Belt Conveyor Rev C en 014555

Belt Conveyor Technical Manual

Key Part Number: 014555, Revision DAugust 30, 2012

Notices
Proprietary RightsThis manual as well as the equipment described in thismanual contains trade secrets, copyrighted works ofauthorship, trademarks and other proprietary intellectualproperty of Key Technology, Inc. Unauthorized use,copying, modification, distribution or disclosure of thatproprietary property is subject to civil and criminalpenalties under both United States and international law. © 2005-2012 Key Technology, Inc. All Rights Reserved.
License GrantKey Technology grants to the original end user customera nonexclusive, nonassignable right to make a reasonablenumber of copies of this manual and to use the Key Tech-nology proprietary property embodied in the KeyTechnology equipment described in this manual, but onlyin connection with its use of that equipment. Except asdescribed above, no one may copy or use Key Tech-nology's proprietary property, and in no event willanyone modify, disclose, distribute, sublicense, assign orreverse engineer that property.

SafetyCustomer will (a) cause each person who receives or usesthe equipment described in this manual to read andcomply with all safety instructions in this manual and anyother safety notices that Key Technology makes availablefrom time to time; (b) instruct its employees and otherswho use the equipment in its proper use; and(c) implement and enforce the safety provisions of allproduct safety notices, warnings, instructions or similardocumentation that Key Technology provides from timeto time. Customer will not remove any shields, guards, orother safety devices from this equipment.

Terms of SaleBy downloading and/or printing these materials, youagree to be bound by the Terms and Conditions of Saleavailable on the Company’s website at www.key.net.

DisclaimerThe information contained in this manual is representa-tive of typical systems and may not apply to specificapplications or to equipment that have been customizedto meet your requirements. Performance of the equip-ment is dependent on many factors not within the scopeof this manual and should be considered with relation tothe entire processing line.

The information contained in this manual does not alter,expand or supplement Key Technology's warranty, andthe only warranty that will apply is the warranty in KeyTechnology's Terms and Conditions of Sale referencedabove.This manual is intended only as an installation and main-tenance reference for typical systems and is subject tochange through revisions and additions withoutnotification.The English version of this manual is the original instruc-tions. All other languages are translations of the originalinstructions.

Trademark Acknowledgments

UNITED STATES OF AMERICA TRADEMARKSKey® is a registered trademark of Key Technology, Inc.,Walla Walla, WA

Intralox® is a registered trademark of Laitram, LLC,Harahan, LA

KVP® is a registered trademark of KVP Holdings, Inc.,Reading, PA

Loctite® is a registered trademark of Henkel Corporation,Rocky Hill, CT.

INTERNATIONAL TRADEMARKSKey® is a registered trademark of Key Technology, Inc.in China, the European Community, India and Mexico

Belt Conveyor Technical Manual iiiRevision C

Declaration of Conformity Template

EC 2A DECLARATION OF CONFORMITY

Key Technology BV, Beijerdstraat 10, 4112 NE Beusichem, The Netherlands, 0345 50 99 00

Declaration of conformity:

We, Key Technology BV, declare completely under our own responsibility that the product:

Model Number: Belt ConveyorDescription of Product: Belt Conveyor

to which this declaration relates, conforms (as the case may be) with the standard(s) or other normative document(s):

- ISO 14121- 1- 2007 (Safety of machines) - IEC 60204-1 Ed. 5.1 2009-2 (Safety of machines, electrical safety)

in accordance with the provisions of directives:

- 2006/42/EC (Machine Safety Directive) - 2004/108/ EC (EMC Directive) - 2006/95/EC (Low-voltage Directive)

Name and address of the person authorized to compile the technical file: C.H. Ruitenbeek, Project Engineering Manager Key Technology BV, Beijerdstraat 10, 4112 NE Beusichem, The Netherlands.

Place Beusichem, The Netherlands

____________________________________ Date

____________________________________ Signature

C.H. Ruitenbeek, Project Engineering Manager

iv Belt Conveyor Technical ManualRevision C

Table of Contents
ContentsSafety Awareness ................................................................................................................1
Signal Word Definitions.....................................................................................................................1Hazard Alert Messages.......................................................................................................................1General Safety Recommendations .....................................................................................................2

Introduction..........................................................................................................................2Contact Information ...........................................................................................................................2

Corporate Headquarters ..................................................................................................................2Key Technology BV.......................................................................................................................2Service Calls ...................................................................................................................................2Ordering Parts.................................................................................................................................3

System Overview ...............................................................................................................................3

Installation............................................................................................................................3Overview ............................................................................................................................................3Receiving the Shipment .....................................................................................................................3

Manufacturer’s Literature...............................................................................................................3Belt Conveyor Technical Manual ...............................................................................................3Engineering Drawings.................................................................................................................3Original Equipment Manufacturer (OEM) Literature.................................................................3

