Intermediate service - mobile crane, all-terrain and truck-mounted (all makes)
Estimated duration: 4 - 6 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 air filter element | REPLACE | ☐ | |
| Hydraulic System (additional to 250-hour) | ||||
| 3 | Replace hydraulic return filter | REPLACE | ☐ | |
| 4 | Take hydraulic oil sample for analysis | SAMPLE | ☐ | |
| Wire Ropes and Rigging (additional to 250-hour) | ||||
| 5 | Measure wire rope diameter at 3 points and record | MEASURE | ☐ | |
| 6 | Count and record broken wires per lay length | MEASURE | ☐ | |
| 7 | Inspect sheave grooves for wear (measure) | MEASURE | ☐ | |
| Brakes and Winch (additional to 250-hour) | ||||
| 8 | Inspect hoist, slew and travel brakes - lining thickness and adjustment | INSPECT | ☐ | |
| 9 | Inspect winch drum - rope winding and flanges | INSPECT | ☐ | |
| Safety Systems (additional to 250-hour) | ||||
| 10 | Check LMI/RCI calibration - compare to load chart | CHECK | ☐ | |
| Slew System (additional to 250-hour) | ||||
| 11 | Torque slew ring mounting bolts | TORQUE | ☐ | |
| Carrier (additional to 250-hour) | ||||
| 12 | Inspect carrier - tyres, brakes, steering and suspension | INSPECT | ☐ | |
| Outriggers (additional to 250-hour) | ||||
| 13 | Check outrigger cylinder seals for leaks | CHECK | ☐ | |
| Structural (additional to 250-hour) | ||||
| 14 | Inspect counterweight mounting | INSPECT | ☐ | |
| 15 | Check all safety decals are legible | CHECK | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 CI-4 / CK-4 | 15 - 30 L |
| Hydraulic oil | ISO VG 46 (AW 46) | 150 - 300 L (system) |
| Coolant | 50/50 ethylene glycol | 25 - 40 L |
| Slew ring gear grease | EP0 or EP1 | As required |
| Wire rope lubricant | Wire rope dressing | As required |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical mobile cranes (all-terrain and truck-mounted). Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by crane class.
Parts / Consumables Required (500-hour additional items)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 15-30 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Fuel filter element | 1 | ☐ | |
| 4 | Air filter element | 1 | ☐ | |
| 5 | Hydraulic return filter | 1 | ☐ | |
| 6 | Fuel/water separator element | 1 | ☐ | |
| 7 | EP2 grease cartridges | 4-6 | ☐ | |
| 8 | Wire rope lubricant | As req. | ☐ | |
| 9 | Oil sample bottle (hydraulic) | 1 | ☐ | |
| 10 | Wire rope measurement log | 1 | ☐ | |
| 11 | Coolant (pre-mixed or concentrate) | As req. | ☐ | |
| 12 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager