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Per-Erik Jönsson Design of belt conveyor systems en M Status Subtitle Plant reference code /object
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Dependence on/from other documents Replaced by
Supplier
Dependence on/from other documents Replaced by
Design, planning, purchasing, operation and maintenance, storage Keywords Supplier’s reference designation
Instruction, code of practice
Document history Revision Date Signature Comments
01 2005-11-29 LS Instruction reworked
02 2005-12-12 MLPRJO Instruction approved
03 2005-12-29 LS Bulk density adjusted
04 2006-01-09 LS Max. inclination of conveyor and bulk density deleted
05 2006-01-10 LS Inclination and bulk density reinserted, minor revisions
06 2006-01-13 MLPRJO Document layout and Table of content revised
07 2006-01-16 MLPRJO Corrected to correspond with Swedish version; max inclination
08 2006-04-19 MLPRJO Caption “Lateral sealing system” inserted above text
09 2006-05-05 LS Safety distance between idlers and skirt plate/feed hopper added
10 2006-05-15 LS Emergency stop device and system for monitoring reworked
11 2006-05-18 LS Revision of text under caption Emergency stop devices
12 2006-06-07 LS Correction of maximum inclination in Table of Material data
13 2006-11-01 MLPRJO Recommendation of crowning inserted on page 17 Pulley shell
14 2007-08-24 MLPRJO Clarification on page 4 of demands for inclined conveyors
15 2008-04-03 KLKEHU Synchronisation between Swedish and English version
16 2008-09-23 KLKEHU Revision page 19 sentence about probe weight inserted
17 2009-04-07 MLPRJO Revision of ”Crowning of pulley shell” page. 17
18 2010-06-15 MLPRJO Caption “Safety functions” inserted, rec. on selection of sensors removed
19 2010-07-07 MLPRJO Synchronization of content in the Swedish and English version
20 2011-01-26 MLPRJO Revision under Safety function, Emergency…, System for …
21 2013-04-09 KLKEHU New logotype
22 2013-06-20 MLPRJO Caption “Guards” inserted. Additions under “LKAB’s requirements”,
“Clearance in conveyor walkways” and “Emergency stop devices for pull-
cord”. Revision of references.
23 2014-02-26 MLCHGA Additions under “System for monitoring of belt conveyor” page 25-26
24 2014-07-02 MLPRJO Ranges for dimension B and D on page 6 added.
25 2015-01-09 MLPRJO Clarification under “Carrying idlers, loading and return idlers”
26 2015-10-29 MLPRJO New caption “Misalignment”. Incorporate SveMin's demands in “Guards”
27 2017-06-29 PEJCO New caption “Selection of guards” inserted. Fire safety clarified.
Revision of references. Minor editorial changes
Translation This document is a translation from Swedish of LKAB Technical Instruction LKT 1520.540.001. In
the event of disagreement concerning the interpretation and content of this text, the Swedish version
shall have priority.
Latest revision: The latest revision of this instruction can be obtained from e-mail address:
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Table of contents
BELT CONVEYORS ....................................................................................................................................................... 3 REFERENCES ................................................................................................................................................................... 3 BACKGROUND AND PURPOSE .......................................................................................................................................... 4 DIMENSIONING ................................................................................................................................................................ 4 LKAB’S REQUIREMENTS ................................................................................................................................................. 4 MATERIAL DATA ............................................................................................................................................................. 5 BELT SPEED ..................................................................................................................................................................... 5 CONVEYOR FRAME .......................................................................................................................................................... 6
CLEARANCE IN CONVEYOR GALLERIES .............................................................................................................. 6 BACKGROUND AND PURPOSE .......................................................................................................................................... 6 REQUIREMENTS ............................................................................................................................................................... 6 SAFETY DISTANCE ........................................................................................................................................................... 7
GUARDS ........................................................................................................................................................................... 8 SELECTION OF GUARDS ................................................................................................................................................... 9 DESIGN OF GUARDS ......................................................................................................................................................... 9 PROTECTION IN CONNECTION WITH WALKWAYS ............................................................................................................. 9
CONVEYOR BELTS ..................................................................................................................................................... 11 REFERENCES ................................................................................................................................................................. 11 REQUIREMENTS ............................................................................................................................................................. 11
Fire safety for conveyor belts within LKAB’s plants in Sweden and Norway .......................................................... 11 Belt designation ........................................................................................................................................................ 11
QUALITY REQUIREMENTS .............................................................................................................................................. 12 Thickness .................................................................................................................................................................. 12 Width ........................................................................................................................................................................ 13 Length ....................................................................................................................................................................... 13 Straightness .............................................................................................................................................................. 13 Adhesion ................................................................................................................................................................... 13 Cover layers ............................................................................................................................................................. 13 Marking .................................................................................................................................................................... 14 Selection table .......................................................................................................................................................... 14 Lateral sealing system .............................................................................................................................................. 14
CARRYING IDLER, LOADING AND RETURN IDLER ........................................................................................... 15 REFERENCES ................................................................................................................................................................. 15 REQUIREMENTS ............................................................................................................................................................. 15
PULLEY .......................................................................................................................................................................... 16 CENTRE DISTANCE BETWEEN BEARING HOUSINGS ......................................................................................................... 16 PULLEY SHELL............................................................................................................................................................... 17 CROWNING OF PULLEY SHELL ....................................................................................................................................... 17 BELT MISALIGNMENT .................................................................................................................................................... 17
SCREW JOINTS IN PULLEY END PLATES ........................................................................................................... 18 GENERAL ...................................................................................................................................................................... 18 TIGHTENING .................................................................................................................................................................. 18 TORQUE ........................................................................................................................................................................ 18 TIGHTENING SEQUENCE ................................................................................................................................................. 19
End plate with a locking assembly type Ringfeder RfN 7012 ................................................................................... 19 End plate with clamp casing ..................................................................................................................................... 20
DRAWINGS OF PULLEYS, AXLES AND BEARINGS ............................................................................................................ 21 CLAMP HUBS AND CLAMP .............................................................................................................................................. 21
REQUIREMENTS FOR BEARING SPECIFICATIONS........................................................................................... 22 REFERENCES ................................................................................................................................................................. 22 BACKGROUND AND PURPOSE ........................................................................................................................................ 22 REQUIREMENTS ............................................................................................................................................................. 22
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Suppliers ................................................................................................................................................................... 22 Assembly ................................................................................................................................................................... 22 Vibration monitoring ................................................................................................................................................ 22
SAFETY FUNCTIONS .................................................................................................................................................. 23 EMERGENCY STOP DEVICES FOR PULL-CORD ................................................................................................ 23
REFERENCES ................................................................................................................................................................. 23 REQUIREMENTS ............................................................................................................................................................. 24 ASSEMBLY AND INSTALLATION OF EMERGENCY STOP DEVICES ..................................................................................... 24
SYSTEM FOR MONITORING OF BELT CONVEYOR ........................................................................................... 25 SYSTEM FOR MONITORING OF BELT SPEED, BREAKAGE, SLIPPAGE AND TENSIONING ..................................................... 25 SYSTEM FOR BELT ALIGNMENT MONITORING ................................................................................................................ 25 ADVANCED SYSTEMS FOR INCREASED BELT MONITORING ............................................................................................. 26 SYSTEM FOR MONITORING OF LEVEL IN CHUTE ............................................................................................................. 26 SYSTEM FOR POSITION MONITORING ............................................................................................................................. 26
GEAR BOXES ............................................................................................................................................................... 27 DRAWING INDEX OF ALL BELT CONVEYOR COMPONENTS ......................................................................... 28 SUGGESTIONS FOR IMPROVEMENTS .................................................................................................................. 29
Belt conveyors References EN 620 Continuous handling equipment and systems - Safety and EMC requirements for
fixed belt conveyors for bulk materials
EN 620 does not meet all of LKAB’s safety requirements for fixed conveyor systems. LKAB therefore
place higher demands on conveyors in its plants than EN 620 specifies. If the requirements in the
directives or harmonised standards exceed the requirements in this instruction, then the directives always
have precedence over the contents of LKAB’s instructions.
ISO 1819 Continuous mechanical handling equipment - Safety code - General rules
SS 2888 Continuous mechanical handling equipment - Belt conveyors - Idlers
EN 954-1 Safety of machinery - Safety-related parts of control systems - Part 1: General
principles for design. Replaced by EN ISO 13849-1. If the requirements of a type C
standard refer to a dated standard, only the requirements of the edition cited apply.
EN-ISO 13849-1 Safety of machinery - Safety-related parts of control systems - Part 1: General
principles for design.
EN-ISO 13849-2 Safety of machinery - Safety-related parts of control systems - Part 2: Validation
EN ISO 13850 Safety of machinery - Emergency stop - Principles for design
EN 62061 Safety of machinery - Functional safety of safety-related electrical, electronic and
programmable electronic control systems
EN ISO 13857 Safety of machinery - Safety distances to prevent hazard zones being reached by
upper and lower limbs
EN ISO 14120 Safety of machinery - Guards - General requirements for the design and construction
of fixed and movable guards
EN ISO 14122-1 Safety of machinery - Permanent means of access to machinery - Part 1: Choice of
fixed means of access between two levels
EN ISO 14122-2 Safety of machinery - Permanent means of access to machinery - Part 2: Working
platforms and walkways
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EN ISO 14122-3 Safety of machinery - Permanent means of access to machinery - Part 3: Stairs,
stepladders and guard-rails
EN ISO 14122-4 Safety of machinery - Permanent means of access to machinery - Part 4: Fixed
ladders
EN 60034-1 Rotating electrical machines - Part 1: Rating and performance
SveMin SveMin’s instruction for vehicles, machinery and technical equipment
LKT 1520.540.013 Calculations - Belt Conveyors (Only in Swedish)
Background and purpose
LKAB strives to follow international standards as much as possible and in our Technical instructions,
called LKTs, the company’s specific requirements and interpretations of standards are precisely
defined. The instructions also express the company’s experience as well as giving information on
LKAB’s choice of alternative solutions within standards.
LKAB can also state requirements that are higher than those found in standards. By following this
instruction, LKAB’s requirements are fulfilled.
LKAB has a long and sound experience of transporting material on conveyor belts, which has led
LKAB to develop this instruction for how conveyor systems should be built in order to obtain fully
acceptable quality and function in a plant.
Dimensioning
The supplier is responsible for dimensioning of belt conveyors. LKAB has developed
recommendations for dimensioning of belt conveyors, instruction LKT 1520.540.013 "Conveyor
Instruction - Calculations".
LKAB’s requirements
LKAB's requirement is that the safety of belt conveyors must meet the level of protection that is
expressed in standard EN 620 and this technical instruction. The requirements of EN 620 and this
instruction are also applicable for use underground at LKAB. For potentially explosive atmospheres,
additional requirements apply. Note that conveyors within LKAB can operate at much lower or higher
ambient temperature than the standard covers and the conveyors therefore must be adapted to current
temperature ranges.
The need for safety equipment shall be assessed case by case, after risk assessment, if the inclination
and the amount of goods being transported can pose a danger of personal injury or plant damages, if
the driving force ceases to function.
In order to prevent conveyor belts from rolling forwards or backwards all inclined conveyors, in
which the transported load through its movement or potential energy could cause an increase in speed,
shall have a safety mechanism which is triggered if the driving force ceases to function. LKAB
requires that the safety mechanism must include a backstop and disc brake.
Dimensioning of the safety mechanism is performed by the conveyor supplier.
For safety functions on a belt conveyor we refer to chapter "Safety Functions"
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Conveyor systems shall be built of objects with set standard dimensions for bearing spacing, axles,
rollers, width across flats, etc. so that interchangeability is achieved regardless of manufacturer or
supplier and so that conveyor-related spare parts inventories can be minimised.
Material data
Data are indications only and shall be verified for each and every project.
Material Material
size
Moisture
content %
Volume weight
tonne/m³
Material
Type
Max. inclination
in degrees
Iron ore -1000 2,1 2 18
Crushed iron ore - 400 2,2 2 18
Crushed iron ore - 100 2,3 2 20
Crushed iron ore - 25 2,5 2 22
Crushed iron ore - 10 2,6 2 22
Waste rock - 1000 1,6 2 18
Crushed waste rock - 400 1,6 2 18
Crushed waste rock - 100 1,7 2 20
Crushed waste rock - 25 1,8 2 22
Ore concentrate 0-2 2,8 1 20
Ore concentrate 2-4 2,8 2 24
Ore concentrate 4-6 2,9 2 20
Ore concentrate 6-8 2,9 3 16
Ore concentrate 8-10 3,0 3 12
Ore concentrate > 10 3,0 3 8
Pellets 2,1 1 18
Belt speed
In order to limit dusting and spillage in the plant, the maximum recommended belt speed is 2,0 m/s.
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Conveyor frame
The principal dimensions for idler brackets and the conveyor frame’s cross section are given in the
figure and table below. The conveyor frame consists of a U-beam with the flange facing out
Beam web inwards
Belt width 650 800 1000 1200 1400 1600 1800 2000
A 950 1150 1350 1600 1800 2000 2200 2400
B * 600 600 600 700 700 700 800 800
The dimension D is dependent on the belt type and / or on if a belt scale is close to the pulley. If D > 0
the idler brackets closest to the pulley preferably are angled up so that the belt gets in contact with
the carrying idlers and reduces the belts swaying movement up and down.
0 ≤ D ≤ Half the trough depth
V = Angle 30° or 45°
Reference: ISO 1819 and SS 2888
"x" = the space between the centre roller and the side rollers shall not exceed 10 mm.
*) dimension B is dependent on required angle of wrap and may differ from the tabulated value.
Clearance in conveyor galleries Background and purpose
LKAB has built up an expertise on enclosed conveyor galleries for providing service areas with good
working conditions and security, based on long and solid experience. The purpose of this instruction
is thus to ensure that LKAB obtains space that is adapted to the company’s conveyor instruction for
conveyor frames.
Requirements
LKAB has greater requirements for spaces around conveyors than the European standard EN 620
specifies and refers to LKAB’s type drawing which specifies service spaces around built-in conveyors
as well as states inclinations that make cleaning and flushing possible in the conveyor walkways. It
is also necessary to take into account the space required for splicing and repair of conveyor belts as
the work may need to be carried out even when the adjacent conveyors are in operation. All walkways,
EDGE OF PULLEY
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stairs, stepladders or platforms shall at least have a clear width of 800 mm and the clear height shall
be at least 2100 mm. Only in exceptional cases, after risk assessment, the width may be reduced to
600 mm if the walkway is used only occasionally and the reduction is limited to a short distance, for
example at a column. For guards in connection with walkways for example in passages where the
walkways width is perceived as narrow/cramped, we refer to chapter "Guards".
The harmonised European standards EN ISO 14122-1 to -4 state requirements for access to machines
(stairways, ramps, walkways, working platforms, guard-rails, etc.) that fulfil the Machine Directive’s
safety requirements. If the requirements in the directive or harmonised standards exceed the
requirements in this instruction, then the directive always has precedence over the contents of
LKAB’s type drawings.
The minimum dimension of 2100 applies to service areas on both sides of the conveyor.
Belt width
B mm
Total conveyor frame width
b mm
Walkway minimum
a mm
Other service area
c mm
650 1050 800 800
800 1250 800 800
1000 1450 800 800
1200 1700 800 800
1400 1900 1000 800
1600 2150 1000 800
1800 2400 1000 800
2000 2650 1000 800
If there are walkways on both sides, replace dimension c with dimension a.
Conveyor gallery, lengthwise Floor incline also here =1:40 ( 1,5°), in the case of
“horizontal” conveyors.
The minimum dimension of 2100 applies to all service areas.
Safety distance
Distance between idler and fixed parts of skirt plate/feed hopper must be larger than 150 mm. See
above.
FEED HOPPER
α
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Guards Mechanical hazards at nip points shall be safeguarded in the manner specified in the harmonized
standard type C, EN 620. For risks in contact points between belt and idlers, the standard already has
identified and marked the potentially dangerous nip points on conveyors. See the picture below. Note
that not all contact points between belt and idler are considered as dangerous nip points. A dangerous
nip point is defined by that the belt cannot lift from the idlers or pulleys to produce a clearance of at
least 50mm where the belt touches the periphery of the idlers.
The belt’s lifting can be hindered by fixed parts, such as cross bars, skirt plates, loading and unloading
areas, convex curve and at transition between flat and troughed belt, where the belt is reversed or
deflected and other places where the pressure between belt and idlers becomes high, that is, affected
by other than the belt and the conveyed material.
Key
1 Feed hopper 9 Tail pulley
2 Idlers at convex curve (brow) position 10 Tripper discharge pulley
3 Direction of belt travel 11 Take up pulley
4 Transition idler 12 Gravity take-up weight
5 Head pulley 13 Bend pulley
6 Snub pulley 14 Typical tripper
7 Scraper 15 Reversible belt
8 Drive pulley 16 Nip point
The potentially dangerous nip points identified and marked (16) above shall be protected if they are
normally accessible to personnel.
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Selection of guards
It is important that the selection of guards and design of guards is preceded by risk assessments so
that the guard itself does not cause any additional risk. In order to maintain the respect for guards,
they must be perceived as justified.
In the standard EN 620 four types of guards are stated that can be used to prevent risk against
entanglement, drawing-in and trapping in potentially dangerous nip points; fixed enclosing guards,
fixed distance guards, interlocking guards or volume-filling guards at the nip point, so called “nip
guards”. Enclosing guards prevents access to the hazard zone from all sides, while distance guards
prevent access to the hazard zone from at least one direction. Interlocking guards are guards with
interlocking device that together with the control system prevents the hazard zone from being
accessible when the conveyor is in motion if the guard is removed or opened. Volume-filling guards,
so called “nip guards”, should fill the area at the point of contact between conveyor belt and idler or
pulley and thereby reduce the risk of drawing-in at the nip point. However, according to the
requirements of the standard EN 620, the gap between the volume-filling guard and the moving belt
must never exceed 5 mm to fulfil as a guard against drawing-in. The requirement cannot be met for
example for conveyors with troughed belt profile. Furthermore, the guard can create new risks, such
as accumulation of dust and spillage from transported material in the gap. If the risk assessment shows
that the nip points must be guarded, LKAB's recommendation is to use distance guards or enclosing
guards, as these are not limited to belt profile, type of conveyor belt, conveyor belt movement or
transported material.
Design of guards
It is important that guards are designed to enable routine adjustments, lubrication and maintenance to
be carried out without opening or removing the guards. The guards shall be designed to permit visual
inspection during operation. Furthermore, the design of the guards should enable spillage to be
cleared without removal of the guards, for instance with a gap or opening that meets the requirements
of EN 620. Guards should be very quick to disassemble and re-assemble, easy to handle, modularly
designed and only in exceptional cases designed for a specific placement.
Where a conveyor passes above working or traffic areas, suitable protection shall be provided against
falling parts of machinery, such as return idlers (with e.g. catching trough) or belt failure (with e.g.
protection plate, wire mesh, etc.).
Protection in connection with walkways
Walkway in angle to the belt conveyor
Belt conveyors should be provided with guards in the area where the walkway connects to a walkway
along the conveyor or where a stair or ladder leads up/down towards the conveyor.
Walkway along the conveyor
Determine which walkways that needs to be used during transfers in the plant. Make risk assessments
on where guards need to be mounted along these walkways. Guards must not lead to new risks.
Remaining possible walkways are provided with warning sign; EJ GÅNGVÄG [=NOT WALKWAY.
Use Swedish designation, English translation is for your information only].
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Primarily, the conditions along the walkway should be eliminated that leads to increased risks to
access dangerous nip points, because one can stumble, fall, slip or get hooked/ trapped in protruding
parts. These may be, for example:
• differences in levels or upstanding objects in the walkways floor
• stairs or ladders in the walkway
• walkways width is perceived as narrow/cramped
• protruding parts in the walkway
• spillage makes the walkway slippery or uneven
• the belt conveyors inclination
At inclined belt conveyors, a handrail may reduce risks by providing support for walking downwards
and upwards as well as directing pedestrian traffic to the side of the walkway where the handrail is
mounted.
Workplace adjacent to belt conveyor
Make risk assessments if guards need to be installed on belt conveyors at workplaces adjacent to
conveyors in operation. By workplaces is meant e.g. inspection panels in feed hoppers, sampling
locations, vulcanization locations and the like.
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Conveyor belts
References
DIN 22109 -1 to - 2 Conveyor belts with textile plies for coal mining; - Part 1: Monoply belts for
underground applications. Dimensions, requirements - Part 2: Rubber belts
with two plies for underground applications. Dimensions, requirements
DIN 22109 -4 Conveyor belts with textile plies for coal mining; - Part 4: Rubber belts with
two plies for above ground applications. Dimensions, requirements
DIN 22129-1 to - 4 Steel cord conveyor belts for underground coal mining; Part 1:
Dimensions, requirements – Part 2: Marking – Part 3: Testing – Part 4: Belt
joints. Dimensions, requirements
DIN 22118 Conveyor belts with textile plies for use in coal mining; fire testing
SMS 2329 Conveyor belts with textile carcass. Dimensions and marking
Requirements
Fire safety for conveyor belts within LKAB’s plants in Sweden and Norway
According to LKAB's requirements for fire safety for conveyor belts in LKAB's plants, all conveyor
belts in underground installations, in buildings and in conveyor galleries must always be self-
extinguishing quality (VLS). Exceptions to the requirement must be approved by LKAB's Fire Safety
Function. The Fire Safety Function also states when sprinklers are required for conveyors.
Belt designation
Belt designations that shall be used in constructing conveyor belts
DIN 22109 is the entrance standard for self-extinguishing conveyor belts with textile
reinforcement
DIN 22109-1 See references above.
DIN 22109-2 See references above.
DIN 22109-4 See references above.
DIN 22129-1 to -4 See references above.
This system states the belt’s total tensile strength, lengthwise.
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Example of a belt designation
800 EP 630/4 6/2 N ID no.
Belt width in mm
Reinforcing material
Ultimate tensile strength in N/mm belt width
Upper/lower cover layer thickness in mm
Cover layer’s quality
Object marking for traceability
Quality requirements
Thickness
See nominal belt thicknesses in the table on page 14. Variation in belt thickness is allowed within the
limits specified in SMS 2329.
Upper cover layer T1
T
Textile layer Lower cover layer T2
The difference in belt thickness for nominal belt thicknesses up to 10 mm can be a maximum of 1 mm
and for belt thicknesses over 10 mm it can be a maximum of 10% of the nominal thickness.
The thickness of the cover layers may deviate from that in the order specification, as long the lower
deviation does not exceed;
- 0.2 mm for base dimensions up to and including 4 mm
- 5 % of the base dimension for base dimensions over 4 mm
Deviations from the upper measure have not been determined.
Thickness is measured according to SMS 2468.
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Width
According to SMS 2329.
Base dimension=B 650 800 1000 1200 1400 1600 1800 2000
Deviation ± 6.5 ± 8 ± 10 ± 12 ± 14 ± 16 ± 18 ± 20
Length
According to SMS 2329.
The belt can be endless or in an open position. There should be no tension on the belt
when it is measured. Endless belts are measured on the belt’s inside.
Endless: Ordered length ± 0.5 %
Open length: Ordered length + 2 -0.5%
Straightness
According to DIN 22102.
The belt shall be straight along its whole length. The maximum sideways deviation is
given in the table below, the values of which are taken from problem-free conveyors
running unloaded.
Belt width, mm
Max allowable
sideways deviation
< 800 ± 40 mm
800-1400 ± 5%
> 1400 ± 75 mm
Adhesion
According to ISO 252, ISO/R 36.
Minimum adhesion
– between cords: 3.5 N/mm
– between cover layers and cords:
2.4 N/mm for cover layers 0.8-1.5 mm
3.0 N/mm for cover layers > 1.5 mm
Maximum adhesion: 9.0 N/mm
Cover layers
Quality V according to: DIN 22102
Tensile strength: min 20 N/mm2
Ductility: min 400 %
Abrasion: max 200 mm3
Self-extinguishing type V, fire resistance test according to DIN 22118
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Marking
Belts are marked according to SMS 2329 so that the type of reinforcement, tensile strength, number
of plies, cover layers’ thickness and quality are described. Deviations allowed only by special
agreement.
Selection table
Belt type
Belt width E400/1
8 + 3
EP400/2
5/1.5
EP630/4
6/2
EP800/5
6/2
EP1250/5
6/2
EP1250/5
8/2
650 2 1* 1*
800 2* 1* 1 1*
1000 2* 1* 1* 1*
1200 1* 1* 1* 1*
1400 1* 1*
1600 1* 1* 1*
1800 1
2000 1*
Nominal belt
thickness
12.5 9.9 12.4 14.0 15.0 17.0
1 = Preferred standard (first choice)
2 = Alternative to EP 400/2 - 5/1,5
* = Stock goods in Kiruna or Malmberget
NOTE: In need of belts that are not stock item at LKAB belts should, if possible, be selected from
the suppliers' stock range or standard assortment.
Special orders must be avoided.
Lateral sealing system
Lateral sealing system shall be of self-extinguishing V quality, NBR
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Carrying idler, loading and return idler References
Selected from Impact Rings type "B" according to SS ISO 4123 “Belt conveyors – Impact rings for
carrying idlers and discs for return idlers – Main dimensions”
Requirements
This instruction shall be applied when purchasing conveyors or replacement idlers.
Idlers coated with rubber or fitted with impact rings must have rubber of the same quality as the
conveyor belt, self-extinguishing V quality, NBR.
Bearings for axles Ø 30: Deep-groove ball bearings with an inner and outer contact seal, according
to LKAB type drawings. (Applies to carrying idlers).
Outside diameter Ø 159 mm of carrying idlers and impact rings on the return idlers. Details according
to the LKAB type drawings. See chapter "Drawing index of all belt conveyor components."
Figure: Dimensions of carrying and loading idler as well as return idler. (Not to scale).
Note: x) Idler Ø 108 mm used only exceptionally, for reasons of space.
xx) Axle Ø 30 mm and A/F 22 mm are used for new investments. In existing plants the
standardized axle is to be introduced in conjunction with major repairs or rebuilds.
(A/F=across the flats)
z) 76.1 mm applies to belt width ≤ 1400 mm
zz) 108 mm applies to belt width > 1400 mm
Recommendation: The conveyor belt sag between the return rollers may not exceed 1% of the
distance between the rollers.
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Pulley Centre distance between bearing housings
This specification describes the relationship between: Belt width, pulley length and carrying idler
distance.
Belt width 650 800 1000 1200 1400 1600 1800 2000
Pulley
length
750 950 1150 1400 1600 1800 2000 2200 Bearing housing
Axle d1 Bearing centre distance c-c
55 1000 1200 1400 1650 1850 2050 SNH 512
60 1000 1200 1400 1650 1850 2050 2250 SNH 513
70 1000 1200 1400 1650 1850 2050 2250 2450 SNH 516
90 1000 1200 1400 1650 1850 2050 2250 2450 SNH 520
110 1000 1200 1400 1650 1850 2050 2250 2450 SNH 524
125 1050 1250 1450 1700 1900 2100 2300 2500 SNH 528
140 1050 1250 1450 1700 1900 2100 2300 2500 SNH 532
160 1100 1300 1500 1750 1950 2150 2350 2250 SD 3136
180 1150 1350 1550 1800 2000 2200 2400 2600 SD 3140
200 1150 1350 1550 1800 2000 2200 2400 2600 SD 3144
220 1150 1350 1550 1800 2000 2200 2400 2600 SD 3148
240 1150 1350 1550 1800 2000 2200 2400 2600 SD 3152
260 1150 1350 1550 1800 2000 2200 2400 2600 SD 3156
280 1250 1450 1650 1900 2100 2300 2500 2700 SD 3160
300 1300 1500 1700 1950 2150 2350 2550 2750 SD 3164
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Pulley shell
Pulley diameter Pulley drawing Kiruna Pulley drawing Malmberget
315 227794 2-4744-97
500 227795 2-4744-98
630 227796 2-4744-99
800 227797 2-4744-103
1000 227798 2-4744-104
1250 227799 2-4744-105
Crowning of pulley shell
To reduce the risk of misalignment of the belt the manufacturers of belts recommend crowning of the
pulley shell. If the crowning is too large it becomes ineffective. To get a crowning to work satisfactory
the belt must be in close contact with the shell uniformly over the pulley. It is very important that a
crowning of a pulley is according to the formula below. For a correct crowning of the pulley the
diameter of the end of the shell is reduced with 1/150 of the diameter of the mid of pulley.
If several pulleys are placed close to each other, only one pulley should be crowned or half the
crowning should be made on two adjacent drums.
Belt misalignment
To reduce the conveyor belt misalignment, it is important to control the flow of material so that the
loading point on the belt is as centred as possible. If the carrying idler sets are tilted forward 1.5° - 3°
the belt is centred towards the middle and the misalignment decreases. The option rotary stabilisation
with return idlers and / or carrying idler sets are superior to crowning. Friction coating increases the
steering effect. The conveyor belt wanders in the direction where the belt first hits the idler/pulley.
Keep in mind that rubber is a "living" material and the conveyor belt may be allowed to move
sideways ± 5% of the belt width. Ensure that there is sufficient lateral movement range on the return
idlers and adjustability for rotary stabilisation.
Suitably, the frame is provided with measurement points to base the alignment of the drive and tail
pulley in 90° angle relative to the frame. A skewed pulley wears the pulley shell, because the belt is
forced to move back and forth over the shell.
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Screw joints in pulley end plates
General
The prerequisite for a safe screw joint is that the screws are mounted with the right torque. An
incorrectly tightened screw joint where the end plate meets the axle can cause breakdowns, as
experience has shown.
Tightening
Tightening with percussive tools does not give sufficiently accurate tightening, even if the tool can
be set to the desired torque. Re-tightening must therefore be performed using a releasing-type torque
wrench set to the torque applicable to the screw dimension and strength class in Table 1.
Torque
Torque in Nm (kpm). These values apply to screw joints with lightly oiled threads and contact
surfaces. NOTE! Do not use Molybdenum sulphite (MoS2).
Table 1
Threads
Strength class 12.9
Torque
Nm kpm
M 12 122.6 (12.6)
M 14 186.3 (18.6)
M 16 289.3 (28.9)
M 18 397.2 (39.7)
M 20 568.8 (56.8)
M 24 980.7 (98.7)
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Tightening sequence
The screw joint is tightened crosswise according to the sequence in the figure below.
End plate with a locking assembly type Ringfeder RfN 7012
1. The outer flange joint is tightened first with torque according to settings in Table 1.
2. The clamp’s screws are first tightened by hand until there is no gap. Accuracy in this step is
crucial for centring.
3. The screws are then tightened to about half of the specified torque, and thereafter to the torque
applicable to the torque appropriate to the screw dimension and strength class 12.9.
4. A check of all the screws should be done crosswise, according to Figure 1.
Hardened steel washer of type BRB, BRFB
Screw strength class 12.9
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End plate with clamp casing
The screw joint is tightened according to the torque in Table 1, the outer flange joint first. The
accumulation space “A” can be used as a check. The clamp casing is tightened until the gap is closed,
and then a further distance as specified in Table 2. During assembly, take care that the clamp casing
slides inwards towards the axle so that the end plate is not forced or bent outwards.
Table 2
Axle diameter D Accumulation space A
x (55) 0.6-0.8
x (60) 0.7-0.9
70 0.8-1.0
90 1.0-1.3
110 1.2-1.6
125 1.4-1.8
x non-standard
Hardened steel washer of type BRB, BRFB
Screw strength class 12.9
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Drawings of pulleys, axles and bearings
Pulley
diameter
Pulley drawing no End plate drawings for
clamp hubs
End plate drawings for
Rfn 7012
Kiruna Malmberget Kiruna Malmberget Kiruna Malmberget
315 227794 2-4744-97 225169 2-4744-56
500 227795 2-4744-98 225168 3-4744-57 332290 3-4744-108
630 227796 2-4744-99 225168 2-4744-57 332290 3-4744-108
800 227797 2-4744-103 151644 1-4744-101 146741 1-4744-102
1000 227798 2-4744-104 151644 1-4744-101 146741 1-4744-102
1250 227799 2-4744-105 151644 1-4744-101 146741 1-4744-102
Clamp hubs and clamp
Axel d1
Axel d2
Clamp hub Drawing No
Clamp Rfn 7012 Kiruna Malmberget
50 70 2-4744-58
55 70 225170/1
60 70 225170/2
70 70 225170/3
90 90 225170/4
110 110 225170/5
125 125 225170/6 2-4744-58
140 140 x 190
160 160 x 210
180 180 x 235
200 200 x 260
220 220 x 285
240 240 x 305
260 260 x 325
280 280 x 355
300 300 x 375
320 320 x 405
340 340 x 425
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Requirements for bearing specifications References
EN 60034-1 Rotating electrical machines. Part 1: Rating and performance
Background and purpose
The purpose of this instruction is to have ball bearings and roller bearings delivered with the following
specifications: assembly instructions, data for vibration monitoring, if service is available from the
supplier (bearing service is principally used for larger bearings, such as those used in drive axles or
mill axles, for example).
Requirements
Suppliers
Suppliers shall deliver specifications, current data for vibration measurement, and necessary service
for bearings. These are best entered on Object card LKT 1500.150.002.
Assembly
Assembly information required to achieve a completely satisfactory result, such as recommended
bearing gaps, pressing onto bushing, service intervals, required tools, etc.
Vibration monitoring
When monitoring vibrations, certain data is required so that satisfactory measurements can be carried
out, such as frequencies of the inner ring and outer ring, number of rollers and bearing casings. This
data is required for ball bearings and roller bearings from the manufacturer so that satisfactory
vibration measurements can be carried out.
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Safety functions
Documented risk assessments of each conveyor belts design, operation and use shall be conducted to
determine the necessary safety functions that have been identified and how they are to be executed.
Identified safety functions' demands on performance level, PL, affects the selection of components
(e.g. sensors) as well as design of and integration into control systems. (See EN ISO 13849-1).
Note: Risk assessments determines if the functions are safety functions or for monitoring.
The harmonized standard, type C, EN 620 defines how the safety functions for monitoring and control
of conveyor belts are to be performed: “The control system and control equipment shall be designed
using proven techniques and shall use proven components (see EN 60204-1:1997, 9.4). The safety
related parts of the control system shall be designed in accordance with the requirements of at least
EN 954-1 Category 1 (see EN 954-1:1996, 6.2.2). Where programmable electronic equipment, or
electronic devices including electronic sub-assemblies are used for safety related purposes, they shall
be in accordance with the requirements of at least EN 954-1 Category 2 (see EN 954-1:1996, 6.2.3).”
NOTE: EN 954-1 has been replaced by EN ISO 13849-1 and Category has been replaced by
Performance level, PL
Electrical safety functions are defined by standard EN 620 and even by suppliers of conveyors and
some examples are listed in this non-exhaustive list below:
□ Pull-cord controlled emergency stop device for assembly along the conveyor belt on one or both
sides, possibly supplemented by a push button controlled emergency stop on an optional location.
□ Lockable safety switch located at the motors.
□ Speed controls in various designs. Non-contact sensors placed at one of the return rollers have
proven to have high availability.
□ Misalignment detection devices are used to warn, and stop the conveyor if the belt has deviated
sideways.
□ Rotating warning light and / or audible warning signals in connection with the start of the
conveyor where it is required.
□ Level sensors for detection of the level in e.g. discharge chutes and / or hoppers.
Emergency stop devices for pull-cord Emergency stop devices shall, in accordance with harmonized standard type C, EN 620, be reachable
at all control stations, working positions and at accessible parts of the machinery including loading
points, unloading points, walkways and transfer points. According to EN ISO 13850 the means to
reset the emergency stop device should be placed so that the entire pull-cord is visible from the
location of the resetting means.
References AFS 2008:3 Machinery [Swedish implementation of Machinery Directive 2006/42/EC]
AFS 2008:13 Signs and signals [Swedish implementation of Directive 92/58/EEC]
AFS 2006:4 Use of work equipment [Swedish implementation of Directive 2009/104/EC ”Use of
Work Equipment” (89/655/EEC codified)]
ASS 128 Conveyors – The National Board of Occupational Safety and Health Instruction No
128 1978 (Repealed 2007-07-01 but may be a guidance)
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Requirements
The supplier shall deliver and mount pull-cord operated emergency stop devices according to EN ISO
13850.
The following emergency stop device systems have proven to function on LKAB’s conveyors:
Emergency stop devices of type Allen-Bradley with switch type Lifeline 4 including indicator
unit 3NC+1NO. E 37 752 04
Following cord tensioning system shall be used:
Conveyor length < 10 m LRTS 10m E 37 723 02
Conveyor length 10 – 20 m LRTS 20m E 37 723 06
Conveyor length 20 – 35 m LRTS 50m E 37 723 12
Stainless tensioning spring E 37 723 83
Sign with Swedish text E 38 025 90
One stainless tensioning spring is needed for each cable tensioning system.
Signs shall be mounted by switch and on each 5 meter on pull cord.
If pull cord gets longer than 35 meters an extra emergency stop device including cable
tensioning system and tensioning spring must be mounted on each 35 meters of the conveyor
length.
According to EN 620, the pull-cord operated emergency stop device shall be actuated by the
application of a horizontal force to the pull-cord of less than 125 N, at a point midway between two
support rings and perpendicular to the cord. The sideways cord movement (between the rest position
and the actuation position) shall be less than 300 mm.
According to EN ISO 13850 clause 4.4.5 and the Work Environment Authority's provision AFS
2008:13 the emergency stop devices, that are, push buttons (mushroom) and pull-cords must be red
and cords shall be fitted with signs or marker flags. Be aware that the symbol on the emergency stop
push button shall comply with EN ISO 13850 section 4.4.6, which means that either the push button
should have a symbol with a triangle pointing down, surrounded by a circle with an exclamation mark
in the middle or have no symbol at all. According to AFS 2008:13, Appendix 1, Chapter 5, the sign
to emergency stop is to be green. If the sign is part of an emergency stop cord, it must be red.
According to Work Environment Authority's provision AFS 2006:4 it is also appropriate that there is
a sign with the text “NÖDSTOPP”. [= “Emergency stop” in Swedish]
Assembly and installation of emergency stop devices
The assembly shall be in accordance with the supplier’s instructions. The National Board of
Occupational Safety and Health’s instruction “ASS 128” can also give guidance.
Extract from ASS 128 regarding emergency stop switches:
8.8 On locations by the conveyor where personnel normally are present or may be present; there
must be emergency stop devices in required extent.
8.9 When the emergency stop switches is activated the main power should be cut (either directly
or indirectly) immediately and with a lasting effect. The stop switch shall be forced into a
breaking mode and shall remain in that mode until reset manually. The conveyor must not
after that be started except from a therefore dedicated place. Emergency stop device shall
function independently of interlocking circuit between conveyors.
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8.10 Emergency stop device shall, wherever appropriate, be activated by emergency stop in the
form of pull-cord, which shall be located so that it is easy to reach and to grasp. Emergency
stop device which is operated by pull-cord shall be designed so that it cuts off in whatever
direction the pull-cord is affected. Where appropriate, the pull-cord must be affected when a
person falls in towards the conveyor.
8.11 Emergency stop in the form of pull-cord shall at the appropriate distance (4-5 m) have durable
marker flags, …
System for monitoring of belt conveyor
The supplier shall deliver and assemble system for monitoring of belt conveyors according to
description below. The systems shall comply with the requirements in chapter "Safety functions".
The descriptions include solutions that have proven to function on LKAB’s conveyors.
For more demanding applications there are systems for advanced belt monitoring with higher
accuracy and increased monitoring.
System for monitoring of belt speed, breakage, slippage and tensioning
Sensors for monitoring of belt speed are, on LKAB conveyors, mounted at the drive, snub and tail
pulley.
The sensor is mounted to sense a metal flag mounted on the shafts of the pulleys. A mount is arranged
on the conveyor to allow an easy adjustment of the sensor. As a bracket for the sensor LKAB’s mount,
drawing No 352144, can be used. The cable of the sensor is connected to a junction box (E 1438481)
attached with wood-screws to a plastic oxylite plate dimension 200x150x20 mm. The plastic plate is
then attached with through screws to the conveyor frame.
The belt monitoring is conducted by sampling of signal to the control system from sensors on drive
pulley, compared with sensor on snub pulley and tail pulley. Warning and alarm conditions must be
determined for deviations between the signals from the sensors. The monitoring can be developed
and implemented in the control system to indicate belt breakage, slippage and tensioning problem.
System for belt alignment monitoring
Mechanical device for monitoring of belt alignment can be arranged according to LKAB drawing No
1041587.
Mount for belt alignment sensor on conveyor frame can be arranged according to LKAB drawing No
1041589.
The height of the mount is adjusted in a way that the conveyor belt, in the event of misalignment, hits
the roller of the belt alignment monitor just below the middle of the roller. The belt alignment monitor
is adjusted so that the sensor is actuated (1) when the alignment is correct and not actuated (0) when
there is misalignment.
The cable of the sensor is connected to a junction box (E 1438481) attached with wood-screws to a
plastic oxylite plate dimension 200x150x12 mm. The plastic plate is then attached with through
screws to the conveyor frame.
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Advanced systems for increased belt monitoring
Advanced systems for increased belt monitoring by "on-line" scanning and image processing are not
part of LKAB's normal practice.
A rough risk and impact assessment for important belt conveyors without redundancy in the "red
production line" may through high levels of risk (R x K), indicate the need to implement advanced
systems for increased belt monitoring.
There are a number of suppliers of advanced systems for increased belt monitoring, suitable to
minimize the risk of production stop due belt damage. These advanced systems may, "on-line", for
example, indicate the following types of belt damage; belt cleavage, puncture damages, penetration,
surface defects, lamination problems, edge defects (rip-off detection), belt elongation, cords fracture
and belt breakage. Above examples of types of damage can be categorised into different level of
severity which may result in a warning and / or interlocking alarm. These alarms should be filtered
and suppressed so that the main control system / operator obtain relevant information for immediate
or planned actions.
LKAB's organisational plant owner evaluates the need and benefit of above advanced systems for
increased belt monitoring.
System for monitoring of level in chute
For monitoring of level in chute, a system of conductive type has proven to function on LKAB’s
conveyors.
The system consists of a probe, mounted in the chute in a way that allows easy adjustment of the
probe. As cable for the probe a steel wire with red plastic sheath, order No E 3772389.
The cable of the probe is fitted with a probe weight according to drawing 462576.
The cable of the probe is connected to a junction box (E 1438481) attached with wood-screws to a
plastic oxylite plate dimension 200x150x12 mm. The plastic plate is then attached with through
screws to the conveyor frame.
System for position monitoring
For monitoring of position, sensors of inductive type have proven to function on LKAB’s equipment.
On objects where position is to be indicated a mount is arranged to allow easy adjustment of the
sensor and a reliable position indication. As a bracket for the sensor LKAB’s mount, drawing No
352144, can be used.
The cable of the sensor is connected to a junction box (E 1438481) attached with wood-screws to a
plastic oxylite plate dimension 200x150x20 mm. The plastic plate is then attached with through
screws to the conveyor frame.
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Gear boxes When conveyors are driven by belt driven transmissions, LKAB has the following preferences:
Preference 1
Gear boxes should preferably be selected from this series.
Type Old designation New designation Comment
Shaft mounted
Speed Reducers of
Sala type
BTV – 32 * J 32
BTV – 52 * J 52
TV – 72 * J 72
TV – 102 * J 72 5-138 kW
TV – 112 * J 100 Hollow shaft
TV – 122 * J 100 Parallel axles
TV – 152 * J 110
TV – 202 J 125
TV – 302 * J 125
TV – 402 * J 140
TV – 512 J 190
BTV – 53
TV – 103
TV – 203
Preference 2
Gears > 138 kW are selected from case to case at the design phase.
* Gear sizes TV-32 up to and including TV-402 are selected with conical mounting devices, so-
called tapered bush of type KIBO.
Note: When selecting gearboxes for new plants, full interchangeability shall prevail, regardless of the
manufacturer chosen.
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Drawing index of all belt conveyor components LKAB Drawing No
Kiruna Malmberget
Assembly drawing 146740 1-4744-93
Pulley shell Dia.315 227794 2-4744-97
-"- 500 227795 2-4744-98
-"- 630 227796 2-4744-99
-"- 800 227797 2-4744-103
-"- 1000 227798 2-4744-104
-"- 1250 227799 2-4744-105
End plates for clamp hubs Dia. 315 225169 2-4744-56
-"- 500 225168 2-4744-57
-"- 630 225168 2-4744-57
-"- 800 151644 1-4744-101
-"- 1000 151644 1-4744-101
-"- 1250 151644 1-4744-101
End plates for Ringfeder Dia 500 332290 3-4744-108
-"- 630 332290 3-4744-108
-"- 800 146741 1-4744-102
-"- 1000 146741 1-4744-102
-"- 1250 146741 1-4744-102
Placement of plough scraper and guide brackets 234797 2-4744-128
Clamp hub 225170 2-4744-58
Bearing housing 146761 1-4744-92
Protective shield for bearing housing 328735 3-4744-106
Covers for locking assembly 436788 4-4744-107
Loading idler 446161 4-4744-23
Carrying idler 446160 4-4744-22
Conveyor Return idler 199347 1-4744-129
Return idler B=1600 245757 2-4744-130
Carrying idler 342173 3-4744-131
Loading idler 342174 3-4744-132
Counterweight 196837 1-4744-24
Attachment for Return idler Assembly 342286 3-4744-47
Details 342287 3-4744-48
Details 342288 3-4744-49
Safeguards, type drawing 451682 4-4744-112
Pull-core controlled emergency stop (assembly drawing) 320604 3-4744-127
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LKAB Drawing No
Axles for drive and tail pulleys Kiruna Malmberget
Drive pulley
Axle diameter 70 329344 3-4744-66
60 342874 3-4744-122
55 342875 3-4744-123
90 329345 3-4744-67
110 329346 3-4744-68
110 342878 3-4744-124
125 TV 201, 202 329347 3-4744-69
125 TV 302 195766 1-4744-114
140 TV 302 195767 1-4744-113
140 TV 402 195761 1-4744-119
140 TV 402 195760 1-4744-120
160 TV 402 195762 1-4744-118
160 TV 402 195763 1-4744-117
160 TV 402 195764 1-4744-116
160 TV 402 195765 1-4744-115
Tail pulley (take-up pulley)
Axle diameter 55 329352 3-4744-79
60 342876 3-4744-125
70 342877 3-4744-126
90 329353 3-4744-80
110 329354 3-4744-81
125 329355 3-4744-82
140 329784 3-4744-83
160 329785 3-4744-84
180 329786 3-4744-85
220 329787 3-4744-86
Axle bushing, plastic, for carrying and return idlers 447376 4-4744-26
System for monitoring
Mount for sensor 352144
Belt alignment monitor, Assembly 1041587
Belt alignment monitor, Detail 1041588
Belt alignment monitor, Assembly instructions 1041589
Suggestions for improvements LKAB carries out continual improvements in accordance with the LKAB quality policy and this also
applies to instructions and codes of practice. Comments and suggested improvements are welcome at
the following e-mail address: [email protected]
The LKAB internal address in Outlook: SE SM Anvisningar LKT