1. Conveyor runs to one side at given point on structure
  1. Idlers or pulleys out-of–square with centre line of belt;  readjust idlers in affected area.
  2. Conveyer frame of structure crooked; straighten in affected area.
  3. Idler stands not centred on belt: readjust idlers in affected area.
  4. Sticking idlers: free idlers and improve maintenance and lubrication.
  5. Build up of material on idlers: remove accumulation; improve maintenance, install scrapers or other cleaning devices.
  6. Structure not level: level in affected area.
2. Particular section of belt runs to one side at all points on conveyor.
  1. Belt not joined squarely: remove affected splice and resplice.
  2. 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.
3. Belt runs to one side for long distance or entire length of conveyor.
  1. Belt running off-centre around the tail pulley and through the loading area: install training idlers on the return prior to tail pulley.
  2. Off centre loading or poor loading: adjust chute to place load on centre of belt; discharge material in direction of belt travel at or near belt speed.
  3. Build up of material on idlers: remove accumulation; improve maintenance, install scrapers or other cleaning devices.
  4. Idlers or pulleys out-of–square with centre line of belt;  readjust idlers in affected area.
  5. Idler stands not centred on belt: readjust idlers in affected area.
4. Belt runs off at tail pulley.
  1. Idlers or pulleys out-of–square with centre line of belt;  readjust idlers in affected area.
  2. Material spillage and buildup: improve loading and transfer condition; install cleaning devices, improve maintenance.
  3. Belt running off-centre around the tail pulley and through the loading area: install training idlers on the return prior to tail pulley.
5. Belt runs off at head pulley
  1. Idlers or pulleys out-of–square with centre line of belt;  readjust idlers in affected area.
  2. Idler stands not centred on belt: readjust idlers in affected area.
  3. Material spillage and buildup: improve loading and transfer condition; install cleaning devices, improve maintenance.
  4. Pulleys lagging worn: replace pulley lagging.
6. Belt slip
  1. Pulleys lagging worn: replace pulley lagging.
  2. Insufficient traction between belt and pulley: lag drive pulley; increase belt wrap; install belt cleaning devices.
  3. Counterweight too light: add counterweight or increase screw take-up tension to value determined from calculations.
  4. Material spillage and buildup: improve loading and transfer condition; install cleaning devices, improve maintenance.
7. Belt slip on starting
  1. Counterweight too light: add counterweight or increase screw take-up tension to value determined from calculations.
  2. Pulleys lagging worn: replace pulley lagging.
  3. Insufficient traction between belt and pulley: lag drive pulley; increase belt wrap; install belt cleaning devices
8. Excessive belt stretch
  1. Improper belt intallation 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
  2. Improper initial positioning of counterweight in its carriage cause apparent excessive belt stretch.
  3. Insufficient counterweight travel.
  4. Tension too high: increase speed; same tonnage; 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.
  5. Counterweight too heavy: lighten counterweight to value required by calculations.
  6. System under belted: recalculate belt tensions and select proper belt.
9. Grooving, gouging or stripping of top cover.
  1. Skirt-board improperly adjusted or wrong material; adjust skirt-board supports to minimum 25mm between metal and belt with gap increasing in direction of belt travel; use skirt-board rubber (not old belt)
  2. Belt spanking down under load impact: install cushion idlers
  3. Material hanging up in or under chute: improve loading to reduce spillage; install baffles; widen chute.
  4. Impact of material on belt: reduce impact by improving chute design; install impact idlers.
10. Excessive top cover wear, uniform around belt.
  1. Dirty, stuck, or misaligned return rolls: remove accumulations; install cleaning devises; use self-cleaning return rolls; improve maintenance and lubrication.
  2. Cover quality too low: replace with belt of heavier cover gauge or higher quality rubber.
  3. Material spillage and buildup: improve loading and transfer condition; install cleaning devices, improve maintenance.
  4. Off centre loading or poor loading: adjust chute to place load on centre of belt; discharge material in direction of belt travel at or near belt speed.
  5. 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.
11. Severe, pulley cover wear.
  1. Sticking idlers: free idlers and improve maintenance and lubrication.
  2. Slippage on drive pulley; increase tension through screw takeup or add counterweight; lag drive pulley; increase arc of contact.
  3. Material spillage and buildup: improve loading and transfer condition; install cleaning devices, improve maintenance.
  4. Bolt heads protruding above lagging; tighten bolts; replace lagging; use vulcanized-on lagging.
  5. Material trapped between belt and pulley; install plows or scrapers on return run ahead of tail pulley.
  6. Excessive forward tilt of trough rolls: reduce forward tilt of idlers to no more than 2 from vertical.
12. Longitudinal grooving or cracking of bottom cover.
  1. Sticking idlers: free idlers and improve maintenance and lubrication.
  2. Material spillage and buildup: improve loading and transfer condition; install cleaning devices, improve maintenance.
  3. Slippage on drive pulley; increase tension through screw takeup or add counterweight; lag drive pulley; increase arc of contact.
  4. Pulleys lagging worn: replace pulley lagging.
13. Covers harden or crack
  1. Heat or chemical damage: use belt designed for specific condition.
  2. Improper storage or handling.
14. Cover swells in spots or streaks.
  1. Spilled oil or grease; over –lubrication of idlers: improve housekeeping; reduce quantity of grease used; check grease seals.
15. Belt breaks at or behind fasteners; fasteners pull out.
  1. Wrong type of fastener, fasteners too tight or too loose: use proper fasteners and splice technique; set up schedule for regular fastener inspection.
  2. Heat or chemical damage: use belt designed for specific condition.
  3. Fastener plates too long for pulley size: replace with smaller fasteners; increase pulley size.
16. Vulcanized splice separation
  1. Belt improperly spliced: resplice using proper method.
  2. Material spillage and buildup: improve loading and transfer condition; install cleaning devices, improve maintenance.
  3. Belt hitting structure; install training idlers on carrying and return run.
  4. 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.
17. Excessive edge wear, broken edges.
  1. Off centre loading or poor loading: adjust chute to place load on centre of belt; discharge material in direction of belt travel at or near belt speed.
  2. Material spillage and buildup: improve loading and transfer condition; install cleaning devices, improve maintenance.
  3. Belt hitting structure; install training idlers on carrying and return run.
  4. 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.
18. Transverse breaks at belt edge.
  1. Belt edges folding up on structure; same corrections as for 1, 2, 3; install limit switches; provide more clearance.
  2. Improper transition between troughed belt and terminal pulleys: adjust transition.
  3. Severe convex (hump) vertical curve: decrease idler spacing in curve; increase curve radius.
19. Short breaks in carcass parallel to belt edge, star breaks in carcass.
  1. Impact of material on belt: reduce impact by improving chute design; install impact idlers.
  2. Material trapped between belt and pulley; install plows or scrapers on return run ahead of tail pulley.
20. Ply separation.
  1. Insufficient transverse stiffness; replace with the proper belt.
  2. Pulleys too small: use larger diameter pulleys.
  3. Heat or chemical damage: use belt designed for specific condition.
21. Carcass fatigue at idler junction.
  1. Improper transition between troughed belt and terminal pulleys: adjust transition.
  2. Severe convex (hump) vertical curve: decrease idler spacing in curve; increase curve radius.
  3. Excessive forward tilt of trough rolls: reduce forward tilt of idlers to no more than 2 from vertical.
  4. Excess gap between idler rolls: replace with the heavier belt.
  5. Insufficient transverse stiffness; replace with the proper belt.
22. Cover blisters or sand blisters
  1. Spilled oil or grease; over –lubrication of idlers: improve housekeeping; reduce quantity of grease used; check grease seals.
  2. Cover cuts or very small cover punctures allow fines to work under cover and cut cover away from carcass: make spot repair with vulcanizer or selfcuring repair material.