Jansen TBDJ001-0500X Series Installation Manual Download

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Trough-shaped manure removal belts

Part 1: Installation order

Read before installation

Edition
English (translation of original
manual)

Revision
G

Revision date
1-4-2020

No.
DOKJ005600-023-01EN

Summary of Contents for TBDJ001-0500X Series

Page 1: ...Trough shaped manure removal belts Part 1 Installation order Read before installation Edition English translation of original manual Revision G Revision date 1 4 2020 No DOKJ005600 023 01EN ...

Page 2: ...e and may vary from reality depending on the situation This is especially the case for the side plank supports and the legs Icons in this manual These icons have been used at several places in this manual This is their meaning General NOTE Idea Safety Service and technical support If necessary contact Jansen Poultry Equipment for further information and support Telephone 0031 0 342 427 000 Fax 003...

Page 3: ... 2 7 Mounting the supporting rollers and tensioning the transport belt 22 2 8 Mounting the leg under the elevating part belt with knee joint 23 2 8 1 Fixed leg 23 2 8 2 OPTION instead of leg suspension 24 2 9 Mounting the return unit support 24 2 9 1 Mounting the swivel base rotatable elevating belt 24 2 9 2 Mounting the wheel set movable elevating belt 25 3 Mounting the manure guiding parts 26 3 ...

Page 4: ... 5 6 Wall transit horizontal belt 41 6 Finishing the elevating belt 42 6 1 Mounting the upper arch 42 6 2 Placing the leg under the elevating belt 43 6 2 1 Fixed leg and accompanying buttress set 43 6 2 2 Rotatable leg rotatable belt 46 6 2 3 Movable leg movable belt 48 7 Commissioning of the manure removal belt 49 Original Dutch manual ...

Page 5: ...anure elevating belt and the horizontal manure removal belt with knee joint 1 Manure belt 2 Return roller cage roller 3 V shaped scraper 4 Troughed idler 5 Supporting roller 6 Leg standard suspension from wall with wall supports is also possible 7 Cover for drive motor 8 Drive roller cage roller 9 Scraper Moving direction of upper part of belt Moving direction of returning part of belt Return side...

Page 6: ...ith knee joint 1 Cover for drive roller 2 Cover for drive motor 3 Adjustable leg 4 Pressure roller of knee joint 5 Supporting roller 6 HDPE guide plate for transport belt 7 Emergency pull cord 8 Emergency pull cord switch 9 Knee joint Figure 1 3 Option flat collector funnel on return side Drive side ...

Page 7: ...s A swivel base under the collector funnel Option movable manure elevating belt The leg has wheels A wheel set instead of the swivel base Figure 1 4 Manure elevating belt 1 Emergency pull cord 2 Emergency pull cord switch 3 Collector funnel 4 Rubber flaps 5 Bracing strips 6 Leg 7 Swivel base 8 Lifting plates 9 Option chute for falling manure Return side Drive side ...

Page 8: ...erflow cap of the elevating belt BW500 ZMMT014762 825 Dump tube incl fastening material for elevating belt BW500 ZMMT014762 831 Small leg elevating belt BW500 ZMMT014762 832 Buttress set for small legs of elevating belt BW500 ZMMT014762 833 Buttress set for upper arch of elevating belt BW500 up to and including a length of 12 8 m ZMMT014762 834 Lifting plate set for elevating belt ZMMT014762 835 L...

Page 9: ...y cord ZMMT014762 855 Downwards knee joint complete BW500 ZMMT014762 856 Roof suspension horizontal belt for longitudinal purlins ZMMT014762 857 Roof suspension for combination with one fixed point ZMMT014762 858 Suspension set for elevating part for two suspension points in the manure storage ZMMT014762 859 Leg straight height 2250 3550 for elevating belt ZMMT082060 Suspension set manure belt ZMM...

Page 10: ...f the return unit is 1 5 m The amount of meters of middle part M This part consists of a number of middle sections that are available in four lengths 1 5 m 2 m 2 5 m and 3 m Figure 1 6 Meters of middle part in case of a manure elevating belt measurements in meters L total length M meters of middle part Figure 1 7 Meters of middle part in case of a belt with knee joint measurements in meters M mete...

