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Jansen TBDJ001-0500X Series Installation Manual

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

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Summary of Contents for Jansen TBDJ001-0500X Series

  • Page 1 Trough-shaped manure removal belts Part 1: Installation order Read before installation Edition Revision Revision date 1-4-2020 English (translation of original DOKJ005600-023-01EN manual)

  • Page 2: Preface

    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: 0031 (0) 342 – 427 001 All rights reserved.

  • Page 3: Table Of Contents

    Table of contents Preface ................................2 Use of this manual ..............................2 Icons in this manual ..............................2 Service and technical support ..........................2 Lists of components and general information ................... 5 Lists of components ............................. 5 1.1.1 Horizontal manure removal belt ......................5 1.1.2 Horizontal manure removal belt with knee joint .................
  • Page 4 5.3.1 Covers ..............................38 5.3.2 Mounting the water drainage strip (elevating belt and belt with knee joint) ........39 Impact plate ............................... 40 Dump tube ..............................40 Wall transit (horizontal belt) ........................41 Finishing the elevating belt ........................42 Mounting the upper arch ........................... 42 Placing the leg under the elevating belt ....................

  • Page 5: Lists Of Components And General Information

    1 Lists of components and general information Lists of components 1.1.1 Horizontal manure removal belt Return side Moving direction of upper part of belt Moving direction of returning part of belt Return side Figure 1.1, Horizontal manure removal belt – operating principle and listed parts are the same for the manure elevating belt and the horizontal manure removal belt with knee joint 1.

  • Page 6: Horizontal Manure Removal Belt With Knee Joint

    1.1.2 Horizontal manure removal belt with knee joint Drive side Figure 1.2, Horizontal manure removal belt with 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.

  • Page 7: Manure Elevating Belt

    1.1.3 Manure elevating belt The standard manure elevating belt cannot be moved. There are two more options.  Option: rotatable manure elevating belt. The leg has wheels. A swivel base under the collector funnel.  Option: movable manure elevating belt. The leg has wheels.

  • Page 8: List Of Article Numbers

    List of article numbers The manure removal belts consist of the following parts. The numbers between brackets in this installation manual correspond with the list below. The installation drawings of these parts are attached at the end of this manual. ...
  • Page 9 ZMMT014762-850 Big leg elevating belt BW500 ZMMT014762-851 Buttress set for big leg elevating belt BW500 ZMMT014762-852 Buttress set for top of elevating belt BW500 from 12.8 m up to and including 20.8 m ZMMT014762-853 Safety kit incl. switch, excl. safety cord ZMMT014762-855 Downwards knee joint complete BW500 ZMMT014762-856...

  • Page 10: Middle Sections Per Length Of Manure Removable Belt

    Middle sections per length of manure removable belt NOTE! 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. The entire manure removal belt length is determined by: ...

  • Page 11: Installation Order

    Installation order The installation order is equal to the structure of this document. See the table of contents for a list of the correct installation order. NOTE! Some sections are only applicable to the horizontal manure removal belt, the horizontal manure removal belt with knee joint or the elevating belt.

  • Page 12: Mounting The Frame

    2 Mounting the frame IDEA! Do not build the parts on the ground, but build them at a healthy working height. NOTE! If you suspend a horizontal manure removal belt with wall supports or suspension sets, then check the following. Is there enough space to lift the entire manure removal belt and fasten it at the correct height? If not, then the prescribed working order changes.
  • Page 13 3. Couple the middle sections by means of the coupling profiles. See Figure 2.3. 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. Front sides of the buttress plates at drive side Figure 2.3, Coupling middle sections...

  • Page 14: Connecting The Knee Joint (Belt With Knee Joint)

    Connecting the knee joint (belt with knee joint) 2.2.1 Upwards knee joint Mount the knee joint (ZMMT014762-845). See Figure 2.4. 1. Remove the troughed idlers before and after the knee joint. 2. Place the knee joint at the desired place, between two middle sections. NOTE! Make sure the front sides of the buttress plates of the troughed idlers are at the same side (drive side).

  • Page 15: Downwards Knee Joint

    2.2.2 Downwards knee joint Mount the knee joint (ZMMT014762-855). See Figure 2.5. The assembly order of a downwards knee joint is equal to the assembly order of an upwards knee joint. Return unit side Drive unit side Figure 2.5, Mounting the downwards knee joint 1.

  • Page 16: Connecting The Drive Unit

    Connecting the drive unit The drive unit is supplied assembled and is available in two versions.  Drive unit with the motor at the right side (FRDJ014762-200).  Drive unit with the motor at the left side (FRDJ014762-201). Connect the drive unit to the middle section. See Figure 2.6.

  • Page 17: Placing The Legs Of The Horizontal Parts (Horizontal Belt And Belt With Knee Joint)

    Placing the legs of the horizontal parts (horizontal belt and belt with knee joint) (horizontal belt and belt with knee joint) 2.4.1 Fixed leg Two leg sets are available for the horizontal parts of a manure removal belt.  Leg set height 650 mm – 800 mm (ZMMT014762-835) ...

  • Page 18: Option Instead Of Leg: Wheel Set (Horizontal Belt)

    2.4.2 OPTION instead of leg: wheel set (horizontal belt) Mount the wheel set (ZMMT014762-804) of the horizontal parts of the manure removal belt. See Figure 2.8. Mount in existing hole Drill hole in side profile Figure 2.8, Wheel set (movable horizontal belt or belt with knee belt) 1.

  • Page 19: Coupling The Return Unit

    Coupling the return unit The return unit is supplied assembled. It is the same for all versions of the manure removal belts. Mount the return unit (FRDJ014762-202). See Figure 2.9. 1. Place the return roller as close as possible to the side of the middle sections. 2.

  • Page 20: Placing The Transport Belt

    Placing the transport belt Place the transport belt (TBDJ001-0500X…). See Figure 2.10 Figure 2.11. 1. Place the return roller as close as possible to the side of the middle sections. 2. Disassemble the end cover and supporting roller of the return unit. See Figure 2.10.
  • Page 21 10. Mount the second supporting roller of the knee joint immediately after the knee joint. See figure 2.6.2 and section 2.7. 11. Mount the scraper and adjust it. 12. In case of a belt with knee joint: put back the cover and (in case of an upward knee joint), the scraper profiles and the pressure set of the knee joint.

  • Page 22: Mounting The Supporting Rollers And Tensioning The Transport Belt

    Mounting the supporting rollers and tensioning the transport belt Where necessary mount the supporting rollers (ROLJ014762-022). See Figure 2.12. 1. Place two supporting roller brackets opposite to each other at the bottom side of the side profiles. 2. Place the supporting roller between the supporting roller 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.

  • Page 23: Mounting The Leg Under The Elevating Part (Belt With Knee Joint)

    Mounting the leg under the elevating part (belt with knee joint) 2.8.1 Fixed leg Mount the leg set that is adjustable in height (ZMMT014762-846). See Figure 2.13. 1. Adjust the elevating part at the correct height. NOTE! Maximum inclination angle is 24⁰! WARNING! Make sure the elevating part can’t fall during the placing of the leg.

  • Page 24: Option Instead Of Leg: Suspension

    5. Mount the buttresses in the leg. 6. Mount the buttress set between the leg and the bottom side of the elevating part. a. Fasten the buttress to the leg. b. Copy the hole of the other end of the buttress onto the side profile of the elevating part. c.

  • Page 25: Mounting The Wheel Set (Movable Elevating Belt)

    2.9.2 Mounting the wheel set (movable elevating belt) Mount the wheel set (ZMMT014762-804) of the movable elevating belt. See Figure 2.15. Mount in existing hole Drill hole in side profile Figure 2.15, Wheel set (movable elevating belt) 1. Leg 2. Swivel wheel 3.

  • Page 26: Mounting The Manure Guiding Parts

    3 Mounting the manure guiding parts Placing the funnel The funnel is supplied assembled and is available in two versions.  Funnel for the elevating belt (FRDJ014762-204).  Funnel for the horizontal belt and belt with knee joint (FRDJ014762-205). NOTE! Before placing the funnel, check if the transport belt is tensioned. NOTE! Place the funnel in such a way that no manure leakage can occur between the rear flap and the return roller.

  • Page 27: Mounting The Side Planks

    Mounting the side planks For each middle section, two side planks of 3 meter and one coupling set for side planks are supplied. 3.2.1 Side planks in case of a funnel Mount the side planks (VUG017X095L3000) and the coupling set for the side planks (ZMMT014762-836). See Figure 3.3.

  • Page 28: Side Planks In Case There Is No Funnel

    3.2.2 Side planks in case there is no funnel Mount the side planks (VUG017X095L3000), the side planks on the return unit (ZMMT014762-841) and the coupling set for side planks (ZMMT014762-836). See Figure 3.4. 1. Mount the side plank set (ZMMT014762-841) on the return unit. 2.

  • Page 29: Side Planks In Case Of A Knee Joint (Belt With Knee Joint)

    3.2.3 Side planks in case of a knee joint (belt with knee joint) Mount the side planks at the knee joint. See Figure 3.5 Figure 3.6. 1. Always mount one side plank support before and one after the knee joint. 2.
  • Page 30 Detail A ± 5 mm Figure 3.6, Mounting the side planks at a downwards knee joint 1. Zijplank 2. Zijplanksteun 3. HDPE-plaat 4. Transportband...

  • Page 31: Mounting The Electrical Parts

    4 Mounting the electrical parts Placing the motor Depending on the type and length of manure removal belt, the following motor powers can be applied:  1,5 kW  2,2 kW  3,0 kW Mount the motor (EMR…). See Figure 4.1.

  • Page 32: Mounting The Isolating Switch

    Mounting the isolating switch NOTE! In case of the elevating belt, wait with the placing of the isolating switch until the fixed leg is placed. See section 6.2.1. Mount the isolating switch (ZMBR011616-272). See Figure 4.2. 1. Determine the position and height of the isolating switch. 2.

  • Page 33: If Applicable: Mounting The Safety Set

    If applicable: mounting the safety set Mount the safety set (ZMMT014762-853). See Figure 4.3. NOTE! The safety set is standard in case of a manure elevating belt and along the elevating part of the belt with knee joint. Option: in case of a horizontal belt. Always mount the safety set if the horizontal belt is easy to reach or if a workplace is nearby.
  • Page 34 4. Mount the spring to an eye bolt at the long side where the pull cord switch is not placed. (So, the spring is placed opposite to the pull cord switch, see Figure 4.3.) 5. Lace the emergency stop pull cable through the eye bolts and pulleys. 6.

  • Page 35: Options

    5 Options Wall support or suspension (horizontal belt) 5.1.1 Wall support (horizontal belt) Figure 5.1., Wall support 1. Installation profile 2. Supporting roller Mount the wall support (ZMMT014762-849). See Figure 5.1. 1. Mount all installation profiles level and at equal height on the concrete wall. (If necessary, use shims.) a.

  • Page 36: Suspension In Manure Storage (Elevating Belt)

    5.1.2 Suspension in manure storage (elevating belt) Mount the suspension (ZMMT014762-858) at your own discretion. Use this module for suspension in a manure storage. See Figure 5.3. This module contains material for two suspension points. Maximum distance between the suspension points is 5 meter. If the distance is longer, use the suspension from section 5.1.3. 1.

  • Page 37: Suspension In Case Of Intermediate Floor (Horizontal Belt)

    5.1.4 Suspension in case of intermediate floor (horizontal belt) Mount the suspension (ZMMT014762-856). This suspension is only applicable in case of an intermediate floor, from which the manure removal belt is suspended lengthwise between two purlins. See Figure 5.5. 1. Mount the suspension legs. 2.

  • Page 38: Covers And Water Drainage Strip

    Covers and water drainage strip 5.3.1 Covers Manure removal belt covering is available in two lengths:  2000 mm including fastening material (ZMMT014762-838)  3000 mm including fastening material (ZMMT014762-842) Mount the manure removal belt covers. See the different situations in Figure 5.7.

  • Page 39: Mounting The Water Drainage Strip (Elevating Belt And Belt With Knee Joint)

    5.3.2 Mounting the water drainage strip (elevating belt and belt with knee joint) In case of the elevating belt and belt with knee joint, a water drainage strip (ZMMT014762-807) is always supplied with the covers of the elevating part. Mount the water drainage strip on the covers. It prevents water from outside from running down over the covers into the house.

  • Page 40: Impact Plate

    Impact plate Mount the impact plate (ZMMT0141762-840). See Figure 5.10. 1. Mount the angle profiles to the inner side of the drive unit. 2. Mount the impact plate at the desired distance. Figure 5.10, Impact plate Dump tube Mount the dump tube (ZMMT014762-825) on the overflow cap. See Figure 5.11.

  • Page 41: Wall Transit (Horizontal Belt)

    Wall transit (horizontal belt) Place the wall transit (ZMMT014762-843). See Figure 5.12. 1. Mount the side plates and lower plate of the wall transit to the side profiles of the manure belt. a. Determine the position of the wall transit. b.

  • Page 42: Finishing The Elevating Belt

    6 Finishing the elevating belt Mounting the upper arch The upper arch is available in two lengths:  ZMMT014762-833: elevating belt up to and including a length of 12.8 m  ZMMT014762-852: elevating belt from 12.8 m up to and including 20.8 m Mount the upper arch.

  • Page 43: Placing The Leg Under The Elevating Belt

    Placing the leg under the elevating belt NOTE! The elevating belt is now ready for positioning. Check all bolts once more and tighten them when necessary. 6.2.1 Fixed leg and accompanying buttress set Two legs are available for placement under the elevating belt. See Figure 6.2.
  • Page 44 Mount the leg and the accompanying buttress set. See Figure 6.2 up to and including Figure 6.6. 1. Assemble the leg. Do not connect the lower part and the upper part yet. 2. Clamp the lifting plates around the side profiles, at the center of gravity of the manure removal belt. Clamp the lifting plates tight with the supplied bolts.
  • Page 45 7. Mount the upper part of the leg (at a right angle to the floor) to the side profiles of the elevating belt. See Figure 6.4. a. Copy the holes of the coupling profiles onto the side profiles. b. Drill the copied holes to a diameter of Ø 12 mm. c.

  • Page 46: Rotatable Leg (Rotatable Belt)

    6.2.2 Rotatable leg (rotatable belt) NOTE! Carefully check if you have a rotatable elevating belt or a movable elevating belt. The installation of the wheels is different for each elevating belt. Both legs (described in the former section) can be fitted with a wheel set, so that the elevating belt is rotatable. ...
  • Page 47 3. Mount the cross profile between the base plates. a. Place the cross profile between the outer profiles of the leg. b. Fasten the cross profile on one side to the outer profile of the leg. c. On the other side, grind off the cross profile, so that it can be mounted on the outer profile.

  • Page 48: Movable Leg (Movable Belt)

    6.2.3 Movable leg (movable belt) For a movable elevating belt, you can install a wheel set under the big leg (ZMMT014762-839) of section 6.2.1. This wheel set and the wheel set under the return unit (see section 2.9.2), make the elevating belt rotatable. NOTE! Carefully check if you have a rotatable elevating belt or a movable elevating belt.

  • Page 49: Commissioning Of The Manure Removal Belt

    7 Commissioning of the manure removal belt Observe the directions below before putting the manure removal belt into use: Check all fastening points and make sure everything is tightened well. Check if the drive roller hangs level. Check if the inclination of the elevating part is maximal 24 degrees. Check if no tools or other materials are left on and in the belt.
  • Page 50 Idee Trogvormige mestafvoerbanden Veiligheid: Deel 1: Montagevolgorde Service en technische ondersteuning Neem als nodig voor verdere informatie en ondersteuning contact op met Jansen Poultry Equipment. Voor montage lezen Telefoon: 0031 (0) 342 – 427 000 Fax: 0031 (0) 342 – 427 001 Alle rechten voorbehouden.

  • Page 51: Overzicht Onderdelen En Algemene Informatie

    1 Overzicht onderdelen en algemene informatie 1.1.2 Knikband Overzichten van onderdelen Aandrijfzijde Figuur 1.2, Horizontale mestafvoerband met knik 1.1.1 Horizontale mestafvoerband 1. Afdekkap voor aandrijfrol 2. Afdekkap voor aandrijfmotor 3. Verstelbare poot 4. Drukset van knikstuk 5. Draagrol 6. HDPE-geleidingsplaat voor transportband 7.

  • Page 52: Middensecties Per Mestafvoerbandlengte

    ZMMT014762-850 Poot opvoerband B500 groot Middensecties per mestafvoerbandlengte ZMMT014762-851 Schorenset t.b.v. grote poot opvoerband B500 LET OP! Lees op de lay-outtekening welke middensecties per deel van de mestafvoerband gebruikt ZMMT014762-852 Bovenboog opvoerband B500 vanaf 12,8 m tot en met 20,8 m dienen te worden, wat hun lengte is en hoeveel van elk gebruikt wordt.

  • Page 53: Knikstuk Koppelen (Knikband)

    3. Koppel de middensecties met de koppelprofielen. Zie Figuur 2.3. Knikstuk koppelen (knikband) a. Monteer alle bouten en moeren losjes. b. Lijn het geheel uit. 2.2.1 Omhooggaand knikstuk c. Draai van het koppelprofiel de bovenste bouten en moeren vast. Monteer het knikstuk (ZMMT014762-845). Zie Figuur 2.4.

