Conveyor System Maintenance Procedures Page 4

Maintenance

Trouble Shooting Guide

The purpose of this section is to provide a means of identifying the most probable causes of problems within a conveyor system.

Problem

Probable Cause

Recommended Action

1.

Motor will not run

a)

Overload or breaker

i)

Inspect conveyor/for

tripped, or blown fuse

obstruction/jams.

ii)

Inpect for shorts in control wiring due to damaged conduit, etc.

iii)

Reset tripped device or replace blown fuse.

b)

Preset not on

i)

Turn on Preset.

c)

Low voltage

i)

Check voltage in MCP.

ii)

Check items in 1.a above.

2.

Motor runs but conveyor does not run

a)

Drive key

i)

Check for proper installation of drive keys in motor sprocket, pulley sprocket and drive pulley. If key is missing replace.

b)

Belt tension

i)

Check belt tension. If to loose, pulley turns but belt does not move. Adjust belt take-up.

c)

Broken chain or worn sprockets

i)

Check drive chain and sprockets. Replace broken chain. If sprockets are worn replace. Consult factory if sprocket wear occured over short period of time.

d)

James

i)

Check conveyor for jam conditions. If drive belt is jammed pulley could be slipping on belt. Note: Check conveyor for damage caused by jam prior to restarting. Look for shaft misalignments, damaged chain or belts, etc.

3.

Motor hums but will not run

a)

James

i)

Check conveyor for jam conditions.

b)

Gearbox failure

i)

Remove chain between gearbox and pulley and check for proper operation of gearmotor. Proceed to item 3.c to check motor, if motor works replace gearbox.

c)

Damage to motor wiring

i)

Remove motor from reducer anc check motor for proper operation. If motor does not operate properly replace motor.

d)

Brake failure (Brake Motors Only)

i)

Remove brake from back of motor and check motor for proper operation. If motor operated properly replace brake.

e)

Clutch Brake Failure

i)

Remove clutch brake from between motor and gearbox, and check motor for properly replaced brake module.

4.

Motor runs but starts slow, runs slow and/or over heats.

a)

Overload condition

i)

Check to see that conveyor loading is within specified parameters.

b)

Jams/binding of components

i)

Check for binding in bearings, misalignment of belts or construction of belts, chain, etc. by foreign materials replace bad bearings, retrack belts and remove foreign material.

c)

Low Line Voltage

i)

Check voltage to motor, MCP panel and power supply panel. Correct as required.

d)

Inadequate reducer lubrication

i)

Inspect gear case for proper level and grade of lubricant.

e)

Dust/dirt in motor

i)

Inspect for dust/dirt in motor housing and ventilation hole. Disassemble housing to clean if necessary. Remove dust/dirt by blowing or vacuuming.

5.

Excessive gear noise or vibration

a)

Inadequate reducer lubrication

i)

Inspect gear case for proper level and grade of lubricant.

b)

Worn or damaged reducer gears

i)

Drain, remove and disassemble unit to confirm. If repairs are required install replacement unit.

c)

Faulty motor or reducer bearing

i)

Listen and feel to locate sluggish bearing, lubricate or replace bearings as appropriate.

d)

Loose mounting

i)

Check gearmotor mounting bolts for proper tightness.

6.

Oil leakage from gearcase

a)

Loose drain plug

i)

Tighten drain plug. Replace plug if threads are damaged.

b)

Worn or damaged bearing seals

i)

Disassemble gear case to replace seal.

c)

Cracked reducer housing

i)

Drain and remove gearmotor or gearcase. Install replacement unit.

d)

Over filling

i)

Drain gearcase to proper fill level.

7.

Abnormal wear to chain and sprockets

a)

Excessive chain tension

i)

Loosen drive mounting bolts and reposition drive sprocket shaft. Align sprockets and tighten down drive. Alternatively, add links to drive roller chain.

b)

Sprockets misaligned

i)

Loosen sprockets on shafts and realign with straight edge across sprocket faces.

c)

Inadequate chain lubrication

i)

Lubricate chain by brushing on approved oil. Wipe away excess.

d)

Dirty chain

i)

Remove chain. Clean thoroughly in solvent. Replace worn links. Remount chain and lubricate by brushing on approved lubricant.

8.

Excessive noise from chain and sprockets

a)

Insufficient chain tension

i)

Loosen drive mounting bolts and reposition drive sprocket shaft. Align sprockets and tighten down drive. Alternatively remove links from chain.

b)

Inadequate chain lubrication

i)

Lubricate chain by brushing on approved oil. Wipe away exess.

c)

Sprockets misaligned

i)

Loosen sprocket and realign with straight edge across sprocket faces.

d)

Chain guard misalignment or obstruction

i)

Look for obstruction to running chain. Remove or adjust as appropriate.

9.

Pulsating chain

a)

Insufficient chain tension

i)

Loosen drive mounting bolts and reposition drive sprocket shaft. Align sprocket and tighten down drive. Alternately remove links from chain.

b)

Overload

i)

Inspect for obstruction to or drag on conveyor.

10.

Brocken chain

a)

Frozen pulley shaft

i)

Inspect for damaged bearings. Replace as required. Check shaft for straightness. Replace chain links as required.

b)

Worn or damaged chain

i)

Replace entire chain. Determine cause of wear (inadequate lubrication, misalignment, etc.) to correct.

11.

Sprocket loose on shaft

a)

Loose set screws

i)

Realign sprockets with straightedge and tighten set screw.

b)

Worn or damaged key

i)

Replace key. Inspect for damage to key seat on shaft and sprocket hub.

12.

Excessive chain slack

a)

Normal wear

i)

Expect rapid chain growth in first two weeks of operation. Loosen drive mounting bolts and reposition sprocket shaft. Align sprockets and tighten down drive.

b)

Abnormal wear after break-in period

i)

Realign sprockets adjust roller chain tension. Badly worn sprockets or chain should be replaced.

13.

Excessive chain stretch

a)

Too much chain tension (screw take-up)

i)

Adjust screw take-up device to decrease chain tension.

14.

Clutch or brake not releasing

a)

Armature sticking

i)

Check air gap between the armature and brake or clutch. If the air gap has closed up, allowing contact when de-energized, the armature should be forced away from the clutch or brake by applying pressure through the ventilation holes until the armature contacts the snap ring in the center of the armature hub. When the unit is next energized, the armature should reset itself automatically. In some cases it may be necessary to apply a small amount of pressure behind the armature to provide the proper adjustment.

15.

Clutch loss torque

a)

Contaminated or worn friction faces

i)

Disassemble clutch brake and check friction faces for wear produces grooves on the friction faces but this is normal and they should not be replaced unless they are worn out. Check friction faces for contamination such as dust, oil, grease, etc.

16.

Excessively noisy clutch assembly

a)

Clutch housing show is improperly assembled

i)

Remove and reassemble per manufacturer's specification.

b)

Clutch has worn parts

i)

Disassemble. Replace worn parts.

17.

Gearmotor and belt of zone accumulation running but carrying rollers not driven

a)

No air pressure

i)

Check FRL setting for that unit. Pressure should be 60 PSI. If no pressure exists check buildings air supply. Note: control system has pressure sensing device to shutdown conveyors if air pressure drops below a predetermined level.

b)

Air leak in feed line

i)

Check air line for leak. Easy to find due to missing sound. Replace pipe, tubing or fittings as required.

18.

Accumulation zones do not disengage properly

a)

Sensor arm damaged

i)

Check "L" shaped arm on sensor assembly to see that it is not rotating in its mounting hole. Short leg should be parallel to rollers. If arm moves, sensor assembly should be replaced.

b)

Whisker valve damaged

i)

Check whisker valve wire to see that it is standing up straight when not actuated. If wire is missing or damaged, replace whisker valve.

c)

Zone control flow valve not adjusted properly

i)

Check valve adjustment, correct as required.

19.

Brake-meter belt stops and will not restart, or will not stop

a)

Control photo-eye not aligned

i)

Check alignment of photo eye at discharge of meter belt. It should be aligned with its reflector.

20.

Blade roller stop does not raise, or raises slowly

a)

No or low are pressure

i)

Check FRL setting for that conveyor should be 60 PSI minimum. If below 60 SPI, readjust, if adjustment not possible check building air supply.

b)

Cam follower binding

i)

Check for free turning of cam followers used as stop arm guides. If binding, replace air supply.

c)

Foreign material jammed in stop mechanism

i)

Inspect stop for foreign material. Remove if found.

d)

Cylinder mounting loose

i)

Inspect cylinder mounting. If loose, tighten. If parts are missing, replace.

21.

Belt not tracking properly

a)

Pulleys, rollers and/or frame not square

i)

Check pulleys and roller for squareness with relation to frame and belt travel.

ii)

Check conveyor frame to see that it is straight. Straighten or replace as required.

b)

Foreign material hung up in rollers, pulleys or frame of conveyor

i)

Inspect conveyor for foreign material that is rubbing on belt or wrapped around rollers or pulleys. Remove if found.

c)

Bearing or shaft failure

i)

Inspect pulleys and rollers to see that they are not damaged. Listen for grinding in bearing. If found, replace required components.

d)

Belt lacing

i)

Inspect lacing, if damaged determine cause and correct it. Replace lacing.

22.

Belting lacing deformed or broken

a)

Belt rubbing on non-rotating part of conveyor

i)

Inspect conveyor for places belt might rub. Move return and snub roller as required to correct.

b)

Belt tension to tight

i)

Check belt, tension should be tight enough for belt to be driven by drive pulley.

c)

Foreign material

i)

Check pulley and roller with 90^o or more belt wrap, for build-up of foreign material on their faces. This increases belt tension at those places. Remove this foreign material.

23.

Excessive wear/damage of conveyor belt

a)

Belt not tracking properly

i)

Check tracking. Belt should track clear of conveyor side frames. If rubbing on frame, adjust tracking.

b)

Belt not tensioned properly

i)

Check belt tension. If to loose, belt will slip on drive pulley damaging belt and pulley.

ii)

If belt tension is to tight, belt will be stretched or lacing damaged. (See 22.b) above.

Problem		Probable Cause		Recommended Action
1.	Motor will not run	a)	Overload or breaker	i)	Inspect conveyor/for
			tripped, or blown fuse		obstruction/jams.

				ii)	Inpect for shorts in control wiring due to damaged conduit, etc.

				iii)	Reset tripped device or replace blown fuse.

		b)	Preset not on	i)	Turn on Preset.

		c)	Low voltage	i)	Check voltage in MCP.

				ii)	Check items in 1.a above.

2.	Motor runs but conveyor does not run	a)	Drive key	i)	Check for proper installation of drive keys in motor sprocket, pulley sprocket and drive pulley. If key is missing replace.

		b)	Belt tension	i)	Check belt tension. If to loose, pulley turns but belt does not move. Adjust belt take-up.

		c)	Broken chain or worn sprockets	i)	Check drive chain and sprockets. Replace broken chain. If sprockets are worn replace. Consult factory if sprocket wear occured over short period of time.

		d)	James	i)	Check conveyor for jam conditions. If drive belt is jammed pulley could be slipping on belt. Note: Check conveyor for damage caused by jam prior to restarting. Look for shaft misalignments, damaged chain or belts, etc.

3.	Motor hums but will not run	a)	James	i)	Check conveyor for jam conditions.

		b)	Gearbox failure	i)	Remove chain between gearbox and pulley and check for proper operation of gearmotor. Proceed to item 3.c to check motor, if motor works replace gearbox.

		c)	Damage to motor wiring	i)	Remove motor from reducer anc check motor for proper operation. If motor does not operate properly replace motor.

		d)	Brake failure (Brake Motors Only)	i)	Remove brake from back of motor and check motor for proper operation. If motor operated properly replace brake.

		e)	Clutch Brake Failure	i)	Remove clutch brake from between motor and gearbox, and check motor for properly replaced brake module.

4.	Motor runs but starts slow, runs slow and/or over heats.	a)	Overload condition	i)	Check to see that conveyor loading is within specified parameters.

		b)	Jams/binding of components	i)	Check for binding in bearings, misalignment of belts or construction of belts, chain, etc. by foreign materials replace bad bearings, retrack belts and remove foreign material.

		c)	Low Line Voltage	i)	Check voltage to motor, MCP panel and power supply panel. Correct as required.

		d)	Inadequate reducer lubrication	i)	Inspect gear case for proper level and grade of lubricant.

		e)	Dust/dirt in motor	i)	Inspect for dust/dirt in motor housing and ventilation hole. Disassemble housing to clean if necessary. Remove dust/dirt by blowing or vacuuming.

5.	Excessive gear noise or vibration	a)	Inadequate reducer lubrication	i)	Inspect gear case for proper level and grade of lubricant.

		b)	Worn or damaged reducer gears	i)	Drain, remove and disassemble unit to confirm. If repairs are required install replacement unit.

		c)	Faulty motor or reducer bearing	i)	Listen and feel to locate sluggish bearing, lubricate or replace bearings as appropriate.

		d)	Loose mounting	i)	Check gearmotor mounting bolts for proper tightness.



6.	Oil leakage from gearcase	a)	Loose drain plug	i)	Tighten drain plug. Replace plug if threads are damaged.

		b)	Worn or damaged bearing seals	i)	Disassemble gear case to replace seal.

		c)	Cracked reducer housing	i)	Drain and remove gearmotor or gearcase. Install replacement unit.

		d)	Over filling	i)	Drain gearcase to proper fill level.

7.	Abnormal wear to chain and sprockets	a)	Excessive chain tension	i)	Loosen drive mounting bolts and reposition drive sprocket shaft. Align sprockets and tighten down drive. Alternatively, add links to drive roller chain.

		b)	Sprockets misaligned	i)	Loosen sprockets on shafts and realign with straight edge across sprocket faces.

		c)	Inadequate chain lubrication	i)	Lubricate chain by brushing on approved oil. Wipe away excess.

		d)	Dirty chain	i)	Remove chain. Clean thoroughly in solvent. Replace worn links. Remount chain and lubricate by brushing on approved lubricant.

8.	Excessive noise from chain and sprockets	a)	Insufficient chain tension	i)	Loosen drive mounting bolts and reposition drive sprocket shaft. Align sprockets and tighten down drive. Alternatively remove links from chain.
		b)	Inadequate chain lubrication	i)	Lubricate chain by brushing on approved oil. Wipe away exess.

		c)	Sprockets misaligned	i)	Loosen sprocket and realign with straight edge across sprocket faces.

		d)	Chain guard misalignment or obstruction	i)	Look for obstruction to running chain. Remove or adjust as appropriate.

9.	Pulsating chain	a)	Insufficient chain tension	i)	Loosen drive mounting bolts and reposition drive sprocket shaft. Align sprocket and tighten down drive. Alternately remove links from chain.
		b)	Overload	i)	Inspect for obstruction to or drag on conveyor.

10.	Brocken chain	a)	Frozen pulley shaft	i)	Inspect for damaged bearings. Replace as required. Check shaft for straightness. Replace chain links as required.

		b)	Worn or damaged chain	i)	Replace entire chain. Determine cause of wear (inadequate lubrication, misalignment, etc.) to correct.

11.	Sprocket loose on shaft	a)	Loose set screws	i)	Realign sprockets with straightedge and tighten set screw.

		b)	Worn or damaged key	i)	Replace key. Inspect for damage to key seat on shaft and sprocket hub.

12.	Excessive chain slack	a)	Normal wear	i)	Expect rapid chain growth in first two weeks of operation. Loosen drive mounting bolts and reposition sprocket shaft. Align sprockets and tighten down drive.

		b)	Abnormal wear after break-in period	i)	Realign sprockets adjust roller chain tension. Badly worn sprockets or chain should be replaced.

13.	Excessive chain stretch	a)	Too much chain tension (screw take-up)	i)	Adjust screw take-up device to decrease chain tension.

14.	Clutch or brake not releasing	a)	Armature sticking	i)	Check air gap between the armature and brake or clutch. If the air gap has closed up, allowing contact when de-energized, the armature should be forced away from the clutch or brake by applying pressure through the ventilation holes until the armature contacts the snap ring in the center of the armature hub. When the unit is next energized, the armature should reset itself automatically. In some cases it may be necessary to apply a small amount of pressure behind the armature to provide the proper adjustment.

15.	Clutch loss torque	a)	Contaminated or worn friction faces	i)	Disassemble clutch brake and check friction faces for wear produces grooves on the friction faces but this is normal and they should not be replaced unless they are worn out. Check friction faces for contamination such as dust, oil, grease, etc.

16.	Excessively noisy clutch assembly	a)	Clutch housing show is improperly assembled	i)	Remove and reassemble per manufacturer's specification.

		b)	Clutch has worn parts	i)	Disassemble. Replace worn parts.

17.	Gearmotor and belt of zone accumulation running but carrying rollers not driven	a)	No air pressure	i)	Check FRL setting for that unit. Pressure should be 60 PSI. If no pressure exists check buildings air supply. Note: control system has pressure sensing device to shutdown conveyors if air pressure drops below a predetermined level.

		b)	Air leak in feed line	i)	Check air line for leak. Easy to find due to missing sound. Replace pipe, tubing or fittings as required.

18.	Accumulation zones do not disengage properly	a)	Sensor arm damaged	i)	Check "L" shaped arm on sensor assembly to see that it is not rotating in its mounting hole. Short leg should be parallel to rollers. If arm moves, sensor assembly should be replaced.

		b)	Whisker valve damaged	i)	Check whisker valve wire to see that it is standing up straight when not actuated. If wire is missing or damaged, replace whisker valve.

		c)	Zone control flow valve not adjusted properly	i)	Check valve adjustment, correct as required.

19.	Brake-meter belt stops and will not restart, or will not stop	a)	Control photo-eye not aligned	i)	Check alignment of photo eye at discharge of meter belt. It should be aligned with its reflector.

20.	Blade roller stop does not raise, or raises slowly	a)	No or low are pressure	i)	Check FRL setting for that conveyor should be 60 PSI minimum. If below 60 SPI, readjust, if adjustment not possible check building air supply.

		b)	Cam follower binding	i)	Check for free turning of cam followers used as stop arm guides. If binding, replace air supply.

		c)	Foreign material jammed in stop mechanism	i)	Inspect stop for foreign material. Remove if found.

		d)	Cylinder mounting loose	i)	Inspect cylinder mounting. If loose, tighten. If parts are missing, replace.

21.	Belt not tracking properly	a)	Pulleys, rollers and/or frame not square	i)	Check pulleys and roller for squareness with relation to frame and belt travel.

				ii)	Check conveyor frame to see that it is straight. Straighten or replace as required.

		b)	Foreign material hung up in rollers, pulleys or frame of conveyor	i)	Inspect conveyor for foreign material that is rubbing on belt or wrapped around rollers or pulleys. Remove if found.
		c)	Bearing or shaft failure	i)	Inspect pulleys and rollers to see that they are not damaged. Listen for grinding in bearing. If found, replace required components.
		d)	Belt lacing	i)	Inspect lacing, if damaged determine cause and correct it. Replace lacing.

22.	Belting lacing deformed or broken	a)	Belt rubbing on non-rotating part of conveyor	i)	Inspect conveyor for places belt might rub. Move return and snub roller as required to correct.

		b)	Belt tension to tight	i)	Check belt, tension should be tight enough for belt to be driven by drive pulley.

		c)	Foreign material	i)	Check pulley and roller with 90^o or more belt wrap, for build-up of foreign material on their faces. This increases belt tension at those places. Remove this foreign material.

23.	Excessive wear/damage of conveyor belt	a)	Belt not tracking properly	i)	Check tracking. Belt should track clear of conveyor side frames. If rubbing on frame, adjust tracking.

		b)	Belt not tensioned properly	i)	Check belt tension. If to loose, belt will slip on drive pulley damaging belt and pulley.

				ii)	If belt tension is to tight, belt will be stretched or lacing damaged. (See 22.b) above.