Table of Contents

• Preface

• Chapter 1 Safety Information

  • 1.1 Safety Warnings

  • 1.2 Preventing Electric Shock

  • 1.3 Preventing Fire

  • 1.4 Preventing Damage

  • 1.5 Other Precautions

• Chapter 2 Product Specifications and Standards

  • 2.1 Introduction to the Telescopic Conveyor

  • 2.2 Standard Specifications for the Telescopic Conveyor

  • 2.3 Technical Requirements

• Chapter 3 Telescopic Conveyor Installation

  • 3.1 Parts List

  • 3.2 Installation Tools

  • 3.3 Installation Sequence

  • 3.4 Installation Precautions

• Chapter 4 Telescopic Belt Conveyor Commissioning

  • 4.1 No-load Operation

  • 4.2 Pre-trial Operation Precautions

  • 4.3 Trial Operation Precautions

• Chapter 5 Operation Diagrams and Instructions

  • 5.1 Control Cabinet Button Layout Diagram

  • 5.2 Front-end Operation Button Diagram

  • 5.3 Inside the Control Cabinet Diagram

  • 5.4 Operating Instructions

• Chapter 6 Pre-startup Preparations

  • 6.1 Pre-startup Precautions

  • 6.2 Setting the Inverter Parameters

  • 6.3 QSO Selector Switch

• Chapter 7 Maintenance and Upkeep

  • 7.1 Maintenance and Repair

  • 7.2 Inspection Intervals

• Chapter 8 Troubleshooting

  • 8.1 Common Faults and Remedies

Preface

Dear User:

Thank you very much for purchasing and using the conveying equipment manufactured by our company. To ensure long-term, stable, and safe operation, please read this manual carefully before use.

This manual mainly provides the following content:

• Installation Instructions

• Usage Instructions

• Troubleshooting and Fault Clearing

• Daily Care and Maintenance

To ensure the safety of personnel, equipment, and property, please read this manual thoroughly before putting the equipment into operation, and operate in accordance with it once you fully understand the performance specifications and usage methods. Please also strictly adhere to this manual during future installation, handling, commissioning, and maintenance processes.

Incorrect use will affect the equipment's normal operation, shorten its service life, and may cause faults. Please keep this manual in a safe place after use. If you encounter difficult problems or have special requirements during use, contact our after-sales service center promptly.

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Chapter 1 Safety Information

The safety provisions in this manual are extremely important and can help you use the telescopic belt conveyor safely, preventing personnel injuries and property losses in the work area. Before continuing to read, please fully familiarize yourself with and remember the safety warnings and hazardous operation requirements below.

1.1 Safety Warnings

Danger

• Danger indicates that failure to take appropriate precautions will very likely result in serious injury or death.

• Never step over or cross the conveyor while it is running, otherwise it may result in injury or death.

• Riding on the conveyor is strictly prohibited.

Warning

• Warning indicates that failure to take appropriate precautions may result in injury or death.

• A warning signal must be issued before starting the conveyor; otherwise, do not start it.

• Because the conveyor is driven by an electric motor, make sure the power is disconnected before performing any maintenance work.

• "Disconnecting the power" means the maintenance personnel have completed tagging, locking, and disconnected the cables from the power supply center; other interpretations are inaccurate.

• Failure to properly disconnect the power may result in personal injury and equipment damage.

Caution

• Caution indicates that failure to take appropriate precautions may result in personal injury or equipment damage; although it usually does not represent the most severe hazard, the consequences can still be very serious.

• Keep the reducer, coupling cover, and motor free of flammable or explosive debris to prevent ignition of combustible materials due to overheating.

• Maintain a safe distance from all moving parts; do not wear loose clothing while inspecting the equipment during operation, paying special attention to collars, cuffs, and pant legs.

• Check and confirm that all components are properly installed before starting the conveyor.

• Ensure all bolts and fasteners are properly installed and tightened.

1.2 Preventing Electric Shock

• Do not open the cabinet door or junction box cover while the equipment is running, as this may cause electric shock.

• When performing maintenance after power disconnection, verify that the control cabinet power indicator is off, and use a multimeter or similar tool to double-check before working.

• All parts of the equipment must be reliably grounded.

• Do not operate the equipment with wet hands to avoid electric shock.

• Do not damage the cables; applying excessive stress to them may lead to short circuits, electric shock, or other hazards.

1.3 Preventing Fire

• Install the equipment away from flammable or explosive items or devices to prevent fire.

• The cables connecting the equipment to external sources must be selected and connected strictly according to this manual to avoid fire hazards.

• When installing the equipment, do not obstruct the forced ventilation openings, otherwise it may cause fire.

1.4 Preventing Damage

• Do not apply voltages exceeding those specified in this manual at any terminal, as this may cause explosion or damage.

• Do not connect the terminals incorrectly, otherwise it may cause explosion or damage.

• Equipment that has been stored unused for more than one year must be inspected and approved by qualified personnel before reuse.

• If the equipment becomes damp, it must be thoroughly dried and inspected by qualified personnel before use.

• After long-distance transportation, drops, collisions, or similar events, ensure that no components are missing or damaged before putting the equipment back into service.

• The control cabinet installation location must have reliable lightning protection and grounding measures.

• When not in commissioning mode, do not manually cover any inspection switches, as this may damage the equipment and cause personal injury.

1.5 Other Notes

Please pay special attention to the following items:

• When handling and installing the equipment, use the correct lifting and handling tools to prevent drops or strong impacts.

• Do not place heavy objects or other miscellaneous items directly on top of the equipment.

• The installation orientation must be strictly followed.

• It is strictly forbidden to allow screws, metal shavings, or other conductive foreign objects, as well as oil or other flammable substances, into the variable frequency control cabinet.

• Commissioning and maintenance should be performed by professional technicians.

• Do not modify the equipment.

• When the equipment is idle for an extended period, please turn off the main power.

• The power cabinet placement must comply with fire safety regulations, leaving room for operation and passage, and must not be obstructed.

• When conveying items, place them gently near the center of the belt surface.

• Do not strike the equipment with hard objects.

• Do not scratch the belt surface with blades or sharp objects.

• After the movable frame extends, do not force it to swing sideways with external force to avoid jamming the frame and causing the belt to track off.

• During operation, if you notice the belt drifting toward one drum, stop immediately, adjust it to a proper position, and then restart.

• If you hear abnormal noises or rollers sticking while the belt is running, stop immediately, inspect, and only restart after resolving the issue.

• Always cut the power and hang warning signs when performing maintenance.

• It is strictly forbidden for anyone to climb over or pass through the equipment.

• It is strictly forbidden for anyone to sit, lie, or walk on the belt surface.

• It is strictly prohibited to clean debris from the belt conveyor while it is running.

• Daily operation and maintenance must not be performed by non-professionals.

• It is strictly forbidden to touch the belt, drums, or other moving parts with hands or any other body parts.

• It is strictly forbidden to touch any moving parts or gaps of the frame with hands or other body parts.

Safety warning illustrations

• Track deviation — operation prohibited:

  

  

• Prohibited operations:

  

  

  

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Chapter 2 Product Specifications and Standards

2.1 Telescopic Conveyor Introduction

The operating principle of a telescopic belt conveyor is essentially the same as that of a standard belt conveyor, both using the belt as the traction and carrying mechanism for continuous transport. Compared to a conventional belt conveyor, the telescopic belt conveyor adds belt storage and retraction devices:

• When retracting, the belt enters the storage device and the tail retracts.

• When extending, the tail extends outward.

As a result, the equipment has telescoping capabilities, offering high efficiency and labor savings. It can be integrated into a complete conveying system or used independently.

The telescopic belt conveyor mainly consists of the following parts:

• Fixed frame

• Movable frame

• Telescoping mechanism

• Belt conveying device

• Front-end protection device

• Control system

2.2 Telescopic Conveyor Standard Specifications

Standard specification table

TC Model	Number of sections	Fixed length A (mm)	Telescopic length B (mm)	Total length C (mm)	Belt width W (mm)	Height H (mm)
TC-6-4-10	2	6000	4000	10000	800	800
TC-5-7-12	3	5000	7000	12000	800	800
TC-6-8-14	3	6000	8000	14000	800	800
TC-7-9-16	3	7000	9000	16000	800	800
TC-6-12-18	4	6000	12000	18000	800	850
TC-7-14-21	4	7000	14000	21000	800	850
TC-8-17-25	4	8000	17000	25000	800	850
TC-6-16-22	5	6000	16000	22000	800	950
TC-7-17-24	5	7000	17000	24000	800	950

Standard model illustration

• Standard three-section telescopic conveyor:

  

• Standard four-section telescopic conveyor A:

  

• Standard four-section telescopic conveyor B:

  

Three-section telescopic belt conveyor standard

Basic Parameters

Item	Specification
Fixed end	6000 mm
Extended end	8000 mm
Height	1900 mm
Equipment weight	≈ 3.2 T
Premium configuration	Nord / SEW motors, Schneider inverters, Siegling / Yongli belts

Main configuration and component requirements

Item	Description
Drive roller	Φ219 seamless steel pipe precision-processed, surface coated with rubber ≥ 10 mm, wall thickness ≥ 6 mm, shaft center made of quenched and tempered 45# steel
Drive roller	φ89 refined seamless steel pipe, wall thickness ≥ 5 mm, 45# steel hardened axles, press-on roller φ50 mm
Conveying speed	15–45 meters/minute (adjustable by VFD)
Telescoping speed	3–15 meters/minute (adjustable by VFD)
Belt	3 mm PVK impact-resistant composite belt (steel-buckle joint)
Hydraulic lifting system	Dongguan Xingya
Motor	Conveying motor: 2.2 KW; telescoping motor: 0.75 KW
Frequency converter	Delta, Korv, or Schneider (matched to motor power)
Power configuration	50 Hz / 380 V / three-phase five-wire system
Configuration at the extended end front	Two 6 W LED lighting fixtures
Electrical control box	Independent distribution box with CHINT or Schneider electrical components
Control switch buttons	Two (front end and control box operation)
Telescoping arm force device	Custom-made
Telescoping stabilization device	Custom-made
Telescoping guide wheel	Custom-made
Cable drag chain	Cable: Wuxi Jiangnan, Far East, Panda, Shangshang, Jinlongyu (copper conductors and wires); drag chain: KAGUTONG, Igus, Xinpengrui
Bearing	Built-in bearing: Harbin / Renben; bearing housing: TR / Renben / FSB
Telescoping rail	Custom-made
Installation method	Fixed installation / mobile installation (with casters)
Rated load	Dynamic load ≤ 60 kg/m², static load ≤ 150 kg/m²
Extended trough beam	Main beam (fixed section): BS700 or T700 steel plate bent with thickness ≥ 6 mm; secondary beam (first extended section): BS700 or T700 steel plate bent with thickness ≥ 5 mm; secondary beam (second extended section): BS700 or T700 steel plate bent with thickness ≥ 4 mm

2.3 Technical requirements

Category	Item	Description
Product model	Universal model	Applicable to two-section / three-section / four-section telescopic conveyors
Belt	Conveying direction	Forward and reverse conveying functions, separate controls for direction switching, smooth transitions
Belt	Conveying speed	0.5 m/s, adjustable by VFD, soft-start function included
Belt	Tracking structure	Equipped with belt tracking structure design, convenient and fast adjustments, easy maintenance
Telescoping structure	Telescoping speed	10 m/min, adjustable by VFD, soft-start function included
Frame structure	Movable / fixed frame	Each section’s support plate is formed by bending 16Mn steel plate, featuring a fully integrated plate-type support structure with sufficient bending strength, rigidity, and strong impact resistance
Side panels / cover plates	Connection method	Connected using 8.8 grade bolts or welding
Side panels / cover plates	Side panel thickness for three-section telescopic conveyor	Section 1 ≥ 6.0 mm, Section 2 ≥ 5.0 mm, Section 3 ≥ 4.0 mm
Side panels / cover plates	Side panel thickness for four-section telescopic conveyor	Section 1 ≥ 6.0 mm, Section 2 ≥ 6.0 mm, Section 3 ≥ 5.0 mm, Section 4 ≥ 4.0 mm
Body end	Anti-collision device	Anti-collision bar installed at the frontmost end; the equipment automatically stops when resistance exceeds 5 kg
Body end	Lighting device	LED light installed at the frontmost end to ensure loading and unloading brightness inside the compartment at night
Internal wiring	Structure	Plastic drag chain design with bend-resistant cables to ensure stable and reliable electrical performance
Electrical cabinet	Protective panel	The electrical cabinet is equipped with protective panels over 4 mm thick to prevent cargo crushing damage
Electrical cabinet	Control circuitry	Cables exit from the side of the electrical cabinet through a protective cover, and 24 V low-voltage control is used to ensure operational safety
Electrical cabinet	Isolation switch	Used to cut off power entirely during maintenance to protect maintenance personnel
Electrical cabinet	Operation switch	The electrical cabinet is equipped with forward/reverse, start/stop, hydraulic lift, and emergency stop buttons
Front-end switch	Frontmost button	Forward/reverse, start/stop, and emergency stop buttons are provided for convenient operation
Front-end switch	Buttons on both sides of the head unit	A cross-shaped control button is installed for easy loading and unloading operations
Motor	Protection features	Includes overload, overcurrent, short-circuit, and phase-loss protection
Chain	Brand	Ziqiang brand
Sprocket	Processing method	The surface undergoes high-frequency quenching treatment
Impact-resistant section	Support plate	Length 200 mm, made of stainless steel plate or galvanized steel plate
Impact-resistant section	Roller	Diameter 60 mm, spacing 75 mm, thickness at least 2.5 mm, surface galvanized; installed using inclined U-shaped grooves so rollers can easily pop out if fingers get in, reducing injury risk

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Chapter 3 Telescopic Conveyor Installation

3.1 Accessories List

Item	Quantity	Unit
Leg support bracket	3	pieces
Support bracket connection mounting base	4	pieces
Shaft mounting base	2	pieces
Oil pump	1	unit
Hydraulic cylinder	2	pieces
Hydraulic hoses	3	pieces
Hydraulic hose connection screws, straight/T	2 / 1	pieces
O-ring oil seal	5	pieces
Oil leak-proof gasket	2	pieces
Locking shaft	2	pieces
Circlip	2	pieces
Baffle	4	pieces
Wheel	4	pieces
M14×50 external hexagon bolt	4	sets
M14×25 external hexagon	24	set
M12×120 external hexagon	2	set
M10×40 external hexagon	4	set
M10×20 internal hexagon	4	set
M5×20 Phillips screw	12	set
Expansion bolt M18×150	20	set
Expansion bolt M8×50	4	set

3.2 Installation tools

• Level

• Rotary hammer

• Rotary hammer drill bits (20×150 mm, 10×60 mm)

• Sledgehammer

• Adjustable wrench

• Open-end wrench (7 / 14 / 17 / 19 / 22 / 24)

• Set of hex keys

• Needle-nose pliers

• External circlip pliers

• Phillips screwdriver

• Flathead screwdriver

• Measuring tape

• Electrical tape

• Gloves

3.3 Installation sequence

Part One: Rear installation

1. Lift the telescopic conveyor with a forklift.

2. Install the left and right fixed seats and stop plates, then tighten the screws.

3. Insert the support frame, align the bolt holes, install the bolts, and tighten them; the same method applies to both sides.

4. Lower the telescopic conveyor, adjust the supports to sit evenly, and keep both sides level.

5. Secure two expansion bolts first to prevent movement during rear installation.

Rear installation diagram:

Part Two: Front installation

1. Lift the front end of the telescopic conveyor with a forklift and position the support frame appropriately.

2. Assemble the hydraulic arm, paying attention to the installation direction and ensuring the hose fittings on both sides align.

3. First install the upper stop plate.

4. Position the lower end by swinging the support frame and coordinating the forklift height to align with the support seat slots.

5. Drive in the locking pin and install the circlip.

6. After lowering the forklift, check that the left-right and front-back gaps of the support seats are consistent to ensure the belt surface is level.

7. Once confirmed, secure the foundation expansion bolts.

Front installation diagram:

Part Three: Hydraulic station and wiring

Hose port precautions: Do not install the seals for the straight and tee fittings incorrectly or reversed.

• Straight fitting installation diagram:

  

• Tee fitting installation diagram:

  

Hydraulic motor wiring

Hydraulic motor wiring diagram:

After wiring and powering on for hydraulic commissioning, please check the following:

• Confirm the motor rotation direction is correct; if not, swap any two wires.

• Do not descend too quickly.

• Check for oil leaks at the hose fittings.

• Ensure the motor base and motor cover are securely fastened.

3.4 Installation Precautions

• The equipment must be installed on a concrete foundation surface with a thickness of at least 200 mm.

• After placing the equipment at the user-specified location, level it, then drill holes for expansion bolts with an impact drill and install the anchors.

• The telescopic belt conveyor leaves the factory as a complete unit, with belt operation and movable frame extension already adjusted; however, due to long-distance transport, a comprehensive inspection and commissioning by professionals is still required before use.

• Only after its performance and parameters meet operational requirements may it be put into service.

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Chapter Four Telescopic Belt Conveyor Commissioning

4.1 No-load Run

• Before trial operation, tighten the conveyor belt so it has sufficient tension to prevent slippage on the drive drum during startup and transportation.

• Relevant adjustments were made before leaving the factory.

• If slippage, tracking deviation, or other abnormalities occur during operation, stop immediately and adjust.

• If tracking deviation occurs during installation, commissioning, or operation, determine the cause based on the belt travel direction and deviation direction, then adjust the tensioning re-direction drums at both ends accordingly.

• Do not draw conclusions immediately after adjustment; observe for several minutes before judging; if the belt shifts excessively in the opposite direction after adjustment, the tension is too high.

• When the belt deviates at a drum, tighten the tensioning bolts on the same side as the deviation; adjust the drum position via the adjustment bolts at the drum bearings.

• Conveyor belt tension should be determined by the throughput and transport distance; too much tension accelerates belt wear, too little leads to slippage.

• Under normal operation, the initial belt tension should be enough to prevent slippage.

Tracking adjustment bolt illustration:

4.2 Precautions Before Trial Operation

• Check whether the foundation and connection bolts of each component have been tightened and whether there are any unwelded seams.

• Check whether the reducer has been filled with lubricating oil or fluid as required.

• Check whether electrical signals, electrical control protections, and insulation comply with the electrical manual.

• Monitor the temperature, operating sounds, and motor currents of the reducer, motor, and load-bearing bearings.

• During initial operation, check the conveyor belt tension and readjust the no-load tension if it changes.

4.3 Precautions During Trial Operation

Begin with a no-load trial run lasting at least 2 hours while observing, inspecting, and adjusting each component to prepare for the loaded trial.

During the no-load trial run, focus on observing:

• Whether moving components exhibit friction or rubbing, especially against the conveyor belt.

• Whether the conveyor belt is tracking correctly; adjust promptly if not.

• Whether any abnormal noises or vibrations are present in the equipment.

• Whether there are oil leaks in the reducer or other lubricated areas.

• Whether the temperature rise at motors, bearings, and other areas is normal.

• Whether the tensioning device operates well and if there are jamming issues.

• Whether the foundation and each component connection bolt are loose.

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Chapter Five Operation Diagram and Instructions

5.1 Control Cabinet Button Layout Diagram

Control cabinet button layout illustration:

1. Power indicator light: stays on when powered.

2. Inverter fault indicator light: illuminates when the inverter faults.

3. Emergency stop indicator light: lights when the stop button is pressed.

4. Buzzer: lights and sounds when the equipment extends or retracts.

5. Belt direction control knob: controls conveyor direction.

6. Belt start button.

7. Extend button: press and hold to extend the telescopic conveyor.

8. Lift button: press and hold to raise the telescopic conveyor.

9. Emergency stop button: pressing immediately halts the telescopic conveyor.

10. Belt stop button.

11. Retract button: press and hold to retract the telescopic conveyor.

12. Descend button: press and hold to lower the telescopic conveyor.

5.2 Front-end Operation Button Diagram

Front-end control box

Front-end control box illustration:

1. LED work light

2. Belt start button

3. Belt stop button

4. Collision indicator light

5. Emergency stop button

6. LED work light switch

7. Anti-collision bumper

Front-end cross button

Front-end cross button illustration:

1. Rise button: press and hold to raise the telescopic conveyor.

2. Extend button: press and hold to extend the telescopic conveyor.

3. Lower button: press and hold to lower the telescopic conveyor.

4. Retract button: press and hold to retract the telescopic conveyor.

5.3 Control cabinet internal diagram

Control cabinet internal diagram:

1. Air switch

2. Fuse: melts when the circuit current is too high, cutting power and protecting the circuit.

3. Maintenance power socket: for maintenance use only.

4. AC contactor

5. 24V power supply

6. Belt inverter: adjusts the conveyor belt speed.

7. Telescopic inverter: adjusts the machine's telescoping speed.

8. Relay

5.4 Operation instructions

1. Select belt running direction

   • When the loading/unloading selector switch knob on the control cabinet is turned to the "Unload" position, the conveyor runs forward.

   • Turning the knob to the "Load" position makes the conveyor run in reverse.

2. Conveyor operation

   • Press the green start button on the control cabinet or the green start button on the front control box to start the conveyor.

   • Rotate the potentiometer knob on the inverter inside the control cabinet to adjust the conveyor speed to the desired value.

   • Press the red belt stop button on the control cabinet or the red belt stop button on the front control box to stop the conveyor.

3. Telescopic operation

   • Press the extend green button on the control cabinet or the front extend switch; the intermediate relay engages and the conveyor extends. Release the button to stop extending.

   • When the conveyor reaches the limit travel switch or anti-collision rod switch, it stops extending.

   • Press the retract green button on the control cabinet or pull back the front main switch; the intermediate relay engages and the conveyor retracts. Release the button to stop retracting.

   • When the conveyor reaches the limit travel switch during retraction, it stops retracting.

   • During extension and retraction, the buzzer will sound intermittently.

4. Telescopic lift/lower operation

   • Press the green lift button on the control cabinet or the front lift button; the relay engages, the hydraulic lifting system starts, and the telescopic conveyor rises. Release the button to stop rising.

   • Press the green lower button on the control cabinet or the front lower button; the relay engages, the hydraulic lifting system starts, and the telescopic conveyor lowers. Release the button to stop lowering.

5. Emergency stop

   • If the conveyor operation poses a hazard to people or equipment, immediately press the emergency stop button on the control cabinet or the front control box; the telescopic conveyor will stop.

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Chapter 6 Preparation before startup

6.1 Startup precautions

1. Check that the power supply voltage is three-phase five-wire AC 380V, 50Hz, with no missing phases, correct phase sequence, and a capacity of 32A.

2. Control power is DC 24V safety voltage.

3. Confirm there are no unsafe conditions on the telescopic conveyor for equipment or personnel.

4. Set the breaker and inverter overload current values according to the motor nameplate.

5. Ensure the emergency stop switch heads on the control cabinet and operation box are pulled out; when the red emergency stop indicator light is off, the stop button is not pressed. Verify before proceeding.

6. Turn the QS0 / QSO switch on the left side of the control cabinet to the ON position to power the main supply.

7. Close the breaker inside the control cabinet to power the control supply; the green DC power indicator will light.

8. Close the breaker inside the control cabinet to power the telescopic motor, conveyor belt, and hydraulic lifting device separately.

6.2 Setting inverter parameters

Schneider inverter

Parameter content	Description
Extended function display selection	Display extended functions
Upper limit frequency	Maximum output frequency limit
Lower limit frequency	Minimum output frequency limit
Acceleration time	Time for the inverter to ramp from the minimum to maximum frequency
Deceleration time	Time for the inverter to ramp from maximum to minimum frequency
Electronic overcurrent protection	Current protection setting during overload; adjust according to motor power.
Inverter start signal control	External control signal
Frequency selection	Can reduce motor noise
Frequency setting allowed on the operation panel	Use the knob on the operation panel as the frequency adjustment knob

Delta inverter

Parameter content	Description
Frequency command selection	Change the frequency using the dial on the digital operator
Run command selection	External control terminals
Maximum frequency	Reference value
Acceleration time	Reference value
Deceleration time	Reference value
Characteristic time selection	Reference value
Multifunction output relay function selection	Fault indication; contacts close when the inverter is abnormal
Motor rated current	Set according to the motor nameplate current
Electronic thermal relay selection	Standard motor
Electronic thermal relay trip time selection	Reference value

6.3 QSO selector switch

• When powering on: rotate the control cabinet QSO selector switch to ON position to connect the main power supply.

• When powering off: rotate the control cabinet QSO selector switch to OFF position to disconnect the main power supply.

QSO selector switch illustration:

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Chapter 7 Maintenance and upkeep

The telescopic conveyor and its main components should be properly maintained as required. Moving parts and drive units should undergo regular inspection, adjustment, servicing, and cleaning; these tasks must be performed only when the equipment is stationary and the drive units are shut off.

7.1 Maintenance and repair

7.1.1 Startup requirements

• Under normal conditions, the conveyor should start empty and avoid frequent short-term starts.

7.1.2 Reducer inspection

• The reducer must be checked regularly for oil leaks, and the oil level should be inspected periodically to ensure it is appropriate, adjusting and replenishing as needed.

7.1.3 Drive drum abnormalities

• If a squealing noise comes from the drive drum, it indicates the belt may be slipping; check whether the belt is properly tensioned.

7.1.4 Belt misalignment

• The running belt should be checked frequently for misalignment and adjusted promptly.

7.1.5 Protective devices

• All protective devices on the conveyor must be complete and assigned personnel should inspect and verify them regularly to ensure reliable operation.

7.1.6 Working with safety guards installed

• Inspections or adjustments during conveyor operation or use should, in principle, be carried out with protective devices installed.

• If some guards must be removed due to operational needs, necessary precautions must be taken and approaching areas with pinch hazards is strictly prohibited.

7.1.7 Requirements after guard removal

• If the removed guard is located in a work area or aisle, the area must be barricaded during equipment operation to prevent personnel from approaching.

• When repairing protective devices, work must be done after the conveyor has stopped and the drive unit cannot be started; the guards must be reinstalled before restarting.

• If maintenance must be performed on equipment running without guards, a watcher must be assigned to supervise continuously. The watcher should be familiar with emergency procedures and stay close to a device that can stop immediately.

7.2 Inspection intervals

7.2.1 Daily inspection

• Check whether the entire machine’s conveyor belt is running properly and whether there are abnormalities such as jamming, grinding, or misalignment.

• Check whether the temperatures of the reducer, motor, and all drum bearings are normal.

• Check for any leakage from the reducer.

• Inspect all drum oil seals and bearing wear levels.

7.2.2 Weekly inspection

• Perform all daily inspection items.

• Check the reducer oil level and top up with the specified grade of lubricant if necessary.

7.2.3 Monthly / annual inspection

• Perform daily and weekly inspection items.

• Check the wear condition of all drum oil seals and bearings.

• Grease all drum bearings and clean debris from the drums.

• Clean the reducer, replace the lubricant, and analyze the next oil change interval.

• Inspect the wear condition of all oil seals and bearings.

Lubrication requirements

The reducer is shipped without oil; before trial operation, add lubricant according to its instructions. Lubrication requirements for other parts are as follows:

Serial number	Location of use	Lubrication method	Grade	Standard number	Oil change interval
1	Gear motor	Oil bath	L-CKC220	GB5903-1995	6–8 months
2	Drive drum bearings	Grease injection	No. 2 lithium-based grease	GB7323-94	3 months
3	Active telescoping bearings	Grease injection	No. 2 lithium-based grease	GB7323-94	3 months

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Chapter 8 Fault Analysis and Troubleshooting

8.1 Common Faults and Remedies

1. The motor fails to start or slows down immediately after starting

Possible causes

• Circuit faults

• Voltage drop

• Contactor fault

• Repeated operation within 1.5 seconds

Remedial actions

• Inspect the wiring

• Check the voltage

• Inspect overload protection devices

• Reduce the number of operations

2. Motor overheating

Possible causes

• Overloading, excessive conveyor length, or belt obstruction increases running resistance, causing the motor to operate under overload.

• Poor lubrication in the drive system increases the motor's load.

Remedial actions

• Measure the motor power, identify the cause of the heavy load, and address it accordingly.

• Add lubricant to all drive components in a timely manner.

• Remove dust.

3. Gearbox overheating

Possible causes

• Excessive or insufficient oil in the gearbox

• Lubricant has been in use for too long

• Deteriorated lubrication leading to bearing failure

Remedial actions

• Fill oil to the specified level.

• Clean the interior and replace the oil promptly.

• Repair or replace bearings and improve lubrication.

4. Conveyor belt tracking deviation

Possible causes

• Frame or rollers are not aligned straight

• Idler axes are not perpendicular to the conveyor belt centerline

Remedial actions

• Adjust the frame or rollers to keep them straight.

• Correct belt tracking by repositioning the idlers.

5. Conveyor belt aging or tearing

Possible causes

• Friction between the belt and frame causes fraying or cracking at the belt edges.

• Interference between the belt and fixed hard objects causes tearing.

Remedial actions

• Adjust promptly to prevent prolonged belt misalignment.

• Prevent the belt from catching on fixed components and keep metal parts from falling onto it.

6. Conveyor belt breakage

Possible causes

• Belt material is unsuitable, becoming hard or brittle when exposed to water or cold.

• Extended use weakens the belt's strength.

• Poor joint quality with cracks left unrepaired or not remade.

Remedial actions

• Choose belt carcass materials with stable mechanical and physical properties.

• Replace damaged or aged belts promptly.

• Regularly inspect joints and address issues immediately.

7. Conveyor belt slipping

Possible causes

• Insufficient belt tension combined with excessive load.

• Water spray reduces the friction coefficient between the drive roller and the belt.

Remedial actions

• Readjust the drive roller tension or reduce the throughput.

• Eliminate water spray and increase tension.

8. DC power indicator off

Possible causes

• Power supply is disconnected

• Circuit breaker QF01 is off

• Switch tripped or circuit shorted

• Indicator HL01 is damaged

Remedial actions

• Turn on the power

• Close circuit breaker QF01

• Check the wiring and close the switch

• Replace the indicator

9. Emergency stop indicator on

Possible causes

• Emergency stop button is depressed

• Contacts are damaged

Remedial actions

• Unscrew the emergency stop button actuator

• Replace the contacts

10. Conveyor belt telescopic mechanism not moving

Possible causes

• Limit switch activated

• Emergency stop button pressed

• Motor overload, breaker tripped

Remedial actions

• Operate in the opposite direction

• Unscrew the emergency stop button actuator

• Inspect motor and switch status

11. Conveyor belt does not run after pressing the start button

Possible causes

• Inverter protection current set too low

• Emergency stop button pressed

• Motor overload, breaker tripped

Remedial actions

• Set an appropriate current value according to the load

• Unscrew the emergency stop button actuator

• Inspect motor and switch status

12. Conveyor belt retraction exceeds limit

Possible causes

• Retraction limit travel switch not engaged, causing the extreme limit travel switch to activate and triggering over-retraction.

• Retraction limit travel switch is too close to the extreme limit switch.

Remedial actions

• Inspect and adjust the roller arms of the limit travel switches, as well as the installation positions of the retraction limit travel switch and the extreme limit switch.

• Press the extension button to move the telescopic mechanism in the opposite direction and clear the extreme limit travel switch.

13. Conveyor belt extension exceeds limit

Possible causes

• Extension limit travel switch not engaged, causing the extreme limit travel switch to activate and triggering over-extension.

• Extension limit travel switch is too close to the extreme limit switch.

Remedial actions

• Inspect and adjust the roller arms of the limit travel switches, along with the installation positions of the extension limit travel switch and the extreme limit switch.

• Press the retraction button to move the telescopic mechanism in the opposite direction and clear the extreme limit travel switch.

14. Buzzer alarm light abnormal

Original description:

• Continuous ringing indicates: fault

• Intermittent ringing indicates: extension/retraction action status

Possible causes

• Inverter overload current setting too low

• Power supply phase loss

• Motor overload

• Reduced motor insulation impedance, unbalanced three-phase winding impedance, motor damage

Remedial actions

• Set the inverter current value according to the nameplate.

• Check whether the power voltage is three-phase 380V, verify for phase loss and loose wiring.

• Inspect for mechanical jamming and eliminate any issues.

• Test the motor insulation impedance and three-phase winding impedance balance, and replace the motor if necessary.