Preventive Maintenance (Weekly / 50h) (All Excavators) is a standardized, field-ready checklist for operators and mechanics covering lubrication, filtration, cooling, undercarriage, fasteners, battery, and basic fluid condition to reduce failures.
- Targeted weekly tasks that extend component life and uptime.
- Clear tools, methods, and measurable acceptance criteria for all steps.
- Reduces overheating, dust ingress, and undercarriage wear on mixed fleets.
- Interactive, commentable, export with QR code for proof and sharing.
The checklist
Lubrication
- Grease boom, arm, and bucket pins using NLGI-2 lithium grease until clean purge; wipe excess; capture a photo at boom foot, arm base, and bucket links; record cartridge count and time.
- Grease swing bearing race via all fittings; rotate upperstructure in 90° increments to distribute; accept uniform purge without grit; photo of purge points; log strokes per fitting.
- Apply OEM gear grease to exposed slew ring gear with brush; thin, even coat across full circumference; photo of coverage; record product name and lot/batch number.
- Lubricate quick coupler and auxiliary joints; cycle functions to seat grease; acceptance: fresh grease visible, no squeaks; short video or photo; operator sign-off captured.
Air Intake System
- Read air filter restriction indicator; accept normal/green (<75% restriction); if red/yellow, service filters; take indicator photo; record hour meter and action taken.
- Remove primary engine air filter; blow from clean side with dry air ≤ 700 kPa; reject oil-soaked or damaged elements; reinstall correctly; photo and part number recorded.
- Inspect secondary/safety element; do not clean; replace if dirty or ≥12 months in service; photo date code; record new element lot and installer signature.
- Inspect intake ducts and clamps for cracks, gaps, or debris; torque clamps per OEM; acceptance: airtight, seated joints; photo of any replaced parts.
Cooling System
- Clean cooling pack (radiator, charge-air, hydraulic cooler) with low-pressure air/water ≤ 550 kPa from fan side out; fins straight; before/after photos attached.
- Check coolant level at expansion tank when cool; top to MAX with 50/50 premix; record litres added and product; photo of sight mark.
- Measure coolant freeze protection with refractometer; target −37 °C ± 2 °C ethylene glycol equivalent; record reading and ambient temperature; attach refractometer photo.
- Inspect fan belts and tensioner; measure belt deflection 10–15 mm under 100 N; replace if cracked or glazed; photo and measurement noted.
Undercarriage
- Remove packed mud/aggregate with scraper and low-pressure washer; ensure rollers spin freely; capture before/after photos; dispose debris per approved project specifications and authority requirements.
- Measure track sag at midpoint; target per OEM (typically 10–35 mm); adjust via grease valve; photo of tape/scale reading; note surface and temperature.
- Inspect track shoe bolts; verify paint marks aligned; re-torque to OEM spec using calibrated torque wrench; apply new witness paint; log torque (N·m) and wrench serial.
- Check carrier rollers, idlers, and seals for leaks or wobble; acceptance: no fresh oil after 10 min; photo; raise defect and tag-out if leaking.
- Inspect sprocket teeth and track links; acceptance: less than 50% tooth profile loss, no severe hooking; photos; plan replacement if exceeded.
Fasteners & Structures
- Walkaround guards, handrails, steps, mirrors, boom/arm stops; tighten loose fasteners to OEM torque; photo of representative points; record torque values (N·m).
- Inspect slew bearing bolts (accessible side); ensure no lifted washers or broken heads; re-torque in star pattern per OEM; photo of marks before/after; supervisor sign-off.
- Check attachment and coupler latch; perform low-height lift/tilt test; acceptance: positive lock, no play; capture photo or short video; operator acknowledgment logged.
Electrical, Fluids & Documentation
- Clean battery terminals with baking soda solution; torque clamps per OEM; apply dielectric grease; measure system voltage 24.6–25.4 V resting; photo multimeter; record values.
- Verify alternator output at 1 500 rpm: 27.0–28.5 V with major loads off; photo of reading; open defect if outside range.
- Check engine oil level after ≥10 min shutdown on level ground; oil between MIN–MAX; top-up with OEM grade; record litres and oil batch number; photo dipstick.
- Inspect hydraulic oil sight glass; acceptance: level within marks, oil clear amber, no foam/milkiness; photo; submit oil sample if abnormal.
- Drain fuel-water separator until clear fuel appears; capture sample photo; dispose water responsibly; date-tag bowl; note volume drained.
- Tidy cab and windows; remove debris under pedals; confirm extinguisher accessible and in-date; photograph cab condition; update digital log; obtain operator and mechanic digital signatures.
Preview the printable checklist
Preview page one below. Open the image or download the PDF for all pages.
At a glance
- Standardized 50-hour tasks keep excavator systems reliable: clean cooling cores to avoid overheating, maintain proper track sag to prevent accelerated wear, and grease high-load pivots to purge contaminants and extend pin and bushing life across varied site conditions.
- Actionable instructions specify tools and tolerances: kPa limits for blowing filters, belt deflection under a 100 N load, coolant refractometer readings to −37 °C, charging voltage at 1 500 rpm, and evidence requirements like photos, lot numbers, and calibrated torque marks.
- Interactive online checklist with tick, comment, and export features secured by QR code. This enables transparent sign-off, quick defect escalation, and auditable records that travel with the machine, simplifying shift handovers, rental returns, and compliance with site documentation control.
- Designed for mixed fleets and varied environments, the checklist emphasizes fast, repeatable tasks that fit a weekly window, reduces unplanned downtime, and supports safer operation by catching loose fasteners, leaks, and clogged airflow paths before they escalate into costly failures.
How to Use the Weekly/50h Excavator PM Interactive Checklist
- Preparation: Park on level ground, lower implements, apply park brake, and isolate if required. Gather PPE, grease gun, torque wrench, refractometer, multimeter, tape/scale, low-pressure air/water, spill kit, OEM specs, tags, and cleaning tools.
- Access the checklist: Scan the machine QR code or open the app, select unit ID and hour meter, then start a new Weekly/50h PM session.
- Work methodically: Follow item order by system. Tick each step, add condition notes, capture photos or short videos, and enter measurements (kPa, mm, V, °C, litres) where prompted.
- Flag defects: If readings fall outside acceptance limits, add a comment with photos, select priority, assign to a maintainer, and apply a tag-out if safety-critical.
- Complete evidence: Record products used (oil grade, lot numbers), torque values, and any adjustments made. Use witness paint where applicable and attach close-up photos.
- Export and share: Generate an export as PDF/Excel including photos and comments. The export is QR-authenticated for verification and easy sharing with supervisors.
- Sign-off and archive: Capture operator and mechanic digital signatures, distribute to stakeholders, and archive the record for audits and service history.
Lubrication and Clean Air Keep Components Alive
Weekly lubrication purges grit from high-load joints, preventing fretting and pin/bushing wear. Apply NLGI-2 grease until clean purge is visible and wipe excess to avoid dust packing. For swing bearings and open slew gears, distribute grease evenly while rotating the upperstructure to ensure full coverage. Air system care is equally critical: read the restriction indicator first, then service the primary element with dry air under 700 kPa from the clean side only. Never clean the safety element—replace it when dirty or out-of-date. Inspect ducts and clamps for airtight seals, since even small leaks allow dust ingress that scours turbocharger and cylinder surfaces. Acceptance cues are practical: uniform grease purge with no squeaks during function tests, indicator within the green band, intact filter pleats, and fully seated clamps without cracking. Capture photos of purge points, indicator status, filter labels, and any replaced parts to create traceable, auditable service evidence.
- Grease to clean purge; wipe excess from joints.
- Dry air clean primaries only, ≤ 700 kPa.
- Do not clean safety elements; replace instead.
- Air ducts must be airtight with seated clamps.
- Photograph indicators, filters, and purge points.
Cooling Packs and Undercarriage: Control Heat and Wear
Cooling packs collect dust that insulates fins and spikes engine and hydraulic temperatures. Blow cores from the fan side out using ≤ 550 kPa to avoid fin damage, and confirm light passes through the core. Verify coolant level cold, then check refractometer readings around −37 °C for freeze/boil protection. Belt deflection between 10–15 mm under 100 N indicates healthy tension. On the undercarriage, remove packed material that blocks rollers and accelerates wear. Measure track sag at the midpoint and adjust per OEM—typical values sit between 10–35 mm depending on track type. Fasteners on shoes and slew bearings should show intact witness marks; re-torque with a calibrated wrench if disturbed. Acceptance signs include straight fins, visible core daylight, correct coolant reading, free-spinning rollers, and aligned paint marks. Photos before and after cleaning, and of measuring tapes and torque marks, provide unambiguous proof.
- Clean cores ≤ 550 kPa from fan side.
- Refractometer target: about −37 °C.
- Belt deflection: 10–15 mm under 100 N.
- Track sag within OEM range, typically 10–35 mm.
- Use calibrated wrench; renew witness marks.
Power, Fluids, and Records: Quick Checks, Big Payoffs
Electrical and fluid checks catch early failures. Battery terminals corrode and raise resistance; clean, torque per OEM, and confirm resting voltage around 24.6–25.4 V for 24 V systems. With the engine running near 1 500 rpm, alternator output should land between 27.0–28.5 V. Engine oil must sit between MIN–MAX after a 10-minute rest on level ground; top up using OEM-approved grade and record litres and batch. Hydraulic oil should appear clear amber in the sight glass without foam or milkiness; if abnormal, capture a sample for lab analysis. Drain the fuel-water separator until clear fuel flows to protect injectors. Finish by cleaning the cab and logging all actions. Acceptance cues are simple: correct voltages, correct levels within marks, clear fuel, and documented evidence. Photos of multimeter readings, dipsticks, sight glasses, and samples, plus signatures, complete a defensible trail.
- Resting 24 V systems: 24.6–25.4 V.
- Charging at 1 500 rpm: 27.0–28.5 V.
- Oil and hydraulic levels within marks.
- Drain water until clear fuel flows.
- Record litres, batches, and signatures.
