Free dozer / bulldozer 250-hour service procedure

• The MapTrack dozer / bulldozer 250-hour service procedure contains 22 checks across 7 sections. Sections covered: Engine, Hydraulic System, Blade / Attachments, Lubrication, Undercarriage / Tracks, Electrical, Safety Devices.
• Engine: drain and replace engine oil (15W-40), replace oil filter, inspect air filter, drain fuel/water separator, check coolant, inspect fan belts.
• Hydraulic system: check hydraulic oil level, inspect blade lift and tilt cylinders for leaks.
• Blade / attachments: check blade cutting edge thickness and end bit wear, inspect ripper shank, tip and pins (if fitted).

Learn more about maintenance and work orders in MapTrack.

• Reduced breakdowns: regular oil, filter and fluid changes prevent engine and hydraulic failures that cause unplanned downtime on site.
• Extended component life: clean oil and correct lubrication reduce wear on engine, hydraulic pump, final drives and undercarriage components.
• Lower repair costs: a 250-hour service costs a fraction of an emergency breakdown repair. Catching issues early prevents cascading damage.
• Operator safety: inspecting safety devices, ROPS structure, blade components and hydraulic hoses at regular intervals reduces the risk of on-site incidents.
• Compliance: documented service records demonstrate that equipment is maintained to WHS standards, supporting insurance and regulatory obligations.
• Resale value: a complete service history with documented 250, 500 and 1,000-hour services increases the machine's value at trade-in or auction.

• Engine: drain and replace engine oil (15W-40), replace oil filter, inspect air filter, drain fuel/water separator, check coolant, inspect fan belts.
• Hydraulic system: check hydraulic oil level, inspect blade lift and tilt cylinders for leaks.
• Blade / attachments: check blade cutting edge thickness and end bit wear, inspect ripper shank, tip and pins (if fitted).
• Lubrication: grease ripper pins, blade pivot pins, push arm pins and equaliser bar.
• Undercarriage / tracks: check and adjust track tension, inspect track pads, rollers, idlers and sprockets.
• Electrical: check battery terminals and charge, test all lights, horn, reversing alarm and beacon.
• Safety devices: check seatbelt, inspect ROPS structure, check fire extinguisher.

1. Park the dozer on level ground, lower the blade to the ground, engage the parking brake and shut down the engine. Allow the engine to cool before draining oil.

   Position on a firm, level surface. Lower the blade flat to the ground and lower the ripper (if fitted). Engage the park brake and shut down the engine. Allow at least 15 minutes for the engine to cool before removing the oil drain plug.

2. Record the equipment details and current hour meter reading at the top of the service procedure form.

   Capture the fleet number, make, model, serial number, blade type, machine weight class and the current engine hour meter reading. Compare the reading against the previous service to confirm the correct 250-hour interval has elapsed.

3. Start with the engine section: drain the old engine oil, replace the oil filter, fill with new oil to the correct level, then inspect the air filter, drain the fuel/water separator and check coolant.

   Use 15W-40 CI-4 or CK-4 diesel engine oil. Typical fill is 20-35 litres depending on machine size. Check the air filter primary indicator and replace the element if in the red zone. Drain the fuel/water separator bowl completely. Check coolant level and visually inspect hoses for cracks or weeping.

4. Check hydraulic oil level, inspect blade lift and tilt cylinders for leaks.

   Check the hydraulic oil level on the sight glass or dipstick with the blade lowered and all cylinders retracted. Inspect the blade lift cylinders, tilt cylinders and any angle cylinder (if fitted) for seal weeping, rod scoring or hose damage.

5. Inspect the blade cutting edge and end bits for wear. Inspect the ripper (if fitted) including shank, tip and pins.

   Measure the remaining cutting edge thickness and compare to the minimum replacement thickness. Check end bits for wear and cracking. On the ripper, inspect the shank for cracking, the tip for wear and the retaining pins for looseness or elongation of pin holes.

6. Grease all specified points: ripper pins, blade pivot pins, push arm pins and equaliser bar. Use EP2 lithium complex grease.

   Apply EP2 grease to every nipple until fresh grease purges from the seal. Count all grease points against the manufacturer chart to ensure none are missed. A typical dozer has 15-25 grease points across the blade, push arms, equaliser and ripper.

7. Inspect the undercarriage: check track tension and adjust if needed, inspect pads, rollers, idlers and sprockets for wear.

   Measure track sag at the midpoint between the front idler and the first top roller. Compare to the manufacturer specification (typically 40-60 mm sag depending on model). Inspect each track pad for cracking, missing grouser bars or bolt looseness. Check rollers, idlers and sprockets for visible wear, cracks or oil leaks from seals.

8. Check the battery, test all lights, test the horn, reversing alarm and beacon, check the seatbelt, ROPS structure and fire extinguisher.

   Inspect battery terminals for corrosion and ensure connections are tight. Test all lights, horn and reversing alarm with an assistant. Inspect the seatbelt webbing and buckle. Visually inspect the ROPS for damage, cracks or modifications. Confirm the fire extinguisher gauge is in the green zone and the expiry date is current.

9. Start the engine and check for leaks, abnormal noises or warning lights. Check the oil pressure gauge and all instrument readings. Record any defects or recommendations in the notes section.

   Run the engine for five minutes and monitor oil pressure, coolant temperature, hydraulic temperature and charge indicators. Walk around the machine checking for fluid leaks. Operate the blade lift, tilt and ripper briefly to check for smooth operation. Record all defects with severity and recommended corrective actions.

10. Set the next service due hours (next 250-hour and next 500-hour intervals). Sign off and update the machine's maintenance log.

    Calculate the next 250-hour and 500-hour service due hours from the current reading. Update the service sticker in the cab, the machine maintenance log and the fleet management system. Obtain sign-off from the service technician.

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.

• AS 2294:1997 - Earth-moving Machinery - Protective Structures (ROPS and FOPS requirements)
• WHS Regulations 2011, Chapter 5 - Plant and Structures (registration, inspection and maintenance of plant)
• ISO 6165:2022 - Earth-moving Machinery - Basic Types, Identification and Terms (classification and terminology)

• Model WHS Regulations (Safe Work Australia)
• ISO 6165:2022, Earth-moving machinery types and vocabulary (ISO catalogue)

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

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