Free concrete mixer truck 250-hour service procedure
Free concrete mixer truck 250-hour service checklist (PDF-ready). Engine oil, drum drive hydraulics, drum rollers and ring gear. Download free.
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Updated 26 Oct 2026
Concrete Mixer Truck 250-Hour Service Procedure
Minor service - concrete mixer / agitator truck (all makes)
Engine and PTO
Drum Drive Hydraulics
Drum and Mixing System
Water System
Lubrication
Chassis and Truck Systems
Safety
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Short answer
A concrete mixer truck 250-hour service checklist records the minor service on an agitator truck: engine oil and filters, PTO and drum drive hydraulics, drum, rollers, ring gear, chutes, water system, guards, emergency drum stop and chassis checks. A mechanic uses it where the truck and mixer body service schedules set a 250-hour interval. Regulation 213 of the model WHS Regulations requires competent-person maintenance of plant.
Checked against Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) on by the MapTrack templates team. How we check templates
Key takeaways
- The MapTrack concrete mixer truck 250-hour service procedure contains 17 checks across 7 sections. Sections covered: Engine and PTO, Drum Drive Hydraulics, Drum and Mixing System, Water System, Lubrication, Chassis and Truck Systems, Safety.
- Check the truck and mixer body service schedules separately; follow each one's hour, distance or calendar limit, whichever falls due first.
- Regulation 213: a competent person maintains plant to the manufacturer's recommendations, or a competent person's if there are none.
- Isolate the drum drive and PTO before hands-on work, then refit every guard and test the emergency drum stop before return to service.
- The NHVIM's brake, steering, tyre and lighting criteria apply to vehicles over 4.5 t GVM or ATM, which includes agitator trucks.
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What is a concrete mixer truck 250-hour service procedure?
A 250-hour service is a scheduled preventive maintenance procedure for concrete mixer and agitator trucks. It covers both the truck engine/chassis and the specialised mixing equipment: the drum drive hydraulic system, mixing drum, rollers, ring gear, chutes, water system and PTO. Unlike a daily washout (which removes residual concrete after each pour), the 250-hour service involves actual maintenance actions: draining and replacing engine oil, replacing hydraulic filters, inspecting drum wear, greasing bearings and testing safety systems. It is typically performed by a qualified mechanic or fitter and takes approximately 2 to 3 hours.
Concrete mixer trucks present unique maintenance challenges because the drum rotates continuously at job sites, accumulating engine hours faster than standard heavy vehicles. Under the WHS Act 2011, the PCBU has a duty to ensure that plant is maintained so it remains safe for use, and regulation 213 of the WHS Regulations 2011 (Part 5.1) reinforces this: the maintenance, inspection and, if necessary, testing of plant must be carried out by a competent person. The National Heavy Vehicle Inspection Manual published by the NHVR sets out minimum inspection standards for brakes, steering, tyres and electrical systems on heavy vehicles, all of which form part of the 250-hour service. Additionally, dangerous parts of machinery, including the ring gear, PTO shaft and drum drive, should be guarded to prevent entanglement and crush injuries. WHS Regulation 208 sets the type of guarding required, and AS/NZS 4024.1601:2024 covers guard design. A documented 250-hour service history provides auditable evidence of compliance during roadside inspections, workplace safety audits and insurance claim assessments.
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Benefits of using this concrete mixer truck 250-hour service procedure
- Reduced breakdowns: regular oil, filter and hydraulic maintenance prevent engine and drum drive failures that cause missed pours and idle batching plant time.
- Extended drum life: inspecting spiral fins, rollers and ring gear at regular intervals catches wear early, extending the life of the drum assembly.
- Lower repair costs: a 250-hour service costs a fraction of replacing a worn drum or failed hydraulic motor.
- Operator safety: testing the emergency drum stop, checking safety guards and inspecting the PTO reduces the risk of entanglement or crush injuries around the drum drive.
- Compliance: documented service records demonstrate that equipment is maintained to WHS standards, supporting insurance and regulatory obligations.
- Resale value: a complete service history increases the vehicle's value at trade-in or auction.
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- Track service intervals by hours, kilometres or calendar date in one place.
- Attach supplier invoices and parts receipts to each maintenance record.
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What to include in a concrete mixer truck 250-hour service procedure
This concrete mixer truck 250-hour service procedure covers 7 key areas:
- Engine and PTO: drain and replace engine oil, replace oil filter, check PTO oil level and condition, check PTO engagement and disengagement.
- Drum drive hydraulics: check hydraulic oil level (drum drive system), replace drum drive hydraulic filter.
- Drum and mixing system: inspect drum for concrete buildup, inspect drum interior wear (spiral fins), check drum roller condition and alignment, inspect ring gear and pinion, inspect chutes, extension chutes and hoppers.
- Water system: check water tank, pump, hoses and nozzle.
- Lubrication: grease drum drive bearings, grease drum support rollers and trunnion.
- Chassis and truck systems: inspect brakes, tyres and lights.
- Safety: check all safety guards around drum drive, test emergency drum stop.
How to use this concrete mixer truck 250-hour service procedure
- Park the mixer truck on level ground, ensure the drum is empty and clean, disengage the PTO and shut down the engine. Allow the engine to cool before draining oil.: Wash out the drum thoroughly after the last pour of the day. Position on a firm, level surface. Disengage the PTO, shut down the engine and apply the park brake. Allow at least 15 minutes for the engine to cool before opening the oil drain plug.
- Record the equipment details and current hour meter reading at the top of the service procedure form.: Capture the registration number, fleet number, make, model, drum capacity and the current engine hour meter reading. Compare the reading against the previous service to confirm the correct 250-hour interval has elapsed.
- Start with the engine and PTO section: drain the old engine oil, replace the oil filter, fill with new oil, then check PTO oil level and test PTO engagement.: Use the engine manufacturer-specified oil grade (typically 15W-40). Refill to the full mark on the dipstick. Check PTO gearbox oil through the level plug or sight glass and top up if low. Engage and disengage the PTO several times to confirm smooth operation and no grinding or slipping.
- Check hydraulic oil level for the drum drive system and replace the drum drive hydraulic filter.: Check the hydraulic oil level on the sight glass or dipstick on the drum drive reservoir. The level should be checked with the drum in the neutral position. Replace the return line hydraulic filter with a genuine or equivalent element of the correct micron rating.
- Inspect the drum exterior and interior for concrete buildup and spiral fin wear. Check drum roller condition, alignment, ring gear and pinion. Inspect chutes and hoppers.: Use a torch to inspect spiral fin height and condition inside the drum. Note any areas where buildup exceeds 25 mm thickness. Check the ring gear teeth for wear, chipping or excessive backlash against the pinion. Inspect roller surfaces for flat spots, cracking or uneven wear. Check chute pivot pins and latch mechanisms.
- Check the water system: tank level, pump operation, hose condition and nozzle function.: Fill the water tank and run the pump to verify flow and pressure at the nozzle. Inspect hoses for cracking, abrasion or loose clamps. Check the nozzle spray pattern is even and unrestricted. Confirm the tank drain valve operates freely.
- Grease drum drive bearings and drum support rollers/trunnion with EP2 lithium complex grease.: Apply EP2 grease to each nipple until fresh grease purges from the seal. Cover all drum drive shaft bearings, support roller bearings and the trunnion bearing. Wipe excess grease from around the seals to prevent dirt accumulation.
- Inspect chassis/truck systems: check brakes, tyres and lights. Check all safety guards around the drum drive. Test the emergency drum stop.: Inspect brake pad thickness visually through the inspection port. Check tyre pressures and tread depth at all positions. Confirm all safety guards around the ring gear, PTO and drum drive are in place and secure. Press the emergency drum stop button and verify the drum ceases rotation immediately.
- Start the engine, engage the PTO and rotate the drum. Check for leaks, abnormal noises or vibration. Record any defects in the notes section.: Rotate the drum in both charge and discharge directions. Listen for grinding from the ring gear or roller area. Check for hydraulic oil leaks at hose connections and cylinder seals. Record all defects with their severity, location and recommended corrective action.
- Set the next service due hours. Sign off and update the vehicle's maintenance log.: Calculate the next 250-hour service due from the current hour meter reading. Update the service sticker in the cab, the vehicle maintenance log book and the fleet management system. Obtain sign-off from the servicing technician.
In MapTrack, you can schedule and track maintenance digitally, by date or meter reading. Each submission is stored as a timestamped PDF against the asset record.
Get the free templateEnter your email above to download the full concrete mixer truck 250-hour service procedure as a PDF.Back to download formHow often should you complete this service procedure?
Concrete mixer trucks should receive a 250-hour minor service every 250 engine hours, which typically equates to every four to six weeks for a truck running five to six days per week. The engine hours accumulate not only from driving but also from drum rotation at job sites, so mixer trucks often reach service intervals faster than standard trucks.
Daily washout of the drum interior after each pour is essential maintenance that is separate from the scheduled service. Without daily washout, concrete buildup accelerates spiral fin wear and reduces mixing capacity. The truck chassis and engine should also follow the truck manufacturer service schedule (typically 10,000-15,000 km intervals), and both hour-based and distance-based services should be tracked so whichever comes first triggers the service.
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Frequently asked questions
Applicable regulatory standards
This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.
| Standard | Edition | Clauses this template relies on | Source |
|---|---|---|---|
| Model Work Health and Safety RegulationsCompetent-person maintenance of plant, and the guarding order for drum drive, ring gear and PTO guards where guarding is used. | Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) |
| Safe Work Australia (drafted by the Parliamentary Counsel's Committee) |
| National Heavy Vehicle Inspection ManualIn-service inspection criteria for brakes, steering, tyres and lights on vehicles over 4.5 t GVM or ATM, such as agitator trucks. | Version 3.2 (August 2026) |
| National Heavy Vehicle Regulator |
| Model Code of Practice: Managing risks of plant in the workplaceModel Code guidance on plant maintenance and on isolating energy before work on the drum drive. | November 2024 version (reviewed May 2018; amended 2021, 2023 and 2024) |
| Safe Work Australia |
| Safety of machinery (AS 4024 and AS/NZS 4024 series)Machinery safety series covering guards and interlocks. Parts carry different editions, so cite the relevant part and its current edition. | Multi-part series; each part has its own edition (for example AS 4024.1100:2019, AS/NZS 4024.1601:2024, AS/NZS 4024.1603:2019) | Whole instrument | Standards Australia and Standards New ZealandSold by the publisher |
Model Work Health and Safety Regulations
Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)
Competent-person maintenance of plant, and the guarding order for drum drive, ring gear and PTO guards where guarding is used.
- reg 213: Plant must be maintained, inspected and, if necessary, tested by a competent person, following manufacturer or competent person recommendations; annual inspection applies only if neither is practicable.
- reg 208: Where guarding is used on plant, sets the order of guard types by access need and practicability: fixed or interlocked barriers, then tool-removable barriers, then presence-sensing systems.
Safe Work Australia (drafted by the Parliamentary Counsel's Committee)
National Heavy Vehicle Inspection Manual
Edition: Version 3.2 (August 2026)
In-service inspection criteria for brakes, steering, tyres and lights on vehicles over 4.5 t GVM or ATM, such as agitator trucks.
- Section 2: Brakes: inspection criteria and reasons for rejection.
- Section 4: Steering and suspension: inspection criteria and reasons for rejection.
- Section 5: Wheels, tyres and hubs: inspection criteria, including tyre tread depth.
- Section 8: Lights and reflectors: inspection criteria and reasons for rejection.
Model Code of Practice: Managing risks of plant in the workplace
Edition: November 2024 version (reviewed May 2018; amended 2021, 2023 and 2024)
Model Code guidance on plant maintenance and on isolating energy before work on the drum drive.
- Section 3.6: Maintenance, repair and cleaning of plant, following manufacturer instructions and by competent people.
- Section 4.5: Isolating energy sources before maintenance, repair or cleaning, with lock-out as the most effective isolation procedure.
Safety of machinery (AS 4024 and AS/NZS 4024 series)
Edition: Multi-part series; each part has its own edition (for example AS 4024.1100:2019, AS/NZS 4024.1601:2024, AS/NZS 4024.1603:2019)
Machinery safety series covering guards and interlocks. Parts carry different editions, so cite the relevant part and its current edition.
Standards Australia and Standards New ZealandSold by the publisher
Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.
Check the current source
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<div style="max-width:480px;font-family:system-ui,-apple-system,'Segoe UI',Roboto,sans-serif;border:1px solid #E5E7EB;border-radius:12px;padding:20px;background:#ffffff;">
<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
<p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Concrete mixer truck 250-hour service procedure</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Engine and PTO: drain and replace engine oil, replace oil filter, check PTO oil level and condition, check PTO engagement and disengagement.</li>
<li style="margin:4px 0;">Drum drive hydraulics: check hydraulic oil level (drum drive system), replace drum drive hydraulic filter.</li>
<li style="margin:4px 0;">Drum and mixing system: inspect drum for concrete buildup, inspect drum interior wear (spiral fins), check drum roller condition and alignment, inspect ring gear and pinion, inspect chutes, extension chutes and hoppers.</li>
<li style="margin:4px 0;">Water system: check water tank, pump, hoses and nozzle.</li>
<li style="margin:4px 0;">Lubrication: grease drum drive bearings, grease drum support rollers and trunnion.</li>
<li style="margin:4px 0;">Chassis and truck systems: inspect brakes, tyres and lights.</li>
</ul>
<p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/concrete-mixer-250-hour-service" style="color:#071D49;font-weight:600;text-decoration:none;">Concrete mixer truck 250-hour service procedure</a> by MapTrack</p>
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The MapTrack concrete mixer truck 250-hour service procedure contains 17 checks across 7 sections.
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- MapTrack Concrete mixer truck 250-hour service procedure, https://www.maptrack.com/templates/concrete-mixer-250-hour-service
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- MapTrack. (2026). Concrete mixer truck 250-hour service procedure [Checklist template]. Retrieved from https://www.maptrack.com/templates/concrete-mixer-250-hour-service
Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/concrete-mixer-250-hour-service.
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