Maintenance: & Troubleshooting Guide
Maintenance: & Troubleshooting Guide
Maintenance
MAINTENANCE
& TROUBLESHOOTING GUIDE
CHAIN DRIVES
GEAR DRIVES
COUPLINGS
SYNCHRONOUS DRIVES
V-BELT DRIVES
SCREW CONVEYORS
DRAG CONVEYORS
BUCKET ELEVATORS
W W W. M A R T I N S P R O C K E T. C O M
Warning & Safety Reminder
Safety must be considered a basic factor in machinery operation at all times. Most
accidents are the results of carelessness or negligence. All rotating power transmission
products are potentially dangerous and must be guarded by the contractor, installer,
purchaser, owner, and user as required by applicable laws, regulations, standards, and good
safety practice. Additional specific information must be obtained from other sources including
the latest editions of American Society of Mechanical Engineers; Standard ANSI B15.1. A
copy of this standard may be obtained from the American Society of Mechanical Engineers
at 345 East 47th Street New York, NY 10017 (212705-7722).
It is the responsibility of the contractor, installer, purchaser, owner, and user to install,
maintain, and operate the parts or components manufactured and supplied by
Sprocket & Gear, Inc., in such a manner as to comply with the Williams-Steiger Occupational
Safety Act and with all state and local laws, ordinances, regulations, and the American
National Standard Institute Safety Code.
Caution
All OSHA Lock Out/Tag Out procedures are to be properly followed prior to removal
of any guards, access doors or covers for inspection or general maintenance. Failure
to follow these instructions may result in severe personal injury and/or property
damage.
Notice
• Chain Drives.................................................................................. 2 - 4
• Gear Drives.................................................................................. 5 - 6
• Couplings...................................................................................... 7 - 8
• Synchronous Drives..................................................................... 9 - 11
• V-Belt Drives.............................................................................. 12 - 14
• Screw Conveyor................................................................................ 15
• Drag Conveyor.................................................................................. 16
• Bucket Elevator................................................................................. 16
• Heavy-Duty Conveyor Pulleys / Belt Conveyors ........................ 17 - 24
1
Chain Drives
PROPER TENSIONING PROPER INSTALLATION & ALIGNMENT
SAG IN INCHES BASED ON 2% OF SPROCKET CENTERS
Sprocket centers
in inches 20 30 40 50 60 70 80 90 100 125
Sag in Inches 1/5 5/8 7/8 1 1-1/4 1-1/2 1-5/8 1-7/8 2 2-1/2
Incorrect Correct
Straight
Scale
Edge
Feeder Bar
If a straight edge is placed from the top of one sprocket to the top of Shafts Parallel
the other sprocket on a horizontal drive, the maximum sag should be
between 2-4% of the center distance. Parallel Shafts Sprocket Alignment
90º
A B
90º
Dial
Indicator Equal
Distance
Broken teeth Wear on side of sprocket teeth Asymmetrical tooth wear Wear on tips of sprocket tooth
Tight Joints
Broken Pins
Fatigue Failure Broken Link Plate
Turned Pins
5% of H
Battered Link Plate Edges Worn Link Plate Contours Pin Galling
6
Chain Couplings
Excessive Noise • Check chain and sprockets to make sure they are not worn, or have broken pin
links. Replace if necessary. Chain may be striking inside of cover.
Excessive Vibration • Loose or damaged chain or sprocket, unbalanced, misalignment. Visually
inspect coupling, replace chain, sprocket or both. Balance and realign if necessary.
Leaking Lubricant • Damaged chain cover, excessive speeds, incorrect lubricant consistency or
excessive lubricant. Visually or stroboscopic inspection, replace cover, correct
speed, or replace lubricant as necessary.
Excessive Temperature • Unbalance, misalignment, excessive loads or speeds, insufficient, improper
or excessive lubricant. Temperature can be checked using infrared temperature
device or thermographic scan.
Noise and Vibration • Visual inspection. Stop coupling, remove the chain cover and inspect the chain
for damaged links or rollers, worn or broken sprocket teeth and misalignment that
is evident by wear on one side of the chain or sprocket teeth. Inspect keys and
keyways for wear or fatigue. If the chain, sprockets, key and keyways are damaged
in any way, replace the coupling.
Excessive Temperature • Infrared temperature device or thermographic scan. Unbalance, misalignment,
excessive loads or speeds, insufficient, improper or excessive lubricant.
Quadra-Flex® Couplings
Troubleshooting Probable Cause / Corrective Action
Element Failure • Check for alignment. Can handle up to 1° angular and up to .062 parallel offset
misalignment.
• Check for proper installation. May be installed in an application not suited for the
coupling; i.e., an internal combustion engine, reciprocating pump, compressor, or fan
and propeller blades.
Teeth Worn on One or Both • Caused by excessive misalignment. Realign coupling.
Sides of Sleeve • Improper service factor. Check design, go to larger coupling.
Sleeve Ruptured • Caused by shock loads. Use a larger coupling.
• Critical speed. Check for excessive vibrations.
Wire Ring Comes Loose • Caused by overload. Use a larger coupling.
Excessive Compression Set • Caused by overload. Use a larger coupling.
or Permanent Wind-up
Crack in Sleeve at 45° • Caused by flex fatigue. Normal mode of failure, if premature, use a larger coupling.
Noise • Loose bolts, ripped or torn rubber, loose key or damaged shaft keyway,
misalignment, unbalanced. Visual inspection: repair replace or re-align.
Excessive Temperature • Unbalanced, misalignment, excessive loads or speeds, inappropriate guard.
Sleeve Thrown Out of • Caused by shock load. Free machine of material causing jam, check for
Coupling misalignment.
• Caused by overspeed. Reduce speed of coupling.
Element Deterioration • If elements are deteriorating due to heat or solvents check sleeve chemical
resistance from table in catalog.
• TPR (Thermo-Plastic Rubber) can operate in conditions of extreme temperatures
50°F to +250°F and in oily or wet conditions.
• Neoprene can operate in temperatures of 0°F to +250°F.
• Hytrel® can operate in temperatures of -65°F to +250°F and oily conditions. Hytrel®
will not withstand hot water.
8
Synchronous Drives - HTS Drives
Drive Alignment
Parallel Misalignment
These ranges of deflection forces are applicable for drive installation. Actual operation
tension depends on the number of teeth mesh, system rigidity, peak loads, etc.
Belt Pitch Belt Width Force* Belt Pitch Belt Width Force*
9mm 9 to 18 oz 40mm 10 to 13 lb
5mm 15mm 1 to 2 lb 14mm 55mm 15 to 18 lb
25mm 1½ to 3 lb 85mm 23 to 28 lb
20mm 3 to 4 lb 115mm 32 to 39 lb
30mm 5 to 6½ lb 170mm 48 to 57 lb
8mm
50mm 9 to 12 lb 115mm 45 to 55 lb
85mm 16 to 20 lb 170mm 70 to 85 lb
230mm 95 to 120 lb
20mm 290mm 120 to 150 lb
340mm 145 to 180 lb
*Force applies to speeds exceeding 600 RPM.
Note: When HP rating is adequate, using multiple belts in matched sets, rather than a single wide belt, will reduce sound emission.
Effective noise reduction for power transmission drives can be accomplished by incorporating a flexible noise-absorbing material
such as acoustical-grade glass fiber with the protective guard. The guard design must allow a cooling air passage on the top and
bottom to prevent overheating the drive.
9
Synchronous Drives - Timing Belt Drives
XL 1
⁄5" 6 8 11 14 17 23 29 35 41 53 64
L 3
⁄8" 15 19 23 31 39 47 55 71 86 101 118 150 185
Belt Pitch
H ½" 59 80 99 120 140 181 218 258 300 381 470 568 666 861 1050 1245 1445
XH 7
⁄8" 191 246 298 351 409 520 642 775 909 1175 1433 1698 1971 2235 2502 2752 3025 3278 3555
XXH 1¼" 234 302 365 431 501 636 786 950 1114 1439 1755 2080 2415 2738 3065 3372 3707 4015 4357
Width
.15 .21 .28 .35 .42 .57 .71 .86 1.0 1.29 1.56 1.84 2.14 2.72 3.36 4.06 4.76 6.15 7.50 8.89 10.32 11.70 13.10 14.41 15.84 17.16 18.62
Factor
11
V-Belt Drives
Sheaves should be checked for wear every time you change a belt!
Indications of sheave wear include:
• Belts are turning over.
• Belts wear out faster than normal.
.00
.00
DA
DA
º
º
38 ER 7.00
38 ER 7.00
-7
-7
TU
TU
34
34
M=
M=
0
0
4.6
4.6
º
º
OV
OV
M=
M=
• Belts are “bottoming” out.
TU
TU
DA
DA
E
B E
B • Belt dressing is used to quiet drive (not
DATUM=3.60 - 4.59
32º
DATUM=3.60 - 4.59
Worn Belt Sides Belt Swelling Cover Fabric Rupture Slip or Spin Burn Belt Cover Splits
13
V-Belt Drives
Type of Failure Probable Cause / Corrective Action
Belt Turnover • Misaligned sheaves. Realign sheaves.
• Belt under tensioned. Retension drive.
• Severe vibration and shock loads. Use Combo belts.
• Incorrectly placed flat pulley. Position idler on slack side of drive, as close
as possible to DriveR sheave.
• Worn sheave grooves (Use groove gauge to check). Replace sheaves.
• Foreign material in grooves. Shield drive with drive guard.
• Tensile cord broken from improper installation. Replace all belts with a
new set, check for proper installation.
Belt Noise • Belt slip. Retension.
• Misaligned sheaves. Realign sheaves.
• Wrong belt type. Replace cut edge with wrapped belt.
Belt Vibration • Shock loads. Use Banded or Combo belts.
• Incorrectly placed flat idler pulley. Position idler on slack side of drive, as
close as possible to DriveR sheave.
• Distance between shafts too long. Install idler.
• Belt lengths uneven. Replace all belts with a new matched set.
• Belt too loose. Retension drive.
Severe Slippage • Spin burns. Retension drive.
• Too few belts. Redesign drive.
• Arc of contact too small. Install back side idler on slack side, or use timing
belt.
• Oil or water on belt. Clean belts and sheave, shield drive with drive guard.
Installation Problems • Design and/or belt selection error. Check catalog for proper design and
Belts Too Long or Short at Installation selection.
Installation Problems • Worn sheave grooves. Replace sheaves.
Belts Mismatched at Installation • Mixed used and new belts. Replace all belts with new belts.
• Mixed belts from different manufacturers. Replace belts from the same
manufacturer.
Hot Bearings • Worn sheave grooves, belts bottom out. Replace sheaves.
Drive Over Tensioned
Hot Bearings • Design error. Redesign drive.
Sheave Diameter Too Small
Hot Bearings • Design error or obstruction. Place sheaves as close to bearing as
Sheaves Too Far Out on Shaft possible.
Hot Bearings • Bearing underdesigned. Check bearing design.
Poor Bearing Condition • Bearing not properly maintained. Align and lubricate bearing.
Hot Bearings • Drive under tensioned. Retension.
Belt Slippage
Damaged or Broken Sheave • Incorrect belt installation. Never pry belts onto sheaves.
• Excessive rim speeds. Maintain operational speeds within recommended
range.
• Sheave installed incorrectly. Follow recommended torque values when
tightening bushings.
• Foreign object interfering with drive operation. Use drive guards.
Severe Sheave Groove Wear • Wrong belt. Check to be sure sheave and belt combination is correct.
• Belt tension is excessive. Check drive design and retension.
• Sand, debris or contamination. Clean and shield drive.
14
Screw Conveyor
Type of Failure Probable Cause / Corrective Action
Premature Trough Failure • Trough Gauge (thickness) too light. Increase thickness. Consult
catalog materials table / component series for recommendation.
• Screw deflection. Eliminate excessive deflection. Consult catalog for
calculation procedure to determine proper pipe size and screw length.
• Bent screw. Straighten or replace. Check before operation.
Accelerated Flight Tip Wear • Gauge (thickness) too light. Increase thickness. Consider hardfacing or use
abrasion resistant materials.
• RPM too high. Slow conveyor down. Consult catalog engineering
section to determine proper trough loading.
Coupling Shaft Breakage • Torque capacity insufficient. Increase torque capacity or use larger shaft.
Check motor amp demand for torque requirements.
• Incorrect alignment. Realign trough assembly and hangers in accordance
with installation instructions.
• Excessive shaft wear. Replace coupling shaft.
Shaft Hole Elongation • Insufficient numbers of bolts. Increase number of bolts.
• Conveyor subject to “jogging” or too frequent stop/start, or frequent
overloads. Cease jogging or frequent stop/start or overload. If this is not
possible increase bearing capacity of shaft and/or increase number of bolts.
Drive Shaft Breakage • Insufficient torque capacity. Increase torque capacity.
• Obstruction in conveyor. Check screw alignment.
Motor / Heaters Overload • Amp demand excessive for motor. Recheck horsepower calculations.
Check material characteristics. Check capacity. Regulate feed.
• Upset loading conditions. Empty trough. Operate under design
specifications.
Inlet Trough End Bearing Failure • Material getting into bearing. Add or upgrade seal to keep material out of
bearing. Change to outboard bearing.
• Insufficient lubrication. Lubricate properly.
• Shaft slope. Align screw. Check for excessive screw deflection and for bent
screw.
Discharge Trough End Bearing • Material getting into bearing. Add or upgrade seal. Change to outboard
Failure bearing. Cut off flight at center of discharge.
Hanger Bearing Failure • Incorrect alignment. Realign trough assembly and hanger.
• Heat due to hot material being conveyed. Use appropriate bearing material.
• Heat due to insufficient lubrication. Properly lubricate.
• Thrust due to pipe pressing on bearing insert. Check coupling bolts
and holes for elongation and wear. Replace as necessary to get proper
clearances.
• Improper bearing material. For material being conveyed consult
catalog for proper bearing.
• Improper speed. For material being conveyed consult catalog for
proper speed.
• Improper trough loading. For material being conveyed consult
catalog for proper trough loading.
15
Drag Conveyor
Type of Failure Probable Cause / Corrective Action
Premature Trough Failure • Gauge too light. Increase thickness. Consult catalog materials table /
component series for recommendation.
• Worn Flights. Replace flights.
• Excessive chain speed. Check speed.
Accelerated Flight Wear • Excessive heat. Change flight material. UHMW limited to 175ºF.
• Speed too high. Slow drag down. Consult catalog engineering section to
determine proper speed.
Chain Breakage • Worn chain. Change chain if worn.
• Take-up loose. Adjust take-up.
Drive Shaft Breakage • Insufficient torque capacity. Increase torque capacity.
• Obstruction in conveyor. Check sprocket alignment.
Motor/Heaters Overload • Amp demand excessive for motor. Recheck horsepower calculations.
Check material characteristics. Check capacity. Assure regulated feed.
Inlet Trough End Bearing Failure • Material getting into bearing. Add or upgrade seal to keep material out of
bearing. Change to outboard bearing.
• Insufficient lubrication. Lubricate properly.
Discharge Trough End Bearing • Material getting into bearing. Add or upgrade seal to keep material out of
Failure bearing. Change to outboard bearing.
Bucket Elevator
Type of Failure Probable Cause / Corrective Action
Elevator Vibrates • Foreign matter in boot.
• Excessively tight chain/belt.
• Excessively loose chain/belt.
• Loose or broken buckets.
• Buckets hitting bib plate.
• Misaligned elevator head and boot shaft. Check alignment.
• Elevator is not adequately braced. Refer to installation instructions.
• Chain/belt hitting inside of casing when casing is not plumb.
Elevator Will Not Start • Obstruction in boot.
• Electrical problem.
• Backstop incorrectly installed.
• Broken V-Belts or drive chains.
• Reducer failure.
• Boot plugged with material.
• Excessively tight chain/belt.
Pillow Blocks Get Hot • Over lubrication. Lubricate properly.
• Under lubrication. Lubricate properly.
• Excessive chain/belt tension.
• Misalignment of head shaft pillow blocks. Check alignment.
• Misalignment between head and boot shaft. Check alignment.
Elevator Not Discharging Properly • Speed incorrect. Consult factory.
• Air cushion. Vent compartment being discharged into.
• Light fluffy materials. Reduce speed up to 15%.
• Certain materials may require perforated buckets*.
• Some materials may be affected by static electricity.*
* Consult with .
16
Heavy-Duty Conveyor Pulleys / Belt Conveyors
TROUGHING IDLER 1 HEAD/DRIVE
PULLEY
Rim Face
R End Disk
T IDLE
IMPAC
BLY
ASSEM
T BED
IMPAC PRIMARY
BELT CLEANER
2 SNUB
PULLEY
SECONDARY
BELT CLEANER
Hub &
Bushing DRUM PULLEY
3 TAKE-UP
6 RETURN
BEND PULLEY
5 TAIL
PULLEY IDLER 3 TAKE-UP
BEND Contact Bar Gusset
PULLEY
4 TAKE-UP
PULLEY Wing
1. Head Pulley. The pulley at the discharge end of a conveyor belt; may be either an
idler or a drive pulley. This is usually a drum pulley and it has a larger diameter than
other pulleys in the system and is often lagged to increase traction and pulley life.
2. Snub Pulley. This is usually a drum pulley and is mounted close to the drive pulley
on the return side of the belt, the snub pulleys primary job is to increase the angle of Hub
wrap around the drive pulley, thereby increasing traction. Its secondary purpose is
reducing belt tension, which is important in maximizing conveyor component life. May
be lagged for longer wear life. WING PULLEY
3. Take-Up Bend Pulley. The bend pulley is usually a drum pulley and is used for
changing the direction of the belt running to the gravity take-up. May be lagged for
longer wear life.
4. Take-Up Pulley. An adjustable idler pulley (usually a wing pulley) to accommodate
changes in the length of a conveyor belt to maintain proper tension.
5. Tail Pulley. A pulley at the tail of the belt conveyor opposite the normal discharge
end; it is usually a wing pulley and adjustable if manual take up is used.
6. Return Idler. The idler or roller on which the conveyor belt rides after the load which
it was carrying has been dumped.
18
Heavy-Duty Conveyor Pulleys / Belt Conveyors
Type of Failure Probable Cause / Corrective Action
Belt Breaks At Or Behind • Belt improperly spliced or wrong fasteners. Use fasteners recommended by the
Fasteners, Or Fasteners manufacturer. Retighten after running for a short while. If improperly spliced remove old
Tear Loose splice and resplice. Set up regular inspection schedule.
• Pulleys too small. Use a larger diameter pulley.
• Excessive tension. Recalculate and adjust tension. Use vulcanized splice with
recommended limits.
• Pulley lagging worn. Replace worn pulley lagging. Use grooved lagging for wet
conditions. Repair loose bolts protruding.
• Material falling between belt and pulley. Use skirtboards properly. Remove
accumulation.
• Drive underbelted. Recalculate maximum belt tensions and select correct belt. If line is
over-extended, consider using two flight system with transfer point. If carcass is not rigid
enough for load, install belt with proper flexibility when service is lost.
• Counterweight too heavy. Recalculate weight and adjust counterweight accordingly.
Reduce take-up tension to point of slippage; retighten slightly.
• Differential speed wrong on dual pulleys. Make necessary adjustment and observe
operation closely.
Excessive Belt Stretch • Tension too high. Increase speed, same tonnage, same speed; improve maintenance
to remove friction and replacement of damaged idlers; decrease tension by increasing
arc of contact or go to lagged pulley; reduce CWT to minimum amount. Use vulcanized
splice with recommended limits.
• System underbelted. Recalculate belt tensions and select proper belt. Recalculate
maximum belt tensions and select correct belt. If line is over-extended, consider using
two flight system with transfer point. If carcass is not rigid enough for load, install belt
with proper flexibility when service is lost.
• Build-up of material on idlers. Remove accumulation; improve maintenance. Install
scrapers or other cleaning devices.
• Counterweight too heavy. Lighten counterweight to value required by calculations.
• Differential speed wrong on dual pulleys. Make necessary adjustment and observe
operation closely.
• Insufficient counterweight travel. Check for recommended minimum distances.
• Damage by acids, chemicals, oils, or deterioration by abrasives, heat or mildew.
Use belt designed for specific condition. For abrasive materials working into cuts
and between plies, repair with cold pack or with permanent repair patch. Seal metal
fasteners or replace with vulcanized step splice. Enclose belt line for protection against
rain, snow, or sun.
Belt Breaks at or Behind • Fastener plates too long for pulley size. Replace with smaller fasteners; increase
Fasteners: Fasteners Pull pulley size.
Out • Wrong type of fastener, fasteners too tight or too loose. Use proper fastener and
splice technique; set up schedule for regular fastener inspection.
• Tension too high for fasteners. Use vulcanized splice.
• Pulleys too small. Use larger diameter pulleys.
• Interference from belt scrapers. Adjust belt scrapers.
• Belt carcass too light. Select stronger carcass.
Excessive Top Cover • Dirty, stuck, or misaligned return rolls. Remove accumulations; install cleaning
Wear, Uniform Around devices; use self-cleaning return rolls; improve maintenance and lubrication.
Belt • Cover quality too low. Replace with belt of heavier cover gauge or higher quality
rubber or other elastomer.
• Material spillage and build-up. 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.
19
Heavy-Duty Conveyor Pulleys / Belt Conveyors
Type of Failure Probable Cause / Corrective Action
Belt’s Top Cover and • Build-up on the snub pulley and return idlers often wears the top cover. Reduce
Belt Edges are Wearing the wear by installing rubber or plastic sleeves on the return idlers and smooth lagging
Excessively on the snub pulley.
• Improper load can also damage the top cover and belt edges.
• 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.
• Create a stable, positive seal between the chute’s bottom edge (or skirtboard) and
the belt by using impact rollers or slider beds below the belt, which shape the belt into a
trough. Use good-quality skirting along the belt conveyor to prevent spillage. Avoid using
old belt scraps to make the skirting because they can wear your conveyor belt.
Excessive Top Cover • Skirt boards improperly adjusted or of wrong material. Adjust skirt board supports
Wear, Grooving, Gouges, to minimum 1” between metal and belt with gap increasing in direction of belt travel; use
Rips, Ruptures, And skirt board rubber (not old belt).
Tears Or Stripping Of Top • Relative loading velocity too high or too low. Adjust chutes or belt speed. Consider
Cover use of impact idlers. Observe operation closely.
• Load jams in chute. Redesign chute for proper angle and width. Feed should be in
direction of belt travel and at belt speed, centered on the belt. Control flow with feeders,
chutes and skirtboards.
• 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, or impact bed.
• Sharp edges of material or tramp iron coming in contact with cover. Use jingle
bars; impact idlers; magnetic removal equipment.
• Damage by acids, chemicals, oils, or deterioration by abrasives, heat or mildew:
use belt designed for specific condition. For abrasive materials working into cuts
and between plies, repair with cold pack or with permanent repair patch. Seal metal
fasteners or replace with vulcanized step splice. Enclose belt line for protection against
rain, snow, or sun.
• Breaker strip missing or inadequate. When service is lost, install belt with proper
breaker strip.
• Sticking or frozen idlers. Free idlers and improve maintenance and lubrication.
Carcass Fatigue at Idler • Improper transition between troughed belt and terminal pulleys. Adjust transition.
• Severe convex (hump) vertical curve. Decrease idler spacing in curve, increase curve
radius.
• Excessive forward tilt of trough rolls. Reduce forward tilt of idlers to no more than 2°
from vertical.
• Excess gap between idlers rolls. Replace with heavier belt.
• Insufficient transverse stiffness. Replace with the proper belt.
• 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.
Fabric Decay, Carcass • Excessive impact of material on belt or fasteners. Use correctly designed chutes
Cracks, Gouges, and baffles. Make vulcanized splices. Install impact idlers. Where possible, load fines
Ruptures, Soft Spots first. Where material is trapped under skirts, adjust skirtboards to minimum clearance or
install cushioning idlers to hold belt against skirts.
• Material falling between belt and pulley. Use skirtboards properly. Remove
accumulation.
• Breaker strip missing or inadequate. When service is lost, install belt with proper
breaker strip.
• Drive underbelted. Recalculate maximum belt tensions and select correct belt. If the
line is over-extended, consider using two flight system with transfer point. If carcass is
not rigid enough for load, install belt with proper flexibility when service is lost.
• Damage by acids, oils, chemicals, or deterioration by heat, abrasives or mildew.
Use belt designed for specific condition. For abrasive materials working into cuts
and between plies, repair with cold pack or with permanent repair patch. Seal metal
fasteners or replace with vulcanized step splice. Enclose belt line for protection against
rain, snow, or sun. Do not over lubricate idlers.
20
Heavy-Duty Conveyor Pulleys / Belt Conveyors
Type of Failure Probable Cause /Corrective Action
Belt Cupping - Old Belt • Spilled oil or grease. Over-lubrication of idlers; improve housekeeping; reduce quantity
(Was OK When New) of grease used; check grease seals.
• Heat or chemical damage. Use belt designed for specific condition.
• Severe pulley crowning. Replace pulley.
• Poor belt construction. Replace belt.
• Belt too Elastic (excessive tension). Replace belt.
Transverse Breaks at Belt • Belt edges folding up on structure. Idlers or pulleys out-of square with center line of
Edge belt: readjust idlers in affected area. Conveyor frame or structure crooked: straighten in
affected area. Idler stands not centered on belt: readjust idlers in affected area. Install
limit switches; provide more clearance.
• Improper transition between troughed belt and terminal pulleys. Adjust transition in
accordance with belt manufacturers recommendations.
• Severe convex (hump) vertical curve. Decrease idler spacing in curve; increase curve
radius.
Excessive Edge Wear, • Off-center loading or poor loading. Adjust chute to place load on center of belt;
Broken Edges discharge material in direction of belt travel at or near belt speed. Control flow with
feeders, chutes and skirtboards.
• Belt strained (or elongated on one side). Allow enough time for new belt to “break in”.
If belt does not break in properly or is not new, remove strained section and splice in
new piece.
• 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.
• Damage by acids, chemicals, oils, or deterioration by abrasives, heat or mildew.
Use belt designed for specific condition. For abrasive materials working into cuts
and between plies, repair with cold pack or with permanent repair patch. Seal metal
fasteners or replace with vulcanized step splice. Enclose belt line for protection against
rain, snow, or sun. Do not over lubricate idlers.
• Material spillage and build-up. Improve loading and transfer conditions; install
cleaning devices; improve maintenance.
• Belt improperly spliced. Resplice using proper method as recommended by belt
manufacturer.
• Belt hitting structure. Install training idlers on carrying and return run.
Pulley / Drive Problems
Severe Pulley Cover Wear • Sticking idlers. Free idlers and improve maintenance and lubrication.
• Slippage on drive pulley. Increase tension through screw take-up or add
counterweight; lag drive pulley; increase arc of contact.
• Material spillage and build-up. 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°
from vertical.
Tracking Problem
Belt Runs To One Side • Idlers or pulley shaft out of square with center line of conveyor. Realign and install
Throughout The Entire limit switches for greater safety. Check conveyor manufacturer’s manual or guide.
Length At Specific Idler • Improperly placed idlers. Relocate idlers or insert additional idlers spaced to support
belt.
• Material build-up (on pulley and idlers). Remove accumulation and install cleaning
devices, scrapers, and inverted “V” decking.
Erratic Tracking - • Off-center loading. Adjust chute and loading conditions so as to place load in the
Belt Runs Off-Line At center of belt.
Intermittent Points • Idlers/pulleys misaligned.
• Insufficient pulley crowning.
• Material buildup.
• Belt is too stiff to train. Use self-aligning idlers. Increase tension/conforms to crowns.
Use more flexible belt on replacement.
• Tilt troughing idlers forward, but not over 2 degrees. Use more troughable belt.
21
Heavy-Duty Conveyor Pulleys / Belt Conveyors
Type of Failure Probable Cause / Corrective Action
Belt Runs Off at Tail • Counterweight too light. Recalculate weight required and adjust or add to
Pulley counterweight or screw takeup accordingly.
• 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 build-up. 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.
• Pulley lagging worn. Replace worn pulley lagging. Use grooved lagging for wet
conditions.
Belt Slips 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.
• Pulleys too small. Use larger diameter pulleys.
• Improper initial positioning of counterweight in its carriage causing apparent
excessive belt stretch. Check for recommended initial position.
• Insufficient counterweight travel. Check for recommended minimum distances.
Belt Mistracks at Head • Idlers/pulleys misaligned. Realign and install limit switches for greater safety. Check
Pulley conveyor manufacturer’s manual or guide.
• Pulley lagging worn. Replace worn pulley lagging. Use grooved lagging for wet
conditions. Repair loose bolts protruding.
• Material buildup (on pulleys and idlers). Remove accumulation and install cleaning
devices, scrapers, and inverted “V” decking.
• Improperly placed idlers. Relocate idlers or insert additional idlers spaced to support
belt.
• Off-center loading.
Belt Runs Off at All • Skirts incorrectly placed. Install skirtboards so that they do not rub against belt.
Points of the Line • Improper Loading. Feed should be in direction of belt travel and at belt speed, centered
on the belt. Control flow with feeders, chutes and skirtboards.
• Idlers or pulley shaft out of square with center line of conveyor. Realign and install
limit switches for greater safety. Check conveyor manufacturer’s manual or guide.
• Material build-up (on pulleys and idlers). Remove accumulation and install cleaning
devices, scrapers, and inverted “V” decking.
• Belt strained (or elongated on one side). Allow enough time for new belt to “break in”.
If belt does not break in properly or is not new, remove strained section and splice in
new piece.
• Improperly placed idlers. Relocate idlers or insert additional idlers spaced to support
belt.
Belt Mistracks at Tail • Insufficient belt tension.
Pulley • Idlers/pulley misaligned. Realign and install limit switches for greater safety. Check
conveyor manufacturer’s manual or guide.
Idlers seized. Free the idlers.
• Material build-up (on pulley and idlers). Remove accumulation and install cleaning
devices, scrapers, and inverted “V” decking.
• Insufficient pulley crowning.
• Counterweight too light: recalculate weight and adjust counter weight or screw take-up
accordingly.
• Improper Loading. Feed should be in direction of belt travel and at belt speed, centered
on the belt. Control flow with feeders, chutes and skirtboards.
22
Heavy-Duty Conveyor Pulleys / Belt Conveyors
Type of Failure Probable Cause / Corrective Action
One Section Runs Off • Pulleys not parallel, level, square.
Line at All Conveyor • Insufficient pulley crowning.
Points • Damage by chemicals, heat, mechanical components.
• Belt camber. Avoid telescoping belt rolls or storing them in damp locations. A new belt
should straighten out when “broken in” or complete system must be reinspected.
• Improper splice procedure/technique. Square ends/resplice. Use fasteners
recommended by the manufacturer. Retighten after running for a short while. If
improperly spliced, remove old splice and resplice. Set up regular inspection schedule.
• Side Loading. Load in direction of belt travel.
• Edge worn or Broken (permitting moisture penetration and belt shrinkage on one
side). Repair belt edge. Remove badly worn or out-of-square section and splice in new
piece of belt.
Belt Runs True When • Off-center loading or poor loading. Adjust chute to place load on center of belt;
Empty, Crooked When discharge material in direction of belt travel at or near belt speed.
Loaded • Variations in nature and formation of load. Use notched chute to keep load peak in
exact center of belt.
• Belt not making good contact with all idlers. Adjust height so all idlers contact belt.
Belt Runs to One Side at • Build-up of material on idlers. Remove accumulation; improve maintenance. Install
Given Point on Structure 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 or 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.
Belt Mistracks and Runs • Spillage and worn lagging can cause material to build-up between the head pulley
Off at the Head Pulley and belt. Prevent the spillage and buildup by installing a slider-bedskirt board system
at the loading point and a belt scraper at the head pulley. If your conveying conditions
are wet and sticky, use grooved lagging on the head pulley; the grooves repel water and
help prevent buildup on the belt. 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.
Belts Runs to One Side • Idlers or pulley shaft out of square with center line of conveyor. Realign and install
Throughout the Entire limit switches for greater safety. Check conveyor manufacturer’s manual or guide.
Length at Specific Idler • Improperly placed idlers. Relocate idlers or insert additional idlers spaced to support
belt.
• Material build-up (on pulley and idlers). Remove accumulation and install cleaning
devices, scrapers, and inverted “V” decking.
Belt Slips • Insufficient traction between belt and pulley. Lag drive pulley - in wet conditions use
grooved lagging. Increase belt wrap with snub pulleys; install belt cleaning devices and
centrifugal switch for safety.
• Pulley lagging worn. Replace pulley lagging. Ceramic lagging provides an excellent
solution when conventional rubber lagging fails to correct belt slippage and premature
wear.
• Counterweight too light. Add counterweight or increase screw take-up tension to value
determined from calculations.
• Material spillage and build-up. Improve loading and transfer conditions; install cleaning
devices; improve maintenance.
• Sticking or frozen idlers. Free idlers and improve maintenance and lubrication.
• Pulleys too small. Use larger diameter pulleys.
23
Heavy-Duty Conveyor Pulleys / Belt Conveyors
Type of Failure Probable Cause / Corrective Action
All Portions of Conveyor • One or more idlers immediately preceding trouble point not at right angles to the
Belt Running to One direction of belt travel. Advance, in the direction of belt travel, the end of the idler to
Side at a Given Point on which the belt has shifted. Square idlers.
Structure • Conveyor frame or structure crooked. Stretch string along edge to determine extent
and make correction.
• One or more idler stands not centered under belt. Center them. Same as above.
• Sticking idlers. Clean and lubricate.
• Belt runs off terminal pulley. Check terminal pulley assignment. Check alignments of
idlers approaching terminal pulley.
• Build-up of material on idlers. Clean them. Install cleaning device.
• Structure not level and belt tends to shift to low side. Level structure.
Particular Section of Belt • Belt not joined squarely. Remove affected splice and resplice.
Runs to One Side at All • Bowed belt. For new belt this condition should disappear during break-in; in rare
Points of Conveyor instances belt must be straightened or replaced; check storage and handling of belt rolls.
• Worn edge. “Press edge”.
Belt Runs to One Side for • Belt running off-center around the tail pulley and through the loading area. Install
Long Distance or Entire training idlers on the return run prior to tail pulley.
Length of Conveyor • Off-center loading or poor loading, the result of buildup in your chutes. Install
non-stick, wear-resistant (rubber for example) chute liners to center and evenly distribute
the load on the belt. Choose the liner material carefully to ensure it can resist wear
from contacting your conveyed material. Adjust chute to place load on center of belt;
discharge material in direction of belt travel at or near belt speed.
• Build-up 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 or structure crooked. Straighten in affected area.
• Idler stands not centered on belt. Readjust idlers in affected area.
24
Properties of Steel
The information shown below is offered as a general guide to physical properties of steel in common use. Lower tensile
properties are to be expected in large sections; the values of strength decrease as the size of the section increases.
These values are not guaranteed and must NOT be used in specifying the raw materials or as a basis for acceptance
or rejection of material. It must not be assumed that these properties will be obtained in all cases as they vary widely
with permissible variations in analysis, size of section, rolling conditions, grain size, and methods of heat treatment.
Dependable physical properties can only be obtained through carefully controlled analysis and heat treatment.
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