Handling Precautions......................................................................................................................4Installation Preparation ......................................................................................................................4

Safety Precautions ..........................................................................................................................4Selecting a Proper Location............................................................................................................4

Proximity, Space, and Clearance Requirements .........................................................................4Utility Requirements ...................................................................................................................4

Recommended Tools, Equipment and Supplies .............................................................................4Floor Mounting Requirements........................................................................................................4

Floor Support Pedestals and Columns ........................................................................................4Installation Procedure.........................................................................................................................6

Wiring .............................................................................................................................................6Modification ...................................................................................................................................6

Start-Up Procedure .............................................................................................................................6Long-Term Shutdown ........................................................................................................................6

Maintenance .........................................................................................................................7Maintenance Schedule........................................................................................................................7Lubrication .........................................................................................................................................7

Bearings ..........................................................................................................................................7Purging ........................................................................................................................................7

Belt Conveyor Technical Manual vRevision C

Lubrication ..................................................................................................................................8Gear Motors ....................................................................................................................................8

Motor Replacement ............................................................................................................................8Bearing Replacement .........................................................................................................................9

Discharge ........................................................................................................................................9Infeed ............................................................................................................................................10

Belts..................................................................................................................................................10Fabric Belts...................................................................................................................................10

Replacement..............................................................................................................................11Tension......................................................................................................................................11Belt Tracking.............................................................................................................................12

Plastic and Polyurethane Belts......................................................................................................13Replacement..............................................................................................................................13Tension......................................................................................................................................15Shaft Bearings ...........................................................................................................................16

System sanitation.............................................................................................................. 16Overall System Sanitation ..............................................................................................................16Non-Metallic Components ...............................................................................................................16

Troubleshooting Guide..................................................................................................... 17

vi Belt Conveyor Technical ManualRevision C

Belt Conveyor
Safety AwarenessAll installation and maintenance personnel must read thismanual before working on a belt conveyor. Employeeswho are unable to read English should have it read tothem in a language that is fully understood. If you needfurther explanation, contact Key Technology, Inc. (Key®)immediately. For telephone numbers, refer to “CustomerService” in the Introduction section of this manual.
SIGNAL WORD DEFINITIONS The following symbols and signal words will be usedthroughout this manual:

HAZARD ALERT MESSAGESThe labels shown in Figure 1 through Figure 3 are affixedto the conveyor.

DANGERIndicates a situation which, if not avoided, willresult in death or serious injury.

WARNINGIndicates a situation which, if not avoided,could result in death or serious injury.

CAUTIONIndicates a situation which, if not avoided, mayresult in minor or moderate injury.

ImportantIndicates an item affecting the installation,maintenance or operation of this equipment.

NoteIndicates a comment or an explanationregarding this equipment.

Figure 1 Affixed to Both Sides of the Frame

Figure 2 Affixed to Both Sides of the Frame

Belt Conveyor Technical Manual 1Revision C

GENERAL SAFETY RECOMMENDATIONS• Ensure that all safety guards and shields are securely

fastened in place before starting the conveyor.• Read the applicable procedures in this manual before

attempting to install or maintain the conveyor.• Permit only authorized, properly trained personnel to

operate, install, or maintain the conveyor.• Before removing any safety guards or covers, turn off

and lock out power to the conveyor.• Keep the work area clean to prevent accidents and

product contamination.• Use this equipment only for tasks that are designated

or intended. Follow all specifications for space, clear-ance, utilities, and environment which are providedon the equipment drawings.

• Keep the conveyor in good working order at all timesby performing maintenance regularly, and conductingperiodic safety inspections. Correct all unsafe condi-tions immediately.

• Do not wear torn or loose clothing or jewelry aroundequipment with moving parts, and always wearapproved eye and ear protection.

• Do not walk or stand on the equipment. It is not safeas a walkway or platform. Personal injuries ordamage to equipment or parts may occur.

• The combination of water and product can causefloors to become slippery and hazardous. To avoidinjury from slipping and falling, exercise extremecare while working near the conveyor.

IntroductionKey Technology provides customer service through all ofour offices. The corporate headquarters and Europeanoffice offers 24-hour customer support. The Australia andMexico offices offer customer support for their locationsduring normal business hours.Support includes:• Telephone support for all Key equipment• Prompt delivery of parts orders• On-site service calls by our field service engineers

CONTACT INFORMATION

Corporate HeadquartersTel: +1 877 878-4631 Fax: +1 509 394-3386Emergency Tel (after hours): +1 509 520-2888

Key Technology BVTel: +31 (0) 345-509900Fax: +31 (0) 345-501594

For all other locations, visit our website at www.key.net.

Service CallsWhen calling for customer service, please have thefollowing information at hand:• Company name and location of your plant• Equipment name, model, and serial number found on

the equipment drawings and the conveyor nameplate(Figure 4 and Figure 5)

• Complete description of problem (including alldetails, equipment drawing numbers, and measure-ments available)

• Name of the person at your plant requestingassistance

• Your telephone and fax numbers

Figure 3 Affixed Near the Motor

2 Belt Conveyor Technical ManualRevision C

Ordering PartsWhen ordering parts, please provide the followinginformation:• Company name and location of your plant• Equipment name, model, and serial number found on

the equipment drawings and the conveyor nameplate(Figure 4 and Figure 5)

• Name of the person at your plant requesting the parts

• Your company purchase order number

SYSTEM OVERVIEWBelt Conveyors are manufactured in a wide variety ofconfigurations which share common components andconstruction. Refer to the equipment drawings and manu-facturer’s literature for specific details about your beltconveyor.

Installation

OVERVIEWRead all the information provided before attempting theinstallation. The installation procedures often direct youto other documentation, such as the equipment drawingsand to the manufacturer’s literature shipped with theequipment.

RECEIVING THE SHIPMENT

Manufacturer’s Literature

Belt Conveyor Technical ManualThis manual provides instruction on safety, installation,operation, maintenance, and troubleshooting of the beltconveyor. The information in this manual pertains to allbelt conveyors. Some points may differ on your equip-ment, depending on the specific design.

Engineering DrawingsThe equipment drawings provide information specific toyour belt conveyor.• Key Technology Equipment Drawings

Dwg. No. = Model Number Job No. = Serial Number

• Key Technology BV Equipment DrawingsDwg. No. = WOS (serial) Number Machine Code = Model Number

Original Equipment Manufacturer (OEM) LiteratureA packet of supplementary vendor literature is alsoshipped with the belt conveyor. These documents cometo Key Technology with parts that are included in theassembled equipment.

Figure 4 Belt Conveyor Nameplate—CE version

Figure 5 Belt Conveyor Nameplate—Non-CE version

WARNINGThis equipment is not balanced or stable until itis correctly mounted and leveled. Improperlyinstalled equipment can be dangerous, ineffi-cient, and costly.


Handling PrecautionsWhen unloading and moving the belt conveyor from thetruck to the permanent location, use extreme care not todistort any part of the equipment.

INSTALLATION PREPARATION

Safety PrecautionsRead and understand all safety precautions listed in theSafety section of this manual, and give special consider-ation to all text headed with DANGER, WARNING,CAUTION, IMPORTANT, and NOTE.In addition, observe all safety precautions provided in theOEM literature. If you do not fully understand theseprecautions, contact Key Technology Customer Servicefor further explanation.

Selecting a Proper LocationWhen selecting a location for belt conveyors, considerthe following:• Plant layout requirements• Ability of the site to support the static loads intro-

duced by the equipment• Cleaning and maintenance clearance• Required mounting surface of steel or reinforced

concrete

Proximity, Space, and Clearance RequirementsRefer to the equipment drawings for proximity, space,and clearance requirements specific to your beltconveyor.

Utility RequirementsRefer to the equipment drawings for utility requirementsspecific to your belt conveyor.

Recommended Tools, Equipment and Supplies

Floor Mounting Requirements

Floor Support Pedestals and ColumnsGenerally, Key Technology provides the column orpedestal supports. Either type of support structure may beused to support the belt conveyor. Contact Key Tech-nology for more information. For an example of supportmounting, refer to Figure 6.

ImportantWhen moving a belt conveyor, use the appro-priate lifting equipment and always lift theequipment by the frame, never by the belt.

ImportantRead and follow all notes and safety precau-tions on the equipment drawings specific toyour belt conveyor installation.

Table A

Tools, Equipment and Supplies4-foot or 5-foot level

Basic mechanic’s tools, standard and metric

C-clamps

Chalk line or Laser transient

Clean shop cloths

Concrete drill bits

Drill motor

Equipment drawings

Hammer drill

Hi-quality, food-grade grease

Lifting equipment (e.g., jacks, forklift, crane, hoist)

Lock out tag and padlock

Manually operated grease gun

Measuring tape

Plumb bob

Steel drill bits

Transit

Welder

Wrist watch or timer that indicated seconds

NoteIt is important to securely fasten the beltconveyor to the floor.


Figure 6 Example of Floor Installation for Columns

Use square tube spacer same size as support tube under base plate or solid steel plate as shim stock

Anchor bolt

Grout as required

All thread in quick setting epoxy. Note 45 degree end cut

Reinforced concrete

Column width

Distance between bolt centerlines

Base plate size

Base plate hole

Product flow

Shim


INSTALLATION PROCEDURETo install the belt conveyor:1. Locate the supports on the floor or deck in accor-

dance with dimensions given on the equipmentdrawings.

2. Shim the bottoms of support columns or pedestals.

Wiring To wire the belt conveyor:1. Make the electrical connection, using at least 18''

(457 mm) of flexible conduit at the motor. The electrical connection must be performed by aqualified electrician in accordance with NEC andlocal codes. At a minimum, the ability to physicallylock out power to the unit must be supplied.

2. Check for the rotation arrow sticker.3. If it is missing, wire the motor for the direction of

belt travel.4. If the belt is running in the wrong directing, switch

any two of the wires to reverse the rotation.

ModificationNever modify, alter, or change the design of any beltconveyors manufactured by Key Technology. If modifi-cation is desired, contact Key Technology CustomerService.

START-UP PROCEDURETo start the belt conveyor:1. Verify there is no shipping damage and all separate

components are present.2. Verify the motor type, with voltage, frequency,

current, HP and rpm rating.3. Verify correct motor rotation. Refer to “Wiring”

earlier in this manual.

LONG-TERM SHUTDOWN

To prepare the belt conveyor for long-term storage:1. Change the oil in the motor gear box.2. Lubricate the bearings and oil the chain.3. Check the unit for any necessary repairs, adjust-

ments, or part replacement.4. Cover the belt to protect it from any foreign materials

that may cause damage.

5. Relieve tension from the belt.

WARNINGKeep the lifting equipment under the beltconveyor during this procedure, the beltconveyor is not stable until it is leveled andopposing nuts are tightened.

WARNINGTo avoid potentially dangerous conditions anddamage to the equipment, do not attachanything else to the frame or belt without firstconsulting Key Technology.

DANGERRunning the motor without the drive guard canresult in injury or death. When guards arepresent they must be on when running due tothe exposed belt and pulleys. This proceduremust be performed by a qualified electrician ormechanic.

NoteUse only spare parts recommended by KeyTechnology.

Tools/Supplies• Clean shop cloth

• Hi-quality, non food-grade grease

• Manually operated grease gun

• Wrist watch or timer that indicated seconds

ImportantWhen belts are removed from the conveyor,they should be stored in a cool, dark, dry place.Wire or fabric belts should not be stored inexcessively wet places or in areas wherecontact with foreign materials, oil, gasoline, oracid may occur. If the belt is laid down, itshould rest on a clean, flat surface. If it isnecessary to lay a belt on the floor, place apallet or cradle under it to avoid contact withthe floor.


Maintenance

MAINTENANCE SCHEDULE

LUBRICATION

Bearings

Purging Bearings are lubricated with a high-quality, type H1,food-grade grease at the Key factory. Purge the bearingsif your application requires the use of non food-gradegrease.

To purge bearings:1. Turn on the conveyor.2. Slowly add one pump of new lubricant every 20

seconds until all of the old lubricant is removed.

Belt Conveyor Maintenance Schedule

Daily

Inspect for product build-up on the belt.

Clean the inside of the belt with an open hose to remove any product that may have become lodged.

Inspect for oil leaks from gear box.

Listen for any unusual noise.

Check the belt tracking.

Weekly

Grease all bearings and fittings, as applicable.

Inspect the sprockets for wear and position (plastic belts only).

Inspect the belt surface, belt underside and the hinge rods for wear.

Check catenary sag or any elongation of belt due to normal hinge wear. Reposition tail shaft or shorten belt if excessive. Belt length elongation of 3–4% over the life of the belt is not unusual.

Include the Daily Inspection Check list to this Weekly Inspection Check List.

Monthly

Inspect drive belts or chain for wear and tension, if applicable and required.

Verify that drive system guards are in place, secured, and undamaged.

Confirm all electrical connections are tightly secured and sealed.

In abrasive applications, pull hinge rods and in-spect for wear. Replace excessively worn rods (more than 1/16" wear) with abrasion resistant material such as nylon.

Lubricate the bearings at the start of an idleperiod longer than one month.

Inspect the condition of the belt surface and drive sprockets.

Inspect the condition of the carryways at infeed.

Verify that side rails and functioning correctly.

Verify that support shoes are properly fastened.

Verify correct belt tracking.

Confirm the levelness and squareness.

Verify properly functioning infeed/discharge chutes.

Inspect condition of floor plate mounting bolts.

Confirm that the return belt is adequately supported.

Include the Daily and Weekly Inspection Check Lists to this Monthly Inspection Check list.

Annually

Change oil.

Replace drive belts, as applicable.


• Hi-quality, non food-grade grease



ImportantPurging bearings faster than one pump everytwenty seconds will damage the seals resultingin premature failure.

Belt Conveyor Maintenance Schedule


3. Clean the grease fittings with a clean shop cloth.

LubricationLubricate the bearings weekly during periods ofoperation.

To lubricate bearings:1. Turn on the conveyor.2. Slowly add one pump of new lubricant every 20

seconds until grease begins to flow from the seals.

3. Clean the grease fittings with a clean shop cloth.

Gear MotorsDue to various types of motors, refer to the OEM litera-ture provided with the belt conveyor.

MOTOR REPLACEMENT

To replace a motor:1. Bypass product flow to the conveyor and wait for all

product to clear the machine.2. Turn off and lock out the conveyor power disconnect

switch.3. Open the motor conduit box and disconnect wires

#456, #457 and #458 from T1, T2 and T3 respec-tively. Disconnect the ground wire.

4. Attach a lifting device and safety strap to the motor.5. Loosen the setscrews on the bearing lock collar

(Figure 7).

6. Remove the mounting bolts from the motor guard(Figure 8).

7. Slide the motor off of the shaft.8. Remove the reducer drip pan and install it onto the

new motor (Figure 9).

9. Slide the new motor onto the shaft.10. Slide the lock collar onto the shaft, insert and tighten

the setscrews.11. Insert and tighten the motor guard mounting bolts,

washers and lock washers.12. Connect wires #456, #457 and #458 to T1, T2 and T3

respectively. Connect the ground wire.13. Replace the motor wire cover and tighten the four

screws.14. Unlock and enable the motor disconnect switch.


• Hi-quality, food-grade grease



ImportantLubricating bearings faster than one pumpevery twenty seconds will damage the sealsresulting in premature failure.

Tools/Supplies• Lifting device

• Safety strap

• Basic mechanic’s tools, standard and metric

Figure 7 Setscrew on the Bearing Lock Collar

Figure 8 Motor Guard Mounting Bolts

NoteKey recommends that while the motor is offand the conveyor is stopped, to replace thebearings. Refer to “Bearing Replacement” laterin this section.

Setscrew

Mounting bolts


15. Cycle power to the belt conveyor and check the rota-tion. If incorrect, lock out power and swap any twowires to reverse the direction of rotation.

16. Restore product flow to the conveyor.

BEARING REPLACEMENT

DischargeTo replace the discharge bearings:1. Bypass product flow to the conveyor and wait for all


switch.3. Support the shaft.

A. Attach safety straps to the shaft.B. Hold a 2x4 that is about 1" (25 mm) longer than

the width of the conveyor and loop the safetystraps around the ends until it is stable and holdsthe shaft in place.

4. Perform the following steps on the idle side (Figure 10):A. Remove the four mounting bolts, washers and

lock washers from the bearings.

B. Loosen the setscrews on the bearing lock collar.

5. Perform the following steps on the drive side (Figure 11):A. Remove the drive motor. Refer to “Motor

Replacement” earlier in this section forinstructions.

B. Remove the four mounting bolts and motorsupport plate.

C. Loosen the setscrews on the bearing lock collar.

D. Slide the lock collar and bearing off of the shaft.

Figure 9 Replaced Motor

Tools/Supplies• Basic mechanics tools, standard and metric

• Lock out tag and padlock

• 2x4 1" (25 mm) longer than the width of the conveyor

• Support Straps

• Anti-seize lubricant

• Loctite®

Reducer drip pan

NoteThere are many different ways to support theshaft.

Figure 10 Idle Side Bearing

Setscrew


6. Apply anti-seize lubricant to the ends of the rollershaft.

7. Install new bearings and insert the four bolts back in,tighten the screws on the bearing lock collars.

8. On the drive side, install the drive motor. For instruc-tions, refer to “Motor Replacement” earlier in themanual.

9. On the idle side, insert and tighten the bolts.10. Remove the support device from the roller.11. Restore power to the conveyor.12. Restore product flow to the conveyor.

Infeed

To replace the infeed bearings:1. Bypass product flow to the conveyor and wait for all


switch.

3. Support the shaft.A. Attach safety straps to the shaft.B. Hold a 2x4 that is about 1" (25 mm) longer than

the width of the conveyor and loop the safetystraps around the ends until it is stable and holdsthe shaft in place.

4. Remove the cover over the bearings.5. Loosen the setscrews and remove the lock collar.6. Remove the four bolts from the tensioning device.7. Remove the entire device from the frame. 8. Remove the bearing from its housing by turning it

90°.9. Apply anti-seize lubricant to the ends of the roller

shaft.10. Install the new bearings and slide the housing back

onto the shaft.11. Replace the four bolts and lock collar and tighten the

bolts and setscrews. Remove the support device fromthe roller.

12. Restore power to the conveyor.13. Restore product flow to the conveyor.

BELTS

Fabric Belts

Figure 11 Drive Side Bearing

Tools/Supplies• Basic mechanics tools, standard and metric


• 2x4 1" (25 mm) longer than the width of the conveyor

• Support Straps

• Anti-seize lubricant

• Loctite®

Setscrew and lock collar

NoteThere are many different ways to support theshaft.

Figure 12 Fabric Belt Conveyor


ReplacementPrior to replacing a belt, verify that the belt has been cutstraight, and square the terminal and return rollers. Afterthe belt is installed, check for belt waver and adjust belttracking.

To replace a fabric belt:1. Lay the belt out on a clean, flat surface.2. Stretch a string along one side of the belt with the

string touching the corners of the belt.3. Check for any offset between the string and the side

of the belt.

4. Square both terminal rollers and all return rollers.

5. Place the belt face down on the return rollers.6. Bring the ends of the belt up and around the terminal

rollers.

7. Mesh the splice together.

8. Check for belt clearance around adjacent equipment.9. Turn on the conveyor.10. Observe the belt to see whether it tracks to one side.

If the belt tracks to one side, tracking adjustment isrequired.(Refer to “Fabric Belts/Belt Tracking” laterin this section)

TensionPeriodic belt tensioning is required due to normal beltstretching. Small adjustments may be made by adjusting

the position of the tail shaft (Figure 13).

Monitor belt stretching by observing the catenary or sagin the belt return. This sag is required to maintain correctbelt tension on the drive shaft sprockets.The normal amount of sag is between 3" (76.2 mm) and6" (152 mm) from a straight line between the two beltsupport points. Adjust the belt if the sag is observed to begreater than 6" (152 mm), or if the return belt is rubbingon crumb pans.To adjust the belt tension:1. Loosen the tail shaft adjuster lock nuts on both sides

of the tail shaft.2. Turn the tail shaft adjusters until the catenary is

between 3" (76.2 mm) and 6" (152 mm).A. To tighten the belt, turn the tail shaft adjusters

clockwise (when viewed from the infeed end ofthe belt conveyor) moving the tail shaft rearward.

B. To loosen the belt, turn the tail shaft adjusterscounterclockwise (when viewed from the infeedend of the belt conveyor) moving the tail shaftforward.

Tools/Supplies• String

• Measuring tape



NoteOut of square rollers can greatly influencetracking and tracking adjustment. Wheninstalling a new belt, always start with squaredterminal and return rollers.

NoteOn an “endless” belt, the belt has already beenspliced and is installed by sliding it over theterminal rollers.

Tools/Supplies• Measuring tape


Figure 13 Tail Shaft Adjuster

Tail shaft Lock nut

AdjusterForward(loosens belt)

Rearward(tightens belt)

Infeed end of belt

conveyor


3. Tighten the tail shaft adjuster lock nuts.If the sag can not be reduced enough by moving the tailshaft, it may be necessary to shorten the belt length.Refer to the manufacturer’s literature for belt shorteninginstructions. When shortening the belt, adjust the tailshaft position fully forward to accommodate future smallbelt tension adjustments.

Periodically, the entire belt may need replaced. Refer to“Fabric/Replacement” earlier in this manual.

Belt Tracking

To adjust belt tracking:1. Turn the conveyor on and quickly off again.2. If the belt appears to track straight, turn the conveyor

on again.

If the belt tracks to one side, tighten the belt on the side itis moving toward. For the discharge (drive) roller,advance the bearing in the direction of belt travel. For theinfeed (tail) roller, advance the bearing in the direction ofreturn belt travel. The belt tends to move toward the looseside and the bearings on that side must advance toincrease the tension, returning the belt to center. Continueobserving and making incremental adjustments until thebelt is properly centered on both rollers.

If, after adjusting the terminal rollers, the belt continuesto track to one side, additional tracking adjustment maybe made by adjusting the return rollers out of square.

3. Adjust the angle of the return rollers as shown inFigure 14.

Side guide rollers on the return pass, found mostly onwire belts, are used to prevent excessive side travel of thebelt. They should be set so that the belt does not touchthem during ordinary operation.

ImportantAlways adjust both tail shaft adjusters in smallincrements. The tail shaft must remain perpen-dicular to the belt.

ImportantNever tension the belt so tight as to remove thecatenary sag, unless the conveyor has beendesigned for that condition.

NoteFrequent belt length adjustment may be a signof hinge rod wear. Inspect the hinge rods andreplace, if needed.

ImportantAlways replace the hinge rods with the samematerial as the original rods, unless you inten-tionally plan to change to a different material.

Important Always replace the belt with the same materialas the original belt, unless you intentionallyplan to change to a different material.

Tools/Supplies• Basic mechanic’s tools, standard and metric

ImportantBe ready to turn the conveyor off quickly if thebelt begins to travel off of the side of the rollersand is in danger of contacting metal surfaces.

ImportantUse caution when belt adjustments are made tothe terminal rollers to prevent damage to thebelt.

ImportantUse caution when adjustments are made to thereturn rollers to prevent damage to the belt.

Figure 14 Adjustment of Return Rollers to Correct forBelt Side Travel

Infeed end

Discharge endProduct flow

Adjust in small increments

toward infeed end

Adjust in small increments

toward discharge end

Belt creep


A certain degree of natural waver is present in every fiberand wire belt, which causes them to weave slightly fromside to side, but overall travel is straight. Belt side travelis a condition where the belt consistently moves towardone side.To distinguish the difference between belt waver and belt side travel:1. Mark a reference point on the belt edge and another

on one of the rollers.2. Turn on the belt conveyor.3. As the belt completes one revolution, observe the

relationship between the two marks.A. The two points will coincide after one complete

belt revolution if there is no side travel.

Plastic and Polyurethane Belts

Replacement

To replace a belt:1. Remove all the guards and covers.2. Securely hold the two sides of the belt that the pin is

going to be removed from.3. The removal procedure for hinge pins differ per belt

design. Refer to Figure 16 and Figure 17 forexamples.

Figure 15 Plastic Belt Conveyor

CAUTIONTwo people are required to safely perform thisprocedure.


• Clamp

• Wood board

• Plastic pin

Figure 16 Locking Tab—Slide the Tab to the Right on Both Sides using a Screwdriver to Remove a Section of the Belt

Figure 17 Smart Fit Rods—Pry the Head of the Pin out using a Screwdriver


4. Pull the plastic pin out through the round hole.5. Allow the discharge end of the belt to fall to the

ground.6. While someone is holding onto the belt, slowly take

if off the frame. 7. Roll the old belt up and discard.8. Place the new belt on clean cardboard at the infeed

end. 9. Have one person pull it through the bottom, with the

right side facing down.10. Have another person unroll it so the belt doesn't get

scratched.11. As you feed it through, connect the pieces of the belt

with the plastic pins. 12. Secure the infeed end of the belt to the frame using a

clamp (Figure 18).

13. When it is fed all the way through the frame, bringthe end toward the clamp.

14. Lift the discharge end of the belt and lay a piece ofwood across the frame (Figure 19).

15. Pull the discharge end of the belt towards the infeedend until the excess slack is removed (Figure 20).

16. Remove the excess sections of the belt. 17. Remove the clamp while holding on to both sides of

the belt.

18. Insert a plastic pin into the round hole (Figure 21).

19. Using a screwdriver, slide the locking tab back to theleft until it clicks (Figure 22). Perform this on bothsides.

20. Slide the wood board out from under the belt.

Figure 18 Clamping the Belt to the Frame

Figure 19 Wood Laid Across the Frame

Figure 20 Shortening the Belt

Figure 21 Inserting the Pin

Figure 22 Locking Tab

NoteThere are many other types of locking systems,the locking tab and smart fit are just two of themain types.


TensionPeriodic belt tensioning is required due to normal beltstretching. Small adjustments may be made by adjustingthe position of the tail shaft (Figure 23).

Monitor belt stretching by observing the catenary or sagin the belt return. This sag is required to maintain correctbelt tension on the drive shaft sprockets (Figure 24).

The normal amount of sag is between 3" (76.2 mm) and6" (152 mm) from a straight line between the two beltsupport points. Adjust the belt if the sag is observed to begreater than 6" (152 mm), or if the return belt is rubbingon crumb pans.

To adjust the belt tension:1. Loosen the tail shaft adjuster lock nuts on both sides

of the tail shaft.2. Turn the tail shaft adjusters until the catenary is

between 3" (76.2 mm) and 6" (152 mm).A. To tighten the belt, turn the tail shaft adjusters

clockwise (when viewed from the infeed end ofthe belt conveyor) moving the tail shaft rearward.

B. To loosen the belt, turn the tail shaft adjusterscounterclockwise (when viewed from the infeedend of the belt conveyor) moving the tail shaftforward.

3. Tighten the tail shaft adjuster lock nuts.If the sag can not be reduced enough by moving the tailshaft, it may be necessary to shorten the belt length.Refer to the manufacturer’s literature for belt shorteninginstructions. When shortening the belt, adjust the tailshaft position fully forward to accommodate future smallbelt tension adjustments.

Periodically, the entire belt may have to be replaced.Refer to the manufacturer’s literature for belt replace-ment instructions.

Figure 23 Tail Shaft Adjuster

Figure 24 Return Belt Catenary


• Tape measure

Tail shaft Lock nut

AdjusterForward(loosens belt)

Rearward(tightens belt)

Infeed end of belt

conveyor

Catenary (sag)

Support points

ImportantAlways adjust both tail shaft adjusters in smallincrements. The tail shaft must remain perpen-dicular to the belt.

ImportantNever tension the belt so tight as to remove thecatenary sag, unless the conveyor has beendesigned for that condition.

NoteFrequent belt length adjustment may be a signof hinge rod wear. Inspect the hinge rods andreplace, if needed.

Important Always replace the hinge rods with the samematerial as the original rods, unless you inten-tionally plan to change to a different material.


