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