  • Page 54: Poten Van Horizontale Delen Monteren (Horizontale Band En Knikband)

    Poten van horizontale delen monteren (horizontale band en knikband) 2.4.2 OPTIE in plaats van poot: wielset (horizontale band) Monteer de wielset (ZMMT014762-804) voor de horizontale delen van een mestafvoerband. Zie Figuur 2.8. 2.4.1 Vaste poot (horizontale band en knikband) Er zijn twee pootsets leverbaar voor de horizontale delen van een mestafvoerband. In bestaand gat ...

  • Page 55: Draagrollen Monteren En Transportband Spannen

    10. Monteer de tweede draagrol van het knikstuk direct na het knikstuk. Zie eventueel paragraaf 2.7. Draagrollen monteren en transportband spannen 11. Monteer de schraper en stel deze af. Monteer waar nodig de draagrollen (ROLJ014762-022). Zie Figuur 2.12. 12. Bij knikband: plaats de overkapping en (bij een opgaand knikstuk) de schraperprofielen en de drukset van 1.

  • Page 56: Wielset Monteren (Verplaatsbare Mestopvoerband)

    2.9.2 Wielset monteren (verplaatsbare mestopvoerband) 3 Monteren van de mestgeleiding Monteer de wielset (ZMMT014762-804) van mestopvoerband die verplaatsbaar is. Zie Figuur 2.15. Stortbak plaatsen De stortbak wordt geassembleerd geleverd. Er zijn twee varianten.  Stortbak voor de opvoerband (FRDJ014762-204)  Stortbak voor de horizontale band en knikband (FRDJ014762-205) LET OP! Controleer voor het plaatsen van de stortbak of de transportband is opgespannen.

  • Page 57: Zijplanken Bij Het Toepassen Van Een Knikstuk (Knikband)

    3.2.3 Zijplanken bij het toepassen van een knikstuk (knikband) Monteer de zijplanken bij het knikstuk. Zie Figuur 3.5 Figuur 3.6. 1. Monteer altijd één zijplanksteun voor en één zijplanksteun na het knikstuk. 2. Monteer de zijplanken van de middensectie zo dicht mogelijk tegen de as van de drukset aan. LET OP! Houd de bovenzijde van de zijplanken gelijk aan de bovenzijde van de zijplanksteunen.

  • Page 58: Als Van Toepassing: Veiligheidsset Monteren

    Als van toepassing: veiligheidsset monteren 4. Monteer de veer aan een oogbout aan de lange zijde waar de trekkoordschakelaar niet wordt geplaatst. (De veer komt dus tegenover de trekkoordschakelaar, zie Figuur 4.3.) Monteer de veiligheidsset (ZMMT014762-853). Zie Figuur 4.3. 5. Rijg de noodstopkabel door de oogbouten en de katrollen. LET OP! De veiligheidsset is standaard bij een mestopvoerband en langs het opvoerdeel van de knikband.
  • Page 59 5.1.4 Ophanging bij tussenvloer (horizontale band) Overkapping en waterafvoerstrip Monteer de ophanging (ZMMT014762-856). Deze ophanging is alleen van toepassing bij een tussenvloer, 5.3.1 Overkapping waar de mestafvoerband in de lengte tussen twee Mestbandoverkapping is leverbaar in twee lengtes: gordingen zal hangen. Zie Figuur 5.5.
  • Page 60 Muurdoorvoer (horizontale band) 6 Afronden opvoerband Monteer de muurdoorvoer (ZMMT014762-843). Zie Figuur 5.12. 1. Monteer de zijplaten en onderplaat van de muurdoorvoer op de zijprofielen van de mestband. Bovenboog monteren a. Bepaal de positie van de muurdoorvoer. De bovenboog is leverbaar in twee lengtes: b.
  • Page 61 7. Monteer het bovenste deel van de poot (haaks ten opzichte van 6.2.2 Draaibare poot (draaibare opvoerband) de grond) aan de zijprofielen van de opvoerband. Zie Figuur 6.4. LET OP! Kijk nauwkeurig of u een draaibare of een verplaatsbare opvoerband heeft. Dit bepaalt namelijk a.
  • Page 62 7 Ingebruikname van mestafvoerband Volg onderstaande punten op voor ingebruikname van de band: Controleer alle bevestigingspunten en zorg dat alles goed vastzit. Controleer of de aandrijfrol waterpas geplaatst hangt. Controleer of de helling van het opvoergedeelte maximaal 24 graden is. Controleer of er geen gereedschap of andere materialen zijn achtergebleven op en in de band.

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