TROUBLESHOOTING   (in order of probable occurrence)

A. Conveyor runs to one side at given point on structure.

  • Buildup of material on idlers:  remove accumulation; improve maintenance, install scrapers or other cleaning devices.
  • Sticking idlers: free idlers and improve maintenance and lubrication.
  • Idlers or pulleys out-of-square with center line of belt: readjust idlers in affected area. 
  • Conveyor frame of structure crooked:  straighten in affected area.
  • Idler stands not centered on belt:  readjust idlers in affected area.
  • Structure not level:  level structure in affected area.

B. Particular section of belt runs to one side at all points on conveyor.

  • Belt not joined squarely:  remove affected splice and resplice. 
  • 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.

C. Belt runs to one side for long distance or entire length of conveyor.

  • Belt running off-center around the tail pulley and through the loading area:  install training idlers on the return run prior to tail pulley.
  • Off-center loading or poor loading:  adjust chute to place load on center of belt; discharge material in direction of belt travel at or near belt speed.
  • Buildup of material on idlers:  remove accumulation; improve maintenance, install scrapers or other cleaning devices.
  • Idlers or pulleys out-of-square with center line of belt: readjust idlers in affected area.
  • Conveyor frame of structure crooked:  straighten in affected area.
  • Idler stands not centered on belt:  readjust idlers in affected area.

D. Belt runs off at tail pulley.

  • Belt running off-center around the tail pulley and through the loading area:  install training idlers on the return run prior to tail pulley.
  • Material spillage and buildup:  improve loading and transfer conditions; install cleaning devices; improve maintenance.
  • Idlers or pulleys out-of-square with center line of belt: readjust idlers in affected area.

E. Belt runs off at head pulley.

  • Pulley lagging worn:  replace pulley lagging.
  • Material spillage and buildup:  improve loading and transfer conditions; install cleaning devices; improve maintenance.
  • Idlers or pulleys out-of-square with center line of belt: readjust idlers in affected area.
  • Idler stands not centered on belt:  readjust idlers in affected area.

F. Belt slip.

  • Insufficient traction between belt and pulley:  lag drive pulley; increase belt wrap; install belt cleaning devices.
  • Pulley lagging worn:  replace pulley lagging.
  • Counterweight too light:  add counterweight or increase screw take-up tension to value determined from calculations.
  • Material spillage and buildup:  improve loading and transfer conditions; install cleaning devices; improve maintenance.
  • Sticking idlers: free idlers and improve maintenance and lubrication.

G. Belt slip on starting.

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

H. Excessive belt stretch.

  • Improper belt installation causing apparent excessive belt stretch:  pull belt through counterweight with a tension equal to at least empty running tension; run belt in with mechanical fasteners.
  • Improper initial positioning of counterweight in its carriage causing apparent excessive belt stretch:  check Goodyear Handbook of Belting for recommended initial position.
  • Insufficient counterweight travel:  consult Goodyear Conveyor and Elevator Belt Selection Manual for recommended minimum distances.
  • Tension too high:  increase speed, same tonnage; reduce tonnage, same speed; reduce friction with better maintenance and replacement of damaged idlers; decrease tension by increasing arc of contact or go to lagged pulley; reduce CWT to minimum amount.
  • Counterweight too heavy:  lighten counterweight to value required by calculations.
    System underbelted: recalculate belt tensions and select proper belt.

I. Grooving, gouging or stripping of top cover.

  • Skirt boards improperly adjusted or of wrong material:  adjust skirt board supports to minimum 1" between metal and belt with gap increasing in direction of belt travel; use skirt board rubber (not old belt).
  • Belt spanking down under load impact:  install cushion idlers.
    Material hanging up in or under chute:  improve loading to reduce spillage; install baffles; widen chute.
  • Impact of material on belt:  reduce impact by improving chute design; install impact idlers.

J. Excessive top cover wear, uniform around belt.

  • Dirty, stuck, or misaligned return rolls:  remove accumulations; install cleaning devices, use self-cleaning return rolls, improve maintenance and lubrication.
  • Cover quality too low:  replace with belt of heavier cove gauge or higher quality rubber.
  • Material spillage and buildup:  improve loading and transfer conditions; install cleaning devices; improve maintenance.
  • Off-center loading or poor loading:  adjust chute to place load on center of belt; discharge material in direction of belt travel at or near belt speed.
  • 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.

K. Severe pulley cover wear.

  • Sticking idlers: free idlers and improve maintenance and lubrication.
  • Slippage of drive pulley:  increase tension thru screw takeup or add counterweight; lag drive pulley; increase arc of contact.
  • Material spillage and buildup:  improve loading and transfer conditions; install cleaning devices; improve maintenance.
  • Material trapped between belt and pulley:  install plows or scrapers on return run ahead of tail pulley.
  • Bolt heads protruding above lagging:  tighten bolts; replace lagging; use vulcanized-on lagging.
  • Excessive forward tilt of trough rolls:  reduce forward tilt of idlers to no more than 2 (degrees symbol) from vertical.

L. Longitudinal grooving or cracking of bottom cover.

  • Sticking idlers: free idlers and improve maintenance and lubrication.
  • Material spillage and buildup:  improve loading and transfer conditions; install cleaning devices; improve maintenance.
  • Slippage of drive pulley:  increase tension thru screw takeup or add counterweight; lag drive pulley; increase arc of contact.
  • Pulley lagging worn:  replace pulley lagging.

M. Covers harden or crack.

  • Heat or chemical damage:  use belt designed for specific condition.
  • Improper storage or handling:  refer to Goodyear for proper storage and handling instructions.

N. Cover swells in spots or streaks.

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

O. Belt breaks at or behind fasteners; fasteners pull out.

  • Fastener plates too long for pulley size:  replace with smaller fasteners; increase pulley size.
  • Wrong type of fastener, fasteners too tight or too loose:  use proper fasteners and splice technique; set up schedule for regular fastener inspection.
  • Tension too high:  increase speed, same tonnage; reduce tonnage, same speed; reduce friction with better maintenance and replacement of damaged idlers; decrease tension by increasing arc of contact or go to lagged pulley; reduce CWT to minimum amount.
  • Heat or chemical damage:  use belt designed for specific condition.