Pty) Ltd liability in respect of
such goods is limited to making the benefits of the manufacturers guarantees available to the customer
to the extent aforesaid. These components include but are not limited to electric motors, electrical
components, and hydraulic components.
Machine Owner’s Responsibilities
During The Machine Warranty Period
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance
items during warranty repairs. Owner is responsible for the cost of all parts required for the repair
except for the defective Part and any Part damaged by a Warrantable Failure of the defective Part.
Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance
items replaced during repair of a Warrantable Failure.
Pilot Crushtec (SA) (Pty) Ltd IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES

MC600 Modular Conveyor: Revision 12 January 2014 Document Number: PCM-03-02-02

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MC600 Modular Conveyor

Operators and Spare

Document MC600 Modular Conveyor Operators and Spare Parts

Revision History Date Revision Comments Author Signature

14/02/2012 10 Revise Lubricants AK

24/02/2012 11 Revise page 27 AK

09/01/2014 12 Revised page 49 MS

MARCH 2014 13 REMOVED SPARE DS

Pilot Crushtec (SA) (Pty) Ltd.

2.2.5. SLEWING AXLE 21

2.3. TECHNICAL DATA 23

2.4. WORKING DIMENSIONS 24

3.6. SHUTTING DOWN 29

CHAPTER 6: SPARE PARTS 48

7.6. ON SITE TRANSPORT 53

Before operation the operator(s) must:

1.2. SAFETY SIGNS

SAFETY SIGNS (cont)

1.3. ELECTRICAL SAFETY

 The electrical equipment of the conveyor should be inspected at regular intervals.

1.4. HYDRAULIC SAFETY (IF FITTED WITH THE HYDRAULIC MOTOR)

1.5. SAFETY BEFORE AND DURING OPERATION

Refer to the detailed checklist before start-up.

 Never work or stand beneath conveyor or attachments as it is raised or

 Never work / stand beneath conveyor as they are loaded with

 Follow safe operating practices. Operate the conveyor controls smoothly.

1.6. SAFETY BEFORE AND DURING MAINTENANCE

 Never attempt repairs or adjustments to the machine while it is running.

1.7. SAFETY BEFORE AND DURING TRANSPORT

Also inspect your tyres for:

 Correct pressure (4.0 bar)

Also inspect your wheels for:

1.8. SAFETY SIGNS IN THIS MANUAL

This indicates an imminently hazardous situation

This indicates a potentially hazardous situation

This indicates a potentially hazardous situation

This indicates a statement of company policy, which

1.9. SAFETY SIGNS ON THE MC600 MODULAR CONVEYOR

Figure 1: Safety Signs on the MC600 Modular Conveyor

1.10. NOISE LEVELS AROUND YOUR CONVEYOR

2.2. KEY COMPONENTS

2.2.1. SYSTEM OVERVIEW

COMPONENT No. DESCRIPTION

1 DRIVE SECTION ASSEMBLY

2 CENTRE SECTION ASSEMBLY

3 TAIL SECTION ASSEMBLY

5 REAR BOOT ASSEMBLY

2.2.2. POWER UNIT

Electric Motor /Gearbox Assembly Hydraulic Motor

Figure 3: Picture of the Power Unit Assembly

Figure 4: Picture of the key components

Figure 5: Feed Boot

2.2.4. FEED BELT/CONVEYOR

600mm Conveyor Belt Troughing Idlers

Figure 6: Troughing Idlers and Conveyor Belt