What is included in a grader 500-hour service?

A 500-hour grader service is an intermediate service that carries forward all 250-hour tasks (engine oil and filter, grease points, fluid level checks, blade and circle inspection, tyre checks) and adds fuel filter replacement, outer air filter replacement, hydraulic return filter replacement, transmission oil check, tandem drive oil check, steering system inspection (ball joints, tie rods, drag link play), full brake inspection (shoes, drums, adjustment), circle gear teeth measurement, wheel nut torque check, hydraulic oil sampling for analysis, A/C service (if fitted), blade tip and cutting edge inspection for replacement, and a check that all guards are secure. It takes approximately 3 to 4 hours.

What additional items does a 500-hour service include compared to a 250-hour service?

Beyond the 250-hour service, the 500-hour interval adds: replacing the fuel filter element, replacing the outer air filter element, replacing the hydraulic return filter, checking transmission oil level and condition, checking tandem drive oil levels, inspecting the steering system (ball joints, tie rods, drag link), full brake inspection (shoes, drums, adjustment), measuring circle gear teeth wear, torquing wheel nuts to specification, taking a hydraulic oil sample for laboratory analysis, servicing the A/C system, inspecting the blade tip and cutting edge for replacement, and verifying all guards and covers are secure.

Why is circle gear measurement important at 500 hours?

The circle gear is a critical wear component on a motor grader. Measuring gear tooth wear at the 500-hour interval allows you to track the rate of wear over time and plan replacement before the teeth strip or the circle fails. Recording measurements at each service builds a wear trend that helps predict when the circle will need rebuilding or replacing, avoiding unexpected failure during grading operations.

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Yes. Download and use the grader 500-hour service procedure for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want digital service procedures linked to each machine with scheduling by hours, cost tracking and alerts, we would be happy to show you MapTrack.

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Free grader 500-hour service checklist

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A step-by-step 500-hour (intermediate) service procedure for motor graders. Carries forward all 250-hour tasks and adds fuel filter, air filter and hydraulic filter replacement, transmission and tandem drive oil checks, steering and brake inspection, circle gear measurement, wheel nut torque, hydraulic oil sampling and A/C service. Includes fluid specifications, parts list and technician sign-off. This page explains what the service involves, how to perform it, and offers a free PDF-ready form you can download straight away.

Last updated: 2026-03-26 · MapTrack

Jarrod Milford

Commercial Director

Updated 26 March 2026

Carry-forward: includes all 250-hour tasks

Complete the grader 250-hour service procedure first, then perform the additional items listed below.

How to use: Complete the 250-hour service first. Then fill equipment details and hour reading on this form, work through each additional service action and tick Done as each task is completed. Set the next service due hours and sign off.

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What is a grader 500-hour service?

A 500-hour service is the second tier of scheduled preventive maintenance for a motor grader. It is performed every 500 engine hours and is classified as an intermediate service. The procedure carries forward all 250-hour tasks and adds filter replacements (fuel, air, hydraulic), transmission and tandem drive oil checks, steering system inspection, full brake inspection, circle gear measurement, wheel nut torque verification, hydraulic oil sampling and A/C service. These additional items address components that wear or degrade over longer intervals and require more thorough inspection than the minor service. It is typically performed by a qualified mechanic or fitter.

Benefits of scheduled grader servicing

Reduced breakdowns: regular filter replacement and fluid analysis prevent engine, hydraulic and drivetrain failures that cause unplanned downtime.
Extended component life: measuring circle gear wear, inspecting steering joints and checking brake linings helps plan component replacements before they fail catastrophically.
Lower repair costs: a 500-hour service catches issues like contaminated hydraulic oil, worn brake shoes or steering play before they cause expensive secondary damage.
Operator safety: inspecting braking systems, steering components, tyres and structural items 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 move from paper or static PDFs to digital forms 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).

Book a demo to see digital service procedures and hour-based scheduling in MapTrack.

Service actions included in the 500-hour procedure

This service procedure covers 13 additional service actions (beyond the 250-hour tasks) across 7 system areas:

Engine: replace fuel filter, replace outer air filter.
Hydraulic system: replace hydraulic return filter, take hydraulic oil sample for analysis.
Drivetrain: check transmission oil level and condition, check tandem drive oil levels and condition.
Steering / brakes: inspect steering system (ball joints, tie rods, drag link play), full brake inspection (shoes, drums, adjustment).
Blade / circle: inspect circle gear teeth (measure wear), inspect blade tip and cutting edge for replacement.
Tyres / wheels: torque wheel nuts to manufacturer specification.
Cab / structural: service A/C system (if fitted), check all guards and covers are fitted and secure.

Fluid specifications

General fluid specifications for motor graders. Capacities vary by machine size and manufacturer.

System	Type / Grade	Approx. Capacity
Engine oil	15W-40 CI-4 / CK-4	15 - 25 L
Hydraulic oil	ISO VG 46 (AW 46)	80 - 150 L (system)
Coolant	50/50 ethylene glycol	20 - 30 L
Tandem drive oil	Per manufacturer specification	10 - 20 L per case
Transmission oil	Per manufacturer specification	Per manufacturer
Grease	EP2 lithium complex	As required

Specifications are general guidelines. Always refer to the manufacturer's service manual for your specific make and model.

Parts and consumables

Have the following parts and consumables ready before starting the 500-hour service (includes 250-hour items):

Engine oil (15W-40 CI-4/CK-4) - 15-25 litres
Engine oil filter - 1
Fuel filter element - 1
Outer air filter element - 1
Hydraulic return filter - 1
Fuel/water separator element - 1
EP2 grease cartridges - 4-6
Oil sample bottle (hydraulic) - 1
Coolant (pre-mixed or concentrate) - as required for top-up
Rags, drip tray and waste oil container

Look up part numbers in the manufacturer's parts manual for your specific make and model before ordering.

How to perform a grader 500-hour service

Complete the full 250-hour service procedure first (engine oil, filter, grease, fluid checks, blade and circle inspection, tyre checks, tandem drive inspection, electrical and safety).
Replace the fuel filter element and outer air filter element.
Replace the hydraulic return filter. Take a hydraulic oil sample from the sample port and label the bottle with machine ID, hours and date.
Check transmission oil level and condition. Check tandem drive oil levels and condition on both cases.
Inspect the steering system: check ball joints, tie rods and drag link for play. Record any excessive movement.
Perform a full brake inspection: check shoes, drums and adjustment. Record measurements.
Inspect circle gear teeth and measure wear. Record measurements for trend monitoring. Inspect blade tip and cutting edge for replacement.
Torque wheel nuts to manufacturer specification on all 6 wheels.
Service the A/C system (if fitted). Check operation and refrigerant level.
Verify all guards and covers are fitted and secure. Start the engine and check for leaks, abnormal noises or warning lights.
Set the next service due hours (next 500-hour and next 1,000-hour intervals). Sign off and update the machine's maintenance log.

In MapTrack, you can schedule services based on hour meter readings, get automatic reminders, complete service procedures on mobile and link every record to the machine. Book a demo to see how.

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Grader service interval hierarchy

Grader maintenance follows a tiered schedule where each level includes all tasks from the level below. This is called carry-forward or cumulative servicing.

250 hours - Minor service

Engine oil and filter, grease points, fluid levels, blade and circle inspection, tyre checks. Estimated 1.5-2.5 hours.

500 hours - Intermediate service (you are here)

All 250-hour tasks plus hydraulic filter, fuel filter, air filter replace, transmission and tandem drive checks, steering and brake inspection, circle gear measurement. Estimated 3-4 hours.

1,000 hours - Major service

All 500-hour tasks plus hydraulic oil change, coolant flush, tandem drive oil change, full transmission service. Estimated 6-8 hours.

2,000 hours - Overhaul service

All 1,000-hour tasks plus circle rebuild assessment, hydraulic pump and motor inspection, structural NDT. Typically 2-3 days.

In MapTrack, you can configure service schedules by engine hours and receive automatic alerts when each interval is due.

Frequently asked questions

What is included in a grader 500-hour service?: A 500-hour grader service is an intermediate service that carries forward all 250-hour tasks (engine oil and filter, grease points, fluid level checks, blade and circle inspection, tyre checks) and adds fuel filter replacement, outer air filter replacement, hydraulic return filter replacement, transmission oil check, tandem drive oil check, steering system inspection (ball joints, tie rods, drag link play), full brake inspection (shoes, drums, adjustment), circle gear teeth measurement, wheel nut torque check, hydraulic oil sampling for analysis, A/C service (if fitted), blade tip and cutting edge inspection for replacement, and a check that all guards are secure. It takes approximately 3 to 4 hours.
What additional items does a 500-hour service include compared to a 250-hour service?: Beyond the 250-hour service, the 500-hour interval adds: replacing the fuel filter element, replacing the outer air filter element, replacing the hydraulic return filter, checking transmission oil level and condition, checking tandem drive oil levels, inspecting the steering system (ball joints, tie rods, drag link), full brake inspection (shoes, drums, adjustment), measuring circle gear teeth wear, torquing wheel nuts to specification, taking a hydraulic oil sample for laboratory analysis, servicing the A/C system, inspecting the blade tip and cutting edge for replacement, and verifying all guards and covers are secure.
Why is circle gear measurement important at 500 hours?: The circle gear is a critical wear component on a motor grader. Measuring gear tooth wear at the 500-hour interval allows you to track the rate of wear over time and plan replacement before the teeth strip or the circle fails. Recording measurements at each service builds a wear trend that helps predict when the circle will need rebuilding or replacing, avoiding unexpected failure during grading operations.
Is the template free to use without MapTrack?: Yes. Download and use the grader 500-hour service procedure for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want digital service procedures linked to each machine with scheduling by hours, cost tracking and alerts, we would be happy to show you MapTrack.

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Register every grader in MapTrack. Set up 250, 500 and 1,000-hour service schedules, complete procedures on mobile, track parts and costs, and get automatic alerts when the next service is due.

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