What is included in a conveyor belt 250-hour service?

A 250-hour conveyor belt service is a minor service that includes checking and adjusting belt tension, checking belt tracking and alignment, inspecting the belt surface for cuts, tears, gouges and edge damage, checking belt splices and joints, inspecting carry rollers (idlers) for spin, seizure and alignment, inspecting return rollers, checking impact rollers at the loading point, inspecting drive pulley lagging, inspecting the tail pulley and take-up mechanism, checking belt scrapers and cleaners (primary and secondary), inspecting the motor for temperature, vibration and noise, checking gearbox oil level and condition, inspecting belt speed, checking all guards and covers, testing emergency stops and pull-cords/rip-cords, greasing all bearings (drive, tail, idler, return), inspecting chute and hopper liners, and checking skirting rubber and seals. It takes approximately 1.5 to 2.5 hours.

How often should a conveyor belt be serviced?

Conveyor belts follow a tiered service schedule based on operating hours. A 250-hour (minor) service covers belt tension and tracking, roller and pulley inspection, scraper and liner checks, motor and gearbox checks, bearing greasing and safety device testing. A 1,000-hour or annual (major) service adds gearbox oil change, motor service, roller replacement, belt scraper replacement, belt splice inspection, belt thickness measurement, tension system service, instrumentation testing, electrical switchgear inspection and full guarding audit. Daily pre-start checks are performed by the operator before each shift. Always refer to the manufacturer service manual for your specific conveyor system.

What grease is used on conveyor belt bearings?

Most conveyor belt bearings use EP2 (extreme pressure, NLGI Grade 2) lithium complex grease. This grade provides good water resistance and load-carrying capacity suitable for the heavy loads and dusty environments typical of conveyor systems. Grease all drive, tail, idler and return roller bearings at the 250-hour interval. Always check the bearing manufacturer specifications for your specific conveyor.

Is the template free to use without MapTrack?

Yes. Download and use the conveyor belt 250-hour service procedure for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want digital service procedures linked to each asset with scheduling by hours, cost tracking and alerts, we would be happy to show you MapTrack.

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Free conveyor belt 250-hour service checklist

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A step-by-step 250-hour (minor) service procedure for portable or fixed conveyor belt systems. Covers belt tension and tracking, roller and pulley inspection, scraper and liner checks, motor and gearbox inspection, bearing greasing and emergency stop testing. Includes fluid specifications, parts list and technician sign-off. This page explains what the service involves, how to perform it, and offers a free PDF-ready form you can download straight away.

Last updated: 2026-03-26 · MapTrack

Jarrod Milford

Commercial Director

Updated 26 March 2026

How to use: Fill equipment details and hour reading, then work through each service action. Tick Done as each task is completed. Record any defects or measurements. Set the next service due hours and sign off.

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What is a conveyor belt 250-hour service?

A 250-hour service is the first tier of scheduled preventive maintenance for a conveyor belt system. It is performed every 250 operating hours and is classified as a minor service. The procedure covers belt tension and tracking adjustment, belt surface inspection, splice and joint checks, roller and pulley inspection (carry, return, impact, drive and tail), scraper and cleaner checks, chute liner and skirting rubber inspection, motor and gearbox checks, bearing greasing, guard checks and emergency stop testing. Unlike a daily pre-start check (which confirms the conveyor is safe to operate), the 250-hour service involves hands-on maintenance: adjusting tension, greasing bearings, inspecting wear components and testing safety devices. It is typically performed by a qualified fitter or maintenance technician.

Benefits of scheduled conveyor belt servicing

Reduced unplanned downtime: regular belt, roller and scraper checks prevent failures that stop production and cause costly delays.
Extended belt life: correct tension, tracking and scraper adjustment reduce belt wear, edge damage and splice failure.
Lower repair costs: catching a seized roller or worn scraper early prevents belt damage that costs thousands to repair or replace.
Operator safety: testing emergency stops, pull-cords and checking guards at regular intervals reduces the risk of conveyor-related incidents.
Compliance: documented service records demonstrate that equipment is maintained to WHS standards, supporting insurance and regulatory obligations.
Throughput consistency: a well-maintained conveyor runs at consistent speed and capacity, supporting production targets.

Benefits of digitising forms in MapTrack

When you move from paper or static PDFs to digital forms in MapTrack, you get:

Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
Automatically get alerts when faults are identified.
Link every form digitally as a PDF to the relevant asset, location or person.
Receive a digital PDF copy with every submission to your email.
Ability to share forms digitally.
Build conditional logic (show or hide questions based on answers).
Take pictures or attach photos. Not possible with a paper-based form.
Electronic signatures.
Edit forms later without reprinting.
Restrict permissions (who can view, complete or approve).
Build forms with AI (describe what you need and MapTrack suggests the form).

Book a demo to see digital service procedures and hour-based scheduling in MapTrack.

Service actions included in the 250-hour procedure

This service procedure covers 18 service actions across 7 system areas:

Belt: check tension and adjust, check tracking and alignment, inspect surface for damage, check splices and joints, inspect belt speed.
Rollers and pulleys: inspect carry rollers (idlers), return rollers, impact rollers, drive pulley lagging, tail pulley and take-up mechanism.
Scrapers and seals: check belt scrapers and cleaners (primary and secondary), inspect chute and hopper liners, check skirting rubber and seals.
Drive system: inspect motor (temperature, vibration, noise), check gearbox oil level and condition.
Lubrication: grease all bearings (drive, tail, idler, return).
Safety: check all guards and covers, test emergency stops and pull-cords/rip-cords.

Fluid specifications

General fluid specifications for conveyor belt systems. Capacities vary by conveyor size and manufacturer.

System	Type / Grade	Approx. Capacity
Gearbox oil	EP 220 or 320 per manufacturer	5 - 15 L
Bearing grease	EP2 lithium complex	As required

Specifications are general guidelines. Always refer to the manufacturer's service manual for your specific conveyor system.

Parts and consumables

Have the following parts and consumables ready before starting the 250-hour service:

EP2 grease cartridges - 2-4
Replacement scrapers (if worn)
Skirting rubber (if worn)
Rags and cleaning supplies

Look up part numbers in the manufacturer's parts manual for your specific conveyor system before ordering.

How to perform a conveyor belt 250-hour service

Isolate and lock out the conveyor. Confirm the belt has stopped and all stored energy is released. Follow your site's isolation procedure.
Record the equipment details and current hour meter reading at the top of the service procedure form.
Start with the belt: check tension and adjust if required, check tracking and alignment, inspect the belt surface for cuts, tears and edge damage, check splices and joints.
Inspect all rollers: carry rollers (idlers) for spin, seizure and alignment, return rollers, impact rollers at the loading point, drive pulley lagging and tail pulley with take-up mechanism.
Check belt scrapers and cleaners (primary and secondary). Inspect chute and hopper liners for wear. Check skirting rubber and seals.
Check the motor (temperature, vibration, noise) and gearbox oil level and condition.
Grease all bearings: drive, tail, idler and return roller bearings. Use EP2 lithium complex grease.
Check all guards and covers are fitted. Test emergency stops and pull-cords/rip-cords.
Remove isolation and run the conveyor. Check belt tracking under load, listen for abnormal noises and observe belt speed. Record any defects in the notes section.
Set the next service due hours (next 250-hour and next 1,000-hour intervals). Sign off and update the conveyor's maintenance log.

In MapTrack, you can schedule services based on operating hours, get automatic reminders, complete service procedures on mobile and link every record to the asset. Book a demo to see how.

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Conveyor belt service interval hierarchy

Conveyor belt maintenance follows a tiered schedule where each level includes all tasks from the level below. This is called carry-forward or cumulative servicing.

250 hours - Minor service (you are here)

Belt tension and tracking, roller and pulley inspection, scraper checks, motor and gearbox checks, bearing greasing, safety device testing. Estimated 1.5-2.5 hours.

1,000 hours / annual - Major service

All 250-hour tasks plus gearbox oil change, motor service, roller replacement, scraper replacement, belt thickness measurement, tension system service, instrumentation testing. Estimated 4-8 hours.

In MapTrack, you can configure service schedules by operating hours and receive automatic alerts when each interval is due.

Frequently asked questions

What is included in a conveyor belt 250-hour service?: A 250-hour conveyor belt service is a minor service that includes checking and adjusting belt tension, checking belt tracking and alignment, inspecting the belt surface for cuts, tears, gouges and edge damage, checking belt splices and joints, inspecting carry rollers (idlers) for spin, seizure and alignment, inspecting return rollers, checking impact rollers at the loading point, inspecting drive pulley lagging, inspecting the tail pulley and take-up mechanism, checking belt scrapers and cleaners (primary and secondary), inspecting the motor for temperature, vibration and noise, checking gearbox oil level and condition, inspecting belt speed, checking all guards and covers, testing emergency stops and pull-cords/rip-cords, greasing all bearings (drive, tail, idler, return), inspecting chute and hopper liners, and checking skirting rubber and seals. It takes approximately 1.5 to 2.5 hours.
How often should a conveyor belt be serviced?: Conveyor belts follow a tiered service schedule based on operating hours. A 250-hour (minor) service covers belt tension and tracking, roller and pulley inspection, scraper and liner checks, motor and gearbox checks, bearing greasing and safety device testing. A 1,000-hour or annual (major) service adds gearbox oil change, motor service, roller replacement, belt scraper replacement, belt splice inspection, belt thickness measurement, tension system service, instrumentation testing, electrical switchgear inspection and full guarding audit. Daily pre-start checks are performed by the operator before each shift. Always refer to the manufacturer service manual for your specific conveyor system.
What grease is used on conveyor belt bearings?: Most conveyor belt bearings use EP2 (extreme pressure, NLGI Grade 2) lithium complex grease. This grade provides good water resistance and load-carrying capacity suitable for the heavy loads and dusty environments typical of conveyor systems. Grease all drive, tail, idler and return roller bearings at the 250-hour interval. Always check the bearing manufacturer specifications for your specific conveyor.
Is the template free to use without MapTrack?: Yes. Download and use the conveyor belt 250-hour service procedure for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want digital service procedures linked to each asset with scheduling by hours, cost tracking and alerts, we would be happy to show you MapTrack.

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Register every conveyor in MapTrack. Set up 250 and 1,000-hour service schedules, complete procedures on mobile, track parts and costs, and get automatic alerts when the next service is due.

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