Minor service - tracked hydraulic excavator (all makes)
Estimated duration: 1.5 - 2.5 hours • Frequency: every 250 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine | ||||
| 1 | Drain and replace engine oil (15W-40 CI-4/CK-4) | DRAIN/FILL | ☐ | |
| 2 | Replace engine oil filter | REPLACE | ☐ | |
| 3 | Inspect air filter outer element - replace if dirty | INSPECT | ☐ | |
| 4 | Drain fuel/water separator and check for contamination | DRAIN | ☐ | |
| 5 | Check coolant level and condition - top up if required | CHECK | ☐ | |
| 6 | Inspect fan belts for wear, cracking and tension | INSPECT | ☐ | |
| 7 | Inspect radiator and hoses for leaks, damage or swelling | INSPECT | ☐ | |
| 8 | Clean or blow out radiator fins (compressed air) | CLEAN | ☐ | |
| Hydraulic System | ||||
| 9 | Check hydraulic oil level in sight glass - top up if low | CHECK | ☐ | |
| 10 | Inspect hydraulic hoses, fittings and cylinders for leaks | INSPECT | ☐ | |
| 11 | Check hydraulic quick-coupler (if fitted) for wear and leaks | CHECK | ☐ | |
| Undercarriage / Tracks | ||||
| 12 | Check track tension and adjust if required | ADJUST | ☐ | |
| 13 | Inspect track pads, links, rollers and idlers for wear | INSPECT | ☐ | |
| 14 | Inspect sprockets for wear pattern and tooth condition | INSPECT | ☐ | |
| Lubrication | ||||
| 15 | Grease boom, arm and bucket pins (all grease points) | GREASE | ☐ | |
| 16 | Grease swing bearing | GREASE | ☐ | |
| 17 | Grease slew ring gear teeth | GREASE | ☐ | |
| 18 | Grease track adjuster grease nipple | GREASE | ☐ | |
| Electrical | ||||
| 19 | Check battery terminals, cable condition and charge | CHECK | ☐ | |
| 20 | Test all lights (work lights, indicators, reverse, beacon) | CHECK | ☐ | |
| Safety Devices | ||||
| 21 | Test horn, reversing alarm and travel alarm | CHECK | ☐ | |
| 22 | Check seatbelt condition and latch operation | CHECK | ☐ | |
| 23 | Check fire extinguisher - pressure, pin, seal, expiry | CHECK | ☐ | |
| 24 | Inspect ROPS/FOPS cab structure and mounting bolts | INSPECT | ☐ | |
| Structural | ||||
| 25 | Inspect boom, arm and bucket for cracks, damage or wear | INSPECT | ☐ | |
| 26 | Inspect bucket teeth and cutting edge - replace if worn | INSPECT | ☐ | |
| 27 | Check all guards and covers are fitted and secure | CHECK | ☐ | |
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 (system) |
| Coolant | 50/50 ethylene glycol | 25 - 40 L |
| 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.
Parts / Consumables Required
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 20-30 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Air filter (outer) - if replacing | 1 | ☐ | |
| 4 | Fuel/water separator element | 1 | ☐ | |
| 5 | EP2 grease cartridges | 2-4 | ☐ | |
| 6 | Coolant (pre-mixed or concentrate) | As req. | ☐ | |
| 7 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager