Major service - tracked hydraulic excavator (all makes)
Estimated duration: 6 - 8 hours • Frequency: every 1,000 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine (additional to 500-hour) | ||||
| 1 | Replace inner air filter element | REPLACE | ☐ | |
| 2 | Check/clean injectors or send for testing | INSPECT | ☐ | |
| 3 | Inspect turbocharger for play and oil leaks | INSPECT | ☐ | |
| 4 | Inspect exhaust manifold and gaskets | INSPECT | ☐ | |
| Hydraulic System (additional to 500-hour) | ||||
| 5 | Drain and replace full hydraulic oil (ISO VG 46) | DRAIN/FILL | ☐ | |
| 6 | Replace hydraulic suction strainer | REPLACE | ☐ | |
| 7 | Inspect hydraulic pump for noise/pressure/wear | INSPECT | ☐ | |
| Drivetrain (additional to 500-hour) | ||||
| 8 | Drain and replace final drive oil (both sides, 80W-90) | DRAIN/FILL | ☐ | |
| 9 | Drain and replace swing gear oil (80W-90 or SAE 30) | DRAIN/FILL | ☐ | |
| Cooling System (additional to 500-hour) | ||||
| 10 | Drain, flush and replace coolant (50/50 EG) | FLUSH/FILL | ☐ | |
| 11 | Pressure test cooling system | TEST | ☐ | |
| 12 | Replace thermostat (if due per manufacturer) | REPLACE | ☐ | |
| Undercarriage (additional to 500-hour) | ||||
| 13 | Full undercarriage measurement report (all components) | MEASURE | ☐ | |
| 14 | Assess undercarriage rebuild/replacement schedule | INSPECT | ☐ | |
| Structural (additional to 500-hour) | ||||
| 15 | Detailed boom and arm pin/bush wear check | INSPECT | ☐ | |
| 16 | Inspect all welds for cracking (visual) | INSPECT | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 CI-4 / CK-4 | 20 - 30 L |
| Hydraulic oil | ISO VG 46 (AW 46) | 150 - 250 L (full change) |
| Coolant | 50/50 ethylene glycol | 25 - 40 L (full system) |
| Final drive oil | 80W-90 GL-5 | 4 - 8 L per side |
| Swing gear oil | 80W-90 GL-5 or SAE 30 | 5 - 10 L |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical tracked excavators (10 - 35 t). Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by machine size. At the 1,000-hour interval, hydraulic oil, coolant, final drive oil and swing gear oil are fully drained and replaced.
Parts / Consumables Required (1000-hour additional items)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 20-30 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Inner air filter element | 1 | ☐ | |
| 4 | Outer air filter element | 1 | ☐ | |
| 5 | Fuel filter element | 1 | ☐ | |
| 6 | Fuel/water separator element | 1 | ☐ | |
| 7 | Hydraulic return filter | 1 | ☐ | |
| 8 | Hydraulic pilot filter | 1 | ☐ | |
| 9 | Hydraulic suction strainer | 1 | ☐ | |
| 10 | Hydraulic oil (ISO VG 46) | 150-250 L | ☐ | |
| 11 | Final drive oil (80W-90) | 8-16 L | ☐ | |
| 12 | Swing gear oil (80W-90 / SAE 30) | 5-10 L | ☐ | |
| 13 | Coolant (pre-mixed or concentrate) | 25-40 L | ☐ | |
| 14 | Thermostat (if replacing) | 1 | ☐ | |
| 15 | EP2 grease cartridges | 2-4 | ☐ | |
| 16 | Rags, drip trays, waste oil containers | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager