通用固定式带式输送机

General Purpose Fixed Belt Conveyor

使用说明书
Installation and Maintenance Manual

芜湖起重运输机器股份有限公司
Wuhu Crane & Conveyor Co., Ltd.

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 目 录
CONTENT
1、 概述 ............................................................................................................................................... 2
GENERAL
1.1. 用途、特点、使用范围 ............................................................................................................2
PURPOSE, CHARACTERISTICS AND SCOPE OF WORK
2、 安装、调试与试运转 ..................................................................................................................... 3
MOUNTING, TEST AND COMMISSIONING
2.1 安装前的准备工作. ...................................................................................................................3
PREPARE WORK BEFORE MOUNTING
2.2 安装调试. ..................................................................................................................................3
ASSEMBLY AND TEST
2.3 空载试运转. ..............................................................................................................................9
NO LOAD TEST RUN
2.4 负载试运转. ..............................................................................................................................9
LOAD TEST RUN
3、 操作规程与维护、保养................................................................................................................ 11
OPERATION REGULATION AND MAINTENANCE
3.1 设备的正常使用. ..................................................................................................................... 11
REGULAR INSPECTION OF BELT CONVEYOR
3.2 操作方面注意事项. .................................................................................................................12
OPERATION PRECAUTIONS
3.3 设备定期检查. ........................................................................................................................12
REGULAR INSPECTION
4、 润滑 ............................................................................................................................................. 13
LUBRICATION
5、 胀套的调整 .................................................................................................................................. 14
ADJUSTMENT OF EXPANSION SLEEVE
6、 随机携带文件 .............................................................................................................................. 14
DOCUMENTS PROVIDED WITH BELT CONVEYOR
7、 安全注意事项 .............................................................................................................................. 14
SAFETY NOTES
8、 警告 ............................................................................................................................................. 15
WARNING
9、 特别提示...................................................................................................................................... 16
SPECIAL NOTICE

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1. 概述 General

1.1 用途、特点、使用范围 Purpose, characteristics and scope of work

1.1.1 固定式带式输送机是以棉帆布、尼龙、聚酯帆布及钢绳芯输送带作曳引构件的连续输送设备,可广泛用于煤碳、冶金、电力、矿山、港口、

化工、轻工、石油及机械等行业，输送各种散状物料及成件物品。

Fixed belt conveyor is continuous handling unit which transports the load with cotton duck, nylon polyester duck and steel wire covered

belt, which can be widely used in coal, metallurgy, chemical industry, light industry, petroleum, port, mechanical etc to convey all kinds of

bulk materials and the piece.

1.1.2 输送物料的松散密度一般为 500~2800Kg/m3，输送物料块度取决于带宽、带速、槽角和倾角及大块料出现的频率。见下表：

Density of handled bulk materials 500~2800kg/m3, lump of handled should depends on belt width, belt speed, trough angle and frequency

of large piece see the following table:

带式输送机输送物料的最大粒度尺寸 Max granular size of the material ( mm)

物料中大块的含量（质量百分率%）percent of big lump material (weight percentage)

带宽 Belt width（mm）
10 20 50 100

500 140~90 130~80 120~70 100~50

650 210~110 190~100 160~90 120~65

800 270~130 250~120 220~110 150~80

1000 340~160 300~150 260~140 180~100

1200 390~200 350~190 300~170 220~130

1400 450~230 400~220 340~200 260~150

1600 500~260 450~240 380~220 290~180

1800 550~290 480~270 420~240 320~200

2000 580~320 500~300 450~260 350~230

2200 600~350 520~320 480~290 380~260

≥2400 620~380 550~360 500~330 410~280

注：1.物料的运行堆积角为 20°时选大值，30°时选小值，2.输送坚硬类物料时最大粒度尺寸不宜超过 350mm。

Notes:1.If the move angle of the material is 20°, choose the max parameter. If the move angle is 30°,choose the min parameter.2. The max

granular size should no more than 350mm when conveying hard material.

1.1.3 工作环境 Ambience

一般在-25~+40℃范围内使用，输送物料的温度在 60℃以下，对于有特殊要求的工作场所，如高温、寒冷、防爆、阻燃、防腐蚀、耐酸碱、

防水等条件，应另行采取相应措施。

Ambient temperature generally -25~+40℃, material temperature to be handled should be under 50℃. It should take other measures for

special requirement such as heat resistant, proof cold, resistant retard, resistant acid and alkali, resistant abrasion, proof explosion, proof

water etc.

1.1.4 典 型 整 机 结 构

（ 见 图 1 ） Typical

Arrangement of

Complete Conveyor

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图 1 带式输送机整机结构 Figure 1 Complete Unit Structure of Belt Conveyor

1.头部漏斗 2.机架 3. 头部清扫器 4.驱动滚筒 5.安全保护装置 6.输送带 7.承载托辊 8.缓冲托辊 9.

导料槽 10 改向滚筒 11..螺旋拉紧装置 12. 尾架 13.空段清扫器 14..回程托辊 15.中间架 16.电动机 17.液力偶合器 18.制

动器 19 减速器 20. 联轴器

1. Head hopper 2. Frame 3. Head belt cleaner 4. Driving pulley 5. Safety guards 6. Belt 7. Carrying idler 8. Impact idler9. Feed chute

10. Bend pulley11. Screw take-ups 12. Tail frame13. Belt cleaner14. Return idler15. Intermediate frame16. Motor17. Fluid coupling18. Brake

19.Gear unit 20. Coupling

2. 安装、调试与试运转 Mounting, Test and Commissioning

2.1 安装前的准备工作 Prepare work before Mounting

2.1.1 安装前应根据验收规格进行验收,并熟悉安装技术要求和输送机图纸要求,安装技术要求见《连续输送设备安装工程施工及验收规范》

GB50270-1998，并按《土建作务书》和基础图，检查基础的尺寸，平面精度等是否符合要求。

Before mounting, the belt conveyor should be inspected in accordance with the specifications of inspection, it is also necessary to get

familiar with the technical requirements for mounting and the requirements illustrated in drawings. The specifications for mounting are

pointed out in “Regulations for Acceptance of Installation of Machinery Equipments GB50270-1998. Foundation dimensions and

plainness accuracy should be inspected according to “ Civil Work Task Document” and “Basic Drawing.”

1.1.3 对照装配图和装箱单清点零部件数量，检查其质量，如有损伤或质量问题应进行修整或更换。

Quantity and quality of part should be inspected in according to assembly drawing and packing list. Any damage and unqualified parts

should be repaired and replaced.

2.1.3 熟悉整机及各部件（配套件、外购件）的产品说明书，了解安装、调试方法、技术要求、注意事项及专用工具等。

It should be familiar with the instruction of complete conveyor and all parts (fittings, outsourcing part) to know method of and test,

technical requirements, cautions and special tools.

2.2 安装调试 Assembly and Test

2.2.1 安装顺序 Installation procedure

一般顺序为：划中心线——安装机架（头部——支腿、中间架——尾架）——安装下托辊及改向滚筒——输送带铺设在下托辊上——安装

上托辊——拉紧装置，传动滚筒和驱动装置——输送带绕过头尾滚筒——输送带接头——张紧输送带——安装清扫器、逆止器、导料槽及

护罩等辅助装置——测定安装精度——补漆——完成试车。

The orders in general is : to draw center line—to mount support frames (head, intermediate and tail) —to mount the return idlers and bend

pulleys—to lay the belt to the return idler— to mount carrying idler—take-ups—driving pulley and driving device —to wind the conveyor

belt over head and tail pulley —belt splice —take-up the belt —mount belt cleaner, hold back, feed chutes, guard cover etc.

2.2.2 机架 Conveyor frame

机架的安装质量对整机的性能有很大影响，安装时要检测下列各项精度指标：

Mounting accuracy of conveyor frame should influence performance of complete conveyor. The following accuracy index should be

inspected before mounting.

2.2.2.1 机架中心线直线度：见下表。另外，在任意 25m 长度范围内，机架中心线的直线度不得大于 5mm，对可逆运行的带式输送机，因其输送

带跑偏可能性较大，应提高安装精度，其中心直线度控制在上述数值的 2/3 以内。

Linear allowance of conveyor frame center should be less 5mm within any 25m. Mounting accuracy should be improved for reversible belt

conveyor, which linear allowance of center should be within 2/3above value.

机长 Conveyor length（m） ＜100 ＞100~300 ＞300~500 ＞500~1000 ＞1000~2000 ＞2000

直线度 Linear allowance（mm） 10 30 50 80 150 200

2.2.2.2 头、尾架安装精度：见下表

Mounting accuracy of head and tail frame see the following table: mm

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 带宽 Belt width ≤800 ＞800

两侧轴承座底面平面度 Base planeness of both

1.0 1.5
sides bearing housing

两侧轴承座底面平面度 Pitch tolerance of bolt

±1.5 ±2.0
holes of both sides bearing housing

孔对角线长度之差 (X-Y) Dimensions difference

≤3.0 ≤4.0
between hole diagonal (X-Y)

2.2.2.3 每付中间架均编号，顺序号的编制方法为从尾架开始用 A、B、C……按顺序编排，安装时注意中间架上的编号，结合总图，按顺序号安

装。中间架安装精度见下表：

Intermediate frame of all belt conveyors should be numbered. The number should be tag No. plus the order, which

should be from 1,2, 3… The intermediate frame should be mounted according as in the order of the number.

Accuracy of the intermediate frame, see table 9.

Table 9. mm

带宽 Belt width ＜1600 ≥1600

中间架间距 A1 Intermediate frame space A1

2.0
中间架间距 A Intermediate frame hole pitch A

中间架孔对角线偏差
2.0 3.0
(X-Y) Dimensions difference between two diagonal (X-Y)

两侧中间架高度差 e Height difference e of between both

2.0 3.0
sides intermediate frame

中间架接头两边高度差 Both sides height difference of

1.0
joint of intermediate frame

注: a 为托辊间距的 2 倍

Note: Space of “a” is two times the space of the idler

2.2.2.4 钢轨工作面应在同一平面内，每段钢轨的轨顶标高差不应超过 2mm。轨道直线度在 1m 长度内为 1.0mm，在 25m 长度内为 4mm，在全

长内为 15mm。轨缝处工作面高低差不应超过 0.5mm。轨道接头间隙不应大于 3.0mm。轨距偏差为±2.0mm。

Steel rail working surface should in the same plate, deviation of the elevation of the top rail should no more than 2 mm. Rail

straightness is 1.0mm every 1m, 4mm every 25m, 15mm in the total length. Deviation of the surface of seam between two rails

should no more than 0.5mm, Rail joint clearance should no more than 3.0mm, the deviation of the rail gauge is ±2.0mm.

2.2.3 驱动装置 Driving device

驱动装置一般已在制造厂组装完毕，现场可按整体部件与传动滚筒相联。对于体积较大，和重量大而易运输的驱动装置，可按部件分别

发往现场进行组装。并按各自的手册（电机、减速器、制动器、逆止器、液力偶合器、联轴器、电动滚筒等）进行去污，清洗，清点安

装调试。

Driving device should be assembled in the manufacturer, the whole part should be connected with driving pulley at site.

Driving device should be shipped to at site to mount for big dimensions, heavy and not to be easy transport part. It should

be removed contamination, cleaned and counted in according to manual of its driving device (motor, gear unit, brake,

backstops, fluid coupling, coupling, motorized pulley)

2.2.3.1 按总图或土建任务书核对基础的位置尺寸，平面精度及其他要求，如需二次洗灌者应符合 JB/226-86《地基设计规范》规定。

Foundation position dimensions, plainness and other requirements should be checked in according to general drawing

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 and civil work document. If required a second grouting, it should be in according to JB/226-86 “Foundations Design

Specification”.

2.2.3.2 由部件在现场组装的驱动单元，首先将机架放在需固定的地基位置上。

Driving unit should be mounted at site. Firstly, the conveyor frame should be located at its foundation position.

2.2.3.3 安装顺序：电机、减速器轴伸上的联接件首先装配——装减速器——装电动机——检测安装精度——调整——紧固螺栓——安装护罩。

各组件的地脚可用金属垫片进行高度调整，每处不得超过三片。

Mounting order of driving device: Shaft extension connections of motor and gear unit should be mounted first —to mount

gear unit —to mount motor. The foot of all drive devices should be adjusted with shims. Each place should be less than

3 pieces.

2.2.3.4 各部件安装精度

Mounting accuracy of each part

1) 弹性柱销齿式联轴器许用补偿量（GB5015-85）见下表

Allowance compensation of elastic pin tooth coupling (GB5015-85) see the following table:

轴向 Axial direction ( △X) l 径向 Radial dircetion( △Y ) 角 向 Angle

型号 Type
mm direction ( △a )

ZL1~ZL3 0.3
+1.5
ZL4~ZL7 0.4

ZL8~ZL13 0.6 O°30′

ZL14~ZL17 ±2.5
1.0
ZL18~ZL21

2) 梅花型联轴器的安装精度（GB5272-85）见下表

Mounting accuracy of spider elastic coupling (GB5272-85) see the following table:

梅花型弹性联轴器许用补偿量

Allowance compensation of spider elastic coupling

型号 ML1 ML2 ML3 ML4 ML5 ML6 ML7 ML8 ML9

项目 MLL1 MLL2 MLL3 MLL4 MLL5 MLL6 MLL7 MLL8 MLL9

△Xmm 1.2 1.5 2.0 2.5 3.0 3.5 4.0 4.5

△Ymm 0.5 0.8 1.0 1.0 1.0 1.5

△amm(°) 2 1.5 1

注：①ZL、ML、MLL 径向补偿量部位在联轴器最大外圆宽度的二分之一处。

②表中数质是由于安装误差、振动、冲击变形、温度变化等因素引起相对偏移量，安装时许用补偿量为表中的 1/2~1/3。

Note: Radial allowance compensation for ZL, ML, MLL should be located at ½ the maximum outside circle width of coupling.

Value in table should be relative deviation amount occurred by mounting error, vibration, impact, temperature change.

Value of allowance compensation should be of ½~1/3 in table value.

3) 制动器安装精度（GB633-86）Mounting accuracy of brake

制动器中心线与制动轮轴线的同轴度：制动轮直径：D﹤315 时为 2 ㎜，D≥315 ㎜时为 3 ㎜，在额定制动力矩下，制动轮工作面与制动衬

垫的结合面积：压制成型的衬垫每块应大于设计面积的 50%，普通夹丝石棉衬垫每块应大于设计面积的 70%。

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 安装后的制动轮径向圆周跳动量符合 JB4102-86 规定,见下表:

Coaxial of brake centerline and axis of brake wheel : diameter of brake wheel D＜315 is 2mm, D≥315 is 3mm. Combined

area of brake working face and brake lining: A shaped lining should be more than 50% of design area and a piece of

common asbestos lining should be more than 70% of design area.

Axial displacement of brake wheel should be in according to JB102-86 after mounted, see the following table:

制动轮径向跳动量

Axial displacement of brake wheel

制动轮直径 Diameter of brake wheel (mm) ＞200~250 ＞250~500 ＞500~800

径向跳动量 Radial displacement (≤mm) 0.1 0.12 0.15

4) 液力偶合器的安装精度,见下表 Assembly accuracy of fluid coupling see the following table:

同轴度、平行度公 差

Tolerance of coaality and parallelism (mm)

Size 规 格 YOXII, YOXIIZ

Input speed
360~450 500~650 750~1150
输入速度 r/min

＞750~1200 ＜0.5 ＜0.6 ＜0.7

＞1200~1500 ＜0.4 ＜0.5 ＜0.6

5) 滚柱逆止器安装时,应将其侧盖拆下取出滚柱及压簧,仔细调整星轮与外套之间的间隙,使其间隙差小于 0.15 ㎜，调整好后拧紧逆止器外套的地

脚螺栓，并暂时不把滚柱及压簧装入，等试运转后安装。

When mounting the roller-type backstops, the side cover should be dismantled to take out the rollers and the compression

spring, and adjust carefully the gaps between the star gear and the housing to ensure that the errors between the gaps

should be less than 0.15 mm. After adjusting, tight up the anchor bolts of the backstops housing. The rollers and the spring

are not put in for the time being. ( Refer to test run)

2.2.3.5 安装调试后起动前应检查：Inspection before start-up

1) 各润滑处所注入的润滑油牌号、数量是否符合要求。

Check the lubricant band and quantity of each lubricating point whether they have reached technical requirements.

2) 检查液力偶合器中注入的介质（油或水）质量、数量是否与传动功率相匹配。

Check quality and quantity of filling media (water or oil) in fluid coupling whether they have matched with driving power.

3) 检查制动器闸瓦与制动轮间隙是否符合要求，制动力矩是否调整到与工作机械相匹配。

Check clearance between brake shoe and brake wheel whether it is in according with the requirement and whether moment torque of break

have adjusted to match with working mechanical.

4) 检查减速器输入轴的转向，逆止器的转向是否和符合要求。

Check rotation direction of input shaft for gear unit and backstop whether they are in according to the requirement.

5) 用手转各传动部分的机械是否灵活，有无卡住现象

Turning each driving parts by hand whether they are flexible and blocked.

2.2.4 传动滚筒和改向滚筒 Driving pulley and bend pulley

2.2.4.1 滚筒安装前应检查轴承座内润滑脂情况，保证轴承内充满锂基润滑脂，轴承座充脂量达到空腔容积的 2/3。

Lubricant in bearing housing should be checked to ensure enough lithium based lubricant in bearing and filled volume

should reach two-thirds of cavity of bearing housing before mounting the pulley.

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2.2.4.2 传动滚筒为人字形沟槽胶面时，注意沟槽方向要与输送带运行方向一致，防止输送带跑偏，且有利于沟槽排水、排污物。见下图

Carefully direction of herringbone grooved is the same with the belt running to prevent the belt running off and good for the groove to drain

water and remove contamination when driving pulley is herringbone grooved rubber cover. See the following figure:

2.2.4.3 在吊装过程中采取必要的保护措施,不得损伤滚筒胶面。

Proper measures should be taken to prevent rubber surface of pulley damage during lifting.

2.2.4.4 安装时可用在滚筒轴承座底下加垫片，用机架上调节螺钉调整等方式，调整滚筒位置，保证轴线和中心线符合下表所列的公差范围：

Shims should be under bearing housing of the pulley on mounting and use adjusting screw on support frame to adjust pulley position to

ensure axis and center line of the pulley in according to tolerance of the following table:

项目 Item 公差值 Tolerance Value

滚 筒 轴 线 与 水 平 面 的 平 行 度 Parallelism between axis of the pulley and

1/1000 滚筒轴线长度 length of pulley axis
horizontal plane

滚筒轴线与机架中心线的垂直度 Verticality between axis of the pulley and

2/1000 滚筒 length of pulley axis
center line of the conveyor frame

滚筒中心线与机架中心线对称度 Symmetry of center line of the pulley and

≤3mm
conveyor frame

多滚筒驱动时同一机架上的传动滚筒轴线的平行度 On muti-pulley driving,

0.4mm
parallelism of axis of the driving pulleys

2.2.5 托辊 Idler

2.2.5.1 托辊种类较多，应按带式输送机总图，将各种托辊安装在指定位置。

There are many kinds of idlers. Each idler should be mounted at specified position in according to General Drawing of Belt

Conveyor.

2.2.5.2 安装前倾托辊时，前倾方向要与输送带运行方向一致，注意空载段前倾方向要与空载段输送带运行方向一致。

When mounting inclined idlers, inclined direction of idler should be the same direction as running of belt conveyor. Pay attention to

inclined direction of return idler is the same direction as return section of belt conveyor.

2.2.5.3 托辊安装后，辊子应转动灵活。

Roller should rotate flexibly after idlers mounted.

2.2.5.4 安装时要求托辊辊子（调心托辊和过渡托辊除外）上表面位于同一平面上（水平或倾斜）或者在一个公共半径的弧面上（输送机凹、凸

弧段托辊），其相邻三组托辊辊子上表面的高低差不得超过 2 ㎜，每一个 100m 长度范围内不得超过 5 ㎜。托辊中心线的对称度为 3 ㎜。

Top surface of rollers should be the same plane (exclude training idler and transition idler) or in common radius arc area ( concave and

convex section idlers of belt conveyor). Height difference of top surface of proximity three set idlers should be not more than 2mm and

not more than 5mm within 100m. Symmetry of center line of the idlers should be of 3mm.

2.2.5.5 安装有挡轮的调心托辊时，应使挡轮位于胶带运行方向上辊子后方。

When mounting training idler, the guard roller should be positioned behind of carrying idlers in direction of the belt movement.

2.2.6 输送带 Belt

2.2.6.1 在吊运和缠绕输送带过程中不得造成损伤。

Belt may be damaged during lifting and winding of belt.

2.2.6.2 输送带接头：一般采用硫化接头，接头时要按照输送带制造厂提供的资料，在专业人员的指导下进行精心的作业。

Splice of belt: Generally, vulcanized splices should be generally used. Belt splice should be carefully guide by professional in according to

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 belt manufacturers specifications.

2.2.6.3 输送带接头后，接头两端输送带中心线在 10m 范围内的偏差 e≤5 ㎜。

Both end center line deviation of belt splice e≤5mm within 10mm after spliced. (see the following figure)

2.2.6.4 接最后一个接头时，
自动张紧的皮带机应将拉紧滚筒在距上极限位置约 400 ㎜处固定，
再拉紧输送带，直到空载段输送带挠度小于 2/1000L

为止。

Take-up pulley should be positioned at 400mm from upper limit position, and then should not tension the belt until deflection of return belt

is less than 2/1000L when the last splice of the belt is spliced

2.2.7 清扫器 Belt cleaner

2.2.7.1 所有清扫器安装后，其刮板与输送带的接触长度不得小于 85%。

Contact length of belt scraper and the belt should be not less than 85%after belt cleaners are mounted.

2.2.7.2 安装 H 型刮板清扫器时，应使其刮片延长线位于滚筒中心线或中心线稍上位置，以免输送带运转时引起清扫器支架振动。

When mounting type H cleaner, extension line of its blade should lie at or above pulley center to avoid frame of belt cleaner vibrating.

2.2.7.3 对于 H 型以及 NPS 型等硬质合金清扫器，安装时应使各组刮板保持在同一平面内。H 型清扫器每组刮片与输送带的接触压力控制在

60~80N，P 型控制在 40~60N。

Each set scraper should be kept in the same line for type H and type NPS hard alloy cleaner on mounting. Pressure of each blade of H

type should be controlled within 40~60N contacted with belt.

2.2.7.4 重锤式清扫器应使其刮板垂直于带面。

Heavy hamper cleaner should put the scraper blade perpendicular to the belt surface.

2.2.7.5 对于弹簧清扫器，安装时应保证压簧的工作行程有 20mm 以上，并使清扫下来的物料能落入漏斗，应视各种物料的清扫性能不同调整压

簧松紧。

When mounting the spring cleaner, a stroke of more than 20mm for the compression spring should be ensured and the cleaned

materials be fall into the hopper.Tension of compression spring should be adjusted in according to cleaning performance.

2.2.7.6 安装空段清扫器时应保证橡胶刮板磨光后金属架不能与输送带接触。调节后确定合适的链条长度。

Frame Rubber scraper should be ensured not to contact the belt after the scraper is worn out. Chain length should be adjusted after the

belt cleaner mounted.

2.3 空载试运转 No load test run

带式输送机各部件安装完毕后，首先进行空载试运转。运转时间不得小于 2 小时，并对各部件进行观察、检验及调整。为负载试运转作好

准备。

A newly installed conveyor should be subjected to 2-hours no load test run and checked, observed and adjusted.

2.3.1 空载试运转前的准备工作 Prepare work before no load test run

1) 检查基础及各部件中联接螺栓是否已紧固，尤其是滚筒涨圈螺栓运转前必须进行一次紧固，工地焊接的焊缝有无漏焊等。

Check foundations and all parts to see whether all bolts are tightened. Especially bolts of pulleys shrink disc should be tightened

once. Welding seam at site whether to be missed.

2) 检查电动滚筒、电动机、减速器、轴承座等润滑部位是否按规定加入足够量的润滑油。

Check motorized pulley, motor, gear unit, bearing housing lubricant point, to see whether they are filled enough lubricant as

8
 required.

3）检查电气信号、电气控制保护、绝缘等是否符合电气说明书的要求。

Check electric signal, electric safety guards, insulation etc to see whether each has reached its instructions requirement.

4) 点动电机，确认电机转动方向。点电机前对装有偶合器的驱动单元，可让偶合器暂不充油，不带偶合器的驱动单元可先拆开高速轴联

轴器。

Start motor to know its rotation direction. Motor with coupling should be not filled before starting for the time being. Driving device

without coupling should dismount high speed coupling firstly.

2.3.2 空载试运转中的观察及调整 Observing and adjustment during no load test run

1) 观察各运转部件有无相蹭现象，特别是输送带相蹭的要及时处理、防止损伤输送带。

Observe all rotation parts whether they have any contacted, in particular, belt contact should be treated in time to prevent damage

it.

2) 输送带有无跑偏，如果跑偏超过带宽的 5%，应进行调整(方法与负载试运转中调偏方法相同)。

Check belt whether they run off, if the amount of run off exceed 5%, it should be adjusted. (adjustment method is the same as load

run )

3) 检查设备各部分有无异常声音和异常振动。

Check all rotation parts of the conveyor no obvious noise should occur.

4) 减速器、液力偶合器以及其他润滑油部位有无漏油现象。

Check gear unit, fluid coupling and other lubricating parts should not have seepage.

5) 检查润滑油、轴承等处温升情况是否正常。

All bearings should not have abnormal temperature rise.

6)制动器、各种限位开关、保护装置等的动作是否灵敏可靠。

Check the sensitivity and reliability of the brake and limit switch and safety devices.

7)清扫器刮板与输送带的接触情况。

Check scraper of belt cleaner whether it contact with the belt.

8) 拉紧装置运行是否良好，有无卡死等现象。Take-ups should run well. There is no blocked.

9) 基础及各部件联接螺栓有无松动。Foundations and all rotation parts should be tightened.

2.4 负载试运转 Load test run

2.4.1 加载方式 Load method

加载量应从小到大逐渐增加，先按 20%额定负荷加载，通过后，再按 50%、80%、100%额定负载进行运转，在各种负荷下试运转的连续

运行时间不得小于 2 小时。

Load amount should be increased by gradually, firstly 20% rated load, and then 50%, 80%, 100% rated load test run, which test run should

be done at least 2 hours.

另外，应根据系统工艺流程要求决定是否进行 110%-125%额定负荷下的满载起动和运转试验。

Full load start and test run of 110%-125% rated load should be depended on process requiremen

2.4.2 试运转中可能出现的故障及排除方法 Trouble and remedy during test run

1) 检查驱动单元有无异常声音，电动机、减速器轴承及润滑油、液力偶合器油等处的温升是否符合要求。

Driving unit should have not abnormal noise. Motor, bearing and lubricant of gear unit, fluid coupling oil temperature rise should be in

according to requirement.

2）检查、托辊等部件有无异常声音，滚筒轴承温升是否正确，如有不转动的托辊应及时调整或更换。

Check pulleys and idlers to see whether they have abnormal noise and bearing temperature rise of pulley are correct. The failure idlers

should be adjusted and replaced in time.

3）观察物料是否位于输送带中心，如有落料不正和偏向一侧现象，可在漏斗口处适当位置加挡板来解决。

Observe material to see whether it is located in center of the belt. Baffle plate of chute should be adjusted if the material on

4) 起动时输送带与传动滚筒间是否打滑，如有打滑现象可逐渐增大拉紧装置的拉紧力，直到不打滑时为准。

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 If the belt slides on the driving pulley when the conveyor is started, tension force of take-up device should be increased until the belt

not slide on driving pulley.

5) 在负载试运转过程中，经常出现输送带跑偏现象，如果跑偏量超过带宽的 5%，则应进行调整，调整方法为：

The belt deviation may often occur during test run, if amount run -off reach 5% of belt width, it should be adjusted. The adjustment

method should be as following:

a. 首先检查物料在输送带上对中情况，并作调整。

Firstly, material on the belt should be checked and adjusted.

b. 根据输送带跑偏位置，调整下、下分支托辊和头尾滚筒的安装位置：见图 a-d，通常调偏效果较好。

The upper side of idler and the bottom side of idler and mounting position of pulleys should be adjusted according to the belt position

of run off. See a~d. It is preferable to use the method to adjust the belt run off.

c. 如果输送带张力较小，适当增加拉紧力对防止跑偏有一定作用。

上述方法无效时，应检查输送带及接头中心线直线度是否合要求，必要时应重新接头。

Tension force of the belt should be increased to prevent running off if the belt tension is sma

If run-off of the belt could not be corrected by aforesaid methods, belt and linear allowance of center line of splice should be

inspected. Splice of the belt should be spliced again if necessary.

胶带跑偏方向 上托辊调整方向

胶带跑偏方向 头部轴承座调整方向

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 胶带跑偏方 回程托辊调整方向

图 c 调整头部机架 To adjust head frame 图 d 调整尾部机架 To adjust tail frame

6) 检查各种清扫器的清扫效果，振动是否过大等，并按本手册进行调整。

Check effectiveness and vibration of all belt cleaners, it should be adjusted in according to the Instruction of Belt Conveyor.

7) 仔细观察输送带有无划痕，并找出原因，防止昂贵的输送带造成意外损伤。

Reason of belt surface scratch should be found to avoid expensive the belt damage.

8) 按保护装置说明书对各种保护装置进行试验，保证动作灵敏可靠。

All guard devices should be tested in according to its instructions to guarantee sensitivity.

9) 测量带速、运量、起动、制动时间等技术参数是否符合设计要求。

Belt speed, capacity, start time and brake time etc. should be in according to design requirement.

10) 测量额定载荷下稳定运行时电机工作电流值，对多电机驱动时，再用工作电流值判断各电机功率均衡情况，如相差较大可用调节

液力偶合器充油量的方法进行调整和平衡。

Measure service current of motor under rated load. Use service current value to judge power balance of each motor for

multi-motor driving. If service current value is out of balance, it should adjust oil filling of fluid coupling to balance motor power.

11) 对各联接部位进行检查，如有螺栓松动应及时紧固。

All connection position should be inspected, if any loose bolt, it should be fastened.

3. 操作规程与维护、保养 Operation regulation and maintenance

安全操作规范和合理的维修保养制度均应由用户根据现场实际情况进行认真制定，制定时应重点考虑下列注意事项。

Safe operational rulers and reasonable maintenance should be made in according with site requirement.

3.1 设备的正常使用

3.1.1 不允许将带式输送机用来完成设计规定以外的任务。

Belt conveyor should be operated in according to design requirement.

3.1.2 不允许超载运行。

Belt conveyors are not allowed to overload run.

3.1.3 应使各安全报警装置牌完好状态

All safe alarming should be in good condition.

3.1.4 通往紧急停机开关的通道应无障碍物，定期检查这些开关是否处于完好状态。

Walkway of emergency switch should be free. The switch should be regular inspected to see whether they are in good

condition.

3.1.5 各转载处应有足够照明设施

All transition load point should have enough light facilities.

3.1.6 人易接近的挤夹处及重锤拉紧装置下部应设防护栅。

Fence should be provided under gravity type tensioning devices and the area where man easily access.

3.2 操作方面注意事项 Operation precautions

3.2.1 严格按操作规程进行操作。

Operators should be in according to operation rulers.

3.2.2 驱动装置的调整及各种安全保护装置的调整应由专职人员操作进行。

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 Adjustment of driving devices and all safety devices should be professional to carry out.

3.2.3 输送机运转过程中，不得对输送带、托辊、滚筒进行人工清扫，拆换零部件或进行润滑保养。

The belt, idler and pulley should be not allowed man-cleaning during running of belt conveyor, the parts should be dismantled

and replaced or lubricated.

3.2.4 不得随意触动各种安全保护装置。

All safety guards are not allowed to touched freely.

3.2.5 运行中操作人员应巡回检查，密切注意设备运行情况，特别注意，主电机温升、噪声、主制动器的动作正常与否，制动轮的接触

状态，减速器的油位、噪声、输送带是否跑偏及操作情况，各轴承处的温升和噪声，转载点的转载状态，漏斗有无阻塞，滚筒、

托辊、清扫器、拉紧装置的工作状态，电控设备的工作状态。

Operators should circuit to inspect to close observe belt conveyor running. Especially, temperature rise and noise of main

motor and the brake working whether they are normal; contact state of the brake and oil level, noise of gear unit and run off

of belt should be noticed; temperature rise and noise of all bearings and state of all transition loads point should be noticed;

notice to see whether the hopper are blocked, working state of pulley, idler, belt cleaner, take-ups and control equipment.

3.2.6 操作人员发现运行有异常时，应做好记录，紧急情况应立即停机。

Operators should make good record if any abnormal. The belt conveyor should be stopped on emergency.

3.3 设备定期检查 Regular inspection

用户应建立健全定期检查保养制度。

Regular maintenance rule should be made.

3.3.1 检修周期：除日常检修外，小修应每月一次，大修为每半年或一年一次(可根据现场条件及实际情况缩短或延长周期)

Periodic overall: Minor overall should be once every monthes besides ordinary maintenance Overhaul should be once half

past year or once every year.

3.3.2 检修内容 Overhauling

＊小修主要检修： Minor overhaul:

输送带磨损量检查、修补；

Check wear condition of the belt, the damaged should be repaired.

减速器润滑油的补充与更换(按减速器说明书进行)；

Lubricant of the gear unit should be refilled and replaced (as Instruction of the Gear Unit )

制动器闸瓦、制动轮磨损量检查、磨损严重的应更换；

The wear condition of brake shoe and brake wheel should be checked, wore-out parts should be replaced.

滚筒胶面磨损量检查，对严重处进行修补；

The wear condition of pulley rubber cover should be checked. The seriously damage area should be repaired.

检查滚筒焊接部位有无裂纹，如有则采取措施进行修补；

Check weld position of the pulley whether it has any crack, Measures should be taken to repair if any crack.

滚筒轴承润滑油的更换；

Lubricant of bearing of the pulley should be replaced.

对磨损严重的清扫器刮板、托辊橡胶圈进行更换；

Scraper of belt cleaner and rubber disc of idlers should be replaced if they are worn out.

检查拉紧行程和安全保护装置，对失灵者须更换；

Check traveling of the take-ups and the safety guards, the failure should be replaced.

更换磨损严重的衬板；

The wear-out lining should be replaced.

＊大修主要检修：Major overhaul:

减速器按手册规定进行逐项检查，拆洗和更换严重磨损零件；

Gear unit should be checked by and by, dismantle and wash gear unit and the wear out parts should be replaced.

滚筒胶面磨损量检查，严重磨损应重新铸胶；

12
 The worn-out rubber cover of pulleys should be replaced.

滚筒筒体发现较大裂纹，难以修补时，则应更换；

Crack of Pulley drum which cannot be repaired should be replaced.

各类轴承座、轴承进行检查清洗，有损伤则修理更换；

Bearing housing and bearing should be checked and washed, they should be replaced if required.

检查各类机架变形情况，焊缝有无裂纹，根据情况进行整形修复；

Deformed conveyor frame should be adjusted and cracks of weld seam should be restored based on the fact.

根据情况修补或更换输送带；

The belt should be repaired and replaced based on the fact.

更换磨损严重的漏斗衬板；

The wore-out lining of the hopper should be replaced.

更换磨损严重的清扫器刮板；

The wore-out of scraper of the belt cleaner should be replaced.

对电器控制，安全保护装置全面检测，更换无器件及失灵的保护装置。

Control equipment and the safety guards should be fully inspected. The damaged unit and the failure safety guards should be

replaced.

4. 润滑 Lubrication

对机械设备各转动部位进行定期润滑是日常保养中的重要内容。

下表列举了各润滑部位所用润滑油名称、牌号、润滑补油周期换油周期。供参考：

Regular lubrication for all rotational parts of mechanical facilities should be daily shift maintenance.

Lubricant name, brand, replace lubricant period should be following:

序 号 润滑部位 Parts to be 换 油 周 期 加油量 Lubricant

润滑油牌号 Brand of lubricant 补油周期 Refill cycle
No. lubricated Lubricant period amount

加油时挤出旧油
ZL-2 锂基润滑脂 ZL-2 Lithium 每半月一次 Once every half
1 滚筒轴承 Pulley bearing Exhausted old oil on
based lubricant month
refilling oil

各 种 滑 轮 组 Various blocks 锂 基 润 滑 脂 Lithium based

2 每季一次 Once every quarter
sets lubricant

拉紧绞车轴承 Bearings of take 锂 基 润 滑 脂 Lithium based

3 每季一次 Once every quarter
up winch lubricant

滑轮绳槽及钢绳表面 Surface 锂 基 润 滑 脂 Lithium based

4 每季一次 Once every quarter
of block wire and steel wire lubricant

拉 紧 小 车 轴 承 Bearing of 锂 基 润 滑 脂 Lithium based

5 每季一次 Once every quarter
take-up trolley lubricant

制 动 器 推 动 器 Propeller of DB-25 变 压 器 油 DB-25

6 半年 Half a year
brake Transformer oil

各转动销轴 Shaft of each HB-30 机 械 油 HB-30

7 每周一次 Once every week 滴油 Lubrication drip
rotating pin Mechanical

N220 工业齿轮油 N220 Industry

按 说 明 书 As the
gear oil
8 减速器 Gear unit 半年 Half a year Instructions of gear
N320 工业齿轮油 N320 Industry
unit
gear oil

13
 ZL-2 锂基润滑脂 ZL-2 Lithium
9 电机轴承 Motor bearing 一年 One year
based lubricant

按 说 明 书 As the
20 号汽轮机油 No 20 Gasoline
10 液力偶合器 Fluid coupling 每季一次 Once every quarter 一年 One year Instructions of gear
engine oil
unit

5.胀套的调整 Adjustment of expansion sleeve

采用胀套的传动滚筒和改向滚筒在 2 小时空运转后再进行一次紧固，并对胀套进行详细检查一次，检查每个螺钉的锁紧力矩是否定

力矩值，以后每运转 3000 小时检查一次。

Driving pulleys and bend pulleys with expansion sleeve should be tighten again after two hours test running. Expansion sleeve should

be carefully checked, toque value of each screw should be ensured, which should be checked once every 3000 hours.

ZT9(Z9) 胀套参数表 sleeve parameters

滚筒轴承处直径
每个螺栓拧紧力矩 N·M
㎜ Diameter of 滚筒扭矩 Pulley
序号 No. 胀套规格 sleeve specification Tightening torque per bolt N·M
the pulley torque KN·M

bearing mm

1 120 12 150x200 145

2 140 20 170x225 145

3 160 27 190x250 230

4 180 40 220x285 355

5 200 52 240x305 355

6 220 66 260x325 355

6.随机携带文件 Documents provided with belt conveyor

带式输送机产品发往用户时携带下列文件：

The following documents with belt conveyor should be supplied including:

安装用设备总图及地基图，

Installation overall drawing, the base drawing and the main parts drawing,

产品安装操作维护手册，

Operation instructions of belt conveyors,

装箱单及有关文件。

Packing list and concerned document should be provided

产品出厂检验合格证书及出厂日期和质量保证期。

Inspection Qualified Certificate and date of left factory and quality guarantee period should be provided.

7.安全注意事项 Security items

7.1 为了安全、正确的使用本机，使用前务必认真阅读本事项，在熟记设备原理、安全信

息及注意事项后使用。

In order to use the product in the safe and correct way, one must read carefully this following items and go ready to handle

after remembering equipment fundamental, security information and notice items.

7.2 使用本产品的用户必须具备本手册，阅读后，请务必妥善保管，以便查询。

The user must have the manual, read it and keep it for aftermath consultation.

7.3 本手册和设备的警告标志是指如果不遵守有关要求，不采取相应的措施，就有可能导

致人员的伤害和设备的损坏。

The warning signals in the manual and on the equipment mean that the related requirements and measures must be observed,

otherwise personnel or equipment will be hurt or damaged.

7.4 对操作本设备的人员要求：Requirement on personnel who handle the equipment:

14
 在本设备上进行工作的人员要熟悉设备的安装、调试、投入运行的步骤和要求，以及

对可能出现的各种紧急情况采取相应的措施，并要求必须具备以下条件。

The handling people must be familiar with installation, testing, operation procedures and requirements and should be capable of

taking proper measures at various emergencies. The following conditions are in need:

经过培训合格，能够按常规和本手册规定的安全操作步骤工作，并能进行对设备的

维修、使用和维护，同时还必须做到：

Qualified after training; capable of handling according to common rules and specified rules of safe operational procedures in the

manual; Capable of maintenance, operation; The following should also be made:

7.4.1 每日检查安全装置是否正常；

Daily check of the security device;

7.4.2 确保开机前所有操作者都保持警戒；

Keep operator’s watching before startup;

7.4.3 保持各零件的清洁；

Keep cleaning of various parts;

7.4.4 未做好保养、准备及妥善的调整前，不得开机。

No startup before proper maintenance, preparation and correct adjustment.

8.警告 Warning

8.1 本设备带有危险电压,设备上电后在运行和操作时，不得打开电柜门和电器控制箱以免触电

带来危险。

Equipment with dangerous electricity. When operation with electricity, electric cabinet and control cabinet door cannot be

open to avoid electricity danger.

8.2 本设备的各调节部位在机器出厂时都已调整到工作状态，任何非专业人员不得任意改变，

如确定需要调整，应由专业人员进行。

All adjustment units have been put into operation position before delivery. No change by any non professionals at will. If

necessary adjustment need to be made, it should be done by professional.

8.3 防止儿童和非机器操作人员接触或接近本设备。

No approach to the equipment by any child and non-operator.

8.4 在安装和调试设备之前，请仔细阅读这些安全规则和警告，以及设备上粘贴的所有警告标志，确保警告标志置于醒目的位置，并更

换损坏和脱落的标志。

Before installation and commissioning, please read these security rules and warnings carefully and all warning signals on the

equipment. Warning signals must be placed where easy to be read and all damaged or disappeared signals need to be

restored.

8.5 只有熟悉本手册所有安全说明和有关安装、调试、操作和维修的规定，正确地进行搬动、

装卸、维护，是实现本设备安全和成功投入运行的可靠保证。

To keep the equipment in safe and reliable operation, all the rules about installation, testing, operation and maintenance on

the manual should be familiarized.

9.特别提示 Special notice

使用设备的安全注意事项：Security notice for operation:

9.1 本机在投入运行之前，必须进行无负荷试车和负荷试车。

Non load and load commissioning before the equipment is put into operation.

9.2 本机须在空载下启动，停车前停止喂料，将物料卸完后方可停车。

The equipment must start non loaded. Feeding stop first and after fully discharging the equipment can be stopped.

9.3 本机在工作过程中应有固定的操作人员，且应进行必要的培训方可上岗。

Particular operator should be matched for handling the equipment and begin his responsibility after necessary training.

9.4 工作过程中发生故障应立即停止运转，消除故障。但当故障程度对运转无影响时应作记录，

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 待检修时消除。

Any problem occurred in operation, the equipment should be stopped and the problem be solved. If minor problem with no

influence to the operation, it can be solved during maintenance.

9.5 操作人员应经常检查各部件工作情况，应绝对禁止在运转时对运行部件进清扫或修理。

Regular check to working parts. No cleaning and repair on the working parts in operation.

9.6 本机在工作过程中应保持各润滑点正常润滑。

Keep normal oiling at all oiling points.

9.7 紧急停机开关的通道应无障碍物，各走道处应有照明设施。

No obstacles in access to emergency switch and all walkways with lighting.

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