Intermediate service for tracked and wheeled asphalt pavers (all makes)
Estimated duration: 3 - 5 hours • Frequency: every 500 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine Oil and Filter (Carried Forward from 250-hr) | ||||
| 1 | Drain and replace engine oil (15W-40 CK-4 per OEM spec) | DRAIN/FILL | ☐ | |
| 2 | Replace engine oil filter | REPLACE | ☐ | |
| Fuel System | ||||
| 3 | Replace fuel filter element | REPLACE | ☐ | |
| 4 | Drain fuel/water separator bowl completely | DRAIN | ☐ | |
| 5 | Bleed fuel system after filter replacement | CHECK | ☐ | |
| Air Intake | ||||
| 6 | Replace primary air filter element | REPLACE | ☐ | |
| 7 | Inspect secondary (safety) element, replace if damaged or 3rd primary change | INSPECT | ☐ | |
| Hydraulic System | ||||
| 8 | Replace hydraulic oil return filter | REPLACE | ☐ | |
| 9 | Take hydraulic oil sample for contamination analysis | CHECK | ☐ | |
| 10 | Inspect all hydraulic hoses, fittings and cylinders for leaks | INSPECT | ☐ | |
| Screed and Material System | ||||
| 11 | Measure screed plate thickness, record wear at centre and edges | INSPECT | ☐ | |
| 12 | Check screed heater elements and thermostat operation | CHECK | ☐ | |
| 13 | Inspect auger flights, shaft bearings, seals and gearbox oil level | INSPECT | ☐ | |
| 14 | Adjust conveyor chain tension, inspect slats and sprockets | ADJUST | ☐ | |
| Cooling System | ||||
| 15 | Check coolant concentration with refractometer (50/50 target) | CHECK | ☐ | |
| 16 | Pressure-test radiator cap (rated pressure, typically 100 kPa) | CHECK | ☐ | |
| 17 | Inspect coolant hoses, clamps, fan belt tension and condition | INSPECT | ☐ | |
| Track / Drive System | ||||
| 18 | Measure and record track sag against manufacturer specification | INSPECT | ☐ | |
| 19 | Check drive motor oil level and condition (both sides) | CHECK | ☐ | |
| 20 | Inspect track pads, idlers, rollers and sprockets, record undercarriage wear | INSPECT | ☐ | |
| Grease Points and Lubrication | ||||
| 21 | Grease all screed pivot, extension cylinder and tow point pins | GREASE | ☐ | |
| 22 | Grease hopper wing pivot, auger bearings and conveyor bearings | GREASE | ☐ | |
| Electrical and Safety | ||||
| 23 | Load-test battery, check terminals and cables | CHECK | ☐ | |
| 24 | Test all lights, horn, reversing alarm, beacon and emergency stop | CHECK | ☐ | |
| 25 | Inspect all guards, covers and safety decals | INSPECT | ☐ | |
| 26 | Full operational test: drive, screed, auger, conveyor, grade control | CHECK | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 CK-4 | 12 - 20 L |
| Hydraulic oil | ISO VG 46 (AW 46) | 80 - 150 L (system) |
| Coolant | 50/50 ethylene glycol | 15 - 30 L |
| Drive motor oil | 80W-90 or synthetic equivalent | 2 - 4 L per side |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical asphalt pavers. Always refer to the manufacturer service manual for your specific make and model. Capacities vary by machine size.
Parts / Consumables Required
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40 CK-4) | 12-20 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Fuel filter element | 1 | ☐ | |
| 4 | Primary air filter element | 1 | ☐ | |
| 5 | Hydraulic return filter | 1 | ☐ | |
| 6 | EP2 grease cartridges | 3-5 | ☐ | |
| 7 | Oil sample bottles (engine + hydraulic) | 2 | ☐ | |
| 8 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager