Mayfran ConSep 2000-125HP Guide

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 1
TECHNICAL DOCUMENTATION
COMMISSIONING/ SERVICE/ MAINTENANCE
Table of Contents
1 REVISION LIST ..........................................................................................................................................2
2 DECLARATION BY THE MANUFACTURER ............................................................................................3
3 GENERAL INFORMATION ........................................................................................................................3
3.1 Mayfran quality statement ..............................................................................................................3
3.2 Mayfran privacy statement .............................................................................................................3
4 UNPACKING AND TRANSPORT ..............................................................................................................4
4.1 Unpacking ......................................................................................................................................4
4.2 Transport........................................................................................................................................4
5 GENERAL WARNINGS AND SAFETY INSTRUCTIONS..........................................................................5
6 GENERAL INSTRUCTIONS FOR REPAIR, MAINTENANCE AND MALFUNCTIONS. ...........................6
7 GENERAL PRODUCT / FUNCTION DESCRIPTION ................................................................................7
7.1 Use of the Consep 2000 ................................................................................................................7
7.2 Important instruction.......................................................................................................................7
7.3 When requesting information or ordering spare parts....................................................................7
7.4 The way in which the system works ...............................................................................................7
7.5 Indexing filter drum.........................................................................................................................8
7.5.1 Filter drum cleaning circuit.................................................................................................9
8 COMMISSIONING THE CONSEP 2000 SYSTEM...................................................................................10
9 STARTING UP THE CONSEP 2000 SYSTEM ........................................................................................11
9.1 Initial start-up procedure...............................................................................................................11
9.2 E-control box ................................................................................................................................11
9.3 How to start the system................................................................................................................11
9.3.1 Conveyors........................................................................................................................11
9.3.2 Pumps..............................................................................................................................12
9.3.3 Pressure switches HP pumps..........................................................................................12
9.3.4 Level indicators additional coolant tank ...........................................................................12
9.3.5 Adjustement of automatic secondary system filter: .........................................................12
9.4 How to stop the system: ...............................................................................................................13
9.5 System malfunction......................................................................................................................13
10 PREVENTIVE MAINTENANCE ACTIONS...............................................................................................15
10.1 General issues .............................................................................................................................15
10.2 Maintenance actions mayfran components..................................................................................15
10.2.1 Driving unit steel belt conveyor / scraper conveyor........................................................15
10.2.2 Filter screen check.........................................................................................................16
10.2.3 Filter screen change procedure .....................................................................................16
10.2.4 Take-up adjustment steel belt conveyor / scraper conveyor .........................................17
10.2.5 Check items ...................................................................................................................18
11 FLOW DIAGRAM .....................................................................................................................................19
11.1 Flow diagram ConSep 2000-125 “L-Series”.................................................................................19
11.2 Flow diagram ConSep 2000-125 “Regular” .................................................................................20
12 REPLACEMENT PARTS LISTS ..............................................................................................................21
12.1 Part list ConSep 2000-125 “L-Series” ..........................................................................................21
12.2 Part list ConSep 2000-125 “Regular” ...........................................................................................22

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 2
1 REVISION LIST
Rev. 0 2008-07 Original release Eare
Revision Date Description Name

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 3
2 DECLARATION BY THE MANUFACTURER
(Directive 98/37/EEC, Art. 4.2 and Annex II, Sub B.)
Prohibition to put into Service
Manufacturer: Mayfran Limburg B.V.
Address: Edisonstraat 7
NL-6372 AK Landgraaf
Herewith declares that
CONSEP 2000®-125HP
- is intended to be incorporated into machinery or to be assembled with other machinery to constitute
machinery covered by Directive 98/37/EEC, as amended;
- does therefore not in every respect comply with the provisions of this directive;
and furthermore declares that it is not allowed to put the machinery into service until the machinery
into which it is to be incorporated or of which it is to be a component has been found and declared
to be in conformity with the provisions of Directive 98/37/EEC and with national implementing
legislation, i.e. as a whole, including the machinery referred to in this declaration.
Landgraaf, July 2008 Signature
3 GENERAL INFORMATION
3.1 MAYFRAN QUALITY STATEMENT
Mayfran is a ISO 9001:2000 Certified company.
Every supplied system has been test-run with coolant in our facility for a period of one hour prior upon shipping.
Deviation of this procedure is stated in the original valid quotation and order confirmation.
3.2 MAYFRAN PRIVACY STATEMENT
All rigths reserved;
no part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any
means, electronic, mechanical, photocopying, recording, or otherwise without written permission of the publisher,
Mayfran International BV Landgraaf.
This publication is designed to provide accurate and authoritative information in regard to the subject matter
covered. The publisher makes no representation, express or implied, with regard to the accuracy of the
information contained in this manual and cannot accept any responsibility or liability for any errors or omissions
that it may contain.

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 4
4 UNPACKING AND TRANSPORT
4.1 UNPACKING
The ConSep unit and additional coolant tank are both shipped / supplied on a separate pallet.
Small parts such as screws etc., are (if necessary) included separately.
4.2 TRANSPORT
Do not stand under the moving unit! The illustrations on this page are to be seen as examples. Always use the
equipment included for lifting and transport.
With crane:
- Original or other (not original) packaging!
- Always use the original lifting eyebolts
With forklift truck:
- Transport only on the original wooden pallet.
- Also secure equipment against falling or slipping.

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 5
5 GENERAL WARNINGS AND SAFETY INSTRUCTIONS
• Stick the included stickers on easily visible places on the conveyor.
• All specifications and instructions in the included operating instructions must be followed at all times!
• Non-qualified persons must not operate the unit!
• If customers attach parts themselves, be sure they do this properly!
• Never take short cuts with regard to safety equipment/ measures!
• The proper functioning of safety equipment must always be ensured!
• Only qualified professionals, taking into consideration all locally applicable specifications,
may do work on electrical parts
• Never stand on the intake opening or reach into the opening.
• Whenever possible, cover the conveyor and all drive elements prior to placement into operation.
• Never remove covering materials while the unit is in use!
• Never reach into the discharge opening!

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 6
6 GENERAL INSTRUCTIONS FOR REPAIR, MAINTENANCE AND MALFUNCTIONS.
• Switch off the main switch!
• Secure unit against unsupervised use!
• Switch off the unit's power!
• Switch off the unit's pressure!
• Close off pipe forwarder!
• Remove all potentially harmful substances!
• Do not permit cooling lubricants to escape into the environment!
If coming into contact with swarf:
• Wear protective clothing, protective shoes, and protective gloves!

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 7
7 GENERAL PRODUCT / FUNCTION DESCRIPTION
7.1 USE OF THE CONSEP 2000
Next to the transport of all types of swarf, the ConSep 2000 system also cleans the cooling lubricant with the aid
of a fine filter in the separation drum.
Further filtering of the cooling lubricant is generally not necessary for most swarf processing systems.
This manual contains instructions for the maintenance and/or replacement of wearing parts.
7.2 IMPORTANT INSTRUCTION
This manual must be made available to the maintenance personal responsible for the ConSep 2000.
The Mayfran guarantee will only apply if the instructions set out in this manual have been strictly adhered to.
7.3 WHEN REQUESTING INFORMATION OR ORDERING SPARE PARTS
Main spare components and wear components are listed on provided parts list! (See Chapter 12).
Please always refer to the Mayfran system number when requesting information or ordering spare parts.
The Mayfran system number can generally be found on the incline section of the conveyor and also on the
E-control box.
7.4 THE WAY IN WHICH THE SYSTEM WORKS
The chips and the cooling fluid emerge from the machine on to the charge section of the steel belt conveyor.
The cooling lubricant passes ‘through’ the steel belt conveyor and drains out of the side of the conveyor into the
‘waste water’ compartment of the scraper conveyor.
The majority of the chips are carried out by the steel belt conveyor into a chip-container below the discharge
section.
The smaller chips pass through the steel belt conveyor together with the cooling lubricant and thus end up in the
‘waste water’ compartment of the scraper conveyor.
The cooling lubricant passes through the polyester filtering cloth mounted on the separation drum and drains out to
the side. The filtering cloth is sprayed clean from the inside out by the nozzle shaft.
Any chips, which have managed to find their way into the ‘waste water’ compartment of the scraper conveyor,
eventually sink to the bottom of the compartment. After a certain length of time the scraper conveyor transports
these chips into the same chip container.
• The ConSep 2000 should only be used for the purpose for which it is originally intended!
• The noise level of ConSep 2000 in operation is < 70 dB (without machine pumps)
Warning:
Please ensure that the conveyor is running continuously when machining centre is operating !

