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Belt Conveyor Troubleshooting: HGRS MASTER - Maintenance
Belt Conveyor Troubleshooting: HGRS MASTER - Maintenance
Belt Conveyor Troubleshooting: HGRS MASTER - Maintenance
o While each conveyor and each transfer point is unique and individual, there
are a number of commonly encountered problems for which general causes
and possible cures can be prescribed.
o The techniques to ensure satisfactory belt tracking are mainly addressed by
the proper design of all belt conveyor components and appropriate
adjustment and maintenance
Fluctuations in load Use notched chute to keep load peak in centre of belt
Belt / idler contact not equal Adjust height of idlers for even contact
Conveyor belt runs to one side at a Idler(s) not at right angles to centre line of Move the end of the idler to which belt has moved in the direction of
particular point along conveyor belt the belt travel
Structure not level, belt climbs to high Align and level structure
side
Build-up of material on idlers Clean idlers; install effective belt cleaning and transfer point sealing
systems
One section of belt runs off to one Splice(s) not square Cut ends square and re-splice
side all along the conveyor
Belt edge worn or broken Repair belt edge; remove worn or out-of-square section and splice
in new section
Crooked or bowed belt If belt is new, it may correct itself when properly broken in.
Otherwise, replace with new belt or section
Conveyor belt runs to one side at Improper belt loading Change loading point and loading conditions so that load is centred
some distance along the conveyor properly
line
Belt has erratic action, following no Belt too stiff to train May be due to new belt, if so allow proper break-in time (It may
certain pattern shorten break-in time if belt is left loaded during downtime).
Use more troughable belt
Install self-aligning training idlers
Pulley lagging worn Replace worn lagging; use grooved lagging for wet conditions
Material accumulations on pulley face Clean up the fugitive material; install effective belt cleaning and
transfer point sealing systems
Build-up material on return idlers and/or Clean up the fugitive material; install effective belt cleaning and
Belt running off at tail pulley pulley transfer point sealing systems
Return rollers out of line Survey and align at right angle to frame
Counterweight too light Recalculate weight required and adjust counter-weight or screw-
take-up accordingly
Idlers frozen Clean and lubricate rollers. Install effective belt cleaning and
transfer point sealing systems to control fugitive material
Belt runs off on certain days Environmental conditions alter tracking Install windscreens and /or conveyor covers to reduce
exposure to elements. Install self-adjusting idlers
Belt Damage
Table 2
Problem Cause Cure
Excessive wear on bottom cover of Slippage between belt and drive pulley or Increase tension on belt take-up device
belt pulleys Lag drive pulleys, or renew worn-out lagging
Increase arc of contact on drive pulley with snub pulley or use
tandem drive
Sticking troughed idlers Clean and lubricate idlers to free rotation or replace
Install effective belt cleaning and transfer point sealing systems to
control fugitive material
Excessive troughed idler tilt Correct to not more than 20 from upright
Material grinding between pulley and belt Remove accumulated material. Install tail protection ploughs and
effective belt cleaning and transfer point sealing systems to control
fugitive material
Excessive impact of material on belt
Wear on top (carrying) side of belt Use correctly designed chutes and baffles, load fines first to
minimise impact level
Install impact cradles or impact idlers to absorb impact force
Excessive sag between idlers
Reduce idler spacing or install belt support rails/bars to maintain
sag-free belt line
Wear on top (carrying) side of belt Dirty, sticking, or misaligned return idlers Clean, repair, lubricate, and align return idlers. Install tail
protection ploughs and effective belt cleaning and transfer
point sealing systems to control fugitive material
Abrasive “pooling” action in loading area
Reduce chutes and feeder belts to feed load in same direction
Belt folding back on self
and at same speed as belt travel
Jamming of material in chute Install impact cradle, impact idlers, or troughed rails under
loading zone to maintain stable belt line
Accumulations of material
Use metal detector or magnetic remover
Star-shaped break or transverse Impact damage Use impact cradle below belt in loading zone to absorb
break in belt cover or carcass impact energy
Soft spots in cover or carcass,
ruptures, cracks, gouges, or general Material impingement between belt and Install tail protection plough to sweep material from return run
fabric decay pulley
of belt
Install decking or guards to prevent material falling onto return
run
Damage from exposure to abrasion,
chemicals, heat, mildew, oil, or Use belt designed for specific conditions
environmental conditions Avoid over-lubrication of idlers
Enclose belt line for protection from environmental conditions
Improper storage and handling of belt
Handle belt in accordance with manufacturer guidelines
Excessive wear on belt edges Improper loading, side loading
Control flow with feeders, chutes, and skirtboards
Belt stained on one side Feed should be in direction of belt travel in centre of conveyor
Insufficient belt stiffness Replace with heavier belt. Replace idlers with new ones with
maximum gap of 10mm
Transverse break in belt immediately Fastener plates too long for pulley size Change to smaller/shorter plates in mechanical splices or
behind mechanical splice increase pulley size
Fastener pull-out Improper fastener or improper installation
Review fastener selection and installation procedures
Excessive tension
Excessive tension
Separation at vulcanised splice Reduce belt tension. Consider “soft” or slower start up
Pulleys too small
Recalculate and adjust tension
Material between belt and pulleys
Use larger diameter pulleys