Belt Conveyor Maintenance

The maintenance schedule for any conveyor can be divided into three stages:1.    Belt shut down and empty2.    Belt running empty

3.    Belt running loaded

(i)           Belt Shut Down and Empty

This is the 1^st step in inspect the conveyor belt because this allows the opportunity to check any damage to the belt or splice. The conveyor should be locked out while making this inspection.

Rubber belt damage should be repaired using the hot vulcanized repair method or the cold repair method. Belt fabrics that are exposed to the weather or to product contamination should be properly cleaned, dried then covered with new rubber. These repairs are critical to prevent moisture from penetrating the belt and breaking down the cover adhesions and to prevent product contamination from abrading the carcass and also breaking down the adhesions.

The splice can also be inspected and if damage in the splice is visible, it is suggested that the splice be repaired or replaced. This is also a good time to walk the conveyor and check the following components.

A)   Tail Pulley free from build-up and trapped material
B)   Tail Pulley damage
C)   Skirting in the loading area
D)   Impact Bed or Impact Idler damage
E)    Slider Bed clean and smooth
F)    Carrying Side Idler damage
G)   Carrying Side Self Trainers (operational and not tied off)
H)   Secondary Loading Stations (skirting, impact bed or impact idler damage)
I)    Tripper Frame damage
J)    Tripper Discharge Pulley – clean
K)   Tripper Bend Pulleys – clean
L)    Head Pulley and/or Drive Pulley (clean, check for worn lagging, re-lag Drive Pulley if rubber is old, worn, smooth and hard)
M)  Head Pulley cleaner or scraper – operational
N)   Head Pulley Snub – clean
O)   Return Idlers – clean and turning freely
P)    Bend Pulley – celan
Q)   Take-up – clean
R)   Return Side Self Trainers – operational and not tied off
S)    Damage to return side frame due to mistraining
T)   Plow or Scraper in front of Tail Pulley – operational.

The preceding list should be used as a guide when inspecting the conveyor while it is empty and shut down. Numerous items in the preceding list contained the words “clean or operational”. Pulleys or idlers that have build up on them will cause tracking problems. The same can be said for pulleys that have some of the rubber lagging worn off.

      Scrapers, plows and self-trainers must be operational to perform their tasks. Belt damage, pulley damage and tracking problems will result if these accessory pieces of hardware are not well maintained.

(ii) Belt Running Empty

The conveyor should be turned on and run empty. The purpose of this is to run the conveyor while running empty to check for any tracking problems, the system will need to be inspected under running conditions when loaded, because empty belts and loaded belts do not necessarily track the same way.

(iii) Belt Running Loaded
The next step in inspection process is to run the belt in a loaded condition. We will add a few new steps in the inspection process and repeat a few on the previous steps. The following is our check list for operating the conveyor while loaded:
A)   Tail Pulley – turning freely without bearing noise, product build up or carryback; belt tracking satisfactorily.
B)   Load area spillage
C)   Carry Side Idlers – turning freely
D)   Carry Side Self-Trainers – functioning
E)    Secondary Loading Station spillage
F)    Tripper Area (tracking and spillage)
G)   Head Pulley and or Drive Pulley (smoothly running, slippage when starting or running, belt cleaners – functioning, and belt tracking)
H)   Head Pulley Snub – turning freely without bearing noise and clean
I)    Return Idler – clean and turning freely
J)    Bend Pulleys – turning freely without bearing noise and clean
K)   Take-up Pulley – turning freely without bearing noise, clean, moving freely in the frame
L)    Return Side Self-Trainers – functioning
M)  General Belt Tracking
N)   Plow or Scraper in front of Tail Pulley – functioning

(iv) Corrective Action
The last step is to take the corrected action required on the conveyor in addition to: A) Clean Up
B) Lubrication
C) Safety concerns – such as installing or repairing conveyor crossovers, safety stop cables, holdbacks on incline conveyors, edge limit switches, motor guards, hand rails and etc.


A conveyor system with carryback on the return side is the single biggest reason that conveyor belts are replaced, return idlers and pulleys are replaced and structure is worn through. Material build up on the belt and hardware causes tracking problems that will lead to edge damage that leads to new belt and new idlers.

    We urge you to use scrapers on the head pulley and plows in front of the tail pulley as prevention for damage in your maintenance planning. Some sticky materials present a real challenge when it comes to preventing carryback. Cleated belts may be reversed to allow better release at the discharge point. A dual scraper system on the head pulley is the most common way to eliminate product carryback.

    A water spray on the belt cover along with wiper blades will effectively remove most products from sticking to the cover. A series of out of round (cam shaped) return idlers will also assist in cleaning. These idlers are spiral wound from the edges towards the center of the idler and work on the premise of a turning beater bar arrangement. A brush may be the only solution for cleated belts. If your belt is not effectively clean on the return run, then any bend pulley or head snub pulley that come in contact with the carry side of the belt will accumulate product.

    Henan Pingyuan would like to offer few hints on pulley and idler cleaning. All return side pulleys that come in contact with the carry cover can be lagged with a soft rubber vulcanized to the pulley. The constant flexing action of the soft lagging will cause material to fall off and reduce material accumulation.

    A lever weighted urethane scraper pressed against the pulley face, is an excellent way to remove build up. This system causes additional wear on the pulley face so it is suggested to use heavier walled return bend pulleys when using a scraper. If a scraper is applied to a head snub or bend pulleys at the take-up area, then deflector plates will have to be installed to deflect the build up away from the belt.

    Return idlers can be rubber covered and will help prevent product from sticking to the return idler. Return idlers can be purchased that are nothing more than disc mounted on a shaft. These discs can be made of soft rubber, urethane or ceramics. This type of return idler can be very effective to prevent build up.

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Henan Pingyuan Mining Machinery Co., Ltd is the most professional manufacturer of Belt conveyor, andVibrating screen, Bucket elevator, Screw conveyor, Scraper conveyor using the world's most advanced technology, we are willing to serve every company to meet your custom needs. our goal is "be the future global leader of mining machinery industry". have any questions, please contact us without any hesitation.