Problem Solving

If your conveyor system is not performing as expected, this page helps you identify the most common causes and the information we need to assist.

Conveyor problem solving

Find the problem that best describes your conveyor, then select a reference number to view its cause and remedy.

Problem		Cause and Remedy
A	Conveyor runs to one side at a given point on the structure.
B	Particular section of belt runs to one side at all points of conveyor.
C	Belt runs to one side for long distances or entire conveyor length.
D	Belt runs off at tail pulley.
E	Belt runs off at head pulley.
F	Belt slips.
G	Belt slips on starting.
H	Excessive belt stretch.
I	Grooving, gouging or stripping of top cover.
J	Excessive top cover wear, uniform around belt.
K	Severe, pulley cover wear.

Problem		Cause and Remedy
L	Longitudinal grooving or cracking of bottom cover.
M	Covers harden or crack.
N	Covers swell in spots or streaks.
O	Belt breaks at or behind fasteners; fasteners pull out.
P	Vulcanised splice separation.
Q	Excessive edge wear or broken edges.
R	Transverse breaks at belt edge.
S	Short breaks in carcass parallel to belt edge; star breaks in carcass.
T	Ply separation.
U	Carcass fatigue at idler junction.
V	Cover blisters or sand blisters.

Find the symptom that best describes your conveyor

Conveyor runs to one side at a given point on the structure. View possible causes and remedies

5.Build up of material on idlers: remove accumulation; improve maintenance, install scrapers or other cleaning devices.
4.Sticking idlers: free idlers and improve maintenance and lubrication.
1.Idlers or pulleys cut-off square with center line of belt. Re-adjust in affected area.
2.Conveyor frame of structure crooked. Straighten affected area.
3.Idler stands not centered on belt: readjust in affected area.
44.Structure not level: level structure in affected area.

Particular section of belt runs to one side at all points of conveyor. View possible causes and remedies

6.Belt not joined squarely: remove affected splice and re-splice.
7.Bowed belt: for new belt this condition should disappear during break-in, in rare instances belt must be straightened or replaced; check storage and handling of belt rolls.

Belt runs to one side for long distances or entire conveyor length. View possible causes and remedies

39.Belt running off-center around tail pulley and through loading area: install training idlers on return run prior to tail pulley.
8.Off center loading or poor loading: adjust chute to replace load on center of belt; discharge material in direction of belt travel at or near belt speed.
5.Build up of material on idlers: remove accumulation; improve maintenance, install scrapers or other cleaning devices.
1.Idlers or pulleys cut-off square with center line of belt. Re-adjust in affected area.
2.Conveyor frame of structure crooked. Straighten affected area.
3.Idler stands not centered on belt: readjust in affected area.

Belt runs off at tail pulley. View possible causes and remedies

39.Belt running off-center around tail pulley and through loading area: install training idlers on return run prior to tail pulley.
10.Material spillage and build-up: improve loading and transfer condition; install cleaning devices, improve maintenance.
1.Idlers or pulleys cut-off square with center line of belt. Re-adjust in affected area.

Belt runs off at head pulley. View possible causes and remedies

33.Pulley lagging worn: replace pulley lagging.
10.Material spillage and build-up: improve loading and transfer condition; install cleaning devices, improve maintenance.
1.Idlers or pulleys cut-off square with center line of belt. Re-adjust in affected area.
3.Idler stands not centered on belt: readjust in affected area.

Belt slips. View possible causes and remedies

34.Insufficient traction between belt and pulley: lag drive pulley; increase belt wrap; install belt cleaning device.
33.Pulley lagging worn: replace pulley lagging.
31.Counterweight too light: add counterweight or increase screw take-up tension to value determined from calculations.
10.Material spillage and build-up: improve loading and transfer condition; install cleaning devices, improve maintenance.

Belt slips on starting. View possible causes and remedies

34.Insufficient traction between belt and pulley: lag drive pulley; increase belt wrap; install belt cleaning device.
31.Counterweight too light: add counterweight or increase screw take-up tension to value determined from calculations.
33.Pulley lagging worn: replace pulley lagging.

Excessive belt stretch. View possible causes and remedies

41.Improper belt installation causing apparent excessive belt stretch: pull belt through counterweight with tension equal to at least empty running tension; run belt in with mechanical fasteners.
42.Improper initial positioning of counterweight in its carriage cause excessive belt stretch.
43.Insufficient counterweight travel.
12.Tension too high: increase speed; same tonnage; reduce friction with better maintenance and replacement of damaged idlers; decrease tension by increasing angle of wrap or install pulley lagging. Reduce CWT to minimum amount.
32.Counterweight too heavy: lighten counterweight to value required by calculations.
35.Insufient belt tension: re-calculate belt tensions and select proper belt.

Grooving, gouging or stripping of top cover. View possible causes and remedies

13.Skirt-board improperly adjusted or wrong material: adjust skirt-board supports to minimum 25mm between metal and belt with gap increasing in direction of belt travel; use skirting rubber (not old belt).
14.Impact of material under loading area: install cushion idlers.
15.Material hanging up in or under chute: improve loading to reduce spillage; install baffles; widen chute.
16.Impact of material on belt: reduce impact by improving chute design; install impact idlers.

Excessive top cover wear, uniform around belt. View possible causes and remedies

19.Dirty, stuck or misaligned return idler rolls: remove accumulations; install cleaning devices; use self-cleaning return idler rolls; improve maintenance and lubrication.
20.Cover quality too low: replace with belt of heavier cover gauge or higher quality rubber.
10.Material spillage and build-up: improve loading and transfer condition; install cleaning devices, improve maintenance.
8.Off center loading or poor loading: adjust chute to replace load on center of belt; discharge material in direction of belt travel at or near belt speed.
36.Excessive sag between idlers causing load to work and shuffle on belt as it passes over idlers; increase tension if unnecessarily low; reduce idler spacing.

Severe, pulley cover wear. View possible causes and remedies

4.Sticking idlers: free idlers and improve maintenance and lubrication.
9.Slippage on drive pulley: increase tension through screw take up or add counterweight; lag drive pulley; increase angle of wrap.
10.Material spillage and build-up: improve loading and transfer condition; install cleaning devices, improve maintenance.
17.Material trapped between belt and pulley: install plows or scrapers on the return in front of the tail pulley.
11.Bolt heads protruding above lagging: tighten bolts; replace lagging; use vulcanized lagging.
27.Excessive forward tilt of trough idler rolls: reduce forward tilt of idlers to no more than 2 from vertical.

Longitudinal grooving or cracking of bottom cover. View possible causes and remedies

4.Sticking idlers: free idlers and improve maintenance and lubrication.
10.Material spillage and build-up: improve loading and transfer condition; install cleaning devices, improve maintenance.
9.Slippage on drive pulley: increase tension through screw take up or add counterweight; lag drive pulley; increase angle of wrap.
33.Pulley lagging worn: replace pulley lagging.

Covers harden or crack. View possible causes and remedies

23.Heat or chemical damage: use belt designed for specific condition.
37.Improper storage or handling.

Covers swell in spots or streaks. View possible causes and remedies

21.Spilled oil or grease: over lubrication of idlers; improve housekeeping; reduce quantity of grease used; check grease seals.

Belt breaks at or behind fasteners; fasteners pull out. View possible causes and remedies

24.Fastener plates too long for pulley size: replace with smaller fasteners; increase pulley size.
22.Wrong type of fasteners. Too tight or too loose: use proper fasteners and splice technique. Set up schedule for regular fastener inspections.
12.Tension too high: increase speed; same tonnage; reduce friction with better maintenance and replacement of damaged idlers; decrease tension by increasing angle of wrap or install pulley lagging. Reduce CWT to minimum amount.
23.Heat or chemical damage: use belt designed for specific condition.

Vulcanised splice separation. View possible causes and remedies

38.Belt improperly spliced: re-splice using proper method.
10.Material spillage and build-up: improve loading and transfer condition; install cleaning devices, improve maintenance.
40.Belt hitting structure: install training idlers on carrying and return run.
7.Bowed belt: for new belt this condition should disappear during break-in, in rare instances belt must be straightened or replaced; check storage and handling of belt rolls.

Excessive edge wear or broken edges. View possible causes and remedies

8.Off center loading or poor loading: adjust chute to replace load on center of belt; discharge material in direction of belt travel at or near belt speed.
10.Material spillage and build-up: improve loading and transfer condition; install cleaning devices, improve maintenance.
40.Belt hitting structure: install training idlers on carrying and return run.
7.Bowed belt: for new belt this condition should disappear during break-in, in rare instances belt must be straightened or replaced; check storage and handling of belt rolls.

Transverse breaks at belt edge. View possible causes and remedies

18.Belt edges folding up on structure: same corrections as 1, 2, 3, install limit switches; provide more clearance.
25.Improper transition between troughed belt and terminal pulleys: adjust transition.
26.Severe convex (hump) vertical curve: decrease idler spacing in curve; increase curve radius.

Short breaks in carcass parallel to belt edge; star breaks in carcass. View possible causes and remedies

16.Impact of material on belt: reduce impact by improving chute design; install impact idlers.
17.Material trapped between belt and pulley: install plows or scrapers on the return in front of the tail pulley.

Ply separation. View possible causes and remedies

29.Insufficient transverse stiffness: replace with proper belt.
30.Pulleys too small: use larger diameter pulleys.
23.Heat or chemical damage: use belt designed for specific condition.

Carcass fatigue at idler junction. View possible causes and remedies

25.Improper transition between troughed belt and terminal pulleys: adjust transition.
26.Severe convex (hump) vertical curve: decrease idler spacing in curve; increase curve radius.
27.Excessive forward tilt of trough idler rolls: reduce forward tilt of idlers to no more than 2 from vertical.
28.Excess gap between idler rollers: replace with heavier belt.
29.Insufficient transverse stiffness: replace with proper belt.

Cover blisters or sand blisters. View possible causes and remedies

45.Cuts on belt cover. Punctures allow fines to penetrate between the cover and the carcass, causing damage. Make spot repairs with a vulcanizer or self curing repair material.
21.Spilled oil or grease: over lubrication of idlers; improve housekeeping; reduce quantity of grease used; check grease seals.

Cause and remedy reference

1.Idlers or pulleys cut-off square with center line of belt. Re-adjust in affected area.
2.Conveyor frame of structure crooked. Straighten affected area.
3.Idler stands not centered on belt: readjust in affected area.
4.Sticking idlers: free idlers and improve maintenance and lubrication.
5.Build up of material on idlers: remove accumulation; improve maintenance, install scrapers or other cleaning devices.
6.Belt not joined squarely: remove affected splice and re-splice.
7.Bowed belt: for new belt this condition should disappear during break-in, in rare instances belt must be straightened or replaced; check storage and handling of belt rolls.
8.Off center loading or poor loading: adjust chute to replace load on center of belt; discharge material in direction of belt travel at or near belt speed.
9.Slippage on drive pulley: increase tension through screw take up or add counterweight; lag drive pulley; increase angle of wrap.
10.Material spillage and build-up: improve loading and transfer condition; install cleaning devices, improve maintenance.
11.Bolt heads protruding above lagging: tighten bolts; replace lagging; use vulcanized lagging.
12.Tension too high: increase speed; same tonnage; reduce friction with better maintenance and replacement of damaged idlers; decrease tension by increasing angle of wrap or install pulley lagging. Reduce CWT to minimum amount.
13.Skirt-board improperly adjusted or wrong material: adjust skirt-board supports to minimum 25mm between metal and belt with gap increasing in direction of belt travel; use skirting rubber (not old belt).
14.Impact of material under loading area: install cushion idlers.
15.Material hanging up in or under chute: improve loading to reduce spillage; install baffles; widen chute.
16.Impact of material on belt: reduce impact by improving chute design; install impact idlers.
17.Material trapped between belt and pulley: install plows or scrapers on the return in front of the tail pulley.
18.Belt edges folding up on structure: same corrections as 1, 2, 3, install limit switches; provide more clearance.
19.Dirty, stuck or misaligned return idler rolls: remove accumulations; install cleaning devices; use self-cleaning return idler rolls; improve maintenance and lubrication.
20.Cover quality too low: replace with belt of heavier cover gauge or higher quality rubber.
21.Spilled oil or grease: over lubrication of idlers; improve housekeeping; reduce quantity of grease used; check grease seals.
22.Wrong type of fasteners. Too tight or too loose: use proper fasteners and splice technique. Set up schedule for regular fastener inspections.
23.Heat or chemical damage: use belt designed for specific condition.
24.Fastener plates too long for pulley size: replace with smaller fasteners; increase pulley size.
25.Improper transition between troughed belt and terminal pulleys: adjust transition.
26.Severe convex (hump) vertical curve: decrease idler spacing in curve; increase curve radius.
27.Excessive forward tilt of trough idler rolls: reduce forward tilt of idlers to no more than 2 from vertical.
28.Excess gap between idler rollers: replace with heavier belt.
29.Insufficient transverse stiffness: replace with proper belt.
30.Pulleys too small: use larger diameter pulleys.
31.Counterweight too light: add counterweight or increase screw take-up tension to value determined from calculations.
32.Counterweight too heavy: lighten counterweight to value required by calculations.
33.Pulley lagging worn: replace pulley lagging.
34.Insufficient traction between belt and pulley: lag drive pulley; increase belt wrap; install belt cleaning device.
35.Insufient belt tension: re-calculate belt tensions and select proper belt.
36.Excessive sag between idlers causing load to work and shuffle on belt as it passes over idlers; increase tension if unnecessarily low; reduce idler spacing.
37.Improper storage or handling.
38.Belt improperly spliced: re-splice using proper method.
39.Belt running off-center around tail pulley and through loading area: install training idlers on return run prior to tail pulley.
40.Belt hitting structure: install training idlers on carrying and return run.
41.Improper belt installation causing apparent excessive belt stretch: pull belt through counterweight with tension equal to at least empty running tension; run belt in with mechanical fasteners.
42.Improper initial positioning of counterweight in its carriage cause excessive belt stretch.
43.Insufficient counterweight travel.
44.Structure not level: level structure in affected area.
45.Cuts on belt cover. Punctures allow fines to penetrate between the cover and the carcass, causing damage. Make spot repairs with a vulcanizer or self curing repair material.