Belt Conveyor Instruction

Contents
I. General description 1
II. Structure introduction 1
1. Driving mechanism 1
(1) Driving method 1
(2) Main parts 3
2. Driven roller and tensioner 4
3. Sweeper 5
(1) V-shaped rubber sweeper 5
(2) H-shaped alloy sweeper 6
(3) Brush sweeper 7
(4) Weight dropper sweeper 8
4. Redirectional roller 8
5. Carrying roller 9
(1) Upper carrying roller set 9
(2) Lower carrying roller 10
(3) Side stopper roller 11
6. Belt 11
7. Conveyor frame 11
8. Pendant emergency stop device 12
9. Pendant device 12
10. Other devices 13
Protective cover, pedal and hand rest 13
Aggregate collector 13
Belt conveyor frame 13
Aggregate feeding and discharging devices 13
III. Commissioning 13
IV. Maintenance of aggregate belt conveyor 14
1. Inspection and maintenance of main components 14
2. Daily maintenance and overhaul 15
3. Regular maintenance and lubrication list 15
V. Troubleshooting 16
1. Common troubles 16
2. Solution to belt deviation 17
VI. Wearing parts 19
Fujian South Highway Machinery Co., Ltd. Nationwide Free Service Hotline: 800-8585898
Aggregate Belt Conveyor
I. General description
1. Scope of application and features
Aggregate belt conveyor is a kind of high-capacity conveyor equipment that features low
operating costs and continuous conveyance. It is applicable for the conveyance of ordinary bulk
materials in a bulk density of 500-2,500kg/m3. Its working environmental temperature is -10℃ to
+40℃. Relevant protective measures shall be taken in case of special working environment, e.g.
hot, cold and corrosive environments. Allowable block sizes are determined by belt width, belt
speed, trough angle and dip angle. The maximum block sizes applicable for various belt widths
are recommended in Table 1 as follows (unit: mm):
Belt width 650 800 1000 1200
Max. block size 150 200 300 350
2. Product model, specifications and code

As an essential part of concrete mixing equipment, aggregate belt conveyor is divided into the
following types based on belt shape: plain belt conveyor, V-shaped belt conveyor, trough belt
conveyor. Normally plain belt conveyor's maximum dip angle α≤20° while the dip angle of
V-shaped and trough belt conveyors is comparatively bigger, as many as 27° for the former and
45°for the latter.
belt length
belt width
general type
Belt type: P: flat R: v-type C: Groove
belt conveyor
For instance: DPT80900 D-belt conveyor P-plain belt T-general purpose 80-belt
width 80cm 900-belt length 90.0m
3. Precautions
(1) The belt conveyor must be operated, maintained and repaired by professionals
(2) Do not dismantle the safety devices
(3) Do not operate and modify the equipment against relevant requirements
In case of equipment structure improvement or parameter changes, we are not obliged to notify
otherwise and the actual products shall prevail.
II. Structure introduction
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Aggregate belt conveyor mainly consists of driving mechanism, driven roller, redirectional roller,
carrying roller, tensioner, belt, sweeper, frame, support, protective device, emergency pendant
switch, feed hopper, repair pedal and hand rest, etc.
The following is an introduction of these parts taking DPT tilted plain belt conveyor as an
example, which shall be a reference for other types of belt conveyors. Please see Figure 1.
1 Driving 2 Alloy 3 Belt 4 Aggregate 5 Pendant 6 Hand

mechanism sweeper frame collector device rest
7 Conveyor 8 Pendant 9 Driven 10 Feed 11 Belt 12 Outside
frame sweeper roller hopper covering
and
tensioner
13 Pendant 14 Redirectional 15 Upper 16 Side 17 Lower
emergence device carrying stopper carrying
stopper roller roller roller
Figure 1 DPT Tilted Plain Belt Conveyor
2
3
1. Driving mechanism
(1) Driving method
Driving mechanism is normally installed on the head of the belt conveyor and usually has the
following three types:
① Driven by electric roller
There are a motor and reducing gears in an electric roller (please see the Instructions Manual of
electric roller). It has a compact structure and small size and thus is only applicable for belt
light-duty conveyors of a short conveyance distance.
Figure 2 Electric Roller
② Triangular belt driving mechanism

Power is transmitted from motor to the shaft-mounted reducer via SPC triangular belts and the
reducer drives the driving roller at a constant speed. When the belt conveyor is installed slantways,
the shaft-mounted reducer shall be furnished with one holdback inside. Figure 3 shows S-direction
(clockwise) configuration. When the motor and the reducer are installed in the opposite direction,
it features N-direction (counterclockwise) configuration and the holdback in the shaft-mounted
reducer shall be installed in the opposite direction as well. Meanwhile, the length of SPC
triangular belt shall be adjusted.
Installation, adjustment and maintenance:

 Various parts are installed in place as Figure 2 shows and various couplings are flexible and
reliable;
 The parallelism between roller axis and horizontal plane is 1/1,000 of roller axis length; the
verticality between roller axis and conveyor frame centerline is 2/1,000 of roller axis length;
the symmetry between roller centerline and conveyor frame centerline is 3.0mm;
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 Adjust the adjusting screws so that both belt pulley axes are parallel and the symmetry planes
of V-shaped grooves of both pulleys shall have coincides with each other with an error of not
over 2mm;
 The triangular belt shall be evenly loaded. Adjust the connecting pieces of shaft-mounted
reducers so that the triangular belt is pretensioned and each belt has an initial tension of about
550-620N;
 Roller bearing seat shall be filled with lithium-based lubricating greases on a regular basis for
the sake of maintenance;
 Reducers shall not show any sign of leakage. Replace the lubricating oils inside reducers on
time. Install the reducer as vertical to the ground as possible with a maximum dip angle of
not over 10°.
Replace severely worn-out and damaged triangular belts and rollers in a timely manner.
Figure 3 Belt Driving Mechanism

1 Driving roller 2 Motor bracket 3 Adjusting screw 4 Driving motor
assembly
5 Small belt 6 Belt protective 7 SPC triangular 8 Big belt pulley
pulley cover belt
9 Shaft-mounted reducer (with 10 Bearing seat
connecting pieces)
③ Chain driving mechanism

Chain driving mechanism is generally the same as triangular belt driving mechanism in that its
power is transmitted to the driving roller through multiple chain transmission of cycloid pin wheel
reducer (with motor braking). The only difference is that it features a compacter structure, the
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more stable transmission, the smaller radial load on driving roller shaft and holdback effects with
the help of motor brakes, as Figure 4 shows. As the chain transmission mechanism is located on
the low-speed shaft of reducer, there is a bigger torque and the chain is more heavily loaded. Thus
it is not applicable for heavy-duty long-distance conveyers.
Figure 4 Chain Driving Mechanism

Driving Big
Bearing Pressure Pressure plate
1 roller 2 3 sprocket 4 5
seat plate bolt
assembly wheel
Small Reducer
Chain
6 Chain 7 8 sprocket 9 (with
cover
wheel motor)
Installation, adjustment and maintenance

Installation, adjustment and maintenance of chain driving mechanism are generally as the same as
those of triangular belt driving mechanism. The only differences are as follows:
 Chains do not need tension but control on sagging is needed, i.e. f=（0.01~0.02）a mm; a
means the central distance between two sprocket wheels.
 Chains need to be frequently lubricated to reduce friction and noises.
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(2) Main parts

① Driving roller
Figure 5 Driving Roller with Polished Steel Surfaces
Driving roller is the main part for power transmission. In order to increase the friction coefficient
with belts, driving roller is normally applied with adhesive tapes on the surface. Polished steel
surfaces may also be adopted for light-duty conveyors in a dry environment. Adhesive tapes are
applied in two methods, i.e. overall covering of adhesive tapes and split friction plate.
Figure 6 Driving Roller with Overall Covering of Adhesive Tapes
Overall covering of adhesive tapes refers to the application of patterned adhesive tapes on the
working surfaces of driving roller. Such patterns may be V-shaped or diamond-shaped. V-shaped
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pattern features a higher friction coefficient and better antiskid and water repellent properties but
has unidirectional. Diamond-shaped pattern is used for bidirectional conveyors.
Figure 7 Driving Roller with Adhesive Tapes Resembling Friction Plates

Welded-in-one-piece Adhesives resembling
1 Batten 2 3
roller friction plates
Driving roller with adhesive tapes resembling friction plates

Driving roller with adhesive tapes resembling friction plates is the latest development of our
Company and features a high friction coefficient, good water repellence, simple repair and
maintenance and long working life. The roller diameter is normally Ø530 and Ø630.
This type of driving roller has the following advantages: the adhesive tapes on the surface of
driving roller will inevitably be worn out so that the friction coefficient is reduced and belts skid
more often than usual. Ordinary overall covering of adhesive tapes will need to be replaced as a
whole if so. In the case of adhesive tapes resembling split friction plates, however, only the
worn-out friction plates need to be replaced as the above figure shows because such friction plates
are secured with battens welded on the roller. What makes it even more convenient is that such
adhesive tapes that resemble friction plates are wearing parts and have been standardized (please
see the spare parts listed hereinafter for details).
② Bearing seat
As Figure 8 shows, its body, blast cap and end cap are high-precision nodular cast iron
components and the bearing is heavy-duty self-aligning ball bearing that is good-looking with a
high loading capacity and long working life.
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Figure 8 Structural Drawing of Bearing Seat

1 Bolt 2 Blast cover 3 Gasket 4 reinforced
seal
5 Heavy-duty 6 Body 7 Oil cup 8 End cap
self-aligning
ball bearing
2. Driven roller and tensioner

Driven roller is installed at the end of the belt conveyor and used to change the traveling direction
of belt. It polished steel surfaces and its diameter is normally Ø400 and Ø500.
① Frame tensioner
1 Tensioning screw 2 Adjusting screw 3 UCK bearing with seat
4 Driven roller 5 frame
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② Sliding block tensioner
Figure 9 Tensioner
There are two commonly used tensioners as the above figure shows. Belt length and motor power
shall be considered to determine which one shall be selected. Under normal circumstances,
tensioners can't be adjusted to a substantial extent. The tensioner is adopted in case of short belt
and light-duty conveyor. Comparatively, sliding block tensioner allows more adjustments than
frame tensioner. Another difference is that the screw of sliding block tensioner remains still while
that of frame tensioner rotates during adjustment.
Working principle: the tensioner works together with the driven roller. Rotate the adjusting screws
on the screw or tensioner to adjust the tension so that the belt is sufficiently stretched. In this way,
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the belt will not skid on the driving roller and the sagging of belt between rollers can be limited to
ensure the normal operation of the belt conveyor.
 Install various parts in place and ensure that all couplings are fast and reliable;
 Bearings with seat shall be filled with lithium-based lubricating greases on a regular basis for
 Screws and guide keys shall be applied with protective greases;
 Properly adjust the angle between roller axis and conveyor centerline to avoid the deviation
of belt;
 Frequently adjust the tensioner as per the tensioning extent to ensure that the belt will not
skid;
 The displacement of driven rollers on each side shall be the same during screw adjustment
and the maximum pulling force shall not be more than 24KN.
Precautions:
In case of long belt and heavy-duty conveyor, a pendant (to be introduced hereinafter) instead of
this device shall be adopted for adjustment of belt tension. Screw tensioner is only used to adjust
the verticality of driven roller axis to conveyor frame centerline.
3. Sweeper
There are various types of sweepers and the commonly used ones include H-shaped alloy sweeper
(head) and V-shaped rubber sweeper (end). Others include weight dropper sweeper, brush sweeper,
etc. As its name indicates, it is used to clean the belt and prevent materials and other foreign
matters from falling into the driven roller or tension roller and thus damaging the belt. The
sweeper at the head can also work to clean away discharged materials.
(1) V-shaped rubber sweeper

V-shaped rubber sweeper is installed near the driven roller to clean the non-working surfaces of
return belt. It is hinged onto the conveyor frame with a connecting rod and keeps scrubbing the
non-working surfaces of belt under its dead load and the belt’s moving force to clean away the
aggregates and other foreign matters on the inner side of the belt.

 As Figure 10 shows, install various parts in place and all couplings are fast and flexible;
 Adjust V-shaped rubber plate to ensure that at least 85% of its working surfaces are in contact
with the belt;
 Adjust the upper hinge position on the hanging plate so that the sweeper’s clearance with the
end rollers is less than 50mm;
 Adjust the tension of backup safety wire ropes so that they shall be slightly loosened when
the sweeper is installed in place;
 Repair or even replace severely worn-out rubber plates if necessary.
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Figure 10 V-shaped Rubber Sweeper

1 Wire rope 2 Wire rope 3 Pin shaft 4 Split pin 5 Plain cushion 10
clamp
6 Fastening and 7 Hanging 8 Sweeper 9 Sweeper
regulating plate cover board
plate
Figure 11 (V-shaped Rubber Sweeper) Hinge Position
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(2) H-shaped alloy sweeper

It is installed on the driving side of the belt conveyor, i.e. the head of the belt conveyor, in a
unidirectional or bidirectional manner. Figure 12 shows H-shaped alloy sweeper that works to
clean away the aggregates, stones, wet mud and other foreign matters on the belt.
Unidirectional alloy sweeper
Local assembly of alloy sweeper
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Bidirectional alloy sweeper
Figure 12 H-shaped Alloy Sweeper

Sweeper Bent rod Connecting Adjusting
1 2 3 4
board assembly plate bolt
Permanent
5 6 Bracket 7 Elastomer
seat
Alloy sweeper is most ideal for belt conveyors. Improper installation and maintenance of alloy
sweeper will affect its sweeping effects and working life. The following illustrate some
requirements on the installation, commissioning and maintenance of H-shaped alloy sweeper.
 Check if the working surfaces of adhesive tapes are damaged and if there is any reinforcing
metal thereon, e.g. iron shackle, iron nail, in which case alloy sweeper can’t be installed
(damaged area shall not exceed 100sqmm);
 Remove the adhesive substances on the surface of driving roller so that the sweeper can
operate in a stable manner;
 Weld the adjusting frame onto the headstock cross beam in the dimensions specified in L1
and L2 of the following table to ensure that the bearing can be sufficiently adjustable on the
adjusting frame (please see the above figure);
Roller diameter D Ø530 Ø630 Ø800
L1 402 434 490
L2 109 165 325
α 30° 30° 15°
Note: the following installing dimensions may be applicable if it is hard to locate the funnel seat
on a conveyor with a roller diameter of Ø 530 or Ø 630.
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Roller diameter D Ø530 Ø630

L1 370 385
L2 208 275
α 15° 15°
 Install the sweeper into the adjusting frame so that it slightly touches the adhesive tapes and
then gently fasten the set bolts;
 Adjust the adjusting screws to make the sweeper board parallel to the traveling direction of
adhesive tapes (an angle of 30°or 15°is ensured). Then insert two Ø16 reinforcing bars
into the pressure holes on both ends of the shaft lever and increase the pressure between
scrubber and adhesive tapes to 100 to 150N;
 Scrubber shall contact with the adhesive tapes in an even manner with a contact area of not
less than 85%;
 The working pressure shall be properly applied. Excessive pressure will increase the friction
resistance and thus the working life of adhesive tapes and elastomers, leading to poor
sweeping effects;
 The removed adhesive substances are stacked up on the scrubber and elastomer and must be
eliminated in a timely manner, failing which the working surface width and elatomer’s
vibration absorption will be increased to affect the sweeping effects and working life;
 The set bolts of the elastomer and various parts will lead to aging, reduced elasticity and
rupture of rubbers and thus loosened bolts after a certain period of time. Replace them in a
timely manner if so.
New-type alloy sweeper
New-type Alloy Sweeper

1 2 3 4
Torsion arm Permanent seat Pressure spring Stud
As an improvement on the original alloy sweeper, new-type alloy sweeper features basically the
same structure and operating method. It has one additional torsion arm and pressuring spring on
both ends. The spring force is applied onto the scrubber through leverage to maintain a contact
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pressure of 100 to 150N between the scrubber and adhesive tape for the sake of good sweeping
effects.
Special precautions:
 Connecting angle steel has been installed on the conveyor frame before ex-works. It is
necessary to adjust the installing position on the connecting angle during installation to
ensure even contact between the scrubber and the surfaces of adhesive tapes. The contact
surface shall not be less than 85% of all;
 The pressure springs on both sides shall have the same compression of about 20-40mm.
(3) Brush sweeper

When belts with patterned surfaces are selected instead of plain ones, e.g. V-shaped belts, brush
sweeper must be provided. Brush sweeper is installed at the head of belt conveyor with the
following working principles (as Figure 13 shows): motor drives the circular brush to rotate
through the triangular belt. The rubber brush sweeps and cleans the working surface of belt.
Figure 13 Brush Sweeper

Bearing with
1 2 Brush 3 Big belt pulley 4 Belt cover
seat
Triangular Motor
5 6 Small belt pulley 7 Motor 8
belt frame

 Install various parts in the correct position as the Figure shows;
 Adjust so that the brush is slightly and evenly in contact with the belt (long holes for motor
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frame and bearing seat) and the brush axle is parallel to the roller axis;
 Proper adjust the triangular belt to ensure sufficient tension thereof;
 Adjust the rotating direction of brush so that is runs adverse to the roller's rotating direction;
 Bearing with seat shall be added with lithium-based lubricating greases on a regular basis for
 Make timely adjustments after the brush is worn-out so that it is slightly and evenly in
contact with the belt.
(4) Weight dropper sweeper

Weight dropper sweeper and alloy sweeper have the same functions and are installed at the head
of belt conveyor.
Working principles: the weight dropper works on the rubber scrubber through leverage so that the
scrubber is touches the belt at a certain pressure. The traveling of belt thus leads to the scrubbing
and removal of adhesive substances on the belt.
Figure 14 Weight Dropper Sweeper

Weight
1 2 Bolt 3 Bracket
dropper
4 Frame 5 Rubber scrubber 6 Batten

 Install various parts in place as the figure shows and all couplings are fast, flexible and
reliable;
 Adjust the set bolts of rubber scrubber so that its contact surface with the belt is at least 85%;
 Adjust the contact pressure between scrubber and belt by adjusting the position of weight
dropper on the frame. Insufficient pressure leads to poor sweeping effects while excessive
pressure easily damages the belt;
 Regularly check the wear and tear of the working surfaces between rubber scrubber and belt
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and make adjustments. Change the direction of or even replace the scrubber if necessary.
4. Redirectional roller
Redirectional roller works to change the traveling direction of conveyor belt or increase the angle
of contact between belt and driving roller and properly adjust the angle between redirectional
roller axis and conveyor frame centerline in order to correct belt deviation.
Redirectional roller is of a welded metal structure (as Figure 15 shows) and its axle is connected
with single key and bushing. Its surface is normally polished steel surface or treated with polishing
adhesives; the roller diameter is determined by belt width, driving roller and redirectional angle.
The normal diameters include Ø270, Ø320 and Ø400.
Figure 15 Redirectional Roller

Redirectional Bearing with
1 2 Adjusting bolt 3 4 Axle
roller seat
5 Roller body 6 Flat key 7 Bushing 8 Spoke

 Install various parts in place as the figure shows and all couplings are fast and reliable;
 Bearings shall be filled with lithium-based lubricating greases on a regular basis for the sake
of maintenance;
 Properly adjust the angle between roller axis and conveyor centerline to avoid the deviation
of belt.
5. Carrying roller
Carrying rollers work to support the belts and the materials thereon to ensure the smooth traveling
of belts.
Carrying rollers include upper carrying roller set, lower carrying roller set and side stopper roller.
Key rollers that constitute carrying roller
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Key rollers have a diameter of Ø 89 or Ø 108. Normally, roller diameter is selected according to
the load that it bears.
There are two types of rollers, i.e. heavy-duty and light-duty rollers.
轻型辊子 Light-duty roller 重型辊子 Heavy-duty roller

Figure 16 Roller
Shaft locking Roller
1 2 Bearing 3 Bearing seat 4 Shaft 5
ring body
Heavy-duty bearing and labyrinth sealing area adopted for heavy-duty roller that is applicable for
complicated onsite working conditions.
Installation and maintenance:

 Lithium-based lubricating greases have been injected between roller’s bearing and O-ring.
Check the waterproof, dustproof and flexibility of roller before installation;
 Take care to protect the rollers from hammering and falling off;
 Regularly check the normal rotation of various rollers during operation and remove adhesive
substances in a timely manner.
(1) Upper carrying roller set

Upper carrying roller set distance: in order to ensure a sufficient bearing capacity of roller’s
bearing and a proper sagging of belt, the distance between upper carrying rollers at bearing branch
is normally 1,200mm; the distance between upper carrying rollers where materials are feed is
determined on the basis of material bulk density, block size and falling height and normally 1/2 to
1/3 of the distance between rollers at bearing branch. The higher the bulk density and falling
height, the smaller the distance will be.
Upper carrying rollers normally include groove rollers and parallel rollers.
As the most commonly adopted roller, groove-type upper carrying roller is good for conveying
bulk materials. It is often used for plain belt conveyor and V-shaped belt conveyor with a groove
angle of α=35°, 45° and 25°. Upper carrying rollers with a smaller groove angle will normally be
installed at the head and end of belt conveyor for the convenience of belt transition. It can also
avoid material spilling during spreading of conveyor belt.
Parallel upper carrying roller is normally used when the bearing branch carries packaged materials
and when groove belts are used.
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Parallel upper carrying roller Groove upper carrying roller

Figure 17 Upper Carrying Roller Set
Carrying Plain
1 2 3 Frame 4 Roller A 5 Roller B
roller set roller

 Upper carrying roller set is normally installed from the head down. Adjust the upper carrying
roller set so that the rollers' upper surfaces are on the same level. The upper surfaces of
adjacent three carrying rollers shall not deviate by more than 2.0mm;
 The symmetry degree between roller centerline and belt conveyor frame centerline shall be
3.0mm;
 Adjust upper carrying roller set so that its centerline runs vertical to belt frame centerline and
then fasten the set bolts;
 When the belt above deviates or zigzags during trial running with zero load, the angle
between upper carrying rollers and belt frame centerline may be properly adjusted;
 Frequently check the operation of rollers and repair or replace inflexible and non-operating
rollers in a timely manner.
(2) Lower carrying roller

It is used to support the belts of the return branch with a distance of 2.4 to 3m.
There are normally two types of lower carrying rollers:
 Roller with polished steel surface;
 Roller with adhesive tapes on the surface, whose structure is illustrated in Figure 18.
Please see the instructions on upper carrying roller set for the installation, adjustment and
maintenance of lower carrying roller set.
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Figure 18 Lower Carrying Roller

Lower Lower Shaft
1 carrying 2 carrying 3 Belt 4 retainer 5 Bearing
roller seat roller ring
Roller Retainer Adhesive
6 Shaft 7 8 9
body ring tape ring
(3) Side stopper roller

Side stopper roller is installed on the conveyor frame to
effectively stop and protect deviated belts. It is usually installed
where the belt is easily deviated.
There are three types of side stopper rollers as Figure 19 shows.
Figure 19 Side stopper roller

NFT.DB1 NFT.TG31 NFT.DB3
Lithium-based lubricating greases have been injected between

roller’s bearing and O-ring. Regularly check if various rollers are operating normally and if there
is any foreign matter on the surface. Remove such foreign matter if any.
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6. Belt
Belt is the towing and carrying device of aggregate belt conveyor and is made of rubber-coated
multi-core polyamide fibers (nylon). At least NN200 type shall be adopted with vulcanized joints.
Single belt shall form a closed loop.
Belt width: 650, 800, 1,000 and 1,200 are normally used
Belt shape: plain belt, V-shaped belt and groove belt. Plain belt is commonly used.
Maintenance
 Avoid contact with various raw chemical materials and oils;
 Avoid collision with sharp objects during operation;
 Avoid overhigh or overlow working temperature and adopt protective measures if necessary;
 Keep the belt clean and dry if out of use;
 Repair any damage in a timely manner to avoid aggravation.
7. Conveyor frame
The conveyor frame is used to support the rollers and the tension of belt. It is made of a welded
H-steel structure for the convenience of transportation and installation. It is fabricated in sections.
The front frame has a standard length of 8.4m while other standard lengths (e.g. Figure 20)
include 7.2m or 4m.
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Figure 20 Conveyor Frame

1 Front 2 Intermediate 3 Intermediate 4 Rear
frame frame frame frame
Connecting plate and high-strength bolts are used to connect conveyor frame, the overall structure
of the conveyor frame features compactness, steeliness and high strength.
Figure 21 Conveyor Frame Connection
Installation and maintenance

 The frame's overall linearity shall be 1/1000 of total length. The difference between two
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diagonals shall not exceed 3/1000 of their mean value.

 The high-strength bolts connecting the frames shall have a pre-stressing moment of 200N.m.
 Do not hit the frame violently or press hard against any part thereof during transportation,
hoisting and installation to avoid deformation
 Keep the frame clean and dry to avoid rusts.
8. Pendant emergency stop device
Figure 22 Pendant Emergency Stop Device

1 2 3 4 5
Pendant emergency Wire rope Wire rope Flat knot bolt OO type
switch clamp rigging screw
As the safety protective device of the belt conveyor, the pendant emergency stop device is
normally distributed on both sides of the belt conveyor so that the operator can pull the pendant
switch at any part of the conveyor in case of fault to cut off power supply and stop the conveyor.
In addition, the pendant switch may also be pulled to stop the conveyor and avoid equipment and
personal safety accident when conveyor startup is not allowed after startup signals have been
given out.
The number of pendant switches is determined by the length of the conveyor. The pendant switch
is normally installed in the middle of pull wire that shall not exceed 40m on one side. Flat knot
bolt is installed at an interval of 3m to avoid excessive sagging of pull wire.
Maintenance
 Check if various flat knot bolts and pull wire lockers are loosened;
 check the operating flexibility of pendant switches;
 Keep the pendant switches waterproof and moistureproof.
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9. Pendant device
The pendant device provides sufficient tension for the belt and can automatically compensate for
the length of belt with its gravity according to the change in tension. Please see Figure 23 for its
structure.
The weight of the pendant may be increased or decreased to achieve the tension required for the
belt. Increase the pendant weight and thus the tension if the belt is loosened; decrease the pendant
weight and thus the tension if the belt is excessively tightened.
Figure 23 Pendant Device

1 Pendant 2 Bearing with 3 Connecting 4 Pendant
roller seat plate frame
5 Clump 6 Guide rod 7 Bracket 8 Pendant box
weight
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Figure 24 Partial Enlarged Drawing

 Regularly inject lithium-based lubricating greases into the bearing for the sake of
maintenance;
 Apply greases onto the guide rod and guide sleeve for the sake of protection;
 Adjust the pendant device as per the tensioning of belt to avoid belt skidding.
10. Other devices

Protective cover, pedal and hand rest
Protective cover is installed above the belt conveyor to protect the environment and prevent
aggregates and dust from flying around and mixing with rainwater. Pedal and hand rest are
provided for the purpose of patrolling, maintenance and overhaul.
Figure 25 Protective Cover, Pedal and Hand Rest
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Aggregate collector
Aggregate collector is provided to collect the aggregates the drop off during conveyance. Such
aggregates are then transported to the ground via a guide pipeline in a safe and clean way.
Belt conveyor frame
A frame is provided to support and secure the conveyor. They are bolted together normally. Pin
shaft hinged connection is adopted when the conveyor frame is high.
Figure 26 Aggregate Collector and Conveyor Frame
Aggregate feeding and discharging devices
Figure 27 Feed Hopper
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III. Commissioning
1. Preparations before commissioning
(1) Check if all parts are installed in place;
(2) Check if reducer or electric rollers are sufficiently lubricated and add lubricating oils if not
before zero load trial running is carried out;
(3) Pay special attention to correct electric wiring and voltage stability;
(4) The scrubber of installed sweeper shall have at least 85% contact surface with the belt along
the roller axis;
(5) Ensure that various bearings and lubricating points are properly lubricated;
(6) Various rotating parts shall be flexible and none shall be stuck fast;
(7) Fittings are not loosened;
(8) Check if there are foreign matters on the belt and clean away if any;
(9) The reducer shall be furnished with a holdback device. Remove the triangular belt and check
the rotational direction of motor before trial running of belt conveyor. Then install the triangular
belt properly and start the trial running.
2. Zero-load trial running

Start the belt conveyor with zero load after the preparatory work and check the following items:
(1) If the rotational parts are flexible and none is stuck;
(2) If various fittings are loosened;
(3) If there is any abnormal noise and carry out troubleshooting if so;
(4) If the belt is operating normally free of interference during the whole journey;
(5) If electric equipment, pendent emergency switch, proximity switch and travel switch are
reliable;
(6) If the scrubber and sweeper are in normal contact along the roller axial direction;
(7) If the belt skids and deviates and solve the problem if so;
(8) If the bidirectional conveyor is capable of operation in the adverse direction and check the
abovementioned items again when the conveyor is operating in the adverse direction.
3. Loaded trial running

After the zero-load trial running is passed, carry out the loaded trial running to test the carrying
and conveying capacity of the conveyor.
(1) The conveyor shall operate in a stable manner and none of the rollers shall be stuck fast
during loaded operation;
(2) The belt shall travel in the middle along the length of the carrying rollers and its edge shall be
more than 30mm away from the outer rim of the carrying rollers. No deviation is allowed;.
(3) The driving mechanism shall not generate any abnormal vibration during loaded operation.
The motor’s actual power shall not exceed the rated power and the bearing temperature shall
not exceed 30 degrees;
(4) The tensioner or pendant shall operate flexibly to prevent roller skidding during conveyor
startup and operation;
(5) The belt shall be properly tensioned so that the belt will not skid on the driving roller. Note
that overtensioned belt will cause improper stresses in the bearing of carrying rollers,
excessive wear and higher power consumption;
28
(6) Neither stuck roller nor spilled materials are allowed during loaded operation;
(7) The sweeper shall operate effectively and stably free of abnormal vibration.
IV. Maintenance of aggregate belt conveyor

