Free grader 250-hour service procedure
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Free grader 250-hour service checklist (PDF-ready). Engine oil, filters, circle and turntable, grease points, tyres and tandem drives. Download free.
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See the first part of the grader 250-hour service procedure below. Download the full version above.
What is a grader 250-hour service procedure?
A grader 250-hour service checklist is a structured preventive maintenance form used by mechanics and fitters to complete the first tier of scheduled servicing on a motor grader. It is performed every 250 engine hours (or approximately every four to six weeks of full-time operation) and is classified as a minor service. The procedure covers engine oil and filter replacement, air filter inspection, fuel system maintenance, hydraulic system checks, blade and circle inspection, greasing all pivot points and joints, tyre pressure and condition checks, tandem drive inspection, electrical system checks and safety device testing.
Unlike a daily pre-start check (which confirms the machine is safe to operate), the 250-hour service involves actual maintenance actions: draining and replacing fluids, replacing filters, adjusting components and inspecting wear items for deterioration. Motor graders are high-value earthmoving assets, and skipping minor service intervals accelerates wear on engine internals, hydraulic pumps and circle drive components. Documented 250-hour services are required under Australian WHS Regulations to demonstrate that plant is maintained in a safe condition, and they support compliance with AS 4024 (Safety of machinery) and ISO 6165 (Earth-moving machinery). The service is typically performed by a qualified mechanic or fitter, not the operator.
In MapTrack, meter-based maintenance triggers can be configured so work orders are generated automatically as each grader approaches its 250-hour service point. This eliminates reliance on operators or supervisors to track hours manually, ensuring no minor service is missed across a fleet of machines working on different sites.
Learn more about maintenance and work orders in MapTrack.
Benefits of using this grader 250-hour service procedure
- Reduced breakdowns: regular oil, filter and fluid changes prevent engine, hydraulic and drivetrain failures that cause unplanned downtime on site.
- Extended component life: clean oil and correct lubrication reduce wear on engine, hydraulic pump, circle drive, tandem drives and steering 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, steering components and tyres 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.
Benefits of digitising forms in MapTrack
When you digitise grader service procedures in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Automatically get alerts when faults are identified.
- Link every form digitally as a PDF to the relevant asset, location or person.
- Receive a digital PDF copy with every submission to your email.
- Ability to share forms digitally.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
- Trigger work orders automatically when a fault is logged during an inspection.
- Track service intervals by hours, kilometres or calendar date in one place.
- Attach supplier invoices and parts receipts to each maintenance record.
Book a demo to see how MapTrack handles grader service procedures.
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What to include in a grader 250-hour service procedure
This grader 250-hour service procedure covers 8 key areas:
- 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.
- Blade / circle / turntable: inspect blade/moldboard condition, inspect circle and turntable mechanism, check circle drive gear teeth for wear.
- Lubrication: grease articulation joint, circle drive and turntable, steering ball joints and tie rod ends, lean cylinder pins.
- Tyres / wheels: check tyre pressures all 6 wheels, inspect tyre condition.
- Drivetrain: inspect tandem drive cases (oil level, leaks).
- Electrical: check battery terminals and charge, test all lights, horn and reversing alarm.
- Safety devices: check seatbelt, inspect ROPS structure, check scarifier (if fitted).
How to use this grader 250-hour service procedure
- Park the grader 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 the machine on a firm, flat surface away from traffic. Lower the blade and ripper (if fitted) fully to the ground to prevent accidental movement. Allow at least 10 minutes for the engine and oil to cool to a safe handling temperature.
- Record the equipment details and current hour meter reading at the top of the service procedure form.: Capture the machine make, model, serial number, fleet ID and site location. Record the exact hour meter reading so the next service interval can be calculated accurately and logged in your maintenance system.
- 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.: Place a drain pan under the sump plug, remove the plug and allow all oil to drain completely. Remove the old oil filter and install a new filter pre-filled with clean 15W-40 oil. Refill the engine to the correct dipstick level, typically 15 to 25 litres depending on model. Inspect the outer air filter element for dust loading and clean or replace. Drain the fuel/water separator bowl and check coolant level and condition.
- Check hydraulic oil level. Inspect the blade/moldboard for wear and cracks, check the circle and turntable mechanism, and inspect circle drive gear teeth.: With the blade lowered, check hydraulic oil level on the sight glass or dipstick and top up with the correct grade if low. Walk around the blade and inspect the cutting edge and end bits for wear, cracks or chipping. Rotate the circle slowly and check for smooth operation, then visually inspect the gear teeth for pitting, chipping or uneven wear patterns.
- Grease all specified points: articulation joint, circle drive and turntable, steering ball joints and tie rod ends, lean cylinder pins. Use EP2 lithium complex grease.: Pump EP2 lithium complex grease into each fitting until fresh grease appears at the seal. A typical motor grader has 15 to 25 grease points. Pay particular attention to the articulation joint and circle drive bearings, as these carry heavy loads and wear quickly when under-lubricated.
- Check tyre pressures on all 6 wheels and inspect tyre condition. Inspect tandem drive cases for oil level and leaks.: Use a calibrated tyre gauge to check pressures on all six tyres against the manufacturer specification, typically 275 to 350 kPa depending on the machine and operating conditions. Inspect tyre sidewalls for cuts, bulges and embedded objects. Check each tandem drive case oil level through the check plug and look for leaks around seals and drain plugs.
- Check the battery, test all lights, test the horn and reversing alarm, check the seatbelt, ROPS structure and scarifier (if fitted).: Inspect battery terminals for corrosion and tighten connections. Test all headlights, tail lights, indicator lights and work lights. Confirm the horn and reversing alarm are audible at a safe distance. Check the seatbelt webbing, buckle and mounting points. Visually inspect the ROPS structure for cracks or damage, and check scarifier shanks and tips if the machine is so equipped.
- 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 at idle and observe all dashboard gauges for correct readings. Oil pressure should rise to the normal range within a few seconds. Walk around the machine and check for any new fluid leaks at the sump, filters, hydraulic fittings and tandem drives. Listen for abnormal knocking, whining or squealing. Record any findings requiring follow-up.
- 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 points based on the current hour meter reading. Update the service sticker on the machine and enter the completed service record into your maintenance management system. Obtain the technician and supervisor signatures.
In MapTrack, you can schedule and track maintenance digitally. Each submission is stored as a timestamped PDF against the asset record.
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Back to download formHow often should you complete this service procedure?
The 250-hour service should be performed every 250 engine hours, which equates to roughly every four to six weeks for a grader running full-time on a construction or civil site. If the machine operates in dusty, sandy or high-temperature environments, consider reducing the interval to 200 hours to protect the engine and hydraulic system. Graders also follow a tiered schedule: a 500-hour intermediate service adds filter replacements, steering and brake inspection and circle gear measurement, while a 1,000-hour major service adds hydraulic oil changes, coolant flushes and tandem drive oil changes. Daily pre-start checks by the operator should be completed before every shift regardless of the service schedule.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- AS 4024 Safety of machinery
- ISO 6165 Earth-moving machinery
- WHS Regulations (plant maintenance duties)
Need to schedule and track maintenance digitally?
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