Free bobcat 500-hour service checklist

• The MapTrack bobcat 500-hour service checklist contains 38 checks across 6 sections. Sections covered: Engine System, Hydraulic System, Undercarriage & Drive, Electrical & Controls, Safety & Structural, Lubrication & Final Checks.
• Engine oil and filter: drain and replace engine oil (10W-30 or 15W-40 CK-4 per manufacturer specification), replace oil filter, check oil level after brief warm-up run.
• Hydraulic filter replacement: replace hydraulic charge filter element, check return filter bypass indicator, top up hydraulic oil if required, inspect all hoses and fittings.
• Fuel system filter: replace fuel filter element, drain fuel/water separator, bleed fuel system, inspect fuel lines for leaks or chafing.

Learn more about maintenance and work orders in MapTrack.

• Hydraulic system protection: replacing the hydraulic charge filter and inspecting the return filter at 500 hours removes contaminants before they damage pumps, motors and control valves.
• Extended engine life: changing the fuel system filter, replacing the primary air filter element and verifying coolant concentration protect the engine from premature wear caused by dirty fuel, restricted airflow or internal corrosion.
• Drive motor reliability: draining and refilling drive motor oil at the 500-hour interval removes metal particles and thermally degraded lubricant, reducing the risk of costly final drive failures on both sides.
• Undercarriage longevity: a formal track tension measurement with documented sag values ensures tracks are neither over-tensioned (accelerating sprocket and idler wear) nor under-tensioned (risking de-tracking during operation on uneven ground).
• Warranty and compliance: completing the 500-hour service within the manufacturer window preserves warranty coverage and provides documented proof that WHS plant maintenance obligations are being met.
• Lower total cost of ownership: the combined cost of filters, oil, labour and consumables for a 500-hour service is a small fraction of the repair cost for a hydraulic pump failure, engine seizure or track replacement caused by deferred maintenance.

• Engine oil and filter: drain and replace engine oil (10W-30 or 15W-40 CK-4 per manufacturer specification), replace oil filter, check oil level after brief warm-up run.
• Hydraulic filter replacement: replace hydraulic charge filter element, check return filter bypass indicator, top up hydraulic oil if required, inspect all hoses and fittings.
• Fuel system filter: replace fuel filter element, drain fuel/water separator, bleed fuel system, inspect fuel lines for leaks or chafing.
• Coolant system: check coolant concentration with refractometer (target 50/50 mix), pressure-test radiator cap, inspect radiator and oil cooler cores, inspect all coolant hoses and clamps.
• Drive motor inspection: drain and replace drive motor oil on both sides, inspect drained oil for metal contamination, record oil condition.
• Undercarriage tension adjustment: measure track sag at the midpoint against manufacturer specification, adjust track tension, inspect track pads, idler wheels, rollers and sprockets for wear.
• Auxiliary hydraulic check: cycle the auxiliary hydraulic circuit, inspect quick-coupler for secure locking, check coupler face seals, verify flow and pressure at the attachment.
• Bucket and attachment pivot lubrication: grease all loader arm pins, tilt cylinder pins, bucket pivot pins and auxiliary coupler pivot using EP2 lithium complex grease.
• Air filter service: replace primary air filter element, inspect secondary safety element (replace if damaged or after third primary change), reset restriction indicator.
• Electrical system check: load-test battery, inspect wiring harness for chafe or heat damage, check all lights, backup alarm, horn, seatbelt, restraint bar interlock and ROPS/FOPS bolt torque.

1. Prepare the machine and work area. Park the Bobcat on firm, level ground, lower the loader arms and bucket flat to the ground, engage the park brake, raise the restraint bar and shut down the engine.

   Allow the engine to cool for at least 15 minutes before draining any fluids. Gather all replacement filters (engine oil filter, fuel filter, primary air filter, hydraulic charge filter), engine oil, drive motor oil, grease cartridges and any other consumables listed in the manufacturer service manual. Place drip trays under the engine sump, both drive motors and the hydraulic filter housing before starting work.

2. Record equipment details at the top of the service form: asset ID, make, model, serial number, unit number and the current engine hour meter reading.

   Cross-reference the hour reading against the previous 250-hour and 500-hour service records to confirm the correct interval has been reached. If the machine has an electronic display, note any active diagnostic fault codes before clearing them. Record the site location, date and the name of the technician performing the service.

3. Complete all 250-hour carryover tasks first. Drain and replace engine oil and the oil filter, inspect or replace the outer air filter, drain the fuel/water separator, check hydraulic oil level and hose condition, grease all standard points and check track tension.

   Use 10W-30 or 15W-40 CK-4 diesel engine oil as specified by the manufacturer. Typical engine oil capacity is 5 to 8 litres. Fill to the full mark on the dipstick, run the engine briefly to prime the new filter, shut down and recheck the level. The 500-hour service carries forward every task from the 250-hour service, so complete the full 250-hour procedure before moving to the additional 500-hour items.

4. Replace the fuel system filter element. Shut off the fuel supply valve, remove the old filter, prime the new filter with clean diesel and install it. Open the fuel supply valve and bleed the fuel system to remove air.

   Dispose of the old filter element in accordance with site waste management procedures. After installation, crank the engine to bleed air from the fuel lines. If the engine does not start after 15 seconds of cranking, wait 30 seconds before trying again to protect the starter motor. Once running, check for leaks around the filter housing and all fuel line connections.

5. Replace the hydraulic charge filter. Depressurise the hydraulic system fully, remove the old charge filter element and install the new one. Check the return filter bypass indicator and replace the return filter if bypass is indicated.

   Follow the manufacturer lockout and depressurisation procedure before opening the filter housing. After installing the new charge filter, start the engine and slowly cycle the loader arms and auxiliary hydraulics through their full range to purge trapped air from the circuit. Recheck the hydraulic oil level in the sight glass once air has been purged and top up if the level has dropped below the minimum mark.

6. Change the drive motor oil on both sides. Rotate the drive sprocket so the drain plug sits at the lowest point, remove the drain and fill plugs, drain old oil into a drip tray and inspect for metal contamination before refilling.

   Typical drive motor capacity is 1.5 to 3 litres per side depending on the model. Use the gear oil grade specified in the service manual (commonly 80W-90 or a synthetic equivalent). If the drained oil contains visible metal flakes or has a burnt odour, flag the drive motor for further inspection by a qualified fitter and record the finding on the service form for follow-up.

7. Test the cooling system. Check coolant concentration with a refractometer, inspect and clean the radiator and oil cooler cores, pressure-test the radiator cap and inspect all coolant hoses for swelling, cracking or weeping.

   Coolant concentration should be a 50/50 ethylene glycol and water mix, providing a freeze point around minus 37 degrees Celsius. If concentration is below 40 per cent or above 60 per cent, drain and refill to the correct ratio. Clean the radiator and oil cooler cores with low-pressure compressed air, working from the clean side outward. Pressure-test the radiator cap to confirm it holds the rated pressure (typically 100 kPa) and replace it if it fails.

8. Measure undercarriage track tension formally. Record the sag measurement at the midpoint between the front idler and rear sprocket and compare to the manufacturer specification. Adjust if out of tolerance.

   Place a straight edge across the top of the track between the front idler and rear sprocket. Measure the distance from the straight edge down to the top of the track at the midpoint. Typical sag specifications range from 25 mm to 50 mm depending on the model and track type. Over-tensioned tracks accelerate wear on sprockets, idlers and rollers, while under-tensioned tracks risk de-tracking during turns on uneven terrain. Record the before and after measurements on the service form.

9. Load-test the battery, check ROPS/FOPS bolt torque and verify all safety devices. Start the engine, operate every function through its full range and record all findings on the service form.

   Use a battery load tester to confirm the battery delivers the rated cranking amps. Torque-check all ROPS/FOPS mounting bolts to the manufacturer specification. Verify the restraint bar interlock prevents engine start when the bar is raised. Test the seatbelt, backup alarm, horn, headlights, tail lights and work lights. Run the engine for at least five minutes, cycle every hydraulic function and drive the machine forward and reverse to confirm smooth operation before signing off.

10. Set the next service due hours. Calculate the next 250-hour and 1000-hour intervals from the current hour reading, update the service sticker on the machine and sign off the completed service form.

    Add 250 to the current reading for the next minor service and 500 for the next intermediate service. Update the fleet maintenance system or digital asset register with all completed tasks, recorded measurements, fluid quantities and any defects or recommendations. If using MapTrack, confirm the next meter-based trigger is set automatically based on the engine hour meter reading so the team receives an alert before the next interval.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• WHS Regulations 2011 - Chapter 5, Plant and Structures (plant maintenance obligations)
• Manufacturer service schedule (Bobcat / compact track loader)
• Safe Work Australia Code of Practice: Managing Risks of Plant in the Workplace

• Model Code of Practice: Managing risks of plant in the workplace (Safe Work Australia)
• Model WHS Regulations (Safe Work Australia)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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