Conveyor Troubleshooting Made Easy: Expert Tips To Keep Your Operations Moving
Conveyor issues can bring production to a halt, and that’s the last thing any facility needs. The good news? Most problems can be solved quickly if you know what to look for.
This guide walks through five common conveyor system faults - how to spot them, what causes them, and what you can do to get back on track fast.
1. Conveyor Won’t Start – Common Causes and Fixes
You press the start button, and nothing happens. Before assuming the worst, check for these typical culprits:
What might be wrong:
- Overloaded belt: Too much material can stall the motor at startup.
- Faulty gear motor: If the motor has failed, the belt won’t move.
- Emergency stop switch triggered: This happens more often than you'd think in busy workspaces.
Quick fixes:
- Reduce the load and restart.
- Check and reset the emergency stop.
- If the motor or fuse is faulty, you may need to replace them. Telford Smith’s service team can help confirm the issue.
Tip: Preventative checks on motors and switches can help you avoid unplanned stops.
2. Conveyor Belt Keeps Stalling? Here’s What to Check
A conveyor that starts but then stops mid-operation is a common frustration. Here’s what might be behind it:
Likely causes:
- Overloaded system: Too much material bogs the belt down.
- Belt misalignment: The belt may be rubbing against the sidewalls.
- PVC sidewall covers too tight: These can grip the belt and slow it down.
How to fix it:
- Stay within the manufacturer’s load limits.
- Check alignment and make sure the belt is centred.
- Loosen the sidewall covers slightly to reduce resistance.
Preventive tip: Regularly inspect belt tracking and tension to catch these issues early.
3. Fixing Overheating Bearings on Conveyor Systems
Bearings that run hot can damage other parts of the system or lead to total failure. Here’s how to cool things down:
Common causes:
- Too much grease: This creates resistance and heat.
- Too much belt tension: Puts added stress on bearings.
- Insufficient lubrication: Without enough grease, friction builds up fast.
What to do:
- Use only the recommended amount of grease.
- Check belt tension - back it off if it feels too tight.
- Keep a regular lubrication schedule.
Tip: Don’t wait for a bearing to fail. Routine maintenance keeps everything running smoother and longer.
4. Conveyor Motor Using Too Much Power? Troubleshoot These First
If your conveyor motor is straining, it’s often due to one of three things - all of which are fixable:
Typical reasons:
- Overloading: Heavier loads increase demand on the motor.
- Belt misalignment: Causes drag and increases resistance.
- Sidewall covers too tight: Adds friction that makes the motor work harder.
Fixes to try:
- Lighten the load where possible.
- Adjust belt tracking to eliminate rubbing.
- Loosen the covers to reduce unnecessary friction.
Maintenance tip: Keep power draw in check by regularly inspecting load conditions and belt alignment.
5. Material Buildup Under the Belt? Here’s How to Fix It Fast
Debris and material buildup in the return section can lead to wear, inefficiency, and jams.
What causes it:
- Worn scraper: A dull or missing edge won’t clean the belt properly.
- Misaligned scraper: Not making full contact with the belt surface.
- Worn brush: A top brush that’s past its lifespan can’t do its job.
What to check:
- Replace or adjust scrapers so they make proper contact.
- Swap out worn brushes with new ones.
Tip: Keep scrapers and brushes clean and functional to avoid major clean-up jobs later.
Keep Things Moving with Preventive Conveyor Maintenance
Most conveyor issues don’t come out of nowhere. Regular inspections and minor adjustments can prevent the bigger problems before they start.
If you're unsure where to begin- or if something still isn’t working - Telford Smith’s service team is here to help. From minor repairs to complete conveyor upgrades, we’ll help you keep production moving without the guesswork.
Need support? Contact Telford Smith today for help with your conveyor system.
Want a quick reference on hand?
Download our free Conveyor Troubleshooting Guide for easy access to fixes and a few bonus tips we didn’t include above. Keep it nearby to help avoid downtime and keep your system running smoothly.
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