LB Series

Asphalt Mixing Plant

Repair and Maintenance

Manual

FUJIAN SOUTH HIGHWAY MACHINERY CO., LTD

 This manual is summary, reemphasis and supplement to the repair

and maintenance issues described in the Operational Instructions, user

shall follow the repair and maintenance procedures mentioned herein in

using the plant, otherwise, our Company will not be responsible for

warranty.

This manual is both routine operational guideline and operation

training material. Please keep it with the documents enclosed to the plant

for future reference.

Chapter I Safe Operation

Chapter II Lubrication

Section I Lubrication Precautions

Section II Lubrication Points, Lubrication Oil, Lubrication

Method

Chapter III Maintenance

Section I Routine Maintenance (every 8-12 working hrs)

Section II First Level Maintenance (every 200-250

working hrs)

Section III Second Level Maintenance (every 1500-2000

1
 working hrs)

Chapter IV Common Failures and Troubleshooting

Chapter I Safe Operation

▲ Do not perform repair and maintenance when the plant is

operating; disconnect the power supply before examination and
repair and hang up the warning plate.
▲ Only operator and manager of the plant are allowed to start the
plant; make sure all people are in a safe enough distance from the
rotary parts before starting the plant.
▲ People with no operation certificate (unqualified after training)
or not authorized by plant manager are not allowed to start or
operate the plant or work for somebody else temporarily.
▲ Maintenance personnel shall have sufficient special technical
know-how and professional training.
▲ Operational procedures shall be established and followed to
avoid maloperation by operator.
▲ Make sure that safety switch is in normal operation, otherwise it
shall be repaired or replaced; never short-circuit it.
▲ Do not make modification to any safety device randomly.
▲ Protective wear such as helmet, protective gloves, insulated
rubber shoes shall be put on before entering the production site.
▲ While performing lifting operation, it shall be under the
command of specialist and no one is allowed to stand around the
lifting arm.
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 ▲ Outdoor aloft work is forbidden in thunderstorm weather to
avoid thunder strike.
▲ People perform aloft work shall be in good mental health and
safety belt shall be worn.
▲ Use of welding machine is not allowed in moisture environment
to avoid electric shock. Oxygen and ethyne shall be kept in safe
enough distance while performing gas cutting. Keep away from
flammable and explosive objects during operation.

Special tip: Safety is helpful for production and production

must be safe; safety is your responsibility. Our Company shall not be

held responsible for personal injury or equipment damage due to

improper use of equipment or maloperation.

3
 Chapter II Lubrication

Lubrication is one of the basic requirements for normal

operation of the plant and also a key priority in its maintenance;

improper lubrication is the very cause of many plant failures. If

you want the plant to create more value, then perform lubrication

properly.

Section I Lubrication Precautions

1. Replenishment of lubricating oil for redactor shall be done in

proper quantity. If there are oil level marks, fill according to the marks;
if there is no mark, measure with a thin wire, and one third of the gear in
oil is OK.
2. Check the vent tap is property installed and the vent hole is
unobstructed.
3. Replenishment of lubricating grease shall be in suitable quantity
also; stop refilling when pressure saturation is obtained except for the
first time that shall see grease overfill.
4. Lubrication of the shaft end of the main unit is not only to
lubricate but also to seal the shaft end, so the refiller shall be kept at
normal conditions.
5. Lubrication interval is not the shorter the better, being suitable is
the best.
6. Use correct and clean lubricating oil (grease).
7. Ambient temperature has an impact on lube; one level lower
viscosity lube of the same type shall be used in winter in the North, for

4
 example: for reductors, N150 intermediate pressure gear oil shall be
used in summer and N68 intermediate pressure gear oil in winter.
8. Except designated lubricating oil (grease), the following parts
usually shall be lubricated with lubricating oil: Reductor, gear, chain,
air compressor and high-speed operation supporting points; while the
following parts shall be lubricated with grease: Bearing, rotating shaft,
traveling track, thread and low-speed operation supporting points.
9. All supporting roller bearing and motor bearing are enclosed-type,
no lubrication is needed;
10. Keep the lubrication point clean and prevent the production of oil
stain. Be sure not to contaminate parts that functioned by friction force
such as conveyor belt, brake shoe with lubricating oil (grease).

Lubrication points, lubricating oil (grease), lubrication interval

1. Feeder

Lubrication Lubricating oil

Marking Service Lubrication
interval (grease)
(Location) Content points
(Hrs) Type
ISO Viscosity VG220
(mineral oil)
Reductor Check oil level 1 Mobil or Shell oil is
100 recommended

Conveyor belt Oil and grease Calcium radical

2
tensioning screw lubrication lubricating grease

Driving, driven Apply lubricating oil Calcium radical

300 4
drum shaft and grease lubricating grease

5
 ISO VISCOSITY
VG220 (MINERAL
Reductor or electric Change lubricating OIL)
1
drum oil (first time) Mobil or Shell oil is

recommended
ISO VISCOSITY
VG220 (MINERAL
Reductor or electric Change lubricating OIL)
1500 1
drum oil Mobil or Shell oil is

recommended

2. Flat belt conveyor and slanting belt conveyor

Lubrication Lubricating oil

Marking Service Lubrication
interval (grease)
(Location) Content points
(Hrs) Type
ISO VISCOSITY
VG220 (MINERAL
OIL)
Reductor Check oil level 1
Mobil or Shell oil is
100
recommended

Conveyor belt Oil and grease Calcium radical

2
tensioning screw lubrication lubricating grease

Driving, driven Apply lubricating oil Calcium radical

4
drum shaft and grease lubricating grease
ISO VISCOSITY
300 VG220 (MINERAL
Change lubricating OIL)
Reductor 1
oil (first time) Mobil or Shell oil is

recommended
ISO VISCOSITY
VG220 (MINERAL
Change lubricating OIL)
1500 Reductor 1
oil Mobil or Shell oil is

recommended

6
3. Dryer drum

Lubrication Lubricating oil

Marking Service Lubrication
interval (grease)
(Location) Content points
(Hrs) Type
ISO VISCOSITY
VG220 (MINERAL
OIL)
100 Reductor Check oil level 4
Mobil or Shell oil is

recommended

Pulley positioning
Oil and grease Lithium radical
30 wheel supporting 10
lubrication lubricating grease
bearing

ISO VISCOSITY
VG220 (MINERAL
Change lubricating OIL)
300 Reductor 4
oil (first time) Mobil or Shell oil is

recommended
ISO VISCOSITY
VG220 (MINERAL
Change lubricating OIL)
1500 Reductor 4
oil Mobil or Shell oil is

recommended

4. Aggregate (powder) hoister

Lubrication Lubricating oil

Marking Service Lubrication
interval (grease)
(Location) Content points
(Hrs) Type
ISO VISCOSITY VG220
(MINERAL OIL)
100 Reductor Check oil level 1 Mobil or Shell oil is

recommended

7
 Chain wheel Oil and grease Calcium radical
2
tensioning screw lubrication lubricating grease

Driving, driven chain Apply lubricating oil Calcium radical

30 4
wheel shaft and grease lubricating grease

ISO VISCOSITY VG220

(MINERAL OIL)
Change lubricating
300 Reductor 1 Mobil or Shell oil is
oil (first time)
recommended
ISO VISCOSITY VG220
(MINERAL OIL)
Change lubricating
1500 Reductor 1 Mobil or Shell oil is
oil
recommended

5. Vibrating screen

A. Only LGHP2 high-temperature lubricating grease manufactured by SKF can be used

on vibrating motor. The vibrating motor shall be lubricated with suitable quantity of

grease; excessive dosage will overheat the bearing and shorten its service life.

B. Attention shall be paid to the lubrication of the bearing of the vibrating motor; its
temperature shall be measured every half a month, a temperature increase of above 10

℃ represents insufficient lubrication and LGHP2 special high-temperature lubricating

grease shall be added from oil filling hole by grease gun.

C. For normal operation of the bearing, only LGHP2 lubricating grease can be used,

and replenishment shall be made according to E. hereunder after every 2000 hrs. Before

applying fresh grease, wipe the enclosure of the vibrating motor around the flow nipple

with clean cloth, and insert the grease gun into the nipple to fill grease. In normal

operation, freshly lubricated or re-lubricated bearing will see increased temperature,

which will last for one or two days.

D. Attention shall be paid to the quality of lubricating grease, because if it is of inferior

quality, out of service life or contain dusts, sand fusion, dirt, etc., it will cause

8
excessively high temperature of the bearing and shorten its life.

E. For LB2000 vibrating motor, 60 g lubricating grease for replenishment and 120 g for
change. For LB3000 vibrating motor, 80 g lubricating grease for replenishment and 150

g for change. For LB4000 vibrating motor, 100 g lubricating grease for replenishment

and 190 g for change。

6. Hot aggregate bin

The shafts of discharge gates need no maintenance (maintenance-free)

7. Hot aggregate scale

Bearing of the discharge gate of the scale needs no maintenance

(maintenance-free)

8. Main mixing unit

Lubrication Lubricating oil
Marking Service Lubrication
interval (grease)
(Location) Content points
(Hrs) Type

Shaft of discharge apply lubricating oil 2# lithium radical

70 2
gate and grease lubricating grease

apply lubricating oil 2# lithium radical

20 Agitating shaft seal 4
and grease lubricating grease

apply lubricating oil 2# lithium radical

70 Main bearing 4
and grease lubricating grease

2# lithium radical
70 Synchronous gear apply grease 1
lubricating grease

For a new plant,

change the grease
ISO viscosity VG220
for the first time
(mineral oil)
1500 Reductor after 500 working 2
Mobil or Shell oil is
hrs, and change
recommended
every 1500 hrs
thereafter

9
9. Finished product hoist
Lubrication Marking Lubrication Lubricating oil
Service
interval (grease)
(Location) Content points
(Hrs) Type
Product trolley apply lubricating oil calcium radical
4
wheel and grease lubricating grease
70
Trolley traction apply lubricating oil calcium radical
2
bracket and grease lubricating grease

apply lubricating oil calcium radical

50 Guide pulley 2
and grease lubricating grease

Shaft of the inlet gate

apply lubricating oil calcium radical
300 of the finished 12
and grease lubricating grease
product bin

apply lubricating oil calcium radical

30 Bearing of hoist 1
and grease lubricating grease

Oil and grease calcium radical

70 Wire cable 2
lubrication lubricating grease

ISO VISCOSITY
VG220 (MINERAL
Change lubricating
1500 Reductor 1 OIL)
oil
Mobil or Shell oil is
recommended

10. Pneumatic system

Lubrication Marking Lubrication Lubricating oil
Service
interval (grease)
(Location) Content points
(Hrs) Type
Change lubricating
oil (first time) ARO super synthetic
150 ARO air compressor 2
Check oil level and special lubricating oil
change if dirty

Change lubricating ARO super synthetic

500 ARO air compressor 2
oil special lubricating oil

10
11. Spiral feeder and vane wheel feeder
Lubrication Lubricating oil
Marking Service Lubrication
interval (grease)
(Location) Content points
(Hrs) Type

N68-N200 Intermediate
Screw reductor Check oil level 1
pressure gear oil
300
apply lubricating oil calcium radical
screw shaft 3
and grease lubricating grease

Change lubricating N68-N200 Intermediate

1000 Screw reductor 1
oil (first time) pressure gear oil

Change lubricating N68-N200 Intermediate

2500 Screw reductor 1
oil pressure gear oil

Vane wheel feeder apply lubricating oil calcium radical

500 1
bearing and grease lubricating grease

vane wheel feeder

600 Check oil level 1 MOBILGEAR320
reductor

vane wheel feeder Change lubricating

2000 1 MOBILGEAR320
reductor oil (first time)

vane wheel feeder Change lubricating

5000 1 MOBILGEAR320
reductor oil

12. Bag-type dust remover and draught fan

Lubrication Lubricating oil
Marking Service Lubrication
interval (grease)
(Location) Content points
(Hrs) Type

ISO VISCOSITY
VG220 (MINERAL
100 reductor Check oil level 2 OIL)
Mobil or Shell oil is
recommended

11
 Driving chain Drip in a little 2 HS13-HS19 machine oil

Dedusting screw apply lubricating oil 2# lithium radical

30 6
shaft and grease lubricating grease
ISO VISCOSITY
VG220 (MINERAL
Change lubricating
300 reductor 2 OIL)
oil (first time)
Mobil or Shell oil is
recommended
ISO VISCOSITY
VG220 (MINERAL
Change lubricating
1500 reductor 2 OIL)
oil
Mobil or Shell oil is
recommended
Mainshaft bearing of apply lubricating oil 2# Lithium radical
10 2
draught fan and grease lubricating grease

Air throttle bearing apply lubricating oil 2# Lithium radical

50 12
of draught fan and grease lubricating grease

Air throttle joint of Oil and grease calcium radical

100 24
draught fan lubrication lubricating grease

Note: The LB4000 plants all have two reductors with driving chain, other models have one reductor
without driving chain

13. Asphalt heat-conducting oil

Lubrication Marking Lubrication Lubricating oil
Service
interval (grease)
(Location) Content points
(Hrs) Type
Heat-conducting oil apply lubricating 7014 Lubricating
1
pump oil and grease grease

50
Asphalt tank
apply lubricating lithium radical
mixer-agitator 2
oil and grease lubricating grease
bearing

N68-N200
Change lubricating
300 reductor 1 Intermediate pressure
oil (first time)
gear oil

N68-N200
Change lubricating
1500 reductor 1 Intermediate pressure
oil
gear oil

12
 Chapter III Maintenance

To emphasize lubrication of the plant, it will be described in

a separate chapter in this Manual and will not be repeated in this
chapter. Besides proper operation and periodic lubrication,
maintenance of the plant shall be focused on check and
adjustment.

Section I Routine Maintenance (every 8-12 working hrs)

Serial
Location Item Requirements and instructions
No.
Main unit of the
Check oil level
mixing plant
1 Main bearing of the main Make sure that the grease is clean

bearing

Check air
Normal air pressure to be 0.7Mpa
Air cylinder pressure

gate-opening Check the

device gate-opening normal operation

connecting rod

Check the

temperature by No abnormal temperature increase in

touching with operation

Transmission
hand
components
Check

synchronous No abnormal noise

gear

13
 Check asphalt
Shaft end No leakage
leakage

Loosening shall be prevented and no

scaleboard
Bolting scraping between the impeller and the
impeller
scaleboard is allowed

Correct belt Be sure to control belt wandering in

wandering operation under 50 mm

Check the
transmission
conveyor belt
components such
No retardness and abnormal noise and
as drum,
temperature increase and oil leakage
Cold material supporting roller,

2 reductor, chain
system
and bearing

Clean up the Check and clear extra-size aggregate on

screen the screen often during production

Body of the bin
Check the
Rotation is smooth and without retardness
discharge gate

surrounding Clear compound leakage and coherent

Clean up
environment masses

The four supporting wheels shall have

supporting wheel
3 dryer drum good contact with the rolling ring of the
adjustment
dryer drum

Supporting
Bearing of No retardness, abnormal noise and
wheel supporting wheel temperature increase

No retardness, abnormal noise and

Motor reductor
temperature increase

14
 Check whether the vane wheel is
Scraper loosened by listening to the abnormal

noise in the drum.

Body of the drum
Check the front
Whether scraping exists between the
and rear
drum and the front and rear housings
housings

surrounding Clear compound leakage and coherent

Clean up
environment masses

Chain check tension is proper

Aggregate No retardness, abnormal noise and

4 Bearing check
hoister temperature increase

Bucket chain check No deformation

Check and clean Whether the mesh screen is tightened or

Mesh screen
up clogged

No abnormal noise and temperature

Vibrating motor check increase, no loosening in the connection

5 vibrating screen of the motor

Whether amplitude of vibration at four

brackets are the same, whether the springs

Screen body check
are damaged or the rivets are loosened

No crack in welding

No retardness, smooth opening, normal

Gate of the bin check
6 Hot feed bin air cylinder operation

Overflow pipe check No clog

Sensor check Sensor is flexible without retardness

7 Weighing scale Smooth gate opening and closing, normal

Gate of the scale check
air cylinder operation

15
 Whether the towing position is in normal

check operation and the door-opening

trolley mechanism flexible

finished
8 Clear the finished product remnants at the
product hoist Clean up
discharge gate of the trolley

diverting dead
check Whether rotation is smooth
pulley

Finished product Check and make Whether gate opening is smooth and air

bin adjustment cylinder is in normal operation

Whether bolting between the shaft

Hoisting Check and make connector and the winding drum is

mechanism adjustment loosened, no abnormal noise in the

bearing

Calcium radical grease shall be applied

Wire cable Oil lubrication where the coil drum contacts with the

pulley

Abnormal noise, belt tension and

Draught fan check
flexibility of the air throttle regulator

Whether the switch of the air cylinder of

the blowback door is in normal operation,

Dedusting Bag-type dust Check and
9
whether the spiral has abnormal noise, the
system remover replenish lube
shaft bearing in the spiral needs

lubrication

Check and make For the rotation to be smooth, the location

Gravity valve
adjustment of the scale weight shall be suitable

10 mountain meal mountain meal Check Tension of the chain suitable

system hoister No retardness, abnormal noise and

check
temperature increase in bearing

16
 check No deformation in bucket chain

Vane wheel
check Rotation is smooth and without noise
feeder

pipeline Check leakage No leakage

pneumatic
11 Pneumatic drain water drain water accumulation in the water
system
components accumulation filter, air compressor and tank

pipeline Check leakage No leakage

12 asphalt
Oil pump check No abnormal noise and oil leakage
heat-conducting
Valve Check leakage Rotation is smooth and without leakage
oil system
tank Check leakage No leakage

Section II First Level Maintenance (every 200-250 working hrs)

Serial
Location Item Requirements and instructions
No.

1 Perform routine maintenance besides maintenance of this level

Main unit of the

Make Make adjustment to the clearance
mixing plant
`2 Inside adjustment to between the impeller and the scaleboard,
keeping it within 5 mm.
mixer-agitator the clearance

tank Check and tighten bolting of the impeller

check tightness
and the mixing arm

If seepage or leakage is detected,

disassemble and check following the

check
Shaft end seal procedures specified in the instructions of
maintenance
the main unit and change the damaged

sealing member if necessary.

Check and Check oil level and leakage, change

reductor
maintenance damaged sealing member if necessary.

17
 Connection Check and
Adjust the nut on the end of the rod to
rod make
fully open or close the door
mechanism adjustment

Check and Check sealing of the observation hole,

Inlet and outlet make inlets and outlets, repair or replace if

adjustment necessary

Check oiling
Oil circuit Check that oiling pipeline is not clogged
pipeline

Adjust the
Make adjustment to the tension of the belt
screw rod

Check oil level and leakage, change

conveyor belt Reductor check
damaged sealing member if necessary
Cold material
3
Sweeper Make adjustment to the position of the
system
scraper scraper, or change if it is damaged

Check and
Bin gate Check whether operation of the
make
mechanism gate-opening mechanism is smooth
adjustment

Adjust the Make adjustment so that the rolling ring

supporting of the dryer drum is positioned in the

Driving
idler wheel middle of the supporting idler wheels
mechanism
4 dryer drum
Check oil level and leakage, change
Reductor check
damaged sealing member if necessary

Body of the Check whether the scraper and the

check
drum product lifting plates are loosened

Check with multimeter and confirm

5 Weighing system Sensor check
performance of the sensor

18
 Scale
Instruments Calibrate the scales for precision
calibration

Clean up and Clean up the valve, make sure that

Safety valve make opening pressure of the safety valve is

6 Powder tank adjustment from 0.05—0.1Kg/Cm2

Dedusting Open the deduster and clear up the sieve

Clean up
sieve core core

Air Clean up filter element, or change if

Clean up
compressor necessary
7 Air supply system
Air-operated
check operation normal
valve

wire If connection loosened or damaged,

check
connection tighten it or replace

Electric
8 Electric apparatus Keep the electric apparatuses clean and
apparatus on Sweeping
prevent dirt and oil stain.
the plant

travel switch check Check response and reliability

Open the inlet and outlet, clear out the

Inlet Clean up
9 Screw reductor agglomeration

Reductor check No abnormal noise and oil leakage

If the chain is abrased or lengthened,

Chain check adjust the screw rod to ensure suitable

10 Aggregate hoister tension of the chain

it shall be changed in case of abrasion or

Bucket chain check
deformation

Measure bearing temperature of vibrating

Vibrating Check and
11 vibrating screen motor; make sure that it does not go
motor measure
beyond 90℃

19
 Check whether there is broken wire or
Wire cable check
strand in the cable

Whether the wheels of the trolley are

Track check
abrased, if yes, change the wheels
Finished product
12 Whether opening and closing of the inlet
Finished
hoisting system
check gate flexible and clear remnants at the
product bin
gate rail

Check the coupling between the counter

Hoisting
check and the winding drum, no excessive
mechanism
eccentricity is allowed

Keep the hop-pocket unclogged and

hop-pocket check
having no greasy filth on its surface
13 Dedusting system
Whether tension of the conveyor belt is
Draught fan check
proper, if not, make adjustment

Section III Second Level Maintenance (every 1500-2000 working hrs)

Serial
Location Item Requirements and instructions
No.

1 Perform first-level maintenance besides maintenance of this level

Inside Check abrasion of the vane wheel,

Clean up and scaleboard, if two thirds of the original area
mixer-agitator (thickness) is worn out, replace with a new
Main unit of the check
mixing plant tank one

If crash, bumping or abnormal noise is

2 Check by heard, dismantle it and check, make
reductor
listening adjustment to the clearance or change the
worn-out parts

Disassemble Disassemble and wash the oil circuit to

Oil circuit
and wash keep it unobstructed

20
 check belt Contact the manufacturer for home visit

abrasion repair if necessary

Disassembly
conveyor belt and check of
Cold material Disassemble and check, wash and lubricate,
3
bearing,
system replace the damaged parts if necessary
transmission

components

Repair and Repair and correct damaged sieve and striker

Body of the bin
correction plates

Supporting
If severely abrased, replace with a new one
wheel abrasion

Driving
Bearing and
mechanism
4 transmission Check, wash and lubricate, change damaged
dryer drum
component parts if necessary

check

Body of the Check and Check abrasion of scraper and product lifting

drum change plates, change if necessary

Disassemble
Disassemble and wash the head, change the
Air compressor and wash the
Air supply worn-out parts
5 head
system
Air-operated Disassemble Disassemble and wash the rotary

valve and wash components and change worn parts

Measure with 500vmΩ meter, resistance

Check between the phases of the motor and the
Motor
insulation ground insulation shall be greater
Electric
6 than0.5mΩ, if lower, dry the motor
apparatus
Connector No condensation, rust and loosening, fine
Sensor
check grounding

21
 Check and Check the chain, if one third of the diameter
Chain
Aggregate replace is worn out, replace with a new one
7
hoister
Check and Check the U-hook, replace with a new one if
U hook
replace it is worn out

Clean and Clean the bearing of motor and replenish

8 vibrating screen Vibrating motor
check bearing with fresh grease

Finished
Clean up Clear material deposit on the hopper ceiling
Finished product bin

9 product Check the bolting, replace with a new one if

Hoisting Check and
hoisting system deformed, wash the bearing housing and
mechanism wash
apply clean grease

Sealing of the Check and If the sealing is time-worn, replace the

blowback door replace sealing gasket

Dedusting Check and If worn-out or oil-contaminated or clogged,

10 hop-pocket
system replace replace with a new hop-pocket

Check and If conveyor belt abrased, change with a new

Draught fan
replace one

Check and
Filter Change with a new one if damaged
asphalt replace
11 heat-conducting Temperature
Check and
oil system and pressure Change with a new one if damaged
replace
gauge

Clear material deposits and stains, derust and

Appearance Clean up
repaint
12 Whole plant
Safety device check normal, reliable

Fixture check Key parts firmly fixed

22
Chapter IV Common Failures and Troubleshooting

1. How to correct belt wandering and prevent belt slipping in rainy

days
● Belt wandering: Belt wandering is one of the failures commonly seen in
the operation of conveyor belts. Dimensional precision and daily
maintenance are critical for the prevention of such failures. There are many
possible reasons for wandering and it shall be handled as the case may
require.

A. Load-bearing supporting roller

assembly: Supporting roller assembly
deviation, the friction force between the
roller and the belt and the running of the belt
are not in the same direction. If the belt
wanders in the central part of the conveyor, adjust the position of the
supporting rollers; the mounting holes at the two ends of the supporting
rollers shall adopt long holes in design and manufacturing to make
adjustment easier. To be more specific, in which direction the belt wanders,
this side of the supporting roller assembly be moved forward along the
direction of the belt or the other side shall be moved back. If it wanders to
the left, move the left roller bracket forward and move the right bracket
backward, and vice versa. If wandering is more serious at two ends,
fending wheel may be installed near the rollers, if this still will not do, belt

23
pulley may be added to the fending wheel to defend the wandering; this
kind of situation is more frequently seen in belt at corner.

B. Make adjustment to the positions of the driving and driven drums:

Adjustment of the driving drums and the driven drums is critical for the

correction of belt wandering. Direction of the drum shall be perpendicular

to the belt. Excessive deviation of the center line along the length of the

conveyor belt will certainly cause wandering. Its adjustment is similar with

that of the supporting rollers. For wandering to the left of the front drums,

the left bearing housing shall be moved forward, vice versa, and it may also

be corrected by moving the left housing or right housing backward

correspondingly. The adjustment of rear drums for correction of wandering

is opposite to that of front drums. Make fine adjustments until ideal result

is obtained. The correct position shall be determined before adjustment of

the driving drums or bend pulley.

C. Adjustment of the belt tensioning device:

24
Adjustment of the belt-tensioning device is one

of the key procedures in the correction of belt

wandering. When using spiral tensioning, the

two bearing housings of the tensioning drum shall be moved in parallel so

that the axis of the drum is perpendicular to the length of the belt. The

adjustment procedures for belt wandering are similar to those for the

drums.

● How to prevent belt slipping: Major reasons for belt slipping are as

follows: 1. Tightness of belt is insufficient. 2. There are slippery

substances such as slurry and oil between the drum and the belt. 3. Rubber

wrappage of the drum gets aged and worn. Solutions: A. Adjust the driven

drum to increase tension. B. Prevent production of slippery substances

such as sludge, oil between the drum and belt, if necessary, belt guard shall

be used at proper location and water flushing or wood dust may be used to

help resolving the problem. C. Change rubber wrappage of the drum.

2. How to handle aggregate bin door-opening problem in weighing

1. Check whether the door is clogged or not properly shut originally;

2. Whether winding of the electromagnetic valve for door-opening is

burnt-out, whether the valve element is obstructed by foreign substance, if

the electromagnetic valve is not functioning well, remove it and wash or

25
replace with a new one; 3. Whether the control circuit is open (open wire,

disconnection, etc.), whether relevant intermediate relay is closed; 4. If air

pressure is not high enough, it is likely to be obstructed by stone, in such a

case, make adjustment to the pressure of the air compressor.

3. How to handle jumping forward and backward of dryer drum

During operation, it is possible that the dryer drum will jump forward or

backward and interfere with the operation of other devices and shorten the

life of the dryer drum, so this shall be prevented.

Center line of the drum shall be parallel to the center lines of the

supporting idler wheels and ensure uniform contact between the rolling

ring and the idler wheels. Due to processing precision, assembly error,

abrasion of the positioning wheel or distortion of the drum, the center line

of the drum goes unparallel to the center lines of the supporting idler

wheels and an upward or downward axial force is produced along the

centerline of the drum, which results in the jumping forward or backward

of the drum. Adjustment of the idler wheels is as illustrated below:

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 In this figure, the Centerline L-L’ of the drum is parallel to the

Centerline X-X’ of the supporting idler wheel.

Make adjustment to the adjusting bolt of the bearing housing until the

centerline of the supporting idler wheel coincide with Y-Y', if the drum

rotate in direction N, an axial force will be produced that will move the

drum toward M.

If such adjustment is made that the centerline of the supporting idler

wheel coincide with Z-Z', then a reverse axial force will be produced.

Remember fine adjustment of all the four supporting idler wheels

shall be made. Mark the original position for reference while making

adjustment.

Excessive adjustment will result in:

1、 excessive contact pressure that will result in eccentric wear of the

supporting idler wheel and the rolling ring

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 2、 The stronger pressure produced by the axial force on the bearing

will shorten its service life

3、 Sliding friction will be produced between the supporting idler

wheel and the rolling ring due to the axial force, resulting in excessive

vibration and noise.

Remember: Never apply lubricating grease to the supporting idler

wheel and the rolling ring, otherwise the drum will slip or jump backward.

4. How to resolve aggregate hoister leakage problem

Aggregate leakage from the hoister is possible in production, i.e.,

from the head of the hoister, some aggregate will fall, it's normal if it is

slight. If it is serious, preventative measures shall be taken.

Possible reason 1: Check tension of the chain, if it is not tight enough,

the chain will slip at the driving wheel and slow down the line speed of the

bucket chain, and the aggregates cannot be completely emptied into the

descent, i.e., some will leak out of the buckets; in such a case, adjust the

screw rod at the lowest stage of the hoister, remember adjustment shall be

made at two sides with the same distance to effectively resolve the leakage

problem.

Possible reason 2: There is an adjusting wearing plate at the head

descent of the hoister, if this plate is too far from the bucket chain, the

material will leak from between the bucket chain and the plate; in such a

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case, move the wearing plate forward to about 10 mm from the edge of the

bucket chain, and then lock the bolt to prevent the wearing plate from

sliding.

5. How to prevent and resolve spiral conveyor clogging

Spiral conveyor won't start or break down unexpectedly in operation:

◆ In case such condition appears, check the conveying quantity or power supply
of the electric apparatuses, in case breakdown due to excessive conveying
quantity, shut the outlet, open the inspection door in the lower part of the spiral
conveyer and turn the impeller in reverse direction to clear some of the contents
and then turn in the original direction; remember not to open the butterfly valve
outlet too wide in order to prevent repeated breakdown.
◆ If it is due to power supply problem, check the corresponding strong current
air switch, contactor and light current board output, whether the intermediate
relay is closed or the motor is in normal operation.
◆ Sometimes excessive voltage drop (mega-power equipment in operation
nearby) will lead to breakdown of the plant, check the voltmeter, resolve
through negotiation if necessary.
◆ Spiral conveyer clogging usually takes place due to long-time stoppage,
which leads to agglomeration of the material or obstruction of the impeller by
foreign substance stuck to the wall of the pipe, so the key priority for the
protection is to prevent the spiral connection from condensation and open and
clear the connection if necessary.

6. How to resolve imprecise weighing

In operation, weighing errors are possible.

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 Reset the weighing scale first, if the problem remains, check whether the

protective bolt contact and scratch with the lower plate of the sensor

module, if yes, remove the protective bolt.

If it is not the case mentioned above, then check the sensor itself with

a multimeter, if the sensor is damaged, replace with a new one.

Remember sensors are fragile and make sure they are properly

grounded and safe from any impact.

7. How to handle power cut in production

In case of unexpected power cut in operation and the whole plant stops

operation, it shall be handled in reverse order.

A. If power supply will be restored in half an hour, open the door

of the mixer-agitator tank and inch the driving motor to discharge

some of the material and then restore operation of the

mixer-agitator tank in full swing to empty it.

B. Turn on the vibrating screen and clear up all remnants on the

screen

C. Start the hoister, if it is impossible, open the observation door at

the lowest stage of the hoister and clear the aggregate out of the

hoister manually until it can be started. Make sure that all people

and tools are kept in a safe distance and close the observation

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 door when starting the hoister. Keep the hoister running until all

the contents in the hoister are cleared.

D. Inch the dryer drum, start in trial and watch, if no abnormal

situation, start the dryer drum and keep it operating to empty the

aggregate in it.

E. Like this, start other equipment according to the

equipment-starting procedures and then begin normal operation.

For longer-time power cut, if there is no finished product (asphalt

added) in the mixer-agitator tank, no special action is needed, handle when

power supply recovers. If there is finished product in the tank, open the

door of the tank with external force immediately and clear the contents

manually to prevent cooling and stuck of the finished products.

8. In manual operation, if the trolley is over-charged, how to handle

cut of power supply to the hoister when the trolley is hoisted to a

certain height

In such a case, when the trolley is hoisted to the intermediate rail, the

load on the hoister motor is the largest, in order to protect the motor, open

the switch, when the motor is out of power, the hoister brake functions and

the trolley will stop there.

In such a case, never to start the hoister motor, lower the trolley

manually instead, i.e., lower the trolley to the product receiving station

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below the mixer-agitator tank. The hoister is provided with a brake which

can be released manually with a hand grip, screw the threaded end of the

hand grip into the brake-releasing lever and pull slowly to lower the trolley

by gravity, when the trolley reaches the product receiving station, open the

door of the trolley and empty the contents to the ground; the motor can be

started now to recover normal operation.

9. Maintenance, operation and troubleshooting of air compressor

● Low air output: ① The air muffler and filter is clogged, clear the filter.②

Air cylinder, piston abrasion or seriously scratched, bore the cylinder or

replace the air cylinder, piston.③ Substandard lube or high compressor

vent temperature lead to seizure of piston ring. Change the lube or lower

the temperature.④ Piston ring is worn out, change such piston ring.⑤ Air

valve is not tight or valve element damaged, check air valve or change

valve element.⑥ Excessive air cylinder clearance, make adjustment to the

upper stop point clearance.

●High vent temperature:① High inlet air temperature, put up shade or take

other cooling measures.② Air valve leakage leads to high temperature air

recycled to air cylinder, check the air valve, grind valve plate or change the

valve element. High oil temperature ① Improper lube is used or it gets

dirty. Change the lube.② Excessive or insufficient assembly clearance

between motional parts, oil film cannot be formed, check the assembly

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clearance and repair.③ Metal grains in the connecting rod oil tank or on

the friction surface, wash and wipe.

Check the assembly clearance and repair.③ Metal grains in the connecting

rod oil tank or on the friction surface, wash and wipe.

●Knocking: ① Foreign substance such as remnants of valve element

debris in the air cylinder, ② Insufficient air cylinder clearance, make

adjustment to the upper stop point clearance.③ Valve element or spring

damaged, replace it.④ In case the piston is seriously worn, change the

piston.⑤ Piston ring obstructed in the piston or serious worn, check and

change the piston ring.⑥ Crankshaft end abrased into oval shape, replace

the crankshaft.

●Valve plate broken: ① Foreign substance bumping in the air cylinder,

clear such foreign substance.② Insufficient upper stop point clearance,

make adjustment to the clearance of the upper stop point.

●Crack or fracture of crankshaft: ① Over-hot bearing leads to seizure of

journal neck and connecting rod or deformation of crankshaft, repair or

replace the connecting rod and filter or change lubricating oil at the same

time.② Forceful impact, urgent braking, over-load operation, eliminate

source of failure. If any failure occurs, timely troubleshooting shall be

made. ③ Unexpected load on the crankshaft, check all motional parts,

repair or replace if crack or deformation is detected.

●Piston ring obstructed or seized: ① Substandard lube, lube supply failure

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or inlet air to the cylinder contains dirt, leading to dry friction between

pistons and the cylinder.② The lube does not meet the requirements.

Check lube supply and wash the filter frequently.③ For motional

mechanism deviation, abnormal piston friction, seizure of piston and

piston ring due to excessive heat, adjust the motional mechanism.④

Opening or end face clearance of piston ring is too small; repair and give it

specified clearance.

●Scratch on the surface of air cylinder:① Air filter damaged and let in

unclean air, periodic maintenance of air compressor shall be done in clean

place.② Lube is out of supply (or improper lube is used) resulting in dry

friction, or the lube itself contains moisture and other foreign substance.

The lube shall meet the requirements and be clean.③ Insufficient assembly

clearance between the air cylinder and piston, or scratch due to abnormal

friction caused by deviation of motional parts, ensure correct clearance

between the piston and air cylinder, correct motional part deviation.④

Interface of piston ring has burrs or too small opening clearance, resulting

in piston scraping. Check and grind the connection, ensure proper

clearance and roughness.⑤ There are burrs or scars on piston or piston

ring; grind, check and clean such piston or piston ring.

Connection rod broken:

● Over-load operation leads to excessive stress on the connecting rod,

avoid overload operation.

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10. Causes for common pneumatic butterfly valve and ball valve

failures

Pneumatic butterfly valve and ball valve won't open or close, most

likely cause is that the sealing ring inside the valve is worn out, the slide

copper sleeve on the piston abrased or the push rod is damaged. Sealing

ring of the ball valve is worn out or the rolling rack on the piston is worn

out due to inhale of foreign substance into the valve, failure of the oil-water

separator to produce oil or insufficient lubrication, shortening its service

life.

11. Common air cylinder failures

The most commonly seen failures for air cylinder

are air leakage, decrease of push and pull force,

improper positioning of switch caused by failure of

sealing. Regular maintenance of the air supply treatment plant can

effectively prevent such failures, if obvious damage is found on the sealing,

change it promptly to prevent further damage.

If positioning of the housing of the air cylinder is not precise, there

exists air cylinder motion distortion or interference, the head of the push

rod of air cylinder may broken, in such a case, replace the air cylinder right

away to prevent potential accident.

12. Remove electromagnetic valve failure

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 Valve element obstruction will lead to failure of

electromagnetic valve, disassemble and wash with

clean oil. In case of burned-out winding, change it.

Pneumatic muffler will be clogged if not washed after long-time use and

slow down motion of the air cylinder, so periodically disassemble and

wash it with diesel oil.

If the electromagnetic valve does not work in the air loop, try the

manual-operating knob and check the electromagnetic socket. If none of

the above problems is found, disassemble the air valve to see whether there

is foreign substance clogging the channel. Generally, normal operation can

be recovered after cleanup. Close the gate valve upstream or the air

compressor before disassembly.

13. Correct installation and maintenance of the triplet

The triplet consists of the water filter, pressure regulating valve and

atomized lubricator.

The water filter filters off moisture from the compressed air with its air

filter, make adjustment to the pressure and atomize the oil into smog

with the atomized lubricator and blend it with the compressed air to

reach each lubrication point. Remember to drain water accumulation in

the water filter, make adjustment to the output of oil of the atomized

lubricator. If the lubrication point is in too long a distance from the triplet,

the oil can hardly reach it; therefore, the triplet shall be positioned near the

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air cylinders and pneumatic butterfly valves to guarantee their lubrication.

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