| SYMPTOMS |
PROBABLE
CAUSE |
SOLUTION |
| |
| Broken
belt(s) |
1.Under-designed
drive |
1.Redesign
using Drive Design Manual (E2/20070). |
| 2.Belt
rolled or prised onto pulley |
2.Use
drive takeup when installing. |
| 3.object
falling into drive |
3.Provide
adequate guard or drive protection. |
| 4.Severe
shock load |
4.Redesign
to accomodate shock load. |
| Belt(s)fail
to carry load (slip);no visible reason |
1.Under-designed
drive |
1.Redesign
using Drive Design Manual(E2/20070). |
| 2.Damaged
tensite menber |
2.Follow
correct installation procedure. |
| 3.Worn
pulley grooves |
3.Check
forgroove wear. replace as needed.
|
| 4.Contre
distance movement |
4.Check
drive for centre distance movement during operation. |
| Fdge
cord failure |
1.Pulley
misalignment
|
1.Check
and correct alignment.
|
| 2.Damaged
tensile menber |
2.Follow
installation procedure. |
Belt
delmination or undercord seaparation
|
1.Pulleys
too small |
1.Check
and design, replace with larger pulleys. |
| 2.Back
idler too small |
2.lncrease
back idler to acceptable diameter. |
| Wear
on belt top surface |
1.Rubbing
against guard |
1.Replace
or repair guard. |
| 2.ldler
malfunction |
2.
Replace idler. |
| Wear
on belt top corner |
1.Belt-to-pulley
fit incorrect
(belt too small for groove) |
1.Use
correct belt-to-pulley combination. |
| Wear
on belt bottom corners |
1.Belt
slip |
1.Retension
until slipping stops |
| 2.Misalignment |
2.Realign
pulleys. |
| 3.Worn
pulleys |
3.Replace
pulleys. |
| 4.lncorrect
belt |
4.Replace
with correct belt size. |
| |
2.
SEVER
OR ABNORMAL BELT WEAR |
| Wear
on belt bottom corners |
1.Belt-to-pulley
fit incorrect
|
1.Use
correct belt-to-pulley combination.
|
| 2.Worm
pulleys |
2.Replace
pulleys. |
| Wear
on belt bottom corners |
1.Belt
bottoming on pulley groove
|
1.Use
correct belt/pulley match. |
| 2.Worn
pulleys |
2.Replace
pulleys. |
| 3.Deberis
in pulleys |
3.Clean
pulleys. |
| Undercord
cracking |
1.Pulley
diameter too small |
1.Use
larger diameter puileys. |
| 2.Belt
slip |
2.Retension. |
3.Back idler too small
|
3.Use
larger diameter back idler. |
| 4.lmproper
storage |
4.Do
not coil belt too tightly, kink or bend. Avoid heat and direct
sunlight. |
| Burn
or hardening on bottom orsidewall |
1.Belt
slip |
1.Retension
until slipping stops. |
| 2.
Worn pulleys |
2.
Replace pulleys. |
| 3.
Under-designed drive |
3.
Redesign using DriveDesign Manual (E2/20070). |
| 4.
Shaft movement |
4.
Check for centre distance changes |
| Extensive
hardening of belt exterior |
1.Hot
drive environment |
1.Improve
ventilation to drive |
| Belt
surface flaking, sticky or swollen |
1.Oil
or chemical contamination |
1.Do
not use belt dressing. Eliminatesources of oil, grease or chemicalcontamination. |
| |
3.
V-BESTURN
OVER OR COME DRIVE |
| lnvolves
single or multiple belts |
1.Shock
loading or vibration |
1.Check
drive design. Use PowerBand'-'" belts. |
| 2.
Foreign material in grooves |
2.
Shield grooves and drive. |
| 3.
Misaligned pulleysWorn pulley grooves |
3.Realign
pulleys. |
| 4.
Worn pulley grooves |
4.
Replace pulleys. |
| 5.
Damaged tensile member |
5.
Use correct installation and beltstorage procedure. |
| 6.
Incorrectly placed flat idler pulley |
6.
Carefully place flat idler on slackside of drive as close as
possible todriveR pulleys. |
| 7.
Mismatched belt set |
7.
Replace with new set of matchedbelts. Do not mix old and new
belts |
| 8.
Poor drive design |
8.
Check for centre distance stabilityand vibration dampening. |
| |
4.
BELT
STRETCHES BEYOND AVAILABLETAKEUP |
| Multiple
belts stretch unequally |
1.Misaligned
drive |
1.Realign
and retension drive. |
| 2.
Debris in pulleys |
2.
Clean pulleys. |
| 3.
Broken tensile member or corddamaged |
3.
Replace all belts, install properly. |
| 4.
Mismatched belt set |
4.
Install matched belt set |
| Single
belt, or where all beltsstretch evenly |
1.Insufficient
takeup allowance |
1.Check
takeup. Use allowancespecified in DriveDesign Manual (E2/20070). |
| 2.
Grossly overloaded or under-designeddrive |
2.
Redesign drive. |
| 3.
Broken tensile members |
3.Replace
belt, install properly |
| |
| |
| Squeal
or "chirp" |
1.Belt
slip
|
1.Retension. |
| 2.
Contamination |
2.Clean
belts and pulleys |
| Slapping
noise |
1.Loose
belts |
1.Retension. |
| 2.
Mismatched set |
2.Install
matched belt set. |
| 3.
Misalignment |
3.
Realign pulleys so all belts share loadequally |
| Rubbing
sound |
Guard
interference |
1.Repair,
replace or redesign guard. |
| Grinding
sound |
Damaged
bearings |
Replace,
align and lubricate |
| Unusually
loud drive |
1.Incorrect
belt |
1.Unusually
loud drive23Use correct belt size. Use correctbelt tooth profile
for sprockets onsynchronous drive. |
| 2.Worn
pulleys |
2.
Replace pulleys. |
| 3.
Debris in pulleys |
3.
Clean pulleys, improve shielding,remove rust, paint or dirt
fromgrooves. |
| |
| |
| Belts
flapping |
|
|
| Excessive
vibration in drive system |
1.Incorrect
belt |
1.Use
correct belt cross-section inpulley. |
| 2.
Poor machine or equipment design |
2.
Check structure and brackets foradequate strength. |
| 3.
Pulley out of round |
3.
Replace pulley. |
| 4.
Loose drive components |
4.
Check machine components andguards, motor mounts, motor pads,bushings,
brackets and framework forstability, adequate design strength,proper
maintenance and properinstallation. |
| |
7.
BANDED
(JOINED)BELT PROBLEMS |
| Tie-band
separation |
1.Worn
pulleys
|
1.
Replace pulleys.
|
| 2.
improper groove spacing |
2.
Use standard groove pulleys |
| Top
of tie-band frayed, worn or damaged |
1.
Interference with guard |
1.Check
guard. |
| 2.
Back idler malfunction or damaged |
2.
Repair' or replace back idler. |
| PowerBand@
comes off drive |
1.Debris
in pulleys |
1.Clean
grooves. Use single belts toprevent debris from being trapped
ingrooves. |
| One
or more ribs run outside of pulley |
1.Misalignment |
1.Realign
drive. |
| 2.
Undertensioned |
2.
Retension. |
| |
| |
| Broken
or damaged pulley |
1.Incorrect
pulley installation |
1.Do
not tighten bushing bolts beyondrecommended torque values. |
| 2.
Foreign objects falling into drive |
2.
Use adequate drive guard. |
| 3.
Excessive rim speedsSevere, rapid groove wear |
3.
Keep pulley rim speeds belowmaximum recommended values. |
| 4.
Incorrect belt installation |
4.Do
not prise belts onto pulleys. |
| Severe,
rapid groove wear |
1.Excessive
belt tension
2. Sand, debris or contamination |
1.Retension,
check drive design.
2. Clean and shield drive as well aspossible. |
| |
9.
PROBLEMS
WITH OTHER DRIVE COMPONENTS |
| Bent
or broken shaft |
1.Extreme
belt overtension |
1.Retension. |
| 2.
Overdesigned drive* |
2.
Check drive design, may need to usesmaller or fewer belts. |
| 3.
Accidental damage |
3.
Redesign drive guard. |
| 4.
Machine design error |
4.
Check machine design. |
| Damaged
guarc |
1.Accidental
damage or poorguard design |
1.Repair,
redesign for durability. |
| |
| |
| Belt
overtensioned |
1.Worn
grooves -belts bottoming and will not transmit power untilovertensioned* |
1.Replace
Pulleys, tension drive properly. |
| 2.Improper
tension |
2.
Retension |
| Pulleys
too small |
1.Motor
manufacturer's pulley diameterrecommendation not followed |
1.Redesign
using DriveDesign Manual (E2/20070). |
| Poor
bearing condition |
1.Bearing
under-designed |
1.Check
bearing design. |
| 2.
Bearing not properly maintained |
2.
Align and lubricate bearing |
| Pulleys
too far out on shaft |
Error
or obstruction problem |
Place
pulleys as close as possible tobearings. Remove obstructions. |
| Belt
slippage |
Drive
undertensioned |
Retension |
| |
| |
| Incorrect
driveN speeds |
1.Design
error |
1.Use
correct driveR/driveN pulley sizefor desired speed ratio. |
| 2.
Belt slip |
2.
Retension drive. |
| |
12.
PROBLEMS
WITH SYNCHRONOUR BELTS |
| Unusual
noise |
1.Misaligned
drive |
1.Correct
alignment.. |
| 2.
Too- low o-r high tension |
2.
Adjust to recommended value |
| 3.
Back idler |
3.
Use inside idler. |
| 4.
Worn sprocket |
4.
Replace sprocket. |
| 5.Bent
guide flange |
5.
Replace guide flange. |
| 6.Belt
sp-eed to high |
6.
Redesign drive. |
| 7.
Incorrect belt profile for sprocket(i.e. HTD\ GT, etc) |
7.
Use proper belt/sprocketcombination. |
| 8.
Subminimal diameter |
8.
Redesign drive using largerdiameters. |
| 9.
Excess load |
9.
Redesign drive for increasedcapacity |
| Tension
loss |
1.Weak
support structure |
1.Reinforce
structure. |
| 2.
Excessive sprocket wear |
2.
Use other sprocket material. |
| 3.
Fixed (non-adjustable) centres |
3.
Use inside idler for belt adjustment. |
| 4.
Excessive debus |
4.
Remove debris, check guard. |
| 5.
Excessive io'ad6. |
5.
Redesign drive for increasedcapacity |
| 6.
Subminimni diameter |
6.
Redesign drive using largerdiameters. |
| 7.
Belt, sprocket or shafts running too hot |
7.
Check for conductive heat transferfrom prime mover. |
| 8.
Unusual bell degradation |
8.
Reduce ambient drive temperatureto+85C (185 F) maximum |
| Excessive
belt edge wear |
1.Damage
due to handling |
1.Follow
proper handling instructions. |
| 2.
Flange damage |
2.
Repair flange or replace sprocket. |
| 3.
Belt too wide |
3.
Use proper width sprocket.
|
| 4.
Belt tension too low |
4.
Adjust tension to recommendedvalue. |
| 5.Rough
flange surface finish |
5.
Replace or repair flange (to eliminateabrasive surface). |
| 6.
Improper tracking |
6.
Correct alignment. |
| 7.
Belt hitting drive guard or bracketry |
7.
Remove obstruction or use insideidler |
| Tensile
break |
1.
Excessive sho'ck load |
1.Redesign
drive for increasedcapacity. |
| 2.Subminimal
diameter |
2.
Redesign drive using largerdiameters. |
| 3.
Improper belt handling and storageprior to installation |
3.
Follow proper handling and storageprocedures. |
| 4.
Debris or foreign object in drive |
4.
Remove object and check guard. |
| 5.
Extreme sprocket run-out |
5.
Replace sprocket. |
| Belt
cracking |
1.Subrniinimal
diameter |
1.Redesign
drive using larger diameter |
| 2.
Back idler |
2.
Use inside idler or increase diameterof back idler. |
| 3.Extreme
low temperature at start-up |
3.
Pre-heat drive environment. |
| 4.
Extended exposure to harsh chemicals |
4.
Protect drive. |
| 5.
Cocked bushing/sprocket assembly |
5.
Install bushing per instructions. |
| Premature
tooth wear |
1.Too
low or too high beit tension |
1.Adjust
to recommended value |
| 2.
Belt running partly off unflangedsprocket |
2.
Correct alignment. |
| 3.
Misaligned drive |
3.
Correct alignment. |
| 4.Incorrect
belt profile for sprocket(i.e. HTD", GT, etc) |
4.
Use proper belt/sprocketcombination. |
| 5.
Worn sprocket |
5.
Replace sprocket. |
| 6.
Rough sprocket teeth |
6.
Replace sprocket. |
| 7.Damaged
sprocket |
7.
Replace sprocket. |
| 8.
Sprocket not to dimensional specification |
8.
Replace sprocket. |
| 9.
Belt hitting drive bracketry or otherstructure |
9.
Remove obstruction or use idler. |
| 10.
Excessive load |
10.
Redesign drive for increasedcapacity. |
| 11.
Insufficient hardness of sprocketmaterial |
11.
Use a more wear-resistant sprocket |
| 12.
Excessive debris |
12.
Remove debris, check guard. |
| 13.
Cocked bushing/sprocket assembly |
13.
Install bushings per instructions |
| Tooth
shear |
1.Excessive
shock loads |
1.Redesign
drive for increasedcapacity. |
| 2.
Less than 6 teeth in mesh |
2.
Redesign drive. |
| 3.
Extreme sprocket run-out |
3.
Replace sprocket. |
| 4.
Worn sprocket |
4.
Replace sprocket. |
| 5.
Back idler |
5.
Use inside idler. |
| 6.
Incorrect belt profile for sprocket(i.e. HTD", GT. etc) |
6.
Use proper belt/sprocket combination |
| 7.
Misaligned drive |
7.
Correct alignment. |
| 8.
Belt undertensioned |
8.
Adjust tension to recommended value |
| |
| |
| Flange
failure |
1.elt
forcing flange off |
1.Correct
alignment or properly secureflange to sprocket. |
| Unusual
sprocket wear |
1.Sprocket
has too little wear resistance(e.g. plastic, soft metals, aluminium) |
1.Use
alternative sprocket material |
| 2.
Misaligned drive |
2.
Correct alignment. |
| 3.
Excessive debris |
3.Remove
debris, check guard. |
| 4.
Excessive load |
4.
Redesign drive for increased capacity |
| 5.
Too low or too high belt tension |
5.
Adjust tension to recommended value |
| 6.
Incorrect belt profile for sprocket(i.e. HTD", GT, etc) |
6.
Use proper belt/sprocket combination. |
| |
14.
PERFORMANCE
PROBLEMS WITH SYNCHRONOUS BELTS |
| Belt
tracking problems |
1.Belt
running partly off unflangedsprocket |
1.Correct
alignment |
| 2.
Centres exceed 8 times small sprocketdiameter and both sprockets
are flanged |
2.Correct
parallel alignment to set beltto track on both sprockets. |
| 3.
Excessive belt edge wear |
3.
Correct alignment. |
| Excessive
temperature: belt, bearings,housings or shafts, etc. |
1.Misaligned
drive |
1.Correct
alignment. |
| 2.
Too low or too high belt tension |
2.
Adjust tension to recommended value |
| 3.
Incorrect belt profile for sprocket(i.e. HTD@ GT, etc) |
3.
Use proper belt/sprocket combination. |
| Shafts
out of synchronisation |
1.Design
error
|
1.Use
correct sprocket sizes.
|
| 2.
Incorrect belt |
2.
Use correct belt with correct toothprofile for grooves. |
| Vibration |
1.Incorrect belt profile for sprocketcombination (i.e. HTD"\
GT, etc) |
1.Use
proper belt/sprocket |
| 2.
Too low or too high belt tension |
2.Adjust
tension to recommended value |
| 3.
Bushing or key loose |
3.
Check and reinstall per instructions. |
| Incorrect
driveN speeds |
1.Design
error |
1.Redesign
drive. |
| |
|
|
