Free grader 1000-hour service checklist

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Free grader 1000-hour service checklist (PDF-ready). Tandem drive, circle drive, hydraulics, blade wear and structural inspections. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

How to use: download the PDF, print or complete digitally on any device.

• ✓PDF format, ready to print or fill on screen
• ✓Use as-is or customise to suit your operation
• ✓Go digital in MapTrack for photos, alerts and audit trails

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Benefits of using this grader 1000-hour service checklist

• Hydraulic system longevity: replacing the full hydraulic oil removes contamination, moisture and degraded additives that cause pump, valve and cylinder wear in grader steering and implement circuits.
• Tandem drive protection: draining and replacing tandem drive case oil at 1,000 hours removes metal particles and degraded lubricant that accelerate gear, bearing and chain wear in these heavily loaded drive cases.
• Circle mechanism reliability: inspecting and lubricating the circle drive gearbox, circle rail and pinion at the major service interval prevents the costly circle rebuild that results from neglected wear.
• Structural integrity: weld inspections on the mainframe, drawbar and circle support detect fatigue cracking early, preventing failures that can occur during heavy grading or road maintenance operations.
• Compliance with WHS legislation: documented 1,000-hour service records satisfy Chapter 5 plant maintenance obligations and demonstrate due diligence during audits and incident investigations.
• Resale value: a grader with documented 250, 500 and 1,000-hour service records commands a higher price at trade-in or sale, as buyers can verify the full maintenance history.

How to use this grader 1000-hour service checklist

1. Complete the full 500-hour service procedure first (which includes all 250-hour tasks). Use the 500-hour service checklist as the starting point.: Verify all 250-hour and 500-hour items are completed and defects documented before starting the 1,000-hour specific tasks. This ensures the cumulative service model is properly followed and no items are missed.
2. Replace the inner air filter element. Check or send injectors for testing. Inspect the turbocharger for shaft play and oil leaks. Inspect the exhaust manifold and gaskets.: Handle the inner element carefully to prevent debris entering the intake manifold. Inspect injector nozzles for carbon buildup and check for visible fuel leaks. Check turbo shaft play by gripping the compressor wheel and testing for radial and axial movement. Inspect the exhaust manifold for heat-related cracks around stud holes.
3. Drain the full hydraulic oil system. Replace the hydraulic suction strainer. Refill with fresh hydraulic oil per manufacturer specification. Test all implement and steering relief pressures.: Grader hydraulic systems typically hold 100 to 200 litres depending on machine size and configuration. Drain the tank, cylinders and lines as thoroughly as possible. Clean the suction strainer housing before fitting the new element. After refilling, cycle all functions at idle to bleed air. Test blade lift, shift, tilt, circle rotate and articulation steering relief pressures against manufacturer specifications.
4. Drain and replace tandem drive case oil in all cases and transmission oil. Inspect drained oil for metal particles. Check circle drive gearbox oil and circle rail condition.: Position each drain plug at the lowest point before draining. Metal particles in the drained oil indicate gear, chain or bearing wear and should be investigated before the grader returns to service. Inspect the circle drive gearbox oil for contamination and top up or replace as required. Check circle rail for scoring, wear and adequate lubrication. Measure circle shoe clearance and adjust shims if necessary.
5. Drain, flush and replace the coolant. Pressure test the cooling system for leaks. Replace the thermostat if due per the manufacturer schedule.: Flush the system with clean water until the discharge runs clear. Refill with pre-mixed 50/50 coolant. Pressure test at the radiator cap rating (typically 100 to 110 kPa) and hold for 10 minutes to check for leaks. Inspect all hoses, clamps and the water pump weep hole.
6. Inspect structural welds on the mainframe, drawbar, A-frame and circle support. Measure moldboard cutting edge and end bit wear. Check all pivot pins and bushes.: Focus on high-stress areas including drawbar heel welds, A-frame connection points, circle support gussets and mainframe side plate welds. Use a strong light for visual inspection. Any suspected cracks should be verified by NDT before the grader returns to service. Measure cutting edge remaining material and compare against the replacement threshold.
7. Test service brake and park brake operation. Inspect brake linings, discs and steering components. Check all lights, safety devices and electrical systems.: Graders operating on public roads must have fully functional brakes and lighting. Test service brakes at low speed for even stopping. Engage the park brake on a grade to verify holding capacity. Inspect brake disc thickness and lining wear against minimum specifications. Check articulation steering cylinders for leaks and rod scoring. Verify all road-going lights, indicators, beacon and reversing alarm operate correctly.
8. Start the engine and cycle all functions. Check for leaks, abnormal noises or warning lights. Record any defects and set the next service intervals.: Run the engine to full operating temperature and cycle blade lift, shift, tilt, circle rotate, articulation and any ripper or scarifier through their full range. Walk around the machine checking for new fluid leaks. Confirm all gauges and indicators read within the normal range. Record next 250, 500 and 1,000-hour service due hours in MapTrack.