Page 11: ...t with knee joint or the elevating belt In these cases the belts to which the information in the section is applicable is added behind brackets and in italics behind the name of the section When no specific version is mentioned the information is applicable to all manure removal belts 1 5 Required tools for installation 2x socket wrenches and or ring spanners no 8 10 13 17 19 Grinder Drill Metal d...

Page 12: ... 809 810 811 812 by means of the coupling profiles 1 Read on the lay out drawing what middle sections have to be used per part of the manure removal belt what their length is and how many of each are used See also Figure 2 1 NOTE Only in case of a manure removal belt with knee joint before installation always check the manure removal belt length before and after the knee joint Keep the available l...

Page 13: ... Place all bolts and nuts loosely b Align the whole c Tighten the upper bolts and nuts in the coupling profile d Tighten the other bolts and nuts Figure 2 3 Coupling middle sections 1 Coupling profile 2 Buttress plate of troughed idler Front sides of the buttress plates at drive side ...

Page 14: ...nee joint 4 Mount a supporting roller immediately before the knee joint at the return unit side See section 2 7 NOTE Do not yet install the second supporting roller of the knee joint Install it after you installed the transport belt See section 2 6 5 Place the cover on the scraper profiles of the knee joint NOTE Before assembly always check the manure belt length after the knee joint Keep the avai...

Page 15: ...pwards knee joint Figure 2 5 Mounting the downwards knee joint 1 Parts that must be removed before and after the knee joint 2 Middle section 3 Knee joint 4 Scraper profile of the knee joint 5 Side plank supports before and after the knee joint 6 Supporting roller immediately before knee joint return unit side 7 Pressure set 8 Cover Drive unit side Return unit side ...

Page 16: ...62 201 Connect the drive unit to the middle section See Figure 2 6 1 Slide the side profiles of the drive unit and the front middle sections into each other 2 Mount the drive unit to the front middle section a Place all bolts and nuts loosely b Align the whole c Tighten the upper bolts and nuts d Tighten the other bolts and nuts Figure 2 6 Mounting the drive unit example 1 Drive unit with motor at...

Page 17: ... Leg set height 650 mm 800 mm ZMMT014762 835 Leg set height 900 mm 1050 mm ZMMT014762 847 Assemble the leg sets See Figure 2 7 NOTE In each case always place one leg set before the knee joint and one leg set at the return unit The maximal center distance of the leg sets is 3 m Figure 2 7 Mounting the legs of horizontal parts 1 Leg set 650 mm 800 mm 2 Leg set 900 mm 1050 mm Leg set before knee join...

Page 18: ...2 8 Wheel set movable horizontal belt or belt with knee belt 1 Leg 2 Swivel wheel 3 Cross profile 1 Assemble the wheel set 2 Place the legs under the manure removal belt at the distance shown in het installation drawing 3 Mount the wheel set to the manure removal belt NOTE You can mount the wheel set at two heights Mount in existing hole Drill hole in side profile ...

Page 19: ...ee Figure 2 9 1 Place the return roller as close as possible to the side of the middle sections 2 Couple the return unit by means of the coupling profiles a Place all bolts and nuts loosely b Align the whole c Tighten the upper bolts and nuts in the coupling profile d Tighten the other bolts and nuts Figure 2 9 Placing the return unit 1 Return unit 2 Coupling profile ...

Page 20: ...ction 2 7 6 Unroll the transport belt along the frame 7 Disassemble the scraper of the drive unit 8 In case of a belt with knee joint a Upwards knee joint disassemble the cover scraper profiles and pressure set of the knee joint If necessary see Figure 2 4 b Downwards knee joint disassemble the cover 9 Place the transport belt around the drive unit and around the knee joint NOTE Place the transpor...

Page 21: ... the pressure set of the knee joint See Figure 2 11 NOTE Align the transport belt when commissioning the manure removal belt Figure 2 11 Mounting the transport belt around the knee joint and drive unit 1 Drive unit 2 Scraper 3 Transport belt 4 Supporting roller before knee joint return side 5 Supporting roller after knee joint drive side 6 Cover 7 Scraper profile 8 Pressure set Side view of upward...

Page 22: ... brackets IDEA Mount the supporting rollers at one side in the slot so that the supporting rollers are almost immediately placed perpendicularly to the frame NOTE Maximal center distance of the supporting rollers is 3 m 3 Tension the transport belt The belt is correctly tensioned if it sags about 3 to 5 cm between the supporting rollers center to center distance of 3 meter Also see the user manual...

Page 23: ...l weight that is to be moved by using these weights 2 Tighten the bolts and nuts of the pivoting point of the knee joint 3 Adjust the leg set at the correct height a Fasten the upper part of the leg to the lower part of the leg b If necessary drill holes 4 Place the leg under the elevating part a Copy the holes of the upright profile of the legs onto the side profile of the elevating part b Drill ...

Page 24: ...N instead of leg suspension In some cases the elevating part is suspended from the roof ZMMT082060 instead of placed on legs Do this last See section 5 1 NOTE When applying suspension instead of a fixed leg the upper arch does not apply 2 9 Mounting the return unit support 2 9 1 Mounting the swivel base rotatable elevating belt Mount the swivel base ZMMT014762 801 of the rotatable elevating belt S...

Page 25: ... wheel set under the elevating belt a Place the legs under the elevating belt at the distance shown in het installation drawing and in Figure 2 15 b Mount the top side of the legs in the existing hole in the side profile c Copy the bottom hole of the legs onto the side profiles NOTE Maximum inclination angle is 24 d Drill the copied holes up to a diameter of Ø 10 mm e Mount the legs in the bottom ...

Page 26: ...turn roller Mount the funnel for the elevating belt Figure 3 1 or the flat funnel for the horizontal belt and the belt with knee joint Figure 3 2 1 Place the funnel on the frame 2 Mount the funnel by using the existing mounting holes Standard is on the third hole from the back of the return unit 3 Mount the protective covers 4 Put the rear rubber flap over the rubber flaps on the sides 5 Shorten t...

Page 27: ...t the side planks with each other by means of the coupling set for side planks ZMMT014762 836 a Keep the angle iron in the correct way and at the correct place against the side planks that have to be connected b Bolt the angle iron to both side planks 3 Saw off the last side planks at the point equal to the front side of the drive unit NOTE To prevent manure leakage make sure the rubber flaps of t...

Page 28: ...ts onto the side planks b Drill the copied holes up to a diameter of Ø 8 mm c Fasten the side planks to the side plank supports 3 Connect the side planks with each other by means of the coupling set for side planks ZMMT014762 836 a Keep the angle iron in the correct way and at the correct place against the side planks that have to be connected b Bolt the angle iron to both side planks 4 Saw off th...

Page 29: ... the holes of the side plank supports onto the side planks b Drill the copied holes up to a diameter of Ø 8 mm c Mount the side planks to the side plank supports 3 Mount the HDPE guide plates a Determine the position of the HDPE guide plate This is 5 mm above the transport belt NOTE The HDPE guide plates must overlap in the middle b Draw a hole in the middle of the slots of the HDPE plate c Drill ...

Page 30: ...30 Figure 3 6 Mounting the side planks at a downwards knee joint 1 Zijplank 2 Zijplanksteun 3 HDPE plaat 4 Transportband 5 mm Detail A ...

Page 31: ...1 Place the cotter pin in the axle of the drive roller 2 Slide the motor over the axle of the drive roller 3 Mount the motor on the motor plate a Place all bolts loosely b Fasten the bolts in a diagonal sequence 4 Mount the protective cover of the motor a Place all bolts and nuts at the bottom side b Place all self tapping screws at the top side Figure 4 1 Mounting the motor 1 Motor 2 Cotter pin 3...

Page 32: ... the isolating switch 2 Copy the holes onto the mounting plate 3 Drill the copied holes up to a diameter of Ø 8 mm 4 Place the isolating switch NOTE Always place the isolating switch on an easily accessible place from where the motor can be seen Figure 4 2 Placing the isolating switch Elevating belt required position of the isolating switch Horizontal belt required position of the isolating switch...

Page 33: ...on where it can easily be reset So outside of the manure pit and at an accessible height NOTE Placement outside of the manure pit mount the pull cord along the entire length of the belt so that the emergency stop can be activated from any position 3 Mount the eye bolts where necessary at the side plank supports For every middle section two eye bolts are supplied a Belt with knee joint place one ey...

Page 34: ...itch see Figure 4 3 5 Lace the emergency stop pull cable through the eye bolts and pulleys 6 Connect the emergency stop pull cable to the pull cord switch 7 Connect the emergency stop pull cable to the spring 8 Tension the emergency stop pull cable NOTE Only adjust the pull cord switch if the manure belt is placed and connected See the user manual ...

Page 35: ... installation profiles 3 Mount the manure removal belt at the correct distance from the wall on the wall supports See Figure 5 2 NOTE For the distance between the manure pit side wall and the center of the manure removal belt distance A Figure 5 2 see the layout plan Use the correct holes 1 Figure 5 2 to adjust the wall support at the correct distance NOTE To ensure free running of the belt place ...

Page 36: ...l 2 Angle profile 3 Suspension point on a purlin 4 Suspension point between purlins 5 Supporting roller 6 Buttress for suspension point on a purlin 7 Buttress for suspension point between purlins 5 1 3 Additional suspension point from wooden or steel purlins Mount the suspension ZMMT014762 857 Use this suspension additionally for all manure removal belts to cross distances of more than 5 m between...

Page 37: ...the girders 5 Connect the manure removal belt to the girders a Decide the position of the girder b Copy the holes of the girder onto the side profile of the manure removal belt c Drill the copied holes up to a diameter of 10 mm d Connect the manure removal belt to the girders NOTE To ensure free running of the belt place for each suspension a supporting roller under the closest troughed idler at t...

Page 38: ...f the covers over the manure belt on the side plank supports 3 Fasten the covers with self tappers on each side plank support 4 Elevating belts and belts with knee joint grind a small corner out of the cover next to the overflow cap see B so that it lies in the overflow cap 5 Belts with knee joint at a knee joint place the covers as close as possible against the pressure set NOTE Always mount the ...

Page 39: ...drainage strip with self tapping screws on the covers The point has to point upwards See Figure 5 9 4 Bend the small plates as indicated in Figure 5 8 Figure 5 8 Preparing the water drainage strip 1 Water drainage strip 2 Small plates break off 5 Mount the small plates that were broken off on the lowest edge of the side profile Make sure the long side extends a bit over the side profile Figure 5 9...

Page 40: ...t 2 Mount the impact plate at the desired distance Figure 5 10 Impact plate 5 5 Dump tube Mount the dump tube ZMMT014762 825 on the overflow cap See Figure 5 11 1 Mount the suspension brackets on the overflow cap 2 Mount the dump tube on the suspension brackets so that it can pivot Figure 5 11 Dump tube 1 Suspension brackets 2 Dump tube ...

Page 41: ...les of the wall transit side plate onto the manure belt side profile c Drill the copied holes up to a diameter of 8 mm d Place the side plates and the lower plate 2 Mount the upper plate on the wall 3 Cut a rubber flap as indicated in Figure 5 12 4 Mount the rubber flap on the upper plate NOTE When applying an emergency pull cord drill holes for the emergency pull cord in both side profiles Figure...

Page 42: ...sses between the upright profiles and the fastening plate 4 Mount the other buttresses to the upright profiles and fasten them to the side plank support a Drill the hole of the side plank support to a diameter of Ø 12 mm 5 Tension the buttresses by means of the cable tensioner until the buttresses are tensioned NOTE Never lift the elevating belt by means of the upper arch Figure 6 1 Upper arch 1 U...

Page 43: ... for a belt entirely on the ground ZMMT014762 850 with accompanying buttress set ZMMT014762 851 Adjustment range 75 cm Big straight leg for a belt entirely on the ground ZMMT014762 859 with accompanying buttress set ZMMT014762 832 Adjustment range 100 cm If necessary grind the outer profile of the leg to size and drill new mounting holes For the placing of the elevating belt a set of lifting plate...

Page 44: ...moved by using these weights 3 Lift the elevating belt and position the swivel base See Figure 6 2 IDEA Keep enough space around the return unit for tightening adjusting maintenance and cleaning 4 Lift the elevating belt at its front side so that it comes at the specified height or inclination angle of the layout plan NOTE Maximum inclination angle is 24 5 Position the leg under the elevating belt...

Page 45: ...ttresses f Drill the copied holes to a diameter of Ø 10 mm g Mount the connecting strip 10 Mount the buttress set between the leg and the bottom side of the elevating belt See Figure 6 5 a Mount the mounting lip on the bottom side of the elevating belt b Fasten the buttress to the mounting lip c Hold the buttress close to the leg and copy the hole in the buttress onto the upright profile of the le...

Page 46: ... on the ground ZMMT014762 839 with accompanying buttress set ZMMT014762 851 The installation order of a leg with wheels is largely equal to the installation of a fixed leg Figure 6 7 Rotatable leg for elevating belt 1 Upper part of the leg 2 Lower part of the leg 3 Cross profile 4 Wheels 5 Angle profile also see figure 6 2 7 6 D shackle Mount the wheel set under the fixed leg as shown in section 6...

Page 47: ...ound at the end of the track of the wheels so that they serve as a stop See Figure 6 9 5 Mount the D shackles on the angle profiles and to the top side of the leg See Figure 6 8 Figure 6 8 Angle profile as stop 1 D shackle 6 Mount the chains between the D shackles a Place the elevating belt with one wheel against one of the two angle profiles b Now mount and tension the chain at the opposite side ...

Page 48: ...ection 6 2 1 and Figure 6 10 1 Assemble the leg including the wheels Do not connect the lower part and the upper part yet See section 6 2 1 NOTE The position of the wheels is different than if a rotatable belt is assembled 2 Position and mount the leg as described in section 6 2 1 NOTE Keep the extra height of the wheels in mind when adjusting the height of the leg 3 Mount the cross profile betwee...

Page 49: ...lers Tension the belt according to the user manual Check if the emergency pull cord is adjusted well If necessary adjust according to the user manual Connect the motor and isolating switch according to the regulations Let the belt run for a short while so that you can check the direction of rotation and if the belt runs straight Check the operation of the isolating switch Check the operation of th...

Page 50: ...estafvoerbandlengte 10 1 4 Montagevolgorde 11 1 5 Benodigde gereedschappen voor montage 11 2 Monteren van het frame 12 2 1 Middensecties koppelen 12 2 2 Knikstuk koppelen knikband 14 2 2 1 Omhooggaand knikstuk 14 2 2 2 Omlaaggaand knikstuk 15 2 3 Aandrijfunit koppelen 16 2 4 Poten van horizontale delen monteren horizontale band en knikband 17 2 4 1 Vaste poot horizontale band en knikband 17 2 4 2 ...

Page 51: ...derstaande lijst De montagetekeningen van deze onderdelen zijn achter dit document toegevoegd L lengte BB bandbreedte kan variëren Artikelnummers TBDJ001 0500X Transportbanden EMR Aandrijfmotor VUG017X095L3000 Zijplanken FRDJ014762 202 Retourunit FRDJ014762 203 Schraper FRDJ014762 200 Aandrijving rechts B500 FRDJ014762 201 Aandrijving links B500 FRDJ014762 204 Stortbak mestopvoerband B500 FRDJ0147...

Page 52: ...t op welke banden de informatie van toepassing is Als er geen specifieke variant genoemd is is het op alle banden van toepassing 1 5 Benodigde gereedschappen voor montage 2x steek en of ringsleutels nr 8 10 13 17 19 Slijptol Boormachine Metaalboor 12 mm Stenenboor 12 mm Waterpas Handzaag Kruiskopbitje Rolmaat 12 2 Monteren van het frame IDEE Bouw de delen niet op de grond op maar op een gezonde we...

Page 53: ...en houd tijdens montage rekening met de beschikbare lengtes middensecties Figuur 2 4 Monteren omhooggaand knikstuk 1 Te verwijderen onderdelen voor en na knikstuk 2 Middensectie 3 Knikstuk 4 Schraperprofiel van knikstuk 5 Zijplanksteunen voor en na knikstuk 6 Draagrol direct voor knikstuk retourrolzijde 7 Drukset 8 Overkapping Aandrijfrolzijd Retourrolzijde 15 2 2 2 Omlaaggaand knikstuk Monteer he...

