Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

BELT CONVEYOR
(Equipment #: 5 - L – 202)

Prepared by: Reviewed by: Approved by:

Doc. No.: SAT-TEC/P-002 Page 1 of 33

Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

Guido F. Cozzi
Site Manager

Naoufal Akhrif
Operations Manager

Remington Tan
Senior Safety Officer

Elvin Tom
Operations Supervisor

Andrews Ackah
Operations Supervisor

Amro Burhan
Oliver Lazo Bibat Operations Supervisor
Operations Superintendent

Date: 13/04/2020 Date: 13/04/2020 Date: 13/04/2020

Doc. No.: SAT-TEC/P-002 Page 2 of 33

Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

Contents
1. Purpose/Scope........................................................................................................................................4
2. Terminology...........................................................................................................................................4
3. References:.............................................................................................................................................4
4. Key Personnel Responsibilities..............................................................................................................5
5. HSE........................................................................................................................................................5
6. Requirements.........................................................................................................................................7
7. Other requirements.................................................................................................................................9
8. Spares, Tools & Special Consumables:.................................................................................................9
9. General Information.............................................................................................................................10
10. Before Execution.................................................................................................................................10
11. During Execution.................................................................................................................................10
12. After Execution....................................................................................................................................11
13. Process / Step- by- Step Methodology:................................................................................................11
14. Records Involved.................................................................................................................................36
15. Attachments.........................................................................................................................................36
16. Revision History..................................................................................................................................37

1. Purpose/Scope

To establish a procedure for overhauling or preventive maintenance of Belt Conveyor facilities

during turnaround, emergency shutdown or breakdown maintenance which is in line with the
Safety and Integrity objectives of the Plant.

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

This procedure provides a generic guideline for the disassembly, cleaning, inspection, assembly,
and maintenance of Belt Conveyor facilities including driver.

All Involved personnel must fully understand the general and specific operating procedures. Any
issues arising during work periods must be brought to the immediate attention of the Team
Leader, Supervisor and Maintenance/Site Manager.

Procedure / guidelines outlined by this document are applicable to all who take part in the process
and must be fully adhered to.
Any deviation from the procedures / guidelines must necessarily have prior explicit approval of
the Maintenance/Site Manager.

2. Terminology

2.1. SMP :Standard Maintenance Procedure

2.2. PPE :Personal Protective Equipment
2.3. G-Urea :Granulated Urea
2.4. SF :SAFCO
2.5. OEM :Original Equipment Manufacturer’s
2.6. EDMS :Electronic Document Management System

3. References:

3.1. SAFCO SMP

3.2. Manual

4. Key Personnel Responsibilities

4.1. Maintenance Supervisor (MS)

4.1.1.Is responsible to carry out Mechanical/Electrical isolations as per JSA requirement.
4.2. Operation’s Supervisor (OS)
4.2.1.Is responsible to carry out Mechanical/Electrical isolations as per JSA requirement.
4.3. Electrical Supervisor (ES)
4.3.1.Is responsible to carry out Mechanical/Electrical isolations as per JSA requirement.

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

4.4. Maintenance Coordinator/Planner

4.4.1.Ensure spare parts and consumables required for the job are available.
4.4.2.Ensure all required resources are available (Manpower, Tools, etc.)
4.5. Helpers
4.5.1.Ensure that the area is clean before and after maintenance activity.
4.6. Techinician
4.6.1.Execute the job according to the job order.
4.6.2.Ensure all the required checklist are properly filled.

5. HSE
5.1. Safety
5.1.1.Approved JSA must be available and posted on site before start the job. In case of special or
unique hazard involved, necessary approved JSA shall be made by Operations, Safety and
Maintenance Team.
5.1.2.Take a valid work permit before starting the job and display at job site.
5.1.3.Barricade work area and only concerned working crew shall be allowed inside the area.
5.1.4.Use only Tested and certified Lifting /Rigging tackles i.e chain block, lever block, slings,
belts, eye bolts, D-shackles etc. as SHEM-08.06.
5.2. Health
5.2.1.Use only appropriate Maintenance Tools for disassembly and assembly as per SHEMS
08.07. Special tools as stated by OEM shall be used whenever applicable.
5.2.2.Use PPE’s compatible with the fluid handled, as per SHEMS 08.08.
5.2.3.Use appropriate PPE & scaffolding while working at height as per the SHEMS 08.09.
5.2.4.Handle lubricants and aerosol sprays carefully as these are flammable materials.
5.2.5.Prohibit use of open flames while dismantling equipment parts at site.
5.2.6.Ensure condition of hydraulic oil hose or tubing, fittings and hydraulic piston in good
conditions in case of any hydraulic jacks are used to avoid injuries due to leak of high
pressure oil.
5.2.7.Ensure hydraulic oil hose rating is compatible for the pressure required and pressure gauge
used shall be calibrated.
5.2.8.Make sure that a standby man is presence during hot works (whenever applicable) to avoid
fire.
5.2.9.Before start of equipment dismantling, it is absolutely necessary to verify the following:

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

5.2.9.1. Equipment internals are completely purged until Exposivity is NIL (whenever
applicable).
5.2.9.2. Equipment is depressurized by opening casing drains.
5.2.9.3. Suction and discharge valve were fully closed.
5.2.9.4. Equipment has cooled down to nearly ambient temperature.
5.2.9.5. Electrical breaker/Module has been disconnected and LOTO (Lock out / Tag out)
requirements are fulfilled.

5.3. Environment
5.3.1.In case of any chemical/hazardous waste leakage to the ground or atmosphere, inform
Environment Engineer and dispose in accordance to the SAFCO Environment procedures.
5.3.2.Keep water hose ready at site in case of any exposure.
5.3.3.Keep oil spill kit ready at site in case of any spills.
5.3.4.Dispose of hazardous waste generated during the work as per SAFCO Environment
procedures.

6. Requirements
 LSR: Life Saving Rules – is a set of critical EHS Rules associated to high risk activities, if
violated may lead to serious consequence. These rules shall never be broken.

Rule Reference SHEM

Safe Systems of Work SHEM 08.00

Confined Space Entry SHEM 08.10

Safety at Height SHEM 08.09

Lifting Operations SHEM 08.06

Energy Isolations SHEM 08.05 & SHEM 08.10

Disabling Safety System SHEM 07.08

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

Created Openings SHEM 08.09

Vehicle Safety SHEM 08.01

Line Breaks SHEM 08.10

Management of Change SHEM 09.00 – SHEM 06.00

6.1 Safety Concerns

6.1.1 Many vehicles and equipment working in same area.
6.1.2 Pedestrians working nearby vehicles.
6.1.3 Working with Riggers
6.1.4 Working at height
6.1.5 Working with rotating equipment
6.1.6 Electrical hazards (Line breaks)
6.1.7 Lifting operation
6.1.8 Disabling safety system
6.1.9 Ammonia/Dust inhalation
6.1.10 Eye and Skin Irritation
6.1.11 Heat stress
6.1.12 Slips, Trips & Fall

6.2 Safety Requirements

6.2.1 Company uniform (Fire resistant)
6.2.2 High visibility Workwear
6.2.3 Hard Hat
6.2.4 Safety Glass (indoor/outdoor)
6.2.5 Steel toed Safety Shoes
6.2.6 Dust Mask (Full face mask when needed)
6.2.7 Hand gloves (as per HSE standards)
6.2.8 Safety harness for working at heights.

7. Other requirements
7.1.1.Supervisor assigned for the job shall have clear instructions on the scope of works, duration
and aware about the equipment problems and history.
7.1.2.Personnel involved in the job must be well trained and wearing required PPEs.

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

7.1.3.Ensure that all required resources (spareparts, tools, manpower, etc.) for the job are
available.
7.1.4.Overhauling works shall be supervised by OEM Representative or SAFCO Specialist.
7.1.5.Ensure proper communications between concerned parties to ensure safety and quality of
jobs done within estimated timeline.
7.1.6.Erect a proper scaffolding whenever required during assembly/disassembly. Ensure proper
tagging on scaffolding before use.

8. Spares, Tools & Special Consumables:

8.1.1.SPARES
8.1.1.1. Refer to SAP and Micro Data Reference Manual.
8.1.2.TOOLS
8.1.2.1. Use only calibrated Precision Instruments to carry out critical dimensional
checks.
8.1.2.2. Special tools supplied by OEM as per Special Tools List shall be made available
and ensure in good condition.
8.1.2.3. Appropriate tools and consumables as required for the job should be made ready.

9. General Information
9.1.1. Before proceeding with the job, review the following preparations:
9.1.1.1. Clean area around the equipment that has to be disassembled.
9.1.1.2. Ensure all equipment parts are protected from dust exposure or other foreign
material.
9.1.1.3. Mobilize all the required tools, tackles and materials on site near the equipment
at the designated area.
9.1.1.4. Ensure equipment was handed over by Operations to Maintenance after
shutdown procedure completed.
9.1.1.5. Allow equipment to cool down to nearly ambient temperature and lube oil
circulation was stopped.

10. Before Execution

S/N ACTIVITY DESCRIPTION RESPONSIBLE

Carry out Mechanical/Electrical isolations as per JSA Operation’s Supervisor (OS) Electrical
1.
requirement. Supervisor (ES) Maintenance Supervisor

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

(MS)

Removed insulation (whenever applicable). Fulfill requirement

2. Services Supervisor (SPS)
of specialized skilled manpower for handling the equipment.

11. During Execution

S/N ACTIVITY DESCRIPTION RESPONSIBLE
Maintenance Supervisor (MS)
Ensure that all Mechanical, Instruments and Electrical works
1. Instrument Supervisor (IS)
have been done as per SMP procedure.
Electrical Supervisor (ES)

2. Fill all Quality Assurance Checklist related to the SMP. Engineers/Supervisors/Technicians

12. After Execution

S/N ACTIVITY DESCRIPTION RESPONSIBLE
Mechanical Supervisor (MS)
1. Returned all unused spares to store through proper procedure.
Maintenance Planner (MP)
Carried out housekeeping upon completion of works and disposed Mechanical Supervisor (MS)
2.
scrap as per SAFCO procedure. Technicians

3. Fixed back insulation as required (whenever applicable). Services Supervisor (SPS)

Scanned and attached filled Quality Assurance Checklist to SAP Mechanical Supervisor (MS)
4.
order. Maintenance Planner (MP)
Operations Supervisor (OS) Electrical
Ensure that all Mechanical and Electrical Isolations have been
5. Supervisor (ES) Maintenance Supervisor
normalized.
(MS)

13. Process / Step- by- Step Methodology:

STEP S/N ACTIVITY DESCRIPTION RESPONSIBLE REMARKS

ACTIVITY 13.1 PREPARATIONS:

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

1
Visit working area and identify the location for tools, consumables, and
1. parts after removal. Plan for dismantling works requirement i.e.
scaffolding erection, cranes etc.

2. Identify any hazards or obstructions around the working area.

Prepare special tools required as per OEM special tools list and ensure
3.
all the tools are in good condition and usable.

Prepare all standard tools and consumables required for the job and shift
4. to the identified location nearby working area. Plastic boxes and bags
are recommended for temporary storage of removed parts.

Prepare lifting tools as required and ensure all lifting tools certificate are
not expired.
Cautions:
5.  Only use appropriate lifting tools capacity during lifting.
 Use soft padding under the sling/wire rope to protect the MS

machine surface.
 Refer OEM lifting procedure (shall any) for proper lifting.

Prepare precision measurement tools as required and ensure all precision

6.
tools being used are calibrated.

Shall hydraulic tools are required, ensure hydraulic tools i.e hydraulic
hose or tubing, fitting and hydraulic cylinder are in good condition.
7.
Pressure gauge must be calibrated and appropriate for the pressure
required.

When disassembling and assembling parts on the floor, use protective

8.
blocks under the part to protect the part surfaces and prevent rolling.

After disassembly, apply temporary appropriate rust prevention material

to the uncovered surfaces such as shaft journals, mating faces etc.
9.
Caution:
1. All threads shall be properly protected from damage.

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

STEP S/N ACTIVITY DESCRIPTION RESP. REMARKS

ACTIVITY
13.2 PRELIMINARY ACTIVITIES:
2
Ensure electrical source is isolated as per Log Out Tag Out
1.
(LOTO) requirement. MS
Ensure protective devices were removed and inspected in OS
2.
good condition (whichever applicable).

3. Disconnect all respective instrumentation cables and probes. IS

ACTIVITY DISASSEMBLY AND REASSEMBLY OF DRIVE DRUM, RETURN DRUM AND BELT
13.3
3 REPLACEMENT:

1. REMOVAL OF DRIVE DRUM AND RETURN DRUM:

Carry out removal of driven drum and return drum as the MS

following:

1. Decouple the gearbox from motor by removing the

half flange of fluid coupling connection.
Refer Activity 9.6.2 (in reverse order).

2. Remove screw and locking bush to release the

gearbox hollow shaft from the drive drum shaft.
Refer Gearbox Drwg attached for details.

3. Unbolt the gearbox base bolts and carefully slide out

gearbox.
Refer Activity 5 for gearbox overhauling procedures.

4. Remove the belt tension be loosening the tension

weights.

5. Separate the belt at joints and carefully pullout the

old belt.
6. Unscrew the upper part of the pillow block bearing
housing and remove the cover.
7. Carefully pullout tensioning sleeve nuts and roller

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

bearings from shaft.

8. Repeat the same process with other pillow block
bearings.
9. Carefully lift the shaft with drive drum by holding it
from both sides by chain blocks.
Caution during lifting not to damage bearings and drum.

10. Shift the drum from its place and keep it in a safe
place.
11. Inspect drive drum thoroughly for any visible
damages.
12. Inspect pillow block for any damages, carry out
thorough cleaning.

STEP S/N ACTIVITY DESCRIPTION RESP. REMARKS

13. Inspect the bearings, replace if needed. MS

14. Carry out same procedure for return drum

replacement.

15. Carefully remove the return drum out and keep in a

safe place.
16. Inspect the shaft for any damages specially at bearing
area.
Clean shaft by using Scotch Brite not to damage shaft
surface.

17. Inspect the bearings, packing rings and lock nut.

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

Replace if needed.
18. Installation of both drive drum and return drum shall
be in reverse order of the disassembly procedure.

Remarks:

 During installation, take extra care so that

bearing area on shaft is not damaged.
 Carefully install bearings on both ends of the
shafts. Bearing heating shall NOT more than
120°C.
 All O-ring shall be replaced new.
 Fix back top cover of pillow blocks after
installation of packing rings.
 Install tensioning assembly for return drum.
Take extra care during bearing installation.

2. BELT INSTALLATION:

Carry out belt installation as the following:

1. After both the drums have been installed completely

along with pillow blocks, shift the new belt roll to
site.
2. Put belt roll behind return station and align it.
3. Bolt the clamping plates to the edge of the belts.
4. Fix a rope winch in front of drive station. MS
5. Fix one end of the rope to the clamp.
6. Make sure that the front of belt (at which clamping
plate was attached initially) is properly laid on the
return drum.
7. Pull the belt towards the drive drum until clamping
plate reaches the drum.

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

STEP S/N ACTIVITY DESCRIPTION RESP. REMARKS

8. Shift the rope winch to the return station and fix it. MS
9. Roll the belt over the drive drum.
10. Pull belt end towards return station to the point where
both belt ends could be vulcanized.
 Do not subject the belt to excessive

stretching stress when it is being pulled by

the wire.
 Tension the belt by means of two rope

winches so that the belt will not sag more

than 1%.

11. Join both belts by vulcanization.

12. Install carrying idler frames carefully after
vulcanization is complete.
 Make sure all bolts of carrying idlers are

tightened as per required torque.

13. Tension the belt properly, refer to Activity 4

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

ACTIVITY 4 13.4 CONVEYOR BELT CENTERING / ALIGNMENT:

13.4.1 ALIGNMENT /CENTERING BY ADJUSTING THE GUIDE AND RETURN ROLLERS

1. Empty the belt and run at least 3-4 complete runs and MS
observe the belt for sway.
2. Confirm whether total belt is shifting on one side or
only in particular area or spans then proceed for the
adjustment.
3. In this method select a span of guide rollers and
return rollers little more than the area where belt shift
is observed.
4. Loosen the bracket holding bolts of the guide roller
and return roller one by one and adjust the angle of
the brackets depending on the direction of belt shift
required.
5. Repeat the same activity for all the rollers in the
observed span.
6. After every small correction observe the belt sway
for 1-2 complete runs and then proceed for the next
correction.
7. Repeat same correction activity until the belt is
running in the center and perpendicular to the rollers
and pulleys.
8. Observe 2-3 complete runs of the belt after correction
and ensure that the belt in running in center and clear
for loading of the belt.

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

9. Observe the belt in loaded condition and confirm that

it is running in center to conclude the adjustment.

STEP S/N ACTIVITY DESCRIPTION RESP. REMARKS

13.4.2 ALIGNMENT /CENTERING BY ADJUSTING THE TAIL END PULLEY:

1. Empty the belt and run at least 3-4 complete runs and MS
observe the belt for sway.
2. Confirm whether total belt is shifting on one side or
only in particular area or spans then proceed for the
adjustment.
3. In this method observe that the distance of the belt
whether is equal on both sides of the tail end pulley or
not and then decide to adjust.
4. Loosen the adjusting screws on either side of the tail
end pulley bearing Plummer block one by one and
move the tail end pulley Plummer block depending on
the direction of belt shift required.
5. After every small correction observe the belt sway for
1-2 complete runs and then proceed for the next
correction.
6. Repeat same correction activity until the belt is
running in the center and perpendicular to the rollers
and pulleys.
7. Lock the bearing Plummer block adjusting screw’s
lock nuts to ensure that the alignment does not
disturb.
8. Observe 2-3 complete runs of the belt after correction
and ensure that the belt in running in center and clear
for loading of the belt.

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

9. Observe the belt in loaded condition and confirm that

it is running in center to conclude the adjustment.

13.4.3 ALIGNMENT /CENTERING BY ADJUSTING THE BELT TAKE UP PULLEY:

1. Empty the belt and run at least 3-4 complete runs and
observe the belt for sway.
2. Confirm whether total belt is shifting on one side or
only in particular area or spans then proceed for the
adjustment.
3. In this method observe that the distance of the belt
whether is equal on both sides of the belt take up
MS
pulley or not and then decide to adjust.
4. Loosen and remove the adjusting pin from the hole of
guide plate and shift the pin to the next hole on either
side depending on the direction of belt shift required.
5. After shifting the pin to the next hole on either side
observe the belt sway for 1-2 complete runs and then
proceed for the next correction.

6. Additionally, depending upon the requirement, the weights

below the take up pulley also can be varied on either side to
shift the belt in the required direction.
7. Repeat same correction activity until the belt is running in
the center and perpendicular to the rollers and pulleys. MS

8. Observe 2-3 complete runs of the belt after correction and

ensure that the belt in running in center and clear for loading
of the belt.
9. Observe the belt in loaded condition and confirm that it is

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

running in center to conclude the adjustment.

13.4.4 ALIGNMENT /CENTERING BY ADJUSTING THE HEAD END PULLEY:

1. Empty the belt and run at least 3-4 complete runs and
observe the belt for sway.
2. Confirm whether total belt is shifting on one side or only in
particular area or spans then proceed for the adjustment.
3. In this method observe that the distance of the belt whether
is equal on both sides of the head end pulley or not and then
decide to adjust.
4. Loosen the adjusting screws on either side of the head end
pulley bearing Plummer block one by one and move the
head end pulley Plummer block depending on the direction
of belt shift required.
5. After every small correction observe the belt sway for 1-2
complete runs and then proceed for the next correction.
6. Repeat same correction activity until the belt is running in MS

the center and perpendicular to the rollers and pulleys.

7. Lock the bearing Plummer block adjusting screw’s lock nuts
to ensure that the alignment does not disturb.
8. Observe 2-3 complete runs of the belt after correction and
ensure that the belt in running in center and clear for loading
of the belt.
9. Observe the belt in loaded condition and confirm that it is
running in center to conclude the adjustment.

In some misalignment cases, a combination of different centering

methods can be combined to center the belt depending upon the
severity of the misalignment.

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

STEP S/N ACTIVITY DESCRIPTION RESP. REMARKS

ACTIVITY OVERHAULING OF GEAR REDUCER (IF APPLICABLE),

13.5
5 MODEL: MRC1 125-U02A-160M4-B3/87.5, ROSSI

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

MS
Refer Gear Reducer Drawing attached.

1. Decouple the gearbox from motor by removing

the half flange of fluid coupling connection.
Refer Activity 9.6.2 (in reverse order).

2. Remove screw and locking bush to release the

gearbox hollow shaft from the drive drum shaft.
3. Shift gearbox to SAFCO workshop.
4. Drain oil from gear box and open the inspection
cover.

5. Check shaft end float for hollow shaft:

a. Fix dial indicator on face of hollow shaft at
one end.
b. Then push the hollow shaft fully on either of
the ends and set the dial at zero.
c. Then push slowly with soft metal or mallet
the hollow shaft from the opposite side and
measure the shaft end float clearances on the
dial and record it.

6. Loosen the bolts connecting the bearing caps and

the gearbox casing.
7. Remove any dowel pins if any in the parting
plane and loosen the parting plane bolts
connecting the top and bottom half of the gear
box casing.
8. Using suitable, tested, and certified slings and
crane, lift the upper half of the gear box casing.
9. Fix back the bearing end covers and tighten its
bolts.

10. Check shaft end float for pinions shaft and

intermediate shaft one by one:
a. Fix dial indicator on suitable place of pinion

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SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

at one end.
b. Then push the pinion fully on either of the
ends and set the dial at zero.
c. Then push slowly with soft metal or mallet
the pinion from the opposite side and measure
the shaft end float clearances on the dial and
record it.

11. Check gear backlash between all mating gears:

a. Fix dial indicator in a suitable place on the
gear to measure the back lash and set the dial
in zero position.

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

b. Using a crowbar slightly move the gear ensuring MS

that other mating gear does not move and record
the backlash.
12. Check gear contact between all mating gears by using
“prussion blue” paste.

13. Loosen the bolts connecting the bearing caps and the
gear box casing.
14. Using a soft nylon rope lift the low speed hollow shaft
along with the gear wheel.
15. Using a soft nylon rope lift the pinion shaft along with
gear wheel.
16. Then remove the intermediate shaft (input pinion).
17. Remove all shaft seals and clean its housings.
18. Carefully remove all the bearings from the shafts.
Then clean thoroughly all the removed parts and gear
box internals.

19. Inspect all the removed parts like the gear box casing,
gears, oil seals, pinions and shafts for any damages
and replace with new ones wherever found damaged.
 Replace all the oil seals irrespective of the
condition of the old oil seals.
 Replace all anti-friction bearings. Caution
during installation, heat bearing NOT more
than 120°C.

20. Measure and record all the assembly dimensions

using appropriate measurement tools to confirm the
fit/tolerances.
21. Examine the gear teeth for any wear, corrosion,
cranks, flaking or chipping.
Carry out dye-penetrant test to ensure no relevant
indication on gear teeth.

22. Measure and record run out of all the shafts and

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SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

pinions.
23. Before starting assembly confirms that the gears are
of matched sets, generally four number figures etched
on the gears.

Assemble the gear box in the reverse order of dismantling.

1. Before fixing the gear box casing top half check,
confirm and record the shaft end floats, gear
backlash and gear contact as explained in Step 5,
Step 9, Step 10 and Step 11 above.

2. After carrying out above checks, fix back the

casing top half and tighten its bolts.

3. Then fix back bearing end caps and tighten its bolts MS
connecting the bearing end caps and gearbox casing.
4. Fix back the gearbox casing covers to complete gear
box assembly.
5. Shift gearbox to site and install back on location.
6. Check the hollow and machine shafts to ensure that
seats and edges are not damaged.
7. Coat with a suitable lubricant to prevent frictional
corrosion of the contact surfaces.
The hollow shaft must be exactly aligned with the machine
shaft to avoid canting.

8. Carefully install gearbox onto drive drum shaft.

9. Secure the hollow shaft axially on the drive drum shaft
with locking ring and end plate.
10. Make sure gearbox is properly aligned, tighten the base
bolts.
The values punched into the alignment surfaces must always
be observed during alignment.

11. Align motor with gearbox, install back fluid half flange

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

coupling as per Activity 13.6.2.

ACTIVITY
13.6 OVERHAULING OF FLUID COUPLING (IF APPLICABLE),
6
DISASSEMBLY FLUID COUPLING FROM ELECTRIC MOTOR AND BEARING
13.6.1
REPLACEMENT:

STEP S/N ACTIVITY DESCRIPTION

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

Disassemble Fluid Coupling as the following steps:

1. Drain the oil from coupling by unscrewing the plug on

cover and fusible plug.

MS

2.
Open screws and lock washer to remove fill chamber.

3. Remove the fixing screw along with washer. MS

4. Insert a long-threaded screw of size M20 into the tapped hole at

the end of the fluid coupling and slowly tighten the screw.
Refer figure 8 above.

5. Gradually tighten the screw until the coupling is released from

the shaft.
Refer Table K, B & E

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Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

Do not force the coupling during its removal to avoid any damage
to the shaft.

Refer figure 16 attached.

6. Unscrew nuts (item 11) and remove screws and washer.
7. Insert two screw drivers through the slot between the bearing
carries (item 14) and cover (item 3) and act to push bearing
for Tightening
carrier and seal (item 15) out.
Torque during
8. Unlock nuts to remove screws and lock washer (item 8 ~ 10). Assembly.
9. Gently tap on cover (item 3) to remove it.
10. Remove ball bearing (item 16) using extractor and oil retainer
(item 47).
11. Remove snap ring (item 18).
12. Remove inner impeller (item 1) carefully.
13. Remove screws (item 9) and plate washer (item 17).
14. Gently tap on the shaft to slide out the bearing carrier along
(item 23) with the seal (item 20).
15. Inspect all the removed parts carefully.
16. Check bearing condition replace as required.
Assembly procedure is exact reverse of disassembly procedure.

13.6.2 INSTALLATION OF FLUID COUPLING WITH ELECTRIC MOTOR AND GEARBOX:

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

MS

Reassemble Fluid Coupling as the following steps:

STEP S/N ACTIVITY DESCRIPTION RESP. REMARKS

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

1. Fit the coupling on the motor shaft by using a long-threaded screw MS

of size M20 and using 2 wrenches (hold “a” to avoid shaft rotation
and turn “b” to draw the coupling on the motor shaft). Refer
Figure 1a.
2. Lubricate the connecting surfaces with oil or anti-seize paste.

3. Fit
half coupling (item 29, Figure 4) on driven shaft (Gearbox), taking
care that the shaft end does not protrude beyond face “X”.
4. Fit the fixing screw and the washer holding the motor shaft still.
Lock the fixing screw with a torque value as per Table A1 and A2.
5. Lock and peg the driven machine, position the motor as far as the
gap “k” in Figure 4 above; the angular gap with a feeler by

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

rotating the coupling at 4 points 90° apart, the misalignment

should not more that value in Table C.

STEP S/N ACTIVITY DESCRIPTION RESP. REMARKS

13.6.3 FLUID COUPLING FILLING INSTRUCTION:

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

Filling oil for Fluid Coupling as the following steps: MS

1. Position the coupling axis horizontally, turn it until the

“X” mark cast into the housing gets at the top vertical
(maximum fill), so that the oil plug (item 13) is inclined
as shown in the Figure 6 below.

2. Fill with oil until it overflows out of the filler hole. While
filling, gently rock the coupling on its axis to make sure
all air excess is vented out of the circuit or if possible,
remove also the cap located in correspondence on the
other rotor. Refer required quantity of oil in Table D1.

3. Screw the cap (or both caps) at the prescribed torque

(Table E) and make sure no leakages occur; otherwise use
thread sealant on filler plug thread.

4. The filling mark X-1-2-3-4, with maximum fill X , a

condition of minimum slip and maximum performance is
achieved. The starting torque / nominal torque ratio gets
higher (values generally comprised between 1.8 ~ 2.0);
decreasing the oil quantity inside the coupling (fill 1-2-3-

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

4), the opposite result is obtained.

5. Type of oil recommended is only ISO HM 32 (or

equivalent SAE 10W). Refer Table D.

STEP S/N ACTIVITY DESCRIPTION RESP. REMARKS

ACTIVITY 7 13.7 PREVENTIVE MAINTENANCE:

Carry out preventive maintenance inspections as the MS

following:

1. Clean/clear for any deposition at foot station.

2. Clean/clear for any deposition at drive station.
3. Clean/clear for any deposition on idler frames.
4. Check and adjust the belt tension.
5. Grease all the pillow block bearings of the drums.
6. Check the belt centering at top and bottom drums
and center it if required.
7. Check the condition of idler frames, replace
damaged frames.
8. Check condition and level of oil in the gear box and
either top up or replace the oil with new one and
correct grade.
9. Check condition and level of oil in the fluid coupling
and either top up or replace the oil with new one and
correct grade.
10. Check for any oil leaks and attend the leakages if

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

any.
11. Clean any deposition on the gear box and motor.
12. Check alignment between gearbox and motor.
13. Ensure all the protective devices are in good
condition and re-installed before started
operation.

14. Records Involved

 Check list
 Belt Conveyor General Arrangement Drawing
 Belt Conveyor Bearings Lubricant Chart
 Belt Conveyor Datasheet
 Belt Conveyor Gearbox Drawing
 Gearbox Tightening Torque Table
 Coupling Troubleshooting

15. Attachments

S/N DOCUMENT REF. # ATTACHMENT

1. Check list SMCL-5-L-202

Belt Conveyor General

2. EDMS
Arrangement Drawing

BOOK & VOLUME #: 37_0.01

Belt Conveyor Bearings
3. DOCUMENT #: SF4-453-M1-VE-0002-023
Lubricant Chart

4. Belt Conveyor Datasheet EDMS

SAP# Material Code# 111237

Belt Conveyor Gearbox Model No: RC1 160-U02A-R15.5 B3
5.
Details

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Classification: General Business Use

SAFCO-II
Maintenance Department - (Elect / Mech / Inst)
BELT CONVEYOR (EQUIPMENT #: 5 - L – 202)
(Subject)

BOOK & VOLUME #: 37_0.01

Gearbox Tightening Torque
6. DOCUMENT #: SF4-453-M1-VE-0002-023
Table

BOOK & VOLUME #: 37_0.01

7. Coupling Troubleshooting DOCUMENT #: SF4-453-M1-VE-0002-014

16. Revision History

Revision History

Rev. No. Date Description of Changes

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