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 8
7.5 INDEXING FILTER DRUM
The ConSep 2000-125HP unit features the latest Mayfran innovation on self-cleaning coolant filtration
equipment. The indexing filter drum is positioned in the upward curve of the conveyor unit. The special drive
mechanism utilizes the motion from the steel belt conveyor to create an indexing rotation of the filter drum.
The filter screen on the drum is cleaned using a maintenance free back wash system. The special backwash
pump is positioned on the main coolant tank. Make sure that the back wash pump always runs simultaneously
with the conveyor.
The indexing & cleaning cycle of the drum can be changed manually.
Four (4) different drum drive modes can be selected by changing the position of the fixation bolt on the
cog-wheel.
Default pre-setting by Mayfran: Drive mode I1.
Should maximum level occur on the ConSep 2000 unit at initial start-up or after machining start-up, check if
conveyor is in continuous running mode (default setting).
If conveyor is running in continuous running mode, drive mode I2 should be selected.
If the problem re-occurs, select drive mode I4 or I5.

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 9
7.5.1 FILTER DRUM CLEANING CIRCUIT
Filter drum back wash pump must always run simultaneously with the conveyor.
Check the drum cleaning function visually
through the side window of the ConSep 2000
conveyor.
Drum cleaning must be clearly visible on
outside of the filter screen (see picture).

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 10
8 COMMISSIONING THE CONSEP 2000 SYSTEM
• Ensure that the system is installed in a stable and safe position.
• Take the necessary measures to ensure that the system cannot be started up unintentionally.
• Check to ensure that there is no risk of jamming.
• Check to ensure that the system is free of tension during the inspection.
• Safety of personnel
If electrical or mechanical work needs to be carried out on the installation, switch off and disconnect the main
switch, since main power supply comes from the machine tool centre.
1. The conveyor must be aligned.
Deviation from the axial line may not be more than 2 mm to either side.
2. The conveyor belt and the chain must be lightly oiled.
3. Before starting up the conveyor, check the tension in the conveyor belt.
You should be able to press the underneath section of the conveyor belt (the part of the conveyor belt which
passes over the drive) inwards with your hand.
4. To re-tension the conveyor belt:
Take-up is factory-adjusted, but take-up bolts may loosen in transport.
Therefore, check tightness of the take-up bolts. If loose, re-adjust as explained in paragraph 10.2.4.
“Adjustment procedures”.
5. The side plates of the conveyor belt must be parallel to one another in direction of transport. If there is too
much play or if the side plates are not properly aligned, the material being transported will get jammed.
6. Foreign objects inside the frame
When installing the ConSep 2000, bolts, tools and packaging materials or other objects can be lost or left
inside the frame. Unless removed, these objects may get trapped in the mechanism, damage the filter or
cause some other sort of trouble. Check there are no foreign objects inside the frame.
7. Motor rotational direction check
To prevent trouble due to reversing, check motor rotational direction. Also, be sure to remove all loaded
work piece from inside the frame to prevent reversing in loaded operation.
8. Bolt tightness
During transport, bolts may loosen whereby displacing aligned parts. To prevent damage to the equipment,
check bolts are tight before performing the test-run.
9. The ConSep 2000 must first run for at least five hours without any load.
During running of conveyor take care that the conveyor belt and/or the grippers are able to move freely without
chafing anywhere.

