Intermediate service - boom lifts, EWPs and truck-mounted platforms (all makes)
Estimated duration: 3 - 4 hours • Frequency: every 500 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine (additional to 250-hour) | ||||
| 1 | Replace fuel filter element | REPLACE | ☐ | |
| 2 | Replace outer air filter element | REPLACE | ☐ | |
| 3 | Test coolant concentration (refractometer) | TEST | ☐ | |
| 4 | Adjust fan belt tension | ADJUST | ☐ | |
| Hydraulic System (additional to 250-hour) | ||||
| 5 | Replace hydraulic return filter | REPLACE | ☐ | |
| 6 | Replace hydraulic pilot filter (if fitted) | REPLACE | ☐ | |
| 7 | Take hydraulic oil sample for analysis | SAMPLE | ☐ | |
| Boom Structure (additional to 250-hour) | ||||
| 8 | Measure boom pin and bush wear at all pivot points | MEASURE | ☐ | |
| 9 | Check for cracking at boom weld joints | INSPECT | ☐ | |
| 10 | Inspect fly boom slide pads or wear strips | INSPECT | ☐ | |
| 11 | Record all measurements for trend monitoring | CHECK | ☐ | |
| Slew System (additional to 250-hour) | ||||
| 12 | Check slew ring bolt torque (calibrated wrench) | CHECK | ☐ | |
| 13 | Inspect slew gear teeth for wear | INSPECT | ☐ | |
| Wire Ropes / Chains (if fitted) | ||||
| 14 | Inspect wire ropes for broken strands, corrosion, kinking | INSPECT | ☐ | |
| 15 | Check chain stretch (pitch over 10 links) | MEASURE | ☐ | |
| Load Moment Indicator (if fitted) | ||||
| 16 | Test LMI calibration and function | TEST | ☐ | |
| Outriggers (additional to 250-hour) | ||||
| 17 | Inspect outrigger beams for cracking or bending | INSPECT | ☐ | |
| 18 | Check outrigger cylinders for leaks and rod scoring | INSPECT | ☐ | |
| Electrical (additional to 250-hour) | ||||
| 19 | Test battery load (CCA) | TEST | ☐ | |
| 20 | Clean and tighten all earth straps | CLEAN | ☐ | |
| Cab (additional to 250-hour) | ||||
| 21 | Check and clean A/C condenser | CLEAN | ☐ | |
| 22 | Test A/C operation and refrigerant | TEST | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 CI-4 / CK-4 | 5 - 12 L |
| Hydraulic oil | ISO VG 46 (AW 46) | 80 - 200 L (system) |
| Coolant | 50/50 ethylene glycol | 8 - 15 L |
| Brake fluid | DOT 3 or DOT 4 | As required |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical boom-type cherry pickers and EWPs. Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by machine size and type.
Parts / Consumables Required (500-hour additional items)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 5-12 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Fuel filter element | 1 | ☐ | |
| 4 | Outer air filter element | 1 | ☐ | |
| 5 | Hydraulic return filter | 1 | ☐ | |
| 6 | Hydraulic pilot filter | 1 | ☐ | |
| 7 | EP2 grease cartridges | 2-4 | ☐ | |
| 8 | Coolant test strips / refractometer | 1 | ☐ | |
| 9 | Oil sample bottle (hydraulic) | 1 | ☐ | |
| 10 | Coolant (pre-mixed or concentrate) | As req. | ☐ | |
| 11 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager