The Ultimate Troubleshooting Guide: 5 Common Conveyor Belt Problems & Fixes
2026-01-10 13:45The Ultimate Troubleshooting Guide: 5 Common Conveyor Belt Problems and How to Fix Them
There is nothing worse for a maintenance manager than the radio crackling to life with reports of a conveyor stoppage. In the harsh environment of mining and heavy industry, belts take a beating. But typically, a belt rarely fails "suddenly"—it gives warning signs.
As manufacturers with decades of field experience, we have compiled this guide to help you identify the 5 most common conveyor belt problems, understand why they happen, and how to fix them before they become disasters.
1. Mistracking (The Silent Killer)
Symptoms: The belt drifts to one side, rubbing against the structure, causing frayed edges and material spillage.
Root Cause Analysis:
Idler Misalignment: If rollers aren't square to the frame, they steer the belt.
Off-Center Loading: If the chute drops material on the left side, the belt will track to the right.
The Fix:
Immediate: Clean any material buildup on rollers. Permanent: Install Self-Aligning Idlers and ensure the loading chute places material dead-center.
2. Drive Pulley Slippage
Symptoms: The motor is running, the drive pulley is turning, but the belt is moving slowly or stalling. You might smell burning rubber.
The Fix:
Check your counterweight tension. If tension is correct, your pulley lagging might be worn smooth. Consider upgrading to Ceramic Lagging, which offers 100% positive traction even in wet or muddy conditions.
3. Material Spillage (Fugitive Material)
Symptoms: Piles of material under the loading zone or along the conveyor path. This creates safety hazards and wastes product.
The Fix:
Often caused by poor loading impact causing the belt to bounce. Install an Impact Bed with slider bars to flatten the belt in the loading zone, and upgrade to a soft, dual-seal skirt rubber system.
4. Ply Separation (Delamination)
Symptoms: The belt looks like it is opening up; the top cover peels away from the fabric, or the fabric layers separate.
Root Cause Analysis:
Usually, the pulley diameter is too small for the belt thickness, creating immense shear stress. Alternatively, oil or chemical contamination is attacking the rubber bond. Ensure your belt spec matches your system design.
5. Excessive Surface Wear (Gouging)
Symptoms: Cuts, tears, and missing chunks of rubber on the top cover. Carcass is visible.
The Fix:
Immediate: Use cold-vulcanized repair strips or mechanical fasteners to patch the hole. Permanent: If this happens frequently, you are likely using the wrong grade. Upgrade to a DIN-X or DIN-W abrasion-resistant belt.
🛠️ Weekly Maintenance Checklist
Prevent 90% of failures by checking these 3 points every week:
Walk the line: Listen for squeaking rollers (indicates bearing failure).
Check the cleaner: Is the scraper blade making good contact? Overtightened cleaners strip rubber.
Inspect the splice: Look for any signs of lifting or cracking in the splice area.
Is your belt beyond repair?
Routine maintenance saves money, but operating a damaged belt is a safety risk. If you need a replacement fast, we stock standard widths.
Check Stock Availability Now