In MapTrack, you can schedule and track maintenance digitally. Each submission is stored as a timestamped PDF against the asset record.

Frequently asked questions

What is included in a grader 1000-hour service?

A 1,000-hour grader service is a major service that carries forward all 500-hour tasks and adds: replacing the inner air filter element, checking injectors, inspecting the turbocharger and exhaust manifold, draining and replacing the full hydraulic oil system, replacing the hydraulic suction strainer, testing all relief pressures, replacing tandem drive case oil, replacing transmission oil, inspecting the circle drive gearbox and circle rail, flushing and replacing coolant, inspecting structural welds on the mainframe, drawbar and circle support, measuring moldboard cutting edge and end bit wear, and testing service brakes, park brake and steering. It typically takes 6 to 10 hours.

What WHS requirements apply to grader maintenance in Australia?

Grader maintenance in Australia must comply with the WHS Act 2011 and WHS Regulations 2011 (Chapter 5, Plant and Structures), which require that plant is maintained in a safe condition with documented records. The regulations place a duty on persons conducting a business or undertaking (PCBU) to ensure that plant is inspected and maintained by competent persons at intervals recommended by the manufacturer or as determined by a risk assessment. Because graders frequently operate on public roads, brake and steering system maintenance is especially critical for compliance. Documented service records at each interval demonstrate compliance during audits and incident investigations.

How often should the grader circle mechanism be inspected?

The circle mechanism should receive a visual check and lubrication at each 250-hour service, a more detailed inspection at the 500-hour interval including circle shoe clearance measurement, and a comprehensive assessment at the 1,000-hour major service including gearbox oil replacement, rail wear measurement, pinion engagement check and shim adjustment. In abrasive conditions such as sandy or gravelly road maintenance, the circle may need more frequent lubrication and inspection to prevent premature rail and shoe wear.

Should a 1000-hour grader service be done in a workshop or on site?

A workshop or hardstand is preferred for a 1,000-hour grader service due to the large fluid volumes (100 to 200 litres of hydraulic oil, tandem drive oil, transmission oil and coolant), the need for brake testing and measurement tools, and better access for structural weld inspections. If the grader cannot be relocated, a field service is possible with adequate containment for waste fluids, a service truck with brake testing equipment, and sufficient lighting for inspections underneath the machine.

What are the critical brake requirements for graders on public roads?

Graders operating on public roads in Australia must comply with state and territory road transport legislation in addition to WHS requirements. Service brakes must bring the machine to a controlled stop from operating speed. Park brakes must hold the machine on the steepest grade it is expected to encounter. Brake disc thickness and lining wear must be within manufacturer specifications. All road-going lights, indicators, reflectors and slow-moving vehicle signage must be operational. A 1,000-hour major service should include a thorough brake system inspection to verify all these requirements are met.