TROUBLESHOOTING

The following tables list problems sometimes encountered and suggests possible solutions.
The causes are in the left-hand column and the corrections in the right hand column.
Conveyor belt problems causes and correctons
!" Conveyor runnn# to one sde at a #ven pont on structure$
A) One or more idlers immediately
preceding trouble point not square (at
right angles) to longitudinal axis of belt.
A.1) Utilising slots in idler stand, foot rotate
entire idler assemblies in same direction as
for the steering wheel of an automobile, to
steer belt back tocentre.
B) on!eyor frame or structure croo"ed.
B.1) Stretch string along to determine extent and
make correction.
) One or more idler stands not centred
under belt.
C.1) Same as B.1 above.
#) $tic"ing idlers. .1) !m"rove maintenance and lubrication.
%) &hen the run-off begins on a terminal
pulley' it follows that terminal pulley is
out of alignment. (ote that a con!eyor
belt shifts to the low or short side.
#.1) $e%align "ulle&.
)) Build-up of material on idlers and
pulleys.
'.1) !m"rove maintenance.
'.() !nstall scra"ers or other cleaning device.
*) $tructure not le!el and belt tends to
shift to low side.
).1) *evel structure.
%" &artcular secton o' conveyor belt runs to one sde at all ponts on a conveyor
A) Belt not +oined squarely. A.1) Cut ends s+uare and re fasten.
B) Bowed belt. B.1) Avoid bad storage conditions such as
telesco"ed rolls or one edge close to dam"
ground or wall.
B.() ,ith a new belt, this condition should
disa""ear as soon as the belt has o"erated
under full load and tension, and becomes
-broken in-.
B..) Use self%aligning idlers, "articularl& on
return run a""roaching tail "ulle& to obtain
central loading.
B./) !n rare instances belt must be re"laced.
(" Conveyor belt runs to one sde 'or lon# dstance alon# bed
A) ,oad being placed on belt off-centre. A.1) Ad0ust chute and loading conditions so as to
"lace load in centre of belt.
) $ee -.% See 1.#
) $ee -.* See 1.)
)" Belt s erratc *'ollo+s no pattern o' per'ormance,
A) Belt too stiff to train. A.1) Use self%aligning idlers.
A.() 1ilt troughing idlers forward, but not more
that ( degrees.
A..) Use more troughable belt.
-" Severe +ear on pulley sde o' conveyor belt
A.) $lippage on dri!e pulley. A.1) !ncrease the tension through screw take%u"
or more counterweight.
A.() *ag drive "ulle&.
A..) !ncrease the arc of contact on the drive
"ulle& with a snub "ulle&.
B) $pillage of material which is ground
between belt and pulley or which
builds up at loading point until belt is
dragging.
B.1) !m"rove loading conditions with a chute.
B.() !f belt is overloaded, increase belt s"eed or
decrease feed onto belt.
B..) install decking between to" and return runs.
B./) !nstall "loughs or scra"ers in front of tail
"ulle& onreturn run
B.2 3revent leakage of abrasive fines at fasteners
b& changing to "late fasteners or vulcanised
s"lice.
) $tic"ing idlers C.1) !m"rove maintenance and lubrication.
#) Bolt head protruding abo!e pulley
lagging.
.1) 1ighten bolts.
.() $e"lace worn lagging.
..) Use vulcanised%on lagging.
%) %xcessi!e tilt to troughing idlers. #.1) Ad0ust to not more that ( degrees from line
"er"endicular to belt.
." E/cessve stretc0 n conveyor
A) Tension too high. A.1) !ncrease s"eed, kee"ing tonnage same.
A.() $educe tonnage at same s"eed.
A..) $educe friction with better maintenance and
re"lacing of worn out and fro4en idlers.
A./) ecrease tension b& im"roving drive with
lagging, increase arc contact and
counterweight take%u".
A.2) $e"lace with heavier belt.
Above is based on the assum"tion that
ade+uate take%u" is available.
1" Belt s0rn2s
A) Belt absorbing moisture. A.1) 3ut in extra "iece, installing with take%u" half
wa& down.
3" Len#t0+se #ou#n# or strppn# o' top cover
A) $"irt board seals too stiff and pressed
against belt.
A.1) Use more "liable seals.
A.() Ad0ust to relieve "ressure on belt.
B) %xcessi!e space between belt and s"irt
seals.
B.1) Ad0ust seals to minimum clearance.
) .etal sides of chute or s"irts too close
to belt and gap not increasing in
direction of tra!el.
C.1) Ad0ust to at least 25mm ga" between metal
and belt and have ga" increasing in direction
of travel so as to "revent material 0amming at
this "oint.
4" Len#t0+se #ou#n# or strppn# o' top cover *Cont",
#) Belt span"s down under impact at
loading point' allowing material to be
trapped under s"irts.
.1) !nstall cushion or "neumatic idlers to hold
belt
u" against skirts.
%) .aterial hanging under bac" panel. #.1) !m"rove loading to "revent s"illage or install
baffle.
)) /amming of material in chute. '.1) ,iden chute.
!5" S0ort brea2s n carcass parallel to belt ed#e and star brea2s n carcass
A) 0mpact of lumps failing on belt. A.1) $educe im"act.
A.() Use cushion idlers.
B) .aterial trapped between belt and
pulley.
B.1) !nstall "lows or scra"ers on return run ahead
of
tail "ulle&.
!!" Transverse brea2s at belt ed#es
A) Belt edges folding up on structure due
to wander or pressing too hard against
side guide idlers.
A.1) See troubles 61), 6(), 6.) and 6/).
A.() !nstall limit switches to sto" belt in cases of
extreme shifting.
B) .ildew. B.1) $e"lace with 7!8'!8!19: belt.
) )inal idler before head pulley located
too close or too high in respect to head
pulley.
C.1) Ad0ust idler "osition in accordance with
normal
design "ractice.
!%" Cover blsters or sand blsters
A) o!er cuts or !ery small co!er
punctures allow fine particles of 1sand1
to wor" under co!er and cut co!er
away from carcass.
A.1) ;ake s"ot re"air with vulcaniser or -cold-
"atches.
A.() !n severe and re"eating cases refer all details
to 7!8'!8!19: for anal&sis.
!(" Belt rses up o'' trou#0n# dlers6 bo+n# to+ards load
A) Oil contamination in material. A.1) $emove source of oil, if "ossible.
A.() 1o eke out the life of "resent belt, cut
longitudinal grooves in cover with t&re
grooving tool to relieve transverse "ressure
exerted b& swelling rubber.
A..) 'or "ro"er selection of re"lacement belt,
send in sam"le of oil to determine best oil
resisting com"ounds.
!)" Cover s+ells n spots6 or lnes o' s+elln# on pulley sde concdent +t0 7uncton or
trou#0n# dler rolls"
A) $pilled oil or grease. A.1) Better housekee"ing.
B) O!er-lubrication of top run idlers. B.1) $educe +uantit& of lubricant used.
!-" E/cessve top cover +ear6 un'orm around belt
A) #irty return rolls. A.1) !nstall cleaning devices.
A.() ,ash belt.
A..) Use rubber disc return idlers.
B) o!er quality too low. B.1) $e"lace with better belt.
) 2ile up of spilled material at tail pulley. C.1) !m"rove housekee"ing and loading.
#) $lide loading' or poor loading' i.e.
speed of deli!ery of material too slow.
.1) $edesign chute to make load feed onto belt in
same direction as belt runs and at
a""roximatel& same s"eed as belt.
%) %xcessi!e sag between idlers causing
load to wor" and shuffle on belt as it
passes o!er idlers.
#.1) !ncrease tension where it is unnecessaril&
low.
#.() $educe idler s"acing.
#..) $e"lace with belt of heavier carcass.
!." 8asteners pulln# out
A) .ildew. A.1) $e"lace with 7!8'!8!19: belt.
B) &rong type of fastener or fasteners
not tight.
B.1) $e fasten belt and set u" schedule for fre+uent
fastener ins"ection. $e%tighten new fasteners
after a few hours run.
) Tension too high. C.1) Check tension in belt and if too high, see item
6<)
for corrections.
C.() Use vulcanised s"lice.
#) 3eat. .1) Use heavier to" covers.
.() Consult 7!8'!8!19:.
!1" Transverse brea2s n belt mmedately be0nd 'asteners
A) )astener plates too long for pulley
si4es.
A.1) Change to smaller, shorter fasteners.
A.() !ncrease "ulle& si4e.
B) .ildew. B.1) $e"lace with 7!8'!8!19: belt.
!3" Len#t0+se rps partally or entrely t0rou#0 belt
A) $ee trouble (5)
B) Belt running off and snagging on
structure.
B.1) See trouble 61), 6(), 6.) and 6/)
) 2uncture by tramp iron at chute. C.1) Use metal detector.
!4" Crescent brea2s n carcass6 or mus0y spots +0ere carcass rotted under cover
A) .ildew. A.1) $e"lace with 7!8'!8!19: belt.
%5" Len#t0+se rupture o' carcass +t0 top cover and possble parts o' pulley cover unbro2en
A) Belt running off against structure and
folding bac" on itself as it passes
around terminal pulley.
A.1) See troubles 61), 6(), 6.) and 6/)
A.() !nstall limit switches.
%!" Hardenn# and crac2n# o' covers +t0 eventual 0ardenn# o' carcass and loss o' duc2
stren#t0
A) 3eat. A.1) Consult 7!8'!8!19: belt for thorough
anal&sis of conditions for a""lication of
correct heat resisting belt.