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6.8 Idler Roller Replacement
The following instructions outline the BSBAC idler roller replacement procedure.
1. Ensure that the power to the AC motor is switched off. Bastian Solutions recommends using
Lockout/Tagout (LOTO) procedures for this operation.
2. Mark/measure the position of the tensioner rods on the drive section of the conveyor.
3. Loosen the take-up equally on both sides of the conveyor. This relaxes the belt tension across
the conveyor. To loosen the take-up pulley, move the take-up bearings towards upstream side of
the conveyor.
4. The idler roller has a spring-loaded hex shaft. Using a punch or similar tool, push the hex of the
idler roller into the side frame.
5. If the idler roller is on the conveying surface, reach over the side frame and pull the idler up and
out of the frame.
6. If the idler roller is under the conveyor as a belt return roller, reach under the side frame and pull
the idler down and out of the frame.
7. Install the replacement (new) idler roller into the side frame and push the hex into the roller.
8. If the idler roller is on the conveying surface, route the roller under the belt and push down the
idler roller into the frame and line up the hex with the hex slot. The hex should pop out through
the hex slot.
9. If the idler roller is under the conveyor as a belt return roller, route the roller against the belt and
push up the idler roller into the frame and line up the hex with the hex slot. The hex should pop
out through the hex slot.
10. Re-track and re-tension the belt. Refer to section 5.4 for further information.
6.9 Bearing Replacement and Maintenance
The BSBAC tail pulleys, drive pulleys and take-up pulleys have bearings that mount the pulleys to the
side frame.
1. To replace the BSBAC tail pulley bearings, refer to section 6.4 and follow all the steps until the tail
pulley is removed from the side frame. Instead of replacing the pulley, replace the bearings and
follow the steps in that section to re-install the bearings to the conveyor.
2. To replace the BSBAC drive pulley bearings, refer to section 6.5 and follow all the steps until the
drive pulley is removed from the side frame. Instead of replacing the pulley, replace the bearings
and follow the steps in that section to re-install the bearings to the conveyor.
3. To replace the BSBAC take-up pulley bearings, refer to section 6.6 and follow all the steps until
the take-up pulley is removed from the side frame. Instead of replacing the pulley, replace the
bearings and follow the steps in that section to re-install the bearings to the conveyor.
To keep the bearings working efficiently with minimum downtime, a bearing inspection and lubrication
schedule must be followed. Bastian Solutions recommends a visual and auditory inspection every 5-6
weeks and lubrication of the bearings every 10-12 weeks. For bearing lubrication, use a No. 2 Lithium
complex base grease. The bearings provided on site have already been greased and are ready for
operation.
Published January 2022
Installation & Maintenance Manual: BSBAC 1 HP
Rev. B
40
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