Intermediate service - tracked hydraulic excavator (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 (antifreeze/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 | ☐ | |
| Undercarriage / Tracks (additional to 250-hour) | ||||
| 8 | Measure track pad height (mm) | MEASURE | ☐ | |
| 9 | Measure track link pitch | MEASURE | ☐ | |
| 10 | Measure roller/idler wear (mm) | MEASURE | ☐ | |
| 11 | Record all measurements for trend monitoring | CHECK | ☐ | |
| Drivetrain (additional to 250-hour) | ||||
| 12 | Check valve clearance and adjust if required | ADJUST | ☐ | |
| Electrical (additional to 250-hour) | ||||
| 13 | Test battery load (CCA) | TEST | ☐ | |
| 14 | Clean and tighten all earth straps | CLEAN | ☐ | |
| Cab (additional to 250-hour) | ||||
| 15 | Check and clean A/C condenser | CLEAN | ☐ | |
| 16 | Test A/C operation and refrigerant | TEST | ☐ | |
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 (500-hour additional items)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 20-30 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 | Fuel/water separator element | 1 | ☐ | |
| 8 | EP2 grease cartridges | 2-4 | ☐ | |
| 9 | Coolant test strips / refractometer | 1 | ☐ | |
| 10 | Oil sample bottle (hydraulic) | 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