Major service - portable or fixed conveyor belt system
Estimated duration: 4 - 8 hours • Frequency: every 1,000 operating hours or annually
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Belt (additional to 250-hour) | ||||
| 1 | Inspect belt splice condition (vulcanised or mechanical) | INSPECT | ☐ | |
| 2 | Measure belt thickness at wear points | MEASURE | ☐ | |
| Scrapers and Liners (additional to 250-hour) | ||||
| 3 | Replace primary and secondary belt scrapers | REPLACE | ☐ | |
| 4 | Inspect chute wear liners and replace if needed | INSPECT | ☐ | |
| Drive System (additional to 250-hour) | ||||
| 5 | Drain and replace gearbox oil | DRAIN/FILL | ☐ | |
| 6 | Motor service (check bearings, perform insulation resistance test/megger) | SERVICE | ☐ | |
| 7 | Check pulley bearings and seals | CHECK | ☐ | |
| Rollers (additional to 250-hour) | ||||
| 8 | Replace seized or worn rollers (idlers, return, impact) | REPLACE | ☐ | |
| Tension System (additional to 250-hour) | ||||
| 9 | Service tension system (gravity or screw take-up) | SERVICE | ☐ | |
| Instrumentation (additional to 250-hour) | ||||
| 10 | Inspect and test belt weigher (if fitted) | TEST | ☐ | |
| 11 | Test belt alignment sensors and switches | TEST | ☐ | |
| Electrical (additional to 250-hour) | ||||
| 12 | Inspect electrical switchgear, overloads and VSD (if fitted) | INSPECT | ☐ | |
| Structural (additional to 250-hour) | ||||
| 13 | Check conveyor frame, supports and foundations for cracking or movement | CHECK | ☐ | |
| 14 | Full guarding audit (all guards fitted, labelled, interlocked) | CHECK | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Gearbox oil | EP 220 or 320 per manufacturer | 5 - 15 L (full change) |
| Bearing grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical conveyor belt systems. Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by conveyor size.
Parts / Consumables Required (1000-hour additional items)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | EP2 grease cartridges | 2-4 | ☐ | |
| 2 | Gearbox oil (EP 220 or 320) | 5-15 L | ☐ | |
| 3 | Replacement rollers (idlers, return, impact) | As req. | ☐ | |
| 4 | Primary belt scraper | 1 | ☐ | |
| 5 | Secondary belt scraper | 1 | ☐ | |
| 6 | Motor bearings (if required) | As req. | ☐ | |
| 7 | Chute liners (if worn) | As req. | ☐ | |
| 8 | Skirting rubber (if worn) | As req. | ☐ | |
| 9 | Rags, cleaning supplies | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager