What is included in an articulated dump truck 250-hour service?

A 250-hour PM1 service on an articulated dump truck includes draining and replacing engine oil and the oil filter, inspecting or replacing the primary air filter element, draining the fuel/water separator, greasing all articulation joint pins, steering cylinder pins, hoist cylinder pins, suspension pins, driveshaft universal joints and body pivot pins, checking hydraulic oil level and filter condition, verifying transmission fluid and differential oil levels, inspecting wet disc brake oil condition and disc wear, testing the park brake and retarder, and checking the cooling system, tyres, suspension, electrical systems and cab controls.

What Australian regulations apply to articulated dump truck maintenance?

No regulation prescribes a 250-hour service interval by name. However, WHS Regulations 2011 (Chapter 5, Plant and Structures) require the PCBU to ensure all mobile plant is maintained in a safe condition. AS 4024.1 (Safety of Machinery) provides the general framework for machinery risk assessment and safe design that underpins maintenance scheduling. The manufacturer service schedule is the industry-accepted benchmark for meeting these obligations. Failing to follow the manufacturer schedule can be used as evidence of non-compliance in a regulator investigation, WorkSafe audit or insurance claim, and will typically void the manufacturer warranty.

Why are wet disc brakes checked at the 250-hour interval on ADTs?

Wet disc brakes are the primary braking system on most modern articulated dump trucks and operate immersed in oil within sealed housings. At the 250-hour interval, the brake oil is inspected for discolouration and metallic particles, which indicate disc wear and reduced braking effectiveness. Because ADTs carry heavy payloads down steep haul roads, any degradation in braking performance creates a serious safety risk. Catching wear indicators early at each PM1 allows the maintenance team to schedule disc replacement or oil change before braking performance drops below safe levels.

How often should an articulated dump truck be serviced overall?

Articulated dump trucks follow a tiered service schedule. The PM1 (250-hour) service covers engine oil, filters, greasing and basic system inspections. The PM2 service (typically 500 or 1000 hours depending on the manufacturer) adds transmission oil change, hydraulic oil sampling or replacement, differential oil changes and a more thorough brake and drivetrain overhaul. Daily pre-start inspections must be completed before every shift. On newer models with extended oil drain intervals, some manufacturers allow up to 1000 hours between engine oil changes, but the 250-hour greasing and inspection interval remains standard across the industry.

Can I use MapTrack to manage articulated dump truck service schedules?

Yes. MapTrack supports meter-based maintenance triggers that automatically schedule services based on engine hour meter readings. When the hour meter approaches a PM1, PM2 or PM3 threshold, MapTrack sends an alert to the maintenance team with the full task list for that service tier. Service completion is recorded against the asset with photos, timestamps and technician sign-off, building a digital service history that supports warranty claims, resale documentation and compliance audits.

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Free ADT 250-hour service checklist (PDF-ready). Engine oil, articulation greasing, hydraulics, wet disc brakes, drivetrain and cooling. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a articulated dump truck 250-hour service?

An articulated dump truck 250-hour service checklist is a structured procedure used to perform the first major tier of scheduled preventive maintenance on an articulated dump truck (ADT) every 250 engine hours. This interval, commonly referred to as the PM1 service, covers engine oil and filter replacement, greasing of all pivot and articulation points, hydraulic system filter inspection, transmission fluid level verification, differential oil checks, wet disc brake inspection, suspension component assessment, cooling system service and a full cab and controls walkthrough. The 250-hour service is the foundation of the ADT maintenance programme and applies across all major manufacturers including Volvo, Caterpillar, Bell, Komatsu and John Deere.

Articulated dump trucks operate in some of the harshest conditions found in mining, quarrying and civil construction. They haul heavy payloads over rough terrain, subjecting every component to sustained vibration, dust ingestion and thermal cycling. The articulation joint, which allows the front and rear chassis to pivot independently, is a critical stress point that demands regular greasing to prevent premature bearing failure and steering drift. The wet disc brake system, used on most modern ADTs, operates immersed in oil and requires periodic inspection of disc thickness, oil condition and cooling circuit flow to maintain reliable stopping performance on steep grades. Under WHS Regulations 2011 (Chapter 5, Plant and Structures) and AS 4024.1 (Safety of Machinery), the person conducting a business or undertaking (PCBU) has a duty to ensure mobile plant is maintained in a condition that is safe and without risk to health. A missed or deferred PM1 service increases the probability of brake fade, hydraulic leaks, articulation joint wear and engine damage, all of which create direct safety risks for the operator and surrounding personnel.

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Benefits of using this articulated dump truck 250-hour service

Engine protection: replacing engine oil and the oil filter at 250 hours removes combustion contaminants, fuel dilution and metal particles, preventing premature bearing, piston ring and turbocharger wear across all ADT engine platforms.
Articulation joint longevity: greasing all pivot and articulation points at the correct interval prevents dry bearing surfaces that lead to joint play, steering drift and costly frame repairs that can sideline the truck for weeks.
Hydraulic reliability: inspecting hydraulic filters and checking oil condition catches contamination early, protecting pumps, cylinders, the hoist system and steering circuit from abrasive damage that compounds rapidly if left unchecked.
Brake safety: inspecting wet disc brake condition, oil level and retarder operation at every PM1 ensures stopping performance is maintained on steep haul roads where loaded ADTs travelling at speed depend on reliable braking.
Drivetrain integrity: checking transmission fluid, differential oil levels and driveshaft universal joints at the 250-hour mark detects leaks and wear before they progress to catastrophic failures that strand the truck mid-haul.
Fleet availability: completing PM1 services on schedule keeps articulated dump trucks in the production cycle, reducing unplanned downtime that disrupts haulage schedules and delays earthworks programmes across the entire site.

Benefits of digitising forms in MapTrack

When you digitise articulated dump truck service procedures in MapTrack, you get:

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What to include in a articulated dump truck 250-hour service

This articulated dump truck 250-hour service covers 11 key areas:

Engine oil and filter: drain and replace engine oil (grade and capacity per manufacturer specification), replace oil filter, verify oil level after brief warm-up run.
Transmission fluid check: verify transmission oil level on the dipstick with the engine off, inspect for discolouration or burnt odour indicating overheating or contamination.
Differential oil check: inspect oil levels at the front, centre and rear differentials via fill plugs, check for leaks at axle hub seals and pinion seals.
Hydraulic system: check hydraulic oil level and condition, inspect filter condition indicator, inspect all hoses and fittings on steering, hoist and brake circuits.
Articulation joint lubrication: grease upper and lower articulation pins, steering cylinder rod ends, hoist cylinder pins and body pivot pins using EP2 lithium complex grease.
Body pivot pins: inspect body pivot pin bushings for wear, grease all body pivot points, check body alignment when raised.
Tyre inspection: check tyre pressures against manufacturer specification, inspect tread depth, sidewalls and bead area for cuts, bulges or embedded objects.
Braking system (wet disc brakes): check brake oil level and condition, inspect brake cooling circuit flow, measure service brake response, test park brake hold on grade, check retarder operation.
Suspension: inspect front and rear suspension cylinders for leaks, check nitrogen pre-charge pressure (if applicable), inspect mounting pins and bushings.
Cooling system: check coolant level and concentration, inspect radiator and charge air cooler for debris, check fan belt tension, inspect all coolant hoses and clamps.
Cab and controls: test all lights, horn, reverse alarm, mirrors, camera system, emergency steering (if fitted), seatbelt, fire suppression system and windscreen wipers.

How to use this articulated dump truck 250-hour service

Park the ADT on firm, level ground with the body fully lowered. Apply the park brake, place the transmission in neutral and shut down the engine. Chock the wheels if on any gradient.: Select a designated service bay or a firm, flat area well clear of active haul roads. Lower the body completely and ensure the body safety prop is disengaged so the body rests fully on the chassis. Allow the engine to cool for at least 15 minutes before draining fluids. Gather all replacement filters, engine oil, grease cartridges and consumables required for the service before starting.
Record the equipment details: asset ID, make, model, serial number, unit number and the current engine hour meter reading. Note any active fault codes from the electronic display.: Cross-reference the hour reading against the previous PM1 record to verify the 250-hour interval has been reached. If the machine has a telematics system (such as Volvo CareTrack, Cat Product Link or Komatsu KOMTRAX), download the fault code history for review alongside the physical service. Record the site name, date and the name of the technician performing the service.
Complete the engine section: drain and replace engine oil, replace the oil filter, inspect the air filter elements and drain the fuel/water separator.: Use the engine oil grade specified by the manufacturer (commonly 15W-40 CK-4 for Tier 4 Final engines or 10W-30 for newer models). ADT engine oil capacity typically ranges from 30 to 50 litres depending on the model. Fill to the full mark on the dipstick, run the engine for two minutes to prime the new filter, shut down and recheck the level. Inspect the primary air filter restriction indicator and replace the element if it shows red. Drain the fuel/water separator bowl completely.
Grease all articulation, steering, hoist, suspension and driveshaft grease points using EP2 lithium complex grease.: An articulated dump truck typically has 30 to 50 grease points depending on the make and model. Apply two to four pumps of EP2 grease per point until fresh grease appears at the seal. Critical points include the upper and lower articulation pins, steering cylinder rod ends, hoist cylinder pins, front and rear suspension cylinder pins, all driveshaft universal joints and body pivot pins. Refer to the manufacturer grease chart to ensure every point is covered and no fitting is missed.
Check the hydraulic system: verify oil level, inspect the hydraulic filter condition indicator and walk around the machine inspecting all hoses and fittings on the steering, hoist and brake circuits.: Check the hydraulic oil level with the body lowered and the engine off. The level should sit between the minimum and maximum marks on the sight glass or dipstick. If the filter condition indicator shows bypass, schedule a filter replacement before the next shift. Inspect every visible hydraulic hose and fitting, paying particular attention to the articulation area, hoist cylinders and steering cylinders where hose movement and abrasion are greatest.
Inspect the drivetrain: check transmission oil level, inspect driveshafts and universal joints for play, check differential oil levels at the front, centre and rear, and inspect axle hub seals for leaks.: Check the transmission oil level on the dipstick with the engine off and the transmission in neutral. Grip each driveshaft and rotate it to detect play in the universal joints; any perceptible movement indicates a joint that needs replacement. Check oil levels at each differential fill plug. Inspect axle hub seals for signs of oil leakage onto the wheel rim or brake area. Record all findings for follow-up.
Inspect the braking system: check wet disc brake oil level and condition, measure service brake response, test the park brake on a slight gradient and check retarder operation.: Wet disc brakes are immersed in oil, so check the brake oil level and inspect its colour and clarity; dark or metallic-looking oil indicates disc wear. Test the park brake by engaging it on a slight slope with the transmission in neutral and confirming the truck does not move. Activate the retarder and confirm smooth, progressive deceleration without judder or abnormal noise. Inspect all brake lines and fittings for leaks, chafing or corrosion.
Check tyres, suspension and cooling system. Inspect cab controls, lights, alarms and safety devices. Start the engine, cycle all functions and drive the truck forward and reverse at low speed.: Check all tyre pressures against the manufacturer specification and inspect for cuts, bulges and embedded objects. Inspect suspension cylinders for oil leaks and mounting pin condition. Check coolant level and fan belt tension. Inside the cab, test all lights, horn, reverse alarm, mirrors, camera, emergency steering, seatbelt and fire suppression system. Run the engine for at least five minutes, raise and lower the body, turn the steering lock to lock and drive the truck forward and reverse to confirm smooth operation.
Set the next service due hours. Calculate the next PM1 (250-hour) and PM2 (500 or 1000-hour) intervals, update the service sticker on the machine and sign off the service form.: Add 250 to the current hour reading for the next PM1 and determine the next major service milestone (PM2 or PM3) based on the manufacturer schedule. Update the service sticker, record all completed tasks in the fleet maintenance system and, if using MapTrack, confirm the next meter-based trigger is set so the maintenance team receives an automated alert before the interval is due.

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How often should you complete this service procedure?

The 250-hour PM1 service should be performed every 250 engine hours, which equates to approximately every 3 to 5 weeks of full-time operation on an active site assuming 10 to 12 hours per day, 5 to 6 days per week. This is the most frequent tier of scheduled maintenance and focuses on engine oil, filters, greasing and foundational system inspections. The next tier is typically a 500-hour or 1000-hour service depending on the manufacturer, which carries forward all PM1 tasks and adds transmission oil change, hydraulic oil sampling or replacement, differential oil changes, thorough brake system overhaul and more detailed drivetrain inspection.

Between PM1 services, operators must complete a daily pre-start inspection before each shift covering walk-around visual checks, fluid levels, tyre condition, lights, brakes and body operation. On high-production sites where ADTs run double shifts, the 250-hour interval may arrive within two to three weeks. Do not defer the service, as engine oil degrades faster under sustained high-load operation and articulation greasing intervals are calibrated to prevent bearing damage at the specified hour mark. Always refer to the manufacturer service manual for the specific intervals, tasks and fluid specifications for your make, model and operating conditions.

Frequently asked questions

What is included in an articulated dump truck 250-hour service?: A 250-hour PM1 service on an articulated dump truck includes draining and replacing engine oil and the oil filter, inspecting or replacing the primary air filter element, draining the fuel/water separator, greasing all articulation joint pins, steering cylinder pins, hoist cylinder pins, suspension pins, driveshaft universal joints and body pivot pins, checking hydraulic oil level and filter condition, verifying transmission fluid and differential oil levels, inspecting wet disc brake oil condition and disc wear, testing the park brake and retarder, and checking the cooling system, tyres, suspension, electrical systems and cab controls.
What Australian regulations apply to articulated dump truck maintenance?: No regulation prescribes a 250-hour service interval by name. However, WHS Regulations 2011 (Chapter 5, Plant and Structures) require the PCBU to ensure all mobile plant is maintained in a safe condition. AS 4024.1 (Safety of Machinery) provides the general framework for machinery risk assessment and safe design that underpins maintenance scheduling. The manufacturer service schedule is the industry-accepted benchmark for meeting these obligations. Failing to follow the manufacturer schedule can be used as evidence of non-compliance in a regulator investigation, WorkSafe audit or insurance claim, and will typically void the manufacturer warranty.
Why are wet disc brakes checked at the 250-hour interval on ADTs?: Wet disc brakes are the primary braking system on most modern articulated dump trucks and operate immersed in oil within sealed housings. At the 250-hour interval, the brake oil is inspected for discolouration and metallic particles, which indicate disc wear and reduced braking effectiveness. Because ADTs carry heavy payloads down steep haul roads, any degradation in braking performance creates a serious safety risk. Catching wear indicators early at each PM1 allows the maintenance team to schedule disc replacement or oil change before braking performance drops below safe levels.
How often should an articulated dump truck be serviced overall?: Articulated dump trucks follow a tiered service schedule. The PM1 (250-hour) service covers engine oil, filters, greasing and basic system inspections. The PM2 service (typically 500 or 1000 hours depending on the manufacturer) adds transmission oil change, hydraulic oil sampling or replacement, differential oil changes and a more thorough brake and drivetrain overhaul. Daily pre-start inspections must be completed before every shift. On newer models with extended oil drain intervals, some manufacturers allow up to 1000 hours between engine oil changes, but the 250-hour greasing and inspection interval remains standard across the industry.
Can I use MapTrack to manage articulated dump truck service schedules?: Yes. MapTrack supports meter-based maintenance triggers that automatically schedule services based on engine hour meter readings. When the hour meter approaches a PM1, PM2 or PM3 threshold, MapTrack sends an alert to the maintenance team with the full task list for that service tier. Service completion is recorded against the asset with photos, timestamps and technician sign-off, building a digital service history that supports warranty claims, resale documentation and compliance audits.

Applicable regulatory standards

This template aligns with the following regulations and standards:

WHS Regulations 2011 - Chapter 5, Plant and Structures (plant maintenance obligations)
AS 4024.1 - Safety of Machinery (general principles for design and risk assessment)

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