Intermediate PM2 service for articulated dump trucks (all makes)
Estimated duration: 4 - 6 hours • Frequency: every 500 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine (Carried Forward from 250-hr PM1) | ||||
| 1 | Drain and replace engine oil (15W-40 CK-4, 30-50 L typical) | DRAIN/FILL | ☐ | |
| 2 | Replace engine oil filter | REPLACE | ☐ | |
| 3 | Drain fuel/water separator | DRAIN | ☐ | |
| Fuel System (500-Hour Additions) | ||||
| 4 | Replace primary fuel filter element | REPLACE | ☐ | |
| 5 | Replace secondary fuel filter element (if dual-stage system) | REPLACE | ☐ | |
| 6 | Bleed fuel system, check for leaks at all fittings | CHECK | ☐ | |
| Air Intake | ||||
| 7 | Replace primary air filter element | REPLACE | ☐ | |
| 8 | Inspect secondary (safety) element, replace if damaged or 3rd change | INSPECT | ☐ | |
| Hydraulic System | ||||
| 9 | Replace hydraulic return filter element | REPLACE | ☐ | |
| 10 | Take hydraulic oil sample for contamination analysis | CHECK | ☐ | |
| 11 | Inspect all hoses and fittings on steering, hoist and brake circuits | INSPECT | ☐ | |
| Transmission and Drivetrain | ||||
| 12 | Replace transmission oil filter | REPLACE | ☐ | |
| 13 | Check transmission oil level and condition | CHECK | ☐ | |
| 14 | Check front, centre and rear differential oil levels | CHECK | ☐ | |
| 15 | Inspect driveshafts and universal joints for play | INSPECT | ☐ | |
| 16 | Inspect axle hub seals for leaks | INSPECT | ☐ | |
| Greasing (All 250-hr Points Plus Additional) | ||||
| 17 | Grease all articulation joint pins (upper and lower) | GREASE | ☐ | |
| 18 | Grease steering, hoist and suspension cylinder pins | GREASE | ☐ | |
| 19 | Grease all driveshaft universal joints and body pivot pins | GREASE | ☐ | |
| Cooling System | ||||
| 20 | Check coolant concentration with refractometer (50/50 target) | CHECK | ☐ | |
| 21 | Pressure-test radiator cap (rated pressure, typically 100 kPa) | CHECK | ☐ | |
| 22 | Clean radiator and charge air cooler cores with low-pressure air | CLEAN | ☐ | |
| Brakes and Safety | ||||
| 23 | Measure service brake pad thickness, compare to minimum spec | INSPECT | ☐ | |
| 24 | Inspect brake discs for scoring, cracking and uneven wear | INSPECT | ☐ | |
| 25 | Test park brake hold on grade, check retarder operation | CHECK | ☐ | |
| 26 | Load-test battery, check all lights, horn and reverse alarm | CHECK | ☐ | |
| Tyres and Body | ||||
| 27 | Check tyre pressures and condition (all positions) | CHECK | ☐ | |
| 28 | Inspect body floor, sides and tailgate for cracks and wear | INSPECT | ☐ | |
| Final Checks | ||||
| 29 | Start engine, cycle all functions, check for leaks and abnormal noise | CHECK | ☐ | |
| 30 | Drive forward and reverse, confirm smooth operation and straight tracking | CHECK | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 CK-4 (or 10W-30) | 30 - 50 L |
| Transmission oil | Per OEM spec (TO-4 or equivalent) | 40 - 60 L |
| Hydraulic oil | ISO VG 46 (AW 46) | 100 - 200 L (system) |
| Differential oil | 80W-90 GL-5 or OEM spec | 8 - 15 L per axle |
| Coolant | 50/50 ethylene glycol | 40 - 80 L |
| Grease | EP2 lithium complex | As required (30-50 points) |
Specifications are general guidelines for typical articulated dump trucks. Always refer to the manufacturer service manual for your specific make and model.
Parts / Consumables Required
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40 CK-4) | 30-50 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Primary fuel filter | 1 | ☐ | |
| 4 | Secondary fuel filter | 1 | ☐ | |
| 5 | Primary air filter element | 1 | ☐ | |
| 6 | Hydraulic return filter | 1 | ☐ | |
| 7 | Transmission oil filter | 1 | ☐ | |
| 8 | EP2 grease cartridges | 6-10 | ☐ | |
| 9 | Oil sample bottles (engine, hydraulic, transmission) | 3 | ☐ | |
| 10 | Rags, drip trays, waste oil containers | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager