Conveyor Belt Troubleshooting Guide
Conveyor systems are complex machines with multiple moving parts, there are numerous conveyor belt issues that can derail your entire production process, which in turn will negatively impact your efficiency and profitability. This conveyor belt troubleshooting guide has been created by our experts to help you resolve some of the most common causes of conveyor belt issues and failures. While we understand that the ultimate goal is to get your conveyor belt running as quickly as possible, please remember to keep safety top of mind and exercise caution whenever troubleshooting conveyor belts. Conveyor belt systems can be extremely dangerous, always make sure to watch your hand placement and be aware of your surrounding environment.
| Problem | Causes | Solutions |
| Material buildup | Belt transports sticky material | 1. Install a belt cleaner at the head pulley |
| 2. Establish a new belt compound material for release; impression top | ||
| Belt slip | 1. Insufficient traction between belt and pulley | 1. Increase belt wrap with snub roller |
| 2. Pulley lagging worn | 2. Lag the drive pulley | |
| 3. Replace the pulley lagging | ||
| Belt runs to one side over long distance | 1. Off-center loading from material buildup in chutes | 1. Install a chute lining for wear resistance |
| 2. Idlers or pulleys are not square with center line of the belt | 2. Readjust idlers in the area affected | |
| 3. Make sure Pulleys are crowned | ||
| Belt breaks at or behind fasteners; fasteners pull out | 1. Fastener plates/legs too long for pulley size | 1. Replace with smaller fasteners; increase pulley size |
| 2. Wrong type of fastener; fasteners too tight or too loose | 2. Use proper fasteners and splice technique; set up schedule for fastener inspection | |
| Belt splices separating / Finger popping up | 1. Too much tension on take-up | 1. Reduce tension on belt. Belts should run at lowest tension possible without slippage |
| 2. Material build up on pulley’s | 2. Remove material build up from pulleys and v-guide grooves | |
| 3. Incorrect splice procedure | 3. Install plow on pulley side of belt | |
| Severe pulley cover (back of belt) wear | 1. Sticking idlers | 1. Free idlers; improve maintenance and lubrication |
| 2. Slippage on the drive pulley | 2. Increase tension through screw take-up or add counterweight | |
| 3. Material spillage and buildup | 3. Improve loading and transfer conditions; install cleaning devices; improve maintenance | |
| 4. Add lagging to drive pulley | ||
| Cleat Failure | 1. In most cases a foreign object is coming into contact with the cleats that are failing | 1. Inspect system for any obstructions that are coming into contact with cleats |
| 2. Product is too heavy for current cleats | 2. Add gussets or fabric reinforcement to cleats | |
| 3. Jams in loading area causing cleats to “dig” material out | 3. More uniform loading of material on belt | |
| V-Guide Failure | 1. Pulley’s are too small | 1. Switch to a notched / Modified V-Guide profile |
| 2. Belt is off tracking continuously | 2. Track belt to run straight | |
| 3. Buildup in V-Guide groove | 3. Improve maintenance and clean all V-Guide grooves | |
| Top cover wear | 1. Abrasive materials being conveyed | 1. Consult Accurate for best abrasive resistant material for your application |
| 2. Exposure to heat or oil | 2. Use belt material rated for heat / oil | |
| 3. Accumulation of material on top side of belt | 3. Try using friction top belt or add stop/start eye sensors | |
| Excessive belt stretch | 1. Over loading belt | 1. Switch to a belt material with a strength rating that will work for the loads on the belt |
| 2. Too much tension on take-ups | 2. Less tension on take-ups | |
| 3. Excessive heat on belt | 3. Add additional heat protection to belt | |
| Cover blisters or sand blisters | Spilled oil or grease, over lubrication of idlers | Improve housekeeping; reduce quantity of grease used; check grease seals |
| Ply separation | 1. Insufficient transverse stiffness | 1. Replace with the proper belt |
| 2. Pulleys are too small | 2. User larger-diameter pulleys | |
| 3. Heat or chemical damage | 3. Use correct belt designed for specific conditions |