Conveyor Belt Maintenance Checklist

Daily Operator Checks (pre-start)

• ☐ Belt aligned centrally — not touching framework on either side
• ☐ No obvious belt damage, tears, or edge fraying visible from safe walkway
• ☐ Belt scrapers and cleaners in contact with belt
• ☐ No spillage accumulation under conveyor at load point or discharge
• ☐ Emergency stop pull cords along entire length — functional (test per site procedure)
• ☐ Belt speed detector operational (no alarm)
• ☐ No unusual noise or vibration during start-up
• ☐ Drive motor cooling fan running freely
• ☐ Loading chute skirt seals in contact with belt — no visible gaps

Weekly Maintenance Tasks

• ☐ Inspect all idler rolls along carry and return strands — listen and look for seized or noisy rollers
• ☐ Replace any seized idlers (they cause belt wear and tracking problems)
• ☐ Check belt scraper blade wear — adjust tension if gap has opened; replace blade if worn below minimum height
• ☐ Clean material build-up from return idlers and pulley lagging
• ☐ Inspect belt edges for fraying, cord exposure, or edge damage
• ☐ Check belt tension — correct sag between carry idlers (typically 1–3% of idler spacing)
• ☐ Lubricate drive gearbox (check oil level; top up if needed)
• ☐ Inspect belt splice — no separation, no exposed wire, no stepped join
• ☐ Check take-up tension device (counterweight or screw) — counterweight free to move; screw take-up at correct setting

Monthly Inspection Items

• ☐ Drive motor: check bearing temperature (IR thermometer at bearing housings)
• ☐ Gearbox: check oil level and condition — sample oil for viscosity and contamination if high-duty unit
• ☐ Drive coupling: check for wear, cracked spider element, or misalignment
• ☐ All idler frames: check structural integrity — corroded, cracked, or missing mounting bolts
• ☐ Self-aligning (training) idlers: verify they are free to pivot; not seized by build-up
• ☐ Head and tail pulleys: check lagging condition — worn, cracked, or missing lagging segments
• ☐ Loading chute: wear liner condition; chute box seal sealing correctly
• ☐ Belt speed monitoring: verify calibration (run belt at known speed; check readout)
• ☐ Emergency stop devices: full functional test per site procedure

Annual Overhaul

• ☐ Full belt inspection — strip belt and lay flat for end-to-end carcass inspection; check for delamination, moisture ingress, or hidden carcass damage
• ☐ Replace all seized or noisy idlers identified during inspection
• ☐ Gearbox oil change (or sample-based, if oil analysis programme in place)
• ☐ Drive motor bearing check — vibration analysis or replacement per interval
• ☐ Pull wire tension and switch operation test — replace any failed switches
• ☐ Structural inspection — walkways, stairways, guarding — complete and secure
• ☐ Belt scraper: replace blade; check arm mechanism and tension spring