Page 54: ...en a Monteer alle bouten en moeren losjes b Lijn het geheel uit c Draai van het koppelprofiel de bovenste bouten en moeren vast d Draai de overige bouten en moeren vast Figuur 2 9 Monteren van retourunit 1 Retourunit 2 Koppelprofiel 20 2 6 Transportband plaatsen Plaats de transportband TBDJ001 0500X Zie Figuur 2 10 en Figuur 2 11 1 Plaats de retourrol zo dicht mogelijk bij de zijde van de middense...

Page 55: ...ijd voor voldoende hijskracht of draagkracht bij het ophijsen en tijdens montage Gewichten van alle losse modules staan op de montagetekeningen vermeld Bereken zo het totale te verplaatsen gewicht Figuur 2 13 Monteren van poot onder opvoerdeel knikband maten in mm 1 Bovenste deel van poot 2 Onderste deel van poot 3 Schorenset tussen poot en onderzijde opvoergedeelte 4 Scharnierpunt knikstuk 2 Draa...

Page 56: ...de zijplanken 50 mm van de voorzijde van de stortbak af LET OP Houd de bovenzijde van de zijplanken gelijk aan de bovenzijde van de zijplanksteunen Zie detail A a Teken de gaten in de zijplanksteunen over op de zijplanken b Boor de afgetekende gaten op naar Ø 8 mm c Monteer de zijplanken op de zijplanksteunen 2 Verbind de zijplanken aan elkaar met behulp van de koppelset voor de zijplanken ZMMT014...

Page 57: ...plaat 4 Transportband 5 mm Detail A 31 4 Monteren van elektrische delen 4 1 Motor monteren Afhankelijk van het type en lengte mestafvoerband worden de volgende motorvermogens toegepast 1 5 kW 2 2 kW 3 0 kW Monteer de motor EMR Zie Figuur 4 1 1 Monteer de spie in de as van de aandrijfrol 2 Schuif de motor over de as van de aandrijfrol 3 Monteer de motor aan de motorplaat a Monteer alle bouten losje...

Page 58: ...tageprofielen 2 Monteer de overige onderdelen van de muursteun aan de montageprofielen 3 Monteer de mestafvoerband op de juiste afstand van de muur op de muursteunen Zie Figuur 5 2 LET OP Voor de afstand tussen de zijkant van de put en het hart van de mestafvoerband afstand A Figuur 5 2 zie het opstellingsplan Gebruik de juiste gaten Figuur 5 2 om de muursteun op de goede afstand af te stellen Fig...

Page 59: ...overstortkap een kleine hoek weg zie B zodat deze in de overstortkap ligt 5 Knikbanden plaats bij een knikstuk de overkappingsdelen zo dicht mogelijk tegen de drukset aan LET OP Monteer de overkappingsdelen altijd zo dat er een waterdichte afdichting ontstaat LET OP Slijp indien nodig overkappingsdelen op maat Figuur 5 7 Mestbandoverkapping 1 Monteren in zijplanksteun 2 Overstortkap 3 Drukset 39 5...

Page 60: ...runit in de put ZMMT014762 831 met bijbehorende schorenset ZMMT014762 832 Verstelbereik 75 cm Grote schuine poot voor een band geheel op de grond ZMMT014762 850 met bijbehorende schorenset ZMMT014762 851 Verstelbereik 75 cm Grote rechte poot voor een band geheel op de grond ZMMT014762 859 met bijbehorende schorenset ZMMT014762 832 Verstelbereik 100 cm Slijp eventueel het buitenprofiel van de poot ...

Page 61: ...n is grotendeels gelijk aan de montagevolgorde van een vaste poot Monteer de draaibare poot en bijbehorende schorenset Zie paragraaf 6 2 1 en Figuur 6 7 1 Assembleer de poot inclusief de wielen Monteer het bovenste en onderste deel alleen nog niet aan elkaar vast Zie paragraaf 6 2 1 2 Positioneer en monteer de poot zoals in paragraaf 6 2 1 beschreven staat LET OP Houd met het op hoogte afstellen v...

Page 62: ...band volgens de gebruikershandleiding Controleer of het noodstoptrekkoord goed is ingesteld Stel de trekkoordschakelaar als nodig af volgens de gebruikershandleiding Sluit de motor en werkschakelaar aan volgens de voorschriften Laat de band kort draaien zodat de draairichting en het recht lopen van de band gecontroleerd kunnen worden Controleer de werking van de werkschakelaar Controleer de werkin...

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