Conveyor Belt Troubleshooting

Common Causes of Belt Failure:

1. Seized or Worn Rollers/Idlers
2. Pulley and Drive Failures 
3. Belt Contamination - Oils, Chemicals, or other foreign materials.
4. Inadequate Belt Tension - Slippage, stretching, mistracking.

Daily Conveyor Belt System Maintenance Checklist 
[ ] Inspect belt tracking and realign if drifting due to aggregate buildup.
[ ] Check belt tension; adjust to prevent slippage on incline under load.
[ ] Examine belt surface for wear, cuts, or gouging from sharp aggregate.
[ ] Clean dust and debris from pulleys, idlers, and return rollers.
[ ] Inspect drive pulley lagging for wear or contamination.
[ ] Check idlers and rollers for free rotation; replace if seized or noisy.
[ ] Ensure belt cleaners/scrapers are in contact and not worn out.
[ ] Verify that chute and loading points are centered and not overloading one side.
[ ] Inspect structure for material spillage and clear as needed.
[ ] Lubricate bearings and moving parts per OEM guidelines (use high-temp grease if required).
[ ] Check motor temperature and listen for abnormal noises.
[ ] Ensure all guards, covers, and emergency stop mechanisms are intact and functional.
[ ] Document findings and any corrective actions taken.

Tracking/Training Belt Procedures

Training or tracking the belt on your radial stacker or conveyor system is a process of adjusting idlers, pulleys and loading conditions in a manner which will correct any tendency of the belt to run other than centrally. The basic rule which must be kept in mind when tracking a conveyor belt is simple, "THE BELT MOVES TOWARD THAT END OF THE ROLL/IDLER IT CONTACTS FIRST."

Conveyor Belt Tracking Guide

1. Understand Belt Tracking Basics
      • Tracking means aligning the belt to run straight on the conveyor.
      • Most belts naturally want to move toward the tighter side of the system.

2. Common Causes of Belt Misalignment
      • Uneven or improper tension
      • Worn or misaligned rollers/pulleys
      • Build-up of material on rollers or belt
      • Poor belt splicing
      • Uneven load distribution

3. Step-by-Step Belt Tracking Procedure

Step 1: Inspect the System

      • Check for material buildup on pulleys or rollers.
      • Inspect belt condition (no tears, frays, or stiff edges).
      • Ensure all pulleys and rollers are square and level.

Step 2: Tension the Belt Properly

      • Set even tension across both sides.
      • Over-tensioning can cause stretching; under-tensioning can cause slippage and misalignment.

Step 3: Adjust the Tail Pulley First

      • To move the belt left, tighten the right side of the tail pulley.
      • To move the belt right, tighten the left side of the tail pulley.
      • Make small adjustments (1/4 turn at a time).

Step 4: Observe and Adjust Drive Pulley (if needed)

      • Typically used as a fine adjustment if tail pulley doesn't solve tracking.
      • Same principle applies: the belt moves toward the tighter side.

Step 5: Use Return Rollers for Fine-Tuning

      • Adjust return idlers (especially training idlers) to help guide the belt back to center.
      • Self-aligning idlers can help automatically correct tracking.

5. Preventive Measures
      • Keep the belt and pulleys clean.
      • Schedule regular inspections.
      • Use crowned pulleys or tracking guides (v-guides) if belt misalignment is persistent.

 

Common Mistakes to Avoid
      • Making large adjustments too quickly.
      • Adjusting too many points at once.
      • Ignoring roller/pulley alignment.
      • Failing to lock components back into place.