1. Inspection and maintenance of main components
(1) Shaft-mounted reducer (TiT type)
 Oil filling standards: oils had better be filled up to oil gauge centerline or 1/4 of reducer
casing. Clogged vent holes of reducer or overfilling of oils will lead to excessive internal
pressure and thus oil leakage of oil seals and the joint face of reducer;
 Lubricating oil replacing intervals: lubricating oil must be replaced one month after initial
operation of the conveyor. Regularly check oil quality thereafter and replace oils if they are
aged. Replace oils once three months during long-term continuous use of the conveyor.
Replace oils once every six months if the conveyor operates less than eight hours a day;
 Grease model: L-CKC100~L-CKC200 middle extreme pressure industrial gear oils and other
equivalent or better lubricating oils;
 Regularly check various fittings to ensure that none is loosened;
 Regularly check the loosening extent of belt to ensure a proper tension. Excessive tension
will cause unnecessary radial loads and thus affect the working life of reducer and other
parts.
(2) Electric roller
 Oil filling standards: add the oils up to 1/3 of roller diameter. Regularly replace oils. The oil
model and filling interval of shaft-mounted reducer shall be applicable;
 Regular check various fittings to ensure that none is loosened;
 After installation of electric rollers, replace the sealing screws at the bracket with vent screws
in a timely manner (each roller is furnished with vent screws) and regularly add lubricating
oils into the bearings inside the bracket;
 Check if the junction box of electric roller is properly sealed and insulated and if there is any
electric leakage and even burnout.
(3) Cycloid pin wheel reducer
 Oil filling standards: add the oils up to 2/3 of reducer oil gauge. Regularly replace oils. The
oil model and filling interval of shaft-mounted reducer shall be applicable;
 Stop the operation, carry out troubleshooting and replace lubricating oils if the temperature
rise exceeds 60℃ or oil temperature exceeds 85℃ and there is abnormal noise.
(4) Replace the carrying roller if it operates inflexibly due to damaged bearing.
(5) Driving roller
 Check if the driving roller gives out an abnormal noise during operation;
 Regular add oils into the bearing seat at least once every two weeks;
 Keep the adhesive tape covering clean to reduce friction and prolong working life.
2. Daily maintenance and overhaul

(1) Inspection and maintenance items per day (shift)
 Check if the upper and lower carrying rollers are operating properly and if there is any
29
abnormal noise;
 If any component is loosened or detached;
 If there is any wooden chip or other foreign matter at the discharge port of mixing station;
 If the belt zigzags or deviates.
(2) Inspection and maintenance items per week
 If the carrying roller frame has any wet mud thereon;
 If the carrying roller and roller have any mud thereon;
 If various bolts of belt conveyor are loosened;
 If the front sweeper and rear sweeper operate improperly due to wear and tear;
 If bearings are clean and timely lubricated;
 If pendant or tensioner is flexible and reliable;
 If belt tension is proper and if the belt is neither skidding nor damaged.
(3) The bearings of all rollers must be lubricated once every half a month.
(4) Inspection and maintenance every half a year
Replace oils and clean the electric roller or reducer 500 working hours after initial use. Then
replace the oils every 1,500 working hours or every half a year.
(5) Bearings of all carrying rollers must be sealed and need not be lubricated.
3. Regular maintenance and lubrication list

Number of
Interval Type of lubricating
Label (position) Description lubricating
(hour) greases
points
Sweeper Check efficiency -
Hopper adhesive tape Check efficiency -
Align centers -
10 Rubber belt
Check tension -
Check oil
Reducer
consumption
L-CKC100~200
middle extreme
100 Reducer Check oil volume 1
pressure industrial
gear oil
Bearings of driving Lithium-based

Inject greases 4
and driven roller lubricating grease
Pendant and bearing Lithium-based

Inject greases 10
500 of redirectional roller lubricating grease
L-CKC100~200
Replace
Reducer or electric middle extreme
lubricating oil 1
roller pressure industrial
(first time)
gear oil
30
L-CKC100~200
Reducer or electric Replace middle extreme
1500 1
roller lubricating oil pressure industrial
gear oil
V. Troubleshooting
1. Common troubles
Common troubles and causes thereof are illustrated as follows:
Trouble Cause Solution
Use a carrying roller of a proper diameter
1. Improper roller diameter and belt
or use a belt that matches the carrying
shape
roller diameter
2. Belt is exposed to dust or chemical
Install protective cover of belt
erosion
Belt bottom
3. Excessive working temperature of Take measures to lower the temperature
is damaged
belt or use a heatproof belt
4. Insufficient belt tension and thus Adjust belt tension or increase pendant
skidding belt weight
5. Lower carrying roller diameter is
Use carrying rollers of a proper diameter
insufficient
1. Material gets into the bottom of belt Install a sweeper
Belt is
2. Insufficient carrying roller diameter Use carrying rollers of a proper diameter
damaged
too early 3. Insufficient belt tension that leads Adjust belt tension or increase pendant
to idle running weight
1. Carrying roller is rusted or covered Thoroughly clean or install belt
with dust protective cover
Belt is worn
Adjust belt tension or increase pendant
out too 2. Insufficient belt tension
weight
early
3. Carrying rollers are severely
Adjust parallelism
unparallel
1. Insufficient carrying roller diameter Use carrying rollers of a proper diameter
Increase angle of contact or make a
2. Insufficient angle of contact
rearrangement
Skidding Adjust belt tension or increase pendant
belt 3. Insufficient belt tension
weight
Thoroughly clean
4. Belt is soaked with water or oil
Install belt protective cover
1. Heat is produced due to belt Adjust belt tension

Hardened skidding
belt 2. Excessive ambient temperature Take measures to lower the temperature
or use a heatproof belt
31
1. Improper belt tension Adjust belt tension

Carefully operate the equipment so that
2. Startup or shutoff
there is time for startup or shutdown
3. Excessive clearance between roller
Abnormal shaft and bearing, reducer or belt
noises pulley, which results in radial
displacement
Move bearing inside so that the bearing
4. There is clearance between shaft
end face is in close contact with roller
shoulder and bearing end face, which
shaft shoulder and there will be no radial
results in axial displacement
displacement
1. Excessive distance between
Belt Install carrying rollers
carrying rollers
vibration
2. Improper belt tension Properly adjust belt tension
2. Solution to belt deviation

Deviation of belt is a commonly seen problem. Focus on installing dimensions and daily
maintenance in order to solve this problem. There are many causes of deviation and solutions shall
be adopted as per different causes.
① Adjust carrying roller set
Direction of belt deviation

Direction of belt running
Direction of adjustment
Running
Diviation
Adjustment
Adjustment
Figure 28 Deviation of Carrying Roller Set
If the deviation takes place in the middle of the conveyor, adjust the position of carrying roller set
32
to correct the deviation; the installing holes on both sides of the carrying roller set shall be long
ones for the sake of adjustment. Please see Figure 1 for the method of adjustment. When the belt is
deviated to one side, the appropriate method is to move that side of the carrying roller set in the
belt traveling direction or the opposite side against the belt traveling direction. As Figure 19 shows,
move the bottom of carrying roller set leftward or the top rightward if the belt is deviated upward.
② Install self-aligning carrying roller set
There are several types of self-aligning carrying rollers, e.g. intermediate axis type, four
connecting rod type, erected roller type, etc. The working principle is that the carrying rollers
rotate to create resistance or transverse pushing force so that the deviated belt is automatically
correct. This method is applicable when conveyor is short or travels in both directions because
conveyor with short belt is easily deviated but not easily corrected. However, it had better not be
adopted for conveyors with a long bet because self-aligning roller set will affect the working life
of belt.
Figure 29 Self-aligning Carrying Roller Set
③ Adjust driving roller and redirectional roller position

The adjustment of driving roller and redirectional roller position is essential to belt adjustment.
One conveyor has at least 2 to 5 rollers and they must be installed vertical to the centerline of belt
conveyor along the lengthways direction. Therefore, traveling deviation will absolutely take place
if the installing position is substantially deviated. The adjustment method is similar to that of
carrying roller set. If the belt is deviated to the right of the front roller, the right bearing seat shall
be moved forward or the left bearing seat backward. If the belt is deviated to the left of the front
roller, the left bearing seat shall be moved forward or the right bearing seat backward. The
adjustment method for belt deviation at the rear roller is just the opposite. Keep adjusting until the
belt is at an ideal position. The driving or redirectional roller had better be installed in the correct
position before adjustment is made.
④ Adjustment where tension is applied
33
Adjustment where tension is applied is a very important step in belt conveyor deviation
adjustment. The two redirectional rollers above the place where pendant is applied shall be
installed vertical to both the belt length and the pendant vertical line, i.e. its axis shall be kept
horizontal. In case screw or hydraulic cylinder is adopted for tensioning, both bearing seats of
tensioners shall be translated simultaneously to ensure verticality of roller axis and belt length.
The deviation adjustment method is similar to that of rollers.
⑤ Impacts on belt deviation by the material falling position where materials are transferred.
There are substantial impacts on belt deviation caused by the material falling position where
materials are transferred, particularly where the projections of both conveyors are vertical on the
plane surface. The lateral impacts on lower belt caused by the horizontal component of material
speed at the transition point and the deviation of falling materials from the belt center finally lead
to belt deviation. Measures may be taken to adjust the positions of conveyor’s lower hopper and
guide groove or increase the number of material stoppers in order to adjust the falling direction
and position of materials and thus avoid belt
deviation.
Figure 30 Indicative Chart of Material Falling Position Where Materials Are Transferred
⑥ Adjustment of deviation of bidirectional belt conveyor

The adjustment of deviation of bidirectional belt conveyor is much more difficult than that of
unidirectional belt conveyor. It is necessary to adjust the deviation in one direction and then the
other. Carefully observe the relationships between belt traveling direction and deviation tendency
34
during adjustment. Focus firstly on the adjustment of driving roller and redirectional roller and
secondly on the adjustment of carrying rollers and material falling position. Meanwhile, please
note that the belt shall be evenly loaded along the length of its cross section where the belt is at
vulcanized joints. Try to balance the loads on both sides when guide chains are used for towing.
VI. Wearing parts

1. Carrying roller
Dwg. No. Roller D-L Shaft d-L1 Installing width b Remarks
NFT.TG11 φ89-250 φ20-286 15

Carrying roller set
NFT.TG12 φ89-370 φ20-406 15
NFT.TG13 φ89-500 φ20-536 15 Upper carrying roller

Lower carrying roller
NFT.TG16 φ89-750 φ20-786 15
Upper carrying roller
NFT.TG17 φ89-900 φ20-936 15
NFT.TG19 φ89-450 φ20-486 15 Carrying roller set
NFT.TG41 φ89-1100 φ25-1136 18
NFT.TG42 φ89-1300 φ25-1336 18
NFT.TG51 φ108-380 φ25-420 18 Carrying roller set
NFT.TG52 φ108-1220 φ25-1260 18
Combed carrying roller
35
Roller Rubber ring

Dwg. No. Shaft length L Remarks
length H distance A
Applicable for belt
500 536 60
width 400
Applicable for belt
600 636 93
width 500~550
Applicable for belt
750 786 143
width 650
NFT.TG2A.0
Applicable for belt
900 936 140
width 800
Applicable for belt
1100 1136 190
width 1000
Applicable for belt
1350 1386 198
width 1200
Side stopper roller
NFT.DB1 NFT.TG31 NFT.DB3
Specifications (roller
Dwg. No diameter x roller length – Installing position Remarks
total length)
Surface
NFT.DB1 φ44x70-116 M12 thread
galvanization
φ60x150-200
NFT.TG31 φ20 shaft（φ8.5
φ89x175-225
pinhole）
NFT.DB3 φ89x205-255
36
2. Driving roller with covering of adhesive tapes resembling friction plate
Dwg. No Length L Arc plate radius R Remarks
DP.BJ80A.1 900 250 Applicable for φ500-900 roller
DP.BJ80.1 900 300 Applicable for φ600-900 roller
DP.BJ100A.1 1100 250 Applicable for φ500-1100 roller
DP.BJ100.1 1100 300 Applicable for φ600-1100 roller
3. H-shaped alloy sweeper

Unidirectional alloy sweeper
Scrubber width
Dwg. No L1 L2 Remarks
B
Applicable
NFT.HQS100.0 1004 1800 1740
1000-wide belt
Applicable
NFT.HQS80.0 803 1600 1540
800-wide belt
Bidirectional alloy sweeper
37
Scrubber width
Dwg. No L1 L2 Remarks
B
Applicable
NFT.HQS101.0 1004 2000 1940
1000-wide belt
Applicable
NFT.HQS81.0 803 1800 1740
800-wide belt
4. V-shaped rubber sweeper

Please see Figure 5 for structure.
Dwg. No Applicable belt width Remarks
NFT.QS8.0 800
NFT.QS9.0 1000
5. Redirectional roller
Shaft length Bearing position

Dwg. No. Roller body DXB Remarks
L dXn
38
DP.GGT100 1368 φ320X1100 φ60X67
DP.GGT80 1072 φ320X880 φ60X67
NFT.GGT100.0 1348 φ273X1100 φ40X51
NFT.GGT80.0 1053 φ273X880 φ40X51
6. Driven roller
Shaft length Bearing position

Dwg. No. Roller body DXB Remarks
L dXn
NFT.CGT11 990 φ216X880 φ30X45
NFT.CGT21 600 φ240X480 φ30X45
NFT.CGT22 700 φ240X580 φ30X45
NFT.CGT23 850 φ240X730 φ30X45
NFT.CGT24 1000 φ240X880 φ30X45
NFT.CGT25 1200 φ240X1080 φ30X45
NFT.CGT31 990 φ240X880 φ30X45
NFT.CGT41 980 φ320X730 φ55X60
NFT.CGT42 1260 φ320X1080 φ55X60
NFT.CGT43 1080 φ320X880 φ55X60
NFT.CGT51 1348 φ325X1100 φ40X51
NFT.CGT61 1345 φ500X1100 φ55X60
NFT.CGT62 1500 φ500X1260 φ55X60
NFT.CGT71 1470 φ630X1150 φ85X100
39
NFT.CGT80.0 1065 φ500X880 φ55X60
NFT.CGT81.0 1053 φ325X880 φ40X51
NFT.CGT82.0 1080 φ400X880 φ55X60
NFT.CGT100.0 1360 φ500X1100 φ55X60
NFT.CGT101.0 1360 φ400X1100 φ55X60
NFT.CGT102.0 1260 φ400X1080 φ55X60
DP.CGT80.0 1092 φ500X880 φ70X80
DP.CGT100.0 1385 φ500X1100 φ70X80
7. Driving roller
Bearing Joining
Shaft Roller body
Dwg. No. position position Remarks
length L DXB
d1Xn1 d2Xn2
φ52X72 Polished steel

NFT.ZGT11 703 φ240X480 φ55X63
surface

NFT.ZGT12 803 φ240X580 φ55X63
surface

NFT.ZGT13 953 φ240X730 φ55X63
surface
NFT.ZGT14 1103 φ240X880 φ55X63 φ52X72 Polished steel
40
surface

NFT.ZGT15 1303 φ240X1080 φ55X63
surface

NFT.ZGT21 1103 φ240X880 φ55X63
surface

NFT.ZGT31 1155 φ320X730 φ55X63
surface

NFT.ZGT41 1175 φ400X900 φ60X80
surface

NFT.ZGT42 1375 φ400X1080 φ60X80
surface

NFT.ZGT51 1550 φ500X1100 φ90X80
surface
φ90X330 Adhesive tape

NFT.ZGT61.1 1520 φ630X900 φ95X43
covering
φ φ Adhesive tape
QD80185B.1.1 1653 φ630X900
130X52 120X403 covering
φ φ Adhesive tape
QD100225B.1.1 1853 φ630X1100
130X52 120X403 covering
φ90X330 Adhesive tape

QD100250.2.1 1720 φ630X1100 φ95X43
covering
Note: there are two types of adhesive tape coverings ① Overall covering of adhesive tapes
② Adhesive tapes resembling friction plate
41

Belt Conveyor Instruction

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Contents

Aggregate Belt Conveyor

2. Product model, specifications and code

II. Structure introduction

1 Driving 2 Alloy 3 Belt 4 Aggregate 5 Pendant 6 Hand

Figure 1 DPT Tilted Plain Belt Conveyor

Figure 2 Electric Roller

② Triangular belt driving mechanism

Installation, adjustment and maintenance:

Figure 3 Belt Driving Mechanism

③ Chain driving mechanism

Figure 4 Chain Driving Mechanism

Installation, adjustment and maintenance

(2) Main parts

Figure 5 Driving Roller with Polished Steel Surfaces

Figure 6 Driving Roller with Overall Covering of Adhesive Tapes

Figure 7 Driving Roller with Adhesive Tapes Resembling Friction Plates

Driving roller with adhesive tapes resembling friction plates

Figure 8 Structural Drawing of Bearing Seat

2. Driven roller and tensioner

1 Tensioning screw 2 Adjusting screw 3 UCK bearing with seat

4 Driven roller 5 frame

② Sliding block tensioner

(1) V-shaped rubber sweeper

Installation, adjustment and maintenance:

Figure 10 V-shaped Rubber Sweeper

Figure 11 (V-shaped Rubber Sweeper) Hinge Position

(2) H-shaped alloy sweeper

Unidirectional alloy sweeper

Local assembly of alloy sweeper

Bidirectional alloy sweeper

Figure 12 H-shaped Alloy Sweeper

Roller diameter D Ø530 Ø630

New-type Alloy Sweeper

(3) Brush sweeper

Figure 13 Brush Sweeper

Installation, adjustment and maintenance

(4) Weight dropper sweeper

Figure 14 Weight Dropper Sweeper

Installation, adjustment and maintenance:

Figure 15 Redirectional Roller

Installation, adjustment and maintenance

轻型辊子 Light-duty roller 重型辊子 Heavy-duty roller

Installation and maintenance:

(1) Upper carrying roller set

Parallel upper carrying roller Groove upper carrying roller

Installation, adjustment and maintenance:

(2) Lower carrying roller

Figure 18 Lower Carrying Roller

(3) Side stopper roller

Figure 19 Side stopper roller

Lithium-based lubricating greases have been injected between

Figure 20 Conveyor Frame

Figure 21 Conveyor Frame Connection

Installation and maintenance

diagonals shall not exceed 3/1000 of their mean value.

8. Pendant emergency stop device

Figure 22 Pendant Emergency Stop Device

Figure 23 Pendant Device