Intermediate service - articulated dump truck and rigid dump truck (all makes)
Estimated duration: 4 - 6 hours • Frequency: every 500 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine (additional to 250-hour) | ||||
| 1 | Replace fuel filter (primary and secondary) | REPLACE | ☐ | |
| 2 | Replace air filter (outer element) | REPLACE | ☐ | |
| 3 | Check fan belt condition and tension | CHECK | ☐ | |
| Transmission and Driveline (additional to 250-hour) | ||||
| 4 | Drain and replace transmission oil and filter | DRAIN/FILL | ☐ | |
| Hydraulic System (additional to 250-hour) | ||||
| 5 | Replace hydraulic return filter | REPLACE | ☐ | |
| 6 | Take hydraulic oil sample for analysis | SAMPLE | ☐ | |
| Brakes (additional to 250-hour) | ||||
| 7 | Full brake inspection - measure pad/shoe thickness all axles | MEASURE | ☐ | |
| Suspension and Steering (additional to 250-hour) | ||||
| 8 | Inspect suspension bushes, pins and dampers | INSPECT | ☐ | |
| 9 | Inspect steering components (ball joints, tie rods, drag link) | INSPECT | ☐ | |
| Dump Body (additional to 250-hour) | ||||
| 10 | Inspect dump body cylinders (seals, rod condition) | INSPECT | ☐ | |
| 11 | Inspect body pivot pins and bushes (measure play) | MEASURE | ☐ | |
| Wheels and Chassis (additional to 250-hour) | ||||
| 12 | Torque wheel nuts all positions | TORQUE | ☐ | |
| 13 | Inspect chassis for cracks or damage | INSPECT | ☐ | |
| Cab (additional to 250-hour) | ||||
| 14 | Service A/C system (check operation and refrigerant) | CHECK | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 CI-4 / CK-4 | 25 - 45 L |
| Hydraulic oil | ISO VG 46 | 40 - 80 L (system) |
| Coolant | 50/50 ethylene glycol | 40 - 60 L |
| Transmission oil | Allison TES 295 or TO-4 | 30 - 50 L (system) |
| Differential oil | 80W-140 GL-5 | 10 - 20 L per diff |
| AdBlue / DEF | ISO 22241 | As required |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical articulated and rigid dump trucks (25 - 60 t). Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by machine size.
Parts / Consumables Required (500-hour additional items)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (15W-40) | 25-45 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Fuel filters (primary and secondary) | 2 | ☐ | |
| 4 | Air filter (outer element) | 1 | ☐ | |
| 5 | Hydraulic return filter | 1 | ☐ | |
| 6 | Transmission oil and filter | 30-50 L + 1 | ☐ | |
| 7 | Fuel/water separator element | 1 | ☐ | |
| 8 | EP2 grease cartridges | 6-10 | ☐ | |
| 9 | Oil sample bottle (hydraulic) | 1 | ☐ | |
| 10 | Coolant (pre-mixed or concentrate) | As req. | ☐ | |
| 11 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager