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mechanical Issue

Conveyor System Problems

Conveyor issues stop your entire paint line. Here's how to diagnose common problems and get production moving.

Emergency: (877) 489-3727Start Diagnosis

What You're Experiencing

The conveyor system serving the paint booth is experiencing problems - it may have stopped, is running erratically, making unusual noises, or not...

Visual Signs:

  • Conveyor completely stopped
  • Chain jumping or skipping on sprockets
  • Carriers or hooks swinging excessively
  • Visible chain wear or elongation
  • Lubricant buildup or dripping
  • Parts jamming or colliding

Sound Signs:

  • Grinding or scraping sounds
  • Squealing from lack of lubrication
  • Rhythmic clunking from worn chain
  • Motor straining or overheating alarm

Safety Risks — Read Before Proceeding

high

Production stoppage

Action: Conveyor failure stops the entire paint line. Quick diagnosis is critical.

medium

Part damage

Action: Parts in the booth may be overexposed or contaminated during conveyor stoppage.

high(OSHA Lockout/Tagout)

Worker safety during troubleshooting

Action: Always follow LOTO procedures when working on conveyors.

Immediate Steps to Take

  1. 1

    Check motor/drive status - is it trying to run?

  2. 2

    Look for obvious obstructions or jams

  3. 3

    Check conveyor controller for fault codes

  4. 4

    Inspect chain tension and take-up position

  5. 5

    Check lubrication system operation

  6. 6

    Follow LOTO before any hands-on investigation

Common Causes

Here are the most likely reasons you're experiencing this problem, ranked by how often we see them.

Chain Wear/Elongation

common

The conveyor chain has stretched beyond specifications, causing poor sprocket engagement and potential jumping.

Lubrication Issues

common

Chain and track lubrication is inadequate, causing increased friction, wear, and potential seizure.

Drive Motor/Gearbox Failure

occasional

The drive motor or gearbox has failed or is struggling due to overload or electrical issues.

Take-Up Adjustment Needed

occasional

Chain take-up (tensioner) has reached its limit or needs adjustment to maintain proper chain tension.

Track or Guide Wear

occasional

Conveyor track, guides, or wear strips have worn, causing friction or misalignment.

Obstruction or Jam

occasional

A part, carrier, or debris has jammed the conveyor, causing it to stop or strain.

Interactive Diagnostic Tool

Conveyor Problem Diagnostic

Step 1 of 5

Is the drive motor running?

If unsafe at any point: Conveyor failure affects your entire production line. Call WERCS at (877) 489-3727 for rapid response service.

When to Call WERCS

While some issues can be resolved with basic troubleshooting, these situations require professional service:

  • Conveyor has stopped and you cannot identify cause
  • Chain needs replacement or major repair
  • Drive motor or gearbox has failed
  • Controller needs service or programming
  • You need conveyor inspection and maintenance
  • Planning conveyor upgrade or modification

Priority Service Available

(877) 489-3727

Expert technicians nationwide

Conveyor System Problems FAQ

Common questions about this issue

Conveyor chains should be measured regularly for elongation. When chain stretch exceeds 2-3% of original pitch, replacement is recommended. Depending on use and maintenance, this may be 3-7 years. WERCS can measure and advise on chain condition.
This depends on your conveyor type and environment. High-temperature areas need appropriate lubricants. Avoid lubricants that can contaminate paint work. WERCS can recommend the right lubricant for your specific system.
WERCS services conveyors from all major manufacturers. We carry common replacement parts and can source specialty components as needed. Our technicians are experienced with monorail, power and free, chain on edge, and other conveyor types.
Measure a section of chain (10-20 links) and compare to the original pitch specification. If the measured length exceeds specification by 2-3%, the chain is stretched. Also watch for the chain "riding high" on sprocket teeth - this indicates elongation.

Have a question not answered here?

Call us at (877) 489-3727

Related Problems

Exhaust Fan Failure

Related Parts & Components

Conveyor DriveConveyor Chain

Can't Fix It? We Can.

WERCS expert technicians service paint booths and extraction systems nationwide. 24/7 emergency service available.

Call (877) 489-3727Request Service Quote