Shaft Bearings

To adjust or replace the bearings:1. Coat the shaft with a small amount of food-grade

grease.2. Locate the bearing in its operating position.3. Tap the shaft lightly with a rubber hammer or piece

of wood to assure proper alignment of the bearing inthe housing. Rotating the shaft will reveal anymisalignment.

4. Set the bearing mounting screws.

System sanitation

OVERALL SYSTEM SANITATION

To clean the belt conveyor:1. Bypass product flow to the belt conveyor and wait for

all product to clear the equipment.2. Turn off and lock out power to the belt conveyor.3. Remove all covers and guards.4. Using a washdown hose, thoroughly clean the

discharge and infeed areas, inside and outsidesurfaces of the belt.

NON-METALLIC COMPONENTSSome Key Technology conveyors have wear componentsincorporating polymers as follows:• Belts of polyester, polyurethane or PVC• Infeed and discharge rollers lagged with polyurethaneMost of the chemicals used for equipment cleaning andsanitizing also eventually degrade the properties of poly-mers and may reduce the useful life of belts and rollerlagging. The effect on polyurethane of chemicalscontaining chlorine is particularly severe.Maintaining equipment in proper sanitary condition isalways the first priority in a food plant but there are somemeasures that can be taken to maximize conveyor beltand roller lagging life:1. Advise your sanitation chemical supplier about the

presence of the above polymers, as appropriate, whengetting material, mixing and applicationrecommendations.

2. Before applying chemicals, remove as much soil aspossible with clear water. Use water at the tempera-ture specified by your sanitation and plant safetydepartments, but not exceeding 140°F (60°C).

3. Ensure that sanitation chemicals are not mixed toconcentrations higher than what the chemicalsupplier and your sanitation department require.

4. Do not leave cleaning and sanitizing chemicals onbelts and rollers longer than the required time. Rinsethoroughly with clear water at the end of that time.

5. Do not allow strong acids such as hydrochloric, nitricor sulfuric to come in contact with belts or rollerlagging.

6. Do not apply solvents such as benzene, gasoline,MEK, trichloroethylene or turpentine to belts orroller lagging. Use a soap solution and a soft scrubbrush to remove greasy stains.

ImportantAlways replace the belt with the same materialas the original belt, unless you intentionallyplan to change to a different material.


• Hi-quality, food-grade grease


• Rubber hammer

ImportantPerform this procedure every 6-8 hours.

Tools/Supplies• Clean, lint-free cloth


• Vinegar

• Sponge

ImportantBefore using a cleaning solution, read theMaterial Safety Data Sheet (MSDS) to be sureit is appropriate for the materials to be cleanedand approved for use in food processing.


Troubleshooting GuideTable B

Symptom(s) Possible Cause Recommended ActionBelt not tracking properly Material buildup on under-side of belt

preventing sprocket tooth engage-ment.

Clean/remove buildup.

A flight may have hit a side rail or re-turn shoe, shifting belt sideways on sprockets.

Realign belt on sprockets confirming sprockets are in proper position.

Belt mis-spliced. Line up flush edges of belting.

Excessive wear on wear strips and belt guides

Excessive buildup on belt that may be abrasive on wear strips and belt guides.

Use wear strip material that is harder than belting. Clean frequently and em-ploy in-place spray wash, if possible. Replace worn components.

Excessive wear on belt Excessive buildup on wear strips and guides that may be abrasive on belt.

Wear strip and guides should not be soft enough for abrasive particles to become imbedded. Clean frequently and employ in-place spray wash, if possible.

Excessive wear on hinge rods

Abrasive material is getting into hinge.

Clean belt more frequently. Employ in-place spray wash, if possible. Replace hinge rods with harder, abrasion resis-tant material.

Excessive sprocket wear Abrasive buildup on under side of belt.

Clean belt more frequently. Employ in-place spray wash, if possible. Replace sprockets with abrasion resistant ma-terials.

Excessive catenary sag Elongation of belt during break-in pe-riod.

This is normal and varies per applica-tion. Monitor closely to avoid catching. Adjust belt length as necessary.

Elongation due to heavy start-up loads.

Reduce loading at start-up, if possible.

Drive component’s tem-perature exceeds normal (reducer, motor)

Belt or flights squeezed between sta-tionary side rails.

Reposition side rails to provide clear-ance.

Shaft bearing failure. Replace bearing.

Low oil level in reducer. Service the reducer.

Excessive lateral sag (width)

Missing or needed center support. Repair or consult Key Technology Ser-vice.

Belt width expansion due to very warm product and worn hinges.

Replace every fourth or fifth hinge rod with stainless steel. Replace belt.


Key Technology – Corporate Office150 Avery Street • Walla Walla, WA 99362 USA

Phone: +1 509 529-2161 • Parts/Service Fax: +1 509 522-3386

For all other locations, visit our website at www.key.net

August 30, 2012

Key Part No. 014555, Revision C

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Belt Conveyor Rev C en 014555

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