Common Conveyor Problems and Fixes

This section provides quick troubleshooting tips for the most common issues that arise with conveyor systems. Each problem is broken down into symptoms, causes, and step-by-step solutions so you can resolve issues quickly and keep your system running smoothly.

Problem #1: Chain or Wearstrip Contamination

Symptoms:

• High friction or resistance while the conveyor is running.
• Unusual noise or overheating.
• Chain derailment or jamming.

Common Causes:

• Dust, dirt, or debris lodged in the chain or wearstrip.
• Contamination from nearby construction, product spills, or environmental debris.

Solution:

1. Stop the Conveyor: Ensure the system is locked out and powered down.
2. Inspect the Chain and Wearstrips: Look for visible signs of contamination like dust, metal chips, or product residue.
3. Clean the Conveyor:
• Wipe down the chain and wearstrips with a cloth moistened with rubbing alcohol or a mild detergent.
• For severe contamination, remove the chain and clean thoroughly.
• Clean both the top and bottom sides of the wearstrips to remove abrasive particles.

1. Prevent Future Contamination:
• Cover the conveyor if operating near construction or heavy dust-producing activities.
• Regularly clean and inspect the conveyor to avoid contamination buildup.

Problem #2: Foreign Object Interference

Symptoms:

• Conveyor chain derails or jams unexpectedly.
• Unusual scraping or grinding sounds during operation.
• Motor strain or sudden shutdowns.

Common Causes:

• Tools, bolts, or debris stuck between conveyor components.
• Foreign objects interfering with the chain’s movement, especially near loading and unloading points.

Solution:

1. Stop the Conveyor: Use the emergency stop button and ensure the system is locked out.
2. Inspect for Interference:
• Check for any foreign objects on or near the chain.
• Pay particular attention to guide rails, brackets, and transfer points.
3. Remove Foreign Objects: Clear away any debris, loose parts, or tools that might be obstructing the chain.
4. Adjust Components: Make sure transfer plates, fingers, and other components are correctly positioned and not interfering with the chain.
5. Preventive Action: Keep the conveyor area clean, remove foreign objects immediately after maintenance, and adjust nearby machinery to avoid contact with the chain.

Problem #3: Misaligned Sprockets

Symptoms:

• Uneven chain wear.
• Chain “jumping” off the sprockets.
• Chain misalignment or pulling to one side.

Common Causes:

• Sprockets not properly aligned across the shaft.
• Worn or damaged sprockets that are not engaging properly with the chain links.

Solution:

1. Stop and Lock Out the Conveyor: Before adjusting sprockets, ensure the system is powered off.
2. Inspect Sprockets for Misalignment:
• Use an alignment tool to check if sprocket teeth are engaging the chain evenly across the width.
3. Realign the Sprockets:
• Loosen the sprocket mounting bolts and adjust the sprockets until they are aligned.
• Ensure that sprocket teeth are engaging properly with the chain links, especially right behind a connecting rod.
4. Tighten and Test:
• Once realigned, tighten the bolts and manually rotate the chain to test engagement.
5. Preventive Action: Regularly check sprocket alignment during routine maintenance to avoid chain damage or failure.

Problem #4: Improper Chain Slack

Symptoms:

• Chain is too tight or too loose.
• Excessive motor strain, especially during start-up.
• Chain skips or jumps teeth on the sprockets.

Common Causes:

• Incorrect chain tension leading to too much or too little slack.
• Normal wear and elongation of chain links over time.

Solution:

1. Measure the Slack:
• After stopping the conveyor, try to compress the chain at three consecutive rows of links.
• If you cannot compress three rows, the chain is too tight. If you can compress more than three rows, the chain is too loose.
2. Adjust Slack:
• If the chain is too tight, add additional rows of links.
• If the chain is too loose, remove some chain links to reduce slack.
3. Recheck and Test:
• After adjusting, recheck the slack by manually rotating the chain. Ensure the chain engages properly with the sprockets.
4. Prevent Future Issues: Regularly check and adjust chain slack during maintenance to avoid excessive wear on the motor and sprockets.

Problem #5: Worn or Damaged Wearstrips

Symptoms:

• Increased friction, causing the motor to work harder.
• Chain derailment or binding.
• Unusual scraping noises during operation.

Common Causes:

• Wearstrips are worn, improperly installed, or overlapping.
• Overheating or expansion causing the wearstrip to warp.

Solution:

1. Stop and Inspect the Conveyor:
• Check the wearstrips for signs of damage, such as cracks, wear, or warping.
• Look for overlapping wearstrips, which can cause chain derailment.
2. Replace Worn Wearstrips:
• If wearstrips are damaged, remove and replace them with new ones.
• Ensure they are installed properly, with a consistent gap size based on the operating temperature.
3. Check for Overlap:
• Ensure wearstrips are properly cut and aligned. The ends should meet without overlap to prevent chain interference.
4. Lubricate the Wearstrips:
• After replacement, ensure the wearstrips are properly lubricated to reduce friction and extend their life.
5. Monitor for Overheating:
• If wearstrips overheat, check for excess load on the conveyor and reduce the operational speed if necessary.

Other Common Conveyor Issues

Chain Elongation

• Symptom: Chain appears stretched, with excessive slack.
• Solution: Measure the chain’s elongation percentage. Replace the chain if the elongation exceeds 4% for MonoSpan and MultiSpan, or 2% for MaxiSpan.

Chemical Contamination

• Symptom: Conveyor parts become brittle, crack, or show signs of chemical degradation.
• Solution: Identify and eliminate exposure to harmful chemicals. Refer to the Chemical Compatibility Chart for more information.

Broken Chain Links/Rods

• Symptom: Chain fails during operation, causing stoppage.
• Solution: Replace broken chain links and rods immediately. Inspect surrounding links for fatigue and replace as needed.

Need Help?

If you’re unable to resolve the issue or require replacement parts, contact our customer support team for assistance. We’re here to help you keep your system running smoothly!