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 11
9 STARTING UP THE CONSEP 2000 SYSTEM
9.1 INITIAL START-UP PROCEDURE
- Position the Mayfran ConSep unit according to Tornos drawings supplied with Tornos documentation.
- Connect ConSep unit electrically.
- Connect hydraulic hoses of pumps according supplied documentation by Mayfran.
(See paragraph 12.1 (drawing F74600.010.00_00) and paragraph 12.2 (drawing F74600.011.00_00)
- Fill the system with cooling liquid: a. Respect vicosty of cooling liquid (max 37 cSt. at 40°C)
b. Approx. total volume cooling liquid indicated on Mayfran assembly
drawing T74600.010.xx or T74600.011.xx
c. Fill at charge section of ConSep unit
Important: Only fill up unit with with lift pump (item 10) running !
d. Fill up to level high (setting SP3 on level indicator / switch (item 20))
9.2 E-CONTROL BOX
All functions of ConSep 2000 system are controlled by Tornos machine.
For detailed information concerning Mayfran E-control box see separate supplied Mayfran electrical diagram.
Important:
When mounting electrical components (by third party), for example pumps, indicators etc. the protection
class should be at least IP55.
9.3 HOW TO START THE SYSTEM
Switch power on of ConSep unit by turning the main switch of E-control box clockwise.
The steel belt conveyor (item 01), scraper conveyor (item 02), ‘internal’ steel belt conveyor (item 04) and the back
wash pump ConSep / cooler Tornos (item 60) will run.
Before start of machining the Tornos machine should send two signals to ConSep system:
1. Signal to start low pressure machine pump (item 1.30) and high pressure machine pump (item 1.40)
2. Signal to start the filter pump (item 1.80) and high pressure machine pumps (items 1.70 and 1.90)
9.3.1 CONVEYORS
− Steel belt conveyor (item 0.01) needs to start as soon as Tornos machine is switched on!
− Drag link conveyor (item 0.02) needs to start as soon as Tornos machine is switched on!
− Steel belt conveyor in Tornos machine (active chip extraction, item 0.08) always needs to start and stop
simultaneously with steel belt conveyor (item 0.01) of ConSep unit, otherwise risk of blockage !.

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 12
9.3.2 PUMPS
− Back wash pump / cooler pump chiller (item 1.60): Adjust pressure with shut valve (item 1.62) to approx.
1.6 bar (50 Hz)
− Low pressure machine pump (item 1.30): Adjust pressure with shut valve (item 31) to approx. 3.5 bar (50 Hz)
− Filter pump (item 1.80): No adjustments necessary
− High-pressure machine pump 1: 40 bar (item 1.40) completely open shut valve (item 1.43).
− High-pressure machine pump 2: 80 / 120 / 150 bar (item 1.70) completely open shut valve (item 1.73).
− High-pressure machine pump 3: 80 / 120 / 150 bar (item 1.90) completely open shut valve (item 1.93).
General remark:
Please switch on pumps in following order:
1. Low pressure pumps (Back wash pump Consep / cooler Tornos (item 1.60) on flow diagram
F74600.010.00_00 / F74600.011.00_00), machine pump (item 1.30), filter pump (item 1.80)
2. High pressure pump 1 (item 40)
3. High pressure pump 2 (item 70). Delay between switching on LP pumps and HP pump 1 and/or 2 is
variable and can be set.
4. High pressure pump 3 (item 90). Delay between switching on HP pump 2 and HP pump 3 is variable and
can be set.
‘Coolant input’ HP pump 2 and HP pump 3 is directly connected to additional filtered coolant from exit of
secondary filter. Only switch on HP pump 2 and HP pump 3 when filter pump is switched on!
The filter pump should only run when HP pumps (HP 2 and HP 3) are switched on!
9.3.3 PRESSURE SWITCHES HP PUMPS
- Pressure switch HP pump 1 (item 1.42): setting at 25 bar
- Pressure switch HP pump 2 (item 1.72): setting at 50 bar with 80 bar pump
Pressure switch HP pump 2 (item 1.72): setting at 100 bar with 120 bar pump
Pressure switch HP pump 2 (item 1.72): setting at 100 bar with 150 bar pump
- Pressure switch HP pump 3 (item 1.92): setting at 50 bar with 80 bar pump
Pressure switch HP pump 2 (item 1.72): setting at 100 bar with 120 bar pump
Pressure switch HP pump 2 (item 1.72): setting at 100 bar with 150 bar pump
For detailed information of pressure switches: see separate supplied supplier
documentation
9.3.4 LEVEL INDICATORS ADDITIONAL COOLANT TANK
- Level indicator (item 1.20): OFS = 7 (cm)
SP1 = 20 (cm) = level min.
SP2 = 25 (cm) = level low
SP3 = 62 (cm) = level high (= stop re-fill)
OP = 64 (cm) = level max (currently not used !)
- Level indicator (item 1.21): level max.
For detailed information of level indicators: see separate supplied supplier
documentation
9.3.5 ADJUSTEMENT OF AUTOMATIC SECONDARY SYSTEM FILTER:
Air inlet pressure to automatic secondary system filter should be set to 6 bar.
For detailed information of secondary system filter: see separate supplied supplier documentation.

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 13
9.4 HOW TO STOP THE SYSTEM:
Turning the main switch counter clockwise will stop the Mayfran system.
9.5 SYSTEM MALFUNCTION
Below you will find a listing of possible faults according Mayfran electrical lay out.
To resolve possible faults please also check supplier documentation of the components mounted on ConSep
system.

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
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Page: 14
Note 1: The item numbers in italic correspond with items on Mayfran flow diagram F74600.009.02.
Note 2: With alarm class 1 (orange), the machine will not stop immediately; machine cycle will finish before stop.
With alarm class 3 (red), the machine will stop immediately
The ConSep 2000 conforms to safety regulations. If it is not possible to remedy troubles as above, contact
Mayfran without attempting further intervention.

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
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Page: 15
10 PREVENTIVE MAINTENANCE ACTIONS
10.1 GENERAL ISSUES
Provided that this MAYFRAN ConSep 2000 is properly maintained, it will last a long time with a minimum of wear.
Please ensure that the belt and chain are lightly oiled at all times. Normally the belt should be oiled on a monthly
basis. In outdoor applications this interval should be shortened and maintenance must be carried out particularly
carefully. Check on a regular basis whether the belt shows signs of damage, so that parts can be replaced as
quickly as possible to avoid possible malfunctions.
Maintenance work on other third party components (pumps, filters etc.) should be carried out in accordance with the
instructions issued by the manufacturer.
10.2 MAINTENANCE ACTIONS MAYFRAN COMPONENTS
10.2.1 DRIVING UNIT STEEL BELT CONVEYOR / SCRAPER CONVEYOR
The gear units are intended for mounting in dry spaces. The gears are of shaft-mounted design and provided with a
hollow shaft. A torque arm serves to secure the unit. To balance out alignment errors and rule out mechanical
strains the torque arm has been attached to the conveyor via a special fixing structure provided with disk springs.
By this arrangement harmful impacts can be avoided. The mounting position of the gear units can vary.
The gears are filled in the Factory with a sufficient amount of lubricant and sealed so as to be oil-tight. They are
functional up to a maximum temperature of 100º C.
To prevent fretting corrosion between motor journal and the bore of the worm wheel, the motor journal must be
coated with a suitable lubricant when the unit is installed.
Mayfran recommends the use of Klüber Microlube GL 261.
The gear units have been equipped with an overload protection element (safety clutch). The safety clutch has been
set in the Factory to the torque rate needed for the respective application.
Adjustments and checks may exclusively be carried out in the factory of supplier of the driving unit.
The micro switch has been checked and precisely adjusted. The switch is connected via a standard plug to DIN
43650 / IS04400 and a suitable socket outlet.
Wiring of plug: 1 = black 2 = grey 3 = blue
Wiring of switch: 1 = black 2 = grey = N/C 4 = blue = N/C.
Grounding of the unit is affected through an earth terminal screw arranged on the switch casing cover.
The gear oil brand filled in is Klübersynth GH6-320, which is synthetic lube oil of standard
PG-LP ISO VG 320 to DIN 51502, featuring excellent sliding and ageing stability characteristics designed to give a
very long service life with the gearbox.
The requirements of standard PG-LP ISO VG 320 are also met by oil brands Mobil Glygoyle HE 320,
Shell Tivela S 320.
Gear Type Gear oil quantity
25.6GS 0,15 L
32.6GS 1,0 L
40.6GS 1,9 L
50.6GS 2,55 L
The gearbox is to be regularly checked to detect leakage, contamination and suspicious noise in due time.
Check before starting:
1. The required motor tension (see how motor is connected)
2. If the required tension is the same as the supplied tension

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 16
10.2.2 FILTER SCREEN CHECK
Check the filter screen on a weekly basis for damage and clogging.
If discovering something abnormal, remove and replace the filter element.
(Service life will vary from part to part depending on the type of chips conveyed, installation and maintenance,
and operating conditions. Therefore life span of filter screen will vary from a few months to a few years.)
10.2.3 FILTER SCREEN CHANGE PROCEDURE
 Drain the ConSep 2000 of coolant until the bottom of the filter is exposed.
 Remove the inspection cover.
 Remove all sludge and waste accumulated on the filter surface. Be careful not to drop sludge and waste
inside the frame. Foreign matter can clog the backwash nozzle, resulting in possible overflow.
 Remove the filter retainer and hose bands, followed by the filter screen (see fig. 1).
 Set a new filter on the filter frame and lay the retainer ‘A‘ on top of it. Then, secure the retainer ’A’ with
bolts. Wind the filter tightly around the frame to eliminate all slack and bunching.
 Similarly, lay the retainer ‘B’ on top of filter.
 Lock the retainer ‘B’ down with the bolts. Attach the hose bands.
 Reattach the inspection cover.
Hose band
Filter frame unit
Filter retainer B
Filter
Filter retainer A
Fig. 1

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 17
10.2.4 TAKE-UP ADJUSTMENT STEEL BELT CONVEYOR / SCRAPER CONVEYOR
As conveyor is used, wearing will stretch the belt. No take-up adjustment will result in excessive wear of belt and
rollers. Please adjust the take-up referring to the instruction below.
Adjustment interval
 After the first eight days from starting operation, the belt needs to be re-tensioned.
 On a monthly basis the belt must be inspected and re-tensioned if necessary.
Adjustment procedures
1. Remove side panels of drive cover and then remove drive cover.
2. Loosen the nuts of the take-up bolts (left and right).
3. Turn the take-up bolts about 3 turns to the pull side. Left and right take-up bolts are independent of one
another; therefore keep tension even on both sides.
4. Re-tighten the nuts of the take-up bolts (left and right).
5. Measure distance ‘A’ between the main sprocket wheel and the inside edge of the frame on both sides,
and make sure the main shaft is not off-centre.
When re-tensioning the conveyor belt, it is important to ensure that both of the tension screws are
tightened to the same extent. Otherwise the drive shaft will not be perpendicular to the direction of
transport.
6. When finished, re-mount drive cover and side panels of the drive cover.
Correct belt tension Incorrect belt tension

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 18
10.2.5 CHECK ITEMS
Daily check
Check items How to check Judgment / adjustment
1 Motor overheating / strange noises. Measure motor current. If near rated current, locate cause.
2 Strange noises / vibration from frame. Remove top cover, etc. Locate cause.
3 Filter screen clogging. Check visually.
Check back wash pump / correct coolant
pressure and replace pump if necessary,
check back wash nozzles and replace if
necessary, clean filter screen.
4 Filter screen damage. Check visually. Replace.
5 Air pressure secondary filter. Visual check pressure gauge. Locate cause.
Weekly check
Check items How to check Judgment / adjustment
1 Drive shaft bearing Overheating /
rotation. Touch parts and check visually. If abnormal locate cause and / or replace bearing.
2 Looseness in drive shaft bearing
installation bolt. Check with wrench etc. Tighten as necessary.
Monthly check
Check items How to check Judgment / adjustment
1 Chain tautness / turn. See paragraph 10.2.4
2 Bent/damaged conveyor chain/cleats. Check visually. Repair or replace as necessary.
3 Discharge section conveyors Check visually. If necessary, clean opening
Yearly check
Check items How to check Judgment / adjustment
1 Tooth wear in main sprocket
wheel / drive sprocket wheel. Visually check or touch parts. Replace if worn approx. 3 mm.
2 Chain pitch elongation.
Measure pitch in several links and
compute average
per link.
Replace chain if elongation is
2% of nominal pitch.
3 Chain roller rotation. Visual check.
Turn by hand. Clean / lubricate the roller.
4 Traction of conveyed works. Visually check complete chain. Clean the chain.
5 Missing / damaged split pins. Visually check belt pins. Replace the split pins as necessary.
6 Chain roller wear. Turn roller by hand and visually
check bottom plate on inside. Replace roller if side bars contacts travel rail.
7 Side bar wear. Visually check or measure with
callipers. Replace chain if worn 1/3 of plate thickness.
8 Back wash nozzles wear. Check visually. Replace.
Next to above described items Mayfran also advises annual complete manual cleaning of ConSep 2000
system to remove small fines and debris from the various clean tank compartments and system
components.

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 19
11 FLOW DIAGRAM
11.1 FLOW DIAGRAM CONSEP 2000-125 “L-SERIES”

ConSep 2000®-125HP
Tornos MultiDECO / MultiAlpha / MultiSigma
Rev. 0 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS 

: (31) 45 5329 292
Internet: www.mayfran.eu
E-mail: [e-mail]
File name:
T74600.010.00 - T74600.011.00_Tornos Multi Spindle Series_Rev.
0_English.doc
Page: 20
11.2 FLOW DIAGRAM CONSEP 2000-125 “REGULAR”